## 2009 PARTICULATE MATTER EMISSION SOURCE TEST REPORT KNAUF INSULATION, GMBH SHASTA LAKE, CALIFORNIA

Prepared For:


### Knauf Insulation, GmbH 3100 Ashby Road Shasta Lake, California 96019



### For Submittal To:


### Shasta County Air Quality Management District 1855 Placer Street, Suite 101 Redding, California 96001



### Prepared By:

Mark Stanfield 

### The Avogadro Group, LLC 2825 Verne Roberts Circle 401 Pech Road Antioch, California 94509 Medford, Oregon 97502 (925) 680-4300 (541) 665-0170

September 4, 2009Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

09090.6m, SCAQMD iii 

### SUMMARY INFORMATION

Source Information

Source Location: Knauf Insulation GmbH Shasta Lake, California Facility 3100 Ashby Road Shasta Lake, CA 96019

Contact: Mr. Chris Mahin Telephone: (317) 398-4434 Facsimile: (317) 398-5501
Units: Glass Melting Furnace
Process: Fiberglass manufacturing
Purpose: Determination of particulate matter emissions compliance
Procedures: EPA Methods 1, 2, 3A (m odified), 4, 5 and 202; Other Test Method (OTM) 028
Permits to Operate: Nos. 97-PO-27a and 97-PO-28a PSD Permit No. NSR-4-4-4, SAC 03-01


### Testing Company Information

Testing Firm: The Avogadro Group, LLC

401 Pech Road 2825 Verne Roberts Circle Medford, OR 97502 Antioch, CA 94509

Contacts: Mr. Mark Stanfi eld Mr. Erick Mirabella Project Manager General Manager
Telephone: (541) 665-0802 (925) 680-0935 Facsimile: (541) 665-0179 (925) 680-4416
Certifications: ARB Independent Tester
Test Date: August 5, 2009Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

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### TABLE OF CONTENTS

SECTION PAGE

1.0 INTRODUCTION ................................................................................................. 1

2.0 SOURCE LOCATION INFORMATION ........................................................... 3 2.1 FACILITY DESCRIPTION ........................................................................ 3 2.2 SAMPLING LOCATION ........................................................................... 3

3.0 TEST DESCRIPTION .......................................................................................... 4 3.1 PROGRAM OBJECTIVES ......................................................................... 4 3.2 TEST CONDITIONS AND TEST PROGRAM SCHEDULE ................... 4 3.3 TEST PROCEDURES................................................................................. 5 3.3.1 Diluent Gases ................................................................................... 6 3.3.2 Particulate Matter (5/202) ................................................................ 7 3.3.3 Particulate Matter (5/028) ................................................................ 7 3.3.4 Volumetric Flow Rate and Moisture Data ....................................... 8

4.0 DISCUSSION OF RESULTS ............................................................................... 9

APPENDICES

A MEASUREMENT PROCEDURES .................................................................... A

B QUALITY ASSURANCE .................................................................................... B B.1 Quality Assurance Program Summary and ARB Certification B.2 CEMS Performance and Equipment Calibration Data B.3 Calibration Gas Certificates

C FIELD DATA SHEETS ....................................................................................... C C.1 Sampling Location C.2 CEMS Test Data C.3 Particulate Matter Diluent Gases

D EMISSION CALCULATIONS ........................................................................... D D.1 General Emission Calculations D.2 Emission Calculation Spreadsheets D.3 Example Calculations

E LABORATORY REPORTS .................................................................................E

F PERMITS TO OPERATE .................................................................................... FKnauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

09090.6m, SCAQMD 1 

### SECTION 1.0

INTRODUCTION

The Avogadro Group, LLC (Avogadro) was cont racted by Knauf GmbH (Knauf) to perform a series of air emission compliance tests on the glass melting furnace at their Shasta Lake, California facility. The test ing was conducted to determine compliance with the particulate matter emission limitations of Permits to Operate #97-PO-27a and #97-PO-28a issued by the Shasta County Air Quality Management District (SCAQMD) and the Prevention of Significant Deteriorati on (PSD) Permit to Operate No. NSR 4-4-4, SAC 03-01 issued by the United States Envi ronmental Protection Agency, Region IX (EPA).

The test program was conducted on August 5, 2009 by Mark Stanfield, Doug Morical and Nishad Patel of Avogadro. Unit operations were coordinated by Randall Peterson of Knauf. Rob Stahl of SCAQMD was present to observe portions of the testing. The tests were conducted according to the July 7, 2009 source test protocol that was submitted to SCAQMD and EPA.

Testing was performed to determine em issions of the following parameters:

 Emission parameters:
 Total Particulate Matter (PM) – lb /hr, tons/yr, lb/ton of glass

 Supporting data:
 O 2 and CO 2 - % volume dry  Stack gas volumetric flow rate (dscfm) and moisture content (%)

This report provides descriptions of the fac ility and test location, descriptions of the testing program, test methods and procedures , test results, and a summary of our quality assurance program. The tests results are summ arized in Table 1-1. Detailed results of individual test runs are presented in S ection 4.0. All supporting data including process data, field data sheets, laboratory reports, calc ulations and spreadsheets are located in the appendices.Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

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### TABLE 1-1 SUMMARY OF PARTICULATE MATTER TEST RESULTS KNAUF GMBH – GLA SS MELTING FURNACE AUGUST 5, 2009

Method 5/202

Test Results Method 5/028 Test Results Applicable Standards

Stack Gas Parameters

O 2 , % volume dry 20.71 20.71 -- CO 2 , % volume dry 0.454 0.454 -- Stack temperature, oF 142.7 142.5 -- Moisture content, % 2.14 2.08 -- Volumetric flow rate, acfm 25,109 25,896 -- Volumetric flow rate, dscfm 20,334 20,994 -- Particulate Matter (PM) --

F1⁄2 (filter), gr/dscf 0.0000 0.0000 -- F1⁄2 (acetone), gr/dscf 0.0002 0.0001 -- Total F1⁄2 grain loading, gr/dscf 0.0002 0.0001 -- F1⁄2 (filter), lb/hr 0.000 0.000 -- F1⁄2 (acetone), lb/hr 0.027 0.022 -- Total F1⁄2 mass emissions, lb/hr 0.027 0.022 -- B1⁄2 (aqueous), gr/dscf 0.0003 0.0003 -- B1⁄2 (organic), gr/dscf 0.0003 0.0003 -- Total B1⁄2 grain loading, gr/dscf 0.0006 0.0006 -- B1⁄2 (aqueous), lb/hr 0.054 0.059 -- B1⁄2 (organic), lb/hr 0.055 0.057 -- Total B1⁄2 mass emissions, lb/hr 0.109 0.116 -- Total grain loading, gr/dscf 0.0008 0.0008 -- Total mass emissions, lb/hr 0.137 0.138 1.0 Total mass emissions, tons/yr 0.599 0.605 4.4

Note: Tons/yr mass emissions are calculated based on 8,760 hours/yr of production. Emission data, expressed in lb/ton of glass units, are reported separately by Knauf.Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

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### SECTION 2.0

SOURCE LOCATION INFORMATION

2.1 FACILITY DESCRIPTION

Knauf Insulation GmbH operates a fiberglass manuf acturing facility located in Shasta Lake, California. In operation since 2002, this plant produces light density glass insulation for use in a wide variety of reside ntial, commercial and i ndustrial applications.

During this test program, emission testing was performed on the facility’s glass melting furnace exhaust stack.



### 2.2 SAMPLING LOCATION

The glass melting furnace exhaust stack is a ve rtical, cylindrical stack with a 37 inch diameter. The duct is equipped with two sa mpling ports oriented 90 degrees from each other on the same horizontal plane. The por ts are located greater than two diameters upstream and eight diameters down stream from the nearest flow disturbances. Sampling was performed at 12 traverse points (6 per diameter). The ports are accessible from a platform approximately three fe et above the main floor deck.

Diagrams of the sampling location and traverse point locations are presented in Appendix C.1.Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

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### SECTION 3.0

TEST DESCRIPTION

3.1 PROGRAM OBJECTIVES

The objective of the program was to determine the compliance status of the source with respect to the facility’s operating permit conditions. The applicable standards are summarized in Table 3-1.



### TABLE 3-1 PERMIT CONDITIONS KNAUF GMBH – GLASS FURNACE STACK

Pollutants Applicable Standards

Total Particulate Matter (PM) Emission Rate, lb/hr 1.0 Emission Rate, tons/yr 4.4 Emission Rate, lb/ton of glass pulled 0.5



### 3.2 TEST CONDITIONS AND TEST PROGRAM SCHEDULE

Testing was performed during normal pro cess operating conditions established and maintained by Knauf personnel. Avogadro communicated with Knauf staff throughout the testing to ensure that representative operating conditions were maintained. Operating data were collected by Knauf during the te st periods. These data are submitted under separate cover.

All tests were performed on August 5, 2009. The test schedule is summarized in Table 3-2.Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

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### TABLE 3-2 TEST SCHEDULE KNAUF GMBH – GLA SS MELTING FURNACE

Day Activity Test Runs Run Duration

August 5, 2009 Emission testing PM (5/O28) PM (5/202) Vol. flow rate & moisture O 2 , CO 2 1A, 2A, 3A 1B, 2B, 3B w/PM 1, 2, 3 120 min. ea. 120 min. ea. 120 min. ea. 120 min. ea.



### 3.3 TEST PROCEDURES

The test procedures used in this program ar e summarized in Table 3- 3. Descriptions of standard procedures are included in Appendix A. Additional information on site-specific applications and any modifications to pro cedures are described in the following subsections. Where any conflicts exist in the de scriptions, the specific description here in Section 3.3 will take precedence.



### TABLE 3-3 TEST PROCEDURES KNAUF GMBH – GLA SS MELTING FURNACE

Parameter Measurement Principle Reference Method Method Detection Limit

O 2 Paramagnetism EPA 3A (modified) 2% of span

CO 2 Non-dispersive infrared EP A 3A (modified) 2% of span

PM Gravimetry EPA 5/202 0.0005 gr/dscf EPA 5/OTM-028 0.0005 gr/dscf Moisture cont. Gravimetry EPA 4 --
Stack flow rate Pitot tube / temp. traverse EPA 1, 2 --Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

09090.6m, SCAQMD 6 3.3.1 Diluent Gases

Diluent gaseous emission tests (O 2 and CO 2 ) were performed concurrently with each particulate matter test. The 120-minute integrated samples we re collected into Tedlar bags via an Orsat sampling system incorporat ed in the EPA Method 5 metering console. The samples were then introduc ed directly to the analyzer s at the continuous emission monitoring system (CEMS) manifold in the same manner as the calibration error check procedure described below.

Concentrations were measured using Avoga dro’s dry extractive CEMS described in Appendix A. This system meets the re quirements of EPA and CARB methods for gaseous species.

The sample conditioning and delivery sy stem includes components to extract a representative sample from the source, rem ove the moisture and particulate matter from the sample stream, and transport the sample to the analyzers. The primary components of this subsystem are:

1) A quartz, titanium, stainless steel or glass probe - heated or insulated as necessary to avoid condensation, 2) Sample filtration – filters located on the probe, pump, and prior to all of the analyzers for removal of particulate matter, 3) Teflon tubing - connecting the prob e to the sample conditioner and the sample conditioner to the analyzer ma nifold - heated or insulated as necessary to avoid condensation, 4) Sample conditioner - glass or stainless steel flasks immersed in an ice bath to remove the moisture from the sample gas stream, 5) Vacuum pump - a leak-free pump with Teflon diaphragm to transport the sample gas through the system, 6) Sample manifold - a distribution syst em, constructed of stainless steel and Teflon tubing, to direct sample gas to the analyzers, and 7) Sample flow rate control - a seri es of rotameters, vacuum gauges and pressure gauges connected to the manifold used to maintain the appropriate sample flow rates.

The calibration gas system utilizes only EPA Protocol gases to verify the operation, linearity, and range settings of the electronic analyzers. The sample gas system allows for the introduction of the protocol gases to the analyzers either directly through the manifold (calibration error check - performe d once daily) or thr ough the sampling system (system bias check - performed with each run).Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

09090.6m, SCAQMD 7 The electronic analyzers are rack-mounted and are maintained in the mobile lab. The data recording and acquisition system is based on a digital system known as STRATA. It includes software for contro lling the collection of calib ration and emission monitoring data, and hardware for connection of the anal yzer outputs to the reco rding system. Test results can be provided in three forms: on-s ite printouts of the digitized data, diskette recordings of the digitized data, and printo uts of strip charts from the monitoring data.

3.3.2 Particulate Matter (5/202)

Emissions of total particulate matter (PM) we re measured at the furnace stack according to EPA Methods 5 and 202. Three 120-minute te st runs were conducted. The apparatus included a heated sampling probe, constructed of Pyrex, attached to an oven containing a heated glass filter holder and filter. The filter holder was connected by a length of Teflon tubing to the impinger train. The impinger tr ain was connected to the control box, which contained the sampling pump and dry gas meter. The sampling rate and nozzle size were chosen to allow isokinetic samp ling at the calculated rate.

The filterable “front-half” PM was recovered from the sampling apparatus as described in the method. The samples included the probe a nd nozzle wash (water and acetone), filter, and rinses from the front-half of the filter hol der (water and acetone). The samples were analyzed gravimetrically to determine the quantity of filterable PM collected.

The condensable PM or “back-half” fraction of the PM was recovered and analyzed as described in EPA Method 202 including the optional post-test nitrogen purge. The impinger contents, the sample line, and the back-half of the filter holder were recovered with water rinses into a sample container. Each collected sample was extracted with dichloromethane in a separatory funnel, an d the aqueous and orga nic fractions were separated for analysis. The analysis then included gravimetric measurement of the residue from the aqueous and organic fractio ns. The organic fraction was reduced to dryness at room temperature, and the aqueous fraction was dried at 105 degrees F for analysis of the residue weight. The resu lts were added together to determine the concentration of condensab le particulate matter.

3.3.3 Particulate Matter (5/028)

Emissions of total particulate matter (PM) we re measured at the furnace stack according to EPA Methods 5 and OTM 028. Three 120- minute test runs were conducted. The apparatus included a heated sampling probe, c onstructed of Pyrex, attached to an oven containing a heated glass filter holder and filter. The filter holder was connected by a heated length of Teflon tubing to the impinger train. The impinger train was connected to the control box, which contained the sampling pump and dry gas meter. The sampling rate and nozzle size were chosen to allow isokinetic sampling at the calculated rate.Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

09090.6m, SCAQMD 8 The filterable “front-half” PM was recovered from the sampling apparatus as described in the method. The samples included the probe a nd nozzle wash (water and acetone), filter, and rinses from the front-half of the filter hol der (water and acetone). The samples were analyzed gravimetrically to determine the quantity of filterable PM collected.

The condensable PM or “back-half” fraction of the PM was recovered and analyzed as described in EPA Other Test Method (OTM ) 028. The impinger contents, the sample line, and the back-half of the filter holder were recovered with water rinses into a sample container. This rinse procedure was then repeated with acetone followed by dichloromethane. These solvent rinses were co llected into a separate sample container. Each collected aqueous sample was extracte d with dichloromethane in a separatory funnel, and the aqueous and organic fractions were separated for analysis. The analysis then included gravimetric measurement of the residue from the aqueous and organic fractions. The results were added together to determine the concentration of condensable particulate matter.

3.3.4 Volumetric Flow Rate and Moisture Content

Stack gas volumetric flow rates were determined according to EPA Methods 2 and 4. Velocity traverses were performed on the exha ust stacks using an S-type Pitot tube and a manometer. Velocity traverse data were co llected as part of the particulate emission tests. Similarly, stack gas moisture data were collected in conjunction with the particulate sampling. The volum etric flow rate results we re corrected to standard conditions and used with the concentrati on data to calculate mass emission rates.Knauf Insulation, GmbH September 4, 2009 2009 PM Emission Test

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### SECTION 4.0

DISCUSSION OF RESULTS

Particulate matter testing was performed using EPA Methods 5/202 and 5/ OTM 028 concurrently.

The test results for each method are summarize d in Table 1-1. Results of the individual test runs are presen ted in Table 4-1.

Referring to Tables 1-1 and 4-1, the particul ate matter emissions test results for both Methods 5/202 and 5/028 are well below the a pplicable standards (AS) for the glass melting furnace stack for the average of all me thod specific test runs as well as for each individual test run.

Additional information is included in the appe ndices. Appendix A contains descriptions of standard measurement procedures. A ppendix B presents th e quality assurance information, including instrument calibration data . Raw field data sheets are included in Appendix C. Appendix D presents the gene ral and specific equations used for the emissions calculations and computer spreadsh eets. Laboratory data are presented in Appendix E. The facility’s operating permits are presented in Appendix F.Knauf Insulation, GmbHSeptember 4, 20092009 PM Emission Test09090.6m, SCAQMD 10TABLE 4-1SUMMARY OF PARTICULATEMATTER TESTRESULTSKNAUF GMBH – GLASS MELTING FURNACEAUGUST 5, 2009Test No:1-PM-2021-PM-028 2-PM-202 2-PM-028 3-PM-202 3-PM-028 202 AVG 028 AVGDate:8/5/09 8/5/09 8/5/09 8/5/09 8/5/09 8/5/09----Time:0715-0921 0715-0921 1005-1208 1005-1209 1229-1431 1229-1431 -- --O2, % volume dry:20.73 20.73 20.71 20.71 20.69 20.69 20.71 20.71CO2, % volume dry:0.426 0.426 0.422 0.422 0.512 0.512 0.454 0.454Stack gas temperature, oF:133.7 133.0 143.4 143.1 150.9 151.5 142.7 142.5Moisture content, % by vol.2.05 2.00 2.07 2.04 2.29 2.20 2.14 2.08Volumetric flow rate, acfm24,857 26,240 25,383 25,907 25,086 25,541 25,109 25,896Volumetric flow rate, dscfm20,548 21,727 20,495 20,935 19,960 20,321 20,334 20,994F1⁄2 (filter), gr/dscf 0.0000 0.0000 0.00000.0000 0.0000 0.0000 0.0000 0.0000F1⁄2 (acetone), gr/dscf 0.0004 0.0003 0.00010.0000 0.0000 0.0000 0.0002 0.0001Total F1⁄2 grain loading, gr/dscf 0.0004 0.0003 0.0001 0.0000 0.0000 0.0000 0.0002 0.0001F1⁄2 (filter), lb/hr 0.000 0.000 0.0000.000 0.000 0.000 0.000 0.000F1⁄2 (acetone), lb/hr 0.065 0.059 0.012 0.005 0.005 0.001 0.027 0.022Total F1⁄2 mass emissions, lb/hr 0.065 0.0590.012 0.005 0.005 0.001 0.027 0.022B1⁄2 (aqueous), gr/dscf 0.0003 0.0004 0.00030.0003 0.0002 0.0003 0.0003 0.0003B1⁄2 (organic), gr/dscf 0.0001 0.0002 0.0004 0.0005 0.0005 0.0003 0.0003 0.0003Total B1⁄2 grain loading, gr/dscf 0.0004 0.0006 0.0008 0.0008 0.0007 0.0006 0.0006 0.0006B1⁄2 (aqueous), lb/hr 0.059 0.069 0.061 0.057 0.043 0.050 0.054 0.059B1⁄2 (organic), lb/hr 0.015 0.034 0.072 0.090 0.079 0.049 0.055 0.057Total B1⁄2 mass emissions, lb/hr 0.074 0.103 0.133 0.147 0.122 0.099 0.109 0.116Knauf Insulation, GmbHSeptember 4, 20092009 PM Emission Test09090.6m, SCAQMD 11TABLE 4-1 (CONTINUED)SUMMARY OF PARTICULATEMATTER TESTRESULTSKNAUF GMBH – GLASS MELTING FURNACEAUGUST 5, 2009Test No: 1-PM-202 1-PM-028 2-PM-202 2-PM-028 3-PM-202 3-PM-028 202 AVG 028 AVGDate:8/5/09 8/5/09 8/5/09 8/5/09 8/5/09 8/5/09----Time:0715-0921 0715-0921 1005-1208 1005-1209 1229-1431 1229-1431 -- --O2, % volume dry:20.73 20.73 20.71 20.71 20.69 20.69 20.71 20.71CO2, % volume dry:0.426 0.426 0.422 0.422 0.512 0.512 0.454 0.454Stack gas temperature, oF:133.7 133.0 143.4 143.1 150.9 151.5 142.7 142.5Moisture content, % by vol.2.05 2.00 2.07 2.04 2.29 2.20 2.14 2.08Volumetric flow rate, acfm24,857 26,240 25,383 25,907 25,086 25,541 25,109 25,896Volumetric flow rate, dscfm20,548 21,727 20,495 20,935 19,960 20,321 20,334 20,994Total grain loading, gr/dscf 0.0008 0.0009 0.0008 0.0008 0.0007 0.0006 0.0008 0.0008Total mass emissions, lb/hr 0.138 0.162 0.145 0.152 0.127 0.100 0.137 0.138Total mass emissions, tons/yr 0.606 0.7100.635 0.667 0.555 0.439 0.599 0.605