FORM A-1PARENT COMPANY INFORMATIONI. Parent Company / Legal Corporate Owner Information1. Legal Parent Company / Legal Corporate NameOwens Corning Insulating Systems, LLC2. AddressOne Owens Corning Parkway3. CityToledo4. StateOhio5. Zip Code436596. CountyLucas7. Size of Company (approximate number of employees includingall subsidiaries, branches, and related establishments owned):16,280FORM A-2FACILITY INFORMATIONII. Facility InformationFacility NameOwens Corning Insulating Systems, LLCFacility AddressStreet3700 North Interstate 35 EastCityWaxahachieStateTexasZip Code751657. Size of Company (approximate number of employees including all subsidiaries, branches, and related establishments owned):EllisFacility CoordinatesLatitude (decimal degrees, six decimal places)32.441478Longitude (decimal degrees, six decimal places)96.848342Specific location represented (e.g., front door of main building, centroidof property, etc.)Centroid of PropertyNumber of employees attached to the wool fiberglass manufacturingfacility:346Design capacity of the plant (tons/yr)Type(s) of process(es) (rotary spin, flame attenuation) at this plantRotary SpinOperation schedule24days/yr365Identify what state and local air pollution rulesand regulations, includingpermit requirements, your plant is subject to. (Please provide copies ofpermit(s) and permit IDs)Applicable requirements referenced in Title V Permit O1094 and StateOperating Permit 6093. Provided on CD.III. Technical ContactNameMike PettisTechnical Contact TitleISB Environmental LeaderTelephone740-877-7087Facsimile (Fax)740-328-2696EmailMike.Pettis@owenscorning.comFORM A-2FACILITY INFORMATIONIV. OtherIs the facility a major source of HAP?Yes, currently.If No, did the facility take a limit of its potential HAP emissions to avoidclassification as a major source:N/ADoes the facility manufacture other productsin addition to woolfiberglass?NoIf Yes, list the other products manufacturedat the facility.N/AAre there any HAP emissions associated with any co-located facilities?List unit operations, e.g., boiler, and pollutant/emissions.N/AFORM B-1PLANT OPERATIONSI. Overview of Plant OperationsNumber of process lines. Include lines that are currentlyoperational or that are temporarily shutdown. (Donotinclude lines permanently shutdown).3For each process line:Process Line 1Process Line 2Process Line 3Process line identification names or numbersV1V2V3Type of process line (e.g., rotary spin, flame attenuation) Rotary Spin Rotary Spin Rotary SpinMaximum annual production rate (tons/yr)7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelatedestablishments owned):47 37 32Remaining economic life of process line (yrs) N/A.Continuedmaintenance canmaintain indefinite life.N/A. Continuedmaintenance canmaintain indefinite life.N/A. Continuedmaintenance canmaintain indefinite life.List of products produced and most recent annualproduction (tons/yr; specify year) for each productPlease attach detailed schematics of each process line. Provided on CD. Provided on CD. Provided on CD.FORM B-2PLANT OPERATIONSII. Process - Raw materials Handling and StorageMolten glass preparationRaw materials and proportions by wt (%) Industry information provided for representativeness.Soda ash (9%), Borax (12%), Cullet (34%), Limestone(9%) and Sand (31%).Method(s) of conveying each raw material to furnace/pots Raw materials are unloaded and conveyedinto a bucketelevator, which carries raw materials to individualstoragesilos. From the silos batch materials are gravityfed into ascale hopper and then into a mixer. For V2/V3 themixedbatch is pneumatically conveyed to mixed batch storagesilos. The mixed batch is auger fed into the batchchargersurge hopper and then gravity feeds into the batchcharger hopper. Batch is delivered into the V2 andV3furnaces from the batch charger. For V1 the mixedbatchdumps onto a transport conveyor and is mechanicallyconveyed to the mixed batch storage silos. The mixedbatch is gravity fed into the V1 batch chargers andthenauger feeds into the melter.Binder and AdditivesList each raw material, including premixed materials, in the binderformulation and its proportion by wt (%)List steps in preparing binder, including storage temperature (°F)and holding time (hrs)The above listed binder ingredients are metered intobinder mix tanks. Mixed binder is transferred to arecirculating tank. All storage temperatures are ambient.Total holding time is approximately 45 minutes.7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):Cost of binder ($/gal) for most recent year (specify year)Are binder storage and mixing tanks vented tooutside/inside? Binder storage tanks are vented inside and the bindermixing tanks are vented outside.Method of treating vent air from storage andmix tanksN/AEmission control during liquid raw material transfer from vehiclesto storage tanks.N/AFORM B-2PLANT OPERATIONSII. Process - Raw materials Handling and StorageDescribe future source reduction plans and schedules toreformulate binders; List each constituent, proportions wt (%), cost($/gal) for reformulationFORM B-3PLANT OPERATIONSIII. Process - Glass Melting FurnaceFor each Glass Melting Furnace:Furnace 1Furnace 2Furnace 3Process unit identification name/numberV1 Furnace (01MELT)V2 Furnace (02MELT)V3 Furnace (03MELT)Process line(s) served (identification name/number) V1 V2 V3Latitude (decimal degrees, six decimal places) 32.4399942 32.4396072 (east) and32.439649232.4394836 (east) and32.4395267 (west)Longitude (decimal degrees, six decimal places) -96.8497775 -96.8491411 (east) and -96.8492286-96.8488961 (east) and -96.8489864 (west)Stack or vent height (units) 53.42 ft 57.78 ft.(each) 57.45 ft. (east) and 57.28 ft.(west)7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and relatedestablishments owned):2.92 ft. 4.00 ft. (each) 4.00 ft. (each)Manufacturer and modelOxy-FuelCold TopCold TopDate of original installation199919731978Estimate of remaining lifetime (yrs) N/A. Continued maintenancecan maintain indefinite life.N/A. Continued maintenancecan maintain indefinite life.N/A. Continued maintenancecan maintain indefinite life.Major rebuilds:What constitutes a major rebuildFrequency of a major rebuildN/AN/AN/ACost of typical major rebuildN/AN/AN/ADate of last major rebuildN/AN/AN/APurpose of last major rebuildN/AN/AN/AIncrease or decrease in emissionsN/AN/AN/AFuel type: electric, gas, or oil Gas/Oxy Electric heat with Natural GasboostElectric heat with Natural GasboostFuel consumption rate (KW/ton of glass or Btu/ton ofglass)Chromium CompoundsChromium CompoundsChromium CompoundsDesign production rate (tons/day)Actual glass pull rate (tons/day)Vent gas flow rate (acfm @°F)Temperature (°F) of molten glass in furnace andforehearth (if applicable)FORM B-3PLANT OPERATIONSIII. Process - Glass Melting FurnaceFor each Glass Melting Furnace:Furnace 1Furnace 2Furnace 3Process unit identification name/numberV1 Furnace (01MELT)V2 Furnace (02MELT)V3 Furnace (03MELT)Process line(s) served (identification name/number) V1 V2 V3Nature and frequency of routine/preventive maintenanceproceduresDaily, visible inspection ofbatch charge operations,furnace condition and burner /oxygen supply system.Repairs and replacements areroutinely completed whenneed is identified. Generalmaintenance activities followa prescribed schedule that isdetailed in the maintenancetracking system. Refractoryrepairs are completedinfrequently and only asnecessary.General maintenanceactivities follow a prescribedschedule that is detailed in themaintenance tracking system.Basic, routine repairs andreplacements are performedweekly for the batch charger.Repairs to the electricalsystems, which includeselectrodes and regulatingtransformers, are completedevery 30 days. Refractoryrepairs are completedinfrequently and only asnecessary.General maintenanceactivities follow a prescribedschedule that is detailed in themaintenance tracking system.Basic, routine repairs andreplacements are performedweekly for the batch charger.Repairs to the electricalsystems, which includeselectrodes and regulatingtransformers, are completedevery 30 days. Refractoryrepairs are completedinfrequently and only asnecessary.Describe process modification(s) since 1999 that reduceemissionsThe Company hasestablished goals to reducethe environmental footprint ofour manufacturing operationsas part of our sustainabilityefforts. These goals arefocused on reducing waste-tolandfill, GHG, waterconsumption, VOC's,particulate matter, NOx andenergy.The Company hasestablished goals to reducethe environmental footprint ofour manufacturing operationsas part of our sustainabilityefforts. These goals arefocused on reducing waste-tolandfill, GHG, waterconsumption, VOC's,particulate matter, NOx andenergy. Installed batchwetting.The Company hasestablished goals to reducethe environmental footprint ofour manufacturing operationsas part of our sustainabilityefforts. These goals arefocused on reducing waste-tolandfill, GHG, waterconsumption, VOC's,particulate matter, NOx andenergy. Installed batchwetting.Describe future source reduction plans and schedules None currently approved orscheduled at this time.None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-4PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame AttenuationFor each Forming Operation -- Rotary Spin/Flame AttenuationForming Operation 1Forming Operation 2Process unit identification name/numberV1 Forming (01FORM)V2 Forming (02FORM)Process line(s) served (identification name/number)V1V2Latitude (decimal degrees, six decimal places)32.440155332.4401Longitude (decimal degrees, six decimal places)-96.8494169-96.8489064Stack or vent height (units)63.50 ft.76.33 ft.7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):9.78 ft. 10.50 ft.Number of fiber forming devices (spinners) per line.Method of attenuating fiber (e.g., air, flame, or air and flame).Indicate type of burner used (if flame).Air and Flame Air and FlameIs there a forehearth between the furnace andthe formingsection?Yes YesMajor rebuilds:What constitutes a major rebuild The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the formingemissions. Therefore, thecompany does not considerthese to be major rebuilds forthe purpose of this ICR.The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the formingemissions. Therefore, thecompany does not considerthese to be major rebuilds forthe purpose of this ICR.Frequency of a major rebuildN/AN/ACost of typical major rebuildN/AN/ADate of last major rebuildN/AN/APurpose of last major rebuildN/AN/AIncrease or decrease in emissionsN/AN/AIf modular, number of modules and plenumsPresence of water overspray and application rate (gpm)Other material applied and application rate (gpm)NoneNoneFORM B-4PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame AttenuationFor each Forming Operation -- Rotary Spin/Flame AttenuationForming Operation 1Forming Operation 2Process unit identification name/numberV1 Forming (01FORM)V2 Forming (02FORM)Process line(s) served (identification name/number)V1V2Temperature of glass fiber when binder is applied (°F)Temperature of binder when applied to fibers(°F)Method of evenly distributing fibers onto forming conveyor Compressed air lapping system Compressed air lapping systemFormed mat thickness (in.)1"-6" as formed, up to 15" onramp.1"-6" as formed, up to 15" onramp.Forming air flow rate (acfm @ °F)Percent of forming air recirculated and percent exhausted None recirculated, 100%exhausted.None recirculated, 100%exhausted.Nature and frequency of routine/preventive maintenanceproceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.Describe process modification(s) since 1999 that reduceemissionsDescribe future source reduction plans and schedules None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-4PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame AttenuationFor each Forming Operation -- Rotary Spin/Flame AttenuationProcess unit identification name/numberProcess line(s) served (identification name/number)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):Number of fiber forming devices (spinners) per line.Method of attenuating fiber (e.g., air, flame, or air and flame).Indicate type of burner used (if flame).Is there a forehearth between the furnace andthe formingsection?Major rebuilds:What constitutes a major rebuildFrequency of a major rebuildCost of typical major rebuildDate of last major rebuildPurpose of last major rebuildIncrease or decrease in emissionsIf modular, number of modules and plenumsPresence of water overspray and application rate (gpm)Other material applied and application rate (gpm)Forming Operation 3V3 Forming (03FORM)V332.4400536-96.848743961.92 ft.13.70 ft.Air and FlameYesThe company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the formingemissions. Therefore, thecompany does not considerthese to be major rebuilds forthe purpose of this ICR.N/AN/AN/AN/AN/ANoneFORM B-4PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame AttenuationFor each Forming Operation -- Rotary Spin/Flame AttenuationProcess unit identification name/numberProcess line(s) served (identification name/number)Temperature of glass fiber when binder is applied (°F)Temperature of binder when applied to fibers(°F)Method of evenly distributing fibers onto forming conveyorFormed mat thickness (in.)Forming air flow rate (acfm @ °F)Percent of forming air recirculated and percent exhaustedNature and frequency of routine/preventive maintenanceproceduresDescribe process modification(s) since 1999 that reduceemissionsDescribe future source reduction plans and schedulesForming Operation 3V3 Forming (03FORM)V3Compressed air lapping system1"-6" as formed, up to 15" onramp.None recirculated, 100%exhausted.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.None currently approved orscheduled at this time.FORM B-5PLANT OPERATIONSV. Process - CuringFor eachCuring Oven:Curing Oven 1Curing Oven 2Process unit identification name/numberV1 Curing (01CURE)V2 Curing (02CURE)Process line(s) served (identification name/number) V1 V2Latitude (decimal degrees, six decimal places)32.440155332.4401Longitude (decimal degrees, six decimal places)-96.8494169-96.8489064Stack or vent height (units)63.50 ft.76.33 ft.7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):9.78 ft. 10.50 ft.Method of curingManufacturer and modelOC Proprietary DesignOC Proprietary DesignDate of original installation19631973Major rebuilds:What constitutes a major rebuild The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the oven emissions.Therefore, the company doesnot consider these to be majorrebuilds for the purpose of thisICR.The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the oven emissions.Therefore, the company doesnot consider these to be majorrebuilds for the purpose of thisICR.Frequency of a major rebuildN/AN/ACost of typical major rebuildN/AN/ADate of last major rebuildN/AN/APurpose of last major rebuildN/AN/AIncrease or decrease in emissionsN/AN/AFuel type: electric, gas, or oilNatural GasNatural GasFuel consumption rate (KW/hr or BTU/hr)inlet2.5 - 5%2 - 4%outlet<0.5%<0.5%FORM B-5PLANT OPERATIONSV. Process - CuringFor eachCuring Oven:Curing Oven 1Curing Oven 2Process unit identification name/numberV1 Curing (01CURE)V2 Curing (02CURE)Process line(s) served (identification name/number) V1 V2Air flow rate (acfm @°F) from curing26,000 acfm @ 450°F26,000 acfm @ 450°FExhaust air temperature (°F)450°F450°FResidence time of product (mins)Binder content of cured product (LOI)Nature and frequency of routine/preventivemaintenance proceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.Describe process modification(s) since 1999 thatreduce emissionsDescribe future source reduction plans andschedulesNone currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-5PLANT OPERATIONSV. Process - CuringFor eachCuring Oven:Process unit identification name/numberProcess line(s) served (identification name/number)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):Method of curingManufacturer and modelDate of original installationMajor rebuilds:What constitutes a major rebuildFrequency of a major rebuildCost of typical major rebuildDate of last major rebuildPurpose of last major rebuildIncrease or decrease in emissionsFuel type: electric, gas, or oilFuel consumption rate (KW/hr or BTU/hr)inletoutletCuring Oven 3V3 Curing (03CURE)V332.4400536-96.848743961.92 ft.13.70 ft.OC Proprietary Design1978The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the oven emissions.Therefore, the company doesnot consider these to be majorrebuilds for the purpose of thisICR.N/AN/AN/AN/AN/ANatural Gas2 - 4%<0.5%FORM B-5PLANT OPERATIONSV. Process - CuringFor eachCuring Oven:Process unit identification name/numberProcess line(s) served (identification name/number)Air flow rate (acfm @°F) from curingExhaust air temperature (°F)Residence time of product (mins)Binder content of cured product (LOI)Nature and frequency of routine/preventivemaintenance proceduresDescribe process modification(s) since 1999 thatreduce emissionsDescribe future source reduction plans andschedulesCuring Oven 3V3 Curing (03CURE)V326,000 acfm @ 450°F450°FGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.None currently approved orscheduled at this time.FORM B-6PLANT OPERATIONSVI. Process - CoolingFor eachCooling Operation: Cooling Operation 1 Cooling Operation 2Process unit identification name/number V1 Cooling (01COOL) V2 Cooling (02COOL)Process line(s) served (identification name/number) V1 V2Latitude (decimal degrees, six decimal places)32.440341932.4403375Longitude (decimal degrees, six decimal places)-96.8492069-96.8487631Stack or vent height (units)45.75 ft46.5 ft.7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):2.92 ft. 3.5 ft.Cooling air flow rate (acfm @°F)110,000 - 120,000 acfm @ 150°F25,000 - 35,000 acfm @ 112 °FPercentage of cooling air recirculated (if any) None NoneCooling air temperature (°F) 120 - 150 °F 100 -150 °FNature and frequency of routine/preventivemaintenance proceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.Describe process modification(s) since 1999 thatreduce emissionsFORM B-6PLANT OPERATIONSVI. Process - CoolingFor eachCooling Operation: Cooling Operation 1 Cooling Operation 2Process unit identification name/number V1 Cooling (01COOL) V2 Cooling (02COOL)Process line(s) served (identification name/number) V1 V2Describe future source reduction plans and schedules None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-6PLANT OPERATIONSVI. Process - CoolingFor eachCooling Operation:Process unit identification name/numberProcess line(s) served (identification name/number)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):Cooling air flow rate (acfm @°F)Percentage of cooling air recirculated (if any)Cooling air temperature (°F)Nature and frequency of routine/preventivemaintenance proceduresDescribe process modification(s) since 1999 thatreduce emissionsCooling Operation 3V3 Cooling (03COOL)V332.4402581-96.848544463.33 ft.3.5 ft.10,000 - 25,000 acfm @ 123 °FNone100 - 150 °FGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.FORM B-6PLANT OPERATIONSVI. Process - CoolingFor eachCooling Operation:Process unit identification name/numberProcess line(s) served (identification name/number)Describe future source reduction plans and schedulesCooling Operation 3V3 Cooling (03COOL)V3None currently approved orscheduled at this time.FORM B-7PLANT OPERATIONSVII. Process - Use of SolventsUse of SolventsVolatile solvents used at your facility (where and how used) N/A. No HAP-containing solvents usedin themanufacturing process.List each solvent used and quantity (gal/yr) N/A. No HAP-containing solvents used in themanufacturing process.Emission control device(s) used to control emissions from solventusage/storage?N/A. No HAP-containing solvents used in themanufacturing process.FORM B-8PROCESS OPERATIONSVIII. Pollution PreventionPlease describe any work practices, pollution prevention techniques,and control strategies evaluated and/or implementedat each processunit at your facility (e.g., binder reformulation,alternative fuels usage,etc.) to reduce emissions of PM and HAPs you identified in Form E.You must specify the year in which the facility implemented thepractice/technique and identify the emission reductions (if measured)from these practices/techniques.FORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:ESP 1Process line(s) (identification name/number)V1 Furnace (01MELT)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)V1 Furnace (01MELT)Latitude (decimal degrees, six decimal places)32.4399942Longitude (decimal degrees, six decimal places)-96.8497775Stack or vent height (units)53.42 ft7. Size of Company (approximate number of employees includingall subsidiaries, branches, and related establishments owned):2.92 ft.Manufacturer and modelAlstom Power 1 FTA 3x45F-35-40Date of original installation2000Number of collection plates and configuration90/fieldGas flow rate to ESP (acfm @°F)19,792 acfm @ 408°FInlet gas temperature (°F)408°FOutlet gas temperature (°F)389°FInlet grain loading (gr/dscf)0.5271 gr/dscfOutlet grain loading (gr/dscf)0.0180 gr/dscfAverage stack opacity (%)<10%Pressure drop across ESP (in. H2O gauge) 3"Plate area (ft2)16,276 ft2Vendor guarantee on ESP efficiency (attach copy)Yes. Provided on CD.Rappers. Periodic cleaning.Flow rate of plate wash water to ESP (gpm), if applicableN/ATemperature of plate wash water to ESP (°F), if applicableN/ASource of plate wash water used for cleaning,if applicableN/AConcentration (mg/l) of dissolved and suspended solids in platewash water, if applicableN/AConditioning agents used and amounts (in gpmor lbs/hr), ifapplicableN/AAmount of wastewater generated (gpd), if applicableN/AAmount of wastewater recycled (gpd), if applicableN/AAmount of wastewater disposed of (gpd), if applicableN/AMethod of wastewater disposal, if applicableN/AFORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:ESP 1Process line(s) (identification name/number)V1 Furnace (01MELT)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)V1 Furnace (01MELT)Quantity of solid waste collected (lbs/yr) 2,500 lbs. Small quantities ofDEP residue becomescontaminated in the processand must be disposed.Quantity of solid waste recycled (lbs/yr)0 lbsQuantity of solid waste disposed of (lbs/yr)2,500 lbsMethod of solid waste disposalHazardous Waste LandfillNature and frequency of routine/preventive maintenanceproceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Systems are continuouslymonitored and notificationsoccur that initiate maintenance.SIR repair and replacement isconducted as needed.Electrode replacement occurson a a12-15 year cycle.Problems experienced with control device within the last fiveyears; how were problems solved?As reported in Title V deviationreports: electrical malfunction /repaired and reset; mechanicalmalfunction / repaired; andequipment failure / repaired.Continuous monitoring method(s) used to monitor ESPperformance, including parameters monitoredSecondary voltage andamperage of 3rd field.Describe any plans to replace or upgrade ESP None currently approved orscheduled at this time.FORM C-2AIR POLLUTION CONTROLNot applicable to thisfacility.II. ScrubberFor each Scrubber:ScrubberProcess line(s) (identification name/number) N/AEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)N/ALatitude (decimal degrees, six decimal places)N/ALongitude (decimal degrees, six decimal places)N/AStack or vent height (units)N/A7. Size of Company (approximate number of employees includingall subsidiaries, branches, and related establishments owned):N/AManufacturer and modelN/ADate of original installationN/AType (e.g., venturi, orifice)N/AGas flow rate to scrubber (acfm @°F)N/AInlet gas temperature (°F)N/AOutlet gas temperature (°F)N/AInlet grain loading (gr/dscf)N/AOutlet grain loading (gr/dscf)N/AAverage stack opacity (%)N/AWater flow rate to scrubber (gpm) N/APercent of scrubber water from recycled wastewater N/ASource of scrubbing water and type of pretreatment. Substance(s)added as part of pretreatment and amount used (gpmor lbs/hr)N/AN/AConcentration (mg/L) of dissolved and suspended solids inscrubbing waterN/AScrubbing water temperature (°F)N/ALiquid/gas ratio (gal/103acfm)N/APressure drop across scrubber (in. H2O gauge) N/AFORM C-2AIR POLLUTION CONTROLNot applicable to thisfacility.II. ScrubberFor each Scrubber:ScrubberProcess line(s) (identification name/number) N/AEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)N/AAmount of wastewater generated (gpd) N/AAmount of wastewater recycled (gpd) N/AAmount of wastewater disposed of (gpd) N/AMethod of wastewater disposalN/AQuantity of solid waste collected (lbs/yr) N/AQuantity of solid waste recycled (lbs/yr) N/AQuantity of solid waste disposed of (lbs/yr) N/AMethod of solid waste disposalN/AVendor guarantee on scrubber efficiency (attach copy) N/ANature and frequency of preventive maintenance procedures N/AProblems experienced with control device within the last five years;how were problems solved?N/AContinuous monitoring method(s) used to monitor scrubberperformance, including parameters monitoredN/APlans to replace or upgrade scrubber N/AFORM C-3AIR POLLUTION CONTROLIII. Mechanical CollectorNot applicable to thisfacility.For each Mechanical Collector:Mechanical CollectorProcess line(s) (identification name/number) N/AEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)N/ALatitude (decimal degrees, six decimal places)N/ALongitude (decimal degrees, six decimal places)N/AStack or vent height (units)N/AStack or vent diameter (units)N/AManufacturer and modelN/ADate of original installationN/AType of mechanical collectorN/AGas flow rate to collector (acfm @°F)N/AInlet gas temperature (°F)N/AOutlet gas temperature (°F)N/AInlet grain loading (gr/dscf)N/AOutlet grain loading (gr/dscf)N/AAverage stack opacity (%)N/AOverall pressure drop (in. H2O gauge) N/AVendor guarantee on mechanical collector efficiency (attachcopy)N/AQuantity of solid waste collected (lbs/yr) N/AQuantity of solid waste recycled (lbs/yr) N/AQuantity of solid waste disposed of (lbs/yr) N/AMethod of solid waste disposal N/ANature and frequency of preventive maintenance procedures N/AProblems experienced with control device within the last fiveyears; how were problems solved?N/AContinuous monitoring method(s) used to monitor performance,including parameters monitoredN/APlans to replace or upgrade mechanical collector N/AFORM C-4AIR POLLUTION CONTROLIV. Fabric FilterFor each Fabric Filter:Fabric Filter 1 Fabric Filter 2 Fabric Filter 3Process line(s) (identification name/number) V1 V2 V2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)V1 Mix Batch Storage Binand Transfer Conveyor(stack 7)V2 Mix Batch Storage Bin V2 Batch ChargerLatitude (decimal degrees, six decimal places) 32.4397278 32.4395364 32.439565Longitude (decimal degrees, six decimal places) -96.8496564 -96.8491253 -96.8491583Stack or vent height (units)79.78 ft.61.37 ft.65.53 ft.7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):0.55 ft. 0.75 ft. 0.42 ft.Manufacturer and model Farr Model GS-1 Flex Kleen Model 58-BVBS16 III GFlex Kleen Model 58-BVBS-16 III GDate of original installation 2008 1972 1991Number of compartments 1 1 1Number of bags per compartment 1 37 37Filter material and coatings applied Non-WovenSpun BondedPolyester Media - TeflonCoated (PTFE)Polyester - No Coating Polyester - No CoatingFabric weight (oz/yd2)8 16 16Filter surface area (ft2) 200 ft2No data available.348 ft2Gas flow rate to filter (acfm @°F)300 acfm @ 100 °F No data available. 600 acfm @ 100 °FInlet gas temperature (°F)Ambient Ambient AmbientOutlet gas temperature (°F)Ambient Ambient AmbientInlet grain loading (gr/dscf) No data available. No data available. No data available.Outlet grain loading (gr/dscf) No data available. No data available. No data available.<5% <5% <5%Overall pressure drop (in. H2O gauge) 10" No data available. 10"FORM C-4AIR POLLUTION CONTROLIV. Fabric FilterFor each Fabric Filter:Fabric Filter 1 Fabric Filter 2 Fabric Filter 3Process line(s) (identification name/number) V1 V2 V2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)V1 Mix Batch Storage Binand Transfer Conveyor(stack 7)V2 Mix Batch Storage Bin V2 Batch ChargerMethod and frequency of bag cleaning Reversedcompressed air.Compressed air by solenoidson a variable timer.Reversed compressed air.Compressed air by solenoidson a variable timer.Reversed compressed air.Compressed air by solenoidson a variable timer.Vendor guarantee on fabric filter efficiency(attachcopy)None provided. None provided. None provided.Quantity of solid waste collected (lbs/yr) N/A(Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)Quantity of solid waste recycled (lbs/yr) N/A(Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)Quantity of solid waste disposed of (lbs/yr) 0lbs 0 lbs 0 lbsMethod of solid waste disposal N/A N/A N/ANature and frequency of preventive maintenanceproceduresGeneral maintenance repairsas needed. Visualinspections and differentialpressure checks areperformed routinely. Bag orcartridge replacement isperformed as needed.General maintenance repairsas needed. Visualinspections and differentialpressure checks areperformed routinely. Bag orcartridge replacement isperformed as needed.General maintenance repairsas needed. Visualinspections and differentialpressure checks areperformed routinely. Bag orcartridge replacement isperformed as needed.Problems experienced with control device within thelast five years; how were problems solved?None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.Continuous monitoring method(s) used to monitorperformance, including parameters monitoredN/A N/A N/APlans to replace or upgrade fabric filter Nonecurrently approved orscheduled at this time.None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-4AIR POLLUTION CONTROLIV. Fabric FilterFor each Fabric Filter:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):Manufacturer and modelDate of original installationNumber of compartmentsNumber of bags per compartmentFilter material and coatings appliedFabric weight (oz/yd2)Filter surface area (ft2)Gas flow rate to filter (acfm @°F)Inlet gas temperature (°F)Outlet gas temperature (°F)Inlet grain loading (gr/dscf)Outlet grain loading (gr/dscf)Overall pressure drop (in. H2O gauge)Fabric Filter 4 Fabric Filter 5V3 V3V3 Mix Batch Storage Bin V3 Batch Charger32.4395042 (east) and32.4395147 (west)32.4394747-96.8490314 (east) and -96.8490539 (west)-96.849009779.03 ft. (each)55.78 ft.0.78 ft. (each) 0.42 ft.Flex Kleen Model 58-BVBS16 III GFlex Kleen Model 58-BVBS-16 III G1978 19911 (each) 1 (each)45 (each) 16 (each)Polyester - No Coating Polyester - No Coating16 16424 ft2(each) 230 ft2(each)No data available. 400 acfm @ 100 °FAmbient AmbientAmbient AmbientNo data available. No data available.No data available. No data available.<5% <5%No data available. 10"FORM C-4AIR POLLUTION CONTROLIV. Fabric FilterFor each Fabric Filter:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)Method and frequency of bag cleaningVendor guarantee on fabric filter efficiency(attachcopy)Quantity of solid waste collected (lbs/yr)Quantity of solid waste recycled (lbs/yr)Quantity of solid waste disposed of (lbs/yr)Method of solid waste disposalNature and frequency of preventive maintenanceproceduresProblems experienced with control device within thelast five years; how were problems solved?Continuous monitoring method(s) used to monitorperformance, including parameters monitoredPlans to replace or upgrade fabric filterFabric Filter 4 Fabric Filter 5V3 V3V3 Mix Batch Storage Bin V3 Batch ChargerReversed compressed air.Compressed air by solenoidson a variable timer.Reversed compressed air.Compressed air by solenoidson a variable timer.None provided. None provided.N/A (Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)0 lbs 0 lbsN/A N/AGeneral maintenance repairsas needed. Visualinspections and differentialpressure checks areperformed routinely. Bag orcartridge replacement isperformed as needed.General maintenance repairsas needed. Visualinspections and differentialpressure checks areperformed routinely. Bag orcartridge replacement isperformed as needed.None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.N/A N/ANone currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-5AIR POLLUTION CONTROLV. Thermal IncineratorFor each Thermal Incinerator: Thermal Incinerator1 Thermal Incinerator 2 Thermal Incinerator 3Process line(s) (identification name/number) V1 V2 V3Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)V1 Curing (01CURE,01INCIN) : Combined Exhaust(Forming/Curing) from MixingChamberV2 Curing (02CURE,02INCIN) : Combined Exhaust(Forming/Curing) from MixingChamberV3 Curing (03CURE,03INCIN) : Combined Exhaust(Forming/Curing) from MixingChamberLatitude (decimal degrees, six decimal places)32.440155332.440132.4400536Longitude (decimal degrees, six decimal places)-96.8494169-96.8489064-96.8487439Stack or vent height (units)63.50 ft.76.33 ft.61.92 ft.7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):9.78 ft. 10.50 ft. 13.70 ft.Manufacturer and model HIRT Combustion TXL-18M-48-XBigelow/Liptak HIRT Combustion TXL-15M-48Date of original installation 1980 1973 1978Fuel type: gas or oil Natural Gas Natural Gas Natural GasFuel consumption rate (BTU/hr) 7,240,000 BTU/hr 8,800,000 BTU/hr 4,050,000 BTU/hrInlet gas flow rate (acfm @°F)26,000 acfm @ 100°F 26,000 acfm @ 100°F 26,000 acfm @ 100°FInlet gas temperature (°F)450°F 450°F 450°FCombustion chamber gas temperature (°F)1300°F 1300°F 1300°FOutlet gas temperature (°F)1300°F 1300°F 1300°FInlet grain loading (gr/dscf) No data available. No data available. No data available.Outlet grain loading (gr/dscf) No data available. No data available. No data available.Average stack opacity (%) <15% <15% <15%Excess air (%)0% 0% 0%0.5 seconds at 1320 °F 2.2 seconds at 1300 °F 0.5 seconds at 1320 °FPercent heat recovery 48% 0% 48%Vendor guarantee on incinerator efficiency (attachcopy)None provided. None provided. None provided.FORM C-5AIR POLLUTION CONTROLV. Thermal IncineratorFor each Thermal Incinerator: Thermal Incinerator1 Thermal Incinerator 2 Thermal Incinerator 3Process line(s) (identification name/number) V1 V2 V3Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)V1 Curing (01CURE,01INCIN) : Combined Exhaust(Forming/Curing) from MixingChamberV2 Curing (02CURE,02INCIN) : Combined Exhaust(Forming/Curing) from MixingChamberV3 Curing (03CURE,03INCIN) : Combined Exhaust(Forming/Curing) from MixingChamberNature and frequency of preventive maintenanceproceduresAnnual inspections performedper MACT requirement andrepairs made as needed.Annual inspections performedper MACT requirement andrepairs made as needed.Annual inspections performedper MACT requirement andrepairs made as needed.Problems experienced with control device within thelast five years; how were problems solved?None reported in Title Vdeviation reports.As reported in Title V deviationreports: installation of newburner caused high NOX /modifications to burner controlsystem; temperature setpointmalfunction / adjusted burnerdamper controls; burner flamefailure / burner damper controland maintenance activities;and unable to maintainincinerator temperature /burner damper control andmaintenance activities.As reported in Title V deviationreports: burner flame failure /burner damper control andmaintenance activities.Continuous monitoring method(s) used to monitorincinerator performance, including parameters monitoredFirebox temperature. Firebox temperature. Firebox temperature.Plans to replace or upgrade thermal incinerator None currently approved orscheduled at this time.None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:HVAF 1 HVAF 2 HVAF 3Process line(s) (identification name/number) V1 V2 V2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)V1 Cooling (01COOL) (HEAF)UnitV2 Stripping (02STRIP)(Smoke Stripper)V2 Cooling (02COOL) (HEAF)Latitude (decimal degrees, six decimal places)32.440341932.440355832.4403375Longitude (decimal degrees, six decimal places)-96.8492069-96.8489-96.8487631Stack or vent height (units)45.75 ft.36.08 ft.46.5 ft.7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):2.92 ft. 1.25 ft. 3.5 ft.Manufacturer and model OC Proprietary Design OCProprietary Design Wheelabrator Size 7272Date of original installation 1975 1975 1973Inlet gas flow rate (acfm @°F)10,000 - 15,000 acfm @ 152°F1,000 - 3,000 acfm @ 169 °F 25,000 - 35,000 acfm @ 100°FInlet gas temperature (°F)100 - 120 °F 110 - 120 °F 100 - 120 °FOutlet gas temperature (°F)100 - 150 °F 100 - 150 °F 100 - 150 °FInlet grain loading (gr/dscf) No data available. No data available. No data available.Outlet grain loading (gr/dscf) No data available. No data available. No data available.Average stack opacity (%) <20% <20% <20%Water spray pressure (sdig), if applicable 30-40 psig 50 psig 30-40 psigWater spray rate (gpm), if applicable No dataavailable. 10 - 20 gpm No data available.Filter face velocity (acfm/ft2)No data available.90-310 acfm/ft2No data available.Maximum pressure drop across mat (in. H2O gauge) 25-30" 25-30" 25-30"N/A N/A None provided.Method and frequency of filter mad advancement Automatic feed based ondifferential pressure.Manually, once per shift. Automatic feed based ondifferential pressure.Amount of wastewater generated (gpd) 0 gpd 0 gpd 0 gpdAmount of wastewater recycled (gpd) 100% 100% 100%Amount of wastewater disposed of (gpd) 0 gpd 0gpd 0 gpdFORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:HVAF 1 HVAF 2 HVAF 3Process line(s) (identification name/number) V1 V2 V2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)V1 Cooling (01COOL) (HEAF)UnitV2 Stripping (02STRIP)(Smoke Stripper)V2 Cooling (02COOL) (HEAF)Method of wastewater disposal N/A N/A N/AQuantity of solid waste collected (lbs/yr) Nodata available. 39,000 lbs/yr No data available.Quantity of solid waste recycled (lbs/yr) 0 lbs/yr 0 lbs/yr 0 lbs/yrQuantity of solid waste disposed of (lbs/yr) No data available. 39,000 lbs/yr No data available.Method of solid waste disposal Local Solid Waste Landfill Local Solid Waste Landfill Local Solid Waste LandfillNature and frequency of preventive maintenanceproceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Cleaning is performed on acycle matched to machinedowntime.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Nozzles and flow patterns arechecked daily; repairs arecompleted as needed.Cleaning is performed on acycle matching machinedowntime.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Cleaning is performed on acycle matched to machinedowntime.Problems experienced with control device within thelast five years; how were problems solved?None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.Continuous monitoring method(s) used to monitorHVAF performance, including parameters monitoredN/A N/A N/APlans to replace or upgrade HVAF None currently approved orscheduled at this time.None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)7. Size of Company (approximate number ofemployees including all subsidiaries, branches, andrelated establishments owned):Manufacturer and modelDate of original installationInlet gas flow rate (acfm @°F)Inlet gas temperature (°F)Outlet gas temperature (°F)Inlet grain loading (gr/dscf)Outlet grain loading (gr/dscf)Average stack opacity (%)Water spray pressure (sdig), if applicableWater spray rate (gpm), if applicableFilter face velocity (acfm/ft2)Maximum pressure drop across mat (in. H2O gauge)Method and frequency of filter mad advancementAmount of wastewater generated (gpd)Amount of wastewater recycled (gpd)Amount of wastewater disposed of (gpd)HVAF 4 HVAF 5V3 V3V3 Stripping (03STRIP)(Smoke Stripper)V3 Cooling (03COOL) (HEAF)32.440157832.4402581-96.8484139-96.848544440.5 ft.63.33 ft.1.17 ft 3.5 ft.OC proprietary design Anderson 2000/DF-44-IV1978 19783,000 - 5,000 acfm @ 120-160°F10,000 - 15,000 acfm @ 123°F110 - 120 °F 100 - 120 °F100 - 150 °F 100 - 150 °FNo data available. No data available.No data available. No data available.<20% <20%50 psig 30-40 psig10 - 20 gpm No data available.90-310 acfm/ft2No data available.25-30" 25-30"N/A None provided.Manually, once per shift. Automatic feed based ondifferential pressure.0 gpd 0 gpd100% 100%0 gpd 0 gpdFORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)Method of wastewater disposalQuantity of solid waste collected (lbs/yr)Quantity of solid waste recycled (lbs/yr)Quantity of solid waste disposed of (lbs/yr)Method of solid waste disposalNature and frequency of preventive maintenanceproceduresProblems experienced with control device within thelast five years; how were problems solved?Continuous monitoring method(s) used to monitorHVAF performance, including parameters monitoredPlans to replace or upgrade HVAFHVAF 4 HVAF 5V3 V3V3 Stripping (03STRIP)(Smoke Stripper)V3 Cooling (03COOL) (HEAF)N/A N/A39,000 lbs/yr No data available.0 lbs/yr 0 lbs/yr39,000 lbs/yr No data available.Local Solid Waste Landfill Local Solid Waste LandfillGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Nozzles and flow patterns arechecked daily; repairs arecompleted as needed.Cleaning is performed on acycle matching machinedowntime.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Cleaning is performed on acycle matched to machinedowntime.None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.N/A N/ANone currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-7AIR POLLUTION CONTROLVII. Mist EliminatorNot applicable to this facility.For each Mist Eliminator:Mist EliminatorProcess line(s) (identification name/number) N/AEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 plot plan)N/ALatitude (decimal degrees, six decimal places)N/ALongitude (decimal degrees, six decimal places)N/AStack or vent height (units)N/A7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):N/AManufacturer and modelN/ADate of original installationN/AType of mist eliminatorN/AGas flow rate to mist eliminator (acfm @°F)N/AInlet gas temperature (°F)N/AOutlet gas temperature (°F)N/AInlet grain loading (gr/dscf)N/AOutlet grain loading (gr/dscf)N/AAverage stack opacity (%)N/AVelocity in mist eliminator (ft/sec) N/APressure drop (in. H2O gauge) N/AFor chevron blade mist eliminators:N/AN/AWashing frequency of blades N/AFor mesh pad mist eliminators:N/ANumber of pads or elements N/AThickness of pad (in.) or element dimensions N/ADensity of pad, (lb/ft3)N/AWashing frequency of padN/AFORM C-7AIR POLLUTION CONTROLVII. Mist EliminatorNot applicable to this facility.For each Mist Eliminator:Mist EliminatorVendor guarantee on mist eliminator efficiency (attach copy) N/AAmount of wastewater generated (gpd) N/AAmount of wastewater recycled (gpd) N/AAmount of wastewater disposed of (gpd) N/AMethod of wastewater disposal N/AQuantity of solid waste collected (lbs/yr) N/AQuantity of solid waste recycled (lbs/yr) N/AQuantity of solid waste disposed of (lbs/yr) N/AMethod of solid waste disposal N/ANature and frequency of preventive maintenance procedures N/AProblems experienced with control device within the last fiveyears; how were problems solved?N/AContinuous monitoring method(s) used to monitor mist eliminatorperformance, including parameters monitoredN/APlans to replace or upgrade mist eliminator N/AFORM C-8AIR POLLUTION CONTROLVIII. Ventilation SystemFor each Ventilation System:Ventilation System 1Process line(s) (identification name/number)Furnace HallEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Fugitive / Furnace VentsLatitude (decimal degrees, six decimal places)Multiple LocationsLongitude (decimal degrees, six decimal places)Multiple LocationsStack or vent height (units)Roof HeightStack or vent diameter (units)Multiple LocationsFor general or building ventilation:Ventilation system usedNatural draft with walland roof louversAirflow control system usedManually adjusted.Number of air changes per hour Estimatedat 4-6 airchanges per hour.For unit or local ventilation:Enclosure or hood design usedN/AVolume of enclosure or hoodN/ACapture velocity (ft/sec)N/ADistance between hood and emission source (ft)N/AFORM C-9AIR POLLUTION CONTROLIX. OtherFor each Other Air Pollution Control Device (APCD): Other APCD 1 Other APCD 2Process line(s) (identification name/number) V1 V2Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)V1 Forming (01FORM) V2 Furnace (02MELT)Latitude (decimal degrees, six decimal places) 32.4401553 32.4396072 (east) and32.4396492Longitude (decimal degrees, six decimal places) -96.8494169 -96.8491411 (east) and -96.8492286Stack or vent height (units)63.50 ft. 57.78 ft. (each)7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):9.78 ft. 4.00 ft. (each)DescriptionDrop Out Box / Penthouse Batch WettingFORM C-9AIR POLLUTION CONTROLIX. OtherFor each Other Air Pollution Control Device (APCD):Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):DescriptionOther APCD 3 Other APCD 4V2 V3V2 Forming (02FORM) V3 Furnace (03MELT)32.4401 32.4394836 (east) and32.4395267 (west)-96.8489064 -96.8488961 (east) and -96.8489864 (west)76.33 ft. 57.45 ft.(east) and 57.28 ft.(west)10.50 ft. 4.00 ft. (each)Drop Out Box / Penthouse Batch WettingFORM C-9AIR POLLUTION CONTROLIX. OtherFor each Other Air Pollution Control Device (APCD):Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):DescriptionOther APCD 5V3V3 Forming (03FORM)32.4400536-96.848743961.92 ft.13.70 ft.Drop Out Box / PenthouseFORM DPROCESS LINE STARTUP AND SHUTDOWN2005 - 2009 Semi-Annual MACT reports provided on CD.1. For each startup and shutdown (SS) that occurred during the lastfive years, please provide the following information requested in A.through J.A. Using the definitions provided above, indicate whether theevent was a startup or shutdown;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.B. A description of the event, including identification of theemissions source or sources associated with the startup orshutdown;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.7. Size of Company (approximate number of employeesincluding all subsidiaries, branches, and related establishmentsowned):As indicated in the 2005 - 2009 Semi-Annual MACT Reports.D. Whether the event was covered by any contingency plan forcontrolling emissions during startup and shutdown events and, if so,whether the plan was followed; if the plan was notfollowed, why not;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.E. The duration of the event;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.F. The actions taken to minimize emissions during the event,including the use of any backup control systems;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.G. Estimates or measurements, if any, of emissions during theevent; if you did not have the ability to quantifyemissions during theevent, please explain why;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.H. Whether the emission profile of each unitwas different duringstartup and shutdown than during normal operating conditions and, ifso, how emissions were different and why; please provide anysupporting information;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.I. All performance test data collected during each period of SS;the test method used for each event; when the testing wasconducted and why; the test conditions at the timeof testing; andwhether the tests were associated with a routine startup or shutdown;andNo data available.J. All monitoring data, including control system parametermonitoring, collected during each period of SS.As indicated in the 2005 - 2009 Semi-Annual MACT Reports.Startup: the setting in operation of an affected source or portion of an affected source for any purpose.Shutdown: the cessation of operation of an affected source or portion of an affected source for any purpose.FORM DPROCESS LINE STARTUP AND SHUTDOWN2005 - 2009 Semi-Annual MACT reports provided on CD.If this information is contained in periodic and immediate SS reports(either stand-alone or contained within the periodic excess emissionsreport) submitted to your permitting authority, youmay submit copiesof those reports instead.2. Are there any types of startup or shutdown events that you havebeen able to eliminate? If so, please describe thetype of event andexplain how these events were eliminated.No.3. Please submit a copy of your SS plan if you arerequired todevelop one.As indicated in the 2005 - 2009 Semi-Annual MACT Reports.No data available.5. Please provide all monitoring data, including control systemparameter monitoring, collected during periods of SS over the last 5years.As indicated in the 2005 - 2009 Semi-Annual MACT Reports.6. Optional: Do you wish to recommend a standardthat would applyduring startup or shutdown? If so, please describethe event to whichthe standard would apply; the recommended standard(this could bean emission limitation, work practice, or operational standard) thatwould apply during the period; the basis for the recommendedstandard; why and how the standard would minimize emissionsduring the event; and how would compliance be determined and/ormonitored.No.FORM EPRESENCE OF AIR POLLUTANTS IN EMISSION POINTSPlease provide any existing emissions information and data coveringhazardous air pollutants (HAP) and particulate matter (PM) for each listedprocess. Identify the appropriate box for which you are providing specificprocess information and/or pollutant emissions data.Melting Furnace Forming Curing CoolingParticulate Matter (PM, PM 2.5, PM Condensable)Chromium Compounds and Hexavalent Chromium (including any Crspeciation data)Other metal HAP (As, Be, Cd, Co, Hg, Mn, Ni, Pb, Sb, Se)Hydrogen Fluoride (HF)Hydrogen Chloride (HCl)FormaldehydePhenolMethanolOther organic HAPThe existing data requested here has been providedto EPA by the industry’s trade association, the NorthAmerican Insulation Manufacturers Association (“NAIMA”). The existing data provided by NAIMA was setforth inNAIMA’s May 5, 2010 letter to EPA. The existing emissions data provided from fiber glass companies includedtest results for the following pollutants: formaldehyde, methanol, phenol, particulate matter, hydrogen fluoride,metals (antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, nickel and selenium),mercury and hexavalent chromium. The existing emissions data provided from mineral wool companies includedtest results for the following pollutants: formaldehyde, methanol, phenol, particulate matter, carbonmonoxide,carbonyl sulfide, hydrogen fluoride, metals (antimony, arsenic, beryllium, cadmium, chromium, cobalt,lead,manganese, nickel and selenium), mercury and hexavalent chromium.The scope of the existing data provided was the result of consensus reached by EPA, NAIMA and industryrepresentatives. In addition to the existing datasubmitted to EPA, extensive new emissions data is being collectedfrom virtually all companies through the “BTEC, Inc. Quality Assurance Project Plan for the Mineral Wool and WoolFiberglass Emissions Test Program.” This Test Program will collect and submit to EPA, through EPA’s ElectronicReporting Tool, representative emissions data for the following pollutants: formaldehyde, methanol, phenol,particulate matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, metals (antimony, arsenic, beryllium,cadmium, chromium, cobalt, lead, manganese, nickeland selenium), mercury and hexavalent chromium.FORM F-1COSTI. Process Unit (e.g., cupola, curing oven, etc.):For each Process Unit:Process Unit IDProcess Line IDII. Capital CostsBase year7. Size of Company (approximate number of employees including allsubsidiaries, branches, and related establishmentsowned):III. Annual Operating CostsBase year (most recent fiscal year)Total annual operating costsMaintenance materials and replacement parts (specify costs by item)Raw materials costsLabor($/yr) for each labor class(hr/hr) for each labor classUtilities (breakdown for each utility)Waste treatment and/or disposalCosts associated with any work practices and pollution preventiontechniques that are employed at your facilitySavings associated with heat recovery and wastewater and/or solid wastereturned to process from APCD (or sold to another user)Other (specify)Please provide the annual report to shareholders orequivalent for the mostrecent fiscal year. If reports are not available,provide annual sales andprofits (or profit margin) for the most recent fiscal year. If company ispublicly owned, please provide a web link to this information.The company objects to this request because it seeks information that is notrelevant to the EPA Administrator's review obligations pursuant to Clean AirAct Section 112(d)(6) and 112(f)(2).FORM F-1COSTThe company objects to this request because it seeks information that is notrelevant to the EPA Administrator's review obligations pursuant to Clean AirAct Section 112(d)(6) and 112(f)(2).Identify the market range (regional, national, international) of your products.Can your product(s) be substituted by another product(s)? If so, please listyour product(s) and substituted product(s).Wool fiberglass insulation comprises the majormarket for residential insulation material used inthe United States. The remaining market consistsof cellulose (scrap newspaper) treated to resistfires, spray foam, foam boards, cotton treated toresist fires, and wool treated to resist fires.Wool fiberglass insulation is preferred over thesealternative insulation materials because it is easily,economically, and safety installed in variousbuilding settings, has superior fire performancecapabilities, and a 70-year history of provenperformance and durability.FORM F-2COSTI. Air Pollution Control Device (APCD)For each APCD:APCD IDProcess Unit IDII. Capital CostsBase year7. Size of Company (approximate number of employees including allsubsidiaries, branches, and related establishmentsowned):List the cost for each piece of auxiliary equipment for each APCD notincluded aboveInstallation costLand purchase costTotal capital costMethod of financining APCDRetrofit installationField erected or modularIII. Annual Operating CostsBase year (most recent fiscal year)Maintenance materials and replacement parts (specify costs by item)Raw materials costs($/yr) for each labor class(hr/hr) for each labor classUtilites (breackdown for each utility)Waste treatment and/or disposalThe company objects to this request because it seeks information that is notrelevant to the EPA Administrator's review obligations pursuant to Clean AirAct Section 112(d)(6) and 112(f)(2).FORM F-2Indirect costsOther (specify)Total annual operating cost (most recent fiscal year)Attach annual report to shareholders or equivalentfor the most recent fiscalyear. Alternatively, if company is publicly owned,you can provide yourcompany's web link to this information.