PREVENTION OF SIGNIFICANT DETERIORATION

PERMIT ISSUED PURSUANT TO THE

REQUIREMENTS AT 40 CFR § 52.21

U.S. ENVIRONMENTAL PROTECTION AGENCY, REGION 9

PSD PERMIT NUMBER: SAC 03-01

PERMITTEE: KnaufInsulation GmbH

One KnaufDrive

Shelbyville, IN 46176

FACILITY LOCATION: 3100 Ashby Road

Shasta Lake, California 96019

This revised Permit is issued pursuant to the Prevention of Significant Deterioration (PSD)

requirements ofthe Clean Air Act, as amended, 42 U.S.C. §§ 7401 - 7671, et seq. Knauf

Insulation GmbH (Knauf) is granted this revised PSD Permit as described herein, in accordance

with the permit application (and plans submitted with the permit application), federal regulations

governing the Prevention of Significant Deterioration of air quality (40 CFR § 52.21), and other

terms and conditions set forth in this revised PSD Permit.

Failure to comply with any condition or term set forth in this PSD Permit is subject to

enforcement action pursuant to Section 113 ofthe Clean Air Act.

This revised PSD Permit does not relieve the Permittee from the responsibility to comply with

any other applicable provisions ofthe Clean Air Act and other federal or Shasta County Air

Quality Management District requirements.

This permit becomes effective immediately.

Date

Director, Air Division
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 2 of 21

TABLE OF CONTENTS 

ABBREVIATIONS & ACRONYMS .......................................................................................... 3

FACILITY DESCRIPTION ........................................................................................................ 4

EQUIPMENT LIST ...................................................................................................................... 4

GENERAL PERMIT CONDITIONS ......................................................................................... 5

RAW MATERIAL HANDLING & MIXING OPERATING CONDITIONS ........................ 9

MOLTEN GLASS PRODUCTION OPERATING CONDITIONS ...................................... 10

FIBERGLASS FORMING/CURING/COOLING OPERATING CONDITIONS ............... 14

FIBERGLASS TRIMMING & PACKAGING OPERATING CONDITIONS .................... 20
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 3 of 21

ABBREVIATIONS & ACRONYMS 

Amps Ampere 

ACFM Actual cubic feet per minute 

BACT Best Available Control Technology 

CEM Continuous Emission Monitoring 

CFR Code of Federal Regulations 

CMS Continuous Monitoring System 

CO Carbon monoxide 

DSCFM Dry standard cubic feet per minute 

EPA United States Environmental Protection Agency, Region IX 

°F degrees Fahrenheit 

g grams 

gph gallons per hour 

GPM gallons per minute 

HAP Hazardous Air Pollutant 

in H2O inches of water 

hr hour 

kg kilogram 

kV kilovolt 

kW kilowatt 

lb pound 

min Minute 

NOx Nitrogen Oxides 

NO2 Nitrogen Dioxide 

NSPS New Source Performance Standard 

NSR New Source Review 

Permittee Knauf Insulation, GmbH 

PM Particulate Matter 

PM10 Particulate matter less than 10 microns in diameter 

ppm parts per million 

PSD Prevention of Significant Deterioration 

psia pounds per square inch absolute 

SO2 Sulfur dioxide 

tpd tons of glass produced or pulled per operating day 

TSP Total suspended particulate 

VOC Volatile organic compounds 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 4 of 21

FACILITY DESCRIPTION 

This PSD permit is an amendment to the PSD permit issued on March 14, 2000, to the Knauf 

Insulation GmbH (Knauf) facility located in Shasta Lake, California. The PSD permit was 

amended on May 11, 2006 and May 7, 2007, with a further administrative amendment on 

December 13, 2010. 

The fiberglass manufacturing operations at Knauf consist of the following: (1) raw materials 

handling and mixing; (2) molten glass production; (3) glass fiber forming, curing, and cooling; 

and (4) fiberglass trimming and packaging. 

The raw materials handling and mixing operations consist of storage bins and tanks that are used 

to store materials which are used to produce the fiberglass insulation. Emissions from this 

operation consist primarily of particulate matter, which are captured in dust collectors within the 

facility and are not vented to the outside air. 

Molten glass production is achieved using an electric glass melting furnace that has a current 

production capacity of 225 tons of glass pulled per day (tpd). Emissions from the furnace are 

vented to the Furnace Stack. 

The forming, curing, and cooling operations make up the manufacturing line where emissions 

are vented to the Main Stack. 

Emissions from the fiberglass trimming and packaging operations are also captured in dust 

collectors which are vented within the facility and not to the outside air. 

EQUIPMENT LIST 

Raw Materials Handling and Mixing

One (1) Raw Material Unloading Dust Collector 

Three (3) Sand Bins Dust Collectors 

Two (2) Consumer Cullet Bin Dust Collectors 

One (1) Dolomite Bin Dust Collector 

One (1) Limestone Bin Dust Collector 

One (1) (Spare) Bin Dust Collector 

One (1) Borax Bin Dust Collector 

One (1) Soda Ash Bin Dust Collector 

One (1) Feldspar Bin Dust Collector 

One (1) Knauf Cullet Dust Collector 

One (1) Weigh Scales/Conveyor Dust Collector 

One (1) Check Scale/Batch Mixer Dust Collector 

One (1) Day Bin #1 Dust Collector 

One (1) Day Bin #2 Dust Collector 

One (1) Liquid Urea Tank 

Two (2) Phenolic Resin Tanks 

Two (2) Resin-Urea Premix Tanks 

One (1) Outdoor Mineral Oil Tank 

One (1) Outdoor Aqueous Ammonia Tank 

Two (2) Ammonium Sulfate Mix Tanks 

One (1) Organosilane Weigh Tank 

One (1) Binder Mix Tank 

Two (2) Binder Supply Hold Tanks 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 5 of 21

Molten Glass Production

225 Tons/Day Molten Glass Production Electric Glass Melting Furnace 

One (1) 25,800 ACFM Custom System Dual Chamber Dust Collector (Model WP238-10) 

Two (2) 15 MMBtu North American Burner Systems (Model 8520) 

One Marley NC Series Cooling Tower, Serial No. 169921-001 

Fiberglass Forming/Curing/Cooling

One (1) Natural Gas-Fired Forming Section 

One (1) Natural Gas-Fired Curing Oven w/ low NOx/CO Burners 

One (1) Volatile Organic Compound Binder Application Process 

Six (6) 10” P Venturi Scrubbers on Bonded Wool Forming Line 

One (1) 10” P Venturi Scrubber on Blowing Wool Forming Line 

One (1) 400,000 ACFM, 600 GPM Wet Electrostatic Precipitator 

One (1) Venturi Scrubber on Cooling Line 

Two (2) Thermal Oxidizers (with low NOx/CO Burners) on Curing Oven 

One (1) Regenerative Thermal Oxidizer on Curing Oven 

Fiberglass Trimming and Packaging

One (1) 9874 ACFM Trimming-Packaging Cyclone (1) & Dust Collector Assembly 

One (1) 9874 ACFM Class B Blowing Wool Cyclones (2) & Dust Collector Assembly 

One (1) 15,708 ACFM Class A Blowing Wool North Dust Collector Assembly 

One (1) 15,708 ACFM Class A Blowing Wool Center Dust Collector Assembly 

Five (5) High Density Filter Modules 

One (1) 10,000 ACFM Class A Summit Wool Production Condenser 

One (1) 10,000 ACFM Class A Premier Tech Refeed Condenser 

GENERAL PERMIT CONDITIONS 

1. Permit Notification Requirements: 

The Permittee shall notify EPA in writing or by electronic mail of the date upon which 

initial performance tests will commence, in accordance with the provisions of this PSD 

Permit, postmarked not less than 30 days prior to such date. Notification may be 

provided with the submittal of the performance test protocol(s) required in this PSD 

permit. 

2. Facility Operation: 

a. At all times, including periods of startup, shutdown and malfunction, the 

Permittee shall, maintain and operate the facility including associated air 

pollution control equipment in a manner consistent with good air pollution control 

practice for minimizing emissions. Determination of whether acceptable 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 6 of 21

operating and maintenance procedures are being used will be based on 

information available to the EPA which may include, but is not limited to, 

performance tests, monitoring results, review of operating maintenance 

procedures and inspection of the source. 

b. The operating staff with management authority at this facility shall be advised of 

and be familiar with all the conditions of this PSD permit. 

3. Malfunction Reporting:

a. The Permittee shall notify EPA by telephone, facsimile, or electronic mail at 

r9.aeo@epa.gov within two (2) working days following the discovery of any 

failure of air pollution control equipment, process equipment, or of a process to 

operate in a normal manner, which results in an increase in emissions above the 

allowable emission limits stated in Conditions 22 and 43 of this Permit. 

b. In addition, the Permittee shall notify EPA in writing or electronic mail within 

fifteen (15) days of any such failure described under Condition 3.a. of this PSD 

Permit. The notification shall include a description of the malfunctioning 

equipment or abnormal operation, the date of the initial malfunction, the period of 

time over which emissions were increased due to the failure, the cause of the 

failure, the estimated resultant emissions in excess of the emission limitations 

contained in this PSD permit, and the methods utilized to mitigate emissions and 

restore normal operations. 

c. Compliance with this malfunction notification provision shall not excuse or 

otherwise constitute a defense to any violation of this permit or any law or 

regulation such malfunction may cause. 

4. Right of Entry: 

The EPA Regional Administrator, and/or an authorized representative, upon the 

presentation of credentials, shall be permitted: 

a. To enter the premises where the source is located or where any records are 

required to be kept under the terms and conditions of this PSD Permit; and 

b. At reasonable times to have access to and to copy any records required to be kept 

under the terms and conditions of this PSD Permit; and 

c. To inspect any equipment, operation, or method subject to requirements in this 

PSD Permit; and 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 7 of 21

d. To sample emissions from any and all emission sources within the facility. 

5. Transfer of Ownership: 

In the event of any changes in control or ownership of the facilities to be constructed and 

operated, this PSD Permit shall be binding on all subsequent owners and operators. 

Within fifteen (15) days of the change in control or ownership, the Permittee shall notify 

the succeeding owner and operator of the existence of this PSD Permit and its conditions 

by letter, a copy of which shall be forwarded to EPA. 

6. Severability: 

The provisions of this PSD Permit are severable, and, if any provision of the PSD Permit 

is held invalid, the remainder of this PSD Permit shall not be affected. 

7. New Source Performance Standards: 

The Permittee is subject to the federal regulations entitled Standards of Performance for 

New Stationary Source (40 CFR Part 60). The owner or operator shall meet all 

applicable requirements of the General Provisions pursuant to 40 CFR Part 60, Subpart 

A, the Standard of Performance for Volatile Organic Liquid Storage Vessels pursuant to 

40 CFR Part 60, Subpart Kb, and the Standard of Performance for Wool Fiberglass 

Insulation Manufacturing Plants pursuant to 40 CFR Part 60, Subpart PPP. 

8. Other Applicable Regulations: 

The Permittee shall construct and operate the stationary source in compliance with all 

other applicable provisions of 40 CFR Parts 52, 60, 61, and 63 and all other applicable 

federal, state and local air quality regulations. 

9. Paperwork Reduction Act: 

Any requirements established by this PSD Permit for the gathering and reporting of 

information are not subject to review by the Office of Management and Budget (OMB) 

under the Paperwork Reduction Act because this permit is not an “information collection 

request” within the meaning of 44 U.S.C. §§ 3502(4), 3502 (11), 3507, 3512, and 3518. 

Furthermore, this PSD Permit and any information gathering and reporting requirements 

established by this permit are exempt from OMB review under the Paperwork Reduction 

Act because it is directed to fewer than ten persons. 44 U.S.C. § 3502(4) and § 3502(11); 

5 CFR § 1320.5(a). 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 8 of 21

10. Recordkeeping and Reporting: 

a. All records and emission test results requested to be kept under the terms and 

conditions of this PSD Permit shall be retained for at least five (5) years from the 

date the record was created and shall be made available to the EPA upon request. 

b. Semiannual reports are due 30 days after end of each calendar half following the 

effective date of the Permit. The reporting periods for each calendar half are 

January 1- June 30 and July 1 - December 31. 

11. Agency Notification: 

a. Unless otherwise directed by the EPA or this permit, the owner or operator shall 

submit a copy of all test plans, reports, certifications, notifications, and other 

information pertaining to compliance with this permit to: 

Director, Air Division (Attn: AIR-5) 

U. S. Environmental Protection Agency Region 9 

75 Hawthorne Street 

San Francisco, CA 94105-3901 

b. The owner or operator shall submit permit applications, permit amendments, and 

other applicable permit information, which includes but not limited to installation 

of control equipment, replacement of an emissions unit, and changes that 

contravene permit terms, to: 

Director, Air Division (Attn: AIR-3) 

U. S. Environmental Protection Agency Region 9 

75 Hawthorne Street 

San Francisco, CA 94105 

c. Copies of all correspondence required by this PSD Permit shall be forwarded to: 

Air Pollution Control Officer 

Air Quality Management District 

Shasta County Department of Resource Management 

1855 Placer Street, Suite 200 

Redding, CA 96001 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 9 of 21

RAW MATERIAL HANDLING & MIXING OPERATING CONDITIONS 

12. All of the material handling vents and tank vents that discharge into the interior of the 

batch plant building shall be controlled by twelve (12) baghouse dust collectors that shall 

prevent any and all particulate matter emissions from escaping the facility. The dust 

collectors shall be equipped with bag leak detectors which shall be maintained, 

continuously operated, and calibrated on a regular basis as recommended by the 

manufacturer to assure reliability. The bag leak detectors shall be equipped with an 

audible alarm which shall sound automatically in the control room to indicate a torn or 

leaking bag. Spare bags shall be kept on site for immediate replacement of leaking or 

torn bags. The Permittee must initiate corrective action within 1 hour of an alarm from 

the bag leak detection system and complete corrective actions immediately. The 

corrective action may include any one or a combination of the following actions: 

a. Inspecting the baghouse for air leaks, torn or broken bags or filter media, or any 

other conditions that may cause an increase in emissions; 

b. Sealing off defective bags or filter media; 

c. Replacing defective bags or filter media, or otherwise repairing the control 

device; 

d. Sealing off a defective baghouse compartment; 

e. Cleaning the bag leak detection system probe, or otherwise repairing the bag leak 

detection system; and 

f. Shutting down the process producing the particulate emissions. 

13. The Permittee shall retain records of (a) each occurrence of the alarm for the bag leak 

detection system, (b) the corrective action(s) taken for each occurrence of the alarm, and 

(c) the duration for completing each corrective action(s). 

14. Day Bin #1 and #2 dust collector emissions in the furnace building shall be discharged 

through the forming section exhausts and be controlled by the forming line scrubbers and 

wet electrostatic precipitator. Emissions from these dust collectors shall be measured as 

emissions from the forming line. 

15. All railcar and bottom-dump hopper truck unloading of raw materials shall be done with 

a “dust boot” that seals the gap between the discharge of the hopper and the delivery 

system. The dust collectors on the material handling system shall be operational 

whenever materials are being delivered and shall prevent any and all particulate matter 

emissions from escaping the batch plant. 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 10 of 21

16. The Permittee shall submit a written report of the following actions on a semiannual 

basis: (a) each occurrence of the alarm for the bag leak detection system, (b) the 

corrective action(s) taken for each occurrence of the alarm, and (c) the duration for 

completing each corrective action(s). The report shall be submitted to EPA and is due on 

the 30th day following the end of each semiannual period after the effective date of this 

permit. 

MOLTEN GLASS PRODUCTION OPERATING CONDITIONS 

17. The glass melting furnace shall be heated only by electricity. No other auxiliary fuels 

may be used except during cold startup of the melting furnace or during prolonged 

electrical outages beyond the control of the facility when portable natural gas burners 

may be used to bring the temperature of the refractory and raw materials up to operating 

temperature. The Permittee shall retain records of all periods when portable burners are 

used and the amount of fuel used. 

18. The Permittee shall retain records of glass production averaged on a daily and weekly 

basis in tons of glass pulled per day. The records shall be available for inspection by the 

EPA. 

19. The method of control of particulate matter from the glass melting furnace shall be the 

use of two baghouse dust collectors capable of meeting the emission standards specified 

in condition 22 of this permit. The dust collectors shall be equipped with bag leak 

detectors which shall be maintained, continuously operated, and calibrated on a regular 

basis as recommended by the manufacturer to assure reliability. The bag leak detectors 

shall be equipped with an audible alarm which shall sound automatically in the control 

room to indicate a torn or leaking bag. Spare bags shall be kept on site for immediate 

replacement of leaking or torn bags. The Permittee must initiate corrective action within 

1 hour of an alarm from the bag leak detection system and complete corrective actions 

immediately. The corrective action may include any one or a combination of the 

following actions: 

a. Inspecting the baghouse for air leaks, torn or broken bags or filter media, or any 

other conditions that may cause an increase in emissions; 

b. Sealing off defective bags or filter media; 

c. Replacing defective bags or filter media, or otherwise repairing the control 

device; 

d. Sealing off a defective baghouse compartment; 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 11 of 21

e. Cleaning the bag leak detection system probe, or otherwise repairing the bag leak 

detection system; and 

f. Shutting down the process producing the particulate emissions. 

20. The Permittee shall retain records of (a) each occurrence of the alarm for the bag leak 

detection system, (b) the corrective action(s) taken for each occurrence of the alarm, and 

(c) the duration for completing each corrective action(s). 

21. The Permittee shall install, and thereafter continuously operate and maintain the 

following air pollution controls capable of meeting the emission standards in Condition 

22 of this permit: 

a. Use of two (2) baghouse dust collectors; and 

b. Use of an all electric glass melting furnace. 

22. PM10 emissions (filterable and condensable) from the Furnace Stack of the combined 

baghouse discharge exhausts from the glass melting furnace shall not exceed the 

following emission limitations: 

a. 0.67 lb/hr and 0.07 lb/ton of glass pulled, based on a 3-hour rolling average; and 

b. 2.9 tons per year, based on a 12-month rolling sum. 

23. The Permittee shall install, calibrate, operate and maintain the following continuous 

monitors. The Permittee shall retain records of the hourly glass pull rate. 

a. A continuous glass pull rate monitor that records glass pull rate on an hourly 

basis; and 

b. A continuous dust collector bag leak detection system that records relative 

particulate matter emissions. 

24. The opacity from the above stack shall not exceed 5 percent opacity based on a six (6) 

minute average and shall apply at all times. An audible alarm shall sound in the control 

room to indicate an opacity exceeding the above opacity limit. 

25. The Permittee shall continuously operate and maintain a stack gas opacity monitor on the 

stack combining the baghouse discharge exhausts from the glass melting furnace. The 

continuous opacity monitor shall meet all applicable design and quality assurance 

requirements specified in 40 CFR 60.13 and 40 CFR Part 60, Specification 1 of 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 12 of 21

Appendix B. A computer data acquisition system which has the capability of interpreting 

the sampling data, providing a graphical trend analysis, and producing a summary report 

of all six (6) minute averages of opacity readings shall also be provided. 

26. The Permittee shall conduct an initial performance test for PM10 within 180 days after 

November 14, 2006. The Permittee shall conduct performance tests (as described in 40 

CFR 60.8) for PM10 on the stack receiving the combined dust collector exhausts from 

the glass melting furnace (Furnace Stack). The Permittee shall retain records of all 

performance test measurements. 

27. The Permittee shall conduct performance testing annually. Annual performance testing 

shall be performed within 30 days after the anniversary of the most recent performance 

test. The Permittee shall conduct performance tests (as described in 40 CFR 60.8) for 

PM10 on the stack receiving the combined dust collector exhausts from the glass melting 

furnace (Furnace Stack). The Permittee shall retain records of performance test 

measurements. 

28. Performance tests shall be conducted in accordance with EPA Methods 1 through 5, and 

202 for PM10. 

29. For each performance test, the Permittee shall submit a performance test protocol to EPA 

no later than 30 days prior to the test to allow review of the test plan and to arrange for an 

observer to be present at the test. The performance test protocol shall be amended if 

required by EPA. The performance test shall be conducted in accordance with the 

submitted protocol, and any changes required by EPA. In lieu of the above mentioned 

test methods, equivalent methods may be used with prior written approval from EPA. 

30. Performance tests shall be performed by an independent testing firm. The Permittee shall 

furnish EPA with a written report of the results of such tests within sixty (60) days after 

the performance tests are conducted. 

31. For performance test purposes, the Permittee shall provide sampling ports, platforms and 

access on the emission unit exhaust system in accordance with the requirements of 40 

CFR 60.8(e). 

32. During each performance test, the Permittee shall monitor and record the glass pull rate 

every fifteen (15) minutes. The Permittee shall determine the arithmetic average of the 

recorded glass pull rate measurements for each test run and calculate the average of the 

three test runs. This shall establish the test glass pull rate until the next performance test. 

The Permittee shall include the test glass pull rate for each performance test in the written 

report of the results of such tests for submission to EPA. The Permittee shall retain 

records of all calculations and measurements. 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 13 of 21

33. For each performance test, the Permittee shall include a calculation of the actual PM10 

emissions (in lb/hr and lb/ton glass pulled) for the glass melting furnace in the written 

report of the results of such tests for submission to EPA. The Permittee shall use the 

emission rate in lb/hr and the test glass pull rate, in average tons of glass pulled per hour, 

determined from the performance test, to determine the emissions in lb/ton glass pulled. 

The Permittee shall use the calculated actual PM10 emissions to determine compliance 

with the lb/ton BACT emission limit for the glass melting furnace (Furnace Stack) in 

Condition 22 of this permit. The Permittee shall retain records of all calculations and 

measurements. 

34. The Permittee shall determine compliance with the lb/hr emission limit for PM10 in 

Condition 22 of this permit on an hourly basis. The lb/hr emissions shall be calculated 

on an hourly basis using the actual glass pull rate for each hour and the PM10 emission 

factor, in lb/ton of glass pulled, determined from the past performance test (only those 

within the last five years) that most closely matches the operating glass pull rate. The 

Permittee shall retain records of all calculations and measurements. 

35. Re-Testing: The Permittee shall conduct a performance test within sixty (60) days if the 

glass pull rate increases by 5 percent or more (as averaged over any daily period) or 

decreases by 10 percent or more (as averaged over any weekly period) from the test glass 

pull rate established during any performance test within the last five (5) years conducted 

after the effective date of this permit. The performance test shall be performed within 5 

percent above or below the glass pull rate that triggered this re-testing requirement. The 

Permittee shall retain records of all calculations and measurements. This performance 

test is not required if the Permittee tested within 5 percent above or below the new glass 

pull rate within the last five (5) years and compliance was demonstrated; if a re-bricking 

of the furnace occurred within the last five (5) years after the performance test, new 

testing is required. 

36. The Permittee shall submit a written report of all excess emissions and monitoring 

systems performance to EPA in accordance with 40 CFR 60.7 (c) and (d) on a 

semiannual basis. The report is due on the 30th day following the end of each semiannual 

period after the effective date of this permit. Excess emissions shall be defined as any 

opacity level exceeding the opacity limitation in Condition 24 of this permit. Excess 

emissions shall be considered violations of the applicable emission limits for the 

purposes of this permit. 

37. The Permittee shall submit a written report of all excess emissions for Condition 22 of 

this permit in accordance with Conditions 33 and 34 of this permit for the Furnace Stack. 

Excess emissions shall be defined as any emissions exceeding the maximum emission 

limits set forth in Condition 22. The report shall be submitted to EPA semiannually and 

is due on the 30th day following the end of each semiannual period after the effective date 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 14 of 21

of this permit. Excess emissions shall be considered violations of the applicable emission 

limits for the purposes of this permit.

38. The Permittee shall submit a written report of the following actions on a semiannual 

basis: (a) each occurrence of the alarm for the bag leak detection system, (b) the 

corrective action(s) taken for each occurrence of the alarm, and (c) the duration for 

completing each corrective action(s). The report shall be submitted to EPA and is due on 

the 30th day following the end of each semiannual period after the effective date of this 

permit. 

39. Upon prior written request and adequate justification from the Permittee, EPA may waive 

the annual performance test. EPA approval shall be in writing. EPA shall give written 

approval of such waiver. Such request must be submitted to EPA no later than 60 days 

prior to the annual performance test date.

FIBERGLASS FORMING/CURING/COOLING OPERATING CONDITIONS 

40. Natural gas shall constitute the only fuel allowed for use in the forming and curing 

operations. 

41. The Permittee shall maintain a log of the throughput of molten glass averaged on an 

hourly, daily and weekly basis in tons of glass pulled per day. The log shall be available 

for inspection by the EPA. 

42. The Permittee shall install, and thereafter continuously operate whenever fiberglass is 

being produced, and maintain the following air pollution control technologies capable of 

meeting the emission limitations specified in Condition 43 of this permit: 

a. Forming Section: Use of combustion controls which minimize peak flame 

temperatures in the fiber forming process for control of NOx. Use of six (6) 

venturi scrubbers on the bonded wool forming line and one (1) venturi scrubber 

on the unbonded wool forming line (each with a minimum of 3” wc pressure 

drop), followed by a wet electrostatic precipitator with continuous water spray 

wash system and four (4) electrical fields (minimum) for the control of particulate 

matter. 

b. Curing Section: Use of low NOx burners burning natural gas for the control of 

NOx. Use of one regenerative thermal oxidizer with a minimum temperature of 

1475°F and a residence time of at least 0.75 second for control of VOC and 

particulate matter. A lower minimum operating temperature, not less then 

1200°F, may be used for the thermal oxidizers if, through emission testing, it is 

demonstrated to the satisfaction of the EPA that the lower temperature offers an 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 15 of 21

equivalent emission control of VOC and particulate matter as provided by the 

1475°F minimum temperature. 

The Permittee may retain the two existing thermal oxidizers. While the existing 

thermal oxidizers are in place, the Permittee shall operate the two existing thermal 

oxidizers during periods when the regenerative thermal oxidizer is shutdown, 

malfunctioning or undergoing maintenance. At no time shall the exhaust from the 

curing oven be vented to the atmosphere. The two thermal oxidizers shall operate 

in parallel with a minimum temperature of 1400°F and a residence time of at least 

0.5 second for the control of VOC and particulate matter. A lower minimum 

operating temperature, not less then 1200°F, may be used for the thermal 

oxidizers if, through emission testing, it is demonstrated to the satisfaction of the 

EPA that the lower temperature offers an equivalent emission control of VOC and 

particulate matter as provided by the 1400°F minimum temperature. 

c. Cooling Section: Use of a venturi wet scrubber for the control of particulate 

matter and VOC with exhaust immediately combined with inlet of the wet 

electrostatic precipitator at the forming section. 

43. Emissions from the Main Stack of the forming/curing/cooling (manufacturing line) 

operations shall not exceed the following emission limitations: 

a. NOx - 16.5 lb/hr and 1.76 lb/ton of glass pulled, based on a 3-hour rolling 

average. 

b. PM10 - 28.4 lb/hr and 3.03 lb/ton of glass pulled, based on a 3-hour rolling 

average. 

44. The opacity of the Main Stack exhaust, excluding condensed water vapor, shall not 

exceed 20 percent based on a six (6) minute average and shall apply at all times. An 

audible alarm shall sound in the control room to indicate an opacity exceeding the above 

opacity limit. 

45. The Permittee shall continuously operate and maintain a stack gas opacity monitor on the 

Main Stack. The continuous opacity monitor shall meet all applicable design and quality 

assurance requirements specified in 40 CFR 60.13 and 40 CFR Part 60, Specification 1 of 

Appendix B. A computer data acquisition system which has the capability of interpreting 

the sampling data, providing a graphical trend analysis, and producing a summary report 

of all six (6) minute averages of opacity readings shall also be provided. 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 16 of 21

46. The Permittee shall continuously operate and maintain the venturi scrubbers for the 

removal of suspended particulate matter and for the pretreatment of the gas upstream of 

the wet electrostatic precipitator. The scrubbers shall maintain a minimum gas pressure 

drop of 3 inches water across the venturi throat and a minimum water flow to each 

scrubber of 200 gal/min. The pressure drop and water flow parameters shall be measured 

and recorded continuously. The solids in the scrubber water shall be removed to the 

extent necessary and fresh make-up water added at all times of operation. 

47. The Permittee shall continuously operate and maintain a wet electrostatic precipitator for 

the control of suspended particulate matter from the outlet of the forming zone venturi 

scrubbers. The wet electrostatic precipitator shall maintain a minimum water flow and a 

minimum total corona power as established during initial emission testing to determine 

compliance with 40 CFR 60, Subpart PPP. 

48. The Permittee shall install, calibrate, maintain, and operate monitoring devices that 

measure the following parameters at the frequency and accuracy as noted in Table 1. All 

monitoring devices required for measuring the parameters in Table 1 are to be 

recalibrated quarterly in accordance with procedures under Section 60.13(b) of 40 CFR 

60. 

Table 1 

Parameters Recording 

Frequency Accuracy 

Gas pressure drop across each scrubber 

(in.H2O) Continuous ±1" WC 

Inlet water flow rate to each scrubber 

(GPM) Continuous ±5% over range 

Wet Electrostatic Precipitator inlet water 

flowrate (GPM) 

Every 15 

minutes ±5% over range 

Wet Electrostatic Precipitator: 

Secondary current (Amps.) 

Secondary voltage (kV) 

Spark rate 

Corona power/T-R set per field 

Inlet temp. (°F) 

Every 15 

minutes ±5% over range 

Regenerative Thermal Oxidizer: 

Exhaust temperature Continuous ±5% over range 

Thermal Oxidizer: Exhaust temperature Continuous ±5% over range 

49. For performance test purposes, the Permittee shall provide sampling ports, platforms and 

access on the emission unit exhaust system in accordance with the requirements of 40 

CFR 60.8(e).
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 17 of 21

50. Four sampling ports must be provided on the Main Stack (located on the same horizontal 

plane, 90 degrees apart, and at least two (2) duct diameters downstream, and one-half 

(1/2) duct diameters upstream of any flow disturbance) and shall consist of 4-inch female 

NPT couplings welded to the stack. The couplings shall be supplied with 4-inch pipe 

plugs. A sampling platform shall also be installed on the Main Stack. 

51. Sampling ports must be provided on the inlet and outlet of the wet electrostatic 

precipitator, and on the outlets of the thermal oxidizers for the purpose of determining 

emission control efficiency. A sampling platform or other means of providing safe 

access to the sampling ports shall be installed. 

Table 2 

Test Location PM10 NOx 

Main Stack Yes Yes 

wet ESP exhaust Yes No 

wet ESP inlet Yes No 

52. The Permittee shall conduct an initial performance test for NOx and PM10 within 180 

days after the effective date of this PSD permit or the date of startup of the regenerative 

thermal oxidizer on the curing oven, whichever date is later. Startup means the setting in 

operation of the regenerative thermal oxidizer on the curing oven for any purpose. The 

Permittee shall conduct performance tests (as described in 40 CFR 60.8) at the Main 

Stack. The Permittee shall retain records of all performance test measurements. 

53. The Permittee shall conduct performance testing annually. Annual performance testing 

shall be performed within 30 days after the anniversary of the most recent performance 

test. The Permittee shall conduct performance tests (as described in 40 CFR 60.8) for the 

NOx and PM10 emission limitations that apply to the Main Stack. The Permittee shall 

retain records of all performance tests measurements. 

54. Performance tests shall be conducted in accordance with EPA Test Methods 1 through 4 

and EPA Test Method 7E for NOx, and EPA Test Method 5E for PM10. 

55. For each performance test, the Permittee shall submit a performance test protocol to EPA 

no later than 30 days prior to the test to allow review of the test plan and to arrange for an 

observer to be present at the test. The performance test protocol shall include the 

operating conditions and type of materials or products that are expected to be formed 

during the performance test. The protocol shall also include a summary of the various 

materials formed over the past year and the percent of time during which those materials 

were produced that would have a higher potential NOx and PM10 emissions. If the test 

is performed while producing a material that does not have the highest potential NOx or 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 18 of 21

PM10 emissions, a retest may be required if the test results do not demonstrate a 

sufficient margin to assure compliance during all operating scenarios. The performance 

test protocol shall be amended if required by EPA. The performance test shall be 

conducted in accordance with the submitted protocol, and any changes required by EPA. 

 In lieu of the above mentioned test methods, equivalent methods may be used with prior 

written approval from EPA. 

56. Performance tests shall be performed by an independent testing firm. The Permittee shall 

furnish EPA with a written report of the results of such tests within sixty (60) days after 

the performance tests are conducted. 

57. During each performance test, the Permittee shall monitor and record the glass pull rate 

every fifteen (15) minutes. The Permittee shall determine the arithmetic average of the 

recorded glass pull rate measurements for each test run and calculate the average of the 

three test runs. This shall establish the test glass pull rate until the next performance test. 

The Permittee shall include the test glass pull rate for each performance test in the written 

report of the results of such tests for submission to EPA. The Permittee shall retain 

records of all calculations and measurements. 

58. For each performance test, the Permittee shall include a calculation of the actual NOx 

and PM10 emissions (in lb/hr and lb/ton glass pulled) for the forming/curing/cooling 

operation (Main Stack) in the written report of the results of such tests for submission to 

EPA. The Permittee shall use the NOx and PM10 emission rates in lb/hr and the test 

glass pull rate, in average tons of glass pulled per hour, determined from the performance 

test, to determine the emissions of NOx and PM10 in lb/ton glass pulled. The Permittee 

shall use the calculated actual NOx and PM10 emissions to determine compliance with 

the lb/ton BACT emission limit for the forming/curing/cooling operation (Main Stack) in 

Condition 43 of this permit. The Permittee shall retain records of all calculations and 

measurements. 

59. The Permittee shall determine compliance with the lb/hr emission limit for NOx and 

PM10 in Condition 43 of this permit on an hourly basis. The lb/hr emissions shall be 

calculated on an hourly basis using the actual glass pull rate for each hour and the NOx 

and PM10 emission factors, in lb/ton of glass pulled, determined from the past 

performance test (only those within the last five years) that most closely matches the 

operating glass pull rate. The Permittee shall retain records of all calculations and 

measurements. 

60. Re-Testing: The Permittee shall conduct a performance test within sixty (60) days if the 

glass pull rate increases by 5 percent or more (as averaged over any daily period) or 

decreases by 10 percent or more (as averaged over any weekly period) from the test glass 

pull rate established during any performance test within the last five (5) years conducted 

after effective date of this permit. The performance test shall be performed within 5 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 19 of 21

percent above or below the glass pull rate that triggered this re-testing requirement. The 

Permittee shall retain records of all calculations and measurements. This performance 

test is not required if the Permittee tested within 5 percent above or below the new glass 

pull rate within the last five (5) years and compliance was demonstrated; if a re-bricking 

of the furnace occurred within the last five (5) years after the performance test, new 

testing is required. 

61. The Permittee shall submit a written report of all excess emissions and monitoring 

systems performance to EPA in accordance with 40 CFR 60.7 (c) and (d) on a 

semiannual basis. The report is due on the 30th day following the end of each semiannual 

period after the effective date of this permit. Excess emissions shall be defined as any 

opacity level exceeding the opacity limitation in Condition 44 of this permit. Excess 

emissions shall be considered violations of the applicable emission limits for the 

purposes of this permit. 

62. The Permittee shall submit a written report of all excess emissions for Condition 43 of 

this permit in accordance with Conditions 58 and 59 of this permit for the 

forming/curing/cooling operation (Main Stack). Excess emissions shall be defined as any 

emissions exceeding the maximum emission limits set forth in Condition 43. The report 

shall be submitted to EPA semiannually and is due on the 30th day following the end of 

each semiannual period after the effective date of this permit. Excess emissions shall be 

considered violations of the applicable emission limits for the purposes of this permit. 

63. The Permittee shall maintain a file of all measurements, including continuous monitoring 

system, monitoring device, and performance testing measurements; all continuous 

monitoring system performance evaluations; all continuous monitoring system or 

monitoring device calibration checks; adjustments and maintenance performed on these 

systems or devices; and all other information required by 40 CFR Part 60 recorded in a 

permanent form suitable for inspection. The file shall be retained for at least five (5) 

years following the date of such measurements, maintenance, reports and records. 

64. Upon prior written request and adequate justification from the Permittee, EPA may waive 

the annual performance test. EPA approval shall be in writing. Such request must be 

submitted to EPA no later than 60 days prior to the annual performance test date. 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 20 of 21

FIBERGLASS TRIMMING & PACKAGING OPERATING CONDITIONS 

65. The method of control of particulate matter from the bonded wool forming line trimming 

and packaging areas, the Class A unbonded blowing wool processing area, and the Class 

B blowing wool processing area of the plant shall be the use of four (4) dust collector 

assemblies each followed by a high density filter module which shall exhaust inside the 

Scrap Building and have no outside vent. 

66. The dust collectors shall be equipped with bag leak detectors which shall be maintained, 

continuously operated, and calibrated on a regular basis as recommended by the 

manufacturer to assure reliability. 

67. The bag leak detectors shall be equipped with an audible alarm which shall sound 

automatically in the control room to indicate a torn or leaking bag. Spare bags shall be 

kept on site for immediate replacement of leaking or torn bags. The Permittee must 

initiate corrective action within 1 hour of an alarm from the bag leak detection system 

and complete corrective actions immediately. The corrective action may include any one 

or a combination of the following actions: 

a. Inspecting the baghouse for air leaks, torn or broken bags or filter media, or any 

other conditions that may cause an increase in emissions; 

b. Sealing off defective bags or filter media; 

c. Replacing defective bags or filter media, or otherwise repairing the control 

device; 

d. Sealing off a defective baghouse compartment; 

e. Cleaning the bag leak detection system probe, or otherwise repairing the bag leak 

detection system; and 

f. Shutting down the process producing the particulate emissions. 

68. The Permittee shall retain records of (a) each occurrence of the alarm for the bag leak 

detection system, (b) the corrective action(s) taken for each occurrence of the alarm, and 

(c) the duration for completing each corrective action(s). 
Knauf Insulation, GmbH 

PSD Permit No. SAC 03-01 

Amended December 13, 2010 

Page 21 of 21

69. The Permittee shall monitor and retain records of the following parameters on a daily 

basis: 

a. Hours of operation 

b. Production rates 

c. Leaks from the dust collectors 

70. The Permittee shall submit a written report of the following actions on a semiannual basis 

for the leak bag detection system: (a) each occurrence of the alarm for the bag leak 

detection system, (b) the corrective action(s) taken for each occurrence of the alarm, and 

(c) the duration for completing each corrective action(s). The report shall be submitted to 

EPA and is due on the 30th day following the end of each semiannual period after the 

effective date of this permit.