**FORM A -1** 

**PA RENT COMPA**  **NY INFORMA TION** 

**I. Parent Company / Legal Corporate Owner Information**

1. Legal Parent Company / Legal Corporate Name USG Corporation/ USG Interiors, Inc. 2. Address 550 W Adam s St 3. City Chicago 4. State IL 5. Zip Code 60661 6. County Cook 7. Size of Company (approximate number of employ ees including all subsidiaries, branches, and related establishments owned): More than 10,000 employ ees worldwide**FORM A -2** 

**FA CILITY INFORMA** 

**TION**

**II. Facility Information**

Facility Name USG Interiors W alworth Plant Facility Address Street 208 Adeline Street City Wa lworth State WI Zip Code 53184 County Wa lworth County Facility Coordinates Latitude (decimal degrees, six decimal places) 42.53621 Longitude (decimal degrees, six decimal places) -88.60172 Specific location represented (e.g., front door of main building, centroid of property , etc.) Unknown, EPA Envirofacts

Number of employees attached to the mineral wool production facility : 15 Production plus 10 support personnel

Design capacity

of the plant (tons/y r) CBI

Ty pe(s) of process(es) (rotary spin, flame attenuation) at this plant cupola

Operation schedule hrs/day 24 days/y r 365

Identify what state and local air pollution rules and regulations, including permit requirements, your plant is subject to. (Please provide copies of permit(s) and permit IDs) See attached Air Emission Permit (Title V) No. 265006830-P01.

**III. Technical Contact**

Name John Bolden Technical Contact Title Environm ental Services Senior Manager Telephone 312-436-5587Facsimile (Fax)

Email 

### jbolden@usg.com

**IV. Other**

Is the facility

a major source of HAP? No

If "No", did the facility take a limit of its potential HAP emissions to avoid classification as a major source? Yes

Does the facility

manufacture other products in addition to mi neral wool? Yes

If "Yes", list the other products manufactured at the facility

. Ceiling Tile

Are there any

HAP em issions associated with any co-located facilities? List unit operations, e.g., boiler, and pollutant/emissions Boiler (B10), Tile Dryers (P32 and P36), Curing Ovens (P34 and P38). Minimal HAPs emissions from fuel combustion (natural gas or propane).**FORM A -2** 

**FA CILITY INFORMA** 

**TION**

**II. Facility Information**

Facility Name Facility Address Street City State Zip Code County Facility Coordinates Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Specific location represented (e.g., front door of main building, centroid of property , etc.)

Number of employees attached to the mineral wool production facility :

Design capacity

of the plant (tons/y r)

Ty pe(s) of process(es) (rotary spin, flame attenuation) at this plant

Operation schedule hrs/day days/y r

Identify what state and local air pollution rules and regulations, including permit requirements, your plant is subject to. (Please provide copies of permit(s) and permit IDs)

**III. Technical Contact**

Name Technical Contact Title Telephone USG Interiors Red W ing Plant

27384 Highway

61 Blvd Red W ing MN 55066 Goodhue County

44.554932 -92.473599

Unknown, EPA Envirofacts

40

CBI

cupola

At full capacity

24 365

See attached Air Emission Permit (Title V) No.04900007-003.

John Bolden Environm ental Services Senior Manager 312-436-5587Facsimile (Fax)

Email

**IV. Other**

Is the facility

a major source of HAP?

If "No", did the facility take a limit of its potential HAP emissions to avoid classification as a major source?

Does the facility

manufacture other products in addition to mi neral wool?

If "Yes", list the other products manufactured at the facility

.

Are there any

HAP em issions associated with any co-located facilities? List unit operations, e.g., boiler, and pollutant/emissions 

### jbolden@usg.com

No

Yes

No

NA

Boiler (EU 005). Minimal HAPs emissions from fuel combustion (natural gas).**FORM A -2** 

**FA CILITY INFORMA** 

**TION**

**II. Facility Information**

Facility Name Facility Address Street City State Zip Code County Facility Coordinates Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Specific location represented (e.g., front door of main building, centroid of property , etc.)

Number of employees attached to the mineral wool production facility :

Design capacity

of the plant (tons/y r)

Ty pe(s) of process(es) (rotary spin, flame attenuation) at this plant

Operation schedule hrs/day days/y r

Identify what state and local air pollution rules and regulations, including permit requirements, your plant is subject to. (Please provide copies of permit(s) and permit IDs)

**III. Technical Contact**

Name Technical Contact Title Telephone At full capacityFacsimile (Fax)

Email

**IV. Other**

Is the facility

a major source of HAP?

If "No", did the facility take a limit of its potential HAP emissions to avoid classification as a major source?

Does the facility

manufacture other products in addition to mi neral wool?

If "Yes", list the other products manufactured at the facility

.

Are there any

HAP em issions associated with any co-located facilities? List unit operations, e.g., boiler, and pollutant/emissions**FORM B-1**

**PLA NT OPERA** 

**TIONS**

**I. Overview of Process Operations**

Number of process lines. Include lines that are currently operational or that are temporarily shutdown. (Do not include lines permanently shutdown). Wa lworth #1, Red W ing #1 and Red W ing #2

For each process line: Process Line 1 Process Line 2 Process Line 3 Process line identification name or numbers Wa lworth #1 Red W ing #1 Red W ing #2

Ty pe of process line (e.g., Fiberization method) Mineral W ool Production Mineral W ool Production Mineral W ool Production Maximum annual production rate (tons/y r) CBI CBI CBI

Age of process line (y rs) Cupola - Plant purchased in 1959 (51 y rs). Title V lists construction/ modfication date as 1969. Cupola - 1973 (37 y rs) Cupola - 1979 (31y rs)

Remaining economic life of process line (y rs) NA, Continued maintenance can provide indefinite life for this equipment. NA, Continued

ma intenance can provide indefinite life for this equipm ent. NA, Continued maintenance can provide indefinite life for this equipment. List of products produced and most recent annual production (tons/y r; specify year) for each product CBI CBI CBI

Please attach detailed schematics of each process line Attachment (CBI) Attachment (CBI) Attachment (CBI)**FORM B-2**

**PROCESS OPERA TIONS** 

**II. Raw Material Handling and Storage**

Cupola charge preparation Raw materials and proportions bywt (%) Wa lworth - Coke (CBI) and Minerals (CBI) Red W ing #1 - Coke (CBI) and Minerals (CBI) Red W ing #2 - Coke (CBI) and Minerals (CBI)

Method(s) of convey ing each raw material to cupola Mechanical (See Confidential Process Line Diagram requested on Form B-1) Binder and Additives USG Interiors does not use binders at either Plant. List each raw material, including premixed materials, in the binder formulation and its proportion bywt (%) NA List steps in preparing binder, including storage temperature ( ° F) and holding time (hrs) NA Total y early

consumption of binder, excluding water, (gal/y r) NA Cost of binder, excluding water, ($/gal) for most recent ye ar (specify

year) NA Are binder storage and mixing tanks vented to outside/inside? NA

Method of treating vent air from storage and mix tanks NA Emission control during liquid raw material transfer from vehicles to storage tanks. NA Describe future source reduction plans and schedules to reformulate binders; List each constituent, proportions wt (%), cost ($/gal) for reformulation NA**FORM B-3**

**PROCESS OPERA**

**TIONS**

**III. Cupola/furnace** Wa lworth #1 Red W ing #1 Red W ing #2 For each cupola: Cupola 1 Cupola 2 Cupola 3 Process unit identification name/number P30 EU001 EU002 Process line(s) served (identification name/number) Mineral W ool Mineral W ool Line 1 Mineral W ool Line 2 Latitude (decimal degrees, six decimal places) 42.53621 44.554932 44.554932 Longitude (decimal degrees, six decimal places) -88.60172 -92.473599 -92.473599

Stack or vent height (units) 68.5 feet 180 feet See RW #1 (one stack for both cupolas)

Stack or vent diameter (units) 3 feet 2.6 feet See RW #1 (one stack for both cupolas) Manufacturer and model Original Original Original

Date of original installation Plant purchased in 1959. Title V lists construction/

mo dfication date as 1969. 1973 1979

Estimate of remaining lifetime (y rs) N/A Continued

ma intenance can

ma ke it an indefinite life. N/A Continued

ma intenance can

ma ke it an indefinite life. N/A Continued

ma intenance can

ma ke it an indefinite life. Major rebuilds:W hat constitutes a major rebuild The industry is not familiar with the term “major rebuild.” Federal and state regulators have agreed that a furnace, cupola, or melter refractory

rebricking or lining replacem ent is properly categorized as routine

ma intenance, repair, or replacement (“RMRR”), which covers a wide variety of activities. The industry is not familiar with the term “major rebuild.” Federal and state regulators have agreed that a furnace, cupola, or melter refractory

rebricking or lining replacement is properly categorized as routine

ma intenance, repair, or replacement (“RMRR”), which covers a wide variety of activities. The industry is not familiar with the term “major rebuild.” Federal and state regulators have agreed that a furnace, cupola, or melter refractory

rebricking or lining replacem ent is properly categorized as routine

ma intenance, repair, or replacement (“RMRR”), which covers a wide variety of activities. Frequency

of a major rebuild NA NA NA Cost of ty pical major rebuild NA NA NA Date of last major rebuild NA NA NA Purpose of last major rebuild NA NA NA Increase or decrease in emissions NA NA NA Fuel ty pe: coke, electric, gas, or oil Coke, natural gas Coke, natural gas Coke, natural gas

Fuel consumption rate (KW /ton of melt or Btu/ton of melt) CBI CBI CBI Design production rate (tons/day ) CBI CBI CBI Actual glass pull rate (tons/day ) CBI CBI CBI Exhaust air flow rate (acfm @ ° F) Unknown Unknown Unknown Temperature ( ° F) of melt as it exits the cupola 2800 deg F 2400-2700 deg F 2400-2700 deg F

Is oxygen enrichment used to supplement combustion air Not used during normal operations Yes Yes Quantity

of oxygen supplied for enrichment (cu. Ft. O2/ton coke) N/A CBI CBINature and frequency of routine/preventive maintenance procedures Routine inspections including: Inspect for leaks and repair -

mo nthly ; Inspection of water jacket - quarterly ; Repair cracks and dye check. Inspect for leaks and repair - monthly ; Inspection of water jacket - quarterly ; Repair cracks, dy e check, and hydro - annually ; Inspect for leaks and repair - monthly ; Inspection of water jacket - quarterly ; Repair cracks, dy e check, and hydro - annually ;

Describe process modification(s) since 1999 that reduce

em issions In 2003 installed new sty le of dust collector bags to reduce PM

em issions. In 1999 the plant installed thermal oxidizer elevating exhaust temperatures to meet a minimum of 1400 degrees F. In 2005 the plant replaced the existing fabric filter.In 2007 the plant repaired leaks in duct work between cupola and baghouse reducing the amount of excess air which required the Plant to burn less natural gas. In 1999 the plant installed thermal oxidizer elevating exhaust temperatures to meet a minimum of 1400 degrees F. In 2005 the plant replaced the existing fabric filter.In 2007 the plant repaired leaks in duct work between cupola and baghouse reducing the amount of excess air which required the Plant to burn less natural gas.

Describe future source reduction plans and schedules None planned None planned None planned**FORM B-4**

**PROCESS OPERA**

**TIONS** NA - USG Interiors lines are unbonded so no HAPs are created. **IV. Fiberization**

For each fiberization operation: Fiberization Operation 1 Fiberization Operation 2 Fiberization Operation 3 Process unit identification name/number Process line(s) served (identification name/number) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Number of fiber forming devices (spinners) per line Method of attenuation fiber (air, centrifical force, or both) Major rebuilds: W hat constitutes a major rebuild Frequency

of a major rebuild Cost of ty pical major rebuild Date of last major rebuild Purpose of last major rebuild Increase or decrease in emissions If forming section is modular, i.e., more than one forming and collection area per line, indicate the number of modules and air plenum s. Presence of water overspray and application range (gpm) Binder applied and application rate (gpm) Other material applied (annealing oil or oil/water emulsion) and application rate (gpm) Temperature of binder when applied to the fibers ( ° F) Forming air flow rate (acfm @ °F)

Percent of forming air recirculated and percent exhausted Nature and frequency of routine/preventive maintenance procedures Describe process modification(s) since 1999 that reduce

em issions Describe future source reduction plans and schedulesFiberization m ethod (e.g., Downey process or Youger/Powell process) Number of rotors Configuration of rotor(s) Amount of material that remains non-fiberized shot Exhaust air flow rate (acfm @ ° F)**FORM B-5**

**PROCESS OPERA**

**TIONS** NA - USG Interiors lines are unbonded so no HAPs are created. **V. Fiber Collection**

For each fiber collection operation: Fiber Collection Operation 1 Fiber Collection Operation 2 Fiber Collection Operation 3 Process unit identification name/number Process line(s) served (identification name/number) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Method of fiber collection from fiberization Manufacturer and model of collection chamber Date of original installation Major rebuilds: W hat constitutes a major rebuild Frequency

of a major rebuild Cost of ty pical major rebuild Date of last major rebuild Purpose of last major rebuild Increase or decrease in emissions

Air flow rate (acfm @ ° F) in pneumatic fiber convey ing Exhaust air flow rate (acfm @ °F) Residence time of product (mins) (time spent in collection device)

Method of evenly

distributing fibers onto conveyor belt Formed mat thickness (in.) Nature and frequency of routine/preventive

ma intenance procedures Describe process modification(s) since 1999 that reduce emissions

Describe future source reduction plans and schedules**FORM B-6**

**PROCESS OPERA**

**TIONS** NA - No Curing at USG Interiors. **VI. Curing**

For each curing oven: Curing Oven 1 Curing Oven 2 Curing Oven 3 Process unit identification name/number Process line(s) served (identification name/number) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Method of curing Manufacturer and model Date of original installation Major rebuilds: W hat constitutes a major rebuild Frequency

of a major rebuild Cost of ty pical major rebuild Date of last major rebuild Purpose of last major rebuild Increase or decrease in emissions Fuel ty pe: electric, gas, or oil Fuel consumption rate (KW /hr or BTU/hr) Curing temperature ( ° F) Moisture content wt (%) of formed mat: inlet outlet Exhaust air flow rate (acfm @ ° F) from curing Residence time of product (mins) Binder content of cured product (LOI) Nature and frequency of routine/preventive maintenance procedures Describe process modification(s) since 1999 that reduce

em issions Describe future source reduction plans and schedules**FORM B-7**

**PROCESS OPERA**

**TIONS** 

### NA - No Cooling at USG Interiors.

**VII. Cooling**

For each cooling operation: Cooling Operation 1 Cooling Operation 2 Cooling Operation 3 Process unit identification name/number Process line(s) served (identification name/number) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Cooling air flow rate (acfm @ ° F) Percentage of cooling air recirculated (if any ) Cooling air temperature (°F) Exhaust air flow rate (acfm @ °F) Nature and frequency of routine/preventive maintenance procedures Describe process modification(s) since 1999 that reduce

em issions Describe future source reduction plans and schedules**FORM B-8**

**PROCESS OPERA**

**TIONS**

**VIII. Pollution Prevention**

Please describe any

work practices, pollution prevention techniques, and control strategies evaluated and/or implemented at each process unit at your facility

(e.g., binder reformulation, alternative fuels usage, etc.) to reduce emissions of PM, CO, and HAPs you identified in Form E. You m ust specify

the year in which the facility im plem ented the practice/technique and identify the emission reductions (if measured) from these practices/techniques. If process modifications were made and records of those

mo difications still exist, companies will provide them to EPA. It is worthwhile noting that the products manufactured at this facility are used to make buildings more energy efficient. A thermally

efficient building reduces the energy required to maintain a comfortable indoor environment. A decrease in energy consumption conserves non-renewable fuel supplies and reduces air pollution and greenhouse gas emissions such as carbon dioxide (CO2) and nitrogen oxide (NOx). According to a Harvard University

School of Public Health study , thermal insulation’s reduction of emissions greatly im proves public health.



### Walworth Cupola

C11 Thermal Oxidizer, 1986 Thermal oxidation of carbon monoxide (99.70%) and hydrogen sulfide (99.90%) C12 Fabric Filter, 1993 Fabric filtration of particulate matter (0.01 gr/dscf)

Red Wing Cupola #1 and #2

Afterburner, 1999 Controls CO, 100% Capture Efficiency, 99% Collection Efficiency

North (Cupola #2) Baghouse, 2002 Controls Metal HAPs, PM10 and PM. Capture Efficiency is 100% for all Pollutants. Collection Efficiency for Metal HAPs is 88%. Collection Efficiency for PM10 and PM is 99%.

South (Cupola #1) Baghouse, 2005 Controls Metal HAPs, PM10 and PM. Capture Efficiency is 100% for all Pollutants. Collection Efficiency for Metal HAPs is 88%. Collection Efficiency for PM10 and PM is 99%.**FORM C-1**

**AI R POLLUTION CONTROL** 

**I. Electrostatic Precipitator (ESP) - NA**

For each ESP: ESP 1 ESP 2 ESP 3 Process line(s) (identification name/number) Equipm ent/process(es) controlled. Include emission point 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) Stack or vent diameter (units) Manufacturer and model Date of original installation Number of collection plates and configuration Gas flow rate to ESP (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%) Pressure drop across ESP (in. H 2 O gauge) Plate area (ft 2 ) Vendor guarantee on ESP efficiency (attach copy ) Method of plate cleaning and frequency Flow rate of plate wash water to ESP (gpm), if applicable Temperature of plate wash water to ESP ( ° F), if applicable Source of plate wash water used for cleaning, if applicable Concentration (mg/l) of dissolved and suspended solids in plate wash water, if applicable Conditioning agents used and amounts (in gpm or lbs/hr), if applicable Amount of wastewater generated (gpd), if applicable Amount of wastewater recy cled (gpd), if applicable Amount of wastewater disposed of (gpd), if applicable Method of wastewater disposal, if applicable Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

of solid waste disposed of (lbs/y r)Method of solid waste disposal

Nature and frequency of routine/preventive maintenance procedures Problems experienced with control device within the last five ye ars; how were problems solved? Continuous monitoring method(s) used to monitor ESP performance, including parameters monitored Describe any

plans to replace or upgrade ESP**FORM C-2**

**AI R POLLUTION CONTROL** 

**II. Scrubber - NA**

For each scrubber: Scrubber 1 Scrubber 2 Scrubber 3 Process line(s) (identification name/number) Equipm ent/process(es) controlled. Include emission point 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) Stack or vent diameter (units) Manufacturer and model Date of original installation Ty pe (e.g., venturi, orifice) Gas flow rate to scrubber (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%) W ater flow rate to scrubber (gpm) Percent of scrubber water from recy cled wastewater

Source of scrubbing water and ty pe of pretreatment. Substance(s) added as part of pretreatment and amount used (gpm or lbs/hr) HAP composition of wastewater (mg/L) Concentration (mg/L) of dissolved and suspended solids in scrubbing water Scrubbing water temperature ( ° F) Liquid/gas ratio (gal/10 3 acfm) Pressure drop across scrubber (in. H 2 O gauge) Amount of wastewater generated (gpd) Amount of wastewater recy cled (gpd) Amount of wastewater disposed of (gpd)Method of wastewater disposal

Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

of solid waste disposed of (lbs/y r) Method of solid waste disposal Vendor guarantee on scrubber efficiency (attach copy ) Nature and frequency of preventive maintenance procedures Problems experienced with control device within the last five years; how were problem s solved? Continuous monitoring method(s) used to monitor scrubber performance, including parameters monitored Plans to replace or upgrade scrubber**FORM C-3**

**AI R POLLUTION CONTROL** 

**III. Mechanical Collector - NA**

For each mechanical collector: Mechanical Collector 1 Mechanical Collector 2 Mechanical Collector 3 Process line(s) (identification name/number) Equipm ent/process(es) controlled. Include emission point 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) Stack or vent diameter (units) Manufacturer and model Date of original installation Ty pe of mechanical collector Gas flow rate to collector (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%) Overall pressure drop (in. H 2 O gauge) Vendor guarantee on mechanical collector efficiency (attach copy ) Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

of solid waste disposed of (lbs/y r) Method of solid waste disposal

Nature and frequency of preventive maintenance procedures Problems experienced with control device within the last five ye ars; how were problems solved? Continuous monitoring method(s) used to monitor performance, including parameters monitored Plans to replace or upgrade mechanical collector**FORM C-4**

**AI R POLLUTION CONTROL** 

**IV. Fabric Filter**

For each fabric filter: 

### Walworth **Red Wing Red Wing**  Process line(s) (identification name/number) 

### Cupola Baghouse (C12) South Baghouse (CE001) North Baghouse (CE004) Equipm ent/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) 

### Mineral Wool Cupola (P30) Cupola #1 (EU001) Cupola #2 (EU002) Latitude (decimal degrees, six decimal places) 42.537219 44.554932 44.554932 Longitude (decimal degrees, six decimal places) -88.603374 -92.473599 -92.473599 Stack or vent height (units) 68 feet 180 feet 180 feet Stack or vent diameter (units) 3.5 feet 2.6 feet 2.6 feet

Manufacturer and model 

### Seneca Environmental,
672-FMTHS-12 Two Size 1318 Model 144 TASB Series 6P, Wheelabrator Modular Jet III Automatic Pulse Type Dust Collector Modules Two Size 1818 Model 144 TASB Series 6P, Wheelabrator Modular Jet III Automatic Pulse Type Dust Collector Modules Date of original installation 

### 1993 2005 2002 Number of compartments 

### 4 2 4 Number of bags per compartment 

### 168 234 162

Filter material and coatings applied 

### Fiberglass with PTFE membrane on PTFE coated glass Woven fiberglass with PTFE membrane Woven fiberglass with PTFE membrane Fabric weight (oz/yd 2 ) 

### 22 22 22 Filter surface area (ft 2 ) 

### 18 9,150 12,672 Gas flow rate to filter (acfm @ ° F) 

### 20,000-25,000 20,000 25,000 Inlet gas temperature ( ° F) 

### Unknown approx 275 deg F approx 300 deg F Outlet gas temperature ( ° F) 

### approx 300 deg F approx 240 deg F approx 240 deg F Inlet grain loading (gr/dscf) 

### N/A N/A N/A Outlet grain loading (gr/dscf) 

### 0.0022 N/A N/A Average stack opacity (%) 

### 0-5% < 10% < 10% Overall pressure drop (in. H 2 O gauge) 

### 0.5"-10" 1"-12" 1"-12"Method and frequency of bag cleaning 

### Compressed Air/On demand Pulse bags based on pressure differential Pulse bags based on pressure differential

Vendor guarantee on fabric filter efficiency (attach copy ) 

### N/A N/A N/A Quantity

of solid waste collected (lbs/y r) 

### Unknown Unknown Unknown Quantity

of solid waste recycled (lbs/y r) 

### 0 0 0 Quantity

of solid waste disposed of (lbs/y r) 

### Unknown Unknown Unknown Method of solid waste disposal 

### Landfill Landfill Landfill

Nature and frequency of preventive maintenance procedures 

### Preventative maintenance procedures include: Checkfor fan vibration – biweekly, check for bad fan belts – bi-weekly, checkfan bearings for heat – biweekly, inspect screw conveyors – bi-weekly,inspect rotary valve – biweekly, check bag poppers – bi-weekly, visually inspect photohelic lines – bi-weekly, Dye check of bags – monthly, inspect augers – monthly, inspect hoppers/ducting – monthly, Lime feeder inspection - monthly Preventative maintenance procedures include: Inspect and clean broken bag detector probe - monthly; Check that all doors and explosion vents are sealed - monthly; Clean differential lines - monthly; Clean draft lines - monthly; Inspect broken bag detector - monthly; Clean and inspect baghouse flow meters - monthly; Clean hopper walls and vacuum dust from the tube sheet - monthly; Check firing of all blow tube solenoids - monthly; Visoliteto check for leaks - bimonthly; Check seals on doors - monthly; Inspect ID fan - quarterly; Inspect auger - quarterly; Preventative maintenance procedures include: Inspect and clean broken bag detector probe - monthly; Check that all doors and explosion vents are sealed - monthly; Clean differential lines - monthly; Clean draft lines - monthly; Inspect broken bag detector - monthly; Clean and inspect baghouse flow meters - monthly; Clean hopper walls and vacuum dust from the tube sheet - monthly; Check firing of all blow tube solenoids - monthly; Visoliteto check for leaks - bimonthly; Check seals on doors - monthly; Inspect ID fan - quarterly; Inspect auger - quarterly;Problems experienced with control device within the last

five years; how were problems solved? 

### None To minimize fires in the fabric filter system due to sulfur accumulation, Red Wing maintains the exhaust temperature higher then the sulfur dew point. To minimize fires in the fabric filter system due to sulfur accumulation, Red Wing maintains the exhaust temperature higher then the sulfur dew point.

Continuous monitoring method(s) used to monitor performance, including parameters monitored 

### Pressure Drop measured each shift. Pressure drop between 0.5" and 10" H20. Broken bag detector; Pressure drop between -1" and -12"H20. Broken bag detector; Pressure drop between -1" and -12"H20. Plans to replace or upgrade fabric filter 

### None None None**FORM C-5**

**AI R POLLUTION CONTROL** 

**V. Thermal Incinerator**

For each thermal incinerator 

### Walworth **Red Wing**

Process line(s) (identification name/number) 

### Afterburner (C11) Thermal Oxidizer (CE003)

Equipm ent/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) 

### Mineral Wool Cupola (P30) Cupola #1 and Cupola #2 (EU001 and EU002) Latitude (decimal degrees, six decimal places) 42.537217 44.554932 Longitude (decimal degrees, six decimal places) -88.603478 -92.473599 Stack or vent height (units) 68 feet 180 feet Stack or vent diameter (units) 3.5 feet 2.6 feet

Manufacturer and model 

### Modern Equipment. Model Unknown. Weishaupt Burner Model No. G70/2-A,ZM Date of original installation 

### 1986 1999 Fuel ty pe: gas or oil 

### Gas Gas

Fuel consumption rate (BTU/hr) 

### 8.4 mmbtu/hr (natural gas or propane) 35 mmBtu/hr (natural gas)
Inlet gas flow rate (acfm @ ° F) 

### Varies Varies Inlet gas temperature ( ° F) 

### 500F-700 deg F approx 240 deg F Combustion chamber gas temperature ( ° F) 

### 1450 deg F 1400-1750 deg F Outlet gas temperature ( ° F) 

### 1375 deg F 171 deg F Inlet grain loading (gr/dscf) 

### N/A Varies Outlet grain loading (gr/dscf) 

### N/A Varies Average stack opacity (%) 

### 0-5% < 10% Excess air (%) 

### 10% Varies Residence time (sec) at temperature ( ° F) 

### Varies Varies Percent heat recovery 

### 0 0

Vendor guarantee on incinerator efficiency (attach copy ) 

### N/A N/ANature and frequency of preventive maintenance procedures 

### Preventative maintenance procedures include: Refractory replacement, Clean pilot valve – annually, Clean burners – Quarterly, Inspect refractory – Quarterly, Inspect interior of incinerator – Quarterly, Calibrate burner air/gas ratio – Semi-annually. Preventative maintenance procedures include: Lube burner linkage - monthly; Clean CO sensor - monthly; Clean O2 sensor - monthly; Inspect high temperature diverting devices - quarterly; Inspect refractory inside burner area for cracks - quarterly; Inspect nozzles and burner - quarterly; Inspect refractory inside stack area for cracks - quarterly; Remove plenum door and inspect inside - quarterly; Visually inspect electrical system - quarterly; Inspect safety interlocks - annually;

Problems experienced with control device within the last five ye ars; how were problems solved? 

### Burner kick-outs resolved by re-lighting burners Occasionally the plant experiences high plenum temperatures, to protect the equipment dilution air is added lowering temperature to an acceptable level.Continuous monitoring method(s) used to monitor incinerator

performance, including parameters monitored 

### Temperature Temperature Plans to replace or upgrade thermal incinerator 

### None None**FORM C-6**

**AI R POLLUTION CONTROL** 

**VI. High Velocity A ir Filter (HVA**  **F) - NA**

For each HVAF: HVAF 1 HVAF 2 HVAF 3 Process line(s) (identification name/number) Equipm ent/process(es) controlled. Include emission point 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) Stack or vent diameter (units) Manufacturer and model Date of original installation Inlet 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 (%) W ater spray

pressure (psig), if applicable W ater spray

rate (gpm), if applicable Filter face velocity

(acfm/ft 2 ) Maximum pressure drop across mat (in. H 2 O gauge) Vendor guarantee on HVAF efficiency (attach copy ) Method and frequency of filter mad advancement Amount of wastewater generated (gpd) Amount of wastewater recy cled (gpd) Amount of wastewater disposed of (gpd) Method of wastewater disposal Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

of solid waste disposed of (lbs/y r) Method of solid waste disposalNature and frequency of preventive maintenance procedures Problems experienced with control device within the last five years; how were problems solved? Continuous monitoring method(s) used to monitor HVAF performance, including parameters monitored Plans to replace or upgrade HVAF**FORM C-7**

**AI R POLLUTION CONTROL** 

**VII. Mist Eliminator - NA**

For each mist eliminator: Mist Eliminator 1 Mist Eliminator 2 Mist Eliminator 3 Process line(s) (identification name/number) Equipm ent/process(es) controlled. Include emission point 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) Stack or vent diameter (units) Manufacturer and model Date of original installation Ty pe of mist eliminator Gas flow rate to mist eliminator (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%) Velocity

in m ist elim inator (ft/sec) Pressure drop (in. H 2 O gauge)
For chevron blade mist eliminators: Spacing between blades (in.) W ashing frequency of blades For mesh pad mist eliminators: Number of pads or elements Thickness of pad (in.) or element dimensions Density

of pad, (lb/ft 3 ) W ashing frequency of pad Vendor guarantee on mist eliminator efficiency (attach copy ) Amount of wastewater generated (gpd) Amount of wastewater recy cled (gpd)Amount of wastewater disposed of (gpd)

Method of wastewater disposal Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

of solid waste disposed of (lbs/y r) Method of solid waste disposal Nature and frequency of preventive maintenance procedures Problems experienced with control device within the last five ye ars; how were problems solved? Continuous monitoring method(s) used to monitor mist eliminator performance, including parameters monitored Plans to replace or upgrade mist eliminator**FORM C-8**

**AI R POLLUTION CONTROL** 

**VIII. Ventilation System - NA**

For each ventilation system: Ventilation System 1 Ventilation System 2 Ventilation System 3 Process line(s) (identification name/number) Equipm ent/process(es) controlled. Include emission point 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) Stack or vent diameter (units) For general or building ventilation: Ventilation system used Airflow control system used Number of air changes per hour For unit or local ventilation: Enclosure or hood design used Volume of enclosure or hood Capture velocity (ft/sec) Distance between hood and emission source (ft)**FORM C-9**

**AI R POLLUTION CONTROL** 

**IX. Other - NA**

For each other air pollution control devide (APCD): Other APCD 1 Other APCD 2 Other APCD 3 Process line(s) (identification name/number) Equipm ent/process(es) controlled. Include emission point 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) Stack or vent diameter (units) Description**FORM D**

**PROCESS LINE STA RTUP A**  **ND SHUTDOWN**

1. For each startup and shutdown (SS) that occurred during the past five years, please provide the following information requested in A. through J. USG does not operate a Major Source of HAPs emissions at the W alworth, WI and Red W ing, MN mineral wool Plants. Due to the fact that USG only operates area HAPs sources, formal startup, shutdown and malfunction plans and procedures are not required. (No SSMP)

A. Using the definitions provided above, indicate whether the event was a startup or shutdown; USG is not required to make a record of each startup and shutdown at its mi neral wool production facilities in W alworth, W I and Red W ing, MN. B. A description of the event, including identification of the

em issions source or sources associated with the startup or shutdown; USG is not required to make a record of each startup and shutdown at its mi neral wool production facilities in W alworth, W I and Red W ing, MN. C. W hether any

permit condition was exceeded and, if so, what permit condition was exceeded; NA

D. W hether the event was covered by any contingency

plan for controlling emissions during startup and shutdown events and, if so, whether the plan was followed; if the plan was not followed, why not; NA E. The duration of the event; NA F. The actions taken to minimize emissions during the event, including the use of any backup control systems; NA G. Estimates or measurements, if any , of emissions during the event; if you did not have the ability to quantify

emissions during the event, please explain why ; NA H. W hether the emission profile of each unit was different during startup and shutdown than during normal operating conditions and, if so, how emissions were different and why ; please provide any supporting information; The emission profile during startup and shutdown is not different than the profile during normal operating conditions. I. All performance test data collected during each period of SS; the test method used for each event; when the testing was conducted and why ; the test conditions at the time of testing; and whether the tests were associated with a routine startup or shutdown; and NA 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.J. All monitoring data, including control system parameter

mo nitoring, collected during each period of SS. NA

If this information is contained in periodic and immediate SS reports (either stand-alone or contained within the periodic excess emissions report) submitted to your permitting authority , you may submit copies of those reports instead.

2. Are there any

ty pes of startup or shutdown events that you have been able to elim inate? If so, please describe the ty pe of event and explain how these events were elim inated. NA 3. Please submit a copy of your SS plan if you are required to develop one. NA 4. Please provide all performance test data collected during periods of SS over the last 5 years. Indicate the test method used for each event. NA 5. Please provide all m onitoring data, including control system parameter monitoring, collected during periods of SS over the last 5 ye ars. NA 6. Optional: Do you wish to recommend a standard that would apply during startup or shutdown? If so, please describe the event to which the standard would apply ; the recommended standard (this could be an emission limitation, work practice, or operational standard) that would apply during the period; the basis for the recommended standard; why and how the standard would m inim ize

em issions during the event; and how would compliance be determined and/or monitored. NA**FORM E**

Please provide any

existing emissions information and data covering hazardous air pollutants (HAP), particulate matter (PM), and carbon

mo noxide (CO) for each listed process. Identify the appropriote box for which you are providing specific process inofrmation and/or pollutant

em issions data. Cupola Fiberization Fiber Collection Curing Cooling Carbon monoxide (CO) Carbony l sulfide (COS) Particulate Matter (PM, PM2.5, PM10, PM condensable) Chromium compounds and Hexavalent Chromium (including any Cr speciation data) Other metal HAP (As, Be, Cd, Co, Hg, Pb, Mn, Sb, Se) Hydrogen Fluoride (HF) Hydrogen Chloride (HCl) Formaldehyde Phenol Methanol The existing data requested here has been provided to EPA by the industry ’s trade association, the North American Insulation Manufacturers Association (“NAIMA”). The existing data provided by NAIMA was set forth in NAIMA’s May 5, 2010 letter to EPA. The representative existing emissions data provided from fiber glass companies included test results for the following pollutants: formaldehyde, methanol, phenol, particulate matter, hydrogen fluoride, metals (antimony , arsenic, bery llium , cadmium, chromium, cobalt, lead, manganese, nickel, and selenium), mercury , and hexavalent chromium. The representative existing emissions data provided from mineral wool companies included test results for the following pollutants: formaldehyde, methanol, phenol, particulate

ma tter, carbon monoxide, carbony l sulfide, hydrogen fluoride, metals (antimony , arsenic, bery llium , cadmium, chromium, cobalt, lead,

ma nganese, nickel, and selenium), mercury , and hexavalent chromium. The scope of the existing data provided was the result of consensus reached by

EPA, NAIMA, and industry representatives. In addition to the existing data submitted to EPA, extensive new

em issions data is being collected from virtually all companies through the “BTEC, Inc. Quality Assurance Project Plan for the Mineral W ool and W ool Fiberglass Emissions Test Program.” This Test Program will collect and subm it to EPA, through EPA’s Electronic Reporting Tool, representative emissions data for the following pollutants: formaldehyde, methanol, phenol, particulate matter, carbon

mo noxide, carbony l sulfide, hydrogen fluoride, metals (antimony

, arsenic, bery llium , cadmium, chromium, cobalt, lead, manganese, nickel, and selenium), mercury , and hexavalent chromium.Other organic HAP

### COMPANY CONFIDENTIAL

**FORM F-1 COST** 

**I. Process Unit (e.g., cupola, curing oven, etc.): WA**  **LWORTH** For each process unit: Process Unit 1 Process Unit ID Mineral Fiber Operation Process Line ID Mineral Fiber Operation

**II. Capital Costs** Base year no data Total capital cost, including costs for individual pieces, if available. no data **III. A nnual Operating Costs**  Base year (most recent fiscal y ear) 2009 Total annual operating costs CBI Maintenance materials and replacement parts (specify costs by item ) CBI Raw m aterials costs CBI Labor ($/y r) for each labor class - Production CBI ($/y r) for each labor class - Maintenance CBI (hr/hr) for each labor class - Production (labor hr / gross hr) CBI (hr/hr) for each labor class - Maintenance (labor hr / gross hr) CBI Utilities (breakdown for each utility ) - Natural gas *see Pollution Control (F-2) Utilities (breakdown for each utility ) - Power CBI W aste treatment and/or disposal CBI Costs associated with any work practices and pollution prevention techniques that are employed at your facility n/a Savings associated with heat recovery and wastewater and/or solid waste returned to process from APCD (or sold to another user) n/a Indirect costs no data Other (specify ) n/a

Please provide the annual report to shareholders or equivalent for the

mo st recent fiscal year. If reports are not available, provide annual sales and profits (or profit margin) for the most recent fiscal y ear. If company is publicly owned, please provide a web link to this information. n/a 

### Financial information provided on the Information Collection **Request Forms F-1 and F-2 are estimates and should not be interpreted as actual cost data.** 

### COMPANY CONFIDENTIAL

Identify the market range (regional, national, international) of your products. International

Can your product(s) be substituted by another product(s)? If so, please list yo ur product(s) and substituted product(s). n/a**FORM F-1 (CBI)**

**COST**

**I. Process Unit (e.g., cupola, curing oven, etc.): RED WING**  **RED WING** For each process unit: Process Unit 1 Process Unit 2 Process Unit ID Melting Process Melting Process Process Line ID Melting Process 1 Melting Process 2

**II. Capital Costs** Base year no data no data

Total capital cost, including costs for individual pieces, if available. no data no data **III. A nnual Operating Costs**  Base year (most recent fiscal y ear) 2009 2009 Total annual operating costs CBI CBI

Maintenance materials and replacement parts (specify costs by item ) CBI CBI Raw m aterials costs CBI CBI Labor ($/y r) for each labor class - Production CBI CBI ($/y r) for each labor class - Maintenance CBI CBI (hr/hr) for each labor class - Production (labor hr / gross hr) CBI CBI (hr/hr) for each labor class - Maintenance (labor hr / gross hr) CBI CBI Utilities (breakdown for each utility ) - Natural gas *see afterburner (F-2) *see afterburner (F-2) Utilities (breakdown for each utility ) - Power CBI CBI W aste treatment and/or disposal no data no data Costs associated with any work practices and pollution prevention techniques that are employed at your facility n/a n/a

Savings associated with heat recovery and wastewater and/or solid waste returned to process from APCD (or sold to another user) n/a n/a Indirect costs no data no data Other (specify ) n/a n/a 

### Financial information provided on the Information Collection **Request Forms F-1 and F-2 are estimates and should not be interpreted as actual cost data. The melting process includes**  **raw materials and equipment through fiberization.**Please provide the annual report to shareholders or equivalent for the

mo st recent fiscal year. If reports are not available, provide annual sales and profits (or profit margin) for the most recent fiscal y ear. If company

is publicly

owned, please provide a web link to this information. n/a

Identify the market range (regional, national, international) of your products. International

Can your product(s) be substituted by another product(s)? If so, please list your product(s) and substituted product(s). n/a

### COMPANY CONFIDENTIAL

**FORM F-2 COST** 

**I. A ir Pollution Control Device (A**  **PCD) WA**  **LWORTH** For each APCD: APCD 1 APCD ID Wo ol Pollution Control Process Unit ID Wo ol PCD

**II. Capital Costs** Base year 1987 APCD equipm ent purchase cost and what was included CBI

CBI List the cost for each piece of auxiliary equipm ent for each APCD not included above None Installation cost CBI Land purchase cost Not Available Total capital cost CBI Method of financing APCD Self-Funded Retrofit installation No Field erected or modular Field Erected

**III. A nnual Operating Costs**  Base year (most recent fiscal y ear) 2009

Maintenance materials and replacement parts (specify costs by item ) CBI Raw m aterials costs no data Labor ($/y r) for each labor class - Maintenance CBI Am ounts are included in F-1 W AL (hr/hr) for each labor class no data Utilities (breakdown for each utility ) - Natural gas CBI Utilities (breakdown for each utility ) - Power CBI Am ounts are included in F-1 W AL 

### Financial information provided on the Information Collection **Request Forms F-1 and F-2 are estimates and should not be interpreted as actual cost data.** 

### COMPANY CONFIDENTIAL

W aste treatment and/or disposal 0 Indirect costs 0 Other (specify ) 0 Total annual operating cost (most recent fiscal year) CBI

Attach annual report to shareholders or equivalent for the most recent fiscal year n/a**FORM F-2 (CBI)**

**COST**

**I. A ir Pollution Control Device (A**  **PCD) RED WING**  **RED WING** For each APCD: APCD 1 APCD 2 APCD ID Thermal Oxidizer South Baghouse

Process Unit ID Cupola 1 and Cupola 2 Cupola 1

**II. Capital Costs** Base year 1999 2005 APCD equipm ent purchase cost and what was included CBI CBI CBI CBI List the cost for each piece of auxiliary equipm ent for each APCD not included above None None

Installation cost CBI CBI Land purchase cost n/a n/a Total capital cost CBI CBI Method of financing APCD Self Funded Self Funded Retrofit installation No Yes Field erected or modular Field Erected Field Erected

**III. A nnual Operating Costs**  Base year (most recent fiscal y ear) 2009 2009

Maintenance materials and replacement parts (specify costs by item ) CBI CBI Raw m aterials costs CBI CBI Labor ($/y r) for each labor class CBI CBI (hr/hr) for each labor class no data no data Utilities (breakdown for each utility ) CBI CBI

W aste treatment and/or disposal CBI CBI Indirect costs CBI CBI Other (specify ) CBI 

### Financial information provided on the Information Collection Request **Forms F-1 and F-2 are estimates and should not be interpreted as actual cost data. The melting process includes raw materials and**  **equipment through fiberization.**Total annual operating cost (most recent fiscal year) CBI CBI

Attach annual report to shareholders or equivalent for the most recent fiscal year n/a**FORM F-2 (CBI)**

**COST**

**I. A ir Pollution Control Device (A**  **PCD)**

For each APCD: APCD ID

Process Unit ID

**II. Capital Costs** Base year APCD equipm ent purchase cost and what was included

List the cost for each piece of auxiliary equipm ent for each APCD not included above

Installation cost Land purchase cost Total capital cost Method of financing APCD Retrofit installation Field erected or modular

**III. A nnual Operating Costs**  Base year (most recent fiscal y ear)

Maintenance materials and replacement parts (specify costs by item ) Raw m aterials costs Labor ($/y r) for each labor class (hr/hr) for each labor class Utilities (breakdown for each utility )

W aste treatment and/or disposal Indirect costs Other (specify ) **RED WING** APCD 3 North Baghouse

Cupola 2

2001

CBI CBI

CBI

CBI n/a CBI Self Funded

No Field Erected

2009

CBI CBI

CBI no data CBI

CBI CBI 

### Financial information provided on the Information Collection Request **Forms F-1 and F-2 are estimates and should not be interpreted as actual cost data. The melting process includes raw materials and** Total annual operating cost (most recent fiscal year)

Attach annual report to shareholders or equivalent for the most recent fiscal year CBI