FORM A-1

PARENT COMPANY INFORMATION

I. Parent Company / Legal Corporate Owner Information

 1. Legal Parent Company / Legal Corporate Name Johns Manville

 2. Address 717 17th Street

 3. City Denver

 4. State CO

 5. Zip Code 80217

 6. County Denver

 7. Size of Company (approximate number of employees including 

all subsidiaries, branches, and related establishments owned): 6,491 (end of 2009)

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM A-2

FACILITY INFORMATION

II. Facility Information Facility 1

 Facility Name Johns Manville Plant 8

 Facility Address

 Street 925 Carpenter Rd.

 City Defiance

 State Ohio

 Zip Code 43512

 County Defiance County

 Facility Coordinates

 Latitude (decimal degrees, six decimal places) 41.302732

 Longitude (decimal degrees, six decimal places) -84.340206

 Specific location represented (e.g., front door of main building, centroid 

of property, etc.) Centroid of property

 Number of employees attached to the wool fiberglass manufacturing 

facility: See CBI Submittal

 Design capacity of the plant (tons/yr) See CBI Submittal

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

Glass melting furnaces, rotary spin manufacturing line, and flame 

attenuation manufacturing line

 Operation schedule

 hrs/day 24

 days/yr 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)

Ohio EPA Facility ID: 0320010005

Title V permit P0086884 (See attachment A)

III. Technical Contact

 Name James Smargiassi

 Technical Contact Title Environmental Manager

 Telephone (419) 784-7963

 Facsimile (Fax) (419) 784-7995

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Email smargiassij@jm.com

IV. Other

 Is the facility a major source of HAP? Yes

 

 If No, did the facility take a limit of its potential HAP emissions to avoid 

classification as a major source: NA

 Does the facility manufacture other products in addition to wool 

fiberglass? No

 If Yes, list the other products manufactured at the facility. NA

 Are there any HAP emissions associated with any co-located facilities? 

List unit operations, e.g., boiler, and pollutant/emissions.

Process Water Settling Pond - phenol, methanol, formaldehyde

RICE Emergency Generators - formaldehyde, benzene, acrolein, 

xylene

Natural Gas Boilers (< 10.0mmbtu/hr) - mercury, dioxin, hydrogen 

chloride, lead

QC Test Ovens - phenol, methanol, formaldehyde

Resin Tanks - phenol, methanol, formaldehyde

Solvent Parts Washers - benzene, toluene

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM A-2

FACILITY INFORMATION

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 wool fiberglass manufacturing 

facility:

 Design capacity of the plant (tons/yr)

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

 Operation schedule

 hrs/day

 days/yr

 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

 Facsimile (Fax)

Facility 2

Johns Manville Plant 2

408 Perry St.

Defiance

Ohio

43512

Defiance County

41.285796

-84.364979

Centroid of property

See CBI Submittal

See CBI Submittal

Glass melting furnaces and flame attenuation manufacturing line

24

365

Ohio EPA Facility ID: 0320010005

Title V permit P0086884 (See attachment A)

James Smargiassi

Environmental Manager

(419) 784-7963

(419) 784-7995

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 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 wool 

fiberglass?

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

 Are there any HAP emissions associated with any co-located facilities? 

List unit operations, e.g., boiler, and pollutant/emissions.

smargiassij@jm.com

Yes

NA

No

NA

RICE Emergency Generators - formaldehyde, benzene, acrolein, xylene

Natural Gas Boilers (< 10.0mmbtu/hr) - mercury, dioxin, hydrogen chloride, lead

QC Test Ovens - phenol, methanol, formaldehyde

Resin Tanks - phenol, methanol, formaldehyde

Solvent Parts Washers - benzene, toluene

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown). 19

For each process line: Process Line 81 

 Process line identification names or numbers Line 81

 Type of process line (e.g., rotary spin, flame attenuation) flame attenuation

 Maximum annual production rate (tons/yr) See CBI Submittal

 Age of process equipment (yrs) 51

 Remaining economic life of process line (yrs) Indefinite (due to rebuild capabilities)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

See CBI Submittal

Please attach detailed schematics of each process line. Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 82 Process Line 84

Line 82 Line 84

flame attenuation flame attenuation

See CBI Submittal See CBI Submittal

50 47

Indefinite (due to rebuild capabilities) Indefinite (due to rebuild capabilities)

See CBI Submittal See CBI Submittal

Not available Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 86

Line 86

flame attenuation

See CBI Submittal

30

Indefinite (due to rebuild capabilities)

See CBI Submittal

Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 87

Line 87

flame attenuation

See CBI Submittal

2

Indefinite (due to rebuild capabilities)

See CBI Submittal

Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 88

Line 88

flame attenuation

See CBI Submittal

36

Indefinite (due to rebuild capabilities)

See CBI Submittal

Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 89

Line 89

rotary spin

See CBI Submittal

15

Indefinite (due to rebuild capabilities)

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 800

Line 800

rotary spin

See CBI Submittal

5

Indefinite (due to rebuild capabilities)

See CBI Submittal

Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 801

Line 801

rotary spin

See CBI Submittal

5

Indefinite (due to rebuild capabilities)

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 802

Line 802

rotary spin

See CBI Submittal

5

Indefinite (due to rebuild capabilities)

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 803

Line 803

rotary spin

See CBI Submittal

5

Indefinite (due to rebuild capabilities)

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 804

Line 804

rotary spin

See CBI Submittal

5

Indefinite (due to rebuild capabilities)

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 805

Line 805

rotary spin

See CBI Submittal

5

Indefinite (due to rebuild capabilities)

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 806

Line 806

rotary spin

See CBI Submittal

5

Indefinite (due to rebuild capabilities)

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 807 Process Line 21

Line 807 Line 21

rotary spin flame attenuation

See CBI Submittal See CBI Submittal

5 51

Indefinite (due to rebuild capabilities) Indefinite (due to rebuild capabilities)

See CBI Submittal See CBI Submittal

See CBI Submittal Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 23

Line 23

flame attenuation

See CBI Submittal

54

Indefinite (due to rebuild capabilities)

See CBI Submittal

Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 24

Line 24

flame attenuation

See CBI Submittal

57

Indefinite (due to rebuild capabilities)

See CBI Submittal

Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

For each process line:

 Process line identification names or numbers

 Type of process line (e.g., rotary spin, flame attenuation)

 Maximum annual production rate (tons/yr)

 Age of process equipment (yrs)

 Remaining economic life of process line (yrs)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product

Please attach detailed schematics of each process line.

Process Line 25

Line 25

flame attenuation

See CBI Submittal

56

Indefinite (due to rebuild capabilities)

See CBI Submittal

Not available

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-2

PLANT OPERATIONS

II. Process - Raw materials Handling and Storage

 Molten glass preparation

 Raw materials and proportions by wt (%) See CBI Submittal

 Method(s) of conveying each raw material to furnace/pots

Silos and calibrated weigh scales, sent to mix by enclosed 

conveyors with bin vents and dust collectors.

 Binder and Additives

 List each raw material, including premixed materials, in the 

binder formulation and its proportion by wt (%) See CBI Submittal

 List steps in preparing binder, including storage temperature (°F) 

and holding time (hrs) See CBI Submittal

 Total yearly consumption of binder (gal/yr) See CBI Submittal

 Cost of binder ($/gal) for most recent year (specify year) See CBI Submittal

 Are binder storage and mixing tanks vented to outside/inside? Resin tanks and pre-react tanks vented outside

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls

 Method of treating vent air from storage and mix tanks

Lines 800-807 have formaline neutralizing filter. Storage 

tanks for line 81 - 88 and 23 - 25 are equipped with 

potassium permanganate filters.

 Emission control during liquid raw material transfer from vehicles 

to storage tanks.

Pressurized unloading with storage tanks vented to 

atmosphere.

 Describe future source reduction plans and schedules to 

reformulate binders; List each constituent, proportions wt (%), cost 

($/gal) for reformulation See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-3

PLANT OPERATIONS

III. Process - Glass Melting Furnace

 For each Glass Melting Furnace: Furnace 2601 Furnace 2603 Melter 89

 Process unit identification name/number Furnace 2601 Furnace 2603 Melter 89 (3 Melters)

 Process line(s) served (identification name/number)

81,82,84,86,87,88,21,

23,24,25

81,82,84,86,87,88,21,

23,24,25 89

 Latitude (decimal degrees, six decimal places) 41.285236 41.285339 41.303383

 Longitude (decimal degrees, six decimal places) -84.364872 -84.365119 -84.340764

 Stack or vent height (units) 75ft 75ft 70ft

 Stack or vent diameter (units) 5 ft 5 ft 3.83 ft

 Manufacturer and model JM Proprietary JM Proprietary JM Proprietary

 Date of original installation 1/1/1960 1/1/1960 11/1/1995

 Estimate of remaining lifetime (yrs)

Indefinite (due to 

continued 

maintenance)

Indefinite (due to 

continued 

maintenance)

Indefinite (due to continued 

maintenance)

 Major rebuilds:

 What constitues a major rebuild

JM is not familiar with 

the term "major 

rebuild." JM conducts 

periodic routine 

maintenace.

JM is not familiar with 

the term "major 

rebuild." JM conducts 

periodic routine 

maintenace.

JM is not familiar with the 

term "major rebuild." JM 

conducts periodic routine 

maintenace.

 Frequency of a major rebuild NA NA NA

 Cost of typical 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 type: electric, gas, or oil gas-fired gas-fired

gas-fired (forhearth), electric 

(melter)

 Fuel consumption rate (KW/ton of glass or Btu/ton of glass) See CBI Submittal See CBI Submittal See CBI Submittal

 List HAPs that are in refractory material

Chromium 

Compounds

Chromium 

Compounds Chromium Compounds

 Design production rate (tons/day) See CBI Submittal See CBI Submittal See CBI Submittal

 Actual glass pull rate (tons/day) See CBI Submittal See CBI Submittal See CBI Submittal

 Vent gas flow rate (acfm @ °F) 75,000 @ 310 75,000 @ 310 25,000 @ 130

 Temperature (°F) of molten glass in furnace and forehearth (if 

applicable) See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures See CBI Submittal See CBI Submittal See CBI Submittal

 Describe process modification(s) since 1999 that reduce 

emissions None See CBI Submittal None

 Describe future source reduction plans and schedules See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-3

PLANT OPERATIONS

III. Process - Glass Melting Furnace

 For each Glass Melting Furnace:

 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)

 Manufacturer and model

 Date of original installation

 Estimate of remaining lifetime (yrs)

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 Fuel type: electric, gas, or oil 

 Fuel consumption rate (KW/ton of glass or Btu/ton of glass)

 List HAPs that are in refractory material

 Design production rate (tons/day)

 Actual glass pull rate (tons/day)

 Vent gas flow rate (acfm @ °F)

 Temperature (°F) of molten glass in furnace and forehearth (if 

applicable)

Melter 100 Melter 200 Furnace 300

M100 M200 M300

801,802,800 803,804,800 805,806,807,800

41.306152 41.306152 41.306152

-84.338994 -84.338994 -84.338994

50ft 50ft 50ft

1.27 ft 1.27 ft 1.27 ft

JM Proprietary JM Proprietary JM Proprietary

3/1/2007 1/1/2007 11/1/2006

Indefinite (due to 

continued 

maintenance)

Indefinite (due to 

continued 

maintenance)

Indefinite (due to 

continued 

maintenance)

JM is not familiar with 

the term "major 

rebuild." JM conducts 

periodic routine 

maintenace.

JM is not familiar with 

the term "major 

rebuild." JM conducts 

periodic routine 

maintenace.

JM is not familiar with 

the term "major 

rebuild." JM conducts 

periodic routine 

maintenace.

NA NA NA

NA NA NA

NA NA NA

NA NA NA

NA NA NA

electric

gas-fired (startup)

electric

gas-fired (startup)

electric

gas-fired (startup)

See CBI Submittal See CBI Submittal See CBI Submittal

Chromium 

Compounds

Chromium 

Compounds

Chromium 

Compounds

See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal

2,960 @ 200 2,960 @ 200 2,960 @ 200

See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal See CBI Submittal

None None None

See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation Process Line 81 Process Line 82

 Process unit identification name/number Unit 81 Hot End Unit 82 Hot End

 Process line(s) served (identification name/number) Line 81 Line 82

 Latitude (decimal degrees, six decimal places) 41.303025/41.303252 See tab C-9

 Longitude (decimal degrees, six decimal places) -84.339297/-84.339375 See tab C-9

 Stack or vent height (units) 38 ft See tab C-9

 Stack or vent diameter (units) 5x6ft rectangle (both stacks) See tab C-9

 Number of fiber forming devices (spinners) per line. See CBI Submittal See CBI Submittal

 Method of attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame). flame attenuation, gas burner flame attenuation, gas burner

 Is there a forehearth between the furnace and the forming 

section? no no

 Major rebuilds:

 What constitues a major rebuild

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

 Frequency of a major rebuild NA NA

 Cost of typical major rebuild NA NA

 Date of last major rebuild NA NA

 Purpose of last major rebuild NA NA

 Increase or decrease in emissions NA NA

 If modular, number of modules and plenums NA NA

 Presence of water overspray and application rate (gpm) See CBI Submittal See CBI Submittal

 Binder applied and application rate (gpm) See CBI Submittal See CBI Submittal

 Other material applied and application rate (gpm) See CBI Submittal See CBI Submittal

 Temperature of glass fiber when binder is applied (°F) See CBI Submittal See CBI Submittal

 Temperature of binder when applied to fibers (°F) See CBI Submittal See CBI Submittal

 Method of evenly distributing fibers onto forming converyor See CBI Submittal See CBI Submittal

 Formed mat thickness (in.) See CBI Submittal See CBI Submittal

 Forming air flow rate (acfm @ °F) 100,000acfm @ 180F 100,000acfm @ 110F

 Percent of forming air recirculated and percent exhausted

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures See CBI Submittal See CBI Submittal

 Describe process modification(s) since 1999 that reduce 

emissions See CBI Submittal See CBI Submittal

 Describe future source reduction plans and schedules See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 84 Process Line 86

Unit 84 Hot End Unit 86 Hot End

Line 84 Line 86

41.303337/41.303347 41.303325/41.303327

-84.339716/-84.339078 -84.339933/-84.340005

35 ft 40 ft

5x6ft rectangle (both stacks)

East: 5 ft square

West: 5 ft square

See CBI Submittal See CBI Submittal

flame attenuation, gas burner flame attenuation, gas burner

no no

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

NA NA

NA NA

NA NA

NA NA

NA NA

NA NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

100,000acfm @ 140F 80,000acfm @ 130F

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 87 Process Line 88

Unit 87 Hot End Unit 88 Hot End

Line 87 Line 88

41.303166 41.303391/41.303395

-84.340118 -84.340263/-84.340327

48 ft 40 ft

7 ft x 5 ft Rect. 6 ft x 6 ft Square (both stacks)

See CBI Submittal See CBI Submittal

flame attenuation, gas burner flame attenuation, gas burner

no no

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

NA NA

NA NA

NA NA

NA NA

NA NA

NA NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

100,000acfm @ 120F 120,000acfm @ 130F

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 89 Process Line 801

Unit 89 Hot End Fiberizer #801

Line 89 Line 801

41.303383 41.306196

-84.340764 -84.338608

70ft 51.6 ft

46in 5 ft

See CBI Submittal See CBI Submittal

rotary disc

natural gas/air

rotary disc & flame attenuation

natural gas/air

Yes Yes

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

NA N/A

NA N/A

NA N/A

NA N/A

NA N/A

3 NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

157,500acfm @ 85F 23,000acfm @ 85 F

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 802 Process Line 803

Fiberizer #802 Fiberizer #803

Line 802 Line 803

41.306196 41.306196

-84.338731 -84.338828

51.6 ft 51.6 ft

5 ft 5 ft

See CBI Submittal See CBI Submittal

rotary disc & flame attenuation

natural gas/air

rotary disc & flame attenuation

natural gas/air

Yes Yes

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

N/A N/A

N/A N/A

N/A N/A

N/A N/A

N/A N/A

NA NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

23,000acfm @ 85 F 23,000acfm @ 85 F

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 804 Process Line 805

Fiberizer #804 Fiberizer #805

Line 804 Line 805

41.306196 41.306196

-84.338932 -84.339042

51.6 ft 51.6 ft

5 ft 5 ft

See CBI Submittal See CBI Submittal

rotary disc & flame attenuation

natural gas/air

rotary disc & flame attenuation

natural gas/air

Yes Yes

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

N/A N/A

N/A N/A

N/A N/A

N/A N/A

N/A N/A

NA NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

23,000acfm @ 85 F 23,000acfm @ 85 F

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 806 Process Line 807

Fiberizer #806 Fiberizer #807

Line 806 Line 807

41.306196 41.306196

-84.339155 -84.339227

51.6 ft 51.6 ft

5 ft 5 ft

See CBI Submittal See CBI Submittal

rotary disc & flame attenuation

natural gas/air

rotary disc & flame attenuation

natural gas/air

Yes Yes

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

N/A N/A

N/A N/A

N/A N/A

N/A N/A

N/A N/A

NA NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

23,000acfm @ 85 F 23,000acfm @ 85 F

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 21 Process Line 23

Unit 21 hot end Unit 23 Hot End

Line 21 Line 23

41.286357/41.286332 41.286260/41.286226

-84.365001/-84.365041 -84.365097/-84.365073

E1: 47.0 ft

E2: 43.0 ft

E4: 40.0 ft

E5: 40.0 ft

E1: 2.38 ft square

E2: 5.64 ft square

E4: 2.12 ft square

E5: 2.12 ft square

See CBI Submittal See CBI Submittal

flame attenuation, gas burner flame attenuation, gas burner

no no

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

NA NA

NA NA

NA NA

NA NA

NA NA

NA NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

80,000acfm @ 125F 65,000acfm @ 175F

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation

 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 attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame).

 Is there a forehearth between the furnace and the forming 

section?

 Major rebuilds:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 If modular, number of modules and plenums

 Presence of water overspray and application rate (gpm)

 Binder applied and application rate (gpm)

 Other material applied and application rate (gpm)

 Temperature of glass fiber when binder is applied (°F)

 Temperature of binder when applied to fibers (°F)

 Method of evenly distributing fibers onto forming converyor

 Formed mat thickness (in.)

 Forming air flow rate (acfm @ °F)

 Percent of forming air recirculated and percent exhausted

Process Line 24 Process Line 25

Unit 24 Hot End Unit 25 Hot End

Line 24 Line 25

41.286183/41.286151 41.286127/41.286095

-84.365132/-84.365116 -84.365159/-84.365170

E6: 40.0 ft

E7: 40.0 ft

E8: 40.0 ft

E9: 40.0 ft

E6: 2.12 ft square

E7: 2.12 ft square

E8: 2.12 ft square

E9: 2.12 ft square

See CBI Submittal See CBI Submittal

flame attenuation, gas burner flame attenuation, gas burner

no no

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

JM is not familiar with the term 

"major rebuild." JM conducts 

periodic routine maintenace.

NA NA

NA NA

NA NA

NA NA

NA NA

NA NA

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

85,000acfm @ 175F 70,000acfm @ 150

0% recirculated

100% exhausted

0% recirculated

100% exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive maintenance 

procedures

 Describe process modification(s) since 1999 that reduce 

emissions

 Describe future source reduction plans and schedules

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-5

PLANT OPERATIONS

V. Process - Curing 

 For each Curing Oven: Curing Oven 81 Curing Oven 82 Curing Oven 86 Curing Oven 87

 Process unit identification name/number P043 P044 P029 P093

 Process line(s) served (identification name/number) Line 81 Line 82 Line 86 Line 87

 Latitude (decimal degrees, six decimal places) 41.303411 41.303411 41.303411 41.303436

 Longitude (decimal degrees, six decimal places) -84.339496 -84.339496 -84.339496 -84.340107

 Stack or vent height (units) 30 ft 30 ft 30 ft 30 ft

 Stack or vent diameter (units) 46" Square 46" Square 46" Square 46" Square

 Method of curing thermal thermal thermal thermal

 Manufacturer and model JM Custom JM Custom JM Custom JM Custom

 Date of original installation 6/1/1959 6/1/1960 6/1/1990 6/1/1954

 Major rebuilds:

 What constitues a major rebuild

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

 Frequency of a major rebuild NA NA NA NA

 Cost of typical major rebuild NA NA NA NA

 Date of last major rebuild NA NA NA NA

 Purpose of last major rebuild NA NA NA NA

 Increase or decrease in emissions NA NA NA NA

 Fuel type: electric, gas, or oil natural gas natural gas natural gas natural gas

 Fuel consumption rate (KW/hr or BTU/hr) See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

 Moisture content wt (%) of formed mat: 

 inlet See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

 outlet <1% <1% <1% <1%

 Air flow rate (acfm @ °F) from curing 64,000 @ 105 65,000 @ 105 60,000 @ 85 17,000 @ 100

 Exhaust air temperature (°F) 105 105 85 100

 Residence time of product (mins) See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

 Binder content of cured product (LOI) 6-22.5% 6-22.5% 6-22.5% 6-22.5%

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive 

maintenance procedures See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

 Describe process modification(s) since 1999 that 

reduce emissions See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

 Describe future source reduction plans and 

schedules See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-5

PLANT OPERATIONS

V. Process - Curing 

 For each Curing Oven:

 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:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 Fuel type: electric, gas, or oil 

 Fuel consumption rate (KW/hr or BTU/hr)

 Moisture content wt (%) of formed mat: 

 inlet

 outlet

 Air flow rate (acfm @ °F) from curing

 Exhaust air temperature (°F)

 Residence time of product (mins)

 Binder content of cured product (LOI)

Curing Oven 89 Curing Oven 800 Curing Oven 801 Curing Oven 802

P051 P085 P065 P068

Line 89

Lines 801, 802, 

803, 804, 805, 

806, and 807. Line 801 Line 802

41.304026 41.305904 41.305823 41.305823

-84.340593 -84.338447 -84.338608 -84.338731

50ft 44 ft 44 ft 44 ft

4' round 1.75' round 1.75' round 1.75' round

thermal thermal thermal thermal

JM Custom JM Custom JM Custom JM Custom

11/1/1995 2/1/2007 7/1/2007 5/1/2007

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

NA NA NA NA

NA NA NA NA

NA NA NA NA

NA NA NA NA

NA NA NA NA

natural gas natural gas natural gas natural gas

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

<1% <1% <1% <1%

17,000 @ 440 5,000 @ 150 2,000 @ 230 1,500 @ 200

440 150 230 200

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

5-16% 5-7% 5-7% 5-7%

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive 

maintenance procedures

 Describe process modification(s) since 1999 that 

reduce emissions

 Describe future source reduction plans and 

schedules

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-5

PLANT OPERATIONS

V. Process - Curing 

 For each Curing Oven:

 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:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 Fuel type: electric, gas, or oil 

 Fuel consumption rate (KW/hr or BTU/hr)

 Moisture content wt (%) of formed mat: 

 inlet

 outlet

 Air flow rate (acfm @ °F) from curing

 Exhaust air temperature (°F)

 Residence time of product (mins)

 Binder content of cured product (LOI)

Curing Oven 803 Curing Oven 804 Curing Oven 805 Curing Oven 806

P071 P074 P077 P080

Line 803 Line 804 Line 805 Line 806

41.305823 41.305823 41.305823 41.305823

-84.338828 -84.338932 -84.339042 -84.339155

44 ft 44 ft 44 ft 44 ft

1.75' round 1.75' round 1.75' round 1.75' round

thermal thermal thermal thermal

JM Custom JM Custom JM Custom JM Custom

3/1/2007 11/1/2006 12/1/2006 8/1/2006

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

NA NA NA NA

NA NA NA NA

NA NA NA NA

NA NA NA NA

NA NA NA NA

natural gas natural gas natural gas natural gas

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

<1% <1% <1% <1%

2,200 @ 185 1,530 @ 200 3,300 @ 220 2,000 @ 270

185 200 220 270

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

5-7% 5-7% 5-7% 5-7%

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive 

maintenance procedures

 Describe process modification(s) since 1999 that 

reduce emissions

 Describe future source reduction plans and 

schedules

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-5

PLANT OPERATIONS

V. Process - Curing 

 For each Curing Oven:

 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:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 Fuel type: electric, gas, or oil 

 Fuel consumption rate (KW/hr or BTU/hr)

 Moisture content wt (%) of formed mat: 

 inlet

 outlet

 Air flow rate (acfm @ °F) from curing

 Exhaust air temperature (°F)

 Residence time of product (mins)

 Binder content of cured product (LOI)

Curing Oven 807 Curing Oven 21 Curing Oven 23 Curing Oven 24

P083 P325 P316 P317

Line 807 Line 21 Line 23 Line 24

41.305823 41.286296 41.286228 41.286165

-84.339227 -84.364896 -84.365009 -84.365052

44 ft 40 ft 40 ft 40 ft

1.75' round 2' square 2' square 2' square

thermal thermal thermal thermal

JM Custom JM Custom JM Custom JM Custom

3/1/2007 1/1/1999 6/1/1956 6/1/1953

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

NA NA NA NA

NA NA NA NA

NA NA NA NA

NA NA NA NA

NA NA NA NA

natural gas natural gas natural gas natural gas

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

<1% <1% <1% <1%

1,700 @ 200 9,000 @ 400 45,000 @ 90 44,000 @ 100

200 400 90 100

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

5-7% 5-15% 5-7% 5-7%

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive 

maintenance procedures

 Describe process modification(s) since 1999 that 

reduce emissions

 Describe future source reduction plans and 

schedules

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

See CBI Submittal See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-5

PLANT OPERATIONS

V. Process - Curing 

 For each Curing Oven:

 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:

 What constitues a major rebuild

 Frequency of a major rebuild

 Cost of typical major rebuild

 Date of last major rebuild

 Purpose of last major rebuild

 Increase or decrease in emissions

 Fuel type: electric, gas, or oil 

 Fuel consumption rate (KW/hr or BTU/hr)

 Moisture content wt (%) of formed mat: 

 inlet

 outlet

 Air flow rate (acfm @ °F) from curing

 Exhaust air temperature (°F)

 Residence time of product (mins)

 Binder content of cured product (LOI)

Curing Oven 25

P318

Line 25

41.286089

-84.365084

40 ft

2' square

thermal

JM Custom

6/1/1954

JM is not familiar 

with the term

"major rebuild." 

JM conducts 

periodic routine 

maintenace.

NA

NA

NA

NA

NA

natural gas

See CBI Submittal

See CBI Submittal

<1%

40,000 @ 75

75

See CBI Submittal

5-7%

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of routine/preventive 

maintenance procedures

 Describe process modification(s) since 1999 that 

reduce emissions

 Describe future source reduction plans and 

schedules

See CBI Submittal

See CBI Submittal

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-6

PLANT OPERATIONS

VI. Process - Cooling

 For each Cooling Operation: Cooling Operation 89

 Process unit identification name/number 89 Cooling Table

 Process line(s) served (identification name/number) Line 89

 Latitude (decimal degrees, six decimal places) 41.305279

 Longitude (decimal degrees, six decimal places) -84.340553

 Stack or vent height (units) 60 ft

 Stack or vent diameter (units) 48 in round

 Cooling air flow rate (acfm @ °F) 22,000

 Percentage of cooling air recirculated (if any) 0

 Cooling air temperature (°F) 90

 Nature and frequency of routine/preventive 

maintenance procedures See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls

 Describe process modification(s) since 1999 that 

reduce emissions See CBI Submittal

 Describe future source reduction plans and schedules See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-7

PLANT OPERATIONS

VII. Process - Use of Solvents

 Use of Solvents

 Volatile solvents used at your facility (where and how used)

By agreement this question was limited to HAP containing 

solvents. We interpret this question to apply to wool 

fiberglass lines, from melting through cooling. None

 List each solvent used and quantity (gal/yr) N/A

 Emission control device(s) used to control emissions from solvent 

usage/storage? N/A

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM B-8

PROCESS OPERATIONS

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 and HAPs you identified in Form E. 

You must specify the year in which the facility implemented the 

practice/technique and identify the emission reductions (if measured) 

from these practices/techniques.

See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-1

AIR POLLUTION CONTROL

I. Electrostatic Precipitator (ESP)

 For each ESP: ESP

 Process line(s) (identification name/number) Furnace ESP

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan)

Furnace 201, Furnace 

203, followed by a 

ipolishing baghouse in 

series to emission point 

E19

 Latitude (decimal degrees, six decimal places) 41.285311

 Longitude (decimal degrees, six decimal places) -84.365384

 Stack or vent height (units) 66

 Stack or vent diameter (units) 5 ft round

 Manufacturer and model

United McGill Model 3-

300

 Date of original installation 4/1/1979

 Number of collection plates and configuration

3 fields - 36 plates per 

field, straight-verticle 

plates

 Gas flow rate to ESP (acfm @ °F) 77000 acfm @ 320 F

 Inlet gas temperature (°F) 460

 Outlet gas temperature (°F) 400

 Inlet grain loading (gr/dscf) 0.076

 Outlet grain loading (gr/dscf) 0.0038

 Average stack opacity (%) 0

 Pressure drop across ESP (in. H2O gauge) (-2) to 20

 Plate area (ft2) 11250

 Vendor guarantee on ESP efficency (attach copy) None

 Method of plate cleaning and frequency

Mechanical Rapping, 70 

minute cycle.

 Flow rate of plate washwater to ESP (gpm), if applicable NA

 Temperature of plate washwater to ESP (°F), if applicable NA

 Source of plate washwater used for cleaning, if applicable NA

 Concentration (mg/l) of dissolved and suspended solids in plate 

washwater, if applicable NA

 Conditioning agents used and amounts (in gpm or lbs/hr), if 

applicable NA

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Amount of wastewater generated (gpd), if applicable NA

 Amount of wastewater recycled (gpd), if applicable NA

 Amount of wastewater disposed of (gpd), if applicable NA

 Method of wastewater disposal, if applicalbe NA

 Quantity of solid waste collected (lbs/yr) 23,000

 Quantitiy of solid waste recycled (lbs/yr) 23,000

 Quantity of solid waste disposed of (lbs/yr) 500

 Method of solid waste disposal

Recycle and Hazardous 

waste

 Nature and frequency of routine/preventive maintenance 

procedures

Daily: Inspect and service 

water pumps.

Weekly: Clean and 

inspect spray nozzles and 

rotary valves on coolers 

and EP motors.

Monthly: Clean and 

inspect compressed air 

driers.

Quarterly: Calibrate 

voltage transmitters.

Semi-Annually: Inspect 

drag chain re-feed 

conveyor and EP 

ductwork.

Annually: Perform EP 

shutdown and cleaning; 

check and replace 

solenoid valves; perform 

inspection of entire unit.

 Problems experienced with control device within the last five 

years; how were problems solved? No major issues

 Continuous monitoring method(s) used to monitor ESP 

performance, including parameters monitored

Inlet/Outlet temperatures, 

primary voltage/current, 

secondary

voltage/current, and field 

spark rate.

 Describe any plans to replace or upgrade ESP See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each Scrubber: Scrubber A Scrubber B Scrubber C

 Process line(s) (identification name/number) 89 Collection Module A 89 Collection Module B 89 Collection Module C

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) P048 P049 P050

 Latitude (decimal degrees, six decimal places) 41.303286 41.303327 41.303357

 Longitude (decimal degrees, six decimal places) -84.340737 -84.340684 -84.340641

 Stack or vent height (units) 90ft 95ft 96ft

 Stack or vent diameter (units) 7' round 6.75' round 6' round

 Manufacturer and model

Clean Gas Systems, Inc., 

Model #156

Clean Gas Systems, Inc., 

Model #144

Clean Gas Systems, Inc., 

Model #126

 Date of original installation 11/1/1995 11/1/1995 11/1/1995

 Type (e.g., venturi, orifice) Venturi Venturi Venturi

 Gas flow rate to scrubber (acfm @ °F) 63,000 54,000 40,500

 Inlet gas temperature (°F) 100 100 100

 Outlet gas temperature (°F) 90 90 90

 Inlet grain loading (gr/dscf) 0.0146 0.0171 0.0152

 Outlet grain loading (gr/dscf) 0.0044 0.0051 0.0046

 Average stack opacity (%) 0 - 15 % 0 - 15 % 0 - 15 %

 Water flow rate to scrubber (gpm) 441 372 271

 Percent of scrubber water from recycled wastewater 92% 91% 91%

 Source of scrubbing water and type of pretreatment. Substance(s) 

added as part of pretreatment and amount used (gpm or lbs/hr)

City water, no 

pretreatment

City water, no 

pretreatment

City water, no 

pretreatment

 HAP composition of wastewater (mg/L)

280.58mg/L phenol, 

80.22mg/L formaldehyde

280.58mg/L phenol, 

80.22mg/L formaldehyde

280.58mg/L phenol, 

80.22mg/L formaldehyde

 Concentration (mg/L) of dissolved and suspended solids in 

scrubbing water

Dissolved = 2784.0mg/L, 

Suspended = 116.0mg/L

Dissolved = 2784.0mg/L, 

Suspended = 116.0mg/L

Dissolved = 2784.0mg/L, 

Suspended = 116.0mg/L

 Scrubbing water temperature (°F) Ambient Ambient Ambient

 Liquid/gas ratio (gal/103 acfm) 7.00 6.89 6.69

 Pressure drop across scrubber (in. H2O gauge) 9.6 9.5 9.5

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Amount of wastewater generated (gpd) 0 0 0

 Amount of wastewater recycled (gpd) 627840 528480 383040

 Amount of wastewater disposed of (gpd) 7200 7200 7200

 Method of wastewater disposal POTW POTW POTW

 Quantity of solid waste collected (lbs/yr) 2,500 2,500 1,500

 Quantity of solid waste recycled (lbs/yr) 0 0 0

 Quantity of solid waste disposed of (lbs/yr) 2,500 2,500 1,500

 Method of solid waste disposal Non-Hazardous Landfill Non-Hazardous Landfill Non-Hazardous Landfill

 Vendor guarantee on scrubber efficiency (attach copy) no guarantee no guarantee no guarantee

 Nature and frequency of preventive maintenance procedures

Quarterly: dp transmitter 

and water flowmeter 

calibrated. 

Annual: shutdown and 

clean out. 

Annual: Inspect and 

rebuild fan and ductwork.

Quarterly: dp transmitter 

and water flowmeter 

calibrated. 

Annual: shutdown and 

clean out. 

Annual: Inspect and 

rebuild fan and ductwork.

Quarterly: dp transmitter 

and water flowmeter 

calibrated. 

Annual: shutdown and 

clean out. 

Annual: Inspect and 

rebuild fan and ductwork.

 Problems experienced with control device within the last five years; 

how were problems solved?

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

CMS

water flow, dp across 

venturi

CMS

water flow, dp across 

venturi

CMS

water flow, dp across 

venturi

 Plans to replace or upgrade scrubber See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each Scrubber:

 Process line(s) (identification name/number)

 Equipment/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

 Type (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 (%)

 Water flow rate to scrubber (gpm)

 Percent of scrubber water from recycled wastewater

 Source of scrubbing water and type 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/103 acfm)

 Pressure drop across scrubber (in. H2O gauge)

Scrubber Cooling Scrubber 801 Scrubber 802

Line 89 Cooling Scrubber Line 801 Scrubber Line 802 Scrubber

P052 P064 P067

41.303905 41.306196 41.306196

-84.340660 -84.338608 -84.338731

60 ft 51.6 ft 51.6 ft

48" round 5' round 5' round

Clean Gas Systems, Inc., 

Model #96

Clean Gas Systems Model 

102

Clean Gas Systems Model 

102

11/1/1995 6/1/2007 5/1/2007

Venturi Venturi Venturi

22,000 23000 23000

92 120 120

65 85 85

0.0066 0.061 0.061

0.0020 0.018 0.018

0 - 10 % 0 - 5 % 0 - 5 %

139 220 220

90% 100% 100%

City water, no 

pretreatment

process water; 

pretreatment RO and 

Hydrofloat

process water; 

pretreatment RO and 

Hydrofloat

280.58mg/L phenol, 

80.22mg/L formaldehyde

Formaldehyde: 702.46

Phenol: 639.97

Formaldehyde: 702.46

Phenol: 639.97

Dissolved = 2784.0mg/L, 

Suspended = 116.0mg/L

Dissolved: 693.0 mg/L

Susp.: 148.0 mg/L

Dissolved: 693.0 mg/L

Susp.: 148.0 mg/L

Ambient Ambient Ambient

6.32 9.57 9.57

8.5 10 - 30 10 - 30

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Amount of wastewater generated (gpd)

 Amount of wastewater recycled (gpd)

 Amount of wastewater disposed of (gpd)

 Method of wastewater disposal

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste 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 problems solved?

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

 Plans to replace or upgrade scrubber

0 0 0

192960 316800 316800

7200 0 0

POTW NA NA

1,000 1,000 1,000

0 0 0

1,000 1,000 1,000

Non-Hazardous Landfill Non-Hazardous Landfill Non-Hazardous Landfill

no guarantee no guarantee no guarantee

Quarterly: dp transmitter 

and water flowmeter 

calibrated. 

Annual: shutdown and 

clean out. 

Annual: Inspect and 

rebuild fan and ductwork.

Bi-monthly: Inspect and 

clean scrubber

Quarterly: Calibrate 

meters

Bi-monthly: Inspect and 

clean scrubber

Quarterly: Calibrate 

meters

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

CMS

water flow, dp across 

venturi

CMS

water flow, dp across 

venturi

CMS

water flow, dp across 

venturi

See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each Scrubber:

 Process line(s) (identification name/number)

 Equipment/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

 Type (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 (%)

 Water flow rate to scrubber (gpm)

 Percent of scrubber water from recycled wastewater

 Source of scrubbing water and type 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/103 acfm)

 Pressure drop across scrubber (in. H2O gauge)

Scrubber 803 Scrubber 804 Scrubber 805

Line 803 Scrubber Line 804 Scrubber Line 805 Scrubber

P070 P073 P076

41.306196 41.306196 41.306196

-84.338828 -84.338932 -84.339042

51.6 ft 51.6 ft 51.6 ft

5' round 5' round 5' round

Clean Gas Systems Model 

102

Clean Gas Systems Model 

102

Clean Gas Systems Model 

102

3/1/2007 2/1/2007 1/1/2007

Venturi Venturi Venturi

23000 23000 23000

120 120 120

85 85 85

0.061 0.061 0.061

0.018 0.018 0.018

0 - 5 % 0 - 5 % 0 - 5 %

220 220 220

100% 100% 100%

process water; 

pretreatment RO and 

Hydrofloat

process water; 

pretreatment RO and 

Hydrofloat

process water; 

pretreatment RO and 

Hydrofloat

Formaldehyde: 702.46

Phenol: 639.97

Formaldehyde: 702.46

Phenol: 639.97

Formaldehyde: 702.46

Phenol: 639.97

Dissolved: 693.0 mg/L

Susp.: 148.0 mg/L

Dissolved: 693.0 mg/L

Susp.: 148.0 mg/L

Dissolved: 693.0 mg/L

Susp.: 148.0 mg/L

Ambient Ambient Ambient

9.57 9.57 9.57

10 - 30 10 - 30 10 - 30

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Amount of wastewater generated (gpd)

 Amount of wastewater recycled (gpd)

 Amount of wastewater disposed of (gpd)

 Method of wastewater disposal

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste 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 problems solved?

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

 Plans to replace or upgrade scrubber

0 0 0

316800 316800 316800

0 0 0

NA NA NA

1,000 1,000 1,000

0 0 0

1,000 1,000 1,000

Non-Hazardous Landfill Non-Hazardous Landfill Non-Hazardous Landfill

no guarantee no guarantee no guarantee

Bi-monthly: Inspect and 

clean scrubber

Quarterly: Calibrate 

meters

Bi-monthly: Inspect and 

clean scrubber

Quarterly: Calibrate 

meters

Bi-monthly: Inspect and 

clean scrubber

Quarterly: Calibrate 

meters

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

CMS

water flow, dp across 

venturi

CMS

water flow, dp across 

venturi

CMS

water flow, dp across 

venturi

See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each Scrubber:

 Process line(s) (identification name/number)

 Equipment/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

 Type (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 (%)

 Water flow rate to scrubber (gpm)

 Percent of scrubber water from recycled wastewater

 Source of scrubbing water and type 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/103 acfm)

 Pressure drop across scrubber (in. H2O gauge)

Scrubber 806 Scrubber 807

Line 806 Scrubber Line 807 Scrubber

P079 P082

41.306196 41.306196

-84.339155 -84.339227

51.6 ft 51.6 ft

5' round 5' round

Clean Gas Systems Model 

102

Clean Gas Systems Model 

102

2/1/2007 1/1/2007

Venturi Venturi

23000 23000

120 120

85 85

0.061 0.061

0.018 0.018

0 - 5 % 0 - 5 %

220 220

100% 100%

process water; 

pretreatment RO and 

Hydrofloat

process water; 

pretreatment RO and 

Hydrofloat

Formaldehyde: 702.46

Phenol: 639.97

Formaldehyde: 702.46

Phenol: 639.97

Dissolved: 693.0 mg/L

Susp.: 148.0 mg/L

Dissolved: 693.0 mg/L

Susp.: 148.0 mg/L

Ambient Ambient

9.57 9.57

10 - 30 10 - 30

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Amount of wastewater generated (gpd)

 Amount of wastewater recycled (gpd)

 Amount of wastewater disposed of (gpd)

 Method of wastewater disposal

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste 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 problems solved?

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

 Plans to replace or upgrade scrubber

0 0

316800 316800

0 0

NA NA

1,000 1,000

0 0

1,000 1,000

Non-Hazardous Landfill Non-Hazardous Landfill

no guarantee no guarantee

Bi-monthly: Inspect and 

clean scrubber

Quarterly: Calibrate 

meters

Bi-monthly: Inspect and 

clean scrubber

Quarterly: Calibrate 

meters

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

scrubbers and venturi 

dampers get plugged from 

debris, require frequent 

cleanouts

CMS

water flow, dp across 

venturi

CMS

water flow, dp across 

venturi

See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-3

AIR POLLUTION CONTROL

III. Mechanical Collector

 For each Mechanical Collector: Mechanical Collector 1

 Process line(s) (identification name/number) None

 Equipment/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

 Type 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. H2O gauge)

 Vendor guarantee on mechanical collector efficiency (attach 

copy)

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste disposal

 Nature 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 performance, 

including parameters monitored

 Plans to replace or upgrade mechanical collector

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-4

AIR POLLUTION CONTROL

IV. Fabric Filter 

 For each Fabric Filter: Furnace Baghouse Line 89 Baghouse Pipe Melter Baghouse

 Process line(s) (identification name/number) Furnace Baghouse Line 89 Melter DC

 Equipment/process(es) controlled. Include emission 

point designations (e.g., E3, E4 from plot plan) Furnace 2601, 2603 Production Line 89

Melter #1, Melter #2, Melter 

#3

 Latitude (decimal degrees, six decimal places) 41.285099 41.303383 41.306152

 Longitude (decimal degrees, six decimal places) -84.365577 -84.340764 -84.338994

 Stack or vent height (units) 75ft 70ft 50ft

 Stack or vent diameter (units) 5' round 4' round 1.27' round

 Manufacturer and model

Wheelabrator Air Pollution 

Control, Model Pulse Jet III, 

4-mod

Hosokawa Mikropul, Model 

TR Mikro-Pulsaire

Flex Kleen - 

100BVB36XL(III)G

 Date of original installation 10/1/1993 6/1/1998 11/1/2006

 Number of compartments 4 3 2

 Number of bags per compartment 288 180 36

 Filter material and coatings applied Nomex felt polyester Nomex felt

 Fabric weight (oz/yd

2

) 14 oz. 16 oz 14 oz.

 Filter surface area (ft2) 26380 2118.6 457

 Gas flow rate to filter (acfm @ °F) 60,000 25,000 8,880

 Inlet gas temperature (°F) 350 90 375

 Outlet gas temperature (°F) 283 90 375

 Inlet grain loading (gr/dscf) 0.0038 0.029 0.825451959

 Outlet grain loading (gr/dscf) 0.0019 0.0029 0.00825452

 Average stack opacity (%) 0 0 0

 Overall pressure drop (in. H2O gauge) 2-20 0.5-10 0.5 - 10 

 Method and frequency of bag cleaning

bags replaced upon bag leak 

alarm, scheduled 

replacement every 4 years

bags replaced upon bag leak 

alarm, scheduled 

replacement every 5 years

bags replaced upon bag leak 

alarm, scheduled 

maintenance

 Vendor guarantee on fabric filter efficiency (attach 

copy) No guarantee No guarantee No guarantee

 Quantity of solid waste collected (lbs/yr) 350000 330000 11000

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Quantity of solid waste recycled (lbs/yr) 348500 0 0

 Quantity of solid waste disposed of (lbs/yr) 1500 330000 11000

 Method of solid waste disposal Hazardous waste landfill Hazardous waste landfill Non-hazardous landfill

 Nature and frequency of preventive maintenance 

procedures

Weekly: baghouse fan motor 

inspected.

Monthly: Inspect and repair 

pulse valves; Bag leak 

functionalty test 

Quarterly: Meter inspection; 

dp monitor calibration

Semiannual: inspect 

ductwork, feed conveyor, 

rotary valves

Annually: One module 

cleanout and bag changes 

on rotating schedule; zero 

calibration of leak detector.

Quarterly: Meter inspection.

Semiannual: baghouse 

inspection (internal). 

Annual: shutdown for 

booster fan and internal 

components.

Monthly: dust collector 

inspection, daily mechanic 

checklist.

Quarterly: Meter inspection.

 Problems experienced with control device within the 

last five years; how were problems solved? None None None

 Continuous monitoring method(s) used to monitor 

performance, including parameters monitored

Bag leak detection system, 

differential pressure monitor.

Bag leak detection system, 

differential pressure monitor.

Bag leak detection system, 

differential pressure monitor.

 Plans to replace or upgrade fabric filter See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-5

AIR POLLUTION CONTROL

V. Thermal Incinerator

 For each Thermal Incinerator: Thermal Oxidizer

 Process line(s) (identification name/number) Line 89 RTO

 Equipment/process(es) controlled. Include emission 

point designations (e.g., E3, E4 from plot plan) P052

 Latitude (decimal degrees, six decimal places) 41.305557

 Longitude (decimal degrees, six decimal places) -84.340553

 Stack or vent height (units) 50 ft

 Stack or vent diameter (units) 4' round

 Manufacturer and model ABB, No Model 

 Date of original installation 6/1/1995

 Fuel type: gas or oil Natural gas

 Fuel consumption rate (BTU/hr) 9,000,000

 Inlet gas flow rate (acfm @ °F) 35,000

 Inlet gas temperature (°F) 1,100

 Combustion chamber gas temperature (°F) 1552F minimum

 Outlet gas temperature (°F) 360

 Inlet grain loading (gr/dscf) 0.1218

 Outlet grain loading (gr/dscf) 0.0024

 Average stack opacity (%) 0%

 Excess air (%) unknown

 Residence time (sec) at temperature (°F) 2sec @1552F

 Percent heat recovery 0

 Vendor guarantee on incinerator efficiency (attach 

copy) No guarantee

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Nature and frequency of preventive maintenance 

procedures

Weekly - 

Drain accumulated tank 

Semiannual - 

Shutdown and rebuild media, 

mechanical, electrical.

 Problems experienced with control device within the 

last five years; how were problems solved?

1) Varying temperature 

throughout TO media; difficult 

to operate efficiently

2) Plugging of media bed 

following process upsets 

inside oven forcing expensive 

rebuild of bed

3) Methane buildup in 

ductwork leading to TO. 

Solved problem by installing 

LEL meters in ductwork.

 Continuous monitoring method(s) used to monitor 

incinerator performance, including parameters monitored

Thermocouples and PLC to 

monitor - temp, air flow, 

differential pressure, LEL, 

power loss, other alarms

 Plans to replace or upgrade thermal incinerator See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-6

AIR POLLUTION CONTROL

VI. High Velocity Air Filter (HVAF)

 For each HVAF: HVAF 1 HVAF 1

 Process line(s) (identification name/number) North HEAF South HEAF

 Equipment/process(es) controlled. Include emission 

point designations (e.g., E3, E4 from plot plan)

Line 21 (P325) and 24 (P317) 

Curing Oven operations

Line 21 (P325) and 24 (P317) 

Curing Oven operations

 Latitude (decimal degrees, six decimal places) 41.286228 41.285847

 Longitude (decimal degrees, six decimal places) -84.364979 -84.365132

 Stack or vent height (units) 40' 36'

 Stack or vent diameter (units) 3.2 ft 3.2 ft

 Manufacturer and model JM Design JM Design

 Date of original installation 1-Jun-1970 1-Jun-1970

 Inlet gas flow rate (acfm @ °F) 55000 @ 150 55000 @ 150

 Inlet gas temperature (°F) 120 120

 Outlet gas temperature (°F) 100 100

 Inlet grain loading (gr/dscf) 0.0008 0.0008

 Outlet grain loading (gr/dscf) 0.00064 0.00064

 Average stack opacity (%) 0-5% 0-5%

 Water spray pressure (sdig), if applicable NA NA

 Water spray rate (gpm), if applicable NA NA

 Filter face velocity (acfm/ft2) 5200 5200

 Maximum pressure drop across mat (in. H2O gauge) None None

 Vendor guarantee on HVAF efficiency (attach copy) No guarentee No guarentee

 Method and frequency of filter mad advancement Rotation chain Rotation chain

 Amount of wastewater generated (gpd) None None

 Amount of wastewater recycled (gpd) None None

 Amount of wastewater disposed of (gpd) None None

 Method of wastewater disposal None None

 Quantity of solid waste collected (lbs/yr) 1500 lbs 1500 lbs

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Quantity of solid waste recycled (lbs/yr) None None

 Quantity of solid waste disposed of (lbs/yr) 1500 lbs 1500 lbs

 Method of solid waste disposal Non hazardous landfill Non hazardous landfill

 Nature and frequency of preventive maintenance 

procedures Bimonthly Cleanouts Bimonthly Cleanouts

 Problems experienced with control device within the 

last five years; how were problems solved? None None

 Continuous monitoring method(s) used to monitor 

HVAF performance, including parameters monitored None None

 Plans to replace or upgrade HVAF No current plans No current plans

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-7

AIR POLLUTION CONTROL

VII. Mist Eliminator

 For each Mist Eliminator: Mist Eliminator 1

 Process line(s) (identification name/number) None

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 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

 Type 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 mist eliminator (ft/sec)

 Pressure drop (in. H2O gauge)

 For chevron blade mist eliminators:

 Spacing between blades (in.)

 Washing frequency of blades

 For mesh pad mist eliminators:

 Number of pads or elements

 Thickness of pad (in.) or element dimensions

 Density of pad, (lb/ft3)

 Washing frequency of pad

 Vendor guarantee on mist eliminator efficiency (attach copy)

 Amount of wastewater generated (gpd)

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Amount of wastewater recycled (gpd)

 Amount of wastewater disposed of (gpd)

 Method of wastewater disposal

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste disposal

 Nature 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 mist eliminator 

performance, including parameters monitored

 Plans to replace or upgrade mist eliminator 

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-8

AIR POLLUTION CONTROL

VIII. Ventilation System 

 For each Ventilation System: Air Makups

 Process line(s) (identification name/number) None

 Equipment/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

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls

 Volume of enclosure or hood

 Capture velocity (ft/sec)

 Distance between hood and emission source (ft)

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM C-9

AIR POLLUTION CONTROL

IX. Other 

 For each Other Air Pollution Control Device (APCD): Line 82 Spray Tower

 Process line(s) (identification name/number) Line 82 Spray Tower

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) P012

 Latitude (decimal degrees, six decimal places) 41.303123

 Longitude (decimal degrees, six decimal places) -84.339584

 Stack or vent height (units)

 Stack or vent diameter (units) 11x7ft rectangle

 Manufacturer and model JM Custom

 Date of original installation 1996

 Inlet gas flow rate (acfm @ °F) 88,560

 Inlet gas temperature (°F) 175

 Outlet gas temperature (°F) 144.8

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls

 Inlet grain loading (gr/dscf) 0.0066

 Outlet grain loading (gr/dscf) 0.0056

 Average stack opacity (%) Not measured regularly

 Description

JM Custom spray tower used 

for PE abatement

 Nature and frequency of preventive maintenance procedures

Filters and spray tower 

cleaned out every 4 weeks.

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM D

PROCESS LINE STARTUP AND SHUTDOWN

1. For each startup and shutdown (SS) that occurred during the last 

five years, please provide the following information requested in A. 

through J. 

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.

Process Unit Furnace 300

Dates of Startup/Shutdown 7/8/2009

 A. Using the definitions provided above, indicate whether the 

event was a startup or shutdown; Shutdown and Startup

 B. A description of the event, including identification of the 

emissions source or sources associated with the startup or 

shutdown;

Emergency refractory repair on the throat section 

of the melter was scheduled to occur. The unit 

was cooled and following repair was restarted to 

production. Upon startup, batch material clogged 

the exhaust vent causing the melter to 

overpressurize

 C. Whether any permit condition was exceeded and, if so, what 

permit condition was exceeded;

PTI 03-16294 conditions exceeded,

Part III.A.III.2

Part III.A.III.5

 D. Whether 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;

Event was not covered under a contingency plan. 

Event was an emergency situation

 E. The duration of the event; 6 hours

 F. The actions taken to minimize emissions during the event, 

including the use of any backup control systems; None

 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;

PM: 90 lbs

Nox: 0.13 lbs

OC: 0.93 lbs

SO2: 2.4 lbs

CO: 4.7 lbs

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 H. Whether 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; No difference expected

 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

No performance testing conducted during S&S 

events

 J. All monitoring data, including control system parameter 

monitoring, collected during each period of SS. not readily available

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. See Attachment C

2. Are there any types of startup or shutdown events that you have 

been able to eliminate? If so, please describe the type of event and 

explain how these events were eliminated.

We have modified the location of the exhaust vents 

on Melter 200 to prevent similar incidents. Melter 

100 exhaust vent will be relocated in Fall of 2010.

3. Please submit a copy of your SS plan if you are required to 

develop one. See CBI Submittal

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.

No performance testing conducted during S&S 

events

5. Please provide all monitoring data, including control system 

parameter monitoring, collected during periods of SS over the last 5 

years. See CBI Submittal

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 minimize 

emissions during the event; and how would compliance be 

determined and/or monitored. No

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM E

PRESENCE OF AIR POLLUTANTS IN EMISSION POINTSa

Please provide any existing emissions information and data 

covering hazardous air pollutants (HAP) and particulate matter 

(PM) for each listed process. Identify the appropriate box for 

which you are providing specific process information and/or 

pollutant emissions data.

Melting Furnace Forming Curing

Particulate Matter (PM, PM 2.5, PM Condensable) 

Chromium Compounds and Hexavalent Chromium (including any

Cr speciation data)

Other metal HAP (As, Be, Cd, Co, Hg, Mn, Ni, Pb, Sb, Se)

Hydrogen Fluoride (HF)

Hydrogen Chloride (HCl)

Formaldehyde

Phenol

Methanol

Other organic HAP

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, beryllium, 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 matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, metals 

(antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, nickel, and 

selenium), mercury, and hexavalent chromium. The scope of the existing data provided 

was the result of consensus reached by EPA, NAIMA, and industry representatives. In 

addition to the existing 

data submitted to EPA, extensive new emissions data is being collected from 

virtually all companies through the “BTEC, Inc. Quality Assurance Project Plan for 

the Mineral Wool and Wool Fiberglass Emissions Test Program.” This Test Program

will collect and submit to EPA, through EPA’s Electronic Reporting Tool, 

representative emissions data for the following pollutants: formaldehyde, methanol, 

phenol, particulate matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, 

metals (antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, 

nickel, and selenium), mercury, and hexavalent chromium.

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM E

PRESENCE OF AIR POLLUTANTS IN EMISSION POINTSa

Please provide any existing emissions information and data 

covering hazardous air pollutants (HAP) and particulate matter 

(PM) for each listed process. Identify the appropriate box for 

which you are providing specific process information and/or 

pollutant emissions data.

Particulate Matter (PM, PM 2.5, PM Condensable) 

Chromium Compounds and Hexavalent Chromium (including any

Cr speciation data)

Other metal HAP (As, Be, Cd, Co, Hg, Mn, Ni, Pb, Sb, Se)

Hydrogen Fluoride (HF)

Hydrogen Chloride (HCl)

Formaldehyde

Phenol

Methanol

Other organic HAP

Cooling

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, beryllium, 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 matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, metals 

(antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, nickel, and 

selenium), mercury, and hexavalent chromium. The scope of the existing data provided 

was the result of consensus reached by EPA, NAIMA, and industry representatives. In 

data submitted to EPA, extensive new emissions data is being collected from 

virtually all companies through the “BTEC, Inc. Quality Assurance Project Plan for 

the Mineral Wool and Wool Fiberglass Emissions Test Program.” This Test Program

will collect and submit to EPA, through EPA’s Electronic Reporting Tool, 

representative emissions data for the following pollutants: formaldehyde, methanol, 

phenol, particulate matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, 

metals (antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, 

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM F-1 

COST

I. Process Unit (e.g., cupola, curing oven, etc.):

 For each Process Unit: Process Unit 1

 Process Unit ID All Units

 Process Line ID

II. Capital Costs

 Base year

JM objects to this request 

in its entirety because it 

seeks information that is 

not relevant to the EPA 

Administrator’s review 

obligations pursuant to 

Clean Air Act Section 

112(d)(6) and 112(f)(2).

 Total capital cost, including costs for individual pieces, if available. See Above 

III. Annual Operating Costs

 Base year (most recent fiscal year) See Above 

 Total annual operating costs See Above 

 Maintenance materials and replacement parts (specify costs by item) See Above 

 Raw materials costs See Above 

 Labor

 ($/yr) for each labor class See Above 

 (hr/hr) for each labor class See Above 

 Utilities (breakdown for each utility) See Above 

 Waste treatment and/or disposal See Above 

 Costs associated with any work practices and pollution prevention 

techniques that are employed at your facility See Above 

 Savings associated with heat recovery and wastewater and/or solid waste 

returned to process from APCD (or sold to another user) See Above 

 Indirect costs See Above 

 Other (specify) See Above 

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
Please provide the annual report to shareholders or equivalent for the most 

recent fiscal year. If reports are not available, provide annual sales and 

profits (or profit margin) for the most recent fiscal year. If company is 

publicly owned, please provide a web link to this information. See Above 

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

N/A

Can your product(s) be substituted by another product(s)? If so, please list 

your product(s) and substituted product(s).

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

Can your product(s) be substituted by another product(s)? If so, please list 

your product(s) and substituted product(s).

Wool fiberglass is used 

as insulation, as are 

cellulose (scrap 

newspaper) treated to 

resist fires, spray foam, 

foam boards, cotton 

treated to resist fires, and 

sheep wool treated to 

resist fires. Wool 

fiberglass insulation is 

preferred over these 

alternative insulation 

materials because it is 

easily, economically, and 

safety installed in various 

building settings, has 

superior fire performance 

capabilities, and a 70-

year history of proven 

performance and 

durability.

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
FORM F-2

COST

I. Air Pollution Control Device (APCD) See form F-1

 For each APCD: APCD 1

 APCD ID

 Process Unit ID

II. Capital Costs

 Base year 

JM objects to this 

request in its entirety

because it seeks 

information that is not 

relevant to the EPA 

Administrator’s review 

obligations pursuant 

to Clean Air Act 

Section 112(d)(6) and 

112(f)(2).

 APCD equipment purchase cost and what was included See Above 

 List the cost for each piece of auxiliary equipment for each APCD 

not included above See Above 

 Installation cost See Above 

 Land purchase cost See Above 

 Total capital cost See Above 

 Method of financining APCD See Above 

 Retrofit installation See Above 

 Field erected or modular See Above 

III. Annual Operating Costs

 Base year (most recent fiscal year) See Above 

 Maintenance materials and replacement parts (specify costs by

item) See Above 

 Raw materials costs See Above 

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls
 Labor

 ($/yr) for each labor class See Above 

 (hr/hr) for each labor class See Above 

 Utilites (breackdown for each utility) See Above 

 Waste treatment and/or disposal See Above 

 Indirect costs See Above 

 Other (specify) See Above 

 Total annual operating cost (most recent fiscal year) See Above 

Attach annual report to shareholders or equivalent for the most 

recent fiscal year. Alternatively, if company is publicly owned, you 

can provide your company's web link to this information. See Above 

EPA-HQ-OAR-2010-1042-DRAFT-0009.xls