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From: Steve Edris [sedris@thermafiber.com]

Sent: Friday, May 20, 2011 10:50 AM

To: Hancy, Cindy Wang

Cc: Reeves, David; Marinshaw, Richard; Fairchild.Susan@epamail.epa.gov; acrane@naima.org

Subject: RE: Thermafiber Test Report Inquiry

Categories: Blue Category

Cindy,

The previously sent report (RTOdata20070516.pdf) was the report generated on 5/16/2007 for the prior day of operation.  Since

the stack test was on 5/16/2007, I included the report generated the next day that recapped the RTO activity during the stack

test.  Sorry for the confusion.

Best regards,

Steve Edris

President & CEO

Thermafiber, Inc.

Phone: (260) 563‐2111 ext. 214

Fax: (260) 563‐8979

www.thermafiber.com

Attention:         

The contents of this message and any attachments are intended only for the use of the addressee and may contain information that is privileged and confidential. If the reader of the message is not the intended recipient or an

authorized representative of the intended recipient, you are hereby notified that any dissemination, retransmission, or other use of this communication is strictly prohibited. If you have received this communication in error, notify the

sender immediately by return email and delete the message and any attachments from your system.

 Please consider the environment before printing this e‐mail.

From: Steve Edris 

Sent: Friday, May 20, 2011 10:46 AM 

To: 'Hancy, Cindy Wang' 

Cc: Reeves, David; Marinshaw, Richard; Fairchild.Susan@epamail.epa.gov; acrane@naima.org

Subject: RE: Thermafiber Test Report Inquiry 

Importance: High 

Cindy,

With respect to the 2007 engineering stack test performed on Thermafiber’s curing oven RTO, please see the attached files and

our comments below.

1. Reviewed curing oven thermal oxidizer (RTO) data for the date of testing 5/16/2007 and saw no abnormalities except for

a brief 15 minute period late in the day when temperatures dropped from the 1341 deg F average to 1200 deg F.  During

the test time frame, the temperature remained above 1300 deg F.  

2. Reviewed shift foreman email of 5/16/2007 at 2:43pm recapping his shift in which he commented “the urea hose had

came apart in the #2 hoffman blower room, that’s why we were not getting any urea.”  This comment indicates an upset

condition.  

3. Reviewed email exchange between Environmental Manager and Plant Manager on 6/27/2007 indicating “We were

aware of an upset condition in the binder mixing room,” and “There was one FF check on the 16th during the testing; it

was 11%.”  FF stands for free formaldehyde.  These comments indicate an upset condition.  

4. Reviewed Stack Testing Notes recorded on the date of the test 5/16/2007 that indicated “Binder system malfunctioned.  

Had higher resin content than normal due to urea not getting into react batches.  At 6:30am started extra ammonia and
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investigating why there was no urea.  Found broken urea line.  Line was immediately repaired.  Manually mixed batches

with urea and transferred to usage tank at 7:15am.”  These comments indicate an upset condition.

We would be happy to discuss this with you, but will be out of the office the rest of today.  If desired, we could talk Monday

morning.  Please let me know if you have time.

Best regards,

Steve Edris

President & CEO

Thermafiber, Inc.

Phone: (260) 563‐2111 ext. 214

Fax: (260) 563‐8979

www.thermafiber.com

Attention:         

The contents of this message and any attachments are intended only for the use of the addressee and may contain information that is privileged and confidential. If the reader of the message is not the intended recipient or an

authorized representative of the intended recipient, you are hereby notified that any dissemination, retransmission, or other use of this communication is strictly prohibited. If you have received this communication in error, notify the

sender immediately by return email and delete the message and any attachments from your system.

 Please consider the environment before printing this e‐mail.

From: Hancy, Cindy Wang [mailto:chancy@rti.org] 

Sent: Thursday, May 19, 2011 4:25 PM 

To: Steve Edris 

Cc: Reeves, David; Marinshaw, Richard; Fairchild.Susan@epamail.epa.gov; acrane@naima.org

Subject: Thermafiber Test Report Inquiry 

Steve,  

We are in the process of calculating floors for Mineral Wool and we found a Formaldehyde test performed at Thermafiber’s

curing oven RTO Outlet on May 16, 2007 resulted in high Formaldehyde emissions (1.41 lb/hr, 0.993 lb/hr, and 0.536 lb/hr). We

looked through the text of the report and found nothing that noted an abnormality. All other test results submitted from the

RTO outlet are at about ~0.2 lb/hr. We would like to know if there was anything unusual about the test (i.e., it was not

performed during normal operating conditions) to determine whether or not it should be included in our analysis.  I have not

attached the test report because it was sent as CBI and we are unable to email CBI material. If you have any questions please

feel free to contact me at the number below.    

Regards,

Cindy Wang Hancy

RTI International

P.O. Box 12194

Research Triangle Park, NC 27709

Phone:  (919) 541‐6623

Fax:  (919) 316‐3420