FORM A-1

PARENT COMPANY INFORMATION

I. Parent Company / Legal Corporate Owner Information

 1. Legal Parent Company / Legal Corporate Name Thermafiber, Inc.

 2. Address 3711 Mill Street

 3. City Wabash

 4. State Indiana

 5. Zip Code 46992

 6. County Wabash

 7. Size of Company (approximate number of employees including all 

subsidiaries, branches, and related establishments owned): 140
FORM A-2

FACILITY INFORMATION

II. Facility Information

 Facility Name Thermafiber, Inc.

 Facility Address

 Street 3711 Mill Street

 City Wabash

 State Indiana

 Zip Code 46992

 County Wabash

 Facility Coordinates

 Latitude (decimal degrees, six decimal places) 40.795177

 Longitude (decimal degrees, six decimal places) 85.862205

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

centroid of property, etc.) Main Office Front Door

 Number of employees attached to the mineral wool production 

facility: 140

 Design capacity of the plant (tons/yr) CBI

 Type(s) of process(es) (rotary spin, flame attenuation) at this plant Cupola melt with rotary spin fiberization

 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)

Indiana Department of Environmental Management (IDEM) Operation Permit No.: 

T169-27436-00009 (Title V Air Permit) (see document "Thermafiber Air Operating 

Permit 169-27436-00009.pdf")

III. Technical Contact

 Name Kale Sparling

 Technical Contact Title Process Improvement Manager

 Telephone 260-563-2111 x224

 Facsimile (Fax) 260-563-7022
 Email ksparling@thermafiber.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? Not Applicable

 Does the facility manufacture other products in addition to 

mineral wool? Yes

 If "Yes", list the other products manufactured at the facility. High temperature insulation board is received, glued, and cut to finished size

 Are there any HAP emissions associated with any co-located 

facilities? List unit operations, e.g., boiler, and pollutant/emissions There are no co-located facilities associated with the Thermafiber Wabash Plant
FORM B-1

PLANT OPERATIONS

I. Overview of Process Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

2

For each process line: Process Line 1 Process Line 2 Process Line 3

Process line identification name or numbers Bonded #2 Line Granulated #4 Line

Type of process line (e.g., Fiberization method) Rotary Spin Rotary Spin

Maximum annual production rate (tons/yr) CBI CBI

Age of process line (yrs) 50+ 50+

Remaining economic life of process line (yrs)

List of products produced and most recent annual 

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

Please attach detailed schematics of each process line See block diagram below See block diagram below

Not applicable, routine and continuous maintenance 

practices can extend the life of this equipment 

indefinitely

Please attach detailed schematics of each process line See block diagram below See block diagram below

FORM B-2

PROCESS OPERATIONS

II. Raw Material Handling and Storage

 Cupola charge preparation

 Raw materials and proportions by wt (%) CBI

 Method(s) of conveying each raw material to cupola Belt conveyors - vibrating feeders - weigh hoppers - skip hoists

 Binder and Additives

 List each raw material, including premixed materials, in 

the binder formulation and its proportion by wt (%) CBI

 List steps in preparing binder, including storage 

temperature (°F) and holding time (hrs)

Resin stored at 60°F, Urea stored at ambient temperature, 

Resin/Urea pre-reacted for 3-5 hours in solution in react tanks, 

Completed formulation mixed in Pre-mix tank then moved to usage 

tank

 Total yearly consumption of binder, excluding water, 

(gal/yr) CBI

 Cost of binder, excluding water, ($/gal) for most recent 

year (specify year) CBI

 Are binder storage and mixing tanks vented to 

outside/inside? Inside

 Method of treating vent air from storage and mix tanks No controls

 Emission control during liquid raw material transfer from 

vehicles to storage tanks. No controls

 Describe future source reduction plans and schedules to 

reformulate binders; List each constituent, proportions wt 

(%), cost ($/gal) for reformulation No current source reduction plans or reformulations.
FORM B-3

PROCESS OPERATIONS

III. Cupola/furnace

 For each cupola: Cupola 1 Cupola 2 Cupola 3

 Process unit identification name/number Cupola #2 (EU-P2) Cupola #4 (EU-P4)

 Process line(s) served (identification name/number) Bonded #2 Line Granulated #4 Line

 Latitude (decimal degrees, six decimal places) 40.796075 40.795928

 Longitude (decimal degrees, six decimal places) -85.861282 -85.861214

 Stack or vent height (units) 58'-5" 58'-5"

 Stack or vent diameter (units) 48" 48"

 Manufacturer and model Internal Design Internal Design

 Date of original installation 1955 1955

 Estimate of remaining lifetime (yrs) 30+ 30+

 Major rebuilds:

 What constitutes a major rebuild

 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

 Fuel type: coke, electric, gas, or oil Coke Coke

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

melt) CBI CBI

 Design production rate (tons/day) CBI CBI

 Actual glass pull rate (tons/day) CBI CBI

 Exhaust air flow rate (acfm @ °F) 9,513 @ 246 °F 14,306 @ 345 °F

 Temperature (°F) of melt as it exits the cupola 2450 F 2450 F

 Is oxygen enrichment used to supplement combustion air Yes Yes

 Quantity of oxygen supplied for enrichment (cu. Ft. O2/ton coke) CBI CBI

 Nature and frequency of routine/preventive maintenance procedures

Thermal stress crack 

welding weekly

Thermal stress crack 

welding weekly

Major rebuild is not a term for which the 

company is familiar. The company conducts 

routine refractory, liner, and shell repair and 

replacement projects every 2 to 10 years. 

Through routine and continuous maintenance 

practices life of this equipment can be 

extended indefinitely. These projects do not 

impact the cupola emissions.
 Describe process modification(s) since 1999 that reduce emissions

2003 Fabric filter 

baghouse, 2009 

thermal oxidizer

2003 Fabric filter 

baghouse, 2009 

thermal oxidizer, 

caustic injection 

system

 Describe future source reduction plans and schedules No current plans No current plans
FORM B-4

PROCESS OPERATIONS

IV. Fiberization

 For each fiberization operation: Fiberization Operation 1 Fiberization Operation 2 Fiberization Operation 3

 Process unit identification name/number Spinner #2

 Process line(s) served (identification name/number) Bonded #2 Line

 Latitude (decimal degrees, six decimal places) 40.796075

 Longitude (decimal degrees, six decimal places) -85.861282

 Stack or vent height (units) Not Applicable

 Stack or vent diameter (units) Not Applicable

 Number of fiber forming devices (spinners) per line 1

 Method of attenuation fiber (air, centrifical force, or both) Both

 Major rebuilds:

 What constitutes a major rebuild

 Frequency of a major rebuild NA

 Cost of typical major rebuild NA

 Date of last major rebuild NA

 Purpose of last major rebuild NA

 Increase or decrease in emissions NA

 If forming section is modular, i.e., more than one forming 

and collection area per line, indicate the number of modules and 

air plenums. One per line

 Presence of water overspray and application range (gpm) None

 Binder applied and application rate (gpm) Binder @ 8-11 gpm

 Other material applied (annealing oil or oil/water emulsion) 

and application rate (gpm) None

 Temperature of binder when applied to the fibers (°F) 70

 Forming air flow rate (acfm @ °F) 12,400 cfm at 120°F

 Percent of forming air recirculated and percent exhausted 100% exhausted

 Nature and frequency of routine/preventive maintenance 

procedures Weekly

Major rebuild is not a term for which the company is familiar. The company conducts 

routine maintenance, repair, and replacement projects as needed. Through routine and 

continuous maintenance practices life of this equipment can be extended indefinitely. 

These projects do not impact the cupola emissions.
 Describe process modification(s) since 1999 that reduce 

emissions None

 Describe future source reduction plans and schedules No current plans

 Fiberization method (e.g., Downey process or Youger/Powell 

process) European

 Number of rotors 4

 Configuration of rotor(s) Horizontal

 Amount of material that remains non-fiberized shot 40%

 Exhaust air flow rate (acfm @ °F) See Blow Chamber #2
FORM B-5

PROCESS OPERATIONS

V. Fiber Collection

 For each fiber collection operation: Fiber Collection Operation 1 Fiber Collection Operation 2 Fiber Collection Operation 3

 Process unit identification name/number Blow Chamber #2 (EU-P8)

 Process line(s) served (identification name/number) Bonded #2 Line

 Latitude (decimal degrees, six decimal places) 40.796078°

 Longitude (decimal degrees, six decimal places) -85.861354°

 Stack or vent height (units)

N/A - Exhausts thru #2 Dry

Filter (See C3)

 Stack or vent diameter (units)

N/A - Exhausts thru #2 Dry

Filter (See C3)

 Method of fiber collection from fiberization Perforated steel belt

 Manufacturer and model of collection chamber Aberg Engineering

 Date of original installation 1955

 Major rebuilds:

 What constitutes a major rebuild

 Frequency of a major rebuild NA

 Cost of typical major rebuild NA

 Date of last major rebuild NA

 Purpose of last major rebuild NA

 Increase or decrease in emissions NA

 Air flow rate (acfm @ °F) in pneumatic fiber conveying Unknown

 Exhaust air flow rate (acfm @ °F) 95,000 @ 150°F

 Residence time of product (mins) (time spent in 

collection device) Unknown

 Method of evenly distributing fibers onto conveyor belt None

 Formed mat thickness (in.) 2

 Nature and frequency of routine/preventive 

maintenance procedures Weekly

 Describe process modification(s) since 1999 that 

reduce emissions None

Major rebuild is not a term for which the company is familiar. The company conducts routine 

screen, chain, roller, and wear component repair and replacement projects every 1 to 5 years. 

Through routine and continuous maintenance practices life of this equipment can be extended 

indefinitely. These projects do not impact the emissions.
 Describe future source reduction plans and schedules No current plans
FORM B-6

PROCESS OPERATIONS

VI. Curing 

 For each curing oven: Curing Oven 1 Curing Oven 2 Curing Oven 3

 Process unit identification name/number Curing Oven #2 (EU-P7)

 Process line(s) served (identification name/number) Bonded #2 Line

 Latitude (decimal degrees, six decimal places) 40.796190°

 Longitude (decimal degrees, six decimal places) -85.860967°

 Stack or vent height (units) 33'

 Stack or vent diameter (units) RTO Outlet = 42" Dia

 Method of curing 

Natural gas heated forced 

air

 Manufacturer and model Jungers Verkstad

 Date of original installation 1978

 Major rebuilds:

 What constitutes a major rebuild

 Frequency of a major rebuild NA

 Cost of typical major rebuild NA

 Date of last major rebuild NA

 Purpose of last major rebuild NA

 Increase or decrease in emissions NA

 Fuel type: electric, gas, or oil 

Natural gas heated forced 

air

 Fuel consumption rate (KW/hr or BTU/hr) 5.7 MMBTU/hr max

 Curing temperature (°F) 450 - 550 °F

 Moisture content wt (%) of formed mat: 

 inlet 4-7% (typical)

 outlet 0.1-0.3% (typical)

 Exhaust air flow rate (acfm @ °F) from curing 15,739 @ 312 °F

 Residence time of product (mins) 2-13 mins

 Binder content of cured product (LOI) 2.50%

 Nature and frequency of routine/preventive maintenance 

procedures Weekly

Major rebuild is not a term for which the company is familiar. The company conducts 

routine inspections and component repairs annually.Through routine and continuous 

maintenance practices life of this equipment can be extended indefinitely. These 

projects do not impact the emissions.
 Describe process modification(s) since 1999 that reduce 

emissions

Added Curing Oven RTO 

(Regenerative Thermal 

Oxidizer) in 2003

 Describe future source reduction plans and schedules No current plans
FORM B-7

PROCESS OPERATIONS

VII. Cooling

 For each cooling operation: Cooling Operation 1 Cooling Operation 2 Cooling Operation 3

 Process unit identification name/number

Cooling Section #2 (EUP10)

 Process line(s) served (identification name/number) Bonded #2 Line

 Latitude (decimal degrees, six decimal places) 40.796211°

 Longitude (decimal degrees, six decimal places) -85.860881°

 Stack or vent height (units) approx. 35'

 Stack or vent diameter (units) 34"

 Cooling air flow rate (acfm @ °F) See exhaust air flow below

 Percentage of cooling air recirculated (if any) None

 Cooling air temperature (°F) Ambient

 Exhaust air flow rate (acfm @ °F) 25,000 cfm @ 144°F

 Nature and frequency of routine/preventive maintenance 

procedures Weekly

 Describe process modification(s) since 1999 that reduce 

emissions None

 Describe future source reduction plans and schedules No current plans
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, CO, 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 "Form B-8 Attachment.pdf" file
FORM C-1

AIR POLLUTION CONTROL

I. Electrostatic Precipitator (ESP)

 For each ESP: ESP 1 ESP 2 ESP 3

 Process line(s) (identification name/number) N/A

 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

 Number of collection plates and configuration

 Gas flow rate to ESP (acfm @ °F)

 Inlet gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Pressure drop across ESP (in. H

2O gauge)

 Plate area (ft

2

)

 Vendor guarantee on ESP efficiency (attach copy)

 Method of plate cleaning and frequency

 Flow rate of plate wash water to ESP (gpm), if applicable

 Temperature of plate wash water to ESP (°F), if applicable

 Source of plate wash water used for cleaning, if applicable

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

wash water, if applicable

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

applicable

 Amount of wastewater generated (gpd), if applicable

 Amount of wastewater recycled (gpd), if applicable

 Amount of wastewater disposed of (gpd), if applicable

 Method of wastewater disposal, if applicable

 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 routine/preventive maintenance 

procedures

 Problems experienced with control device within the last five 

years; how were problems solved?

 Continuous monitoring method(s) used to monitor ESP 

performance, including parameters monitored

 Describe any plans to replace or upgrade ESP
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each scrubber: Scrubber 1 Scrubber 2 Scrubber 3

 Process line(s) (identification name/number) N/A

 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)

 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
FORM C-3

AIR POLLUTION CONTROL

III. Mechanical Collector

 For each mechanical collector: Mechanical Collector 1 Mechanical Collector 2

 Process line(s) (identification name/number) #2 Dry Filter (S6)

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) Blow Chamber #2 (EU-P8)

 Latitude (decimal degrees, six decimal places) 40.796069°

 Longitude (decimal degrees, six decimal places) -85.860961°

 Stack or vent height (units) approx. 36'

 Stack or vent diameter (units) NA

 Manufacturer and model Internal design

 Date of original installation 1955, 1978

 Type of mechanical collector Woven screen mesh

 Gas flow rate to collector (acfm @ °F) 95,000 @ 150°F

 Inlet gas temperature (°F) 150° F

 Outlet gas temperature (°F) Unknown

 Inlet grain loading (gr/dscf) Unknown

 Outlet grain loading (gr/dscf) Unknown

 Average stack opacity (%)

In compliance with section 

C.2 of air permit, the average 

opacity is less than 40% 

during any averaging period.

 Overall pressure drop (in. H2O gauge) Unknown

 Vendor guarantee on mechanical collector efficiency (attach 

copy) None

 Quantity of solid waste collected (lbs/yr) Not tracked at this level

 Quantity of solid waste recycled (lbs/yr) Not tracked at this level

 Quantity of solid waste disposed of (lbs/yr) Not tracked at this level

 Method of solid waste disposal Landfill

 Nature and frequency of preventive maintenance procedures

Weekly cleaning, inspection & 

repair

 Problems experienced with control device within the last five 

years; how were problems solved? None
 Continuous monitoring method(s) used to monitor performance, 

including parameters monitored None

 Plans to replace or upgrade mechanical collector No current plans
FORM C-4

AIR POLLUTION CONTROL

IV. Fabric Filter 

 For each fabric filter: Fabric Filter 1 Fabric Filter 2 Fabric Filter 3

 Process line(s) (identification name/number) Bag House #2 (S1) Bag House #4 (S3) Dust Collector #2 (CE7)

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) Cupola #2 (EU-P2) Cupola #4 (EU-P4)

Bonded Sizing Equipment 

(EU-P9)

 Latitude (decimal degrees, six decimal places) 40.795648° 40.795648° 40.796217°

 Longitude (decimal degrees, six decimal places) -85.860946° -85.860946° -85.860968°

 Stack or vent height (units) 58'-5" 58'-5" ~40'

 Stack or vent diameter (units) 48" 48" 18" x 36"

 Manufacturer and model Kirk & Blum Kirk & Blum Industrial Clean Air

 Date of original installation 2003 2003 1978

 Number of compartments 5 5 1

 Number of bags per compartment 108 (9 rows of 12) 108 (9 rows of 12) 200

 Filter material and coatings applied Huyglass 1105 (fiberglass) Huyglass 1105 (fiberglass)

Spunbond Polyester Pulse 

Pleat with a Polyurethane 

Top and Bottom and 

Polypropylene Inner Core

 Fabric weight (oz/yd

2

) 27 27 unknown

 Filter surface area (ft2) 8600 8600 1500

 Gas flow rate to filter (acfm @ °F) 15,900 @ 290°F 14,700 @ 310°F unknown

 Inlet gas temperature (°F) 350°F 370°F unknown

 Outlet gas temperature (°F) 290°F 310°F unknown

 Inlet grain loading (gr/dscf) unknown unknown unknown

 Outlet grain loading (gr/dscf) unknown unknown unknown
 Average stack opacity (%)

In compliance with section 

C.2 of air permit, the 

average opacity is less 

than 40% during any 

averaging period.

In compliance with section 

C.2 of air permit, the 

average opacity is less 

than 40% during any 

averaging period.

In compliance with section 

C.2 of air permit, the 

average opacity is less 

than 40% during any 

averaging period.

 Overall pressure drop (in. H2O gauge) 5.5 7 3.5

 Method and frequency of bag cleaning Pulse jet Pulse jet Pulse jet

 Vendor guarantee on fabric filter efficiency (attach copy)

System designed to meet 

MACT requirements of 

0.10 lb PM per ton melt, 

compliance test upon start 

up validated the design 

requirement

System designed to meet 

MACT requirements of 

0.10 lb PM per ton melt, 

compliance test upon start 

up validated the design 

requirement unknown

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

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

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

 Method of solid waste disposal Landfill Landfill Landfill

 Nature and frequency of preventive maintenance 

procedures

Weekly inspection, 

cleaning & repair

Weekly inspection, 

cleaning & repair

Weekly inspection, 

cleaning & repair

 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 

monitors, delta P

Bag leak detection 

monitors, delta P delta P (daily)

 Plans to replace or upgrade fabric filter No current plans No current plans No current plans
FORM C-5

AIR POLLUTION CONTROL

V. Thermal Incinerator

 For each thermal incinerator Thermal Incinerator 1 Thermal Incinerator 2 Thermal Incinerator 3

 Process line(s) (identification name/number)

#2 Thermal Oxidizer (EUP2A)#4 Thermal Oxidizer (EUP4A) Curing Oven RTO (S5)

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) Cupola #2 (EU-P2) Cupola #4 (EU-P4) Curing Oven #2 (EU-P7)

 Latitude (decimal degrees, six decimal places) 40.795851° 40.795849° 40.796190°

 Longitude (decimal degrees, six decimal places) -85.861236° -85.861264° -85.860967°

 Stack or vent height (units)

N/A - Vents thru #2 

Baghouse

N/A - Vents thru #4 

Baghouse 33'-1"

 Stack or vent diameter (units)

N/A - Vents thru #2 

Baghouse

N/A - Vents thru #4 

Baghouse 42"

 Manufacturer and model Kuttner Kuttner Kirk & Blum

 Date of original installation 2009 2009 2003

 Fuel type: gas or oil Natural gas Natural gas Natural gas

 Fuel consumption rate (BTU/hr) 10 MMBtu/hr max 10 MMBtu/hr max 4.5 MMBtu/hr max

 Inlet gas flow rate (acfm @ °F) 7500 SCFM 7500 SCFM 14,306 @ 345 °F

 Inlet gas temperature (°F) 600 600 345

 Combustion chamber gas temperature (°F) 1425 1425 1300

 Outlet gas temperature (°F) 1450 1450 312

 Inlet grain loading (gr/dscf) unknown unknown unknown

 Outlet grain loading (gr/dscf) unknown unknown unknown

 Average stack opacity (%) NA NA

In compliance with section 

C.2 of air permit, the 

average opacity is less than 

40% during any averaging 

period.

 Excess air (%) 6% O2 6% O2 unknown

 Residence time (sec) at temperature (°F) unknown unknown unknown

 Percent heat recovery unknown unknown unknown
 Vendor guarantee on incinerator efficiency (attach copy) NA NA

System designed to meet 

MACT (formaldehyde) 

requirement of 0.06 lb per 

ton or 80% reduction of 

uncontrolled emission. 

Copmliance testing upon 

started validated design 

met requirment.

 Nature and frequency of preventive maintenance procedures

Weekly inspection, 

cleaning & repair

Weekly inspection, cleaning 

& repair

Weekly inspection, cleaning 

& repair

 Problems experienced with control device within the last five 

years; how were problems solved? New system New system None

 Continuous monitoring method(s) used to monitor incinerator 

performance, including parameters monitored

Temperature, Natural Gas 

Usage, % O2

Temperature, Natural Gas 

Usage, % O2

Temperature, Natural Gas 

Usage

 Plans to replace or upgrade thermal incinerator No current plans No current plans No current plans
FORM C-6

AIR POLLUTION CONTROL

VI. High Velocity Air Filter (HVAF)

 For each HVAF: HVAF 1 HVAF 2 HVAF 3

 Process line(s) (identification name/number) N/A

 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

 Inlet gas flow rate (acfm @ °F)

 Inlet gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Water spray pressure (psig), if applicable

 Water spray rate (gpm), if applicable

 Filter face velocity (acfm/ft

2

)

 Maximum pressure drop across mat (in. H

2O gauge)

 Vendor guarantee on HVAF efficiency (attach copy)

 Method and frequency of filter mad advancement

 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
 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 

HVAF performance, including parameters monitored

 Plans to replace or upgrade HVAF
FORM C-7

AIR POLLUTION CONTROL

VII. Mist Eliminator

 For each mist eliminator: Mist Eliminator 1 Mist Eliminator 2 Mist Eliminator 3

 Process line(s) (identification name/number) N/A

 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 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)

 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 
FORM C-8

AIR POLLUTION CONTROL

VIII. Ventilation System 

 For each ventilation system: Ventilation System 1 Ventilation System 2 Ventilation System 3

 Process line(s) (identification name/number) N/A

 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

 Volume of enclosure or hood

 Capture velocity (ft/sec)

 Distance between hood and emission source (ft)
FORM C-9

AIR POLLUTION CONTROL

IX. Other 

 For each other air pollution control devide (APCD): Other APCD 1 Other APCD 2 Other APCD 3

 Process line(s) (identification name/number)

Fab Shop Baghouse (DC30) Caustic Injection System

 Equipment/process(es) controlled. Include emission point 

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

Fiber Board Cutting (EUP30) Cupola #4

 Latitude (decimal degrees, six decimal places) 40.795499° 40.795793°

 Longitude (decimal degrees, six decimal places) -85.862336° -85.861047°

 Stack or vent height (units) N/A - Vents indoors

N/A - Vents through #4 

Baghouse

 Stack or vent diameter (units) N/A - Vents indoors

N/A - Vents through #4 

Baghouse

 Description

Custom fabrication of 

heavy density fiber board. 

Ofline process.

Sodium bicarbonate 

injection system for SO2 

control from cupola
FORM D

PROCESS LINE STARTUP AND SHUTDOWN

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

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

through J. 

 A. Using the definitions provided above, indicate whether the 

event was a startup or shutdown;

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

emissions source or sources associated with the startup or 

shutdown;

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

permit condition was exceeded;

 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;

 E. The duration of the event;

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

including the use of any backup control systems;

 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;

 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;

 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

 J. All monitoring data, including control system parameter 

monitoring, collected during each period of SS.

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.

The typical cupola campaign for the Thermafiber melting operation is less 

than one week. At the beginning of the production week, the cupola is set in 

operation (start up) and then shutdown at the end of each production week 

which is based on market demand and the need for preventative 

maintenance to the production equipment.The internal standard operating 

procedure is for the downstream control devices to be operational 

throughout the start up and shutdown processes. Stack testing has only

been conducted during normal operation.
If this information is contained in periodic and immediate SS reports 

(either stand-alone or contained within the periodic excess emissions 

report) submitted to your permitting authority, you may submit copies 

of those reports instead.

2. Are there any 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.

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

develop one.

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. None available

5. Please provide all monitoring data, including control system 

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

years. 

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. 
FORM E

PRESENCE OF AIR POLLUTANTS IN EMISSION POINTS

Please provide any existing emissions information and data covering 

hazardous air pollutants (HAP), particulate matter (PM), and carbon 

monoxide (CO) for each listed process. Identify the appropriote box for 

which you are providing specific process inofrmation and/or pollutant 

emissions data.

Cupola Fiberization Fiber Collection Curing Cooling

Carbon monoxide (CO)

Carbonyl sulfide (COS)

Particulate Matter (PM, PM2.5, PM10, PM condensable) 

Chromium compounds and Hexavalent Chromium (including any Cr 

speciation data)

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

Hydrogen Fluoride (HF)

Hydrogen Chloride (HCl)

Formaldehyde

Phenol

Methanol

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.
FORM F-1 

COST

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

 For each process unit: Process Unit 1 Process Unit 2 Process Unit 3

 Process Unit ID Cupola #2 (EU-P2) Spinner #2 Blowchamber #2 (EU-P8)

 Process Line ID Bonded #2 Line Bonded #2 Line Bonded #2 Line

II. Capital Costs

 Base year

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

III. Annual Operating Costs

 Base year (most recent fiscal year)

 Total annual operating costs

 Maintenance materials and replacement parts (specify costs by 

item)

 Raw materials costs

 Labor

 ($/yr) for each labor class

 (hr/hr) for each labor class

 Utilities (breakdown for each utility)

 Waste treatment and/or disposal

 Costs associated with any work practices and pollution prevention 

techniques that are employed at your facility

 Savings associated with heat recovery and wastewater and/or solid 

waste returned to process from APCD (or sold to another user)

 Indirect costs

 Other (specify)

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.

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

products. International

The company objects to this request 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).
Can your product(s) be substituted by another product(s)? If so, 

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

There are alternatives to mineral wool insulation, but these substitutes are not 

likely to possess the same fire performance capabilities (mineral wool is nonflammable or non-combustible) as mineral wool, nor have the same versatility 

to be installed in various applications as mineral wool, nor have recycled 

content (mineral wool can have up to 90% recycled content), nor possess 

many other attributes of mineral wool insulation products. Therefore, while 

substitutes exist, they lack the same performance characteristics that make 

mineral wool a unique insulation choice. Moreover, substitutes cannot be 

universally installed or applied in the traditional mineral wool applications.
FORM F-1 

COST

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

 For each process unit: Process Unit 1 Process Unit 2 Process Unit 3

 Process Unit ID Curing Oven #2 (EU-P7)

Cooling Section #2 (EUP10)#2 Trimming/Sizing (EUP9)

 Process Line ID Bonded #2 Line Bonded #2 Line Bonded #2 Line

II. Capital Costs

 Base year

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

III. Annual Operating Costs

 Base year (most recent fiscal year)

 Total annual operating costs

 Maintenance materials and replacement parts (specify costs by 

item)

 Raw materials costs

 Labor

 ($/yr) for each labor class

 (hr/hr) for each labor class

 Utilities (breakdown for each utility)

 Waste treatment and/or disposal

 Costs associated with any work practices and pollution prevention 

techniques that are employed at your facility

 Savings associated with heat recovery and wastewater and/or solid 

waste returned to process from APCD (or sold to another user)

 Indirect costs

 Other (specify)

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.

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

products. International

The company objects to this request 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).
Can your product(s) be substituted by another product(s)? If so, 

please list your product(s) and substituted product(s). See response in F-1
FORM F-1 

COST

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

 For each process unit: Process Unit 1 Process Unit 2 Process Unit 3

 Process Unit ID Cupola #4 (EU-P4) Spinner #4 Blowchamber #4 (EU-P6)

 Process Line ID Granulated #4 Line Granulated #4 Line Granulated #4 Line

II. Capital Costs

 Base year

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

III. Annual Operating Costs

 Base year (most recent fiscal year)

 Total annual operating costs

 Maintenance materials and replacement parts (specify costs by 

item)

 Raw materials costs

 Labor

 ($/yr) for each labor class

 (hr/hr) for each labor class

 Utilities (breakdown for each utility)

 Waste treatment and/or disposal

 Costs associated with any work practices and pollution prevention 

techniques that are employed at your facility

 Savings associated with heat recovery and wastewater and/or solid 

waste returned to process from APCD (or sold to another user)

 Indirect costs

 Other (specify)

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.

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

products.

The company objects to this request 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).
Can your product(s) be substituted by another product(s)? If so, 

please list your product(s) and substituted product(s). See response in F-1
FORM F-2 

COST

I. Air Pollution Control Device (APCD)

 For each APCD: APCD 1 APCD 2 APCD 3

 APCD ID

#2 Thermal Oxidizer 

(EU-P2A) Baghouse #2 (S1) Dry Filter #2 (S6)

 Process Unit ID Cupola #2 (EU-P2) Cupola #2 (EU-P2)

Blowchamber #2 (EUP8)

II. Capital Costs

 Base year

 APCD equipment purchase cost and what was included

 List the cost for each piece of auxiliary equipment for each APCD not 

included above

 Installation cost

 Land purchase cost

 Total capital cost

 Method of financing APCD

 Retrofit installation

 Field erected or modular

III. Annual Operating Costs

 Base year (most recent fiscal year)

 Maintenance materials and replacement parts (specify costs by item)

 Raw materials costs

 Labor

 ($/yr) for each labor class

 (hr/hr) for each labor class

 Utilities (breakdown for each utility)

 Waste treatment and/or disposal

 Indirect costs

 Other (specify)

 Total annual operating cost (most recent fiscal year)

Attach annual report to shareholders or equivalent for the most recent 

fiscal year

The company objects to this request 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).
FORM F-2 

COST

I. Air Pollution Control Device (APCD)

 For each APCD: APCD 4 APCD 5 APCD 6

 APCD ID Curing Oven RTO (S5) Dust Collector #2 (CE7)

 Process Unit ID Curing Oven #2 (EU-P7)

#2 Trimming/Sizing (EUP9)

II. Capital Costs

 Base year

 APCD equipment purchase cost and what was included

 List the cost for each piece of auxiliary equipment for each APCD not 

included above

 Installation cost

 Land purchase cost

 Total capital cost

 Method of financing APCD

 Retrofit installation

 Field erected or modular

III. Annual Operating Costs

 Base year (most recent fiscal year)

 Maintenance materials and replacement parts (specify costs by item)

 Raw materials costs

 Labor

 ($/yr) for each labor class

 (hr/hr) for each labor class

 Utilities (breakdown for each utility)

 Waste treatment and/or disposal

 Indirect costs

 Other (specify)

 Total annual operating cost (most recent fiscal year)

Attach annual report to shareholders or equivalent for the most recent 

fiscal year

The company objects to this request 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).
FORM F-2 

COST

I. Air Pollution Control Device (APCD)

 For each APCD: APCD 7 APCD 8 APCD 9

 APCD ID

Thermal Oxidizer #4 

(EU-P4A) Baghouse #4 (S3) Dry Filter #4 (S4)

 Process Unit ID Cupola #4 (EU-P4) Cupola #4 (EU-P4)

Blowchamber #4 (EUP6)

II. Capital Costs

 Base year

 APCD equipment purchase cost and what was included

 List the cost for each piece of auxiliary equipment for each APCD not 

included above

 Installation cost

 Land purchase cost

 Total capital cost

 Method of financing APCD

 Retrofit installation

 Field erected or modular

III. Annual Operating Costs

 Base year (most recent fiscal year)

 Maintenance materials and replacement parts (specify costs by item)

 Raw materials costs

 Labor

 ($/yr) for each labor class

 (hr/hr) for each labor class

 Utilities (breakdown for each utility)

 Waste treatment and/or disposal

 Indirect costs

 Other (specify)

 Total annual operating cost (most recent fiscal year)

Attach annual report to shareholders or equivalent for the most recent 

fiscal year

The company objects to this request 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).
FORM F-2 

COST

I. Air Pollution Control Device (APCD)

 For each APCD: APCD 10 APCD 11 APCD 12

 APCD ID

Caustic Injection 

System

 Process Unit ID Cupola #4

II. Capital Costs

 Base year

 APCD equipment purchase cost and what was included

 List the cost for each piece of auxiliary equipment for each APCD not 

included above

 Installation cost

 Land purchase cost

 Total capital cost

 Method of financing APCD

 Retrofit installation

 Field erected or modular

III. Annual Operating Costs

 Base year (most recent fiscal year)

 Maintenance materials and replacement parts (specify costs by item)

 Raw materials costs

 Labor

 ($/yr) for each labor class

 (hr/hr) for each labor class

 Utilities (breakdown for each utility)

 Waste treatment and/or disposal

 Indirect costs

 Other (specify)

 Total annual operating cost (most recent fiscal year)

Attach annual report to shareholders or equivalent for the most recent 

fiscal year

The company objects to this request 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).