**FORM A -1** 

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

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

1. Legal Parent Company / Legal Corporate Name Thermafiber, Inc. 2. Address 3711 Mill Street 3. City Wa bash 4. State Indiana 5. Zip Code 46992 6. County Wa bash 7. Size of Company (approximate number of employees including all subsidiaries, branches, and related establishments owned): 140**FORM A -2** 

**FA CILITY INFORMA** 

**TION**

**II. Facility Information**

Facility Name Thermafiber, Inc. Facility Address Street 3711 Mill Street City Wa bash State Indiana Zip Code 46992 County Wa bash 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/y r) CBI

Ty pe(s) of process(es) (rotary spin, flame attenuation) at this plant Cupola m elt with rotary spin fiberization

Operation schedule hrs/day 24 days/y r 365

Identify what state and local air pollution rules and regulations, including permit requirements, your plant is subject to. (Please provide copies of permit(s) and permit IDs) 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) 260-563-7022Email 

### 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 mi neral 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 em issions 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 W abash Plant**FORM B-1**

**PLA NT OPERA** 

**TIONS**

**I. Overview of Process Operations**

Number of process lines. Include lines that are currently operational or that are temporarilyshutdown. (Do not include lines permanentlyshutdown). 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 Ty pe of process line (e.g., Fiberization method) Rotary Spin Rotary Spin Maximum annual production rate (tons/y r) CBI CBI Age of process line (y rs) 50+ 50+

Remaining economic life of process line (y rs) List of products produced and most recent annual production (tons/y r; 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 OPERA TIONS** 

**II. Raw Material Handling and Storage**

Cupola charge preparation Raw materials and proportions bywt (%) CBI Method(s) of convey ing 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 bywt (%) 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/y r) CBI Cost of binder, excluding water, ($/gal) for most recent ye ar (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 OPERA**

**TIONS**

**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 (y rs) 30+ 30+ Major rebuilds:

W hat constitutes a major rebuild Frequency

of a major rebuild NA NA Cost of ty pical 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 ty pe: 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 im pact 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 OPERA**

**TIONS**

**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:

W hat constitutes a major rebuild Frequency

of a major rebuild NA Cost of ty pical 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 plenum s. 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 We ekly 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

em issions None Describe future source reduction plans and schedules No current plans Fiberization m ethod (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 Cham ber #2**FORM B-5**

**PROCESS OPERA**

**TIONS**

**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 Cham ber #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:

W hat constitutes a major rebuild Frequency

of a major rebuild NA Cost of ty pical 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 convey ing 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

ma intenance procedures We ekly 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 OPERA**

**TIONS**

**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:

W hat constitutes a major rebuild Frequency

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

Fuel ty pe: 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% (ty pical) outlet 0.1-0.3% (ty pical) 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 We ekly 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

ma intenance practices life of this equipment can be extended indefinitely . These projects do not impact the emissions.Describe process modification(s) since 1999 that reduce

em issions Added Curing Oven RTO (Regenerative Thermal Oxidizer) in 2003 Describe future source reduction plans and schedules No current plans**FORM B-7**

**PROCESS OPERA**

**TIONS**

**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

em issions 

### None Describe future source reduction plans and schedules 

### No current plans**FORM B-8**

**PROCESS OPERA**

**TIONS**

**VIII. Pollution Prevention**

Please describe any

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

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

the year in which the facility im plem ented the practice/technique and identify the emission reductions (if measured) from these practices/techniques. See "Form B-8 Attachment.pdf" file**FORM C-1**

**AI R POLLUTION CONTROL** 

**I. Electrostatic Precipitator (ESP)**

For each ESP: ESP 1 ESP 2 ESP 3 Process line(s) (identification name/number) N/A Equipm ent/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Manufacturer and model Date of original installation Number of collection plates and configuration Gas flow rate to ESP (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%) Pressure drop across ESP (in. H 2 O gauge) Plate area (ft 2 ) Vendor guarantee on ESP efficiency (attach copy ) Method of plate cleaning and frequency Flow rate of plate wash water to ESP (gpm), if applicable Temperature of plate wash water to ESP ( ° F), if applicable Source of plate wash water used for cleaning, if applicable Concentration (mg/l) of dissolved and suspended solids in plate wash water, if applicable Conditioning agents used and amounts (in gpm or lbs/hr), if applicable Amount of wastewater generated (gpd), if applicable Amount of wastewater recycled (gpd), if applicable Amount of wastewater disposed of (gpd), if applicable Method of wastewater disposal, if applicable Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

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

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

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

**AI R POLLUTION CONTROL** 

**II. Scrubber**

For each scrubber: Scrubber 1 Scrubber 2 Scrubber 3 Process line(s) (identification name/number) 

### N/A Equipm ent/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Manufacturer and model Date of original installation Ty pe (e.g., venturi, orifice) Gas flow rate to scrubber (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%)
W ater flow rate to scrubber (gpm) Percent of scrubber water from recycled wastewater

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

Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

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

**AI R POLLUTION CONTROL** 

**III. Mechanical Collector**

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. H 2 O 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? 

### NoneContinuous monitoring method(s) used to monitor performance,

including parameters monitored 

### None Plans to replace or upgrade mechanical collector 

### No current plans**FORM C-4**

**AI R 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) Equipm ent/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 (ft 2 ) 

### 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 unknownAverage 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. H 2 O 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/y r) 

### unknown unknown unknown Quantity

of solid waste recycled (lbs/y r) 

### 0 0 0 Quantity

of solid waste disposed of (lbs/y r) 

### unknown unknown unknown Method of solid waste disposal 

### Landfill Landfill Landfill Nature and frequency of preventive maintenance procedures 

### Weekly inspection, cleaning & repair Weekly inspection, cleaning & repair Weekly inspection, cleaning & repair Problems experienced with control device within the last five ye ars; 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**

**AI R 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) Equipm ent/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 ty pe: 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 unknownVendor 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 ye ars; 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**

**AI R POLLUTION CONTROL** 

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

For each HVAF: HVAF 1 HVAF 2 HVAF 3 Process line(s) (identification name/number) 

### N/A Equipm ent/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Manufacturer and model Date of original installation Inlet gas flow rate (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%)
W ater spray

pressure (psig), if applicable
W ater spray

rate (gpm), if applicable Filter face velocity

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

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

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

**AI R POLLUTION CONTROL** 

**VII. Mist Eliminator**

For each mist eliminator: Mist Eliminator 1 Mist Eliminator 2 Mist Eliminator 3 Process line(s) (identification name/number) 

### N/A Equipm ent/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) Manufacturer and model Date of original installation Ty pe of mist eliminator Gas flow rate to mist eliminator (acfm @ ° F) Inlet gas temperature ( ° F) Outlet gas temperature ( ° F) Inlet grain loading (gr/dscf) Outlet grain loading (gr/dscf) Average stack opacity (%) Velocity

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

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

Method of wastewater disposal Quantity

of solid waste collected (lbs/y r) Quantity

of solid waste recycled (lbs/y r) Quantity

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

**AI R POLLUTION CONTROL** 

**VIII. Ventilation System**

For each ventilation system: Ventilation System 1 Ventilation System 2 Ventilation System 3 Process line(s) (identification name/number) N/A Equipm ent/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Latitude (decimal degrees, six decimal places) Longitude (decimal degrees, six decimal places) Stack or vent height (units) Stack or vent diameter (units) For general or building ventilation: Ventilation system used Airflow control system used Number of air changes per hour For unit or local ventilation: Enclosure or hood design used Volume of enclosure or hood Capture velocity (ft/sec) Distance between hood and emission source (ft)**FORM C-9**

**AI R POLLUTION CONTROL** 

**IX. Other**

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 Equipm ent/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 STA RTUP A**  **ND SHUTDOWN**

1. For each startup and shutdown (SS) that occurred during the past five years, please provide the following information requested in A. through J.

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

em issions source or sources associated with the startup or shutdown; C. W hether any

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

D. W hether the event was covered by any contingency

plan for controlling emissions during startup and shutdown events and, if so, whether the plan was followed; if the plan was not followed, why not; 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. W hether the emission profile of each unit was different during startup and shutdown than during normal operating conditions and, if so, how emissions were different and why ; please provide any supporting information; 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

mo nitoring, 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 ty pical 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

ma intenance 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

ty pes of startup or shutdown events that you have been able to elim inate? If so, please describe the ty pe of event and explain how these events were elim inated. 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 m onitoring data, including control system parameter monitoring, collected during periods of SS over the last 5 ye ars. 6. Optional: Do you wish to recommend a standard that would apply during startup or shutdown? If so, please describe the event to which the standard would apply ; the recommended standard (this could be an emission limitation, work practice, or operational standard) that would apply during the period; the basis for the recommended standard; why and how the standard would m inim ize

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

**PRESENCE OF A IR POLLUTA**  **NTS 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. Identifythe appropriote box for which you are providing specific process inofrmation and/or pollutant emissions data. Cupola Fiberization Fiber Collection Curing Cooling Carbon monoxide (CO) Carbony l sulfide (COS) Particulate Matter (PM, PM2.5, PM10, PM condensable) Chromium compounds and Hexavalent Chromium (including any Cr speciation data) Other metal HAP (As, Be, Cd, Co, Hg, Pb, Mn, Sb, Se) Hydrogen Fluoride (HF) Hydrogen Chloride (HCl) Formaldehyde Phenol Methanol 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 May5, 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, hy drogen fluoride, metals (antimony , arsenic, bery llium , cadmium, chromium, cobalt, lead, manganese, nickel, and selenium), mercury , and hexavalent chromium. The representative existing emissions data provided from mineral wool companies included test results for the following pollutants: formaldehy de, methanol, phenol, particulate matter, carbon monoxide, carbony l sulfide, hydrogen fluoride, metals (antimony , arsenic, bery llium , 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 virtuallyall companies through the “BTEC, Inc. Quality Assurance Project Plan for the Mineral W ool and W ool Fiberglass Emissions Test Program.” This Test Program will collect and submit to EPA, through EPA’s Electronic Reporting Tool, representative emissions data for the following pollutants: formaldehyde, methanol, phenol, particulate matter, carbon monoxide, carbony l sulfide, hydrogen fluoride, metals (antimony

, arsenic, bery llium , 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. A nnual 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) W aste 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 notlikely 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. A nnual 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) W aste 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. A nnual 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) W aste 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. A ir Pollution Control Device (A**  **PCD)**

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) Blowcham ber #2 (EUP8)

**II. Capital Costs** Base year

APCD equipm ent purchase cost and what was included List the cost for each piece of auxiliary equipm ent for each APCD not included above Installation cost Land purchase cost Total capital cost Method of financing APCD Retrofit installation Field erected or modular

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

Maintenance materials and replacement parts (specify costs by item ) Raw m aterials costs Labor ($/y r) for each labor class (hr/hr) for each labor class Utilities (breakdown for each utility ) W aste treatment and/or disposal Indirect costs Other (specify ) 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 Adm inistrator’s review obligations pursuant to Clean Air Act Section 112(d)(6) and 112(f)(2).**FORM F-2**

**COST**

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

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 equipm ent purchase cost and what was included List the cost for each piece of auxiliary equipm ent for each APCD not included above Installation cost Land purchase cost Total capital cost Method of financing APCD Retrofit installation Field erected or modular

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

Maintenance materials and replacement parts (specify costs by item ) Raw m aterials costs Labor ($/y r) for each labor class (hr/hr) for each labor class Utilities (breakdown for each utility ) W aste treatment and/or disposal Indirect costs Other (specify ) 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 Adm inistrator’s review obligations pursuant to Clean Air Act Section 112(d)(6) and 112(f)(2).**FORM F-2**

**COST**

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

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) Blowcham ber #4 (EUP6)

**II. Capital Costs** Base year

APCD equipm ent purchase cost and what was included List the cost for each piece of auxiliary equipm ent for each APCD not included above Installation cost Land purchase cost Total capital cost Method of financing APCD Retrofit installation Field erected or modular

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

Maintenance materials and replacement parts (specify costs by item ) Raw m aterials costs Labor ($/y r) for each labor class (hr/hr) for each labor class Utilities (breakdown for each utility ) W aste treatment and/or disposal Indirect costs Other (specify ) 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 Adm inistrator’s review obligations pursuant to Clean Air Act Section 112(d)(6) and 112(f)(2).**FORM F-2**

**COST**

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

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 equipm ent purchase cost and what was included List the cost for each piece of auxiliary equipm ent for each APCD not included above Installation cost Land purchase cost Total capital cost Method of financing APCD Retrofit installation Field erected or modular

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

Maintenance materials and replacement parts (specify costs by item ) Raw m aterials costs Labor ($/y r) for each labor class (hr/hr) for each labor class Utilities (breakdown for each utility ) W aste treatment and/or disposal Indirect costs Other (specify ) 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 Adm inistrator’s review obligations pursuant to Clean Air Act Section 112(d)(6) and 112(f)(2).