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ENCLOSURE 1

INFORMATION COLLECTION REQUEST FOR

Flexible Polyurethane Foam Production

We are conducting this Information Collection Request (ICR) to assist the EPA Administrator in 

developing emission standards for Flexible Polyurethane Foam under Clean Air Act (CAA) 

section 112. We are sending this ICR to you under the authority of Section 114 of the CAA. 

BACKGROUND:

We are required by section 112(f)(2) of the Clean Air Act (CAA) to assess the risk remaining 

(residual risk) eight years after the application of maximum achievable control technology 

(MACT) standards under section 112(d). If we find the residual risk fails to protect public health 

with an ample margin of safety or to prevent (taking into consideration various factors) adverse 

environmental effects, we are required to promulgate more stringent standards. The Flexible 

Polyurethane Foam MACT standard was promulgated in October 1998 (see 63 FR 53980). We are 

preparing to initiate our residual risk review. Please note this survey is for flexible polyurethane 

foam production only and does not cover flexible polyurethane foam fabrication, other than 

identifying if flexible polyurethane foam fabrication is conducted as a co-located operation.

Section 114(a) of the CAA gives us the authority to require you to provide us with information for 

the following purposes:

1. Developing or assisting in the development of the following:

a. State implementation plans (§§ 110 and 111(d));

b. New Source Performance Standards (NSPS) (§ 111);

c. National Emissions Standards for Hazardous Air Pollutants (NESHAP) (§ 112);

d. Solid waste combustion or other related solid waste regulations (§ 129);

2. Determining whether any person is in violation of any standards or requirements developed 

under the authorities cited above; or

3. Carrying out any provision under the CAA (except certain provisions under Title II). 

The Administrator may require that those persons identified above do the following so the 

Administrator may have the information necessary for the items listed in #1-3:

 make reports; 

 establish and maintain records; 

 install, use, and maintain monitoring equipment, and use audit procedures, or methods; 

 sample emissions (in accordance with such procedures or methods, at such locations, at 

such intervals, during such periods, and in such manner as we shall prescribe); 

 keep records on control equipment parameters, production variables or other indirect data 

when direct monitoring of emissions is impractical; 

 submit compliance certifications in accordance with section 114(a)(3); and 

 provide such other information as we may reasonably require.
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We seek information on existing flexible polyurethane foam production sources in this survey in 

order to collect information needed to conduct the residual risk review required by section 112 of 

the Act. 

DIRECTIONS FOR COMPLETING THIS SURVEY: 

You must complete and return this survey by December 6, 2011. You must identify clearly any 

response(s) that you consider to be confidential business information (CBI). Any responses 

not so identified will be included in a publicly available database. You may refer to Enclosures , 

3, 4, 5, and 6 to learn how we will treat CBI as well as what information you may be asked to 

submit later to substantiate a claim of confidentiality.

DEFINITIONS: For the purposes of this ICR only, use the following definitions:

Auxiliary blowing agent, or ABA, means a low-boiling point liquid added to assist foaming by 

generating gas beyond that resulting from the isocyanate-water reaction.

Flexible polyurethane foam means a flexible cellular polymer containing urea and carbamate 

linkages in the chain backbone produced by reacting a diisocyanate, polyol, and water. Flexible 

polyurethane foams are open-celled, permit the passage of air through the foam, and possess the 

strength and flexibility to allow repeated distortion or compression under stress with essentially 

complete recovery upon removal of the stress.

Flexible polyurethane foam process means the equipment used to produce a flexible polyurethane 

foam product. For the purpose of this survey, the flexible polyurethane foam process includes raw 

material storage; production equipment and associated piping, ductwork, etc.; and curing and 

storage areas.

HAP ABA means methylene chloride, or any other HAP compound used as an auxiliary blowing 

agent.

Initial startup means the first time a new or reconstructed affected source begins production of 

flexible polyurethane foam.

Rebond foam means the foam resulting from a process of adhering small particles of foam (usually 

scrap or recycled foam) together to make a usable cushioning product. Various adhesives and 

bonding processes are used. A typical application for rebond foam is for carpet underlay.

Rebond foam process means the equipment used to produce a rebond foam product. For the 

purpose of this subpart, the rebond foam process includes raw material storage; production 

equipment and associated piping, ductwork, etc.; and curing and storage areas.

Recovery device means an individual unit of equipment capable of and used for the purpose of 

recovering chemicals for use, reuse, or sale. Recovery devices include, but are not limited to, 

carbon adsorbers, absorbers, and condensers.

Slabstock flexible polyurethane foam means flexible polyurethane foam that is produced in large 

continuous buns that are then cut into the desired size and shape.
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Slabstock flexible polyurethane foam production line includes all portions of the flexible 

polyurethane foam process from the mixhead to the point in the process where the foam is 

completely cured.

Storage vessel means a tank or other vessel that is used to store diisocyanate or HAP ABA for use 

in the production of flexible polyurethane foam. Storage vessels do not include vessels with

capacities smaller than 38 cubic meters (or 10,000 gallons).

CONFIDENTIAL BUSINESS INFORMATION (CBI): 

Please indicate if any CBI is included in this survey response: Y N 
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Flexible Polyurethane Foam Production Survey Form

PART I. OWNER INFORMATION

For questions 3 through 5, provide a separate Part I form for each facility, if you own or 

operate more than one facility.

1. Name of Legal Owner: FXI, Inc.

a. Address: 1400 North Providence Road, Suite 2000 

b. City: Media 

c. State: Pennsylvania 

d. Zip: 19063

e. County: Delaware 

2.Facility Name: FXI – Corry Facility

3. Complete street address of facility (physical location):

a. Address: 466 South Shady Avenue 

b. City: Corry

c. State: Pennsylvania

d. Zip: 16407

e. County: Erie

f. Longitude and Latitude coordinates [in decimal degrees with five significant figures to the 

right of the decimal place (e.g., 38.27941, -85.64371)]: 41.916276, -79.614119_

4. Facility Contact:

a. Name (First Name, Last Name): Matt Johnson 

b. Title: EHS and Quality Manager 

c. Telephone Number: (814) 664-7771 Ext 228

d. Fax Number: ( )

e. E-mail address: majohnson@fxi.com

f. Primary NAICS code for the facility: 326150
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5. Flexible Polyurethane Foam Production

We believe that you own or operate a facility that engages in production of slabstock, molded 

or rebond flexible polyurethane foam. If you believe that this survey does not pertain to you, 

please indicate your reason below: 

 Plant is permanently shut down. Please also identify the date the Foam Production plant 

was shut down and what steps were taken to close the Foam Production plant. Include date 

the permit was inactivated.

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

 No slabstock, rebond, or molded flexible polyurethane foam production plant 

is located at this facility.

If you do not operate a flexible polyurethane foam production plant (i.e., you check either 

box for question 5), we will review that information and respond as to whether you need to 

complete any other part of the survey 

Please mail, fax, or e-mail Part I to: 

U.S. EPA Mailroom

Attn: Sharon Nizich

Mail Code: D243-04

Research Triangle Park, NC 27711

Phone: 919 541 2825

Fax: 919 541-5450

Email address: Nizich.sharon@epa.gov
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PART II. GENERAL FACILITY INFORMATION

1. Please provide the following general information for each flexible polyurethane foam 

production plant:

a. Number of employees at the facility where the flexible polyurethane foam production is 

located: 186 (as of November 2011)

b. Number of employees at the parent company, organization or institution (e.g. municipality, 

university, etc.) that owns the facility: 1,869 (as of November 2011)

c. Is the legal owner a small entity as defined by the Regulatory Flexibility Act?

Refer to the Small Business Administration’s Size Standards at:

http://www.sba.gov/sites/default/files/Size_Standards_Table.pdf

 Y N Unknown

[insert the following if applicable]

d. Any other co-located operations and if so, what type of operation?

FXI – Corry does not operate any co-located operations.

e. Are any operations on site subject to federal and State emission standards and if yes, which 

standards? 

Yes, according to Pennsylvania Department of Environmental Protection 

(PADEP)(Title V/State Operating Permit No. 25-00326), FXI - Corry Facility is 

subject to the following emission standards:

25 Pa. Code §123.1 – Prohibition of Certain Fugitive Emissions

25 Pa. Code §123.31 – Odor Emissions

25 Pa. Code §123.41 – Visible Emissions

40 CFR Part 63 Subpart A – National Emission Standards for Hazardous Air 

Pollutants

40 CFR Part 63, Subpart III – National Emission Standards for Hazardous Air 

Pollutants for Flexible Polyurethane Foam Production 
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f. Is the facility a major source or area source? Major sources are all activities

located on contiguous area under common control where the aggregate potential to emit for the 

activities exceeds ten (10) tons per year of a single HAP or twenty-five (25) tons per year of a 

combination of HAPs.

FXI-Corry was a major source at the time of the compliance date (October 8, 2001) 

established in 40 CFR Part 63, Subpart III, Section §63.1291. FXI is submitting this 

ICR as requested for facilities that were a major HAP source at the time of the 

compliance date. The FXI – Corry facility ceased the use of HAP ABA in August, 

2004.

g. Type of plant. Check all that apply.

 Molded Flexible Polyurethane Foam

 Slabstock Flexible Polyurethane Foam

 Rebond Foam Production

h. Please list information concerning storage tanks at this facility, including size, contents, 

estimated emissions of emitted pollutants, and piping characteristics. Utilize a flow 

diagram if necessary. See Appendix A, Table 1 and Figure 1 in CBI Submittal

2. Please provide a flow diagram of the process units associated with the flexible polyurethane 

foam production process at your facility. Label each process unit and emission point with a 

unique identification code and complete the table below.

The flow diagram should display an identification code for streams entering (raw 

materials/feedstocks) and exiting the process unit (product streams), and emission streams. The 

flow diagram should also display an identification code for add-on control devices and streams 

entering and exiting the add-on control devices. Where applicable, include in-process streams, 

waste streams, wastewater streams, and emission release points in the flow diagram. 

Identification code Description of item submitted with survey response

101 Figure 1 – Contains a generalized drawing of the items 

requested above for both sources 101 (Slabstock Foam 

Line) and TS1 ((Four (4) 10,000 gallon TDI storage tanks)). 

 TS1
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3. List Federal air pollution control regulations applicable to each process unit. 

Process unit name

Process unit 

identification code Federal air pollution control regulation

MAXFOAM 

Machine 

(Slabstock Foam 

Line)

101 40 CFR Part 63, Subpart III

TDI Storage Tanks 

(4) 10,000 gallons 

each

TS1 40 CFR Part 63, Subpart III
Enclosure 2

2010 2009 2008 2010 2009 2008

101

MAXFOAM 

MACHINE 

(Slabstock Foam 

Pouring Line)

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

tons of foam 

produced 575 418 595

TS1 (a) 

Four (4) TDI Storage 

Tanks (10,000) 

gallons each 

4,820,089 3,831,772 5,645,123 lbs of TDI 

feedstock N/A N/A N/A

(a) The quantity of TDI in the four TDI storage tanks is not tracked individually. 

 Process unit name Production Amount Production units 

PART III. FEEDSTOCK, RAW MATERIAL, AND PRODUCTION INFORMATION

1. Please complete the following table for production information for each process unit.

Average time each product was 

manufactured (hours) Process unit name
Enclosure 2

2010 2009 2008

Slabstock Foam Line TDI lbs 4,820,089 3,831,772 5,645,123

TS1 (TDI Tanks) (a) TDI lbs 4,820,089 3,831,772 5,645,123

(a) The quantity of TDI in the four TDI storage tanks is not tracked individually. 

Process unit name

Raw 

material/feedstock

Raw material/feedstock 

amount

Raw material/feedstock

2. Please complete the following table for Raw Materials/feedstocks entering each process unit. 

 Include only HAP-containing feedstock.
Enclosure 2

Raw material 

products/feedstock

Auxiliary Blowing 

Agents

Chemical Compounds % of each chemical 

compound

N/A 2,4-Toluene Diisocyante 80

N/A 2,6-Toluene Diisocyante 20

3. Provide composition information for feedstock/raw materials.

TDI 80/20
Enclosure 2

Adhesive Name HAP Contained HAP Content (wt%) Annual Usage (lbs)

4. Are any HAP-containing adhesives utilized in repair of foam as part of the production process? No

FXI - Corry does not use adhesives in the foam production process that contain HAP. 
Enclosure 2a

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

 Process Unit ID: 101 and TS1 

Hours Per (e.g., week, 

month, year)

101 Submitted 

as CBI

Submitted as 

CBI Submitted as CBI 18,720 lb/hr of TDI Submitted as CBI

Submitted as 

CBI

TS1 Submitted 

as CBI

Submitted as 

CBI Submitted as CBI 55 gallons/hr each tank

Submitted 

as CBI

Submitted as 

CBI

PART IV. GENERAL FLEXIBLE POLYURETHANE FOAM PRODUCTION INFORMATION

Process unit ID

Year unit 

originally 

installed

Original capital 

cost of unit(s)

Remaining useful life 

of unit

Maximum design capacity 

(e.g., lbs/day)

Please complete the following questions for each Flexible Polyurethane Foam Production process unit. You are not expected to 

generate new information for this survey. Only supply data that are readily available to you.

Typical unit operation

1. Please provide the following information for each Flexible Polyurethane Foam Production process unit: 

a. Provide general information for each process unit
Enclosure 2a

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

Process Unit ID: 101 and TS1 

101 Foam Pouring 

Line Submitted as CBI Submitted as CBI Submitted as CBI Submitted as CBI

TS1 - Four (4) 

10,000 gallons 

tanks 

Submitted as CBI Submitted as CBI Submitted as 

CBI Submitted as CBI

 trains.

b. Provide information on upgrades to each flexible polyurethane foam production process unit and associated air 

Description of 

upgrades made to 

Description of upgrades 

made to the process unit

Year(s) upgrade was 

Process unit ID made

Year(s) upgrade was 

made
Enclosure 2a

 Process Unit ID: 101 and TS1 

Process Unit ID

Total operating and 

maintenance costs 2008 2009 2010

101 Submitted as CBI Submitted 

as CBI

Submitted 

as CBI

Submitted 

as CBI

c. Using the format on this page, include operating and maintenance cost information for each 

 process unit. Definitions for different types of costs are taken from EPA Air Pollution Control

 Cost Manual at http://epa.gov/ttn/catc/products.html#cccinfo

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility
Enclosure 2a

Process Unit ID: 101 and TS1 

2. Include yearly emissions information in the following table (include source of information). 

Emission Point Process Unit ID HAP Pollutant Tons per year 2006

Tons per year 

2007

Tons per year 

2008

Tons per year 

2009

Tons per year 

2010

Stacks: S1P, S2P, S3P, 

S4P, S5P, S6P, S7P, S8P, 

S9P

101 Slabstock Pouring 

Line 2,4-Toluene Diisocyanate 0.082 0.072 0.064 0.102 0.128

Tanks TS1 - Four (4) TDI 

Storage Tanks 2,4-Toluene Diisocyanate 0.001 0.001 0.001 0.006 0.007

(a) Emissions are from FXI - Corry's Toxic Release Inventory (TRI) Form R annual reports. Stack emissions are from the slabstock foam line and 

fugitive emissions from tanks.

 unit.

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

 Include storage tanks or any auxiliary equipment on site, per unit ID and label each as type of
Enclosure 2a

 Process Unit ID: 101 and TS1 

No emission tests have been performed at the FXI-Corry facility during the last five (5) years. 

e. Submit a copy of the test reports.

f. For pollutants measured with continuous emissions monitoring systems (CEMS), please submit a copy of the 

most recent Relative Accuracy Test Audit (RATA) for the last 30 day period including those days where manual testing was conducted.

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

3. Provide information on each emission test conducted at each specific process unit. Please copy this page and provide the following 

information for each test conducted at anytime in the last 5 years.

a. Identify the Process Unit ID: ___________________________________

c. Date of test: ______________________________________

d. Specify the test method(s) used: ___________________________________________________________________

 _________________________________________________________________________________________________
Process Unit ID: 101 and TS1 

Submitted as CBI

Operating cost 

information 2008 2009 2010

Control device ID:

Total operating costs

Electricity costs

Wastewater treatment 

costs

Fuel costs

Water costs

Waste disposal costs

Process unit operating 

labor costs

Monitoring, 

recordkeeping, and 

reporting

Other (please describe): 

________________

Other (please describe): 

________________

b. Does the process unit have a control device that reduces air pollution : _____ Yes _____ No

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

4. For each flexible polyurethane foam production process unit, provide the following 

i. List the elements that are included in the installed cost estimate in question IV.5.h 

c. Describe the release point(s) that are being controlled (e.g., equipment or unit operation 

 where the release point is located): __________________________________________________

 __________________________________________________________________________________

 __________________________________________________________________________________

 __________________________________________________________________________________

 __________________________________________________________________________________

 information regarding air pollution control devices. Please copy this page and provide the

 following information for each unit: 

 __________________________________________________________________________________

d. Type of control device: _____________________________________________________________

e. Year installed: _____________________________________________________________________

f. Manufacturer: _____________________________________________________________________

g. Model No: ________________________________________________________________________

h. Original installed cost of the control device (capital cost of the control plus installation cost): 

 control device.

 (e.g., ductwork, piping, foundation/supports, site preparation): __________________________

 ___________________________________________________________________________________

 ___________________________________________________________________________________

 ___________________________________________________________________________________

 __________________________________________________________________________________

j. Use the following table to provide the annual cost for operating and maintenance of each 
Enclosure 2a

 Process Unit ID: 101 and TS1 

Process unit ID Measures or modification made to 

minimize emissions

Estimated emission reduction 

(lb/yr) 

101 Elimination of HAP ABA

Methylene chloride usage 

was 723,659 lbs in 2002, 

336,957 lbs in 2003, and 

18,054 lbs in 2004. HAP 

ABA usage was 

completely eliminated in 

August 2004.

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

5. For each process unit identify measures (e.g., annual tune-ups or burners, good combustion practices, 

pollution prevention measures, or any other emission control approaches that reduce HAP emissions) or 

modifications made to the process unit to reduce emissions:
Enclosure 2a

Process Unit ID: 101 and TS1 

Submitted as CBI

Emission reduction technique 

descriptions Pollutants affected Reduction efficiency

________________________ ________________________________________

________________________ ________________________________________

________________________ ________________________________________

________________________ ________________________________________

________________________ ________________________________________

________________________ ________________________________________

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

c. At what frequency is parameter monitoring done? ___________________________________________

d. Describe initial and ongoing parameter monitoring quality assurance/control: 

 _______________________________________________________________________________________

 reduce emissions, such as substitutions or product reformulation.

a. Complete for each emission reduction technique utilized that is not a control device.

b. What parameters are monitored to ensure operation of the emission reduction technique?

6. Other emission reduction techniques. Include any information about changes made in raw material usage to

 ___________________________________________________________________________________________

e. At what frequency is parameter monitor quality assurance/control (e.g., calibration) performed?

7. Please submit a copy of any cost information you have for the modification or emission reduction method (other than addon control devices) listed above.

 _______________________________________________________________________________________

 ___________________________________________________________________________________________

f. What is annual parameter monitoring cost?

 _______________________________________________________________________________________
Enclosure 2a

 Process Unit ID: 101 and TS1 

Submitted as CBI

Emission 

source(s) causing 

event

Description 

of event

Permit conditions 

exceeded 

(Y/N)

Date of 

Event

Duration 

of each 

event 

(hours)

Was the event 

covered by a 

contingency plan 

for controlling 

emissions? 

(Y/N)

Estimates 

of 

emissions 

during 

event 

(pounds)

Basis for 

emissions 

estimate

Any monitoring 

data or control 

system parameter 

monitoring 

collected during 

event? 

(Y/N)

a. Please indicate number of times over the last 3 years that a shutdown and start-up event has occurred: ____________________________________________

b. Complete the following table for each shutdown and start-up event occurring over the last three years.

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

8. Please provide the following information for each process unit during start-up and shutdown operation:
Process Unit ID: 101 and TS1 

 

 _______________________________________________________________________________

Enclosure 2a

c. Please list the procedures that are followed or any activities that occur during start-up and shutdown at this 

process unit to minimize emissions (e.g., turn off unit, monitor pressure):

d. Is the emission profile of the flexible polyurethane foam production unit different during start-up and 

shutdown than during normal operating conditions? _____ Yes _____No

e. If the answer to Part IV 9.d. is yes, please explain, in detail, how and why emissions are different during start-

__________________________________________________________________________________

__________________________________________________________________________________

f. Do you have test data that show emissions during start-up or shutdown? __ Yes __ No

g. If yes, when and why did you conduct such testing? __________________________________

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

 _______________________________________________________________________________

 _______________________________________________________________________________

h. Please identify the emissions test method(s) used during start-up or shutdown.

 ______________________________________________________________________________

 _______________________________________________________________________________

 of the flexible polyurethane foam production process unit.

k. Are you required to submit periodic and immediate start-up and shutdown reports

 (either stand-alone or constrained within the periodic excess emissions report) to your

 permitting authority? ___________________________________________________________

 _______________________________________________________________________________

i. What were the test conditions at the time of testing ? ________________________________

 _______________________________________________________________________________

 _______________________________________________________________________________

 _______________________________________________________________________________

j. Please submit a copy of any test data you have conducted during any start-up or shutdown

Submitted as CBI
Enclosure 2a

Process Unit ID: 101 and TS1 

Longitude Latitude

S1P Stack 1 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S2P Stack 2 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S3P Stack 3 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S4P Stack 4 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S5P Stack 5 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S6P Stack 6 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S7P Stack 7 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S8P Stack 8 Pourline

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

S9P Stack 9 Pourline 

Submitted as 

CBI

Submitted as 

CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

Height of 

release point 

(feet)

Exit of velocity of 

vent release point 

(feet/second)

Exit 

temperature of 

vent/flue gas 

(F)

Diameter of 

release point 

(feet)

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

9. Stack Release Parameters for Emission Points

 Please provide the following information for all emission release points for use in risk modeling

Location of release point (decimal 

degrees, minimum 5 digits beyond 

Emission decimal)

Point Process Unit ID
Process Unit ID: 101 and TS1 

Height of 

release point Release Height

Angle of 

Rotation 

Longitude Latitude (ft) (ft) x (length, ft) y (width, ft) (degrees)

Fugitive Tank 

Emissions 

Building 

Ventilation 

TS1 Submitted as 

CBI

Submitted 

as CBI

Submitted 

as CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

Submitted as 

CBI

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

10. Non point releases. Please include a listing of fugitive releases, including the following

 information per release point. Please include "no releases" if this question does not

 apply. Notes on modeling data definitions are below.

Dimension of Source

Location of release point 

(decimal degrees, minimum 5 

digits beyond decimal)

Process Unit 

ID

Emission Point
Enclosure 2a

Process Unit ID: 101 and TS1 

Submitted as CBI

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

11. Scrubber 

a. Does the flexible polyurethane foam production process unit have a scrubber? 

____ Yes ___No

k. Mist eliminator: _____ Yes _____ No

 _______________________________________________________________________________

 _______________________________________________________________________________

c. Type of scrubber: _______________________________________________________________

d. Design pollutant-laden gas inlet flow rate: ______acfm

e. Design pollutant-laden gas inlet temperature: ________oF

f. Scrubbing medium (describe): ____________________________________________________

g. Influent scrubbing medium pH: ___________________________________________________

h. Effluent scrubbing medium pH: ___________________________________________________

i. Scrubber water flow: _________________________________________________ gals/min (?)

j. Scrubber pressure drop (across each scrubber--provide units): _________________________

 _______________________________________________________________________________

n. What control devices are upstream of the scrubber? _________________________________

o. What control devices are downstream of the scrubber? ______________________________

l. Average outlet gas temperature for each scrubber: ________________________________oF

m. Please describe the source and quality of the water fed to the scrubber (e.g., effluent 

 water with a total solids content of _____): _________________________________________

 _______________________________________________________________________________

 _______________________________________________________________________________

 _______________________________________________________________________________
Enclosure 2a

Submitted as CBI

Facility Name:

Process Unit ID:

Process Unit ID for controlled processes:

Stack or Vent Height (ft)

Stack or Vent Diameter (ft)

Manufacturer/Model

Original Installation Date

Gas flow rate to condenser (acfm)

Inlet gas temperature (oF)

Compound Name

Volume Fraction

Compound Name

Volume Fraction

Compound Name

Volume Fraction

Compound Name

Volume Fraction

Describe any plans to replace or upgrade the adsorber

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

12. Carbon Adsorber

 Please include a copy of this table for each carbon adsorber controlling emissions from 

 flexible polyurethane foam production process unit.

CARBON ADSORBER

Organic compounds in inlet gas stream

Vendor guarantee on adsorber efficient (attach copy)

Describe preventative maintenance procedures and frequency

List all monitoring methods used, including parameters and frequency
Enclosure 2a

Process Unit ID: 101 and TS1 

Longitude Latitude

S1P Stack 1 Pourline -79.616027 41.916778 30 34.1 70 1.8

S2P Stack 2 Pourline -79.615972 41.916757 50 31.7 70 1.8

S3P Stack 3 Pourline -79.615889 41.916728 50 21.5 70 1.8

S4P Stack 4 Pourline -79.615834 41.916708 50 24.9 70 2

S5P Stack 5 Pourline -79.615609 41.916627 30 14.8 70 3.6

S6P Stack 6 Pourline -79.615505 41.916589 30 16.3 70 3.6

S7P Stack 7 Pourline -79.615383 41.916555 50 11.0 70 3.6

S8P Stack 8 Pourline -79.615274 41.916517 30 9.9 70 3.6

S9P Stack 9 Pourline -79.615200 41.916488 30 18.0 70 2.4

20.24853333 2.688888889

Height of 

release point 

(feet)

Exit of velocity of 

vent release point 

(feet/second)

Exit 

temperature of 

vent/flue gas 

(F)

Diameter of 

release point 

(feet)

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

9. Stack Release Parameters for Emission Points

 Please provide the following information for all emission release points for use in risk modeling

Location of release point (decimal 

degrees, minimum 5 digits beyond 

Emission decimal)

Point Process Unit ID
Process Unit ID: 101 and TS1 

Height of 

release point Release Height

Angle of 

Rotation 

Longitude Latitude (ft) (ft) x (length, ft) y (width, ft) (degrees)

Fugitive Tank 

Emissions 

Building 

Ventilation 

TS1 -79.616216° 41.916883° 30 30 2 2 N/A

Owner Name: FXI, Inc. Facility Name: FXI - Corry, PA Facility

10. Non point releases. Please include a listing of fugitive releases, including the following

 information per release point. Please include "no releases" if this question does not

 apply. Notes on modeling data definitions are below.

Dimension of Source

Location of release point 

(decimal degrees, minimum 5 

digits beyond decimal)

Process Unit 

ID

Emission Point