800 Oven and 801 Forming and 

Collection Formaldehyde Compliance

Emissions Test Summary Report 

Prepared for: 

Johns Manville 

Defiance Plant 

925 Carpenter Road 

Defiance, Ohio 

Project No. 08-3738.00 

October 23, 2008 

BT Environmental Consulting, Inc. 

2615 Wolcott Street 

Ferndale, Michigan 48220 

(248) 548-8070
Executive Summary

BT Environmental Consulting, Inc. (BTEC) was retained by Johns Manville to evaluate exhaust 

gas flowrates and formaldehyde emission rates from two exhaust stacks serving Unit 800 offline 

sear roll and curing oven, including its mandrel vacuum, and Unit 801 forming and collection 

scrubber at the Johns Manville facility in Defiance, Ohio. The compliance test program was 

conducted on October 7th, 2008.

Testing of the sources consisted of triplicate 60-minute test runs at each sampling location. 

Sampling was performed utilizing United States Environmental Protection Agency (USEPA) 

reference test methods. The results of the emissions test program are summarized by Table 1. 

Table 1 

Overall Emission Rates 

Source Pollutant Average Test 

Result (lb/hr) 

Average Test Result 

(lb/ton glass) 

Unit 800 Formaldehyde 0.16 0.58

Unit 801 Scrubber Formaldehyde 0.23 1.11

Johns Manville BTEC Project No. 07-3645.00 

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TABLE OF CONTENTS

1.0 INTRODUCTION............................................................................................................... 1

2.0 PROCESS DESCRIPTION ............................................................................................... 1

3.0 SAMPLING AND ANALYTICAL METHODOLOGIES.............................................. 1

3.1 EXHAUST GAS VELOCITY, MOLECULAR WEIGHT, AND MOISTURE CONTENT ................................................2

3.2 FORMALDEHYDE (USEPA METHOD 316).......................................................................................................2

4.0 TEST RESULTS ................................................................................................................. 3

TABLES

Table 1 – Overall Emissions Summary 

Table 2 – Unit 800 Formaldehyde Emission Rates 

Table 3 – Unit 801 Scrubber Formaldehyde Emission Rates 

FIGURES

Figure 1 – Unit 800 Exhaust Stack Traverse Point Diagram 

Figure 2 – Unit 801 Scrubber Exhaust Stack Traverse Point Diagram 

Figure 3 – USEPA Method 316 Sampling Train Diagram 

APPENDICES

Appendix A – Field and Computer Generated Raw Data and Field Notes 

Appendix B – Calibration Data 

Appendix C – Example Calculations 

Appendix D – Laboratory Analytical Results 

Appendix E – Production Data 

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1.0 Introduction

BT Environmental Consulting, Inc. (BTEC) was retained by Johns Manville to evaluate exhaust 

gas flowrates and formaldehyde emission rates from two exhaust stacks serving Unit 800 offline 

sear roll and curing oven, including its mandrel vacuum, and Unit 801 forming and collection 

scrubber at the Johns Manville facility in Defiance, Ohio. The compliance test program was 

conducted on October 7th, 2008.

The following BTEC professionals participated in conducting the testing program: Barry 

Boulianne, and James Sharp, Senior Project Managers; Thomas Snyder, Project Manager; and 

Brandon Chase and Jeff Peitzch, Staff Environmental Engineers. 

The purpose of the project was to evaluate the exhaust gas flow rates and formaldehyde emission 

rates from two exhaust stacks. The emissions data will be used to determine compliance with the 

applicable title V permit requirements for Johns Manville facility No. 03-20-01-0005. Mr. Nick 

Brueckner, and Mr. Jim Smargiassi with Johns Manville, provided the on-site coordination for 

this project. Mr. Jay Leibrict with the Ohio EPA was on site to witness the test program. 

2.0 Process Description

Lines 801 through 807 employ a melter that receives glass batch trucked from JM Defiance Plant 

02 to a new batch system that serves the pipe manufacturing lines at Defiance 08. The batch is 

melted using electric current flowing between electrodes within each melter. The heat produced 

cause the batch to melt to form molten glass. Molten glass from the melters is transported to 

manufacturing line via an electric forehearth. Molten glass from the forehearth enters one of 

seven individual manufacturing lines. The first part of each line is the fiber forming and 

collection unit. This unit consists of a perforated spinner disk through which the molten glass 

passes to form fine glass fibers. The unit then utilizes flame-attenuation to produce the proper 

fiber characteristics. Through the use of a suction fan, the fiber laden air stream is directed 

towards a collection system. Prior to collection, the fibers are sprayed with thermosetting binder 

that causes the fibers to adhere to one another. The binder consists primarily of a phenolic resin 

and serves to facilitate collection of extruded fiberglass onto the collection chain via induced 

draft to form a blanket of uncured wool fiberglass. Emissions from the collection section vent to 

atmosphere through one stack and is controlled by a venturi scrubber.

From the forming and collection unit, the fiber glass blanket is transferred to its in-line curing 

oven or is manually rolled and transferred to the off-line curing unit where it is rolled into a pipe 

section, seared and cured and finally sent to a finishing process. 

3.0 Sampling and Analytical Methodologies

Sampling and analytical methodologies for the emissions test program can be separated into two 

categories as follows: 

(1) Measurement of exhaust gas velocity, molecular weight, and moisture content; 

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(2) Measurement of Formaldehyde Emissions utilizing Method 316 

Descriptions of sampling and analytical methodologies by category are summarized by Sections 

3.1 through 3.2, respectively. 

3.1 Exhaust Gas Velocity, Molecular Weight, and Moisture Content

Measurement of exhaust gas velocity, molecular weight, and moisture content were conducted 

using the following reference test methods codified at 40 CFR 60, Appendix A: 

Method 1 -“Location of the Sampling Site and Sampling Points”

 Method 2 -“Determination of Stack Gas Velocity and Volumetric Flowrate” 

 Method 3 -“Determination of Molecular Weight of Dry Stack Gas”(Fyrite)

 Method 4 - “Determination of Moisture Content in Stack Gases”

Stack gas velocity traverses were conducted in accordance with the procedures outlined in 

Methods 1 and 2 (see Figures 1-2 for exhaust stack traverse point diagrams). An S-type pitot 

tube with a thermocouple assembly, calibrated in accordance with Method 2, Section 4.1.1, was 

used to measure exhaust gas velocity pressures (using a manometer) and temperatures during 

testing. The S-type pitot tube dimensions were within specified limits, therefore, a baseline pitot 

tube coefficient of 0.84 (dimensionless) was assigned. 

A cyclonic flow check was performed at the sampling location. The existence of cyclonic flow 

is determined by measuring the flow angle at each sample point. The flow angle is the angle 

between the direction of flow and the axis of the stack. If the average of the absolute values of 

the flow angles is greater than 20 degrees, cyclonic flow exists. The null angle was determined 

to be less than 20 degrees at each sampling point. 

Molecular weight was determined according to USEPA Method 3, “Gas Analysis for the 

Determination of Dry Molecular Weight.” The equipment used for this evaluation consisted of a 

one-way squeeze bulb with connecting tubing and a set of Fyrite® combustion gas analyzers. 

Carbon dioxide and oxygen content were analyzed using the Fyrite® procedure.

Exhaust gas moisture content was evaluated using Method 4. Exhaust gas was extracted as part 

of the Formaldehyde (see figure 3 for a schematic of the sampling train) and passed through (i) 

two impingers, each with 100 ml ultra-filtered deionized water, (ii) an empty impinger, and (iii) 

an impinger filled with silica gel. Exhaust gas moisture content is then determined 

gravimetrically. 

3.2 Formaldehyde (USEPA Method 316)

40 CFR 60, Appendix A, Method 316, “Sampling and Analysis for Formaldehyde Emissions 

from Stationary Sources in the Mineral Wool and Wool Fiberglass Industries” was used to 

measure formaldehyde concentrations and calculate formaldehyde emission rates (see Figure 3 

for a schematic of the sampling train). Triplicate 60 minutes test runs were conducted on all 

sample locations.

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BTEC’s Nutech® Model 2010 modular isokinetic stack sampling system consisted of (1) a 

stainless-steel nozzle, (2) a steel probe w/borosilicate glass liner, (3) a set of four GreenburgSmith (GS) impingers with the first and third modified and second standard GS impingers with 

the first two each containing 100 ml ultra-filtered deionized water, and a fourth modified GS 

impinger containing approximately 300 g of silica gel desiccant, (5) a length of sample line, and 

(6) a Nutech® control case equipped with a pump, dry gas meter, and calibrated orifice. 

A pitot tube and sampling train leak test was conducted before and after each test run. After 

completion of the final leak test for each test run the nozzle, probe, and filter bypass were triple 

rinsed with ultra-filtered deionized water which was collected in a pre-cleaned sample container. 

The impinger solution was measured gravimetrically and collected in the same sample container 

as the probe/bypass rinse. The impingers were then triple-rinsed with ultra-filtered deionized 

water and collected. 

BTEC labeled each container with the test number, test location, and test date, and marked the 

level of liquid on the outside of the container. In addition a blank sample of the ultra-filtered DI 

water was collected. All samples were immediately placed in a cooler with ice. The 

Formaldehyde samples were shipped overnight via fed-ex to Enthalpy Analytical in Durham, 

North Carolina. Field and computer generated Formaldehyde data is presented in Appendix A. 

4.0 Test Results

The results of the emissions test program are summarized by Table 1. 

Table 1 

Overall Emission Rates 

Source Pollutant Average Test 

Result (lb/hr) 

Average Test Result 

(lb/ton glass) 

Unit 800 Formaldehyde 0.16 0.58

Unit 801 Scrubber Formaldehyde 0.23 1.11

Field and computer generated data for each test run are available in Appendix A, as well as all 

other applicable field data. Equipment calibration information is presented in Appendix B.

Example calculations for equations used to determine emission rates are presented in Appendix 

C. Laboratory analysis is available in Appendix D. Production data is available in Appendix E.

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Limitations

The information and opinions rendered in this report are exclusively for use by Johns Manville. 

BTEC will not distribute or publish this report without Johns Manville’s consent except as 

required by law or court order. BTEC accepts responsibility for the competent performance of 

its duties in executing the assignment and preparing reports in accordance with the normal 

standards of the profession, but disclaims any responsibility for consequential damages. 

This report was prepared by: 

Brandon V. Chase 

Staff Environmental Engineer 

This report was reviewed by: 

Barry P. Boulianne 

Senior Project Manager 

Johns Manville BTEC Project No. 08-3738.00 

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