**Title 40: Protection of Environment**

PART 63

—NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLU TANTS FOR SOURCE CATEGORIES (CONTINUED) Subpart DDD

—National Emission Standards for Hazardous Air Pollutants for Mineral Wool Production **Source:** 64 FR 29503, June 1, 1999, unless otherwise noted. §63.1175 What is the purpose of this subpart ? This subp art establishes national emission standards for hazardous air pollutants emitted from existing, new, and reconstructed cupolas and curing ovens at facilities that produce mineral wool. § 63.1176 Where can I find definitions of key words used in this subpar t ? The definitions of key words used in this subpart are in the Clean Air Act (Act), in §63.2 of the general provisions in subpart A of this part, and in §63.1196 of this subpart. § 63.1177 Am I subject to this subpart ? You are subject to this subpart if you own or operate an existing, new, or reconstructed mineral wool production facility that is located at a plant site that is a major source of hazardous air pollutant (HAP) emissions, meaning the plant emits or has the potential to emit any single HAP at a rate of 9.07 megagrams (10 tons) or more per year or any combination of HAPs at a rate of 22.68 megagrams (25 tons) or more per year.Page 2 of 41

**Standards** § 63.1178 For cupolas, what standards must I meet ? (a) You must control emissions from each cupola as follows: (1) Limit emissions of particulate matter (PM) from each existing, new, or reconstructed cupola to 0.05 kilograms (kg) of PM per megagram (MG) (0.10 pound [lb] of PM per ton) of melt or less. (2) Limit emissions of carbonyl sulfide (COS) from each existing, new , or reconstructed cupola to the following: (i) 3.3 lb of COS per ton of melt or less for existing cupolas. (ii) 0.017 lb of COS per ton of melt or less for ne w or reconstructed cupolas. (3) Limit emissions of hydrogen fluoride (HF) from each existing, new, or reconstructed cupola to 0.014 lb of HF per ton of melt or less. (4) Limit emissions of hydrogen chloride (HCl) from each existing, new, or reconstructed cupola to 0.0096 lb of HCl per ton of melt or less. (b) You must meet the following operating limits for each cupola: (1) Begin within one hour after the alarm on a bag leak detection system so unds, and complete in a timely manner,Page 3 of 41

corrective actions as specified in your operations, maintenance, and monitoring plan required by §63.1187 of this subpart. (2) When the alarm on a bag leak detection system sounds for more than five percent of the tot al operating time in a six

month reporting period, develop and implement a written quality improvement plan (QIP) consistent with the compliance assurance monitoring requirements of §64.8(b)

– (d) of 40 CFR part 64. (3) Additionally, for each new or reconstructed cupola, maintain the operating temperature of the incinerator so that the average operating temperature for each three

- hour block period never falls below the average temperature established during the performance test. § 63.1179 For combined collect ion/ curing operations , what standards must I meet ? (a) You must control emissions from each existing, new, or reconstructed combined collection/ curing operation by limiting emissions of formaldehyde , phenol, and methanol to the followi ng: (1) For combined drum collection/curing operations: (i) 0.067 lb of formaldehyde per ton of melt or less, (ii) 0.0023 lb of phenol per ton of melt or less, and (iii) 0. 00077 lb of methanol per ton of melt or less. (2) For combined horizontal collection/curing operations: (i) 0.054 lb of formaldehyde per ton of melt or less,Page 4 of 41

(ii) 0.15 lb of phenol per ton of melt or less, and (iii) 0.022 lb of methanol per ton of melt or less. (3) For combined vertical collection/curing operations: (i) 0.46 lb of formaldehyde per ton of melt or less, (ii) 0.52 lb of phenol per ton of melt or less, and (iii) 0.63 lb of methanol per ton of melt or less. (b) You must meet the following operating limits for each combined collection/ curing operations subcategory : (1) Maintain the free

- formaldehyde content of each resin lot and the formaldehyde content of each bin der formulation at or below the specification ranges of the resin and binder used during the performance test. (2) Maintain the operating temperature of each incinerator so that the average operating temperature for each three

- hour block period never falls below the average temperature established during the performance test. § 63.1180 When must I meet these standards ? (a) Existing cupolas and combined collection/curing operations . (1) Except as noted in paragraph (2) of this section, the compliance da te for an owner or operator of an existing plant or source subject to the provisions of this subpart is June 2, 2002 or June 3, 2003 if you applied for and received a one

- year extension under section 112(i)(b)(3)(B) of the Act.Page 5 of 41

(2) The compliance dates for existing plants and sources

are: (i) [INSERT DATE 3 YEARS AFTER PUBLICATION OF THE FINAL RULE IN THE FEDERAL REGISTER] for cupolas and combined collection/curing operations subject to emission limits in §§63.1178 and 63.1179 which became effective [INSERT DATE OF PUBLICATION OF THE FINAL RULE IN THE FEDERAL REGISTER]. (ii) [INSERT DATE OF PUBLICATION OF THE FINAL RULE IN THE FEDERAL REGISTER] for the provisions related to malfunctions and affirmative defense provisions of paragraph (e) of this section and the electronic reporting provisions of §§63.1192(d) and 63.1193(b)(1) and (g). (b) New and reconstructed cupolas and combined collection/curing oven s. For affected sources that commenced construction or reconstruction after [INSERT DATE OF PUBLICATION OF THIS PROPOSED RULE IN THE FEDERAL REGISTER], you must demonstrate compliance with the requirements of this subpart no later than the effective date o f the rule or upon start

- up. (c) You must comply with the standards in §§63.1178 and 63.1179 of this subpart on and after the dates in paragraphs (a) and (b) of this section. (d) See §63.1197 for requirements during startups and shut downs. (e) Affirmative Defense for Exceedance of Emissions limits During Malfunction. In response to an action to enforcePage 6 of 41

the standards set forth in this subpart, you may assert an affirmative defense to a claim for civil penalties for exceedances of such standards that are caused by malfunction, as defined at §63.2. Appropriate penalties may be assessed, however, if you fail to meet your burden of proving all of the requirements in the affirmative defense. The affirmative defense must not be available for claims for injunctive relief. (1) To establish the affirmative defense in any action to enforce such a limit, you must timely meet the notificatio n requirements in §63.1191 of this subpart, and must prove by a preponderance of evidence that: (i) The excess emissions: (A) Were caused by a sudden, infrequent, and unavoidable failure of air pollution control and monitoring equipment, process equipment , or a process to operate in a normal or usual manner; and (B) Could not have been prevented through careful planning, proper design or better operation and maintenance practices; and (C) Did not stem from any activity or event that could have been forese en and avoided, or planned for; and (D) Were not part of a recurring pattern indicative of inadequate design, operation, or maintenance. (ii) Repairs were made as expeditiously as possible when the applicable emissions limitations were being exceeded. Off

-Page 7 of 41

shift and overtime labor were used, to the extent practicable to make these repairs; and (iii) The frequency, amount and duration of the excess emissions (including any bypass) were minimized to the maximum extent practicable during periods of such emissio ns; and (iv) If the excess emissions resulted from a bypass of control equipment or a process, then the bypass was unavoidable to prevent loss of life, personal injury, or severe property damage; and (v) All possible steps were taken to minimize the impact of the excess emissions on ambient air quality, the environment and human health; and (vi) All emissions monitoring and control systems were kept in operation if at all possible, consistent with safety and good air pollution control practices; and (vii) All of the actions in response to the excess emissions were documented by properly signed, contemporaneous operating logs; and (viii) At all times, the affected source was operated in a manner consistent with good practices for minimizing emissions; and (i x) A written root cause analysis has been prepared, the purpose of which is to determine, correct, and eliminate the primary causes of the malfunction and the excess emissionsPage 8 of 41

resulting from the malfunction event at issue. The analysis must also specify, u sing best monitoring methods and engineering judgment, the amount of excess emissions that were the result of the malfunction. (2) Notification . The owner or operator of the affected source experiencing an exceedance of its emissions limit(s) during a mal function, must notify the Administrator by telephone or facsimile transmission as soon as possible, but no later than two business days after the initial occurrence of the malfunction, s/he wishes to be able to use an affirmative defense to civil penalties for that malfunction. The owner or operator seeking to assert an affirmative defense, must also submit a written report to the Administrator within 45 days of the initial occurrence of the exceedance of the standards in this subpart. This report must demo nstrate that the owner/operator met the requirements set forth in paragraph (e) of this section and must include all necessary supporting documentation. The owner or operator may seek an extension of this deadline for up to 30 additional days by submitting a written request to the Administrator before the expiration of the 45 day period. Until a request for an extension has been approved by the Administrator, the owner or operator is subject to the requirement to submit such report within 45 days of the ini tial occurrence of the exceedance.Page 9 of 41

**Compliance With Standards** § 63.1181 How do I comply with the particulate matter standards for existing, new, and reconstructed cupolas ? To comply with the PM standards, you must meet all of the following: (a) Install, adj ust, maintain, and continuously operate a bag leak detection system for each fabric filter. (b) Do a performance test as specified in §63.1188 of this subpart and show compliance with the PM emission limits while the bag leak detection system is installed, operational, and properly adjusted. (c) Begin corrective actions specified in your operations, maintenance, and monitoring plan required by §63.1187 of this subpart within one hour after the alarm on a bag leak detection system sounds. Complete the correc tive actions in a timely

manner. (d) Develop and implement a written QIP consistent with compliance assurance monitoring requirements of 40 CFR 64.8(b) through (d) when the alarm on a bag leak detection system sounds for more than five percent of the total operating time in a six

month reporting period. § 63.1182 How do I comply with the carbonyl sulfide, hydrogen fluoride, and hydrogen chloride standards for existing, new , and reconstructed cupolas?Page 10 of 41

To comply with the CO S, HF, and HCl standa rds, you must meet the following: (a) Install, calibrate, maintain, and operate a device that continuously measures the operating temperature in the firebox of each thermal incinerator. For the purposes of this rule, the term ‘incinerator’ means ‘re generative thermal oxidizer’ (RTO). (b) Conduct a performance test as specified in §63.1188 of this subpart that show s compliance with the CO S, HF, and HCl emission s limits while the device for measuring incinerator (regenerative thermal oxidizer) operating temperature is installed, operational, and properly calibrated. Establish the average operating temperature as specified in §63.1185(a) of this subpart. (c) Following the performance test, measure and record the average operating temperature of th e incinerator as specified in §63.1185(b) of this subpart. (d) Maintain the operating temperature of the incinerator so that the average operating temperature for each three

- hour block period never falls below the average temperature established during the performance test. (e) Operate and maintain the incinerator as specified in your operations, maintenance, and monitoring plan required by §63.1187 of this subpart.Page 11 of 41

§ 63.1183 How do I comply with the formaldehyde , phenol, and methanol standards for existing , new, and reconstructed combined collection/ curing operations ? To comply with the formaldehyde , phenol, and methanol standards, you must meet all of the following: (a) Install, calibrate, maintain, and operate a device that continuously measures the operating temperature in the firebox of each thermal incinerator. (b) Conduct a performance test as specified in §63.1188 of this subpart while manufacturing the product that requires a binder formulation made with the resin containing the highest free

- formaldehyde content specification range. Show compliance with the formaldehyde , phenol, and methanol emission s limits while the device for measuring the control device operating temperature is installed, operational, and properly calibrated. E stablish the average operating temperature as specified in §63.1185(a) of this subpart. (c) During the performance test that uses the binder formulation made with the resin containing the highest free

formaldehyde content specification range, record the fr ee formaldehyde content specification range of the resin used, and the formulation of the binder used, including the formaldehyde content and binder specification.Page 12 of 41

(d) Following the performance test, monitor and record the free

- formaldehyde content of each resin lot and the formulation of each batch of binder used, including the formaldehyde , phenol, and methanol content. (e) Maintain the free

- formaldehyde content of each resin lot and the formaldehyde , phenol, and methanol content of each binder formulatio n at or below the specification ranges established during the performance test. (f) Following the performance test, measure and record the average operating temperature of the incinerator as specified in §63.1185(b) of this subpart. (g) Maintain the operat ing temperature of the incinerator so that the average operating temperature for each three

- hour block period never falls below the average temperature established during the performance test. (h) Operate and maintain the incinerator as specified in your operations, maintenance, and monitoring plan required by §63.1187 of this subpart. (i) With prior approval from the Administrator, you may do short

- term experimental production runs using resin where the free

- formaldehyde content, or binder formulations whe re the formaldehyde content, is higher than the specification ranges of the resin and binder used during previous performance tests, or using experimental pollution prevention process modificationsPage 13 of 41

without first doing additional performance tests. Notifica tion of intent to perform a short

- term experimental production run must include the following information: (1) The purpose of the experimental run. (2) The affected production process. (3) How the resin free

- formaldehyde content or binder formulation will deviate from previously approved levels or what the experimental pollution prevention process modifications are. (4) The duration of the experimental run. (5) The date and time of the experimental run. (6) A description of any emissions testing to be done during the experimental run. **Additional Monitoring Information** § 63.1184 What do I need to know about the design specifications, installation, and operation of a bag leak detection system ? A bag leak detection system must meet the following requirements: ( a) The bag leak detection system must be certified by the manufacturer to be capable of detecting PM emissions at concentrations of 10 milligrams per actual cubic meter (0.0044 grains per actual cubic foot) or less.Page 14 of 41

(b) The sensor on the bag leak detection system must provide output of relative PM emissions. (c) The bag leak detection system must have an alarm that will sound automatically when it detects an increase in relative PM emissions greater than a preset level. (d) The alarm must be located in an a rea where appropriate plant personnel will be able to hear it. (e) For a positive

- pressure fabric filter, each compartment or cell must have a bag leak detector. For a negative

- pressure or induced

- air fabric filter, the bag leak detector must be installed downstream of the fabric filter. If multiple bag leak detectors are required (for either type of fabric filter), detectors may share the system instrumentation and alarm. (f) Each triboelectric bag leak detection system must be installed, operated, adjuste d, and maintained so that it follows EPA's “Fabric Filter Bag Leak Detection Guidance” (EPA

– 454/R

– 98

– 015, September 1997). Other bag leak detection systems must be installed, operated, adjusted, and maintained so that they follow the manufacturer's written specifications and recommendations. (g) At a minimum, initial adjustment of the system must consist of establishing the baseline output in both of the following ways:Page 15 of 41

(1) Adjust the range and the averaging period of the device. (2) Establish the alarm set points and the alarm delay time. (h) After initial adjustment, the range, averaging period, alarm set points, or alarm delay time may not be adjusted except as specified in the operations, maintenance, and monitoring plan required by §63.1187 of this subp art. In no event may the range be increased by more than 100 percent or decreased by more than 50 percent over a 365 day period unless a responsible official as defined in §63.2 of the general provisions in subpart A of this part certifies in writing to th e Administrator that the fabric filter has been inspected and found to be in good operating condition. § 63.1185 How do I establish the average operating temperature of an incinerator ? (a) During the performance test, you must establish the average operati ng temperature of an incinerator as follows: (1) Continuously measure the operating temperature of the incinerator. (2) Determine and record the average temperatures in consecutive 15

-minute blocks.Page 16 of 41

(3) Determine and record the arithmetic average of the

re corded average temperatures measured in consecutive 15

-minute blocks for each of the one

- hour performance test runs. (4) Determine and record the arithmetic average of the three one

- hour average temperatures during the performance test runs. The average of the three one

- hour performance test runs establishes the temperature level to use to monitor compliance. (b) To comply with the requirements for maintaining the operating temperature of an incinerator after the performance test, you must measure and recor d the average operating temperature of the incinerator as required by §§63.1182 and 63.1183 of this subpart. This average operating temperature of the incinerator is based on the arithmetic average of the one

hour average temperatures for each consecutive three

- hour period and is determined in the same manner described in paragraphs (a)(1) through (a)(4) of this section. § 63.1186 How may I change the compliance levels of monitored parameters ? You may change control device and process operating parameter le vels established during performance tests and used to monitor compliance if you do the following: (a) You must notify the Administrator of your desire to expand the range of a control device or process operating parameter level.Page 17 of 41

(b) Upon approval from the Administrator, you must conduct additional performance tests at the proposed new control device or process operating parameter levels. Before operating at these levels, the performance test results must verify that, at the new levels, you comply with the emission limits in §§63.1178 and 63.1179 of this subpart. § 63.1187 What do I need to know about operations, maintenance, and monitoring plans ? (a) An operations, maintenance, and monitoring plan must be submitted to the Administrator for review and approval as part of your application for the title V permit. (b) The operations, maintenance, and monitoring plan must include the following: (1) Process and control device parameters you will monitor to determine compliance, along with established operating levels or ranges for each process or control device. (2) A monitoring schedule. (3) Procedures for properly operating and maintaining control devices used to meet the standards in §§63.1178 and 63.1179 of this subpart. These procedures must include an inspect ion of each incinerator at least once per year. At a minimum, you must do the following as part of an incinerator inspection:Page 18 of 41

(i) Inspect all burners, pilot assemblies, and pilot sensing devices for proper operation. Clean pilot sensor if necessary. (ii) E nsure proper adjustment of combustion air, and adjust if necessary. (iii) Inspect, when possible, all internal structures (such as baffles) to ensure structural integrity per the design specifications. (iv) Inspect dampers, fans, and blowers for proper ope ration. (v) Inspect motors for proper operation. (vi) Inspect, when possible, combustion chamber refractory lining. Clean, and repair or replace lining if necessary. (vii) Inspect incinerator shell for proper sealing, corrosion, and/or hot spots. (viii) Fo r the burn cycle that follows the inspection, document that the incinerator is operating properly and make any necessary adjustments. (ix) Generally observe whether the equipment is maintained in good operating condition. (x) Complete all necessary repairs as soon as practicable. (4) Procedures for keeping records to document compliance. (5) Corrective actions you will take if process or control device parameters vary from the levels established duringPage 19 of 41

performance testing. For bag leak detection system alarms, example corrective actions that may be included in the operations, maintenance, and monitoring plan include: (i) Inspecting the fabric filter for air leaks, torn or broken bags or filter media, or any other condition that may cause an increase in emiss ions. (ii) Sealing off defective bags or filter media. (iii) Replacing defective bags or filter media, or otherwise repairing the control device. (iv) Sealing off a defective fabric filter compartment. (v) Cleaning the bag leak detection system probe, or

o therwise repairing the bag leak detection system. (vi) Shutting down the process producing the particulate emissions.

**Performance Tests and Methods** § 63.1188 What performance test requirements must I meet ? You must meet the following performance test requ irements: (a) All monitoring systems and equipment must be installed, operational, and properly calibrated before the performance tests. (b) Conduct a performance test, consisting of three test runs, for each cupola and /or combined collection / curing operation subject to this subpart at the maximum production ratePage 20 of 41

to demonstrate compliance with each of the applicable emission limits in §§63.1178 and 63.1179 of this subpart. (c) Following the initial performance or compliance test to be conducted wit hin 120 days of [INSERT PROMULGATION DATE OF THE RULE] you must conduct a performance test to demonstrate compliance with each of the applicable emissions limits in §§63.1178 and 63.1179 of this subpart at least once every 5 years and as often as the raw material ingredients change by more than 10 percent of those processed during the previous performance test. ( d ) Measure emissions of PM , COS, HF, HCl from each existing , new, or reconstructed cupola. (e) Measure emissions of formaldehyde , phenol, and methanol from each existing, new , or reconstructed combined collecti o n/ curing operation . (f) Measure emissions at the outlet of the control device for PM, CO S , HF, HCl, formaldehyde, phenol, or methanol. (g) To determine the average melt rate, measure and record t he amount of raw materials, excluding coke, charged into and melted in each cupola during each performance test run. Determine and record the average hourly melt rate for each performance test run. Determine and record the arithmetic average of the average hourly melt rates associated with the three performance test runs. The average hourly melt rate of thePage 21 of 41

three performance test runs is used to determine compliance with the applicable emission limits. (h) Compute and record the average emissions of the thr ee performance test runs and use the equations in §63.1190 of this subpart to determine compliance with the applicable emission limits. (i) Comply with control device and process operating parameter monitoring requirements for performance testing as specif ied in this subpart. § 63.1189 What test methods do I use ? You must use the following test methods to determine compliance with the applicable emission limits: (a) Method 1 in appendix A to part 60 of this chapter for the selection of the sampling port lo cations and number of sampling ports. (b) Method 2 in appendix A to part 60 of this chapter for stack gas velocity and volumetric flow rate. (c) Method 3 or 3A in appendix A to part 60 of this chapter for oxygen and carbon dioxide for diluent measurements needed to correct the concentration measurements to a standard basis. (d) Method 4 in appendix A to part 60 of this chapter for moisture content of the stack gas. (e) Method 5 in appendix A to part 60 of this chapter for the concentration of PM. Each PM te st run must consist of aPage 22 of 41

minimum run time of three hours and a minimum sample volume of 3.75 dscm (135 dscf). (f) Method 10 in appendix A to part 60 of this chapter for the concentration of CO, using the continuous sampling option described in section 7.1. 1 of the method. Each CO test run must consist of a minimum run time of one hour. (g) Method 318 in appendix A to this part for the concentration of formaldehyde , phenol, methanol, or CO S . (h) Method to determine the free

- formaldehyde content of each resin lot in appendix A of this subpart. (i) Method 26A or 320 in appendix A to this part for the concentration of HF and HCl. § 63.1190 How do I determine compliance ? (a) Using the results of the performance tests, you must use the following equation to determine compliance with the PM emission limit:

P K O C E 1

   (Eq. 1) Where: E = Emission rate of PM, kg/Mg (lb/ton) of melt. C = Concentration of PM, g/dscm (gr/dscf). Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr). K 5 1 = Convers ion factor, 1 kg/1,000 g (1 lb/7,000 gr). P = Average melt rate, Mg/hr (ton/hr). b) Using the results of the performance tests, you must use the following equation to determine compliance with the CO S, HF,Page 23 of 41

HCl, formaldehyde , phenol, and methanol nume rical emission limits:

6 3 2

1 10        P K K K O MW C E (Eq. 2) Where: E = Emission rate of measured pollutant, kg/Mg (lb/ton) of

melt. C = Measured volume fraction of pollutant, ppm. MW = Molecular weight of measured pollutant, g/g

-mole: COS = 60 .07, HF = 20.01, HCl = 36.46 , Formaldehyde = 30.03 ,

Phenol = 94.11, Methanol = 32.04. Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr). K 1 = Conversion factor, 1 kg/1,000 g (1 lb/453.6 g). K 2 = Conversion factor, 1,000 L/m 3 (28.3 L/ft 3 ). K 3 = Conversion factor, 24.45 L/g

-mole. P = Average melt rate, Mg/hr (ton/hr).

**Notification, Recordkeeping, and Reporting** § 63.1191 What notifications must I submit ? You must submit written or electronic notifications to the Administrator as required by §63.9(b)

– (h) of the general provisions in subpart A of this part. Electronic notifications are encouraged when possible. These notifications include, but are not limited to, the following: (a) Notification that the followi ng types of sources are subject to the standard: (1) An area source that increases its emissions so that it becomes a major source.Page 24 of 41

(2) A source that has an initial startup before the effective date of the standard. (3) A new or reconstructed source that h as an initial startup after the effective date of the standard and doesn't require an application for approval of construction or reconstruction under §63.5(d) of the general provisions in subpart A of this part. (b) Notification of intention to construct a new major source or reconstruct a major source where the initial startup of the new or reconstructed source occurs after the effective date of the standard and an application for approval of construction or reconstruction under §63.5(d) of the general pr ovisions in subpart A of this part is required. (c) Notification of special compliance obligations for a new source that is subject to special compliance requirements in §63.6(b)(3) and (4) of the general provisions in subpart A of this part. (d) Notificat ion of a performance test at least 60 calendar days before the performance test is scheduled to begin. (e) Notification of compliance status. § 63.1192 What recordkeeping requirements must I meet ? You must meet the following recordkeeping requirements:Page 25 of 41

(a) Maintain files of all information required by §63.10(b) of the general provisions in subpart A of this part, including all notifications and reports. (b) Maintain records of the following information also: (1) Cupola production (melt) rate (Mg/hr (tons/hr ) of melt). (2) All bag leak detection system alarms. Include the date and time of the alarm, when corrective actions were initiated, the cause of the alarm, an explanation of the corrective actions taken, and when the cause of the alarm was corrected. (3) The free

- formaldehyde content of each resin lot and the binder formulation, including formaldehyde content, of each binder batch used in the manufacture of bonded products. (4) Incinerator operating temperature and results of incinerator inspections. For all periods when the average temperature in any three

- hour block period fell below the average temperature established during the performance test, and all periods when the inspection identified incinerator components in need of repair or maintenance, incl ude the date and time of the problem, when corrective actions were initiated, the cause of the problem, an explanation of the corrective actions taken, and when the cause of the problem was corrected. (c) Retain each record for at least five years followin g the date of each occurrence, measurement, corrective action,Page 26 of 41

maintenance, record, or report. The most recent two years of records must be retained at the facility. The remaining three years of records may be retained off site. (d) Records must be maintai ned in a form suitable and readily available for expeditious review, according to §63.10 of the General Provisions that are referenced in Table 3 to this subpart. Electronic recordkeeping is encouraged. (e) Report the required information on paper or on a labeled computer disk using commonly available and compatible computer software. § 63.1193 What reports must I submit ? You must prepare and submit repo rts to the Administrator as required by this subpart and §63.10 of the general provisions in subpart A of this part. These reports include, but are not limited to, the following: (a) A performance test report, as required by §63.10(d)(2) of the general provisions in subpart A of this part, that documents the process and control equipment operating parameters during the test period, the test methods and procedures, the analytical procedures, all calculations, and the results of the performance tests. (b) (1) As of January 1, 2012 and within 60 days after the date of completing each performance test, as defined in §63.2, and as required in this subpart, you must submit performancePage 27 of 41

test data, except opacity data, electronically to the EPA’s Central Data Exchange by using the ERT (see http://www.epa.gov/ttn/chief/ert/erttool.html/) or other compatible electronic spreadsheet. Only data collected using test methods compatible with the ERT are subject to this requirement to be submitted electronically into the EPA’s WebFIRE database. (2) Corrective actions you will take if a process or control device malfunctions, including procedures for recording the actions taken to correct the malfunction or minimize emission s. (3) An inspection and maintenance schedule for each process and control device that is consistent with the manufacturer's instructions and recommendations for routine and long

- term maintenance. (c) A report of each event as required by §63.10(b) of the general provisions in subpart A of this part, including a report if an action taken during a startup, shutdown, or malfunction is inconsistent with the procedures in the plan as described in §63.6(e)(3) of the general provisions in subpart A of this part. (d) An operations, maintenance, and monitoring plan as specified in §63.1187 of this subpart. (e) A semiannual report as required by §63.10(e)(3) of the general provisions in subpart A of this part if measuredPage 28 of 41

emissions exceed the applicable standard or a monitored parameter varies from the level established during performance testing. The report must contain the information specified in §63.10(c) of the general provisions, as well as the relevant records required by §63.1192(b) of this subpart. (f) A semia nnual report stating that no excess emissions or deviations of monitored parameters occurred during the reporting period as required by §63.10(e)(3)(v) of the general provisions in subpart A of this part if no deviations have occurred. (g) All reports requ ired by this subpart not subject to the requirements in paragraph (b) of this section must be sent to the Administrator at the appropriate address listed in §63.13. If acceptable to both the Administrator and the owner or operator of a source, these report s may be submitted on electronic media. The Administrator retains the right to require submittal of reports subject to paragraph (b) of this section in paper format. **Other Requirements and Information** § 63.1194 Which general provisions apply ? The general p rovisions in subpart A of this part define requirements applicable to all owners and operators affected by NESHAP in part 63. See Table 1 of this subpart for generalPage 29 of 41

provisions that apply (or don't apply) to you as an owner or operator subject to the requi rements of this subpart. § 63.1195 Who implements and enforces this subpart ? (a) This subpart can be implemented and enforced by the U.S. EPA, or a delegated authority such as the applicable State, local, or Tribal agency. If the U.S. EPA Administrator has delegated authority to a State, local, or Tribal agency, then that agency, in addition to the U.S. EPA, has the authority to implement and enforce this subpart. Contact the applicable U.S. EPA Regional Office to find out if implementation and enforcement of this subpart is delegated to a State, local, or Tribal agency. (b) In delegating implementation and enforcement authority of this subpart to a State, local, or Tribal agency under subpart E of this part, the authorities contained in paragraph (c) of thi s section are retained by the Administrator of U.S. EPA and cannot be transferred to the State, local, or Tribal agency. (c) The authorities that cannot be delegated to State, local, or Tribal agencies are as specified in paragraphs (c)(1) through (4) of t his section. (1) Approval of alternatives to the requirements in §§63.1177 through 63.1180.Page 30 of 41

(2) Approval of major alternatives to test methods under §63.7(e)(2)(ii) and (f), as defined in §63.90, and as required in this subpart. (3) Approval of major alter natives to monitoring under §63.8(f), as defined in §63.90, and as required in this subpart. (4) Approval of major alternatives to recordkeeping and reporting under §63.10(f), as defined in §63.90, and as required in this subpart. [68 FR 37356, June 23, 20 03] §63.1196 What definitions should I be aware of ? Terms used in this subpart are defined in the Act, in §63. 2 of the general provisions in subpart A of this part, and in this section as follows: Affirmative defense means, in the context of an enforcement proceeding, a response or defense put forward by a defendant, regarding which the defendant has the burden of proof, and the merits of which are independently and objectively evaluated in a judicial or administrative proceeding. Bag leak detection system means a monitoring device for a fabric filter that identifies an increase in particulate matter emissions resulting from a broken filter bag or other malfunction and sounds an alarm.Page 31 of 41

Bonded product means mineral wool to which a hazardous air pollutant

–bas ed binder (containing such hazardous air pollutants as phenol or formaldehyde) has been applied. Combined collection/curing operations means the combination of fiber collection operations and curing ovens used to make bonded products. Cupola means a large, water

- cooled metal vessel to which is charged a mixture of fuel, rock, and/or slag, and additives. As the fuel is burned, the charged mixture is heated to a molten state for later processing to form mineral wool. Curing oven means a chamber in which heat is used to thermoset a binder on the mineral wool fiber used to make bonded products. Fabric filter means an air pollution control device used to capture particulate matter by filtering gas streams through fabric bags. It also is known as a baghouse. Hazardous air polluta nt means any air pollutant listed in or pursuant to section 112(b) of the Act. I means the owner or operator of a mineral wool production facility. Incinerator means an enclosed air pollution control device that uses controlled flame combustion to convert combustible materials to noncombustible gases. For the purposes of thisPage 32 of 41

rule, the term ‘incinerator’ means ‘regenerative thermal oxidizer’ (RTO). Melt means raw materials, excluding coke, that are charged into the cupola, heated to a molten state, and disc harged to the fiber forming and collection process. Melt rate means the mass of molten material discharged from a single cupola over a specified time period. Mineral wool means a fibrous glassy substance made from natural rock (such as basalt), blast furna ce slag or other slag, or a mixture of rock and slag. It may be used as a thermal or acoustical insulation material or in the making of other products to provide structural strength, sound absorbency, fire resistance, or other required properties. New source means any affected source the construction or reconstruction of which is commenced after May 8, 1997. PM means , for purposes of this subpart, emissions of particulate matter that serve as a surrogate for metals (in particulate or volatile form) on the l ist of hazardous air pollutants in section 112 of the Act, including but not limited to: antimony, arsenic, beryllium, cadmium, chromium, lead, manganese, nickel, and selenium. You means the owner or operator of a mineral wool production facility. §63.1197 Startups and shutdowns .Page 33 of 41

(a) The provisions set forth in this subpart apply at all times. (b) The owner or operator must not shut down items of equipment that are utilized for compliance with this subpart. (c) Table 1 to subpart DDD summarizes the emissi ons limits during startups and shutdowns for existing, new, and reconstructed cupolas. **Table 1 to Subpart DDD -** **Emissions limits During Startups and Shutdowns for Existing, New, and Reconstructed Cupolas, pound of**  **pollutant per hour**

**Pollutant Emission Limit**  **(lb/hr) Existing Cupolas**  **New and Reconstructed**  **Cupolas** PM 1.0 1.0 COS 32 0.17 HF 0.13 0.13 HCl 0.092 0.092 (d) Table 2 to subpart DDD summarizes the emissions limits during startups and shutdowns for existing, new, and reconstructed combined collec tion/curing operations. **Table 2 to Subpart DDD -** **Emissions limits During Startups and Shutdowns for Existing, New, and Reconstructed Combined**  **Collection/Curing Operations, pound of pollutant per hour**

**Design Pollutant**  **Emission Limit (lb/hr)**  Vertical Formalde hyde 4.5 Phenol 5.0 Methanol 6.0 Horizontal Formaldehyde 0.52 Phenol 1.4 Methanol 0.21 Drum Formaldehyde 0.64

Phenol 0.022Page 34 of 41

**Design Pollutant**  **Emission Limit (lb/hr)**  Methanol 0.0074

§ § 63.119 8

- 63.1199 [Reserved]

**Table 3**  **to Subpart DDD of Part 63 —**  **Applicability of General Provisio** **ns (40 CFR Part 63, Subpart A) to Subpart DDD of Part 63**
**General provisions**  **citation Applies to**  **subpart DDD? Explanation**  63.1 Yes 63.2 Yes Additional definitions in §63.1196. 63.3 Yes 63.4 Yes 63.5 Yes 63.6(a) Yes 63.6(b) Yes 63.6(c) Yes §63.1180 specifies compliance dates. 63.6(d) No [Reserved]. 63.6(e)(1)(i) No See 63.1180 for general duty requirement. 63.6(e)(1)(ii) No 63.6(e)(1)(iii) 63.6(e)(1)(iii) 63.6(e)(2) No §63.1187 specifies additional requirements. 63.6(e)(3) No 63.6(f) (1) No 63.6(g) YesPage 35 of 41

**General provisions**  **citation Applies to**  **subpart DDD? Explanation** 
63.6(h) No Subpart DDD does not include VE/opacity standards. 63.6(i) Yes §63.1180 specifies date. 63.7(a)

– (d) Yes 63.7(e) (1) No See §63.118 0 . 63.7(e)(2)

- (e)(4) Yes 63.7(f)

– (h) Yes 63.8(a)

– (b) Yes 63.8(c)(1) (i) No 63.8(c)( ii) Yes 63.8(c)(2)

- (d)(2) Yes
63.8(d) (3) Yes, except for last sentence 63. 8(e)

– (g) Yes 63.9(a) , (b), (c), (e), (g), (h)(1)

- (3), (h)(5) and (6), (i), and (j) Yes

63.9(f) No Subpart DDD does not include VE/opacity standards.

63. 9(g) No Subpart DDD does not require CMS performance evaluation, COMS, or CEMS.Page 36 of 41

**General provisions**  **citation Applies to**  **subpart DDD? Explanation**  63.9(h)(4) No [Reserved]. 63.10(a) Yes 63.10(b) (1) Yes §63.1192 includes additional requirements. 63.10 (b)(2)(i) No

63.10(b)(2)(ii) No See § 63.1193(c) for recordkeeping of occurrence and duration of malfunctions and recordkeeping of actions taken during malfunction. 63.10(b)(2)(iii) Yes 63.10(b)(2)(iv)

- (b)(2)(v) No 63.10(b)(2)(vi)

- (b)(2)(xiv) Yes 63.(10)(b)(3) Yes 63.10(c)(1)

– (9) Yes 63.10(c) (10)

– ( 11 ) No See § 63.1192 f or recordkeeping of malfunctions. 63.10(c) (12)

- (14) Yes 63.10(c)(15) No 63.10(d)(1)

– (4) Yes
63.10(d)( 5) No See §63.1193 for reporting of malfunctions.Page 37 of 41

**General provisions**  **citation Applies to**  **subpart DDD? Explanation**  63.10(e )

– (f) Yes

63.11 No Flares will not be used to comply with the emissions limits. 63.12 to 63.15 Yes **Appendix A to Subpart DDD of Part 63 —** **Free Formaldehyde Analysis of Insulation Resins by the Hydroxylamine Hydrochloride Method**  1. Scope The method in t his appendix was specifically developed for water - soluble phenolic resins that have a relatively high free

formaldehyde (FF) content such as insulation resins. It may also be suitable for other phenolic resins, especially those with a high FF content.

2. Principle 2.1 a. The basis for this method is the titration of the hydrochloric acid that is liberated when hydroxylamine hydrochloride reacts with formaldehyde to form formaldoxine:

HCHO + NH2OH:HCl → CH2:NOH + H2O + HCl b. Free formaldehyde in phenolic resins is present as monomeric formaldehyde, hemiformals, polyoxymethylene hemiformals, and polyoxymethylene glycols. Monomeric formaldehyde and hemiformals react rapidly with hydroxyl aminePage 38 of 41

hydrochloride, but the polymeric forms of formaldehyde must hydrolyze to the monomeric state before they can react. The greater the concentration of free formaldehyde in a resin, the more of that formaldehyde will be in the polymeric form. The hydrol ysis of these polymers is catalyzed by hydrogen ions. 2.2 The resin sample being analyzed must contain enough free formaldehyde so that the initial reaction with hydroxylamine hydrochloride will produce sufficient hydrogen ions to catalyze the depolymeriz ation of the polymeric formaldehyde within the time limits of the test method. The sample should contain approximately 0.3 grams (g) free formaldehyde to ensure complete reaction within 5 minutes. 3. Apparatus 3.1 Balance, readable to 0.01 g or better. 3. 2 pH meter, standardized to pH 4.0 with pH 4.0 buffer and pH 7 with pH 7.0 buffer. 3.3 50

-mL burette for 1.0 N sodium hydroxide. 3.4 Magnetic stirrer and stir bars. 3.5 250

-mL beaker. 3.6 50

-mL graduated cylinder. 3.7 100

-mL graduated cylinder. 3.8 Timer. 4. ReagentsPage 39 of 41

4.1 Standardized 1.0 N sodium hydroxide solution. 4.2 Hydroxylamine hydrochloride solution, 100 grams per liter, pH adjusted to 4.00. 4.3 Hydrochloric acid solution, 1.0 N and 0.1 N. 4.4 Sodium hydroxide solution, 0.1 N. 4.5 50/50 v /v mixture of distilled water and methyl alcohol. 5. Procedure 5.1 Determine the sample size as follows: a. If the expected FF is greater than 2 percent, go to Part A in 5.1.c to determine sample size. b. If the expected FF is less than 2 percent, go to P art B in 5.1.d to determine sample size. c. Part A: Expected FF ≥2 percent. Grams resin = 60/expected percent FF I. The following table shows example levels:

**Expected percent free formaldehyde**  **Sample size, grams**  2 30.0 5 12.0 8 7.5 10 6.0 12 5.0 15 4 .0 ii. It is very important to the accuracy of the results that the sample size be chosen correctly. If the milliliters ofPage 40 of 41

titrant are less than 15 mL or greater than 30 mL, reestimate the needed sample size and repeat the tests. d. Part B: Expected FF < 2 percent Grams resin = 30/expected percent FF I. The following table shows example levels:

**Expected percent free formaldehyde**  **Sample size, grams**  2 15 1 30 0.5 60

ii. If the milliliters of titrant are less than 5 mL or greater than 30 mL, reestimate the needed sample size and repeat the tests. 5.2 Weigh the resin sample to the nearest 0.01 grams into a 250

-mL beaker. Record sample weight. 5.3 Add 100 mL of the methanol/water mixture and stir on a magnetic stirrer. Confirm that the resin has dissolve d. 5.4 Adjust the resin/solvent solution to pH 4.0, using the prestandardized pH meter, 1.0 N hydrochloric acid, 0.1 N hydrochloric acid, and 0.1 N sodium hydroxide. 5.5 Add 50 mL of the hydroxylamine hydrochloride solution, measured with a graduated cyl inder. Start the timer.Page 41 of 41

5.6 Stir for 5 minutes. Titrate to pH 4.0 with standardized 1.0 N sodium hydroxide. Record the milliliters of titrant and the normality.

6. Calculations sample of grams normality hydroxide sodium mL FF 003

. 3 %    (Eq. 3)

7. Method Precision an d Accuracy Test values should conform to the following statistical precision:

Variance = 0.005 Standard deviation = 0.07 95% Confidence Interval, for a single determination = 0.2 8. Author This method was prepared by K.K. Tutin and M.L. Foster, Tacoma R&D Laboratory, Georgia

- Pacific Resins, Inc. (Principle written by R. R. Conner.)

9. References 9.1 GPAM 2221.2. 9.2 PR&C TM 2.035. 9.3 Project Report, Comparison of Free Formaldehyde Proc edures, January 1990, K. Tutin.