Title 40: Protection of Environment

PART 63—NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS 

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 subpart 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 

subpart?

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.
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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 new 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 sounds, and complete in a timely manner, 
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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 total operating time in a sixmonth 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 collection/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 

following:

(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, 
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(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 binder 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 date 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.
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(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 ovens. 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 of 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 

shutdowns. (e) Affirmative Defense for Exceedance of Emissions 

limits During Malfunction. In response to an action to enforce 
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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 notification 

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 foreseen 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-
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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 emissions; 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

(ix) 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 emissions 
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resulting from the malfunction event at issue. The analysis must 

also specify, using 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 malfunction, 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 demonstrate 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 

initial occurrence of the exceedance.
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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, adjust, 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 corrective 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 sixmonth 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 COS, HF, and HCl standards, 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 ‘regenerative thermal oxidizer’ (RTO).

(b) Conduct a performance test as specified in §63.1188 of 

this subpart that shows compliance with the COS, HF, and HCl

emissions 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 the 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 emissions limits 

while the device for measuring the control device operating 

temperature is installed, operational, and properly calibrated. 

Establish 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 freeformaldehyde content specification range, record the freeformaldehyde 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 formulation 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 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.

(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 where 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 modifications 
Page 13 of 41

without first doing additional performance tests. Notification 

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 area 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, adjusted, 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 subpart. 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 the 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 operating 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 

recorded 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 record 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 onehour 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 levels 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 

inspection 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) Ensure 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 

operation.

(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) For 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 during 
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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 emissions.

(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 

otherwise 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 requirements:

(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 rate 
Page 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 within 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 

collection/curing operation.

(f) Measure emissions at the outlet of the control device 

for PM, COS, HF, HCl, formaldehyde, phenol, or methanol.

(g) To determine the average melt rate, measure and record 

the 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 the 
Page 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 three 

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 

specified 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 locations 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 test run must consist of a 
Page 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 COS.

(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

C O K

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 51 = Conversion 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 COS, HF, 
Page 23 of 41

HCl, formaldehyde, phenol, and methanol numerical emission 

limits:

6

3

1 2

 10

   



K P

C MW O K K

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).

K1 = Conversion factor, 1 kg/1,000 g (1 lb/453.6 g).

K2 = Conversion factor, 1,000 L/m3 (28.3 L/ft3 ).

K3 = 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 following 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 has 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 

provisions 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) Notification 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:
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(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, include 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 following 

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 maintained 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 reports 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 performance 
Page 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 

emissions.

(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 measured 
Page 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 semiannual 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 required 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 reports 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 provisions 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 general 
Page 29 of 41

provisions that apply (or don't apply) to you as an owner or 

operator subject to the requirements 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 this 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 this 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 alternatives 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, 2003]

§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–based 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 pollutant 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 this 
Page 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 discharged 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 furnace 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 list 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 emissions 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 collection/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

Formaldehyde 4.5

Phenol 5.0

Methanol 6.0

Horizontal

Formaldehyde 0.52

Phenol 1.4

Methanol 0.21

Drum

Formaldehyde 0.64

Phenol 0.022
Page 34 of 41

Design Pollutant

Emission Limit 

(lb/hr)

Methanol 0.0074

§§63.1198-63.1199 [Reserved]

Table 3 to Subpart DDD of Part 63—Applicability of General 

Provisions (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) Yes
Page 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 §63.1180.

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 for 

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 this appendix was specifically developed for 

water-soluble phenolic resins that have a relatively high freeformaldehyde (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 hydroxylamine 
Page 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 

hydrolysis 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 depolymerization 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. Reagents
Page 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 Part 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 of 
Page 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 dissolved.

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 cylinder. 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

grams of sample

mL sodium hydroxide normality FF 3.003 % 

 (Eq. 3)

7. Method Precision and 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 

Procedures, January 1990, K. Tutin.