FORM A-1PARENT COMPANY INFORMATIONI. Parent Company / Legal Corporate Owner Information1. Legal Parent Company / Legal Corporate NameOwens Corning Insulating Systems, LLC2. AddressOne Owens Corning Parkway3. CityToledo4. StateOhio5. Zip Code436596. CountyLucas7. Size of Company (approximate number of employees includingall subsidiaries, branches, and related establishments owned):16,280FORM A-2FACILITY INFORMATIONII. Facility InformationFacility NameOwens Corning Insulating Systems, LLCFacility AddressStreet1277 Feura Bush RoadCityFeura BushStateNew YorkZip Code12067CountyAlbanyFacility CoordinatesLatitude (decimal degrees, six decimal places)42.586150Longitude (decimal degrees, six decimal places)73.871367Specific location represented (e.g., front door of main building, centroidof property, etc.)Centroid of PropertyNumber of employees attached to the wool fiberglass manufacturingfacility:180Design capacity of the plant (tons/yr)Type(s) of process(es) (rotary spin, flame attenuation) at this plantRotary SpinOperation schedulehrs/day24days/yr365Identify what state and local air pollution rulesand regulations, includingpermit requirements, your plant is subject to. (Please provide copies ofpermit(s) and permit IDs)Applicable requirements referenced in Title V Permit 4-0122-00004-0039. Provided on CD.III. Technical ContactNameMike PettisTechnical Contact TitleISB Environmental LeaderTelephone740-877-7087Facsimile (Fax)740-328-2696EmailMike.Pettis@owenscorning.comFORM A-2FACILITY INFORMATIONIV. OtherIs the facility a major source of HAP?Yes, currently.If No, did the facility take a limit of its potential HAP emissions to avoidclassification as a major source:N/ADoes the facility manufacture other productsin addition to woolfiberglass?NoIf Yes, list the other products manufacturedat the facility.N/AAre there any HAP emissions associated with any co-located facilities?List unit operations, e.g., boiler, and pollutant/emissions.N/AFORM B-1PLANT OPERATIONSI. Overview of Plant OperationsNumber of process lines. Include lines that are currentlyoperational or that are temporarily shutdown. (Donotinclude lines permanently shutdown).2For each process line:Process Line 1Process Line 2Process line identification names or numbersDM1DM2Type of process line (e.g., rotary spin, flame attenuation) Rotary Spin Rotary SpinMaximum annual production rate (tons/yr)Age of process equipment (yrs)3432Remaining economic life of process line (yrs) N/A.Continuedmaintenance canmaintain indefinite life.N/A. Continuedmaintenance canmaintain indefinite life.List of products produced and most recent annualproduction (tons/yr; specify year) for each productPlease attach detailed schematics of each process line. Provided on CD. Provided on CD.FORM B-2PLANT OPERATIONSII. Process - Raw materials Handling and StorageMolten glass preparationRaw materials and proportions by wt (%) Industry information provided for representativeness.Soda ash (9%), Borax (12%), Cullet (34%), Limestone(9%) and Sand (31%).Method(s) of conveying each raw material to furnace/pots Batch raw materials are delivered by truck or rail car andmechanically transferred to storage silos. Raw batchmaterials are mixed in the batch house and pneumaticallyconveyed to batch bins, where batch is augered intothefurnaces.Binder and AdditivesList each raw material, including premixed materials, in the binderformulation and its proportion by wt (%)List steps in preparing binder, including storage temperature (°F)and holding time (hrs)The above listed binder ingredients are metered intobinder mix tanks. Mixed binder is transferred to arecirculating tank. All storage temperatures are ambient.Total holding time is approximately 45 minutes.Total yearly consumption of binder (gal/yr)Cost of binder ($/gal) for most recent year (specify year)Are binder storage and mixing tanks vented tooutside/inside? Binder mix and storage tanks are vented inside.Method of treating vent air from storage andmix tanksN/AEmission control during liquid raw material transfer from vehiclesto storage tanks.N/ADescribe future source reduction plans and schedules toreformulate binders; List each constituent, proportions wt (%), cost($/gal) for reformulationFORM B-3PLANT OPERATIONSIII. Process - Glass Melting FurnaceFor each Glass Melting Furnace:Furnace 1Furnace 2Process unit identification name/numberDM1 Melter (U-00002)DM2 Melter (U-00012)Process line(s) served (identification name/number) DM1 DM2Latitude (decimal degrees, six decimal places)42.586976942.5869769Longitude (decimal degrees, six decimal places)-73.8734197-73.8734197Stack or vent height (units)160 ft.160 ft.Stack or vent diameter (units)4.83 ft.4.83 ft.Manufacturer and modelOxy-FuelOxy-FuelDate of original installation20011999Estimate of remaining lifetime (yrs)N/A. Continued maintenancecan maintain indefinite life.N/A. Continued maintenancecan maintain indefinite life.Major rebuilds:What constitutes a major rebuildFrequency of a major rebuildN/AN/ACost of typical major rebuildN/AN/ADate of last major rebuildN/AN/APurpose of last major rebuildN/AN/AIncrease or decrease in emissionsN/AN/AFuel type: electric, gas, or oilOxy-FuelOxy-FuelFuel consumption rate (KW/ton of glass or Btu/ton ofglass)List HAPs that are in refractory materialChromium CompoundsChromium CompoundsDesign production rate (tons/day)Actual glass pull rate (tons/day)Vent gas flow rate (acfm @°F)FORM B-3PLANT OPERATIONSIII. Process - Glass Melting FurnaceFor each Glass Melting Furnace:Furnace 1Furnace 2Temperature (°F) of molten glass in furnace andforehearth (if applicable)Nature and frequency of routine/preventive maintenanceproceduresDaily, visible inspection ofbatch charge operations,furnace condition and burner/ oxygen supply system.Repairs and replacementsare routinely completed whenneed is identified. Generalmaintenance activities followa prescribed schedule that isdetailed in the maintenancetracking system. Refractoryrepairs are completedinfrequently and only asnecessary.Daily, visible inspection ofbatch charge operations,furnace condition and burner/ oxygen supply system.Repairs and replacementsare routinely completed whenneed is identified. Generalmaintenance activities followa prescribed schedule that isdetailed in the maintenancetracking system. Refractoryrepairs are completedinfrequently and only asnecessary.Describe process modification(s) since 1999 that reduceemissionsThe Company hasestablished goals to reducethe environmental footprint ofour manufacturing operationsas part of our sustainabilityefforts. These goals arefocused on reducing waste-tolandfill, GHG, waterconsumption, VOC's,particulate matter, NOx andenergy. Converted to oxyfuel.The Company hasestablished goals to reducethe environmental footprint ofour manufacturing operationsas part of our sustainabilityefforts. These goals arefocused on reducing waste-tolandfill, GHG, waterconsumption, VOC's,particulate matter, NOx andenergy. Converted to oxyfuel.Describe future source reduction plans and schedules None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-4PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame AttenuationFor each Forming Operation -- Rotary Spin/Flame AttenuationForming Operation 1Forming Operation 2Process unit identification name/numberDM1 Forming (U-00003)DM2 Forming (U-00013)Process line(s) served (identification name/number)DM1DM2Latitude (decimal degrees, six decimal places) 42.5830081 (C WEP) and42.5830372 (D WEP)42.5830081 (C WEP) and42.5830372 (D WEP)Longitude (decimal degrees, six decimal places) -73.87455 (C WEP) and -73.8745042 (D WEP)-73.87455 (C WEP) and -73.8745042 (D WEP)Stack or vent height (units)105 ft. (each)105 ft. (each)Stack or vent diameter (units)4.58 ft. (each)4.58 ft. (each)Number of fiber forming devices (spinners) per line.Method of attenuating fiber (e.g., air, flame, or air and flame).Indicate type of burner used (if flame).Air and Flame Air and FlameIs there a forehearth between the furnace andthe formingsection?Yes YesMajor rebuilds:What constitutes a major rebuild The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the formingemissions. Therefore, thecompany does not considerthese to be major rebuilds forthe purpose of this ICR.The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the formingemissions. Therefore, thecompany does not considerthese to be major rebuilds forthe purpose of this ICR.Frequency of a major rebuildN/AN/ACost of typical major rebuildN/AN/ADate of last major rebuildN/AN/APurpose of last major rebuildN/AN/AIncrease or decrease in emissionsN/AN/AIf modular, number of modules and plenumsPresence of water overspray and application rate (gpm)Binder applied and application rate (gpm)Other material applied and application rate (gpm)NoneNoneTemperature of glass fiber when binder is applied (°F)FORM B-4PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame AttenuationFor each Forming Operation -- Rotary Spin/Flame AttenuationForming Operation 1Forming Operation 2Process unit identification name/numberDM1 Forming (U-00003)DM2 Forming (U-00013)Process line(s) served (identification name/number)DM1DM2Temperature of binder when applied to fibers(°F)Method of evenly distributing fibers onto forming conveyor Compressed air lapping system Compressed air lapping systemFormed mat thickness (in.)1"-6" as formed, up to 24" onramp.1"-6" as formed, up to 24" onramp.Forming air flow rate (acfm @ °F)Percent of forming air recirculated and percent exhausted None recirculated; 100%exhausted.None recirculated; 100%exhausted.Nature and frequency of routine/preventive maintenanceproceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.FORM B-4PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame AttenuationFor each Forming Operation -- Rotary Spin/Flame AttenuationForming Operation 1Forming Operation 2Process unit identification name/numberDM1 Forming (U-00003)DM2 Forming (U-00013)Process line(s) served (identification name/number)DM1DM2Describe process modification(s) since 1999 that reduceemissionsDescribe future source reduction plans and schedules None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-5PLANT OPERATIONSV. Process - CuringFor eachCuring Oven:Curing Oven 1Curing Oven 2Process unit identification name/numberDM1 Curing (U-00003)DM2 Curing (U-00013)Process line(s) served (identification name/number) DM1 DM2Latitude (decimal degrees, six decimal places)42.582730842.5849706Longitude (decimal degrees, six decimal places)-73.8736803-73.8738547Stack or vent height (units)60.99 ft.59.09 ft.Stack or vent diameter (units)9.97 ft.9.97 ft.Method of curingManufacturer and modelOC Proprietary DesignOC Proprietary DesignDate of original installation19761978Major rebuilds:What constitutes a major rebuild The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the oven emissions.Therefore, the company doesnot consider these to be majorrebuilds for the purpose of thisICR.The company undertakesroutine repair and replacementprojects. As with the furnace,these projects are normally “asis” maintenance projects that donot impact the oven emissions.Therefore, the company doesnot consider these to be majorrebuilds for the purpose of thisICR.Frequency of a major rebuildN/AN/ACost of typical major rebuildN/AN/ADate of last major rebuildN/AN/APurpose of last major rebuildN/AN/AIncrease or decrease in emissionsN/AN/AFuel type: electric, gas, or oilNatural GasNatural GasFuel consumption rate (KW/hr or BTU/hr)Moisture content wt (%) of formed mat:inlet2.5 - 5%2.5 - 5%outlet<0.5%<0.5%Air flow rate (acfm @°F) from curing20000 acfm @ 4250F20000 acfm @ 4250FExhaust air temperature (°F)425°F425°FResidence time of product (mins)FORM B-5PLANT OPERATIONSV. Process - CuringFor eachCuring Oven:Curing Oven 1Curing Oven 2Process unit identification name/numberDM1 Curing (U-00003)DM2 Curing (U-00013)Process line(s) served (identification name/number) DM1 DM2Binder content of cured product (LOI)Nature and frequency of routine/preventivemaintenance proceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when required duringunscheduled downtimes.Basic, routine cleaning occursevery 6 to 12 weeks.Significant repairs such aschain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.FORM B-5PLANT OPERATIONSV. Process - CuringFor eachCuring Oven:Curing Oven 1Curing Oven 2Process unit identification name/numberDM1 Curing (U-00003)DM2 Curing (U-00013)Process line(s) served (identification name/number) DM1 DM2Describe process modification(s) since 1999 thatreduce emissionsDescribe future source reduction plans andschedulesNone currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-6PLANT OPERATIONSVI. Process - CoolingFor eachCooling Operation: Cooling Operation 1 Cooling Operation 2Process unit identification name/number DM1 Cooling (U-00003) DM2 Cooling (U-00014)Process line(s) served (identification name/number) DM1 DM2Latitude (decimal degrees, six decimal places)42.58492342.584923Longitude (decimal degrees, six decimal places)-73.8727164-73.8727164Stack or vent height (units)44.22 ft.44.22 ft.Stack or vent diameter (units)1.17 ft.1.17 ft.Cooling air flow rate (acfm @°F)18,300 acfm @ 117 °F 17,400 acfm @ 131 °FPercentage of cooling air recirculated (if any) None NoneCooling air temperature (°F) 117 °F 131 °FNature and frequency of routine/preventivemaintenance proceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when requiredduring unscheduleddowntimes. Basic, routinecleaning occurs every 6 to 12weeks. Significant repairssuch as chain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Repairs and replacements areperformed when requiredduring unscheduleddowntimes. Basic, routinecleaning occurs every 6 to 12weeks. Significant repairssuch as chain and sprocketreplacement, frame repair andtrack replacement generallyoccur with refractoryreplacement of the furnace.FORM B-6PLANT OPERATIONSVI. Process - CoolingFor eachCooling Operation: Cooling Operation 1 Cooling Operation 2Process unit identification name/number DM1 Cooling (U-00003) DM2 Cooling (U-00014)Process line(s) served (identification name/number) DM1 DM2Describe process modification(s) since 1999 thatreduce emissionsDescribe future source reduction plans and schedules None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM B-7PLANT OPERATIONSVII. Process - Use of SolventsUse of SolventsVolatile solvents used at your facility (where and how used) N/A. No HAP-containing solvents usedin themanufacturing process.List each solvent used and quantity (gal/yr) N/A. No HAP-containing solvents used in themanufacturing process.Emission control device(s) used to control emissions from solventusage/storage?N/A. No HAP-containing solvents used in themanufacturing process.FORM B-8PROCESS OPERATIONSVIII. Pollution PreventionPlease describe any work practices, pollution prevention techniques,and control strategies evaluated and/or implementedat each processunit at your facility (e.g., binder reformulation,alternative fuels usage,etc.) to reduce emissions of PM and HAPs you identified in Form E.You must specify the year in which the facility implemented thepractice/technique and identify the emission reductions (if measured)from these practices/techniques.FORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:ESP 1 ESP 2Process line(s) (identification name/number) DM1 DM1Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)DM1 Melter (U-00002) (DEP -DM1EP)DM1 Forming and Cooling (U00003) (C WEP - FZEP1)Latitude (decimal degrees, six decimal places) 42.586977 42.585097Longitude (decimal degrees, six decimal places) -73.873420 -73.873685Stack or vent height (units)160 ft. 105.0 ft.Stack or vent diameter (units)4.83 ft. 4.58 ft.Manufacturer and modelAlstom Power 1FTA 3x45F-35-40Alstom Power 1FTA 3x45F-35-40Date of original installation2000 2000Number of collection plates and configuration90/field 38/38/76 (fields 1-3)Gas flow rate to ESP (acfm @°F)28,700 acfm @ 479 °F 38,460 acfm @ 102 °FInlet gas temperature (°F)479 °F 102 °FOutlet gas temperature (°F)450 °F 92 °FInlet grain loading (gr/dscf)0.4737 gr/dscf 0.0174 gr/dscfOutlet grain loading (gr/dscf)0.0229 gr/dscf 0.0059 gr/dscfAverage stack opacity (%)<20% <20%Pressure drop across ESP (in. H2O gauge) 3" 1"Plate area (ft2)16,276 15,501Vendor guarantee on ESP efficiency (attach copy) Yes. Provided on CD. Yes. Provided on CD.Method of plate cleaning and frequency Rappers. Every 5 minutes. Water Flush - ContinuousFlow rate of plate wash water to ESP (gpm), if applicable N/A 200 - 300 gpmTemperature of plate wash water to ESP (°F), if applicableN/A 100 °FSource of plate wash water used for cleaning,if applicable N/A WEP Wash waterConcentration (mg/l) of dissolved and suspended solids in platewash water, if applicableN/A Total Solids <0.75% avg.Conditioning agents used and amounts (in gpmor lbs/hr), ifapplicableN/A NoneAmount of wastewater generated (gpd), if applicable N/A 0 gpdFORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)Stack or vent diameter (units)Manufacturer and modelDate of original installationNumber of collection plates and configurationGas flow rate to ESP (acfm @°F)Inlet gas temperature (°F)Outlet gas temperature (°F)Inlet grain loading (gr/dscf)Outlet grain loading (gr/dscf)Average stack opacity (%)Pressure drop across ESP (in. H2O gauge)Plate area (ft2)Vendor guarantee on ESP efficiency (attach copy)Method of plate cleaning and frequencyFlow rate of plate wash water to ESP (gpm), if applicableTemperature of plate wash water to ESP (°F), if applicableSource of plate wash water used for cleaning,if applicableConcentration (mg/l) of dissolved and suspended solids in platewash water, if applicableConditioning agents used and amounts (in gpmor lbs/hr), ifapplicableAmount of wastewater generated (gpd), if applicableESP 3 ESP 4DM1 DM2DM1 Forming and Cooling (U00003) (D WEP - FZEP2)DM2 Melter (U-00012) (DEP -DM2EP)42.585126 42.586977-73.873640 -73.873420105.0 ft. 160 ft.4.58 ft. 4.83 ft.Alstom Power 1FTA 3x45F-35-40Alstom Power 1FTA 3x45F-35-402000 199938/38/76 (fields 1-3) 90/field38,770 acfm @ 97 °F 249,980 acfm @ 484 °F97 °F 484 °F92 °F 400 °F0.0165 gr/dscf 0.4583 gr/dscf0.0047 gr/dscf 0.0161 gr/dscf<20% <20%1" 3"15,501 16,276Yes. Provided on CD. Yes. Provided on CD.Water Flush - Continuous Rappers. Every 5 minutes.200 - 300 gpm N/A100 °F N/AWEP Wash water N/ATotal Solids <0.75% avg. NANone N/A0 gpd N/AFORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:ESP 1 ESP 2Process line(s) (identification name/number) DM1 DM1Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)DM1 Melter (U-00002) (DEP -DM1EP)DM1 Forming and Cooling (U00003) (C WEP - FZEP1)Amount of wastewater recycled (gpd), if applicable N/A 0 gpdAmount of wastewater disposed of (gpd), if applicable N/A 0 gpdMethod of wastewater disposal, if applicable N/A N/AQuantity of solid waste collected (lbs/yr) 2,000 - 3,000 lbs. Smallquantities of DEP residuebecomes contaminated in theprocess and must be disposed.N/AQuantity of solid waste recycled (lbs/yr) 0 lbs N/AQuantity of solid waste disposed of (lbs/yr) 2,000 - 3,000 lbs N/AMethod of solid waste disposalHazardous Waste Landfill N/ANature and frequency of routine/preventive maintenanceproceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Systems are continuouslymonitored and notificationsoccur that initiate maintenance.SIR repair and replacement isconducted as needed.Electrode replacement occurson a a12-15 year cycle.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Systems are continuouslymonitored and notificationsoccur that initiate maintenance.SIR repair and replacement isconducted as needed.Electrode replacement occurson a a12-15 year cycle.Problems experienced with control device within the last fiveyears; how were problems solved?As reported in Title V deviationreports: controller failure / repaired;and power loss / power restored.As reported in Title V deviationreports: mechanical malfunctions /repaired and reset; and equipmentfailure / repaired.FORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Amount of wastewater recycled (gpd), if applicableAmount of wastewater disposed of (gpd), if applicableMethod of wastewater disposal, if applicableQuantity of solid waste collected (lbs/yr)Quantity of solid waste recycled (lbs/yr)Quantity of solid waste disposed of (lbs/yr)Method of solid waste disposalNature and frequency of routine/preventive maintenanceproceduresProblems experienced with control device within the last fiveyears; how were problems solved?ESP 3 ESP 4DM1 DM2DM1 Forming and Cooling (U00003) (D WEP - FZEP2)DM2 Melter (U-00012) (DEP -DM2EP)0 gpd N/A0 gpd N/AN/A N/AN/A 2,000 - 3,000 lbs. Smallquantities of DEP residuebecomes contaminated in theprocess and must be disposed.N/A 0 lbsN/A 2,000 - 3,000 lbsN/A Hazardous Waste LandfillGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Systems are continuouslymonitored and notificationsoccur that initiate maintenance.SIR repair and replacement isconducted as needed.Electrode replacement occurson a a12-15 year cycle.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Systems are continuouslymonitored and notificationsoccur that initiate maintenance.SIR repair and replacement isconducted as needed.Electrode replacement occurson a a12-15 year cycle.As reported in Title V deviationreports: equipment failure /repaired.As reported in Title V deviationreports: electrical malfunction /repaired and reset.FORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:ESP 1 ESP 2Process line(s) (identification name/number) DM1 DM1Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)DM1 Melter (U-00002) (DEP -DM1EP)DM1 Forming and Cooling (U00003) (C WEP - FZEP1)Continuous monitoring method(s) used to monitor ESPperformance, including parameters monitoredSecondary voltage andamperage of 3rd field.Secondary voltage andamperage of 3rd field.Describe any plans to replace or upgrade ESP None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-1AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP)For each ESP:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Continuous monitoring method(s) used to monitor ESPperformance, including parameters monitoredDescribe any plans to replace or upgrade ESPESP 3 ESP 4DM1 DM2DM1 Forming and Cooling (U00003) (D WEP - FZEP2)DM2 Melter (U-00012) (DEP -DM2EP)Secondary voltage andamperage of 3rd field.Secondary voltage andamperage of 3rd field.None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-2AIR POLLUTION CONTROLII. ScrubberFor each Scrubber:Scrubber 1 Scrubber 2 Scrubber 3Process line(s) (identification name/number) DM1 DM1 DM1Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)DM1 Forming (U-00003)(Scrubber DM1S1)DM1 Forming (U-00003)(Scrubber DM1S2)DM1 Forming (U-00003)(Scrubber DM1S3)Latitude (decimal degrees, six decimal places)42.58482042.58482042.585097Longitude (decimal degrees, six decimal places)-73.872816-73.872816-73.873685Stack or vent height (units)60.99 ft.60.99 ft.105.0 ft.Stack or vent diameter (units)9.97 ft.9.97 ft.4.58 ft.Manufacturer and modelOC Proprietary Design OC Proprietary Design OC Proprietary DesignDate of original installation2000 2000 2000Type (e.g., venturi, orifice)Venturi Venturi VenturiGas flow rate to scrubber (acfm @°F)30,000 acfm @ 100 °F 30,000 acfm @ 100 °F 44,500 acfm@ 99 °FInlet gas temperature (°F)No data available. No data available. No data available.Outlet gas temperature (°F)No data available. No data available. 100 °FInlet grain loading (gr/dscf)No data available. No data available. No data available.Outlet grain loading (gr/dscf)No data available. No data available. 0.0169 gr/dscfAverage stack opacity (%)<20% <20% <20%Water flow rate to scrubber (gpm) >170 gpm >100 gpm >200 gpmPercent of scrubber water from recycled wastewater 100% 100% 100%Source of scrubbing water and type of pretreatment. Substance(s)added as part of pretreatment and amount used (gpmor lbs/hr)Scrubber wash watersystem. No pretreatment.Scrubber wash watersystem. No pretreatment.Scrubber wash watersystem. No pretreatment.HAP composition of wastewater (mg/L) No data available. No data available. No data available.Concentration (mg/L) of dissolved and suspended solids inscrubbing waterNo data available. No data available. No data available.Scrubbing water temperature (°F)90-100 °F 90-100 °F 90-100 °FLiquid/gas ratio (gal/103acfm)No data available. No data available. No data available.Pressure drop across scrubber (in. H2O gauge) >4" >4" >4"Amount of wastewater generated (gpd) 0 gpd 0 gpd 0 gpdAmount of wastewater recycled (gpd) 100% 100% 100%Amount of wastewater disposed of (gpd) 0 gpd 0gpd 0 gpdFORM C-2AIR POLLUTION CONTROLII. ScrubberFor each Scrubber:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)Stack or vent diameter (units)Manufacturer and modelDate of original installationType (e.g., venturi, orifice)Gas flow rate to scrubber (acfm @°F)Inlet gas temperature (°F)Outlet gas temperature (°F)Inlet grain loading (gr/dscf)Outlet grain loading (gr/dscf)Average stack opacity (%)Water flow rate to scrubber (gpm)Percent of scrubber water from recycled wastewaterSource of scrubbing water and type of pretreatment. Substance(s)added as part of pretreatment and amount used (gpmor lbs/hr)HAP composition of wastewater (mg/L)Concentration (mg/L) of dissolved and suspended solids inscrubbing waterScrubbing water temperature (°F)Liquid/gas ratio (gal/103acfm)Pressure drop across scrubber (in. H2O gauge)Amount of wastewater generated (gpd)Amount of wastewater recycled (gpd)Amount of wastewater disposed of (gpd)Scrubber 4 Scrubber 5 Scrubber 6DM1 DM1 DM1DM1 Forming (U-00003)(Scrubber DM1S4)DM1 Forming (U-00003)(Scrubber DM1S5)DM1 Forming (U-00003)(Scrubber DM1S6)42.58512642.58482042.584820-73.873640-73.872816-73.872816105.0 ft.60.99 ft.60.99 ft.4.58 ft.9.97 ft.9.97 ft.OC Proprietary Design OC Proprietary Design OC Proprietary Design2000 2000 2000Venturi Venturi Venturi44,800 acfm @ 91 °F 30,000 acfm @ 100 °F 30,000 acfm@ 100 °FNo data available. No data available. No data available.97 °F No data available. No data available.No data available. No data available. No data available.0.0206 gr/dscf No data available. No data available.<20% <20% <20%>200 gpm >100 gpm >170 gpm100% 100% 100%Scrubber wash watersystem. No pretreatment.Scrubber wash watersystem. No pretreatment.Scrubber wash watersystem. No pretreatment.No data available. No data available. No data available.No data available. No data available. No data available.90-100 °F 90-100 °F 90-100 °FNo data available. No data available. No data available.>4" >4" >4"0 gpd 0 gpd 0 gpd100% 100% 100%0 gpd 0 gpd 0 gpdFORM C-2AIR POLLUTION CONTROLII. ScrubberFor each Scrubber:Scrubber 1 Scrubber 2 Scrubber 3Process line(s) (identification name/number) DM1 DM1 DM1Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)DM1 Forming (U-00003)(Scrubber DM1S1)DM1 Forming (U-00003)(Scrubber DM1S2)DM1 Forming (U-00003)(Scrubber DM1S3)Method of wastewater disposalN/A N/A N/AQuantity of solid waste collected (lbs/yr) Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Quantity of solid waste recycled (lbs/yr) N/A N/A N/AQuantity of solid waste disposed of (lbs/yr) Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Method of solid waste disposalLocal Solid Waste Landfill Local Solid Waste Landfill Local Solid Waste LandfillVendor guarantee on scrubber efficiency (attach copy) N/A N/A N/ANature and frequency of preventive maintenance procedures General maintenanceactivities follow aprescribed schedule that isdetailed in themaintenance trackingsystem. Nozzles and flowpatterns are checked daily;repairs are completed asneeded. Cleaning isperformed on a cyclematching machinedowntime.General maintenanceactivities follow aprescribed schedule that isdetailed in themaintenance trackingsystem. Nozzles and flowpatterns are checked daily;repairs are completed asneeded. Cleaning isperformed on a cyclematching machinedowntime.General maintenanceactivities follow aprescribed schedule that isdetailed in themaintenance trackingsystem. Nozzles and flowpatterns are checked daily;repairs are completed asneeded. Cleaning isperformed on a cyclematching machinedowntime.FORM C-2AIR POLLUTION CONTROLII. ScrubberFor each Scrubber:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Method of wastewater disposalQuantity of solid waste collected (lbs/yr)Quantity of solid waste recycled (lbs/yr)Quantity of solid waste disposed of (lbs/yr)Method of solid waste disposalVendor guarantee on scrubber efficiency (attach copy)Nature and frequency of preventive maintenance proceduresScrubber 4 Scrubber 5 Scrubber 6DM1 DM1 DM1DM1 Forming (U-00003)(Scrubber DM1S4)DM1 Forming (U-00003)(Scrubber DM1S5)DM1 Forming (U-00003)(Scrubber DM1S6)N/A N/A N/AApproximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.N/A N/A N/AApproximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Approximately 1,200,000lbs/yr solid waste fromwash water system fromall DM-1 sources.Local Solid Waste Landfill Local Solid Waste Landfill Local Solid Waste LandfillN/A N/A N/AGeneral maintenanceactivities follow aprescribed schedule that isdetailed in themaintenance trackingsystem. Nozzles and flowpatterns are checked daily;repairs are completed asneeded. Cleaning isperformed on a cyclematching machinedowntime.General maintenanceactivities follow aprescribed schedule that isdetailed in themaintenance trackingsystem. Nozzles and flowpatterns are checked daily;repairs are completed asneeded. Cleaning isperformed on a cyclematching machinedowntime.General maintenanceactivities follow aprescribed schedule that isdetailed in themaintenance trackingsystem. Nozzles and flowpatterns are checked daily;repairs are completed asneeded. Cleaning isperformed on a cyclematching machinedowntime.FORM C-2AIR POLLUTION CONTROLII. ScrubberFor each Scrubber:Scrubber 1 Scrubber 2 Scrubber 3Process line(s) (identification name/number) DM1 DM1 DM1Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)DM1 Forming (U-00003)(Scrubber DM1S1)DM1 Forming (U-00003)(Scrubber DM1S2)DM1 Forming (U-00003)(Scrubber DM1S3)Problems experienced with control device within the last five years;how were problems solved?As reported in Title Vdeviation reports: flow ratemonitoring devicemalfunctioned / repaired;plugged water supply line /cleaned line; pump failure /repaired; water flow loss /monitored flow rate; andequipment failure / repairsmade.As reported in Title Vdeviation reports: flow ratemonitoring devicemalfunctioned / repaired;plugged water supply line /cleaned line; pump failure /repaired; water flow loss /monitored flow rate; andequipment failure / repairsmade.As reported in Title Vdeviation reports: flow ratemonitoring devicemalfunctioned / repaired;plugged water supply line /cleaned line; pump failure /repaired; water flow loss /monitored flow rate; andequipment failure / repairsmade.Continuous monitoring method(s) used to monitor scrubberperformance, including parameters monitoredFlow and Pressure Drop Flow and Pressure Drop Flowand Pressure DropPlans to replace or upgrade scrubber None currently approvedor scheduled at this time.None currently approvedor scheduled at this time.None currently approvedor scheduled at this time.FORM C-2AIR POLLUTION CONTROLII. ScrubberFor each Scrubber:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Problems experienced with control device within the last five years;how were problems solved?Continuous monitoring method(s) used to monitor scrubberperformance, including parameters monitoredPlans to replace or upgrade scrubberScrubber 4 Scrubber 5 Scrubber 6DM1 DM1 DM1DM1 Forming (U-00003)(Scrubber DM1S4)DM1 Forming (U-00003)(Scrubber DM1S5)DM1 Forming (U-00003)(Scrubber DM1S6)As reported in Title Vdeviation reports: flow ratemonitoring devicemalfunctioned / repaired;plugged water supply line /cleaned line; pump failure /repaired; and water flowloss / monitored flow rate.As reported in Title Vdeviation reports: flow ratemonitoring devicemalfunctioned / repaired;plugged water supply line /cleaned line; pump failure /repaired; and water flowloss / monitored flow rate.As reported in Title Vdeviation reports: flow ratemonitoring devicemalfunctioned / repaired;plugged water supply line /cleaned line; and pumpfailure / repaired.Flow and Pressure Drop Flow and Pressure Drop Flowand Pressure DropNone currently approvedor scheduled at this time.None currently approvedor scheduled at this time.None currently approvedor scheduled at this time.FORM C-3AIR POLLUTION CONTROLIII. Mechanical CollectorNot applicable to thisfacility.For each Mechanical Collector:Mechanical CollectorProcess line(s) (identification name/number) N/AEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)N/ALatitude (decimal degrees, six decimal places)N/ALongitude (decimal degrees, six decimal places)N/AStack or vent height (units)N/AStack or vent diameter (units)N/AManufacturer and modelN/ADate of original installationN/AType of mechanical collectorN/AGas flow rate to collector (acfm @°F)N/AInlet gas temperature (°F)N/AOutlet gas temperature (°F)N/AInlet grain loading (gr/dscf)N/AOutlet grain loading (gr/dscf)N/AAverage stack opacity (%)N/AOverall pressure drop (in. H2O gauge) N/AVendor guarantee on mechanical collector efficiency (attachcopy)N/AQuantity of solid waste collected (lbs/yr) N/AQuantity of solid waste recycled (lbs/yr) N/AQuantity of solid waste disposed of (lbs/yr) N/AMethod of solid waste disposal N/ANature and frequency of preventive maintenance procedures N/AProblems experienced with control device within the last fiveyears; how were problems solved?N/AContinuous monitoring method(s) used to monitor performance,including parameters monitoredN/APlans to replace or upgrade mechanical collector N/AFORM C-4AIR POLLUTION CONTROLIV. Fabric FilterFor each Fabric Filter:Fabric Filter 1 Fabric Filter 2Process line(s) (identification name/number) DM1 DM2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)DM1 Mixed Batch Bin (U00001)DM2 Mixed Batch Bin (U-00001)Latitude (decimal degrees, six decimal places)42.58442142.584502Longitude (decimal degrees, six decimal places)-73.873346-73.873496Stack or vent height (units)94.62 ft.94.38 ft.Stack or vent diameter (units)0.75 ft.0.75 ft.Manufacturer and model Camfil FARR APC, ModelGS4Camfil FARR APC, ModelGS4Date of original installation 2007 2007Number of compartments 1 1Number of bags per compartment 4 4Filter material and coatings applied Polyester- Cellulosic Fibers Polyester - Cellulosic FibersFabric weight (oz/yd2)No data available. No data available.Filter surface area (ft2) 585 ft2585 ft2Gas flow rate to filter (acfm @°F)No data available. No data available.Inlet gas temperature (°F)Ambient AmbientOutlet gas temperature (°F)Ambient AmbientInlet grain loading (gr/dscf) No data available. No data available.Outlet grain loading (gr/dscf) <0.02 gr/dscf <0.02 gr/dscfAverage stack opacity (%) <20% <20%Overall pressure drop (in. H2O gauge) 2 - 6" 2 - 6"Method and frequency of bag cleaning Pulse JetCleaning Pulse Jet CleaningVendor guarantee on fabric filter efficiency(attachcopy)Provided on CD. Provided on CD.Quantity of solid waste collected (lbs/yr) N/A(Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)FORM C-4AIR POLLUTION CONTROLIV. Fabric FilterFor each Fabric Filter:Fabric Filter 1 Fabric Filter 2Process line(s) (identification name/number) DM1 DM2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)DM1 Mixed Batch Bin (U00001)DM2 Mixed Batch Bin (U-00001)Quantity of solid waste recycled (lbs/yr) N/A(Closed system returnscollected dust to process.)N/A (Closed system returnscollected dust to process.)Quantity of solid waste disposed of (lbs/yr) 0lbs 0 lbsMethod of solid waste disposal N/A N/ANature and frequency of preventive maintenanceproceduresGeneral maintenance repairsas needed. Visualinspections and differentialpressure checks areperformed routinely. Bag orcartridge replacement isperformed as needed.General maintenance repairsas needed. Visualinspections and differentialpressure checks areperformed routinely. Bag orcartridge replacement isperformed as needed.Problems experienced with control device within thelast five years; how were problems solved?None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.Continuous monitoring method(s) used to monitorperformance, including parameters monitoredN/A N/APlans to replace or upgrade fabric filter Nonecurrently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-5AIR POLLUTION CONTROLV. Thermal IncineratorFor each Thermal Incinerator: Thermal Incinerator1 Thermal Incinerator 2Process line(s) (identification name/number) DM1 DM2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)DM1 Curing: CombinedExhaust (Forming/Curing)from Mixing Chamber (U00003)DM2 Curing: CombinedExhaust (Forming/Curing)from Mixing Chamber (U00013)Latitude (decimal degrees, six decimal places)42.582730842.5849706Longitude (decimal degrees, six decimal places)-73.8736803-73.8738547Stack or vent height (units)60.99 ft.59.09 ft.Stack or vent diameter (units)9.97 ft.9.97 ft.Manufacturer and model C & H Combustion/Hirt Hirt TXL-15M-48Date of original installation 1974 1978Fuel type: gas or oil Natural Gas Natural GasFuel consumption rate (BTU/hr) 5,846,400 BTU/hr 7,080,000 BTU/hrInlet gas flow rate (acfm @°F)34,000 acfm @ 450 °F 34,000 acfm @ 450 °FInlet gas temperature (°F)425 - 450 °F 425 - 450 °FCombustion chamber gas temperature (°F)1300 °F 1303 °FOutlet gas temperature (°F)1320 °F (prior to heatrecovery)1320 °F (prior to heatrecovery)Inlet grain loading (gr/dscf) No data available. No data available.Outlet grain loading (gr/dscf) Mixing chamberexhaust,including forming section:0.0153 gr/dscfMixing chamber exhaust,including forming section:0.0164 gr/dscfAverage stack opacity (%) <20% <20%Excess air (%)0 (fume air incincerator) 0 (fume air incincerator)Residence time (sec) at temperature (°F)1.7 seconds at 1300 °F 0.5 seconds at 1320 °FPercent heat recovery 60% 48%Vendor guarantee on incinerator efficiency (attachcopy)None provided. None provided.FORM C-5AIR POLLUTION CONTROLV. Thermal IncineratorFor each Thermal Incinerator: Thermal Incinerator1 Thermal Incinerator 2Process line(s) (identification name/number) DM1 DM2Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)DM1 Curing: CombinedExhaust (Forming/Curing)from Mixing Chamber (U00003)DM2 Curing: CombinedExhaust (Forming/Curing)from Mixing Chamber (U00013)Nature and frequency of preventive maintenanceproceduresAnnual inspections performedper MACT requirement andrepairs made as needed.Annual inspections performedper MACT requirement andrepairs made as needed.Problems experienced with control device within thelast five years; how were problems solved?None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.Continuous monitoring method(s) used to monitorincinerator performance, including parameters monitoredFirebox Temperature Firebox TemperaturePlans to replace or upgrade thermal incinerator None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:HVAF 1 HVAF 2 HVAF 3Process line(s) (identification name/number) DM1 DM1 DM1Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)DM1 Cooling (U-00003)(Smoke Stripper): CommonExhaust with DM1 C WEPDM1 Cooling (U-00003)(HEAF - DM1F1)DM1 Cooling (U-00003)(Smoke Stripper - DM1F2):Common Exhaust with DM1 DWEPLatitude (decimal degrees, six decimal places)42.58509742.58498142.585126Longitude (decimal degrees, six decimal places)-73.873685-73.8724856-73.873640Stack or vent height (units)105.0 ft.50.13 ft.105.0 ft.Stack or vent diameter (units)4.58 ft.3.5 ft.4.58 ft.Manufacturer and model OC Proprietary Design Wheelabrator HEAF unit OC Proprietary DesignDate of original installation 1990 1974 1990Inlet gas flow rate (acfm @°F)3,000 - 5,000 acfm @ 110 -120°F25,000 - 35,000 acfm @ 100 -120°F3,000 - 5,000 acfm @ 110 -120°FInlet gas temperature (°F)110 - 120 °F 100 - 120 °F 110 - 120 °FOutlet gas temperature (°F)100 - 150 °F 100 - 120 °F 100 - 150 °FInlet grain loading (gr/dscf) No data available. No data available. No data available.Outlet grain loading (gr/dscf) 0.003-0.15 gr/dscf .005-.010 gr/dscf 0.003-0.15 gr/dscfAverage stack opacity (%) <20% <20% <20%Water spray pressure (sdig), if applicable Nodata available. No data available. No data available.Water spray rate (gpm), if applicable 10 - 20gpm No data available. 10 - 20 gpmFilter face velocity (acfm/ft2)No data available. No data available. No data available.Maximum pressure drop across mat (in. H2O gauge) 50" 32" 50"Vendor guarantee on HVAF efficiency (attach copy) N/A None provided. N/AMethod and frequency of filter mad advancement Manually, once/twice per shift. Autofeed, as required bydifferential pressure.Manually, once/twice per shift.Amount of wastewater generated (gpd) 0 gpd 0 gpd 0 gpdAmount of wastewater recycled (gpd) 100% 100% 100%Amount of wastewater disposed of (gpd) 0 gpd 0gpd 0 gpdFORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)Latitude (decimal degrees, six decimal places)Longitude (decimal degrees, six decimal places)Stack or vent height (units)Stack or vent diameter (units)Manufacturer and modelDate of original installationInlet gas flow rate (acfm @°F)Inlet gas temperature (°F)Outlet gas temperature (°F)Inlet grain loading (gr/dscf)Outlet grain loading (gr/dscf)Average stack opacity (%)Water spray pressure (sdig), if applicableWater spray rate (gpm), if applicableFilter face velocity (acfm/ft2)Maximum pressure drop across mat (in. H2O gauge)Vendor guarantee on HVAF efficiency (attach copy)Method and frequency of filter mad advancementAmount of wastewater generated (gpd)Amount of wastewater recycled (gpd)Amount of wastewater disposed of (gpd)HVAF 4 HVAF 5DM2 DM2DM2 Cooling (U-00014)(HEAF)DM-2 Cooling (U-00014)(Smoke Stripper)42.58515742.584963-73.8726875-73.872660350.14 ft.44.24 ft.5.00 ft.1.17 ft.Wheelabrator Ultra Dyne 7248 OC Proprietary Design1974 199825,000 - 35,000 acfm @ 100 -120°F3000-5000 acfm @ 1150F115 °F 110 - 120 °F115 °F 100 - 150 °FNo data available. No data available..005-.010 gr/dscf .003-.015 gr/dscf<20% <20%No data available. No data available.No data available. 10 - 20 gpmNo data available. No data available.32" 50"None provided. N/AAutofeed, as required bydifferential pressure.Manually, once/twice per shift.0 gpd 0 gpd100% 100%0 gpd 0 gpdFORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:HVAF 1 HVAF 2 HVAF 3Process line(s) (identification name/number) DM1 DM1 DM1Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)DM1 Cooling (U-00003)(Smoke Stripper): CommonExhaust with DM1 C WEPDM1 Cooling (U-00003)(HEAF - DM1F1)DM1 Cooling (U-00003)(Smoke Stripper - DM1F2):Common Exhaust with DM1 DWEPMethod of wastewater disposal N/A N/A N/AQuantity of solid waste collected (lbs/yr) 20,000 lbs/yr 100,000 lbs/yr 20,000 lbs/yrQuantity of solid waste recycled (lbs/yr) 0 lbs/yr 0 lbs/yr 0 lbs/yrQuantity of solid waste disposed of (lbs/yr) 20,000 lbs/yr 100,000 lbs/yr 20,000 lbs/yrMethod of solid waste disposal Local Solid Waste Landfill Local Solid Waste Landfill Local Solid Waste LandfillNature and frequency of preventive maintenanceproceduresGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Nozzles and flow patterns arechecked daily; repairs arecompleted as needed.Cleaning is performed on acycle matching machinedowntime.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Cleaning is performed on acycle matched to machinedowntime.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Nozzles and flow patterns arechecked daily; repairs arecompleted as needed.Cleaning is performed on acycle matching machinedowntime.Problems experienced with control device within thelast five years; how were problems solved?No malfunctions reported inTitle V deviation reports.No malfunctions reported inTitle V deviation reports.None reported in Title Vdeviation reports.Continuous monitoring method(s) used to monitorHVAF performance, including parameters monitoredN/A N/A N/APlans to replace or upgrade HVAF None currently approved orscheduled at this time.None currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-6AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF)For each HVAF:Process line(s) (identification name/number)Equipment/process(es) controlled. Include emissionpoint designations (e.g., E3, E4 from plot plan)Method of wastewater disposalQuantity of solid waste collected (lbs/yr)Quantity of solid waste recycled (lbs/yr)Quantity of solid waste disposed of (lbs/yr)Method of solid waste disposalNature and frequency of preventive maintenanceproceduresProblems experienced with control device within thelast five years; how were problems solved?Continuous monitoring method(s) used to monitorHVAF performance, including parameters monitoredPlans to replace or upgrade HVAFHVAF 4 HVAF 5DM2 DM2DM2 Cooling (U-00014)(HEAF)DM-2 Cooling (U-00014)(Smoke Stripper)N/A N/A100,000 lbs/yr 20,000 lbs/yr0 lbs/yr 0 lbs/yr100,000 lbs/yr 20,000 lbs/yrLocal Solid Waste Landfill Local Solid Waste LandfillGeneral maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Cleaning is performed on acycle matched to machinedowntime.General maintenance activitiesfollow a prescribed schedulethat is detailed in themaintenance tracking system.Nozzles and flow patterns arechecked daily; repairs arecompleted as needed.Cleaning is performed on acycle matching machinedowntime.None reported in Title Vdeviation reports.None reported in Title Vdeviation reports.N/A N/ANone currently approved orscheduled at this time.None currently approved orscheduled at this time.FORM C-7AIR POLLUTION CONTROLVII. Mist EliminatorNot applicable to this facility.For each Mist Eliminator:Mist EliminatorProcess line(s) (identification name/number) N/AEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 plot plan)N/ALatitude (decimal degrees, six decimal places)N/ALongitude (decimal degrees, six decimal places)N/AStack or vent height (units)N/AStack or vent diameter (units)N/AManufacturer and modelN/ADate of original installationN/AType of mist eliminatorN/AGas flow rate to mist eliminator (acfm @°F)N/AInlet gas temperature (°F)N/AOutlet gas temperature (°F)N/AInlet grain loading (gr/dscf)N/AOutlet grain loading (gr/dscf)N/AAverage stack opacity (%)N/AVelocity in mist eliminator (ft/sec) N/APressure drop (in. H2O gauge) N/AFor chevron blade mist eliminators:N/ASpacing between blades (in.) N/AWashing frequency of blades N/AFor mesh pad mist eliminators:N/ANumber of pads or elements N/AThickness of pad (in.) or element dimensions N/ADensity of pad, (lb/ft3)N/AWashing frequency of padN/AVendor guarantee on mist eliminator efficiency (attach copy) N/AAmount of wastewater generated (gpd) N/AFORM C-7AIR POLLUTION CONTROLVII. Mist EliminatorNot applicable to this facility.For each Mist Eliminator:Mist EliminatorAmount of wastewater recycled (gpd) N/AAmount of wastewater disposed of (gpd) N/AMethod of wastewater disposal N/AQuantity of solid waste collected (lbs/yr) N/AQuantity of solid waste recycled (lbs/yr) N/AQuantity of solid waste disposed of (lbs/yr) N/AMethod of solid waste disposal N/ANature and frequency of preventive maintenance procedures N/AProblems experienced with control device within the last fiveyears; how were problems solved?N/AContinuous monitoring method(s) used to monitor mist eliminatorperformance, including parameters monitoredN/APlans to replace or upgrade mist eliminator N/AFORM C-8AIR POLLUTION CONTROLVIII. Ventilation SystemFor each Ventilation System:Ventilation System 1Process line(s) (identification name/number)Furnace HallEquipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)Fugitive / Furnace VentsLatitude (decimal degrees, six decimal places)42.5845503Longitude (decimal degrees, six decimal places)-73.8732922Stack or vent height (units)Roof HeightStack or vent diameter (units)Multiple LocationsFor general or building ventilation:Ventilation system usedNatural draft with walland roof louvers.Airflow control system usedManually adjusted.Number of air changes per hour Estimatedat 4-6 airchanges per hour.For unit or local ventilation:Enclosure or hood design usedN/AVolume of enclosure or hoodN/ACapture velocity (ft/sec)N/ADistance between hood and emission source (ft)N/AFORM C-9AIR POLLUTION CONTROLIX. OtherFor each Other Air Pollution Control Device (APCD): Other APCD 1 Other APCD 2Process line(s) (identification name/number) DM1 DM2Equipment/process(es) controlled. Include emission pointdesignations (e.g., E3, E4 from plot plan)DM1 Forming (U-00003) DM2 Forming (U-00013)Latitude (decimal degrees, six decimal places)42.58482042.584971Longitude (decimal degrees, six decimal places)-73.872816-73.87299Stack or vent height (units)60.99 ft.59.09 ft.Stack or vent diameter (units)9.97 ft.9.97 ft.DescriptionDrop-Out Boxes andPenthouseDrop-Out Boxes andDemisterFORM DPROCESS LINE STARTUP AND SHUTDOWN2005 - 2009 Semi-Annual MACT reports provided on CD.1. For each startup and shutdown (SS) that occurred during the lastfive years, please provide the following information requested in A.through J.A. Using the definitions provided above, indicate whether theevent was a startup or shutdown;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.B. A description of the event, including identification of theemissions source or sources associated with the startup orshutdown;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.C. Whether any permit condition was exceededand, if so, whatpermit condition was exceeded;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.D. Whether the event was covered by any contingency plan forcontrolling emissions during startup and shutdown events and, if so,whether the plan was followed; if the plan was notfollowed, why not;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.E. The duration of the event;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.F. The actions taken to minimize emissions during the event,including the use of any backup control systems;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.G. Estimates or measurements, if any, of emissions during theevent; if you did not have the ability to quantifyemissions during theevent, please explain why;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.H. Whether the emission profile of each unitwas different duringstartup and shutdown than during normal operating conditions and, ifso, how emissions were different and why; please provide anysupporting information;As indicated in the 2005 - 2009 Semi-Annual MACT Reports.I. All performance test data collected during each period of SS;the test method used for each event; when the testing wasconducted and why; the test conditions at the timeof testing; andwhether the tests were associated with a routine startup or shutdown;andNo data available.J. All monitoring data, including control system parametermonitoring, collected during each period of SS.As indicated in the 2005 - 2009 Semi-Annual MACT Reports.Startup: the setting in operation of an affected source or portion of an affected source for any purpose.Shutdown: the cessation of operation of an affected source or portion of an affected source for any purpose.FORM DPROCESS LINE STARTUP AND SHUTDOWN2005 - 2009 Semi-Annual MACT reports provided on CD.If this information is contained in periodic and immediate SS reports(either stand-alone or contained within the periodic excess emissionsreport) submitted to your permitting authority, youmay submit copiesof those reports instead.2. Are there any types of startup or shutdown events that you havebeen able to eliminate? If so, please describe thetype of event andexplain how these events were eliminated.No.3. Please submit a copy of your SS plan if you arerequired todevelop one.As indicated in the 2005 - 2009 Semi-Annual MACT Reports.4. Please provide all performance test data collected during periodsof SS over the last 5 years. Indicate the test method used for eachevent.No data available.5. Please provide all monitoring data, including control systemparameter monitoring, collected during periods of SS over the last 5years.As indicated in the 2005 - 2009 Semi-Annual MACT Reports.6. Optional: Do you wish to recommend a standardthat would applyduring startup or shutdown? If so, please describethe event to whichthe standard would apply; the recommended standard(this could bean emission limitation, work practice, or operational standard) thatwould apply during the period; the basis for the recommendedstandard; why and how the standard would minimize emissionsduring the event; and how would compliance be determined and/ormonitored.No.FORM EPRESENCE OF AIR POLLUTANTS IN EMISSION POINTSPlease provide any existing emissions information and data coveringhazardous air pollutants (HAP) and particulate matter (PM) for each listedprocess. Identify the appropriate box for which you are providing specificprocess information and/or pollutant emissions data.Melting Furnace Forming Curing CoolingParticulate Matter (PM, PM 2.5, PM Condensable)Chromium Compounds and Hexavalent Chromium (including any Crspeciation data)Other metal HAP (As, Be, Cd, Co, Hg, Mn, Ni, Pb, Sb, Se)Hydrogen Fluoride (HF)Hydrogen Chloride (HCl)FormaldehydePhenolMethanolOther organic HAPThe existing data requested here has been providedto EPA by the industry’s trade association, the NorthAmerican Insulation Manufacturers Association (“NAIMA”). The existing data provided by NAIMA was setforth inNAIMA’s May 5, 2010 letter to EPA. The existing emissions data provided from fiber glass companies includedtest results for the following pollutants: formaldehyde, methanol, phenol, particulate matter, hydrogen fluoride,metals (antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, nickel and selenium),mercury and hexavalent chromium. The existing emissions data provided from mineral wool companies includedtest results for the following pollutants: formaldehyde, methanol, phenol, particulate matter, carbonmonoxide,carbonyl sulfide, hydrogen fluoride, metals (antimony, arsenic, beryllium, cadmium, chromium, cobalt,lead,manganese, nickel and selenium), mercury and hexavalent chromium.The scope of the existing data provided was the result of consensus reached by EPA, NAIMA and industryrepresentatives. In addition to the existing datasubmitted to EPA, extensive new emissions data is being collectedfrom virtually all companies through the “BTEC, Inc. Quality Assurance Project Plan for the Mineral Wool and WoolFiberglass Emissions Test Program.” This Test Program will collect and submit to EPA, through EPA’s ElectronicReporting Tool, representative emissions data for the following pollutants: formaldehyde, methanol, phenol,particulate matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, metals (antimony, arsenic, beryllium,cadmium, chromium, cobalt, lead, manganese, nickeland selenium), mercury and hexavalent chromium.FORM F-1COSTI. Process Unit (e.g., cupola, curing oven, etc.):For each Process Unit:Process Unit IDProcess Line IDII. Capital CostsBase yearTotal capital cost, including costs for individual pieces, if available.III. Annual Operating CostsBase year (most recent fiscal year)Total annual operating costsMaintenance materials and replacement parts (specify costs by item)Raw materials costsLabor($/yr) for each labor class(hr/hr) for each labor classUtilities (breakdown for each utility)Waste treatment and/or disposalCosts associated with any work practices and pollution preventiontechniques that are employed at your facilitySavings associated with heat recovery and wastewater and/or solid wastereturned to process from APCD (or sold to another user)Indirect costsOther (specify)Please provide the annual report to shareholders orequivalent for the mostrecent fiscal year. If reports are not available,provide annual sales andprofits (or profit margin) for the most recent fiscal year. If company ispublicly owned, please provide a web link to this information.Identify the market range (regional, national, international) of your products.The company objects to this request because it seeks information that is notrelevant to the EPA Administrator's review obligations pursuant to Clean AirAct Section 112(d)(6) and 112(f)(2).FORM F-1Can your product(s) be substituted by another product(s)? If so, please listyour product(s) and substituted product(s).Wool fiberglass insulation comprises the major market forresidential insulation material used in the UnitedStates.The remaining market consists of cellulose (scrapnewspaper) treated to resist fires, spray foam, foamboards, cotton treated to resist fires, and wool treated toresist fires.Wool fiberglass insulation is preferred over thesealternative insulation materials because it is easily,economically, and safety installed in various buildingsettings, has superior fire performance capabilities, and a70-year history of proven performance and durability.FORM F-2COSTI. Air Pollution Control Device (APCD)For each APCD:APCD IDProcess Unit IDII. Capital CostsBase yearAPCD equipment purchase cost and what was includedList the cost for each piece of auxiliary equipment for each APCD notincluded aboveInstallation costLand purchase costTotal capital costMethod of financing APCDRetrofit installationField erected or modularIII. Annual Operating CostsBase year (most recent fiscal year)Maintenance materials and replacement parts (specify costs by item)Raw materials costsLabor($/yr) for each labor class(hr/hr) for each labor classUtilities (breakdown for each utility)Waste treatment and/or disposalIndirect costsOther (specify)The company objects to this request because it seeks information that is notrelevant to the EPA Administrator's review obligations pursuant to Clean AirAct Section 112(d)(6) and 112(f)(2).FORM F-2Total annual operating cost (most recent fiscal year)Attach annual report to shareholders or equivalentfor the most recent fiscalyear. Alternatively, if company is publicly owned,you can provide yourcompany's web link to this information.