FORM A-1

PARENT COMPANY INFORMATIONI. Parent Company / Legal Corporate Owner Information 1. Legal Parent Company / Legal Corporate Name Owens Corning Insulating Systems, LLC 2. Address One Owens Corning Parkway 3. City Toledo 4. State Ohio 5. Zip Code 43659 6. County Lucas 7. Size of Company (approximate number of employees including all subsidiaries, branches, and related establishments owned):

16,280
FORM A-2

FACILITY INFORMATIONII. Facility Information Facility Name Owens Corning Insulating Systems, LLC Facility Address Street 1277 Feura Bush Road City Feura Bush State New York Zip Code 12067 County Albany Facility Coordinates Latitude (decimal degrees, six decimal places) 42.586150 Longitude (decimal degrees, six decimal places) 73.871367 Specific location represented (e.g., front door of main building, centroid of property, etc.)

Centroid of Property

 Number of employees attached to the wool fiberglass manufacturing 

facility:

180

 Design capacity of the plant (tons/yr) Type(s) of process(es) (rotary spin, flame attenuation) at this plant Rotary Spin Operation schedule hrs/day 24 days/yr 365 Identify what state and local air pollution rules and regulations, including permit requirements, your plant is subject to. (Please provide copies of permit(s) and permit IDs)

Applicable requirements referenced in Title V Perm0039. Provided on CD.

III. Technical Contact Name Mike Pettis Technical Contact Title ISB Environmental Leader Telephone 740-877-7087 Facsimile (Fax) 740-328-2696 Email Mike.Pettis@owenscorning.com
FORM A-2

FACILITY INFORMATIONIV. Other Is the facility a major source of HAP? Yes, currently. If No, did the facility take a limit of its potential HAP emissions to avoid classification as a major source:

N/A

 Does the facility manufacture other products in addition to wool 

fiberglass?

No

 If Yes, list the other products manufactured at the facility. N/A Are there any HAP emissions associated with any co-located facilities? List unit operations, e.g., boiler, and pollutant/emissions.

N/A
FORM B-1

PLANT OPERATIONSI. Overview of Plant OperationsNumber of process lines. Include lines that are currently operational or that are temporarily shutdown. (Do not include lines permanently shutdown).

2

For each process line: Process Line 1 Process Line 2 Process line identification names or numbers DM1 DM2 Type of process line (e.g., rotary spin, flame attenuation) Rotary Spin Rotary Spin Maximum annual production rate (tons/yr) Age of process equipment (yrs) 34 32 Remaining economic life of process line (yrs) N/A. Continued 

maintenance can maintain indefinite life.

N/A. Continued maintenance can maintain indefinite life.

 List of products produced and most recent annual 

production (tons/yr; specify year) for each productPlease attach detailed schematics of each process line. Provided on CD. Provided on CD.
FORM B-2

PLANT OPERATIONSII. Process - Raw materials Handling and Storage Molten glass preparation Raw 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 and 

mechanically transferred to storage silos. Raw batch materials are mixed in the batch house and pneumatically conveyed to batch bins, where batch is augered into the 

furnaces.

Binder and Additives

 List each raw material, including premixed materials, in the binder formulation 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 into 

binder 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 to outside/inside? Binder mix and storage tanks are vented inside. Method of treating vent air from storage and mix tanks N/A Emission control during liquid raw material transfer from vehicles to storage tanks.

N/A

 Describe future source reduction plans and schedules to reformulate binders; List each constituent, proportions wt (%), cost 

($/gal) for reformulation
FORM B-3

PLANT OPERATIONSIII. Process - Glass Melting Furnace For each Glass Melting Furnace: Furnace 1 Furnace 2 Process unit identification name/number DM1 Melter (U-00002) DM2 Melter (U-00012) Process line(s) served (identification name/number) DM1 DM2  Latitude (decimal degrees, six decimal places) 42.5869769 42.5869769 Longitude (decimal degrees, six decimal places) -73.8734197 -73.8734197 Stack or vent height (units) 160 ft. 160 ft. Stack or vent diameter (units) 4.83 ft. 4.83 ft. Manufacturer and model Oxy-Fuel Oxy-Fuel Date of original installation 2001 1999 Estimate of remaining lifetime (yrs) N/A. Continued maintenance 

can maintain indefinite life.

N/A. Continued maintenance can maintain indefinite life.

 Major rebuilds: What constitutes a major rebuild Frequency of a major rebuild N/A N/A Cost of typical major rebuild N/A N/A Date of last major rebuild N/A N/A Purpose of last major rebuild N/A N/A Increase or decrease in emissions N/A N/A Fuel type: electric, gas, or oil Oxy-Fuel Oxy-Fuel Fuel consumption rate (KW/ton of glass or Btu/ton of glass) List HAPs that are in refractory material Chromium Compounds Chromium Compounds Design production rate (tons/day) Actual glass pull rate (tons/day) Vent gas flow rate (acfm @ °F)
FORM B-3

PLANT OPERATIONSIII. Process - Glass Melting Furnace For each Glass Melting Furnace: Furnace 1 Furnace 2 Temperature (°F) of molten glass in furnace and forehearth (if applicable) Nature and frequency of routine/preventive maintenance procedures

Daily, visible inspection of batch charge operations, furnace condition and burner / oxygen supply system. Repairs and replacements 

are routinely completed when need is identified. General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Refractory repairs are completed infrequently and only as necessary. 

Daily, visible inspection of batch charge operations, furnace condition and burner / oxygen supply system. Repairs and replacements 

are routinely completed when need is identified. General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Refractory repairs are completed infrequently and only as necessary. 

 Describe process modification(s) since 1999 that reduce emissions

The Company has established goals to reduce 

the environmental footprint of our manufacturing operations as part of our sustainability efforts. These goals are focused on reducing waste-tolandfill, GHG, water consumption, VOC's, particulate matter, NOx and energy. Converted to oxyfuel.

The Company has established goals to reduce 

the environmental footprint of our manufacturing operations as part of our sustainability efforts. These goals are focused on reducing waste-tolandfill, GHG, water consumption, VOC's, particulate matter, NOx and energy. Converted to oxyfuel.

 Describe future source reduction plans and schedules None currently approved or 

scheduled at this time.

None currently approved or scheduled at this time.
FORM B-4

PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame Attenuation For each Forming Operation -- Rotary Spin/Flame Attenuation Forming Operation 1 Forming Operation  Process unit identification name/number DM1 Forming (U-00003) DM2 Forming (U-00013 Process line(s) served (identification name/number) DM1 DM2  Latitude (decimal degrees, six decimal places) 42.5830081 (C WEP) and 

42.5830372 (D WEP)

42.5830081 (C WEP) an42.5830372 (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 Flame

 Is there a forehearth between the furnace and the forming 

section?

Yes Yes

 Major rebuilds: What constitutes a major rebuild The company undertakes

routine 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 undroutine repair and replaprojects. As with the these projects are normis” maintenance projects not impact the emissions. Thereforecompany does not cthese to be major rebthe purpose of this ICR.

 Frequency of a major rebuild N/A N/A Cost of typical major rebuild N/A N/A Date of last major rebuild N/A N/A Purpose of last major rebuild N/A N/A Increase or decrease in emissions N/A N/A If modular, number of modules and plenums Presence of water overspray and application rate (gpm) Binder applied and application rate (gpm) Other material applied and application rate (gpm) None None Temperature of glass fiber when binder is applied (°F)
FORM B-4

PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame Attenuation For each Forming Operation -- Rotary Spin/Flame Attenuation Forming Operation 1 Forming Operation  Process unit identification name/number DM1 Forming (U-00003) DM2 Forming (U-00013 Process line(s) served (identification name/number) DM1 DM2  Temperature of binder when applied to fibers (°F) Method of evenly distributing fibers onto forming conveyor Compressed air lapping system Compressed air lapping 

 Formed mat thickness (in.) 1"-6" as formed, up to 24" on 

ramp.

1"-6" as formed, up to 2ramp.

 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 maintenance procedures

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Repairs and replacements are 

performed when required during unscheduled downtimes. Basic, routine cleaning occurs every 6 to 12 weeks. Significant repairs such as chain and sprocket replacement, frame repair and track replacement generally occur with refractory replacement of the furnace.

General maintenance acfollow a prescribed schethat is detailed in the maintenance tracking syRepairs and replacemen

performed when requireunscheduled downtimesBasic, routine cleaning oevery 6 to 12 weeks. Significant repairs such chain and sprocket replacement, frame repatrack replacement geneoccur with refractory replacement of the furna
FORM B-4

PLANT OPERATIONSIV. Process - Forming -- Rotary Spin / Flame Attenuation For each Forming Operation -- Rotary Spin/Flame Attenuation Forming Operation 1 Forming Operation  Process unit identification name/number DM1 Forming (U-00003) DM2 Forming (U-00013 Process line(s) served (identification name/number) DM1 DM2  Describe process modification(s) since 1999 that reduce emissions Describe future source reduction plans and schedules None currently approved or 

scheduled at this time.

None currently approved scheduled at this time.
FORM B-5

PLANT OPERATIONSV. Process - Curing  For each Curing Oven: Curing Oven 1 Curing Oven 2 Process unit identification name/number DM1 Curing (U-00003) DM2 Curing (U-00013) Process line(s) served (identification name/number) DM1 DM2  Latitude (decimal degrees, six decimal places) 42.5827308 42.5849706 Longitude (decimal degrees, six decimal places) -73.8736803 -73.8738547 Stack or vent height (units) 60.99 ft. 59.09 ft. Stack or vent diameter (units) 9.97 ft. 9.97 ft. Method of curing  Manufacturer and model OC Proprietary Design OC Proprietary Design Date of original installation 1976 1978 Major rebuilds: What constitutes a major rebuild The company undertakes

routine 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 rebuild N/A N/A Cost of typical major rebuild N/A N/A Date of last major rebuild N/A N/A Purpose of last major rebuild N/A N/A Increase or decrease in emissions N/A N/A Fuel type: electric, gas, or oil Natural Gas Natural Gas Fuel consumption rate (KW/hr or BTU/hr) Moisture content wt (%) of formed mat:  inlet 2.5 - 5% 2.5 - 5% outlet <0.5% <0.5% Air flow rate (acfm @ °F) from curing 20000 acfm @ 4250F 20000 acfm @ 4250F Exhaust air temperature (°F) 425 °F 425 °F Residence time of product (mins)
FORM B-5

PLANT OPERATIONSV. Process - Curing  For each Curing Oven: Curing Oven 1 Curing Oven 2 Process unit identification name/number DM1 Curing (U-00003) DM2 Curing (U-00013) Process line(s) served (identification name/number) DM1 DM2  Binder content of cured product (LOI) Nature and frequency of routine/preventive maintenance procedures

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Repairs and replacements are 

performed when required during unscheduled downtimes. Basic, routine cleaning occurs every 6 to 12 weeks. Significant repairs such as chain and sprocket replacement, frame repair and track replacement generally occur with refractory replacement of the furnace.

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Repairs and replacements are 

performed when required during unscheduled downtimes. Basic, routine cleaning occurs every 6 to 12 weeks. Significant repairs such as chain and sprocket replacement, frame repair and track replacement generally occur with refractory replacement of the furnace.
FORM B-5

PLANT OPERATIONSV. Process - Curing  For each Curing Oven: Curing Oven 1 Curing Oven 2 Process unit identification name/number DM1 Curing (U-00003) DM2 Curing (U-00013) Process line(s) served (identification name/number) DM1 DM2  Describe process modification(s) since 1999 that reduce emissions Describe future source reduction plans and schedules

None currently approved or scheduled at this time.

None currently approved or scheduled at this time.
FORM B-6

PLANT OPERATIONSVI. Process - Cooling For each Cooling Operation: Cooling Operation 1 Cooling Operation 2

 Process unit identification name/number DM1 Cooling (U-00003) DM2 Cooling (U-00014) Process line(s) served (identification name/number) DM1 DM2 

 Latitude (decimal degrees, six decimal places) 42.584923 42.584923 Longitude (decimal degrees, six decimal places) -73.8727164 -73.8727164 Stack 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 °F

 Percentage of cooling air recirculated (if any) None None Cooling air temperature (°F) 117 °F 131 °F Nature and frequency of routine/preventive maintenance procedures

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Repairs and replacements are performed when required during unscheduled downtimes. Basic, routine cleaning occurs every 6 to 12 weeks. Significant repairs such as chain and sprocket replacement, frame repair and track replacement generally occur with refractory replacement of the furnace.

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Repairs and replacements are performed when required during unscheduled downtimes. Basic, routine cleaning occurs every 6 to 12 weeks. Significant repairs such as chain and sprocket replacement, frame repair and track replacement generally occur with refractory replacement of the furnace.
FORM B-6

PLANT OPERATIONSVI. Process - Cooling For each Cooling Operation: Cooling Operation 1 Cooling Operation 2

 Process unit identification name/number DM1 Cooling (U-00003) DM2 Cooling (U-00014) Process line(s) served (identification name/number) DM1 DM2 

 Describe process modification(s) since 1999 that reduce emissions Describe future source reduction plans and schedules None currently approved or 

scheduled at this time.

None currently approved or scheduled at this time.
FORM B-7

PLANT OPERATIONSVII. Process - Use of Solvents Use of Solvents Volatile solvents used at your facility (where and how used) N/A. No HAP-containing solvents used in the 

manufacturing process.

 List each solvent used and quantity (gal/yr) N/A. No HAP-containing solvents used in the 

manufacturing process.

 Emission control device(s) used to control emissions from solvent usage/storage?

N/A. No HAP-containing solvents used in the manufacturing process.
FORM B-8

PROCESS OPERATIONSVIII. Pollution PreventionPlease describe any work practices, pollution prevention techniques, and control strategies evaluated and/or implemented at each process unit 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 the practice/technique and identify the emission reductions (if measured) from these practices/techniques.
FORM C-1

AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP) For each ESP: ESP 1 ESP 2 Process line(s) (identification name/number) DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Melter (U-00002) (DEP - DM1EP)

DM1 Forming and Coo00003) (C WEP - FZEP

 Latitude (decimal degrees, six decimal places) 42.586977 42.585097 Longitude (decimal degrees, six decimal places) -73.873420 -73.873685 Stack or vent height (units) 160 ft. 105.0 ft. Stack or vent diameter (units) 4.83 ft. 4.58 ft. Manufacturer and model Alstom Power 1FTA 3x45F-35-

40

Alstom Power 1FTA 3x40

 Date of original installation 2000 2000 Number of collection plates and configuration 90/field 38/38/76 (fields 1-3) Gas flow rate to ESP (acfm @ °F) 28,700 acfm @ 479 °F 38,460 acfm @ 102 °F

 Inlet gas temperature (°F) 479 °F 102 °F

 Outlet gas temperature (°F) 450 °F 92 °F

 Inlet grain loading (gr/dscf) 0.4737 gr/dscf 0.0174 gr/dscf Outlet grain loading (gr/dscf) 0.0229 gr/dscf 0.0059 gr/dscf Average stack opacity (%) <20% <20% Pressure drop across ESP (in. H2O gauge) 3" 1"

 Plate area (ft2) 16,276 15,501

 Vendor 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 - Continuo

 Flow rate of plate wash water to ESP (gpm), if applicable N/A 200 - 300 gpm Temperature of plate wash water to ESP (°F), if applicable N/A 100 °F

 Source of plate wash water used for cleaning, if applicable N/A WEP Wash water Concentration (mg/l) of dissolved and suspended solids in plate 

wash water, if applicable

N/A Total Solids <0.75% av

 Conditioning agents used and amounts (in gpm or lbs/hr), if 

applicable

N/A None

 Amount of wastewater generated (gpd), if applicable N/A 0 gpd
FORM C-1

AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP) For each ESP: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point 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 model Date of original installation Number of collection plates and configuration Gas 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 frequency Flow rate of plate wash water to ESP (gpm), if applicable Temperature of plate wash water to ESP (°F), if applicable

 Source of plate wash water used for cleaning, if applicable Concentration (mg/l) of dissolved and suspended solids in plate 

wash water, if applicable Conditioning agents used and amounts (in gpm or lbs/hr), if applicable Amount of wastewater generated (gpd), if applicable

ESP 3 ESP 4

DM1 DM2 DM1 Forming and Cooling (U00003) (D WEP - FZEP2) DM2 Melter (U-00012) 

DM2EP)

42.585126 42.586977-73.873640 -73.873420105.0 ft. 160 ft.4.58 ft. 4.83 ft.Alstom Power 1FTA 3x45F-35-40

Alstom Power 1FTA 3x40

2000 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 minu200 - 300 gpm N/A100 °F N/AWEP Wash water N/ATotal Solids <0.75% avg. NANone N/A0 gpd N/A
FORM C-1

AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP) For each ESP: ESP 1 ESP 2 Process line(s) (identification name/number) DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Melter (U-00002) (DEP - DM1EP)

DM1 Forming and Coo00003) (C WEP - FZEP

 Amount of wastewater recycled (gpd), if applicable N/A 0 gpd Amount of wastewater disposed of (gpd), if applicable N/A 0 gpd Method of wastewater disposal, if applicable N/A N/A Quantity of solid waste collected (lbs/yr) 2,000 - 3,000 lbs. Small 

quantities of DEP residue becomes contaminated in the process and must be disposed.

N/A

 Quantity of solid waste recycled (lbs/yr) 0 lbs N/A Quantity of solid waste disposed of (lbs/yr) 2,000 - 3,000 lbs N/A Method of solid waste disposal Hazardous Waste Landfill N/A Nature and frequency of routine/preventive maintenance procedures

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Systems are continuously monitored and notifications 

occur that initiate maintenance. SIR repair and replacement is conducted as needed. Electrode replacement occurs on a a12-15 year cycle.

General maintenance afollow a prescribed schthat is detailed in the maintenance tracking sSystems are continuoumonitored and notificat

occur that initiate maintSIR repair and replacemconducted as needed. Electrode replacement on a a12-15 year cycle

 Problems experienced with control device within the last five years; how were problems solved?

As reported in Title V deviation reports: controller failure / repaired; and power loss / power restored.

As reported in Title V devreports: mechanical malfurepaired and reset; and efailure / repaired.
FORM C-1

AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP) For each ESP: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Amount of wastewater recycled (gpd), if applicable Amount of wastewater disposed of (gpd), if applicable Method of wastewater disposal, if applicable Quantity 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 disposal Nature and frequency of routine/preventive maintenance procedures Problems experienced with control device within the last five years; how were problems solved?

ESP 3 ESP 4

DM1 DM2 DM1 Forming and Cooling (U00003) (D WEP - FZEP2) DM2 Melter (U-00012) 

DM2EP)

0 gpd N/A0 gpd N/AN/A N/AN/A 2,000 - 3,000 lbs. Sma

quantities of DEP residbecomes contaminated process and must be d

N/A 0 lbsN/A 2,000 - 3,000 lbsN/A Hazardous Waste LandGeneral maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Systems are continuously monitored and notifications occur that initiate maintenance. SIR repair and replacement is conducted as needed. Electrode replacement occurs on a a12-15 year cycle.

General maintenance afollow a prescribed schthat is detailed in the maintenance tracking sSystems are continuoumonitored and notificat

occur that initiate maintSIR repair and replacemconducted as needed. Electrode replacement on a a12-15 year cycle

As reported in Title V deviation reports: equipment failure / repaired.

As reported in Title V devreports: electrical malfuncrepaired and reset.
FORM C-1

AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP) For each ESP: ESP 1 ESP 2 Process line(s) (identification name/number) DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Melter (U-00002) (DEP - DM1EP)

DM1 Forming and Coo00003) (C WEP - FZEP

 Continuous monitoring method(s) used to monitor ESP performance, including parameters monitored

Secondary voltage and amperage of 3rd field.

Secondary voltage and amperage of 3rd field.

 Describe any plans to replace or upgrade ESP None currently approved or 

scheduled at this time.

None currently approvescheduled at this time.
FORM C-1

AIR POLLUTION CONTROLI. Electrostatic Precipitator (ESP) For each ESP: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Continuous monitoring method(s) used to monitor ESP performance, including parameters monitored Describe any plans to replace or upgrade ESP

ESP 3 ESP 4

DM1 DM2 DM1 Forming and Cooling (U00003) (D WEP - FZEP2) DM2 Melter (U-00012) 

DM2EP)

Secondary voltage and amperage of 3rd field.

Secondary voltage and amperage of 3rd field.

None currently approved or scheduled at this time.

None currently approvescheduled at this time.
FORM C-2

AIR POLLUTION CONTROLII. Scrubber For each Scrubber: Scrubber 1 Scrubber 2  Process line(s) (identification name/number) DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Forming (U-00003) (Scrubber DM1S1)

DM1 Forming (U-00003) (Scrubber DM1S2)

 Latitude (decimal degrees, six decimal places) 42.584820 42.584820  Longitude (decimal degrees, six decimal places) -73.872816 -73.872816  Stack or vent height (units) 60.99 ft. 60.99 ft.  Stack or vent diameter (units) 9.97 ft. 9.97 ft.  Manufacturer and model OC Proprietary Design OC Proprietary Design 

 Date of original installation 2000 2000  Type (e.g., venturi, orifice) Venturi Venturi  Gas flow rate to scrubber (acfm @ °F) 30,000 acfm @ 100 °F 30,000 acfm @ 100 °F 

 Inlet gas temperature (°F) No data available. No data available. 

 Outlet gas temperature (°F) No data available. No data available. 

 Inlet grain loading (gr/dscf) No data available. No data available.  Outlet grain loading (gr/dscf) No data available. No data available.  Average stack opacity (%) <20% <20%  Water flow rate to scrubber (gpm) >170 gpm >100 gpm 

 Percent of scrubber water from recycled wastewater 100% 100% 

 Source of scrubbing water and type of pretreatment. Substance(s) added as part of pretreatment and amount used (gpm or lbs/hr)

Scrubber wash water system. No pretreatment.

Scrubber wash water system. No pretreatment.

 HAP composition of wastewater (mg/L) No data available. No data available.  Concentration (mg/L) of dissolved and suspended solids in 

scrubbing water

No data available. No data available. 

 Scrubbing water temperature (°F) 90-100 °F 90-100 °F 

 Liquid/gas ratio (gal/103 acfm) No data available. No data available. 

 Pressure drop across scrubber (in. H2O gauge) >4" >4" 

 Amount of wastewater generated (gpd) 0 gpd 0 gpd  Amount of wastewater recycled (gpd) 100% 100%  Amount of wastewater disposed of (gpd) 0 gpd 0 gpd 
FORM C-2

AIR POLLUTION CONTROLII. Scrubber For each Scrubber: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point 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 model Date of original installation Type (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 wastewater

 Source of scrubbing water and type of pretreatment. Substance(s) added as part of pretreatment and amount used (gpm or lbs/hr) HAP composition of wastewater (mg/L) Concentration (mg/L) of dissolved and suspended solids in scrubbing water Scrubbing water temperature (°F)

 Liquid/gas ratio (gal/103 acfm)

 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 

DM1 DM1 DM1 Forming (U-00003) 

(Scrubber DM1S4)

DM1 Forming (U-00003) (Scrubber DM1S5)

42.585126 42.584820 -73.873640 -73.872816 105.0 ft. 60.99 ft. 4.58 ft. 9.97 ft. OC Proprietary Design OC Proprietary Design 2000 2000 Venturi Venturi 44,800 acfm @ 91 °F 30,000 acfm @ 100 °F No data available. No data available. 97 °F No data available. No data available. No data available. 0.0206 gr/dscf No data available. <20% <20% >200 gpm >100 gpm 

100% 100% Scrubber wash water system. No pretreatment.

Scrubber wash water system. No pretreatment.

No data available. No data available. No data available. No data available. 90-100 °F 90-100 °F No data available. No data available. >4" >4" 

0 gpd 0 gpd 100% 100% 0 gpd 0 gpd 
FORM C-2

AIR POLLUTION CONTROLII. Scrubber For each Scrubber: Scrubber 1 Scrubber 2  Process line(s) (identification name/number) DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Forming (U-00003) (Scrubber DM1S1)

DM1 Forming (U-00003) (Scrubber DM1S2)

 Method of wastewater disposal N/A N/A  Quantity of solid waste collected (lbs/yr) Approximately 1,200,000 

lbs/yr solid waste from wash water system from all DM-1 sources.

Approximately 1,200,000 lbs/yr solid waste from wash water system from all DM-1 sources.

 Quantity of solid waste recycled (lbs/yr) N/A N/A  Quantity of solid waste disposed of (lbs/yr) Approximately 1,200,000 

lbs/yr solid waste from wash water system from all DM-1 sources.

Approximately 1,200,000 lbs/yr solid waste from wash water system from all DM-1 sources.

 Method of solid waste disposal Local Solid Waste Landfill Local Solid Waste Landfill  Vendor guarantee on scrubber efficiency (attach copy) N/A N/A  Nature and frequency of preventive maintenance procedures General maintenance 

activities follow a 

prescribed schedule that is detailed in the maintenance tracking system. Nozzles and flow patterns are checked daily; repairs are completed as needed. Cleaning is performed on a cycle matching machine downtime.

General maintenance activities follow a 

prescribed schedule that is detailed in the maintenance tracking system. Nozzles and flow patterns are checked daily; repairs are completed as needed. Cleaning is performed on a cycle matching machine downtime.
FORM C-2

AIR POLLUTION CONTROLII. Scrubber For each Scrubber: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Method of wastewater disposal Quantity 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 disposal Vendor guarantee on scrubber efficiency (attach copy) Nature and frequency of preventive maintenance procedures

Scrubber 4 Scrubber 5 

DM1 DM1 DM1 Forming (U-00003) 

(Scrubber DM1S4)

DM1 Forming (U-00003) (Scrubber DM1S5)

N/A N/A Approximately 1,200,000 lbs/yr solid waste from wash water system from all DM-1 sources.

Approximately 1,200,000 lbs/yr solid waste from wash water system from all DM-1 sources.

N/A N/A Approximately 1,200,000 lbs/yr solid waste from wash water system from all DM-1 sources.

Approximately 1,200,000 lbs/yr solid waste from wash water system from all DM-1 sources.

Local Solid Waste Landfill Local Solid Waste Landfill N/A N/A General maintenance activities follow a 

prescribed schedule that is detailed in the maintenance tracking system. Nozzles and flow patterns are checked daily; repairs are completed as needed. Cleaning is performed on a cycle matching machine downtime.

General maintenance activities follow a 

prescribed schedule that is detailed in the maintenance tracking system. Nozzles and flow patterns are checked daily; repairs are completed as needed. Cleaning is performed on a cycle matching machine downtime.
FORM C-2

AIR POLLUTION CONTROLII. Scrubber For each Scrubber: Scrubber 1 Scrubber 2  Process line(s) (identification name/number) DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Forming (U-00003) (Scrubber DM1S1)

DM1 Forming (U-00003) (Scrubber DM1S2)

 Problems experienced with control device within the last five years; how were problems solved?

As reported in Title V deviation reports: flow rate monitoring device malfunctioned / repaired; plugged water supply line / 

cleaned line; pump failure / repaired; water flow loss / monitored flow rate; and equipment failure / repairs made. 

As reported in Title V deviation reports: flow rate monitoring device malfunctioned / repaired; plugged water supply line / 

cleaned line; pump failure / repaired; water flow loss / monitored flow rate; and equipment failure / repairs made. 

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

Flow and Pressure Drop Flow and Pressure Drop 

 Plans to replace or upgrade scrubber None currently approved 

or scheduled at this time.

None currently approved or scheduled at this time.
FORM C-2

AIR POLLUTION CONTROLII. Scrubber For each Scrubber: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point designations (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 scrubber performance, including parameters monitored Plans to replace or upgrade scrubber

Scrubber 4 Scrubber 5 

DM1 DM1 DM1 Forming (U-00003) 

(Scrubber DM1S4)

DM1 Forming (U-00003) (Scrubber DM1S5)

As reported in Title V deviation reports: flow rate monitoring device malfunctioned / repaired; plugged water supply line / cleaned line; pump failure / repaired; and water flow loss / monitored flow rate. 

As reported in Title V deviation reports: flow rate monitoring device malfunctioned / repaired; plugged water supply line / 

cleaned line; pump failure / repaired; and water flow loss / monitored flow rate. 

Flow and Pressure Drop Flow and Pressure Drop None currently approved or scheduled at this time.

None currently approved or scheduled at this time.
FORM C-3

AIR POLLUTION CONTROLIII. Mechanical Collector Not applicable to this 

facility.

 For each Mechanical Collector: Mechanical Collector Process line(s) (identification name/number) N/A Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

N/A

 Latitude (decimal degrees, six decimal places) N/A Longitude (decimal degrees, six decimal places) N/A Stack or vent height (units) N/A Stack or vent diameter (units) N/A Manufacturer and model N/A Date of original installation N/A Type of mechanical collector N/A Gas flow rate to collector (acfm @ °F) N/A

 Inlet gas temperature (°F) N/A

 Outlet gas temperature (°F) N/A

 Inlet grain loading (gr/dscf) N/A Outlet grain loading (gr/dscf) N/A Average stack opacity (%) N/A Overall pressure drop (in. H2O gauge) N/A

 Vendor guarantee on mechanical collector efficiency (attach 

copy)

N/A

 Quantity of solid waste collected (lbs/yr) N/A Quantity of solid waste recycled (lbs/yr) N/A Quantity of solid waste disposed of (lbs/yr) N/A Method of solid waste disposal N/A Nature and frequency of preventive maintenance procedures N/A Problems experienced with control device within the last five 

years; how were problems solved?

N/A

 Continuous monitoring method(s) used to monitor performance, 

including parameters monitored

N/A

 Plans to replace or upgrade mechanical collector N/A
FORM C-4

AIR POLLUTION CONTROLIV. Fabric Filter  For each Fabric Filter: Fabric Filter 1 Fabric Filter 2 Process line(s) (identification name/number) DM1 DM2  Equipment/process(es) controlled. Include emission point 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) 42.584421 42.584502 Longitude (decimal degrees, six decimal places) -73.873346 -73.873496 Stack 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, Model 

GS4

Camfil FARR APC, Model GS4

 Date of original installation 2007 2007 Number of compartments 1 1 Number of bags per compartment 4 4 Filter material and coatings applied Polyester - Cellulosic Fibers Polyester - Cellulosic Fibers Fabric weight (oz/yd2) No data available. No data available.

 Filter surface area (ft2) 585 ft2 585 ft2

 Gas flow rate to filter (acfm @ °F) No data available. No data available.

 Inlet gas temperature (°F) Ambient Ambient

 Outlet gas temperature (°F) Ambient Ambient

 Inlet grain loading (gr/dscf) No data available. No data available. Outlet grain loading (gr/dscf) <0.02 gr/dscf <0.02 gr/dscf Average stack opacity (%) <20% <20% Overall pressure drop (in. H2O gauge) 2 - 6" 2 - 6"

 Method and frequency of bag cleaning Pulse Jet Cleaning Pulse Jet Cleaning Vendor guarantee on fabric filter efficiency (attach 

copy)

Provided on CD. Provided on CD.

 Quantity of solid waste collected (lbs/yr) N/A (Closed system returns 

collected dust to process.)

N/A (Closed system returns collected dust to process.)
FORM C-4

AIR POLLUTION CONTROLIV. Fabric Filter  For each Fabric Filter: Fabric Filter 1 Fabric Filter 2 Process line(s) (identification name/number) DM1 DM2  Equipment/process(es) controlled. Include emission point 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 returns 

collected dust to process.)

N/A (Closed system returns collected dust to process.)

 Quantity of solid waste disposed of (lbs/yr) 0 lbs 0 lbs Method of solid waste disposal N/A N/A Nature and frequency of preventive maintenance procedures

General maintenance repairs as needed. Visual inspections and differential pressure checks are performed routinely. Bag or cartridge replacement is 

performed as needed.

General maintenance repairs as needed. Visual inspections and differential pressure checks are performed routinely. Bag or cartridge replacement is performed as needed.

 Problems experienced with control device within the last five years; how were problems solved?

None reported in Title V deviation reports. 

None reported in Title V deviation reports. 

 Continuous monitoring method(s) used to monitor performance, including parameters monitored

N/A N/A

 Plans to replace or upgrade fabric filter None currently approved or 

scheduled at this time.

None currently approved or scheduled at this time.
FORM C-5

AIR POLLUTION CONTROLV. Thermal Incinerator For each Thermal Incinerator: Thermal Incinerator 1 Thermal Incinerator 2 Process line(s) (identification name/number) DM1 DM2  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Curing: Combined Exhaust (Forming/Curing) from Mixing Chamber (U00003)

DM2 Curing: Combined Exhaust (Forming/Curing) from Mixing Chamber (U00013)

 Latitude (decimal degrees, six decimal places) 42.5827308 42.5849706 Longitude (decimal degrees, six decimal places) -73.8736803 -73.8738547 Stack 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-48 Date of original installation 1974 1978 Fuel type: gas or oil Natural Gas Natural Gas Fuel consumption rate (BTU/hr) 5,846,400 BTU/hr 7,080,000 BTU/hr Inlet gas flow rate (acfm @ °F) 34,000 acfm @ 450 °F 34,000 acfm @ 450 °F

 Inlet gas temperature (°F) 425 - 450 °F 425 - 450 °F

 Combustion chamber gas temperature (°F) 1300 °F 1303 °F

 Outlet gas temperature (°F) 1320 °F (prior to heat 

recovery)

1320 °F (prior to heat recovery)

 Inlet grain loading (gr/dscf) No data available. No data available. Outlet grain loading (gr/dscf) Mixing chamber exhaust, 

including forming section: 

0.0153 gr/dscf

Mixing chamber exhaust, including forming section: 0.0164 gr/dscf

 Average 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 °F 

 Percent heat recovery 60% 48% Vendor guarantee on incinerator efficiency (attach 

copy)

None provided. None provided.
FORM C-5

AIR POLLUTION CONTROLV. Thermal Incinerator For each Thermal Incinerator: Thermal Incinerator 1 Thermal Incinerator 2 Process line(s) (identification name/number) DM1 DM2  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Curing: Combined Exhaust (Forming/Curing) from Mixing Chamber (U00003)

DM2 Curing: Combined Exhaust (Forming/Curing) from Mixing Chamber (U00013)

 Nature and frequency of preventive maintenance procedures

Annual inspections performed per MACT requirement and repairs made as needed.

Annual inspections performed per MACT requirement and repairs made as needed.

 Problems experienced with control device within the 

last five years; how were problems solved?

None reported in Title V deviation reports. 

None reported in Title V deviation reports. 

 Continuous monitoring method(s) used to monitor incinerator performance, including parameters monitored

Firebox Temperature Firebox Temperature

 Plans to replace or upgrade thermal incinerator None currently approved or 

scheduled at this time.

None currently approved or scheduled at this time.
FORM C-6

AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF) For each HVAF: HVAF 1 HVAF 2  Process line(s) (identification name/number) DM1 DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Cooling (U-00003) (Smoke Stripper): Common Exhaust with DM1 C WEP

DM1 Cooling (U-00003) (HEAF - DM1F1)

DM1 (SmoComm

WEP

 Latitude (decimal degrees, six decimal places) 42.585097 42.584981 42.58 Longitude (decimal degrees, six decimal places) -73.873685 -73.8724856 -73.8 Stack or vent height (units) 105.0 ft. 50.13 ft. 105.0  Stack or vent diameter (units) 4.58 ft. 3.5 ft. 4.58 f Manufacturer and model OC Proprietary Design Wheelabrator HEAF unit OC P Date of original installation 1990 1974 1990 Inlet gas flow rate (acfm @ °F) 3,000 - 5,000 acfm @ 110 - 

120 °F

 25,000 - 35,000 acfm @ 100 - 120 °F

3,000 120 °

 Inlet gas temperature (°F) 110 - 120 °F 100 - 120 °F 110 - 

 Outlet gas temperature (°F) 100 - 150 °F 100 - 120 °F 100 - 

 Inlet grain loading (gr/dscf) No data available. No data available. No da Outlet grain loading (gr/dscf) 0.003-0.15 gr/dscf .005-.010 gr/dscf 0.003 Average stack opacity (%) <20% <20% <20% Water spray pressure (sdig), if applicable No data available. No data available. No da Water spray rate (gpm), if applicable 10 - 20 gpm No data available. 10 - 2 Filter face velocity (acfm/ft2) No data available. No data available. No da

 Maximum pressure drop across mat (in. H2O gauge) 50" 32" 50"

 Vendor guarantee on HVAF efficiency (attach copy) N/A None provided. N/A Method and frequency of filter mad advancement Manually, once/twice per shift. Autofeed, as required by 

differential pressure.

Manu

 Amount of wastewater generated (gpd) 0 gpd 0 gpd 0 gpd Amount of wastewater recycled (gpd) 100% 100% 100% Amount of wastewater disposed of (gpd) 0 gpd 0 gpd 0 gpd
FORM C-6

AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF) For each HVAF: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point 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 model Date of original installation Inlet 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 applicable Water spray rate (gpm), if applicable Filter 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 advancement Amount of wastewater generated (gpd) Amount of wastewater recycled (gpd) Amount of wastewater disposed of (gpd)

HVAF 4 HVAF 5

DM2 DM2DM2 Cooling (U-00014) (HEAF)

DM-2 Cooling (U-00014) (Smoke Stripper)

42.585157 42.584963-73.8726875 -73.872660350.14 ft. 44.24 ft.5.00 ft. 1.17 ft.Wheelabrator Ultra Dyne 7248 OC Proprietary Design1974 1998 25,000 - 35,000 acfm @ 100 - 120 °F

3000-5000 acfm @ 1150F

115 °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 by differential pressure.

Manually, once/twice per shift.

0 gpd 0 gpd100% 100%0 gpd 0 gpd
FORM C-6

AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF) For each HVAF: HVAF 1 HVAF 2  Process line(s) (identification name/number) DM1 DM1 DM1  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Cooling (U-00003) (Smoke Stripper): Common Exhaust with DM1 C WEP

DM1 Cooling (U-00003) (HEAF - DM1F1)

DM1 (SmoComm

WEP

 Method of wastewater disposal N/A N/A N/A Quantity of solid waste collected (lbs/yr) 20,000 lbs/yr 100,000 lbs/yr 20,00 Quantity of solid waste recycled (lbs/yr) 0 lbs/yr 0 lbs/yr 0 lbs/ Quantity of solid waste disposed of (lbs/yr) 20,000 lbs/yr 100,000 lbs/yr 20,00 Method of solid waste disposal Local Solid Waste Landfill Local Solid Waste Landfill Local 

 Nature and frequency of preventive maintenance procedures

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Nozzles and flow patterns are checked daily; repairs are completed as needed. Cleaning is performed on a cycle matching machine downtime.

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Cleaning is performed on a cycle matched to machine downtime.

Genefollow that is maintNozzcheckcompCleancycle down

 Problems experienced with control device within the 

last five years; how were problems solved?

No malfunctions reported in Title V deviation reports. 

No malfunctions reported in Title V deviation reports. 

None devia

 Continuous monitoring method(s) used to monitor HVAF performance, including parameters monitored

N/A N/A N/A

 Plans to replace or upgrade HVAF None currently approved or 

scheduled at this time.

None currently approved or scheduled at this time.

None sched
FORM C-6

AIR POLLUTION CONTROLVI. High Velocity Air Filter (HVAF) For each HVAF: Process line(s) (identification name/number) Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan) Method of wastewater disposal Quantity 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 disposal Nature and frequency of preventive maintenance procedures Problems experienced with control device within the last five years; how were problems solved? Continuous monitoring method(s) used to monitor HVAF performance, including parameters monitored Plans to replace or upgrade HVAF

HVAF 4 HVAF 5

DM2 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 activities follow a prescribed schedule that is detailed in the maintenance tracking system. Cleaning is performed on a cycle matched to machine downtime.

General maintenance activities follow a prescribed schedule that is detailed in the maintenance tracking system. Nozzles and flow patterns are checked daily; repairs are completed as needed. Cleaning is performed on a cycle matching machine downtime.

None reported in Title V 

deviation reports. 

None reported in Title V deviation reports. 

N/A N/ANone currently approved or scheduled at this time.

None currently approved or scheduled at this time.
FORM C-7

AIR POLLUTION CONTROLVII. Mist Eliminator Not applicable to this facility. For each Mist Eliminator: Mist Eliminator Process line(s) (identification name/number) N/A Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 plot plan)

N/A

 Latitude (decimal degrees, six decimal places) N/A Longitude (decimal degrees, six decimal places) N/A Stack or vent height (units) N/A Stack or vent diameter (units) N/A Manufacturer and model N/A Date of original installation N/A Type of mist eliminator N/A Gas flow rate to mist eliminator (acfm @ °F) N/A

 Inlet gas temperature (°F) N/A

 Outlet gas temperature (°F) N/A

 Inlet grain loading (gr/dscf) N/A Outlet grain loading (gr/dscf) N/A Average stack opacity (%) N/A Velocity in mist eliminator (ft/sec) N/A Pressure drop (in. H2O gauge) N/A

 For chevron blade mist eliminators: N/A

 Spacing between blades (in.) N/A Washing frequency of blades N/A For mesh pad mist eliminators: N/A Number of pads or elements N/A Thickness of pad (in.) or element dimensions N/A Density of pad, (lb/ft3) N/A

 Washing frequency of pad N/A Vendor guarantee on mist eliminator efficiency (attach copy) N/A Amount of wastewater generated (gpd) N/A
FORM C-7

AIR POLLUTION CONTROLVII. Mist Eliminator Not applicable to this facility. For each Mist Eliminator: Mist Eliminator Amount of wastewater recycled (gpd) N/A Amount of wastewater disposed of (gpd) N/A Method of wastewater disposal N/A Quantity of solid waste collected (lbs/yr) N/A Quantity of solid waste recycled (lbs/yr) N/A Quantity of solid waste disposed of (lbs/yr) N/A Method of solid waste disposal N/A Nature and frequency of preventive maintenance procedures N/A Problems experienced with control device within the last five years; how were problems solved?

N/A

 Continuous monitoring method(s) used to monitor mist eliminator performance, including parameters monitored

N/A

 Plans to replace or upgrade mist eliminator N/A
FORM C-8

AIR POLLUTION CONTROLVIII. Ventilation System  For each Ventilation System: Ventilation System 1 Process line(s) (identification name/number) Furnace Hall Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

Fugitive / Furnace Vents

 Latitude (decimal degrees, six decimal places) 42.5845503 Longitude (decimal degrees, six decimal places) -73.8732922 Stack or vent height (units) Roof Height Stack or vent diameter (units) Multiple Locations For general or building ventilation: Ventilation system used Natural draft with wall 

and roof louvers.

 Airflow control system used Manually adjusted. Number of air changes per hour Estimated at 4-6 air 

changes per hour.

 For unit or local ventilation: Enclosure or hood design used N/A Volume of enclosure or hood N/A Capture velocity (ft/sec) N/A Distance between hood and emission source (ft) N/A
FORM C-9

AIR POLLUTION CONTROLIX. Other  For each Other Air Pollution Control Device (APCD): Other APCD 1 Other APCD 2 Process line(s) (identification name/number) DM1 DM2  Equipment/process(es) controlled. Include emission point designations (e.g., E3, E4 from plot plan)

DM1 Forming (U-00003) DM2 Forming (U-00013)

 Latitude (decimal degrees, six decimal places) 42.584820 42.584971 Longitude (decimal degrees, six decimal places) -73.872816 -73.87299 Stack or vent height (units) 60.99 ft. 59.09 ft. Stack or vent diameter (units) 9.97 ft. 9.97 ft.

Description Drop-Out Boxes and 

Penthouse

Drop-Out Boxes and Demister
FORM D

PROCESS LINE STARTUP AND SHUTDOWN 2005 - 2009 Semi-Annual MACT reports provided on CD.1. For each startup and shutdown (SS) that occurred during the last five years, please provide the following information requested in A. through J.  A. Using the definitions provided above, indicate whether the event was a startup or shutdown;

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

 B. A description of the event, including identification of the emissions source or sources associated with the startup or 

shutdown;

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

 C. Whether any permit condition was exceeded and, if so, what 

permit condition was exceeded;

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

 D. Whether the event was covered by any contingency plan for controlling emissions during startup and shutdown events and, if so, whether the plan was followed; if the plan was not followed, why not;

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

 E. The duration of the event; As indicated in the 2005 - 2009 Semi-Annual MACT Repo 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 Repo

 G. Estimates or measurements, if any, of emissions during the event; if you did not have the ability to quantify emissions during the 

event, please explain why;

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

 H. Whether the emission profile of each unit was different during startup and shutdown than during normal operating conditions and, if so, how emissions were different and why; please provide any 

supporting information;

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

 I. All performance test data collected during each period of SS; the test method used for each event; when the testing was conducted and why; the test conditions at the time of testing; and 

whether the tests were associated with a routine startup or shutdown; and

No data available.

 J. All monitoring data, including control system parameter 

monitoring, collected during each period of SS.

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

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 D

PROCESS LINE STARTUP AND SHUTDOWN 2005 - 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 emissions report) submitted to your permitting authority, you may submit copies of those reports instead.2. Are there any types of startup or shutdown events that you have been able to eliminate? If so, please describe the type of event and explain how these events were eliminated.

No.

3. Please submit a copy of your SS plan if you are required to 

develop one.

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

4. Please provide all performance test data collected during periods of SS over the last 5 years. Indicate the test method used for each 

event.

No data available.

5. Please provide all monitoring data, including control system parameter monitoring, collected during periods of SS over the last 5 

years. 

As indicated in the 2005 - 2009 Semi-Annual MACT Repo

6. Optional: Do you wish to recommend a standard that would apply 

during startup or shutdown? If so, please describe the event to which the standard would apply; the recommended standard (this could be an emission limitation, work practice, or operational standard) that would apply during the period; the basis for the recommended standard; why and how the standard would minimize emissions during the event; and how would compliance be determined and/or monitored. 

No.
FORM E

PRESENCE OF AIR POLLUTANTS IN EMISSION POINTSPlease provide any existing emissions information and data covering hazardous air pollutants (HAP) and particulate matter (PM) for each listed process. Identify the appropriate box for which you are providing specific process information and/or pollutant emissions data.

Melting Furnace Forming Curin

Particulate Matter (PM, PM 2.5, PM Condensable) 

Chromium Compounds and Hexavalent Chromium (including any Cr speciation 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 provided to EPA by the industry’s trade association, the North 

American Insulation Manufacturers Association (“NAIMA”). The existing data provided by NAIMA was set forth in 

NAIMA’s May 5, 2010 letter to EPA. The existing emissions data provided from fiber glass companies included 

test 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 included 

test results for the following pollutants: formaldehyde, methanol, phenol, particulate matter, carbon monoxide, 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 industry

representatives. In addition to the existing data submitted to EPA, extensive new emissions data is being collected from virtually all companies through the “BTEC, Inc. Quality Assurance Project Plan for the Mineral Wool and Wool Fiberglass Emissions Test Program.” This Test Program will collect and submit to EPA, through EPA’s Electronic Reporting 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, nickel and selenium), mercury and hexavalent chromium.
FORM F-1 

COSTI. Process Unit (e.g., cupola, curing oven, etc.):

For each Process Unit:

 Process Unit ID Process Line IDII. Capital Costs Base year Total capital cost, including costs for individual pieces, if available.III. Annual Operating Costs Base year (most recent fiscal year) Total annual operating costs Maintenance materials and replacement parts (specify costs by item) Raw materials costs Labor ($/yr) for each labor class (hr/hr) for each labor class Utilities (breakdown for each utility) Waste treatment and/or disposal Costs associated with any work practices and pollution prevention techniques that are employed at your facility Savings associated with heat recovery and wastewater and/or solid waste returned to process from APCD (or sold to another user) Indirect costs Other (specify)Please provide the annual report to shareholders or equivalent for the most recent fiscal year. If reports are not available, provide annual sales and profits (or profit margin) for the most recent fiscal year. If company is publicly 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 serelevant to the EPA Administrator's review obligatioAct Section 112(d)(6) and 112(f)(2).
FORM F-1 

Can your product(s) be substituted by another product(s)? If so, please list your product(s) and substituted product(s).

Wool fiberglass insulation comprises the major maresidential insulation material used in the United SThe remaining market consists of cellulose (scrap newspaper) treated to resist fires, spray foam, foaboards, cotton treated to resist fires, and wool trearesist fires.Wool fiberglass insulation is preferred over these alternative insulation materials because it is easilyeconomically, and safety installed in various buildinsettings, has superior fire performance capabilities70-year history of proven performance and durabil
FORM F-2

COSTI. Air Pollution Control Device (APCD) For each APCD: APCD ID Process Unit IDII. Capital Costs Base year  APCD equipment purchase cost and what was included List the cost for each piece of auxiliary equipment for each APCD not included above Installation cost Land purchase cost Total capital cost Method of financing APCD Retrofit installation Field erected or modularIII. Annual Operating Costs Base year (most recent fiscal year) Maintenance materials and replacement parts (specify costs by item) Raw materials costs Labor ($/yr) for each labor class (hr/hr) for each labor class Utilities (breakdown for each utility) Waste treatment and/or disposal Indirect costs Other (specify)

The company objects to this request because it serelevant to the EPA Administrator's review obligatioAct Section 112(d)(6) and 112(f)(2).
FORM F-2

 Total annual operating cost (most recent fiscal year)Attach annual report to shareholders or equivalent for the most recent fiscal year. Alternatively, if company is publicly owned, you can provide your company's web link to this information.