Title 40: Protection of Environment

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fr"  PART 63—NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS
FOR SOURCE CATEGORIES (CONTINUED) 

Subpart DDD—National Emission Standards for Hazardous Air Pollutants
for Mineral Wool Production

Source:   64 FR 29503, June 1, 1999, unless otherwise noted. 

§63.1175  What is the purpose of this subpart?

This subpart establishes national emission standards for hazardous air
pollutants emitted from existing, new, and reconstructed cupolas and
curing ovens at facilities that produce mineral wool.

§63.1176  Where can I find definitions of key words used in this
subpart?

The definitions of key words used in this subpart are in the Clean Air
Act (Act), in §63.2 of the general provisions in subpart A of this
part, and in §63.1196 of this subpart.

§63.1177  Am I subject to this subpart?

You are subject to this subpart if you own or operate an existing, new,
or reconstructed mineral wool production facility that is located at a
plant site that is a major source of hazardous air pollutant (HAP)
emissions, meaning the plant emits or has the potential to emit any
single HAP at a rate of 9.07 megagrams (10 tons) or more per year or any
combination of HAPs at a rate of 22.68 megagrams (25 tons) or more per
year.

Standards

§63.1178  For cupolas, what standards must I meet?

(a) You must control emissions from each cupola as follows:

(1) Limit emissions of particulate matter (PM) from each existing, new,
or reconstructed cupola to 0.05 kilograms (kg) of PM per megagram (MG)
(0.10 pound [lb] of PM per ton) of melt or less.

(2) Limit emissions of carbonyl sulfide (COS) carbon monoxide (CO) from
each existing, new, or reconstructed cupola to either of the following:

(i) 3.3 lb of COS per ton of melt or less for existing cupolas.0.05 kg
of CO per MG (0.10 lb of CO per ton) of melt or less

(ii) 0.017 lb of COS per ton of melt or less for new or reconstructed
cupolas.A reduction of uncontrolled CO emissions by at least 99 percent.

(3) Limit emissions of hydrogen fluoride (HF) from each existing, new,
or reconstructed cupola to 0.014 lb of HF per ton of melt or less.

(4) Limit emissions of hydrogen chloride (HCl) from each existing, new,
or reconstructed cupola to 0.0096 lb of HCl per ton of melt or less.

(b) You must meet the following operating limits for each cupola:

(1) Begin within one hour after the alarm on a bag leak detection system
sounds, and complete in a timely manner, corrective actions as specified
in your operations, maintenance, and monitoring plan required by
§63.1187 of this subpart.

(2) When the alarm on a bag leak detection system sounds for more than
five percent of the total operating time in a six-month reporting
period, develop and implement a written quality improvement plan (QIP)
consistent with the compliance assurance monitoring requirements of
§64.8(b)–(d) of 40 CFR part 64.

(3) Additionally, for each new or reconstructed cupola, maintain the
operating temperature of the incinerator so that the average operating
temperature for each three-hour block period never falls below the
average temperature established during the performance test.

§63.1179  For combined collection/curing operations ovens, what
standards must I meet?

(a) You must control emissions from each existing, new, or reconstructed
combined collection/curing oven operation by limiting emissions of
formaldehyde, phenol, and methanol to either of the following:

(1) For combined drum collection/curing operations: 0.03 kg of
formaldehyde per MG (0.06 lb of formaldehyde per ton) of melt or less.

(i) 0.067 lb of formaldehyde per ton of melt or less, 

(ii) 0.0023 lb of phenol per ton of melt or less, and 

(iii) 0.00077 lb of methanol per ton of melt or less. 

(2) For combined horizontal collection/curing operations:

(i) 0.054 lb of formaldehyde per ton of melt or less, 

(ii) 0.15 lb of phenol per ton of melt or less, and 

(iii) 0.022 lb of methanol per ton of melt or less.A reduction of
uncontrolled formaldehyde emissions by at least 80 percent.

(3) For combined vertical collection/curing operations:

(i) 0.46 lb of formaldehyde per ton of melt or less, 

(ii) 0.52 lb of phenol per ton of melt or less, and 

(iii) 0.63 lb of methanol per ton of melt or less. 

(b) You must meet the following operating limits for each combined
collection/curing ovenoperations subcategory:

(1) Maintain the free-formaldehyde content of each resin lot and the
formaldehyde content of each binder formulation at or below the
specification ranges of the resin and binder used during the performance
test.

(2) Maintain the operating temperature of each incinerator so that the
average operating temperature for each three-hour block period never
falls below the average temperature established during the performance
test.

§63.1180  When must I meet these standards?

(a) Existing cupolas and combined collection/curing ovensoperations. (1)
Except as noted in paragraph (2) of this section, the compliance date
for an owner or operator of an existing plant or source subject to the
provisions of this subpart is June 2, 2002 or June 3, 2003 if you
applied for and received a one-year extension under section
112(i)(b)(3)(B) of the Act.

(2) The compliance dates for existing plants and sources are:

(i) [INSERT DATE 3 YEARS AFTER PUBLICATION OF THE FINAL RULE IN THE
FEDERAL REGISTER] for cupolas and combined collection/curing operations
subject to emission limits in §§63.1178 and 63.1179 which became
effective [INSERT DATE OF PUBLICATION OF THE FINAL RULE IN THE FEDERAL
REGISTER].

(ii) [INSERT DATE OF PUBLICATION OF THE FINAL RULE IN THE FEDERAL
REGISTER] for the provisions related to malfunctions and affirmative
defense provisions of paragraph (e) of this section and the electronic
reporting provisions of §§63.1192(d) and 63.1193(b)(1) and (g).

. You must install any control devices and monitoring equipment
necessary to meet the standards in this subpart, complete performance
testing, and demonstrate compliance with all requirements of this
subpart no later than the following:

(1) June 2, 2002; or

(2) June 3, 2003 if you apply for and receive a one-year extension under
section 112(i)(3)(B) of the Act.

(b) New and reconstructed cupolas and combined collection/curing ovens.
For affected sources that commenced construction or reconstruction after
[INSERT DATE OF PUBLICATION OF THIS PROPOSED RULE IN THE FEDERAL
REGISTER], you must demonstrate compliance with the requirements of this
subpart no later than the effective date of the rule or upon
start-up.You must install any control devices or monitoring equipment
necessary to meet the standards in this subpart, complete performance
testing, and demonstrate compliance with all requirements of this
subpart by the dates in §63.7 of the general provisions in subpart A of
this part.

(c) You must comply with the standards in §§63.1178 and 63.1179 of
this subpart on and after the dates in paragraphs (a) and (b) of this
section.

(d) See §63.1197 for requirements during startups and shutdowns. You
must comply with these standards at all times except during periods of
startup, shutdown, or malfunction.

(e) Affirmative Defense for Exceedance of Emissions limits During
Malfunction. In response to an action to enforce the standards set forth
in this subpart, you may assert an affirmative defense to a claim for
civil penalties for exceedances of such standards that are caused by
malfunction, as defined at §63.2. Appropriate penalties may be
assessed, however, if you fail to meet your burden of proving all of the
requirements in the affirmative defense. The affirmative defense must
not be available for claims for injunctive relief.

(1) To establish the affirmative defense in any action to enforce such a
limit, you must timely meet the notification requirements in §63.1191
of this subpart, and must prove by a preponderance of evidence that:

(i) The excess emissions: 

(A) Were caused by a sudden, infrequent, and unavoidable failure of air
pollution control and monitoring equipment, process equipment, or a
process to operate in a normal or usual manner; and

(B) Could not have been prevented through careful planning, proper
design or better operation and maintenance practices; and 

(C) Did not stem from any activity or event that could have been
foreseen and avoided, or planned for; and

(D) Were not part of a recurring pattern indicative of inadequate
design, operation, or maintenance.

(ii) Repairs were made as expeditiously as possible when the applicable
emissions limitations were being exceeded. Off-shift and overtime labor
were used, to the extent practicable to make these repairs; and

(iii) The frequency, amount and duration of the excess emissions
(including any bypass) were minimized to the maximum extent practicable
during periods of such emissions; and

(iv) If the excess emissions resulted from a bypass of control equipment
or a process, then the bypass was unavoidable to prevent loss of life,
personal injury, or severe property damage; and

(v) All possible steps were taken to minimize the impact of the excess
emissions on ambient air quality, the environment and human health; and

(vi) All emissions monitoring and control systems were kept in operation
if at all possible, consistent with safety and good air pollution
control practices; and

(vii) All of the actions in response to the excess emissions were
documented by properly signed, contemporaneous operating logs; and 

(viii) At all times, the affected source was operated in a manner
consistent with good practices for minimizing emissions; and

(ix) A written root cause analysis has been prepared, the purpose of
which is to determine, correct, and eliminate the primary causes of the
malfunction and the excess emissions resulting from the malfunction
event at issue. The analysis must also specify, using best monitoring
methods and engineering judgment, the amount of excess emissions that
were the result of the malfunction. 

(2) Notification. The owner or operator of the affected source
experiencing an exceedance of its emissions limit(s) during a
malfunction, must notify the Administrator by telephone or facsimile
transmission as soon as possible, but no later than two business days
after the initial occurrence of the malfunction, s/he wishes to be able
to use an affirmative defense to civil penalties for that malfunction.
The owner or operator seeking to assert an affirmative defense, must
also submit a written report to the Administrator within 45 days of the
initial occurrence of the exceedance of the standards in this subpart.
This report must demonstrate that the owner/operator met the
requirements set forth in paragraph (e) of this section and must include
all necessary supporting documentation. The owner or operator may seek
an extension of this deadline for up to 30 additional days by submitting
a written request to the Administrator before the expiration of the 45
day period. Until a request for an extension has been approved by the
Administrator, the owner or operator is subject to the requirement to
submit such report within 45 days of the initial occurrence of the
exceedance.

Compliance With Standards

§63.1181  How do I comply with the particulate matter standards for
existing, new, and reconstructed cupolas?

To comply with the PM standards, you must meet all of the following:

(a) Install, adjust, maintain, and continuously operate a bag leak
detection system for each fabric filter.

(b) Do a performance test as specified in §63.1188 of this subpart and
show compliance with the PM emission limits while the bag leak detection
system is installed, operational, and properly adjusted.

(c) Begin corrective actions specified in your operations, maintenance,
and monitoring plan required by §63.1187 of this subpart within one
hour after the alarm on a bag leak detection system sounds. Complete the
corrective actions in a timely manner.

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

§63.1182  How do I comply with the carbon monoxidecarbonyl sulfide,
hydrogen fluoride, and hydrogen chloride standards for existing, new,
and reconstructed cupolas?

To comply with the COS, HF, and HCl standards, you must meet all of the
following:

(a) Install, calibrate, maintain, and operate a device that continuously
measures the operating temperature in the firebox of each thermal
incinerator. For the purposes of this rule, the term ‘incinerator’
means ‘regenerative thermal oxidizer’ (RTO).

(b) Do Conduct a performance test as specified in §63.1188 of this
subpart and that shows compliance with the COS, HF, and HCl emissions
limits while the device for measuring incinerator (regenerative thermal
oxidizer) operating temperature is installed, operational, and properly
calibrated. Establish the average operating temperature as specified in
§63.1185(a) of this subpart.

(c) Following the performance test, measure and record the average
operating temperature of the incinerator as specified in §63.1185(b) of
this subpart.

(d) Maintain the operating temperature of the incinerator so that the
average operating temperature for each three-hour block period never
falls below the average temperature established during the performance
test.

(e) Operate and maintain the incinerator as specified in your
operations, maintenance, and monitoring plan required by §63.1187 of
this subpart.

§63.1183  How do I comply with the formaldehyde, phenol, and methanol
standards for existing, new, and reconstructed combined
collection/curing operationsovens?

To comply with the formaldehyde, phenol, and methanol standards, you
must meet all of the following:

(a) Install, calibrate, maintain, and operate a device that continuously
measures the operating temperature in the firebox of each thermal
incinerator.

(b) Do Conduct a performance test as specified in §63.1188 of this
subpart while manufacturing the product that requires a binder
formulation made with the resin containing the highest free-formaldehyde
content specification range. Show compliance with the formaldehyde,
phenol, and methanol emissions limits while the device for measuring
incinerator the control device operating temperature is installed,
operational, and properly calibrated. Establish the average operating
temperature as specified in §63.1185(a) of this subpart.

(c) During the performance test that uses the binder formulation made
with the resin containing the highest free-formaldehyde content
specification range, record the free-formaldehyde content specification
range of the resin used, and the formulation of the binder used,
including the formaldehyde content and binder specification.

(d) Following the performance test, monitor and record the
free-formaldehyde content of each resin lot and the formulation of each
batch of binder used, including the formaldehyde, phenol, and methanol
content.

(e) Maintain the free-formaldehyde content of each resin lot and the
formaldehyde, phenol, and methanol content of each binder formulation at
or below the specification ranges established during the performance
test.

(f) Following the performance test, measure and record the average
operating temperature of the incinerator as specified in §63.1185(b) of
this subpart.

(g) Maintain the operating temperature of the incinerator so that the
average operating temperature for each three-hour block period never
falls below the average temperature established during the performance
test.

(h) Operate and maintain the incinerator as specified in your
operations, maintenance, and monitoring plan required by §63.1187 of
this subpart.

(i) With prior approval from the Administrator, you may do short-term
experimental production runs using resin where the free-formaldehyde
content, or binder formulations where the formaldehyde content, is
higher than the specification ranges of the resin and binder used during
previous performance tests, or using experimental pollution prevention
process modifications without first doing additional performance tests.
Notification of intent to perform a short-term experimental production
run must include the following information:

(1) The purpose of the experimental run.

(2) The affected production process.

(3) How the resin free-formaldehyde content or binder formulation will
deviate from previously approved levels or what the experimental
pollution prevention process modifications are.

(4) The duration of the experimental run.

(5) The date and time of the experimental run.

(6) A description of any emissions testing to be done during the
experimental run.

Additional Monitoring Information

§63.1184  What do I need to know about the design specifications,
installation, and operation of a bag leak detection system?

A bag leak detection system must meet the following requirements:

(a) The bag leak detection system must be certified by the manufacturer
to be capable of detecting PM emissions at concentrations of 10
milligrams per actual cubic meter (0.0044 grains per actual cubic foot)
or less.

(b) The sensor on the bag leak detection system must provide output of
relative PM emissions.

(c) The bag leak detection system must have an alarm that will sound
automatically when it detects an increase in relative PM emissions
greater than a preset level.

(d) The alarm must be located in an area where appropriate plant
personnel will be able to hear it.

(e) For a positive-pressure fabric filter, each compartment or cell must
have a bag leak detector. For a negative-pressure or induced-air fabric
filter, the bag leak detector must be installed downstream of the fabric
filter. If multiple bag leak detectors are required (for either type of
fabric filter), detectors may share the system instrumentation and
alarm.

(f) Each triboelectric bag leak detection system must be installed,
operated, adjusted, and maintained so that it follows EPA's “Fabric
Filter Bag Leak Detection Guidance” (EPA–454/R–98–015, September
1997). Other bag leak detection systems must be installed, operated,
adjusted, and maintained so that they follow the manufacturer's written
specifications and recommendations.

(g) At a minimum, initial adjustment of the system must consist of
establishing the baseline output in both of the following ways:

(1) Adjust the range and the averaging period of the device.

(2) Establish the alarm set points and the alarm delay time.

(h) After initial adjustment, the range, averaging period, alarm set
points, or alarm delay time may not be adjusted except as specified in
the operations, maintenance, and monitoring plan required by §63.1187
of this subpart. In no event may the range be increased by more than 100
percent or decreased by more than 50 percent over a 365 day period
unless a responsible official as defined in §63.2 of the general
provisions in subpart A of this part certifies in writing to the
Administrator that the fabric filter has been inspected and found to be
in good operating condition.

§63.1185  How do I establish the average operating temperature of an
incinerator?

(a) During the performance test, you must establish the average
operating temperature of an incinerator as follows:

(1) Continuously measure the operating temperature of the incinerator.

(2) Determine and record the average temperatures in consecutive
15-minute blocks.

(3) Determine and record the arithmetic average of the recorded average
temperatures measured in consecutive 15-minute blocks for each of the
one-hour performance test runs.

(4) Determine and record the arithmetic average of the three one-hour
average temperatures during the performance test runs. The average of
the three one-hour performance test runs establishes the temperature
level to use to monitor compliance.

(b) To comply with the requirements for maintaining the operating
temperature of an incinerator after the performance test, you must
measure and record the average operating temperature of the incinerator
as required by §§63.1182 and 63.1183 of this subpart. This average
operating temperature of the incinerator is based on the arithmetic
average of the one-hour average temperatures for each consecutive
three-hour period and is determined in the same manner described in
paragraphs (a)(1) through (a)(4) of this section.

§63.1186  How may I change the compliance levels of monitored
parameters?

You may change control device and process operating parameter levels
established during performance tests and used to monitor compliance if
you do the following:

(a) You must notify the Administrator of your desire to expand the range
of a control device or process operating parameter level.

(b) Upon approval from the Administrator, you must conduct additional
performance tests at the proposed new control device or process
operating parameter levels. Before operating at these levels, the
performance test results must verify that, at the new levels, you comply
with the emission limits in §§63.1178 and 63.1179 of this subpart.

§63.1187   What do I need to know about operations, maintenance, and
monitoring plans?

(a) An operations, maintenance, and monitoring plan must be submitted to
the Administrator for review and approval as part of your application
for the title V permit.

(b) The operations, maintenance, and monitoring plan must include the
following:

(1) Process and control device parameters you will monitor to determine
compliance, along with established operating levels or ranges for each
process or control device.

(2) A monitoring schedule.

(3) Procedures for properly operating and maintaining control devices
used to meet the standards in §§63.1178 and 63.1179 of this subpart.
These procedures must include an inspection of each incinerator at least
once per year. At a minimum, you must do the following as part of an
incinerator inspection:

(i) Inspect all burners, pilot assemblies, and pilot sensing devices for
proper operation. Clean pilot sensor if necessary.

(ii) Ensure proper adjustment of combustion air, and adjust if
necessary.

(iii) Inspect, when possible, all internal structures (such as baffles)
to ensure structural integrity per the design specifications.

(iv) Inspect dampers, fans, and blowers for proper operation.

(v) Inspect motors for proper operation.

(vi) Inspect, when possible, combustion chamber refractory lining.
Clean, and repair or replace lining if necessary.

(vii) Inspect incinerator shell for proper sealing, corrosion, and/or
hot spots.

(viii) For the burn cycle that follows the inspection, document that the
incinerator is operating properly and make any necessary adjustments.

(ix) Generally observe whether the equipment is maintained in good
operating condition.

(x) Complete all necessary repairs as soon as practicable.

(4) Procedures for keeping records to document compliance.

(5) Corrective actions you will take if process or control device
parameters vary from the levels established during performance testing.
For bag leak detection system alarms, example corrective actions that
may be included in the operations, maintenance, and monitoring plan
include:

(i) Inspecting the fabric filter for air leaks, torn or broken bags or
filter media, or any other condition that may cause an increase in
emissions.

(ii) Sealing off defective bags or filter media.

(iii) Replacing defective bags or filter media, or otherwise repairing
the control device.

(iv) Sealing off a defective fabric filter compartment.

(v) Cleaning the bag leak detection system probe, or otherwise repairing
the bag leak detection system.

(vi) Shutting down the process producing the particulate emissions.

Performance Tests and Methods

§63.1188   What performance test requirements must I meet?

You must meet the following performance test requirements:

(a) All monitoring systems and equipment must be installed, operational,
and properly calibrated before the performance tests.

(b) Do Conduct a performance test, consisting of three test runs, for
each cupola and/or combined collection /curing oven operation subject to
this subpart at the maximum production rate to demonstrate compliance
with each of the applicable emission limits in §§63.1178 and 63.1179
of this subpart.

(c) Following the initial performance or compliance test to be conducted
within 120 days of [INSERT PROMULGATION DATE OF THE RULE] you must
conduct a performance test to demonstrate compliance with each of the
applicable emissions limits in §§63.1178 and 63.1179 of this subpart
at least once every 5 years and as often as the raw material ingredients
change by more than 10 percent of those processed during the previous
performance test.

(cd) Measure emissions of PM, COS, HF, HCl from each existing, new, or
reconstructed cupola.

 (d) Measure emissions of PM and CO from each new or reconstructed
cupola.

(e) Measure emissions of formaldehyde, phenol, and methanol from each
existing, new, or reconstructed combined collection/curing
ovenoperation.

(f) Measure emissions at the outlet of the control device if complying
with a numerical emission limit for PM, COS, HF, HCl, or formaldehyde,
phenol, or methanol.or at the inlet and outlet of the control device if
complying with a percent reduction emission limit for CO or
formaldehyde.

(g) To determine the average melt rate, measure and record the amount of
raw materials, excluding coke, charged into and melted in each cupola
during each performance test run. Determine and record the average
hourly melt rate for each performance test run. Determine and record the
arithmetic average of the average hourly melt rates associated with the
three performance test runs. The average hourly melt rate of the three
performance test runs is used to determine compliance with the
applicable emission limits.

(h) Compute and record the average emissions of the three performance
test runs and use the equations in §63.1190 of this subpart to
determine compliance with the applicable emission limits.

(i) Comply with control device and process operating parameter
monitoring requirements for performance testing as specified in this
subpart.

§63.1189   What test methods do I use?

You must use the following test methods to determine compliance with the
applicable emission limits:

(a) Method 1 in appendix A to part 60 of this chapter for the selection
of the sampling port locations and number of sampling ports.

(b) Method 2 in appendix A to part 60 of this chapter for stack gas
velocity and volumetric flow rate.

(c) Method 3 or 3A in appendix A to part 60 of this chapter for oxygen
and carbon dioxide for diluent measurements needed to correct the
concentration measurements to a standard basis.

(d) Method 4 in appendix A to part 60 of this chapter for moisture
content of the stack gas.

(e) Method 5 in appendix A to part 60 of this chapter for the
concentration of PM. Each PM test run must consist of a minimum run time
of three hours and a minimum sample volume of 3.75 dscm (135 dscf).

(f) Method 10 in appendix A to part 60 of this chapter for the
concentration of CO, using the continuous sampling option described in
section 7.1.1 of the method. Each CO test run must consist of a minimum
run time of one hour.

(g) Method 318 in appendix A to this part for the concentration of
formaldehyde, phenol, methanol, or COS.

(h) Method to determine the free-formaldehyde content of each resin lot
in appendix A of this subpart.

(i) Method 26A or 320 in appendix A to this part for the concentration
of HF and HCl.

§63.1190   How do I determine compliance?

(a) Using the results of the performance tests, you must use the
following equation to determine compliance with the PM emission limit:

 	(Eq. 1)

Where:

E 	=	Emission rate of PM, kg/Mg (lb/ton) of melt.

C 	=	Concentration of PM, g/dscm (gr/dscf).

Q 	=	Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr).

K 51	=	Conversion factor, 1 kg/1,000 g (1 lb/7,000 gr).

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

b) Using the results of the performance tests, you must use the
following equation to determine compliance with the COS, HF, HCl, and
formaldehyde, phenol, and methanol numerical emission limits:

 	(Eq. 2)

Where:

E 	= 	Emission rate of measured pollutant, kg/Mg (lb/ton) of melt.

C 	= 	Measured volume fraction of pollutant, ppm.

MW 	= 	Molecular weight of measured pollutant, g/g-mole:

COS 	= 	60.07, HF = 20.01, HCl = 36.46CO = 28.01, Formaldehyde = 30.03,
Phenol = 94.11, Methanol = 32.04..

Q 	= 	Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr).

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

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

K3	= 	Conversion factor, 24.45 L/g-mole.

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

(c) Using the results of the performance tests, you must use the
following equation to determine compliance with the CO and formaldehyde
percent reduction performance standards:

 

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where:

%R = Percent reduction, or collection efficiency of the control device.

Li= Inlet loading of pollutant, kg/Mg (lb/ton).

Lo= Outlet loading of pollutant, kg/Mg (lb/ton).

Notification, Recordkeeping, and Reporting

§63.1191  What notifications must I submit?

You must submit written or electronic notifications to the Administrator
as required by §63.9(b)–(h) of the general provisions in subpart A of
this part. Electronic notifications are encouraged when possible. These
notifications include, but are not limited to, the following:

(a) Notification that the following types of sources are subject to the
standard:

(1) An area source that increases its emissions so that it becomes a
major source.

(2) A source that has an initial startup before the effective date of
the standard.

(3) A new or reconstructed source that has an initial startup after the
effective date of the standard and doesn't require an application for
approval of construction or reconstruction under §63.5(d) of the
general provisions in subpart A of this part.

(b) Notification of intention to construct a new major source or
reconstruct a major source where the initial startup of the new or
reconstructed source occurs after the effective date of the standard and
an application for approval of construction or reconstruction under
§63.5(d) of the general provisions in subpart A of this part is
required.

(c) Notification of special compliance obligations for a new source that
is subject to special compliance requirements in §63.6(b)(3) and (4) of
the general provisions in subpart A of this part.

(d) Notification of a performance test at least 60 calendar days before
the performance test is scheduled to begin.

(e) Notification of compliance status.

§63.1192  What recordkeeping requirements must I meet?

You must meet the following recordkeeping requirements:

(a) Maintain files of all information required by §63.10(b) of the
general provisions in subpart A of this part, including all
notifications and reports.

(b) Maintain records of the following information also:

(1) Cupola production (melt) rate (Mg/hr (tons/hr) of melt).

(2) All bag leak detection system alarms. Include the date and time of
the alarm, when corrective actions were initiated, the cause of the
alarm, an explanation of the corrective actions taken, and when the
cause of the alarm was corrected.

(3) The free-formaldehyde content of each resin lot and the binder
formulation, including formaldehyde content, of each binder batch used
in the manufacture of bonded products.

(4) Incinerator operating temperature and results of incinerator
inspections. For all periods when the average temperature in any
three-hour block period fell below the average temperature established
during the performance test, and all periods when the inspection
identified incinerator components in need of repair or maintenance,
include the date and time of the problem, when corrective actions were
initiated, the cause of the problem, an explanation of the corrective
actions taken, and when the cause of the problem was corrected.

(c) Retain each record for at least five years following the date of
each occurrence, measurement, corrective action, maintenance, record, or
report. The most recent two years of records must be retained at the
facility. The remaining three years of records may be retained off site.

(d) Records must be maintained in a form suitable and readily available
for expeditious review, according to §63.10 of the General Provisions
that are referenced in Table 3 to this subpart. Electronic recordkeeping
is encouraged. Retain records on microfilm, on a computer, on computer
disks, on magnetic tape disks, or on microfiche.

(e) Report the required information on paper or on a labeled computer
disk using commonly available and compatible computer software.

§63.1193  What reports must I submit?

You must prepare and submit reports to the Administrator as required by
this subpart and §63.10 of the general provisions in subpart A of this
part. These reports include, but are not limited to, the following:

(a) A performance test report, as required by §63.10(d)(2) of the
general provisions in subpart A of this part, that documents the process
and control equipment operating parameters during the test period, the
test methods and procedures, the analytical procedures, all
calculations, and the results of the performance tests.

(b) (1) As of January 1, 2012 and within 60 days after the date of
completing each performance test, as defined in §63.2, and as required
in this subpart, you must submit performance test data, except opacity
data, electronically to the EPA’s Central Data Exchange by using the
ERT (see http://www.epa.gov/ttn/chief/ert/erttool.html/) or other
compatible electronic spreadsheet. Only data collected using test
methods compatible with the ERT are subject to this requirement to be
submitted electronically into the EPA’s WebFIRE database.A startup,
shutdown, and malfunction plan, as described in §63.6(e)(3) of the
general provisions in subpart A of this part, that contains specific
procedures for operating and maintaining the source during periods of
startup, shutdown, and malfunction and a program of corrective action
for malfunctioning process and control systems used to comply with the
emission standards. In addition to the information required by
§63.6(e)(3), your plan must include the following:

(1) Procedures to determine and record what caused the malfunction and
when it began and ended.

(2) Corrective actions you will take if a process or control device
malfunctions, including procedures for recording the actions taken to
correct the malfunction or minimize emissions.

(3) An inspection and maintenance schedule for each process and control
device that is consistent with the manufacturer's instructions and
recommendations for routine and long-term maintenance.

(c) A report of each event as required by §63.10(b) of the general
provisions in subpart A of this part, including a report if an action
taken during a startup, shutdown, or malfunction is inconsistent with
the procedures in the plan as described in §63.6(e)(3) of the general
provisions in subpart A of this part.

(d) An operations, maintenance, and monitoring plan as specified in
§63.1187 of this subpart.

(e) A semiannual report as required by §63.10(e)(3) of the general
provisions in subpart A of this part if measured emissions exceed the
applicable standard or a monitored parameter varies from the level
established during performance testing. The report must contain the
information specified in §63.10(c) of the general provisions, as well
as the relevant records required by §63.1192(b) of this subpart.

(f) A semiannual report stating that no excess emissions or deviations
of monitored parameters occurred during the reporting period as required
by §63.10(e)(3)(v) of the general provisions in subpart A of this part
if no deviations have occurred.

(g) All reports required by this subpart not subject to the requirements
in paragraph (b) of this section must be sent to the Administrator at
the appropriate address listed in §63.13. If acceptable to both the
Administrator and the owner or operator of a source, these reports may
be submitted on electronic media. The Administrator retains the right to
require submittal of reports subject to paragraph (b) of this section in
paper format.

Other Requirements and Information

§63.1194  Which general provisions apply?

The general provisions in subpart A of this part define requirements
applicable to all owners and operators affected by NESHAP in part 63.
See Table 1 of this subpart for general provisions that apply (or don't
apply) to you as an owner or operator subject to the requirements of
this subpart.

§63.1195  Who implements and enforces this subpart?

(a) This subpart can be implemented and enforced by the U.S. EPA, or a
delegated authority such as the applicable State, local, or Tribal
agency. If the U.S. EPA Administrator has delegated authority to a
State, local, or Tribal agency, then that agency, in addition to the
U.S. EPA, has the authority to implement and enforce this subpart.
Contact the applicable U.S. EPA Regional Office to find out if
implementation and enforcement of this subpart is delegated to a State,
local, or Tribal agency.

(b) In delegating implementation and enforcement authority of this
subpart to a State, local, or Tribal agency under subpart E of this
part, the authorities contained in paragraph (c) of this section are
retained by the Administrator of U.S. EPA and cannot be transferred to
the State, local, or Tribal agency.

(c) The authorities that cannot be delegated to State, local, or Tribal
agencies are as specified in paragraphs (c)(1) through (4) of this
section.

(1) Approval of alternatives to the requirements in §§63.1177 through
63.1180.

(2) Approval of major alternatives to test methods under
§63.7(e)(2)(ii) and (f), as defined in §63.90, and as required in this
subpart.

(3) Approval of major alternatives to monitoring under §63.8(f), as
defined in §63.90, and as required in this subpart.

(4) Approval of major alternatives to recordkeeping and reporting under
§63.10(f), as defined in §63.90, and as required in this subpart.

[68 FR 37356, June 23, 2003]

§63.1196 What definitions should I be aware of?

Terms used in this subpart are defined in the Act, in §63.2 of the
general provisions in subpart A of this part, and in this section as
follows:

Affirmative defense means, in the context of an enforcement proceeding,
a response or defense put forward by a defendant, regarding which the
defendant has the burden of proof, and the merits of which are
independently and objectively evaluated in a judicial or administrative
proceeding. 

Bag leak detection system means a monitoring device for a fabric filter
that identifies an increase in particulate matter emissions resulting
from a broken filter bag or other malfunction and sounds an alarm.

Bonded product means mineral wool to which a hazardous air
pollutant–based binder (containing such hazardous air pollutants as
phenol or formaldehyde) has been applied.

CO means, for purposes of this subpart, emissions of carbon monoxide
that serve as a surrogate for emissions of carbonyl sulfide, a compound
included on the list of hazardous air pollutants in section 112 of the
Act.

Combined collection/curing operations means the combination of fiber
collection operations and curing ovens used to make bonded products. 

Cupola means a large, water-cooled metal vessel to which is charged a
mixture of fuel, rock, and/or slag, and additives.  As the fuel is
burned, the charged mixture is heated to a molten state for later
processing to form mineral wool.

Curing oven means a chamber in which heat is used to thermoset a binder
on the mineral wool fiber used to make bonded products.

Fabric filter means an air pollution control device used to capture
particulate matter by filtering gas streams through fabric bags. It also
is known as a baghouse.

Formaldehyde means, for the purposes of this subpart, emissions of
formaldehyde that, in addition to being a HAP itself, serve as a
surrogate for organic compounds included on the list of hazardous air
pollutants in section 112 of the Act, including but not limited to
phenol.

Hazardous air pollutant means any air pollutant listed in or pursuant to
section 112(b) of the Act.

I means the owner or operator of a mineral wool production facility.

Incinerator means an enclosed air pollution control device that uses
controlled flame combustion to convert combustible materials to
noncombustible gases. For the purposes of this rule, the term
‘incinerator’ means ‘regenerative thermal oxidizer’ (RTO).

Melt means raw materials, excluding coke, that are charged into the
cupola, heated to a molten state, and discharged to the fiber forming
and collection process.

Melt rate means the mass of molten material discharged from a single
cupola over a specified time period.

Mineral wool means a fibrous glassy substance made from natural rock
(such as basalt), blast furnace slag or other slag, or a mixture of rock
and slag. It may be used as a thermal or acoustical insulation material
or in the making of other products to provide structural strength, sound
absorbency, fire resistance, or other required properties.

New source means any affected source the construction or reconstruction
of which is commenced after May 8, 1997.

PM means, for purposes of this subpart, emissions of particulate matter
that serve as a surrogate for metals (in particulate or volatile form)
on the list of hazardous air pollutants in section 112 of the Act,
including but not limited to: antimony, arsenic, beryllium, cadmium,
chromium, lead, manganese, nickel, and selenium.

You means the owner or operator of a mineral wool production facility.

§63.1197  Startups and shutdowns. 

(a) The provisions set forth in this subpart apply at all times.

(b) The owner or operator must not shut down items of equipment that are
utilized for compliance with this subpart.

(c) Table 1 to subpart DDD summarizes the emissions limits during
startups and shutdowns for existing, new, and reconstructed cupolas.

Table 1 to Subpart DDD-Emissions limits During Startups and Shutdowns
for Existing, New, and Reconstructed Cupolas, pound of pollutant per
hour

Pollutant	Emission Limit (lb/hr)

	Existing Cupolas	New and Reconstructed Cupolas

PM	1.0	1.0

COS	32	0.17

HF	0.13	0.13

HCl	0.092	0.092



(d) Table 2 to subpart DDD summarizes the emissions limits during
startups and shutdowns for existing, new, and reconstructed combined
collection/curing operations.

Table 2 to Subpart DDD-Emissions limits During Startups and Shutdowns
for Existing, New, and Reconstructed Combined Collection/Curing
Operations, pound of pollutant per hour

Design	Pollutant	Emission Limit (lb/hr)

Vertical	Formaldehyde	4.5

	Phenol	5.0

	Methanol	6.0

Horizontal	Formaldehyde	0.52

	Phenol	1.4

	Methanol	0.21

Drum	Formaldehyde	0.64

	Phenol	0.022

	Methanol	0.0074



§§63.11987-63.1199   [Reserved]

Table 1 3 to Subpart DDD of Part 63—Applicability of General
Provisions (40 CFR Part 63, Subpart A) to Subpart DDD of Part 63

General provisions

citation	Requirement	Applies to subpart DDD?	Explanation

63.1(a)(1)–(a)(4)	General Applicability	Yes

	63.1(a)(5)

No	[Reserved].

63.1(a)(6)–(a)(8)

Yes

	63.1(a)(9)

No	[Reserved].

63.1(a)(10)–(a)(14)

Yes

	63.1(b)	Initial Applicability Determination	Yes

	63.1(c)(1)	Applicability After Standard Established	Yes

	63.1(c)(2)

Yes	Some plants may be area sources.

63.1(c)(3)

No	[Reserved].

63.1(c)(4)–(c)(5)

Yes

	63.1(d)

No	[Reserved].

63.1(e)	Applicability of Permit Program	Yes

	63.2	Definitions	Yes	Additional definitions in §63.1196.

63.3	Units and Abbreviations	Yes

	63.4(a)(1)–(a)(3)	Prohibited Activities	Yes

	63.4(a)(4)

No	[Reserved].

63.4(a)(5)

Yes

	63.4(b)–(c)	Circumvention/Severability	Yes

	63.5(a)	Construction/Reconstruction Applicability	Yes

	63.5(b)(1)	Existing, New, Reconstructed Sources Requirements	Yes

	63.5(b)(2)

No	[Reserved].

63.5(b)(3)–(b)(6)

Yes

	63.5(c)

No	[Reserved].

63.5(d)	Application for Approval of Construction/Reconstruction	Yes

	63.5(e)	Approval of Construction/Reconstruction	Yes

	63.5(f)	Approval of Construction/Reconstruction Based on State Review
Yes

	63.6(a)	Compliance with Standards and Maintenance Applicability	Yes

	63.6(b)(1)–(b)(5)	New and Reconstructed Sources Dates	Yes

	63.6(b)(6)

No	[Reserved].

63.6(b)(7)

Yes

	63.6(c)(1)	Existing Sources Dates	Yes	§63.1180 specifies compliance
dates.

63.6(c)(2)

Yes

	63.6(c)(3)–(c)(4)

No	[Reserved].

63.6(c)(5)

Yes

	63.6(d)

No	[Reserved].

63.6(e)(1)(i)

No	See 63.1180 for general duty requirement.

63.6(e)(1)(ii)

No

	63.6(e)(1)(iii)

	63.6(e)(1)(iii)

63.6(e)(2)	Operation & Maintenance Requirements	YesNo	§63.1187
specifies additional requirements.

63.6(e)(3)	Startup, Shutdown, and Malfunction Plan	YesNo

	63.6(f)(1)	Compliance with Emission Standards	YesNo

	63.6(g)	Alternative Standard	Yes

	63.6(h)	Compliance with Opacity/VE Standards	No	Subpart DDD does not
include VE/opacity standards.

63.6(i)(1)–(i)(14)	Extension of Compliance	Yes	§63.1180 specifies
date.

63.6(i)(15)

No	[Reserved].

63.6(i)(16)

Yes

	63.6(j)	Exemption from Compliance	Yes

	63.7(a) – (d)	Performance Test Requirements Applicability	Yes

	63.7(b)	Notification	Yes

	63.7(c)	Quality Assurance/Test Plan	Yes

	63.7(d)	Testing Facilities	Yes

	63.7(e)(1)	Conduct of Tests	YesNo	See §63.11808 specifies additional
requirements.

63.7(e)(2)-(e)(4)

Yes

	63.7(f) – (h)	Alternative Test Method	Yes

	63.7(g)	Data Analysis	Yes

	63.7(h)	Waiver of Tests	Yes

	63.8(a) – (b)(1)	Monitoring Requirements Applicability	Yes

	63.8(a)(2)

No	Subpart DDD does not require CMS performance specifications.

63.8(a)(3)

No	[Reserved].

63.8(a)(4)

Yes

	63.8(b)	Conduct of Monitoring	Yes

	63.8(c)(1)(i)–(c)(3)	CMS Operation/Maintenance	YesNo

	63.8(c)(4)–(c)(8)ii)

NoYes	Subpart DDD does not require COMS or CMS performance
specifications.

63.8(c)(2)-(d)(2)

Yes

	63.8(d)(3)	Quality Control	Yes, except for last sentenceNo	Subpart DDD
does not require a CMS quality control program.

63.8(e) – (g)	CMS Performance Evaluation	NoYes	Subpart DDD does not
require CMS performance evaluations.

63.8(f)(1)–(f)(5)	Alternative Monitoring Method	Yes

	63.8(f)(6)	Alternative to RATA Test	No	Subpart DDD does not require
CEMS.

63.8(g)(1)	Data Reduction	Yes

	63.8(g)(2)

No	Subpart DDD does not require COMS or CEMS.

63.8(g)(3)–(g)(5)

Yes

	63.9(a), (b), (c), (e), (g), (h)(1) - (3), (h)(5) and (6), (i), and (j)
Notification Requirements Applicability	Yes

	63.9(b)	Initial Notifications	Yes

	63.9(c)	Request for Compliance Extension	Yes

	63.9(d)	New Source Notification for Special Compliance Requirements	Yes

	63.9(e)	Notification of Performance Test	Yes

	63.9(f)	Notification of VE/Opacity Test	No	Subpart DDD does not include
VE/opacity standards.

63.9(g)	Additional CMS Notifications	No	Subpart DDD does not require CMS
performance evaluation, COMS, or CEMS.

63.9(h)(1)–(h)(3)	Notification of Compliance Status	Yes

	63.9(h)(4)

No	[Reserved].

63.9(h)(5)–(h)(6)

Yes

	63.9(i)	Adjustment of Deadlines	Yes

	63.9(j)	Change in Previous Information	Yes

	63.10(a)	Recordkeeping/Reporting-Applicability	Yes

	63.10(b)(1)	General Recordkeeping Requirements	Yes	§63.1192 includes
additional requirements.

63.10(b)(2)(i)

No

	63.10(b)(2)(ii)

No	See §63.1193(c) for recordkeeping of occurrence and duration of
malfunctions and recordkeeping of actions taken during malfunction.

63.10(b)(2)(iii)

Yes

	63.10(b)(2)(iv)-(b)(2)(v)

No

	63.10(b)(2)(vi)-(b)(2)(xiv)

Yes

	63.(10)(b)(3)

Yes

	63.10(c)(1) – (9)	Additional CMS Recordkeeping	Yes

	63.10(c)(2)–(c)(4)

No	[Reserved].

63.10(c)(5)

Yes

	63.10(c)(6)

No	Subpart DDD does not require CMS performance specifications.

63.10(c)(7)–(c)(8)

Yes

	63.10(c)(9)

No	[Reserved].

63.10(c) (10)–(c11)(13)

YesNo	See §63.1192 for recordkeeping of malfunctions.

63.10(c)(12) - (14)

NoYes	Subpart DDD does not require a CMS quality control program.

63.10(c)(15)

YesNo

	63.10(d)(1) – (4)	General Reporting Requirements	Yes	Additional
requirements in §63.1193.

63.10(d)(2)	Performance Test Results	Yes

	63.10(d)(3)	Opacity or VE Observations	No	Subpart DDD does not include
VE/opacity standards.

63.10(d)( 4)–(d)(5)	Progress Reports/ Startup, Shutdown, and
Malfunction Reports	YesNo	See §63.1193 for reporting of malfunctions.

63.10(e) – (f)(1)–(e)(2)	Additional CMS Reports	NoYes	Subpart DDD
does not require CEMS or CMS performance evaluations.

63.10(e)(3)	Excess Emissions/CMS Performance Reports	Yes

	63.10(e)(4)	COMS Data Reports	No	Subpart DDD does not require COMS.

63.10(f)	Recordkeeping/Reporting Waiver	Yes

	63.11(a)	Control Device Requirements Applicability	YesNo	Flares will
not be used to comply with the emissions limits.

63.11(b)	Flares	No	Flares not applicable.

63.12 to 63.15	State Authority and Delegations	Yes

	63.13	Addresses	Yes

	63.14	Incorporation by Reference	Yes

	63.15	Information Availability/Confidentiality	Yes

	Appendix A to Subpart DDD of Part 63—Free Formaldehyde Analysis of
Insulation Resins by the Hydroxylamine Hydrochloride Method

1. Scope

The method in this appendix was specifically developed for water-soluble
phenolic resins that have a relatively high free-formaldehyde (FF)
content such as insulation resins. It may also be suitable for other
phenolic resins, especially those with a high FF content.

2.
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HCHO + NH2OH:HCl → CH2:NOH + H2O + HCl

b. Free formaldehyde in phenolic resins is present as monomeric
formaldehyde, hemiformals, polyoxymethylene hemiformals, and
polyoxymethylene glycols. Monomeric formaldehyde and hemiformals react
rapidly with hydroxylamine hydrochloride, but the polymeric forms of
formaldehyde must hydrolyze to the monomeric state before they can
react. The greater the concentration of free formaldehyde in a resin,
the more of that formaldehyde will be in the polymeric form. The
hydrolysis of these polymers is catalyzed by hydrogen ions.

2.2  The resin sample being analyzed must contain enough free
formaldehyde so that the initial reaction with hydroxylamine
hydrochloride will produce sufficient hydrogen ions to catalyze the
depolymerization of the polymeric formaldehyde within the time limits of
the test method. The sample should contain approximately 0.3 grams (g)
free formaldehyde to ensure complete reaction within 5 minutes.

3. Apparatus

3.1  Balance, readable to 0.01 g or better.

3.2  pH meter, standardized to pH 4.0 with pH 4.0 buffer and pH 7 with
pH 7.0 buffer.

3.3  50-mL burette for 1.0 N sodium hydroxide.

3.4  Magnetic stirrer and stir bars.

3.5  250-mL beaker.

3.6  50-mL graduated cylinder.

3.7  100-mL graduated cylinder.

3.8  Timer.

4. Reagents

4.1  Standardized 1.0 N sodium hydroxide solution.

4.2  Hydroxylamine hydrochloride solution, 100 grams per liter, pH
adjusted to 4.00.

4.3  Hydrochloric acid solution, 1.0 N and 0.1 N.

4.4  Sodium hydroxide solution, 0.1 N.

4.5  50/50 v/v mixture of distilled water and methyl alcohol.

5. Procedure

5.1  Determine the sample size as follows:

a. If the expected FF is greater than 2 percent, go to Part A in 5.1.c
to determine sample size.

b. If the expected FF is less than 2 percent, go to Part B in 5.1.d to
determine sample size.

c. Part A: Expected FF ≥2 percent.

Grams resin = 60/expected percent FF

I. The following table shows example levels:

Expected percent free formaldehyde	Sample size, grams

2	30.0

5	12.0

8	7.5

10	6.0

12	5.0

15	4.0



ii. It is very important to the accuracy of the results that the sample
size be chosen correctly. If the milliliters of titrant are less than 15
mL or greater than 30 mL, reestimate the needed sample size and repeat
the tests.

d. Part B: Expected FF < 2 percent

Grams resin = 30/expected percent FF

I. The following table shows example levels:

Expected percent free formaldehyde	Sample size, grams

2	15

1	30

0.5	60



ii. If the milliliters of titrant are less than 5 mL or greater than 30
mL, reestimate the needed sample size and repeat the tests.

5.2  Weigh the resin sample to the nearest 0.01 grams into a 250-mL
beaker. Record sample weight.

5.3  Add 100 mL of the methanol/water mixture and stir on a magnetic
stirrer. Confirm that the resin has dissolved.

5.4  Adjust the resin/solvent solution to pH 4.0, using the
prestandardized pH meter, 1.0 N hydrochloric acid, 0.1 N hydrochloric
acid, and 0.1 N sodium hydroxide.

5.5  Add 50 mL of the hydroxylamine hydrochloride solution, measured
with a graduated cylinder. Start the timer.

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

6. Calculations

 	(Eq. 3)

7. Method Precision
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This method was prepared by K.K. Tutin and M.L. Foster, Tacoma R&D
Laboratory, Georgia-Pacific Resins, Inc. (Principle written by R. R.
Conner.)

9. References

9.1  GPAM 2221.2.

9.2  PR&C TM 2.035.

9.3  Project Report, Comparison of Free Formaldehyde Procedures,
January 1990, K. Tutin.

Page   PAGE  3  of   NUMPAGES   49 

