HomeMy WebLinkAboutAQ_F_7300082_20211114_EI_Cmb-EI-File_2021 EI2021 Emissions Inventory Review / Data Tracking Form
Facility Name: CertainTeed Roxboro Wallboard Facility
Facility
Classification:
Title V
Assigned to:
Will Wike
Data Entry:
Person County
Confidential Copy Submitted?
YES
NO
Enter date received into ED. Date Received: _________________
Assigned to appropriate individual. Date Assigned: _________________ Date Due: __________________
Paper copy submitted: One copy received with supporting documentation, certification form signed by responsible
official, and appears generally complete; OR
Electronic copy submitted: All supporting documentation and certification form (with time/date stamp) signed by
responsible official has been received.
Comments:
Facility ID: 7300082
Initial Review / Data Entry
Inventory Review
All forms and supporting documentation appear to be complete if paper submission (check ED OS data if electronic).
Contact, address, phone number changes entered into I-Beam/Facilities if necessary.
All known operating scenarios, control devices, and emission release points have been entered for each emission
source (permitted, insignificant, and unpermitted) or note that the emission source was not operated or not required to report.
Check if SCC codes for each OS are accurate and update if needed.
Evaluate "U" sources for significance and address according to policy.
Calculations / forms appear to add up correctly.
All compliance issues are being addressed (e.g. Toxics limits, above TV thresholds, large emissions
increase/decrease, installation without a permit).
All volatile HAPs/TAPs were included in the VOC total.
Calculations and control efficiencies appear correct. Emission factors are the best available and most current factors
appropriate for the reporting facility (e.g. stack testing, AP-42, etc.).
Review facility comments and address any issues.
Update ED (Data Entry Main) if additional information is required (corrections due date and date received).
Check all ED QA/QC reports.
Comparison with previous emission inventory must be made and outliers (> 10%) must be investigated and explained.
Put inventory review comments and summarize any changes in ED - Data Entry Main "DAQ internal comments".
Date Review Complete: ___________________ Signature: _____________________________
Date Submitted to EI Coordinator: ___________________
Date Approved: ___________________ Initials: ___________________
Date Info Requested: ______________ Date Info Received: ______________ Total Days on Hold: ______
11/10/2022
11/09/2022
See notes at end of Facility Summary for explanation of each +/-10% difference in
emissions. Additional comments below will be shared with the facility (such as corrections made to throughputs
in the electronic submission).
11/14/2022
CertainTeed Roxboro Wallboard Facility 10024T05
7300082
Facility Name:
Facility ID #:
Permit #(s):
Facility Total CY 2021 Emission Summary Recorded in ED
Pollutant CAS CY 2021
from ED
CY 2020
from Fees
Green House Gases Pollutants (GHG)Actual Emissions
Tons/Yr %
ChangeDemini-
mus
Methane (CH4)74-82-8 0.975000 1.08 -9.8%10.0
Carbon Dioxide (CO2)124389 50,481.39 56,462.93 -10.6%5,000.0
Nitrous Oxide (N2O)10024972 0.130000 0.131300 -1.0%1.0
CO2 equivalent (sum of individual GHG pollutant emission
times their 1995 IPCC Global Warming Potential (GWP),
converted to metric tons)
45,851.85 metric tons
Criteria Pollutants
CY 2021
from ED
CY 2020
from Fees
(Tons/Year)
Actual Emissions
%
ChangePollutantCASDemini-
mus
14.3%44.6751.08CO 0.5CO
9.7%28.3131.07NOx 0.5NOx
15.8%27.3831.71TSP 0.5PM(TSP)
15.7%27.3331.62PM10 0.5PM10
15.6%27.2831.53PM2.5 0.5PM2.5
-14.7%0.3400000.290000SO2 0.5SO2
15.7%17.9820.80VOC 0.5VOC
Hazardous Air Pollutants (HAPs)
and/or Toxic Air Pollutants (TAPs)
CY 2021
from ED
CY 2020
from Fees
(Pounds/Year)
Actual Emissions
%
ChangePollutantCASDemini-
mus
Arsenic & Compounds (total mass of elemental AS, arsine and
all inorganic compounds)
0.198690 0.193780 2.5%0.01
N/A0.0009700.0011807784-42-1 0.01Arsenic Compounds - Arsine gas (Component of ASC)
2.4%0.1928100.197510ASC-Other 0.01Arsenic Unlisted Compounds - Specify Compound
(Component of ASC)
Beryllium & compounds (Total mass)0.011570 0.012370 -6.5%1.0
-6.5%0.0123700.0115707440-41-7 1.0Beryllium Metal (unreacted) (Component of BEC)
Page 1 of 411/10/2022
CertainTeed Roxboro Wallboard Facility 10024T05
7300082
Facility Name:
Facility ID #:
Permit #(s):
Facility Total CY 2021 Emission Summary Recorded in ED
Hazardous Air Pollutants (HAPs)
and/or Toxic Air Pollutants (TAPs)
CY 2021
from ED
CY 2020
from Fees
(Pounds/Year)
Actual Emissions
%
ChangePollutantCASDemini-
mus
Cadmium & compounds (total mass includes elemental metal)0.936130 1.02 -8.2%0.1
-8.3%1.020.9361307440-43-9 0.1Cadmium Metal, elemental, unreacted (Component of
CDC)
Chromium - All/Total (includes Chromium (VI) categories,
metal and others)
1.19 1.30 -8.5%0.1
-8.5%1.301.197738-94-5 0.01Chromic acid (VI) (Component of SolCR6 & CRC)
N/A0.0002700.000330CRC-Other 0.1Chromium Unlisted Compounds - Specify Compound
(Component of CRC)
Chromium (VI) Soluble Chromate Compounds (Component of
CRC)
1.19 1.30 -8.5%0.01
-8.5%1.301.197738-94-5 0.01Chromic acid (VI) (Component of SolCR6 & CRC)
Lead & compounds 0.449260 0.510140 -11.9%1.0
-11.9%0.5101400.449260PBC-Other 10.0Lead Unlisted Compounds - Specify Compound
(Component of PBC)
Manganese & compounds 0.497850 0.907130 -45.1%10.0
-45.1%0.9071300.497850MNC-Other 10.0Manganese Unlisted Compounds - Specify Compound
(Component of MNC)
Mercury & Compounds - all total mass includes Hg Vapor 0.228360 0.234810 -2.7%0.001
N/A0.0002500.000310HGC-Other 0.001Mercury Unlisted Compounds - Specify Compound
(Component of HGC)
-2.8%0.2345600.2280507439-97-6 0.001Mercury, vapor (Component of HGC)
Nickel & Compounds, sum total mass includes elemental 1.85 1.99 -7.0%1.0
-7.1%1.991.857440-02-0 1.0Nickel metal (Component of NIC)
Polycyclic Organic Matter (7 PAH Compounds for NIF)0.001070 0.001150 N/A1.0
N/A0.0011500.00107050-32-8 1.0Benzo(a)pyrene (Component of 83329/POMTV &
56553/7PAH)
Polycyclic Organic Matter (Specific Compounds from OAQPS
for TV)
0.536370 0.585650 -8.4%1.0
Page 2 of 411/10/2022
CertainTeed Roxboro Wallboard Facility 10024T05
7300082
Facility Name:
Facility ID #:
Permit #(s):
Facility Total CY 2021 Emission Summary Recorded in ED
Hazardous Air Pollutants (HAPs)
and/or Toxic Air Pollutants (TAPs)
CY 2021
from ED
CY 2020
from Fees
(Pounds/Year)
Actual Emissions
%
ChangePollutantCASDemini-
mus
N/A0.0011500.00107050-32-8 1.0Benzo(a)pyrene (Component of 83329/POMTV &
56553/7PAH)
-8.4%0.5845000.53530091-20-3 1.0Naphthalene (Component of 83329/POMTV)
-4.0%0.0365400.03509075-07-0 10.0Acetaldehyde
-25.8%0.0123300.009150107-02-8 10.0Acrolein
8.5%2,529.662,744.607664-41-7 100.0Ammonia (as NH3)
-9.8%2.171.9571-43-2 1.0Benzene
8.6%1,191.981,294.3850-00-0 10.0Formaldehyde
-10.6%1,727.031,543.30110-54-3 100.0Hexane, n-
-3.8%0.0339000.032600POM 1.0Polycyclic Organic Matter (Inc PAH, dioxins, etc. NC
& AP 42 historic)
-8.1%0.0245600.022580SEC 10.0Selenium Compounds
-10.5%3.322.97108-88-3 100.0Toluene
-1.7%0.0404800.0398001330-20-7 100.0Xylene (mixed isomers)
Largest Individual HAP
1,543.30 lbs
2,848.64 lbsTotal HAP Emissions
Hexane, n-
Largest Individual CAP 51.08 tons
Total CAP Emissions 134.86 tons
Total TAP Emissions 5,592.00 lbs
Total Aggregate
Emissions
136.23 tons
CO
Page 3 of 411/10/2022
DAQ's Comments Regarding Inventory
Natural gas combusted was not entered into AERO by the facility like it was for 2020. I followed up
with Neil Gresham and verified the 2021 natural gas values. I then updated the throughputs for the
four major sources of natural gas combustion (OS-16, -5, -9, and -10).
Explanation of +/-10% differences are as follows. Criteria pollutants (excluding SO2) appear to be
overestimated as reported, yet not overly significantly, and we have run out of review time in order to
make corrections. Criteria pollutants increased roughly 16% yet natural gas combustion decreased
(from the four largest sources) by 8.5%. The only other pollutant that was +/-10% and above
deminius levels is n-hexane. Emissions of n-hexane decreased by the same 8.5% as predicted by
natural gas usage.
Comments to facility
1 The Throughput values (line #5) on the emission inventory pages are all showing 4161 hours.
These values were modified to reflect the actual operating hours as shown on table 1 of the
customer¿s calculation sheets. These hours were not actually used on the DAQ sheets for the
calculation, but in order to gain consistency these values now agree with table 1.
2 Page 1 of AERO- no customer date after signature. This is not a major concern because the red
copy record date is on the top of the page.
3 Page 3 AERO ¿ No AERO entry sheet for IES-54. This item vents inside the building so it is
exempt.
4 Page 50 AERO- IES-50 is incomplete. I think that it did not operate. If so, this needs to be
designated as not operating.
5 First page of customer tables- Tables need to be identified. There are 6 tables on the first page.
The second page starts with table 2. Tables are not well identified and difficult to follow calculations .
6 First page of customer tables- the TWP links totals do not add up to 1242 lbs./yr. This column
adds up to 180. The totals do not adversely change any annual summaries because they are a low
value.
7 Customer table 8 Portland cement. Where is the calculation to get 271 lb./yr.? Table 1 shows
throughput of 14,836 pounds. AERO page 12 ¿ OS31 shows 0.33 tons = 660 pounds. The calculation
is not apparent.
8 General- The operation hours only make sense for items which use fuel. The fuel rate is known
for each burner. The hours of operation for material processing are not a determination for
throughput. Tons or pounds would correlate to emissions and emission factors .
9 More representative calculations need to be identified for the different processes .
Page 4 of 411/10/2022
CertainTeed Roxboro Wallboard Facility
7300082 10024T05
Facility Name:
Facility ID:Permit Number(s):
Emissions by Operating Scenario
for
CO
Operating Scenario
2021 Emission
Rate
(Tons/Yr)
Process
ID
Emission
Source ID
2021 Inventory
Emission
Source ID
2020 Emission
Rate
(Tons/Yr)
16 Remove moisture from finished
board - COMBUSTION
25.19 20.76
ES-40 ES-40
9 Removing some chemically
bonded moisture -
COMBUSTION
12.41 10.80
ES-09 ES-09
10 Removing some chemically bonded moisture -
COMBUSTION
12.18 10.70
ES-10 ES-10
5 Drying off free moisture from DSG in Cage Mill -
COMBUSTION
0.39 0.33
ES-02 ES-02
41 Natural gas hot water heater 0.29 0.48
IES-46 IES-46
42 Heating process water for the mixer 0.29 0.48
IES-46 IES-46
45 Impact Mill Scrap Processing- COMBUSTION 0.25 0.99
ES-42 ES-42
36 Back up power for fire pumps 0.06 0.06
ES-G1 ES-G1
37 Back up power for critical plant systems 0.02 0.02
IES-G2 IES-G2
39 Provide Infrared Heating to
paper before mixer
0.05
IES-50
51.08Total: 44.67
CertainTeed Roxboro Wallboard Facility
7300082 10024T05
Facility Name:
Facility ID:Permit Number(s):
Emissions by Operating Scenario
for
Hexane, n-
Operating Scenario
2021 Emission
Rate
(Pounds/Yr)
Process
ID
Emission
Source ID
2021 Inventory
Emission
Source ID
2020 Emission
Rate
(Pounds/Yr)
16 Remove moisture from finished
board - COMBUSTION
1,080.00 929.00
ES-40 ES-40
9 Removing some chemically
bonded moisture -
COMBUSTION
149.00 216.00
ES-09 ES-09
5 Drying off free moisture from DSG in Cage Mill -
COMBUSTION
148.00 303.00
ES-02 ES-02
10 Removing some chemically bonded moisture -
COMBUSTION
143.00 214.00
ES-10 ES-10
42 Heating process water for the mixer 12.50 20.60
IES-46 IES-46
45 Impact Mill Scrap Processing- COMBUSTION 10.80 42.40
ES-42 ES-42
39 Provide Infrared Heating to
paper before mixer
2.03
IES-50
1,543.30Total: 1,727.03