2018 Advanced Foundry Environmental Air Seminar

Cleveland Marriott East
October 7-8, 2018


This seminar is for individuals with a basic knowledge and understanding of EPA air regulations and air emission calculations. It will build on this basic knowledge, including concepts presented at the AFS Foundry Environmental 101 Seminar, with advanced practical knowledge, tools and techniques needed to address relatively complex air issues in foundries. This two-day seminar will cover four main topics – emission estimation, permitting, regulatory requirements, and compliance demonstration. For each topic, classroom instruction will be followed by a working group session where the class will be divided into subgroups to complete a hypothetical foundry air emission problem relating to that topic. Results will be reported to the class. 

Please bring your laptop computer. Each work group will need at least one laptop with Microsoft Excel to work on their group assignments, but two or three computers per table will be helpful. The instructors will provide pre-programmed electronic templates for completing the group assignments. 


  • Cleveland Marriott East
  • Warrensville Heights, Ohio
  • October 7-8, 2018
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Hotel Information

  • Cleveland Marriott East
  • Warrensville Heights, Ohio
  • $145/night

Group Name: AFS Advanced Air Seminar and EHS Conference

Room Block Release Date: September 21, 2018

Reservations must be received on or before 12:00 p.m. on September 21. At the cutoff the hotel will review the reservation pickup and release any unreserved rooms for general sale. Room reservations made after the cutoff date will be made on a space- and rate-available basis at the AFS group rate after this date.

Parking: Complimentary on-site parking.

The Hotel is expecting to sell out as October is their busiest month.  Please make your hotel reservations as soon as possible.

Travel Information

Airport/Hotel Transportation:

Cleveland Hopkins International Airport (CLE)


The Cleveland Marriott East does not provide shuttle service.

Estimated taxi fare: 45 USD (one way) / Hotel direction: 21 miles E

Driving Directions:

I-480 East to I-271 North. Exit 28B / Harvard Rd. Turn left at end of ramp. Hotel on left.

Rental Cars:

CLE has a consolidated rental car facility located off the airport grounds. Shuttle service is available for all rental car customers from the main terminal to the rental car facility. The rental car shuttle departs from the rental car shuttle door across from baggage claim 7. Rental car shuttles return customers to door 4 on arrivals level. Travelers can utilize the 2 banks of elevators across from the welcome center or escalators by claim 9 and claim 3 to access the departures level. For travelers needing assistance, a telephone center with rental car information is located at the info counter at Baggage Claim.

The shuttle bus ride from the terminal to the rental car facility takes approximately 5-7 minutes. The shuttle buses run continuously 24 hours a day, 7 days a week, 365 days a year.

The rental car facility is located at: 19601 Maplewood Avenue, Cleveland, OH 44135

Conference Agenda

Sunday, October 7, 2018
8:20 – 8:30 a.m.
Welcome, Introductions, and Announcements

Juliette Garesché, Sr. EHS Tech. Dir. AFS | IL

8:30 – 11:40 a.m.
Emission Estimation | Emission Estimation - Exercise 1

Jeet Radia, McWane Inc. | AL
Jim Schifo, Keramida Inc. | IN

  • Purposes for Emission Inventories
  • Foundry Sources & Pollutants
  • Emission Estimation Techniques & Tools
  • Emission Factors: Sources, Reliability,  & Errors Variability        
  • Estimating Greenhouse Gas Emissions

Tom Rarick, ERM | IN
Break into groups to calculate emissions for a foundry. If class demographics warrant, there will be both an iron/steel foundry example and a non-ferrous foundry example. The focus of the groups will be on calculation methods and factors, not regulatory concepts. Each group will present their solutions to the entire class.

11:45 a.m. – 12:45 p.m.
12:45 - 1:15 p.m.
Lunch Speaker

Speaker TBA

1:15 – 3:45 p.m.
Compliance Demonstration | Compliance Demonstration - Exercise 2

Bryant Esch, Waupaca Foundry Inc. | WI
Dan Plant, Metal Technologies Inc. | IN
Greg Kramer, ME Global Inc. | MN

  • Source Testing    
  • Compliance Monitoring
  • Title V Compliance Certification    
  • MACT Compliance     
  • Compliance Management in a Changing Environment    

Bryant Esch, Dan Plant, & Greg Kramer
Return to your assigned group. Using stack test results, determine if facility is within their permit limits and/or MACT rule requirements. Completing semiannual monitoring and annual compliance reports/certifications. Audit your facility relative to its permit and compliance requirements. Discuss the results of your exercise with the class.

Monday, October 8, 2018
8 – 11:30 a.m.
Permitting | Permitting - Exercise #3

Tom Rarick, ERM | IN
Craig Schmeisser, Covia | MI
Kathy Moore, Keramida Inc. | IN

  • Construction Permitting
  • State Permitting
  • NSR/PSD Permitting
  • Permitting Strategies and Avoidance (NSR/PSD, MACT)    
  • Operating Permits (including Title 5)

Tom Rarick

Return to groups formed during prior day’s sessions. Each group will determine the level of permitting required for the sources inventoried in the previous exercise. Modified emission units will be introduced. Determinations will be investigated as to whether and how the modification could avoid a higher-level permit review using a “synthetic minor” approach or by utilization of an alternative PSD applicability approach. Each group will discuss their solutions with the class.

11:30 a.m. - 12:30 p.m.
12:30 – 1:30 p.m.
Regulatory Requirements

Tom Rarick

  • Federal Regulations Impacting the Foundry Industry
  • State Regulations Impacting the Foundry Industry
  • NESHAPs (MACT & GACT) Affecting the Foundry Industry
  • Climate Change Legislation and Regulations
1:30 – 3:30 p.m.
Practical Control Technologies

Michael Johnson, BHA/Parker Hannifin Corp. | KS    

  • Practical Aspects of Control System Design/Selection
  • Common Foundry Emissions Control Systems                                                  
  • Control System Integration with Process
  • Control Device Troubleshooting
3:30 – 4 p.m.

Course ends no later than 4 p.m.


Cancellations & Substitutions

Substitutions will be accepted anytime. However, cancellations of confirmed registrants with full refund of fees will not be accepted unless received at least two weeks prior to the conference date. In the unlikely event the conference is cancelled for any reason, AFS liability is limited to the return of the registration fee.