Project XL
Project XL is a national pilot program of the U.S. Environmental Protection Agency(EPA) based on eXcellence and Leadership in environmental performance. It tests innovative ways of achieving the best performance and flexibility for manufacturers and increased involvement and local communities.
Andersen was the first company in Minnesota to have an XL project approved, and only the thirteenth nationally. In 1999, Andersen's Project XL Final Project Agreement was signed with the Environmental Protection Agency (EPA), Minnesota Pollution Control Agency (MPCA), and Washington County.
The Final Project Agreement provided the goals and commitments made by Andersen for superior environmental performance; which would be made enforceable through a Minnesota XL Permit. In May 2006, Andersen was issued the first XL Permit in Minnesota. This 10-year multi-media permit includes air, water, and waste requirements.
View Andersen Project XL Information.
Project XL Goals
Project Commitments
Other Environmental Demostrations
The Final Project Agreement established four overarching goals for the Andersen XL project.
Goal 1: Improve Environmental Performance
This project will test an innovative Performance Ratio measurement based on Volatile Organic Compound (VOC) emissions per standard measure of production. The Performance Ratio essentially locks in the best performing production methods and processes, preventing a return to historic methods with higher emission rates, while allowing the flexibility to search for even greater efficiencies and emissions improvements.
Goal 2: Maximize Local Public Understanding
Community members and other stakeholders will be informed about Project XL through the provision of easily accessible, understandable, verifiable and timely information. Stakeholders will continue to be engaged in the Project XL program through the Community Advisory Committee (CAC), the Andersen Community Update newsletter, Internet postings, news media contacts, open houses, displays and responses to community inquiries.
Goal 3: Remove Pollution Prevention Barriers
Andersen Corporation pioneered the production of high-performance, long-lasting, energy-efficient windows and patio doors. The company continues to develop new, more environmentally efficient products and processes. This Minnesota Project XL will shorten the implementation time of such changes by pre-authorizing more environmentally efficient products and processes. The facility emission caps will ensure that emissions from the Bayport Facility will not exceed past actual emissions.
Goal 4: Minimize Administrative Burden for Regulatory Agencies and Andersen Corporation
The Minnesota XL Permit will, to the extent possible, reduce the administrative burden through simplified monitoring, reporting and record keeping.
Andersen made commitments in the Final Project Agreement for Superior Environmental Performance that became enforceable through the XL permit.
Air Quality Emissions Caps
- Volatile Organic Compound (VOC) emissions are capped at a level of 2,397 tons per year under the Plantwide Applicability Limit (PAL). VOC PAL
- Particulate emissions from non-milling sources are initially capped at a level of 83 tons per year, and will eventually decrease to 55 tons per year after one full year of operation of the new boilers installed in 2007. Non-Milling Particulate Cap
Air Emissions Control
- VOC emissions from the Door Plant paintline will be controlled by a Regenerative Thermal Oxidizer (RTO).
- Particulate emissions from milling operations will be controlled with baghouse filters.
VOC Content
- Any new or reconstructed preservative application process shall not emit VOCs at a rate greater than 2.0 pounds per gallon of preservative used if the potential to emit is >40 tons per year.
- Any new or reconstructed paintline shall not emit VOCs at a rate greater than 4.5 pounds per gallon of coating applied if the potential to emit is >40 tons per year.
Health Risk Analysis
- Andersen conducted a health risk analysis for toxic air emissions, which included an air emissions risk analysis (AERA) and an inhalation assessment. The results of the analysis show that impacts of chemical emissions are within acceptable limits set by the Minnesota Department of Health. This analysis was approved by the MPCA in February 2003. Andersen will reassess the Health Risk Analysis throughout the life of the XL Permit as necessary when modifications occur.
Other Environmental Demonstrations
Andersen and the MPCA completed a variety of technical demonstrations during development of the XL Permit to assess environmental conditions.
Particulate Matter Air Dispersion Modeling - A condition of the XL Permit is that Andersen must show compliance with national ambient air quality standards for particulate matter through air quality modeling. Sources of particulates at Andersen include sawdust filters, boilers and vinyl processes. The modeling program is a computer simulated analysis of emissions, emission rates and weather conditions at receptor locations throughout Bayport and the surrounding area. The results of the analysis conform with both the national and the Minnesota ambient air quality standards. The MPCA approved this modeling. The XL Permit contains requirements for ongoing updates to the modeling as modifications to the facility occur.
Health Risk Analysis (one of the enforceable Project Commitments) – The air emissions risk analysis (AERA) and inhalation assessment was a study that examined the potential for impacts on the general population in and around Bayport due to Andersen's emissions of chemicals. A computer modeling study similar to that for particulate matter modeling was conducted. The results of the analysis show that impacts of chemical emissions are within acceptable limits set by the Minnesota Department of Health. The MPCA approved this analysis. The XL Permit contains requirements for reevaluations of the analysis as modifications to the facility occur.
Environmental Assessment Worksheet – The MPCA completed an Environmental Assessment Worksheet (EAW), which summarized the results of the particulate matter air dispersion modeling, the results of the air emissions risk analysis, and the evaluation of impacts to the surrounding environment. The EAW was placed on a 45-day public comment period by the MPCA in September 2003. On December 30, 2003, the MPCA Commissioner signed the “Findings of Fact, Conclusions of Law, and Order” document, which completed the EAW process.
