carolinas cement co. llc revised application quality/permits/psd... · the proposed barge loading...
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October 20, 2008
Dr. Donald R. van der Vaart, Ph.D, P.E.
Chief, Permitting Section
North Carolina Department of Environment and Natural Resources
2728 Capital Blvd.
Raleigh, North Carolina 27604
Re: Revised PSD Construction Permit Application
Carolinas Cement Company LLC
Dear Dr. van der Vaart:
Enclosed are revisions to our permit application (6 copies) to construct a Portland cement
manufacturing facility near Castle Hayne, North Carolina. This revision reflects several
requested changes and additions to the application as per the enclosed list.
The following items are highlighted:
Additional testing of onsite raw materials conducted after the original application was
submitted revealed significantly higher sulfur (sulfide) content in the rock. Because
uncontrolled SO2 emissions will be higher than previously estimated, we propose to install a
lime slurry injection system to control SO2 emissions from the kiln system during both raw
mill off and raw mill on operating conditions. We are also requesting that the SO2 emission
limit (30-day average) be increased. A revised Best Available Control Technology (BACT)
analysis and revised SO2 modeling analyses have been prepared in association with these
changes.
The proposed barge loading equipment and associated emission points (cement storage,
transfer, and loading spouts) are being removed, resulting in a decrease in particulate matter
emissions near the Northeast Cape Fear River.
Dr. Donald R. van der Vaart 2 October 20, 2008
We recognize that the U.S. Environmental Protection Agency (EPA) has recently proposed
significant changes to the New Source Performance Standards (NSPS) for Portland Cement
Plants (40 CFR Part 60, Subpart F), Nonmetallic Mineral Processing Plants (Subpart OOO),
and Coal Preparation Plants (Subpart Y) and may likely propose changes to the National
Emission Standards for Hazardous Air Pollutants (NESHAP) from the Portland Cement
Manufacturing Industry (40 CFR 63, Subpart LLL) that would potentially affect the proposed
permit. These regulations will not likely be finalized prior to completion of the processing of
our application; however, our facility would still be subject to the final NSPS and NESHAP
requirements. For this reason, Carolinas Cement Company agrees to comply with either the
emission limits in the final NSPS and NESHAP as issued, or the BACT limits proposed in
the application, whichever are more stringent.
Because we understand your office has some additional questions regarding the air quality
dispersion modeling, the revised modeling and reports (Tabs E and F) will be submitted
separately at a later date in order to address those issues.
If you have any questions or need additional information, please give me a call at (757) 858-
6523.
Sincerely yours,
Russell A Fink
Vice President/General Counsel
Enclosure
SUMMARY OF PERMIT APPLICATION CHANGES
Increase in estimated uncontrolled SO2 emissions.
Add lime slurry injection system to control SO2; set new SO2 emission limit.
Revise BACT for SO2. Add additional information on consideration of SCR systems for
NOx control and reasons for rejection.
Remove barge loading sources.
Add emissions from drilling and blasting activities in the quarry area.
Change VOC continuous monitoring to periodic testing (note THC will be continuously
monitored under the NESHAP).
Added biomass fuels to the list of fuels that may be burned
Miscellaneous, minor corrections in document text.
INDEX TO REVISED CAROLINAS CEMENT COMPANY
PSD CONSTRUCTION PERMIT APPLICATION
TAB
A Regulatory Analysis Report - Revised
B Permit Application Forms – Revised pages
C Plantwide Potential Emissions Inventory - Revised
D Control Technology Analysis - Revised
E Class II and Ambient Air Quality Standards Air Dispersion Modeling Report –
Discussion of Revised Modeling for SO2 (to be submitted separately)
F Class I Air Dispersion Modeling Report – Revised pages (to be submitted
separately)
G Plot Plans, Survey Maps, and Process Flow Diagrams – Revised pages
H Zoning Consistency Determination Letter – No change
Enclosures
Class I, Class II, and AAQS Modeling Files (2 CDs) (to be submitted
separately)
TAB A
REGULATORY ANALYSIS REPORT – REVISED
REGULATORY ANALYSIS REPORT
Prepared for:
Carolinas Cement Company LLC
Castle Hayne, North Carolina Plant
PN 050020.0051
Prepared by:
Environmental Quality Management, Inc.
Cedar Terrace Office Park, Suite 250
3325 Durham-Chapel Hill Boulevard
Durham, North Carolina 27707
February 25, 2008
(Revised October 20, 2008)
CONTENTS
Section Page
Tables ............................................................................................................................................ iii
1 Project Description...............................................................................................................1
2 Applicable Regulations........................................................................................................3
New Source Performance Standards (NSPS) – 40 CFR Part 60 .............................3
National Emission Standards for Hazardous Air Pollutants (NESHAP) -
40 CFR Part 63.............................................................................................5
Compliance Assurance Monitoring (CAM).............................................................6
New Source Review (NSR) .....................................................................................7
North Carolina’s Emission Limiting Rules..............................................................8
3 Requested Permit Limits....................................................................................................10
Kiln/Raw Mill/Cooler/Coal Mill Emission Limit..................................................10
Finish Mills and Miscellaneous Baghouses...........................................................12
Fugitive Emissions.................................................................................................12
Diesel Emergency Generator Set ...........................................................................12
Throughput Limits .................................................................................................12
Fuel Limitations .....................................................................................................12
Operating Hour Assumptions ................................................................................13
ii
TABLES
Number Page
1-1 Comparison of Potential Annual Emissions Increase from the Project to the
PSD Major Source Emission Rates......................................................................................2
iii
1
SECTION 1
PROJECT DESCRIPTION
Carolinas Cement Company LLC (CCC) is proposing to construct a modern Portland
cement manufacturing facility at the site of an existing cement storage terminal operated by
Roanoke Cement Company near Castle Hayne, North Carolina. The plant will include a multi-
stage preheater-precalciner kiln with an in-line raw mill, coal mill, and clinker cooler venting
through the main stack. Production is expected to be 6000 tons per day (tons/day) and 2,190,000
tons per year (tons/yr) of clinker and approximately 2,400,000 tons/yr of cement. Fuels may
include coal, petroleum coke, fuel oil, biomass fuels and natural gas. The raw materials for
clinker production may include limestone/marl, clay, quarry spoils, bauxite, slag, fly ash/bottom
ash, sand, and/or mill scale. Synthetic gypsum or natural gypsum will be milled with the clinker
to produce cement. Associated processes will include mining, crushing, blending, grinding,
material handling, storage for raw materials, fuels, clinker, and finished cement, and cement
packing and bulk loadout. Cement will be shipped by rail and truck. The project will also
include a diesel emergency generator set.
The Castle Hayne area is in attainment with all the National Ambient Air Quality
Standards (NAAQS). The existing Roanoke Cement terminal is considered a minor source under
North Carolina’s Prevention Significant Deterioration (PSD) rules at 15A NCAC 02D.0530 for
all PSD pollutants. A modification to a PSD minor source is subject to PSD if the modification
itself exceeds the major source threshold for any PSD regulated pollutant. In the case of
Portland cement plants, the major source threshold is 100 tons/yr, which includes all quantifiable
fugitive emissions.
Pursuant to current U.S. Environmental Protection Agency (EPA) guidance, until EPA
issues rules and guidance for addressing PM2.5, PM10 will be used as a surrogate for PM2.5.
Although modeling for PM2.5 will not be required for this project, estimates of PM2.5 emissions
(including condensables, which are highly uncertain) are included in the application.
As shown in Table 1-1, the emissions from the project of particulate matter (PM), PM
less than 10 microns in diameter (PM10), sulfur dioxide (SO2), carbon monoxide (CO), nitrogen
2
oxides (NOx), and volatile organic compounds (VOC) will exceed the PSD major source
emission rate.
TABLE 1-1. COMPARISON OF POTENTIAL ANNUAL EMISSIONS INCREASE
FROM THE PROJECT TO THE PSD MAJOR SOURCE EMISSION RATES
Pollutant
Future Potential
Emissions (tons/yr)
PSD Major Source
Emission Rate
(tons/year)
Review
Required?
(Yes/No)
NOx 2,138 100 Yes
PM (TSP) 663 100 Yes
PM10 527 100 Yes
PM2.5 348 NA No
SO2 1,456 100 Yes
CO 3,068 100 Yes
VOCs 175 100 Yes
Lead 0.09 100 No
Fluorides 1.0 100 No
Note: PM, PM10, and PM2.5 include condensables.
3
SECTION 2
APPLICABLE REGULATIONS
2.1 New Source Performance Standards (NSPS) – 40 CFR Part 60
Equipment constructed or modified after August 31, 1983 used for processing of
limestone [crushers, screens, conveyor transfer points (except to a pile), and storage bins] from
the quarry up to the storage facility just prior to the raw mill is subject to NSPS Subpart OOO
(Nonmetallic Mineral Processing Plants). Truck dumping to a hopper is exempt. Fugitive
emissions from the crushers are limited to 15 percent opacity and 10 percent from other affected
sources (zero percent for transfer points processing saturated materials). The new quarry
crushers will be subject to the 15 percent opacity limit). On April 22, 2008, EPA proposed
changes to Subpart OOO which would lower grain loading and opacity limits for affected
sources commencing construction after April 22, 2008.
The coal handling and crushing equipment is subject to NSPS Subpart Y (Coal
Preparation Plants). On April 28, 2008, EPA proposed changes to Subpart Y which, once
finalized, will apply to these affected facilities. The opacity from affected sources is limited to
20 percent. The coal mill will be vented through the main stack, which is subject to
requirements as specified in Section 2.2.
On June 16, 2008, EPA proposed major changes to the NSPS for Portland cement (PC)
plants (Subpart F) which, when finalized, will apply to this project. Currently, the PC NSPS
regulates only PM. The proposed NSPS changes would reduce the PM emission limits for new
or modified kilns and clinker coolers commencing construction after June 16, 2008. In addition,
new or modified cement kilns would be subject to new limits for NOx and SO2 emissions. CCC
will comply with the final PC NSPS limits as issued.
There will be no new storage tanks that would be subject to NSPS Subpart Kb.
On July 11, 2006, EPA promulgated final NSPS for stationary compression ignition
(diesel) engines constructed or ordered after July 11, 2005 (40 CFR Part 60, Subpart IIII). The
4
rules limit emissions of NOx, PM, SO2, CO, and HC to the same levels required by EPA’s
nonroad diesel engine regulations. The rules take effect in three increasingly stringent stages:
1. Transition period for engines built after July 11, 2005 and before model year 2007.
Generally, owners or operators will purchase a certified nonroad engine for stationary
use.
2. Beginning in model year 2007, owners must purchase certified engines meeting more
stringent emission limits.
3. Beginning with 2011 model year engines, add-on controls will be required to achieve the
emission limits for non-emergency engines.
The requirements vary depending on the size and designated use (e.g., emergency versus non-
emergency engines, fire pump engines, etc.). The main burden for meeting the emission limits
will fall on the manufacturers, but owners/operators have monitoring, recordkeeping, and
reporting requirements, including use of specified low sulfur fuel. The following table
summarizes the Subpart IIII emission limits for the emergency generator.
NEW EMERGENCY DIESEL GENERATOR EMISSION REQUIREMENTS
Pollutant Units
Emission Standards NSPS Subpart IIII
(New Requirements)*
NOx g/kW-hr -
NMHC g/kW-hr -
NMHC +
NOx
g/kW-hr 6.4
CO g/kW-hr 3.5
PM g/kW-hr 0.20
S (6/1/07) ppm 500
S(6/1/10) ppm 15
Applicable Requirements
1. 40 CFR 60.4200 et al: Standards of Performance for Stationary Compression
Ignition Internal Combustion Engines.
2. 40 CFR 89.112 Oxides of nitrogen, carbon monoxide, hydrocarbon, and
particulate matter exhaust emission standards.
3. 40 CFR 80.510 Standards and marker requirements for NRLM diesel fuel.
*Standards for 2007 model year and later emergency diesel engines with
displacement < 30 liters/cylinder and > 560 kW rated power.
5
2.2 National Emission Standards for Hazardous Air Pollutants (NESHAP) – 40 CFR
Part 63
CCC stipulates that it will be a major source as defined under 40 CFR Part 63 and subject
to NESHAP Subpart LLL (Portland Cement Manufacturing Industry). The kiln is subject to
emission limits for particulate matter (PM) (0.3 lb/ton of dry feed) and dioxins and furans (D/F)
(see Section 3.1.7) and an opacity limit of 20 percent. The clinker cooler and coal mill will be
vented through the kiln stack. All other stack and fugitive process sources, except those subject
to the NSPS noted above, are subject to an opacity limit of 10 percent. There is no separate raw
material dryer subject to the total hydrocarbon standard. CCC must be in compliance with these
limits upon startup of the new equipment.
On December 20, 2006, EPA promulgated amendments to Subpart LLL; the most
significant changes involve setting mercury (Hg) and total hydrocarbon (THC) emission limits
for new or reconstructed kilns commencing construction after December 2, 2005.
The requirements applicable to the new kiln at Castle Hayne are:
A ban on the use of fly ash where the fly ash Hg content has been increased through the
use of activated carbon or other sorbent for Hg control at the power plant. A certification
must be obtained from the supplier for each shipment of fly ash received to demonstrate
compliance with this requirement. Alternately, the facility must demonstrate that Hg
emissions will not increase as a result of such fly ash.
Cement kiln dust (CKD) recycle to the kilns must be minimized consistent with
maintaining desired product quality. Records must be kept of the amount of CKD
removed from the kiln system on an annual basis. Records must also be kept of the
amount of CKD recycled on an hourly basis.
Mercury – 41 µg/dscm or, if this limit cannot be met, an alternative limit based on
application of a packed-bed or spray tower wet scrubber.
THC – 20 ppmv or 98 percent reduction.
Initial testing is required for Hg and continuous monitoring for THC. Operating requirements
are specified for certain types of control systems that may be employed. Also on December 20,
2006, EPA announced the reconsideration of the new source standards to allow for additional
public comment, since the emission limits were not specifically included in the earlier proposal.
CCC reserves the right to request deletion or modification of any permit conditions imposed as a
result of the December 20, 2006 EPA amendments that may be changed by EPA at a later date.
6
As required by 40 CFR 63.1350(a) and 63.6(e)(3), CCC must submit to the Department
of Environment and Natural Resources (DENR) a written operation and maintenance (O&M)
plan and a startup, shutdown, and malfunction plan for the facility prior to commencing
operation. Among other things, these plans provide procedures for: proper O&M of the
emission units and their control devices; corrective actions and measures to be taken to minimize
emissions in cases of startup, shutdown, or malfunction; and procedures used in inspecting and
monitoring the emission units and control equipment.
The new emergency diesel generator set is exempt from Part 63, Subpart ZZZZ
[Stationary Reciprocating Internal Combustion Engines (RICE)], except for the initial
notification requirements, pursuant to § 63.6590(b)(1).
2.3 Compliance Assurance Monitoring (CAM)
The CAM rules at 40 CFR Part 64 apply to air pollution emission units that meet all the
following criteria:
1. The unit is located at a plant that is subject to the Title V operating permit program.
2. The unit is subject to an emission limitation or standard under a State Implementation
Plan (SIP) or EPA rule such as an NSPS.
3. The unit uses a control device to achieve compliance with the emission limitation or
standard. A control device does not include passive control measures such as low-
sulfur fuels, low-NOx burners, or good operating practices.
4. The unit has potential emissions before the control device of the regulated pollutant(s)
that are 100 percent or more of the major source thresholds, as defined under the Title
V program.
There are several exemptions to CAM applicability, including the following types of
emission standards or limitations:
a) Standards proposed by EPA after November 15, 1990 [e.g., all Maximum
Achievable Control Technology (MACT) rules are exempt from the CAM
requirements].
b) Standards subject to a continuous compliance determination method (CCDM).
7
All PM emission limits for sources controlled by baghouses are exempt from CAM under
a) above. The gaseous emission limits for the kiln system are not met by a control device except
for NOx and SO2.
Per 40 CFR 64.1, CCDM means a method, specified by the applicable standard or an
applicable permit condition, which:
1. Is used to determine compliance with an emission limitation or standard on a
continuous basis, consistent with the averaging period established for the emission
limitation or standard.
2. Provides data either in units of the standard or correlated directly with the compliance
limit.
As discussed in Section 3, CCC is requesting NOx and SO2 emission limits in lb/ton of
clinker. Emissions will be measured by a continuous emission rate monitor (CERM). The
CERM data will be linked with clinker production data to produce output in lb/ton of clinker,
thus qualifying the NOx and SO2 limits for exemption under the CAM rules.
2.4 New Source Review (NSR)
As noted above, the project will trigger the PSD rules under 15A NCAC 020.0530, which
requires the following:
1. A Best Available Control Technology (BACT) analysis for each pollutant that
exceeds the PSD major source thresholds (PM, PM10, SO2, CO, NOx, and VOC).
2. An analysis of impacts on Federal Class I areas, including Class I PSD increments
and air quality related values.
3. A demonstration of compliance with the Ambient Air Quality Standards (AAQS)
(Section .0400) and Class II PSD increments, as applicable.
4. An additional impacts analysis (potential impacts on soils, vegetation, visibility,
and secondary growth).
In addition, the project will trigger the toxic air pollutant (TAP) procedures for new
facilities under 15A NCAC 2Q.0700. These procedures require that a new facility which
exceeds certain emission rates specified at 2Q.0711 must demonstrate compliance with the
acceptable ambient levels (AAL’s) set forth at 15A NCAC 02D.1104. Emission factors for most
TAP’s are highly uncertain and site-specific, depending on the raw material mix, kiln, design,
8
and operating conditions. Nonetheless, emission estimates have been made using available
emission factors and AAL compliance demonstrations have made for the applicable TAPs.
These analyses are contained in separate reports attached to the application.
2.5 North Carolina’s Emission Limiting Rules
Several provisions of North Carolina’s air rules are applicable to the proposed CCC plant,
although they are less stringent than the NSPS, NESHAP, or BACT requirements. Applicable
provisions in 15A NCAC 2D include:
Section 0510 – Particulates from Sand, Gravel, or Crushed Stone Operations
Section 0513 – Particulates from Portland Cement Plants
Section 0515 – Particulates from Miscellaneous Industrial Processes
Section 0516 – Sulfur Dioxide from Combustion Sources
Section 0540 – Particulates from Fugitive Dust Emission Sources
Section 0510 requires a) measures to limit PM emissions so as to attain the TSP and PM10
NAAQS beyond the property line, b) fugitive emissions must meet Section 0540, and c) crushers
must be controlled by wet suppression, and conveyors, screens and transfer points must be
controlled so as to meet opacity standards in Sections 0521 or 0524 (NSPS). The NAAQS
modeling demonstration under the PSD rules meets the requirements under Item a; compliance
with Section 0540 is discussed below; materials processed by the crusher will generally be
saturated with moisture; and the sources under Item c) must meet the opacity standards under
NSPS Subpart 000.
Section 0513 requires that PM from the kiln be controlled by at least 99.7 percent and
that the emission rate not exceed 0.327 lb/barrel of cement. The proposed BACT for the kiln is a
baghouse with control efficiency exceeding 99.9 percent and an emission limit of 0.14 lb/ton of
kiln feed (equivalent to 0.0425 lb/barrel of cement). Section 0513 also requires that PM from
other stacks or vents not exceed the process weight limits in Section 0515. The proposed BACT
for other sources is baghouse controls meeting a limit of 0.01 gr/scf, which results in much lower
emissions than the limits in Section 0515.
Section 0516 requires that SO2 from fuel combustion sources not exceed 2.3 lb/million
Btu heat input. The proposed BACT is 1.80 lb/ton of clinker, maximum 24-hour average. This
limit is equivalent to 0.67 lb/million Btu.
9
Section 0540 requires that fugitive dust emissions not cause or contribute to substantive
complaints, excessive fugitive dust emissions at the property boundary, or NAAQS violations.
BACT will be applied for fugitive dust sources and NAAQS compliance, including fugitive dust
sources, is demonstrated as part of this permit application.
10
SECTION 3
REQUESTED PERMIT LIMITS
The permit limits, including the regulatory basis and the associated testing and
monitoring requirements, being requested by CCC are discussed below. Where there are
multiple regulatory bases (e.g., BACT, NESHAPs, PSD increment compliance), the most
restrictive limits that will ensure compliance with other applicable requirements are
recommended. CCC requests elimination of multiple redundant forms of emission limits and
throughput limits. The kiln emission limits below are applicable for all combinations of fuel to
be burned. The emission limits proposed below for PM will ensure the application of BACT for
PM10; thus, CCC requests that separate PM10 emission limits not be established.
CCC recognizes that alternate emission limits may be imposed under the final NSPS and
NESHAP rules and agrees to comply with those limits as required.
Pursuant to current EPA guidance at 79 FR 20652 (April 25, 2007), CCC requests that
the PM emission limits include filterable PM but not condensables. The current estimate of
condensable PM emissions is highly uncertain based on an AP-42 emission factor for inorganic
condensables of questionable reliability. Based on experience with cement kilns, condensable
emissions are site-specific and variable. In addition, EPA has indicated that additional time is
needed to implement a program to assess and improve available test methods for condensable
PM.
3.1 Kiln/Raw Mill/Cooler/Coal Mill Emission Limit
3.1.1 PM
0.14 lb/ton kiln feed as determined by Method 5 test every 5 years (BACT).
3.1.2 Opacity
Ten percent as measured by continuous opacity monitor (COM) on the main stack
(BACT).
11
3.1.3 CO
2.80 lb/ton of clinker, 30-day rolling average, as measured using a CERM meeting
Performance Specification (PS) 4B (BACT).
3.1.4 VOC (non-methane)
0.16 lb/ton of clinker as determined by Methods 25A and 18 every 5 years. Note that
THC will be measured by CEM under the NESHAP (see 3.1.8); thus, continuous monitoring of
VOC should not be required.
3.1.5 SO2
1.33 lb/ton of clinker, 30-day rolling average and 1.80 lb/ton of clinker, maximum 24-
hour average, as measured using a CERM meeting PS 6 (BACT).
3.1.6 NOx
1.95 lb/ton of clinker, 30-day rolling average, as measured using a CERM meeting PS 6
(BACT). This averaging time is appropriate to account for the variability in NOx emissions from
cement kilns and is consistent with EPA’s State Implementation Plan (SIP) call guidance for
cement kilns. Averaging times for NO2 air quality concentrations (NAAQS and PSD
increments) are based on annual concentrations.
As per the BACT analysis, NOx will be controlled by selective non-catalytic reduction
(SNCR). Because of the uncertainty and lack of experience with SNCR on cement kilns, CCC
requests that for the first year of operation, the emission limits be set at 3.0 lb/ton of clinker to
allow shakedown and optimization of the SNCR systems.
3.1.7 Dioxins/Furans
0.4 ng/dscm (TEQ) corrected to 7 percent oxygen as measured by Method 23 initially and
every 30 months (NESHAP). The average temperature during the test may not exceed 204ºC
(400ºF).
3.1.8 THC and Mercury
THC: Twenty ppmv, 1-hour block average, as measured by CEM meeting PS 8A
(NESHAP).
Hg: 41 µg/dscm, as measured by a Method 29 initial compliance test (NESHAP).
Both corrected to 7 percent oxygen. It should be noted that these NESHAP limits are currently
under reconsideration by EPA. CCC reserves the right to revise these emission limits if the
NESHAP limits are modified or recinded.
12
3.1.9 TAP’s
Because CCC has demonstrated compliance with the AAL’s for various TAP’s and the
BACT and NESHAP requirements directly or indirectly (via surrogates such as PM for TAP
metals and THC for TAP organics), CCC requests that no additional emission limits be set for
individual TAPs.
3.2 Finish Mills and Miscellaneous Baghouses
3.2.1 PM
0.01 gr/scf (BACT) determined by implementation of 10 percent opacity limit (see
below).
3.2.2 Opacity
Ten percent as determined by initial and every 5 year Method 9 test and monitoring
scheme under 40 CFR 63.1350.
3.3 Fugitive Emissions
Quarry crushers – 15 percent opacity. All other process fugitive sources (except those
processing fugitive materials) – 10 percent opacity (BACT).
3.4 Diesel Emergency Generator Set
NSPS Subpart IIII limits as described in Section 2.2 above.
3.5 Throughput Limits
Throughput limits are needed to limit the potential to emit (PTE) for sources that are
subject to lb/ton emission limits and for sources that are not effectively limited by the emission
limits outlined above (e.g., fugitive process sources). Throughput limits are not needed for other
miscellaneous sources. For example, the handling of cement is controlled by baghouses
permitted at 0.01 gr/scf and 8760 h/yr. This defines the PTE for these sources and thus a cement
throughput limit would not be necessary or appropriate. CCC requests a throughput limit of
2,190,000 tons/yr clinker, rolling 12-month sum. The clinker throughput limit effectively limits
the throughput of all raw materials required for production.
13
3.6 Fuel Limitations
Emissions of NOx, SO2, and CO will be monitored by CERM, and there is little
relationship between the sulfur and nitrogen content of kiln/calciner fuels and resulting emissions
(see BACT report). The clinker production limit effectively limits the total quantity of fuel
required. Because of these reasons, CCC requests that no limits be set on the amount or quality
of the fuels to be burned.
3.7 Operating Hour Assumptions
The modeling analyses assume that all sources operate 24 hours per day, 365 days per
year except for the following:
Emergency generator – 500 h/yr
Under EPA guidance, States can assume that the potential to emit (PTE) for emergency
generators can be based on 500 h/yr. Thus, CCC requests that no operating hour limits be
included in the permit.
TAB B
PERMIT APPLICATION FORMS – REVISED PAGES
REVISED 11/01/02 A1
Legal Corporate/Owner Name:
Site Name:
Site Address (911 Address) Line 1:
Site Address Line 2:
City: State:
Zip Code: County:
Permit/Technical Contact: Facility/Inspection Contact:
Name/Title: Name/Title:
Mailing Address Line 1: Mailing Address Line 1:
Mailing Address Line 2: Mailing Address Line 2:
City: Troutville State: Virginia Zip Code: 24175 City: Troutville State: Virginia Zip Code: 24175
Phone No. (area code) 540-966-6534 Fax No. (area code) 540-966-6812 Phone No. ( area code ) 540-966-6534 Fax No. ( area code) 540-966-6812
Email Address: Email Address:
Responsible Official/Authorized Contact: Invoice Contact:
Name/Title: Name/Title:
Mailing Address Line 1: Mailing Address Line 1:
Mailing Address Line 2: Mailing Address Line 2:
City: Norfolk State: Virginia Zip Code: 23502 City: Troutville State: Virginia Zip Code: 24175
Phone No. (area code) 757-858-6523 Fax No. ( area code ) 757-288-1339 Phone No. (area code) 540-966-6534 Fax No. (area code ) 540-966-6812
Email Address: Email Address:
General Small
Describe nature of (plant site) operation(s): Facility ID No. : 08/65/00296
Primary SIC/NAICS Code: Current/Previous Air Permit No. 07300R07 Expiration Date 1/1/2012
Facility Coordinates: Latitude: Longitude:
Does this application contain confidential data? YES NO
Person Name: Firm Name:
Mailing Address Line 1: Mailing Address Line 2:
City: State: Zip Code: County:
Phone No. ( area code ) 919-489-5299 Fax No. ( area code ) 919-489-5552 Email Address:
Name (typed): Title:
X Signature(Blue Ink): Date:
6071 Catawba Road6071 Catawba Road
North Carolina
NOTE- APPLICATION WILL NOT BE PROCESSED WITHOUT THE FOLLOWING:
Local Zoning Consistency Determination (if required) Facility Reduction & Recycling Survey Form (Form A4) Application Fee
28429 New Hanover
Castle Hayne
Carolinas Cement Company LLC
CONTACT INFORMATION
New Non-permitted Facility/Greenfield
jwillis@titanamerica.com
Rfink@titanamerica.com
James S. Willis / Corporate Environmental Manager
6071 Catawba Road
jwillis@titanamerica.com
Vice President, General Counsel, and Secretary
Modification of Facility (permitted)
Renewal (TV Only)
Manufacturing of Portland cement
FACILITY CLASSIFICATION AFTER APPLICATION (Check Only One)
Prohibitory Small Synthetic Minor
jwillis@titanamerica.com
Title V
27707
James S. Willis / Corporate Environmental Manager James S. Willis / Corporate Environmental Manager
1151 Azalea Garden Road
Russell A. Fink, Vice President/General Counsel
Renewal with Modification
APPLICATION IS BEING MADE FOR
FORM A1FACILITY (General Information)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
PO Box 37
Responsible Official/Authorized Contact Signature Appropriate Number of Copies of Application P.E. Seal (if required)
GENERAL INFORMATION
6411 Ideal Cement Road
Carolinas Cement Company LLC
kberry@eqm-rtp.com
Environmental Quality Management, Inc.
Attach Additional Sheets As Necessary
FACILITY (Plant Site) INFORMATION
PERSON OR FIRM THAT PREPARED APPLICATION
SIGNATURE OF RESPONSIBLE OFFICIAL/AUTHORIZED CONTACT
34D, 20M, 19S
3241 / 327310
Russell A. Fink
77D, 52M, 00S
D. Kent Berry
North Carolina Durham
3325 Durham-Chapel Hill Boulevard, Suite 250
Durham
REVISED 04/10/07 A2
FQ Quarry crushing and handling NARMHS Raw material unloading, handling, and storage NARMKF Raw mill and kiln feed Fabric filtersCOAL Coal/coke handling and storage Fabric filtersKS Kiln system SNCR
Lime injectionFabric filters
CHS Clinker handling and storage Fabric filtersFM Finish mills Fabric filtersCHSL Cement handling, storage, and loadout Fabric filtersGEN Emergency generator NASP Storage piles NAMINE Mining operations NAPLTRD Plant roads NAQURD Quarry roads NA
Is your facility subject to 40 CFR Part 68 "Prevention of Accidental Releases" - Section 112(r) of the Federal Clean Air Act? No
If No, please specify in detail how your facility avoided applicability: Aqueous ammonia less than 20%
If your facility is Subject to 112(r), please complete the following:
A. Have you already submitted a Risk Management Plan (RMP) to EPA Pursuant to 40 CFR Part 68.10 or Part 68.150?
Yes G No G Specify required RMP submittal date: _____________ If submitted, RMP submittal date: _____________
B. Are you using administrative controls to subject your facility to a lesser 112(r) program standard?
Yes G No G If yes, please specify:
NANANA
Attach Additional Sheets As Necessary
112(r) APPLICABILITY INFORMATION
Existing Permitted Equipment To Be MODIFIED By This Application
Equipment To Be DELETED By This Application
CD1-4, 14-18
CD22-31, 45-47CD32-34, 40-43
CD5-13
CD44A, BCD44S
CONTROL DEVICE
NA
NA
ID NO.
NA
Equipment To Be ADDED By This Application (New, Previously Unpermitted, or Replacement)
NA
CD44N
CD19-21
DESCRIPTIONID NO. DESCRIPTION
CONTROL DEVICE
FORMs A2, A3
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE LISTING: New, Modified, Previously Unpermitted, Replaced, Deleted
EMISSION SOURCE LISTING FOR THIS APPLICATION - A2
112r APPLICABILITY INFORMATION - A3
EMISSION SOURCE EMISSION SOURCE
A 3
FORM A4
SURVEY OF AIR EMISSIONS AND FACILITY - WIDE REDUCTION & RECYCLING ACTIVITIES
DATE:
Facility Name: Carolinas Cement Company LLC Permit Number: 07300R07
Facility ID: 08/65/00296 County: New Hanover Environmental Contact: James S. Willis / Corporate Environmental Manager
Mailing Address Line 1: 6071 Catawba Road Phone No. 540-966-6534 Fax No. 540-966-6812
Zip Code: 24175 County: New Hanover
City: Troutville State: Virginia Email Address: jwillis@titanamerica.com
AIR EMISSIONS SOURCE REDUCTIONSEnter Code for Date Reduction Quantity Emitted Quantity Emitted Has reduction activity been
Source Description and ID Air Pollutant Emission Reduction Option Implemented from prior annual from current annual discontinued? If so, when
Option (See Codes) (mo/yr) report to DAQ (lb/yr) report to DAQ (lb/yr) was it discontinued? (mo/yr)
Does facility have an environmental mangement system in place? ( ) YES (X) NO If so, is facility ISO 14000 Certified? ( ) YES (X) NO
Mailing Address Line 2:
Any Air Emissions Source Reductions in the past year? ( ) YES (X) NO
Addition detail about source
Comments:
Pollutant Enter Code for Date Reduction Quantity Emitted Quantity Emitted Has reduction activity been
Source Description or Activity or Emission Reduction Option Implemented from prior annual from current annual discontinued? If so, when
Recycled or Reduced Material Option (See Codes) (mo/yr) report report was it discontinued? (mo/yr)
Comments: None
REVISED 1/07 Attach Additional Sheets As Necessary
FACILITY - WIDE REDUCTIONS & RECYCLING ACTIVITIES Any Reductions or Recycling Activities in the past year? ( ) YES (X) NO
Addition detail about source
The requested information above shall be used for fulfilling the requirements of North Carolina General Statute 143-215.108(g). The permit holder shall submit to the
Department a written description of current and projected plans to reduce the emissions of air pollutants by source reduction or recycling. The written description shall
accompany any application for a new permit, modification of an existing permit and for each annual air quality permit fee payment. Source reduction is defined as reducing
the amount of any hazardous substance, pollutant, or contaminant entering any waste stream or otherwise released into the environment (including fugitive emissions) prior
to recycling, treatment, or disposal. If no activity has taken place since the previous report, simply indicate so by checking the no box in that section. Once completed, this
form should be submitted along with your fee payment. Examples are listed on the first line of each section of the form for your benefit.
REVISED 12/01/01 BEMISSION SOURCE ID NO: FQ
CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?): OOO NESHAP (SUBPART?):________ MACT (SUBPART?):__________
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 1.60 6.99 NA NA 1.60 6.99
PARTICULATE MATTER<10 MICRONS (PM10) Attached 0.73 3.20 NA NA 0.73 3.20
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.13 0.55 NA NA 0.13 0.55
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 4.79E-05 2.10E-04 NA NA 4.79E-05 2.10E-04
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 3.19E-06 1.40E-05 NA NA 3.19E-06 1.40E-05
Attached 3.19E-06 1.40E-05 NA NA 3.19E-06 1.40E-05
Attached 3.04E-06 1.33E-05 NA NA 3.04E-06 1.33E-05
Attached 2.98E-05 1.31E-04 NA NA 2.98E-05 1.31E-04
Attached 3.02E-04 1.32E-03 NA NA 3.02E-04 1.32E-03
Attached 1.76E-08 7.69E-08 NA NA 1.76E-08 7.69E-08
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
lb/day
(AFTER CONTROLS / LIMITS) (AFTER CONTROLS / LIMITS)
Mercury
BEFORE CONTROLS / LIMITS
(AFTER CONTROLS / LIMITS)
Arsenic
7.66E-05 2.80E-02
EMISSION SOURCE DESCRIPTION:
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
LEAD
Cadmium
Manganese
Mercury
EXPECTED ACTUAL
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/yr
Chromium (VI)
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: NA % OPACITY
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
Primary crushers (2) for marl/limestone and overburden/spoils, secondary crusher, and conveyor transfer points.
OPERATING SCENARIO 1 OF 1
Attach Additional Sheets As Necessary
(AFTER CONTROLS / LIMITS)
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
lb/hr
Arsenic
Beryllium
Manganese
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
Chromium (Total)
Quarry crushing and handling
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
POTENTIAL EMSSIONS
BEFORE CONTROLS / LIMITS
Cadmium 2.66E-02
3.19E-06
POTENTIAL EMSSIONSEXPECTED ACTUAL
3.02E-04 7.25E-03 2.65E+00
1.76E-08 4.21E-07 1.54E-04
7.66E-05 2.80E-02
Beryllium 3.19E-06
1.60E-07 3.83E-06 1.40E-03
3.04E-06 7.29E-05
REVISED 12/01/01 BEMISSION SOURCE ID NO: RMHS
CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?): Y, OOO NESHAP (SUBPART?):________ MACT (SUBPART?):__________
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 1.05 4.62 NA NA 1.05 4.62
PARTICULATE MATTER<10 MICRONS (PM10) Attached 0.50 2.18 NA NA 0.50 2.18
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.08 0.33 NA NA 0.08 0.33
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 4.14E-05 1.81E-04 NA NA 4.14E-05 1.81E-04
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 2.57E-06 1.12E-05 NA NA 2.57E-06 1.12E-05
Attached 1.75E-06 7.67E-06 NA NA 1.75E-06 7.67E-06
Attached 2.20E-06 9.63E-06 NA NA 2.20E-06 9.63E-06
Attached 6.22E-05 2.72E-04 NA NA 6.22E-05 2.72E-04
Attached 2.34E-04 1.02E-03 NA NA 2.34E-04 1.02E-03
Attached 6.97E-08 3.05E-07 NA NA 6.97E-08 3.05E-07
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Raw material unloading, handling, and storage
OPERATING SCENARIO 1 OF 1
Unloading, handling, and storage of quarried raw materials, additives, gypsum, and solid fuels (coal, coke) (fugitve transfer points)
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: NA % OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
LEAD
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS
Beryllium
Cadmium
Manganese
Mercury
(AFTER CONTROLS / LIMITS)
Arsenic
Chromium (Total)
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
Attach Additional Sheets As Necessary
Arsenic
Cadmium
Chromium (VI)
Manganese
Mercury
2.57E-06 6.16E-05 2.25E-02
Beryllium 1.75E-06 4.20E-05 1.53E-02
2.20E-06 5.28E-05 1.93E-02
4.70E-07 1.13E-05 4.11E-03
2.34E-04 5.62E-03 2.05E+00
6.97E-08 1.67E-06 6.10E-04
REVISED 12/01/01 BEMISSION SOURCE ID NO: RMKF
CONTROL DEVICE ID NO(S): CD5-CD13
EMISSION POINT (STACK) ID NO(S): E5 - E13
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?): ______ NESHAP (SUBPART?):________ MACT (SUBPART?): LLL
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 4.77 20.90 NA NA 4.77 20.90
PARTICULATE MATTER<10 MICRONS (PM10) Attached 4.01 17.56 NA NA 4.01 17.56
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 2.15 9.41 NA NA 2.15 9.41
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 4.02E-04 1.76E-03 NA NA 4.02E-04 1.76E-03
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 1.53E-05 6.69E-05 NA NA 1.53E-05 6.69E-05
Attached 8.98E-06 3.93E-05 NA NA 8.98E-06 3.93E-05
Attached 1.41E-05 6.16E-05 NA NA 1.41E-05 6.16E-05
Attached 2.31E-04 1.01E-03 NA NA 2.31E-04 1.01E-03
Attached 1.09E-03 4.77E-03 NA NA 1.09E-03 4.77E-03
Attached 3.14E-07 1.37E-06 NA NA 3.14E-07 1.37E-06
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Raw mill and kiln feed
OPERATING SCENARIO 1 OF 1
Raw mill feed storage and handling; kiln feed storage and handling; kiln dust bins
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: 10% OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
LEAD
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS
Beryllium
Cadmium
Manganese
Mercury
(AFTER CONTROLS / LIMITS)
Arsenic
Chromium (Total)
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
Attach Additional Sheets As Necessary
Arsenic
Cadmium
Chromium (VI)
Manganese
Mercury
1.53E-05 3.66E-04 1.34E-01
Beryllium 8.98E-06 2.16E-04 7.87E-02
1.41E-05 3.38E-04 1.23E-01
1.71E-06 4.11E-05 1.50E-02
1.09E-03 2.62E-02 9.55E+00
3.14E-07 7.53E-06 2.75E-03
REVISED 12/01/01 BEMISSION SOURCE ID NO: COAL
CONTROL DEVICE ID NO(S): CD1-4, CD14-18
EMISSION POINT (STACK) ID NO(S):E1-E4, E14-E18
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?): Y NESHAP (SUBPART?):________ MACT (SUBPART?):__________
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 2.87 12.58 NA NA 2.87 12.58
PARTICULATE MATTER<10 MICRONS (PM10) Attached 2.41 10.57 NA NA 2.41 10.57
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 1.29 5.66 NA NA 1.29 5.66
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 2.90E-06 1.27E-05 NA NA 2.90E-06 1.27E-05
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 5.46E-07 2.39E-06 NA NA 5.46E-07 2.39E-06
Attached 1.01E-06 4.40E-06 NA NA 1.01E-06 4.40E-06
Attached 1.21E-06 5.28E-06 NA NA 1.21E-06 5.28E-06
Attached 1.44E-05 6.29E-05 NA NA 1.44E-05 6.29E-05
Attached 1.67E-06 7.30E-06 NA NA 1.67E-06 7.30E-06
Attached 2.87E-07 1.26E-06 NA NA 2.87E-07 1.26E-06
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Coal/coke handling system and mill
OPERATING SCENARIO 1 OF 1
Coal/coke unloading, conveying, and storage bins
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: ______OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
LEAD
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Arsenic
Beryllium
Cadmium
Chromium (Total)
Manganese
Mercury
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
Arsenic 5.46E-07 1.31E-05 4.78E-03
Beryllium 1.01E-06 2.41E-05 8.81E-03
Cadmium 1.21E-06 2.90E-05 1.06E-02
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
Attach Additional Sheets As Necessary
6.89E-06 2.52E-03
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
Mercury 2.87E-07
Chromium (VI) 1.44E-07
4.00E-05 1.46E-02Manganese 1.67E-06
3.45E-06 1.26E-03
REVISED 12/01/01 BEMISSION SOURCE ID NO: KSCONTROL DEVICE ID NO(S): CD44A, B, N, SEMISSION POINT (STACK) ID NO(S): E44
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?): LLL
EXPECTED ANNUAL HOURS OF OPERATIO 7008
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 98.77 346.07 NA NA 98.77 346.07
PARTICULATE MATTER<10 MICRONS (PM10) Attached 89.36 313.13 NA NA 89.36 313.13
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 66.44 232.82 NA NA 66.44 232.82
SULFUR DIOXIDE (SO2) Attached 303.13 1062.15 NA NA 303.13 1062.15
NITROGEN OXIDES (NOx) Attached 487.50 1708.20 NA NA 487.50 1708.20
CARBON MONOXIDE (CO) Attached 700.00 2452.80 NA NA 700.00 2452.80
VOLATILE ORGANIC COMPOUNDS (VOC) Attached 40.00 140.16 NA NA 40.00 140.16
Attached 0.02 0.07 NA NA 0.02 0.07
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 3.00E-03 1.05E-02 NA NA 3.00E-03 1.05E-02
Attached 7.75E-01 2.72E+00 NA NA 7.75E-01 2.72E+00
Beryllium Attached 1.65E-04 5.78E-04 NA NA 1.65E-04 5.78E-04
Attached 5.50E-04 1.93E-03 NA NA 5.50E-04 1.93E-03
Attached 3.50E-02 1.23E-01 NA NA 3.50E-02 1.23E-01
Formaldehyde Attached 1.15E-01 4.03E-01 NA NA 1.15E-01 4.03E-01
Hydrogen Chloride Attached 7.18E+00 2.51E+01 NA NA 7.18E+00 2.51E+01
Manganese Attached 2.15E-01 7.53E-01 NA NA 2.15E-01 7.53E-01
Attached 3.00E-02 1.05E-01 NA NA 3.00E-02 1.05E-01
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Beryllium Attached
Attached
Attached
Attached
Formaldehyde Attached
Hydrogen Chloride Attached
Manganese Attached
Attached
8.06E+02
5.03E+04
2.76E+00
1.72E+02
2.10E+02
1.75E+04
2.10E+01
5.43E+03
1.16E+00
3.85E+00
7.01E-01
1.58E+03
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
7.20E-01
2.25E-01
1.15E-01
7.18E+00
2.15E-01
3.00E-02
5.16E+00 1.51E+03
5.40E+00
Kiln system - Raw mill on
OPERATING SCENARIO 1 OF 2
Kiln with in-line raw mill, clinker cooler, and coal mill. The raw mill runs approximately 80% of the time that the kiln is operating.
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
1.32E-02
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
6.00E+01
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: 10% OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
LEAD
LETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SO
Arsenic
Benzene
Cadmium
Chromium (Total)
Mercury
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
7.20E-02
1.86E+01
3.96E-03
2.40E-03
Benzene
Cadmium
(AFTER CONTROLS / LIMITS)BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
Attach Additional Sheets As Necessary
Ammonia
Fluorides
Mercury
Arsenic
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of
operation, emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this
source
Chromium (VI)
2.50E+00
3.00E-03
7.75E-01
1.65E-04
1.00E-04
5.50E-04
REVISED 12/01/01 BEMISSION SOURCE ID NO: KS
CONTROL DEVICE ID NO(S): CD44A, B, N, SEMISSION POINT (STACK) ID NO(S): E44
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?): LLL
EXPECTED ANNUAL HOURS OF OPERATIO 1752
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 98.77 86.52 NA NA 98.77 86.52
PARTICULATE MATTER<10 MICRONS (PM10) Attached 89.36 78.28 NA NA 89.36 78.28
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 66.44 58.21 NA NA 66.44 58.21
SULFUR DIOXIDE (SO2) Attached 450.00 394.20 NA NA 450.00 394.20
NITROGEN OXIDES (NOx) Attached 487.50 427.05 NA NA 487.50 427.05
CARBON MONOXIDE (CO) Attached 700.00 613.20 NA NA 700.00 613.20
VOLATILE ORGANIC COMPOUNDS (VOC) Attached 40.00 35.04 NA NA 40.00 35.04
Attached 0.02 0.02 NA NA 0.02 0.02
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 3.00E-03 2.63E-03 NA NA 3.00E-03 2.63E-03
Attached 7.75E-01 6.79E-01 NA NA 7.75E-01 6.79E-01
Beryllium Attached 1.65E-04 1.45E-04 NA NA 1.65E-04 1.45E-04
Attached 5.50E-04 4.82E-04 NA NA 5.50E-04 4.82E-04
Attached 3.50E-02 3.07E-02 NA NA 3.50E-02 3.07E-02
Formaldehyde Attached 1.15E-01 1.01E-01 NA NA 1.15E-01 1.01E-01
Hydrogen Chloride Attached 7.18E+00 6.29E+00 NA NA 7.18E+00 6.29E+00
Manganese Attached 2.15E-01 1.88E-01 NA NA 2.15E-01 1.88E-01
Attached 3.00E-02 2.63E-02 NA NA 3.00E-02 2.63E-02
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Beryllium Attached
Attached
Attached
Attached
Formaldehyde Attached
Hydrogen Chloride Attached
Manganese Attached
Attached 3.00E-02 7.20E-01 5.26E+01
7.18E+00 1.72E+02 1.26E+04
2.15E-01 5.16E+00 3.77E+02
1.15E-01 2.76E+00 2.01E+02
Chromium (VI) 1.00E-04 2.40E-03 1.75E-01
1.65E-04 3.96E-03 2.89E-01
2.25E-01 5.40E+00 3.94E+02
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Cadmium 5.50E-04 1.32E-02 9.64E-01
1.86E+01 1.36E+03
7.20E-02 5.26E+00
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: 10% OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
LEAD
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Kiln system - Raw mill off
OPERATING SCENARIO 2 OF 2
Kiln with in-line raw mill, clinker cooler, and coal mill. The raw mill does not run and is bypassed approximately 20% of the time that the kiln is
operating.
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
(AFTER CONTROLS / LIMITS)BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
LETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SO
Arsenic
Benzene
Chromium (Total)
Cadmium
Mercury
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
Arsenic
Attach Additional Sheets As Necessary
Ammonia
Fluorides
Mercury
2.50E+00
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of
operation, emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this
source
3.00E-03
Benzene 7.75E-01
6.00E+01 4.38E+03
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
REVISED 12/01/01 BEMISSION SOURCE ID NO: KS
CONTROL DEVICE ID NO(S): CD44A, B, N, SEMISSION POINT (STACK) ID NO(S): E44
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?): LLL
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 98.77 432.59 NA NA 98.77 432.59
PARTICULATE MATTER<10 MICRONS (PM10) Attached 89.36 391.41 NA NA 89.36 391.41
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 66.44 291.03 NA NA 66.44 291.03
SULFUR DIOXIDE (SO2) Attached 450.00 1456.35 NA NA 450.00 1456.35
NITROGEN OXIDES (NOx) Attached 487.50 2135.25 NA NA 487.50 2135.25
CARBON MONOXIDE (CO) Attached 700.00 3066.00 NA NA 700.00 3066.00
VOLATILE ORGANIC COMPOUNDS (VOC) Attached 40.00 175.20 NA NA 40.00 175.20
Attached 0.02 0.08 NA NA 0.02 0.08
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 3.00E-03 1.31E-02 NA NA 3.00E-03 1.31E-02
Attached 7.75E-01 3.39E+00 NA NA 7.75E-01 3.39E+00
Beryllium Attached 1.65E-04 7.23E-04 NA NA 1.65E-04 7.23E-04
Attached 5.50E-04 2.41E-03 NA NA 5.50E-04 2.41E-03
Attached 3.50E-02 1.53E-01 NA NA 3.50E-02 1.53E-01
Formaldehyde Attached 1.15E-01 5.04E-01 NA NA 1.15E-01 5.04E-01
Hydrogen Chloride Attached 7.18E+00 3.14E+01 NA NA 7.18E+00 3.14E+01
Manganese Attached 2.15E-01 9.42E-01 NA NA 2.15E-01 9.42E-01
Attached 3.00E-02 1.31E-01 NA NA 3.00E-02 1.31E-01
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Beryllium Attached
Attached
Attached
Attached
Formaldehyde Attached
Hydrogen Chloride Attached
Manganese Attached
Attached
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of
operation, emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this
source.
3.00E-03
LETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SO
Arsenic
Benzene
lb/yr
Arsenic
Benzene
Chromium (Total)
Cadmium
Attach Additional Sheets As Necessary
Ammonia
Fluorides
Mercury
2.50E+00
(AFTER CONTROLS / LIMITS)BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Mercury
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
6.00E+01 2.19E+04
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day
(AFTER CONTROLS / LIMITS)BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
Kiln system
OPERATING SCENARIO Combined (maximum) operations
7.20E-02 2.63E+01
LEAD
Kiln with in-line raw mill, clinker cooler, and coal mill. The raw mill runs approximately 80% of the time and is off (bypassed) approximately
20% of the time that the kiln is operating.
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: 10% OPACITY
7.75E-01 1.86E+01 6.79E+03
1.15E-01 2.76E+00
1.65E-04 3.96E-03 1.45E+00
2.25E-01 5.40E+00
5.16E+00
Chromium (VI) 1.00E-04 2.40E-03 8.76E-01
Cadmium 5.50E-04 1.32E-02 4.82E+00
1.88E+03
1.97E+03
1.01E+03
3.00E-02 7.20E-01 2.63E+02
7.18E+00 1.72E+02 6.29E+04
2.15E-01
REVISED 12/01/01 BEMISSION SOURCE ID NO: CHS
CONTROL DEVICE ID NO(S): CD19-21
EMISSION POINT (STACK) ID NO(S): E19 - E21
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?): LLL
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 0.66 2.91 NA NA 0.66 2.91
PARTICULATE MATTER<10 MICRONS (PM10) Attached 0.56 2.45 NA NA 0.56 2.45
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.30 1.31 NA NA 0.30 1.31
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 5.32E-08 2.33E-07 NA NA 5.32E-08 2.33E-07
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 5.12E-07 2.24E-06 NA NA 5.12E-07 2.24E-06
Attached 9.97E-08 4.37E-07 NA NA 9.97E-08 4.37E-07
Attached 2.93E-07 1.28E-06 NA NA 2.93E-07 1.28E-06
Attached 4.74E-05 2.07E-04 NA NA 4.74E-05 2.07E-04
Attached 6.85E-05 3.00E-04 NA NA 6.85E-05 3.00E-04
Attached 5.98E-08 2.62E-07 NA NA 5.98E-08 2.62E-07
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
6.85E-05
4.48E-03
8.74E-04
1.44E-06
6.64E-02
7.02E-06
1.82E-04
1.64E-03 6.00E-01
5.24E-04
2.56E-03
Chromium (Total)
Beryllium
5.12E-07
9.97E-08
2.93E-07
7.58E-06
Clinker discharge from clinker cooler, clinker dome, off-spec clinker bin
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
5.98E-08
1.23E-05
BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
LEAD
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Clinker handling and storage
OPERATING SCENARIO 1 OF 1
Arsenic
Beryllium
Cadmium
Manganese
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: 10% OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Mercury
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
Attach Additional Sheets As Necessary
Arsenic
Cadmium
Chromium (VI)
Manganese
Mercury
2.39E-06
REVISED 12/01/01 BEMISSION SOURCE ID NO: FM
CONTROL DEVICE ID NO(S): CD22-31, CD45-47
EMISSION POINT (STACK) ID NO(S): E22-31, E45-47
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?): LLL
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 13.19 57.79 NA NA 13.19 57.79
PARTICULATE MATTER<10 MICRONS (PM10) Attached 11.08 48.55 NA NA 11.08 48.55
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 5.94 26.01 NA NA 5.94 26.01
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 1.52E-04 6.65E-04 NA NA 1.52E-04 6.65E-04
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 2.27E-04 9.92E-04 NA NA 2.27E-04 9.92E-04
Attached 1.38E-05 6.06E-05 NA NA 1.38E-05 6.06E-05
Attached 2.78E-06 1.22E-05 NA NA 2.78E-06 1.22E-05
Attached 7.73E-04 3.39E-03 NA NA 7.73E-04 3.39E-03
Attached 3.05E-03 1.33E-02 NA NA 3.05E-03 1.33E-02
Attached 7.78E-07 3.41E-06 NA NA 7.78E-07 3.41E-06
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
Attach Additional Sheets As Necessary
Arsenic
Cadmium
Chromium (VI)
Manganese
Mercury
Beryllium
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
Mercury
Chromium (Total)
Beryllium
Arsenic
Cadmium
Manganese
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Finish mills
OPERATING SCENARIO 1 OF 1
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
2.27E-04 5.44E-03
LEAD
Finish mills 1 and 2, feed bins, and cement transfer
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: 10% OPACITY
1.98E+00
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
1.38E-05 3.32E-04 1.21E-01
2.78E-06 6.68E-05 2.44E-02
7.78E-07 1.87E-05 6.81E-03
1.23E-04 2.95E-03 1.08E+00
3.05E-03 7.31E-02 2.67E+01
REVISED 12/01/01 BEMISSION SOURCE ID NO: CHSL
CONTROL DEVICE ID NO(S): CD32-34, 40-43
EMISSION POINT (STACK) ID NO(S): E32 - E43
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) !X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?): LLL
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 4.35 19.03 NA NA 4.35 19.03
PARTICULATE MATTER<10 MICRONS (PM10) Attached 3.65 15.99 NA NA 3.65 15.99
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 1.96 8.57 NA NA 1.96 8.57
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 5.39E-05 2.36E-04 NA NA 5.39E-05 2.36E-04
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 8.21E-05 3.60E-04 NA NA 8.21E-05 3.60E-04
Attached 5.00E-06 2.19E-05 NA NA 5.00E-06 2.19E-05
Attached 7.95E-07 3.48E-06 NA NA 7.95E-07 3.48E-06
Attached 2.80E-04 1.23E-03 NA NA 2.80E-04 1.23E-03
Attached 1.10E-03 4.80E-03 NA NA 1.10E-03 4.80E-03
Attached 1.65E-07 7.23E-07 NA NA 1.65E-07 7.23E-07
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
Attach Additional Sheets As Necessary
Arsenic
Cadmium
Chromium (VI)
Manganese
Mercury
8.21E-05
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Cadmium
Manganese
Mercury
Chromium (Total)
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Arsenic
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)
(AFTER CONTROLS / LIMITS)
Cement handling, storage, and loadout
OPERATING SCENARIO 1 OF 1
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
LEAD
Cement dome; cement transport; truck and rail loadouts; and packing plant.
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: 10% OPACITY
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS
Beryllium 5.00E-06 1.20E-04 4.38E-02
1.97E-03 7.19E-01
Beryllium
7.95E-07 1.91E-05 6.97E-03
4.48E-05 1.07E-03 3.92E-01
1.10E-03 2.63E-02 9.59E+00
1.65E-07 3.96E-06 1.45E-03
REVISED 12/01/01 BEMISSION SOURCE ID NO: GEN
CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): GEN
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
X Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) ! !Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: TBD
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?): IIII NESHAP (SUBPART?):________ MACT (SUBPART?): ZZZZ
EXPECTED ANNUAL HOURS OF OPERATIO 500
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 0.35 0.09 NA NA 0.35 0.09
PARTICULATE MATTER<10 MICRONS (PM10) Attached 0.29 0.07 NA NA 0.29 0.07
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.28 0.07 NA NA 0.28 0.07
SULFUR DIOXIDE (SO2) Attached 0.40 0.10 NA NA 0.40 0.10
NITROGEN OXIDES (NOx) Attached 11.11 2.78 NA NA 11.11 2.78
CARBON MONOXIDE (CO) Attached 6.17 1.54 NA NA 6.17 1.54
VOLATILE ORGANIC COMPOUNDS (VOC) Attached 0.18 0.04 NA NA 0.18 0.04
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 6.08E-03 1.52E-03 NA NA 6.08E-03 1.52E-03
Attached 6.18E-04 1.55E-04 NA NA 6.18E-04 1.55E-04
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
AttachedFormaldehyde
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
Attach Additional Sheets As Necessary
Benzene
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
Benzene
Formaldehyde
POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
6.18E-04 1.48E-02 3.09E-01
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
Emergency generator
OPERATING SCENARIO 1 OF 1
6.08E-03 1.46E-01
LEAD
800 kW diesel generator set
3.04E+00
EXPECTED OP. SCHEDULE: ___ HR/DAY ___ DAY/WK ___ WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: <5% OPACITY
REVISED 12/01/01 BEMISSION SOURCE ID NO: SP
CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) X Other (Form B9)
START CONSTRUCTION DATE: NA OPERATION DATE: Oct-11 DATE MANUFACTURED: NA
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?):________
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 1.92 8.40 NA NA 1.92 8.40
PARTICULATE MATTER<10 MICRONS (PM10) Attached 0.96 4.20 NA NA 0.96 4.20
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.14 0.63 NA NA 0.14 0.63
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 9.42E-05 4.13E-04 NA NA 9.42E-05 4.13E-04
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 5.72E-06 2.50E-05 NA NA 5.72E-06 2.50E-05
Attached 2.93E-06 1.28E-05 NA NA 2.93E-06 1.28E-05
Attached 4.56E-06 2.00E-05 NA NA 4.56E-06 2.00E-05
Attached 1.67E-04 7.32E-04 NA NA 1.67E-04 7.32E-04
Attached 4.54E-04 1.99E-03 NA NA 4.54E-04 1.99E-03
Attached 2.22E-07 9.71E-07 NA NA 2.22E-07 9.71E-07
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
Attach Additional Sheets As Necessary
Arsenic
Cadmium
Chromium (VI)
Manganese
Mercury
5.72E-06
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Cadmium
Manganese
Mercury
Chromium (Total)
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Arsenic
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)
(AFTER CONTROLS / LIMITS)
Storage piles
OPERATING SCENARIO 1 OF 1
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
LEAD
Wind erosion from storage piles in quarry and raw material piles in the plant
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: NA % OPACITY
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS
Beryllium 2.93E-06 7.02E-05 2.56E-02
1.37E-04 5.01E-02
Beryllium
4.56E-06 1.09E-04 3.99E-02
1.07E-06 2.58E-05 9.41E-03
4.54E-04 1.09E-02 3.98E+00
2.22E-07 5.32E-06 1.94E-03
REVISED 12/01/01 BEMISSION SOURCE ID NO: MINE
CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) X Other (Form B9)
START CONSTRUCTION DATE: NA OPERATION DATE: Oct-11 DATE MANUFACTURED: NA
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?):________
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 3.54 15.53 NA NA 3.54 15.53
PARTICULATE MATTER<10 MICRONS (PM10) Attached 1.78 7.78 NA NA 1.78 7.78
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.24 1.05 NA NA 0.24 1.05
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
Attached 1.06E-04 4.66E-04 NA NA 1.06E-04 4.66E-04
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
Attached 7.09E-06 3.11E-05 NA NA 7.09E-06 3.11E-05
Attached 7.09E-06 3.11E-05 NA NA 7.09E-06 3.11E-05
Attached 6.91E-06 3.03E-05 NA NA 6.91E-06 3.03E-05
Attached 8.27E-05 3.62E-04 NA NA 8.27E-05 3.62E-04
Attached 5.06E-04 2.22E-03 NA NA 5.06E-04 2.22E-03
Attached 4.60E-08 2.01E-07 NA NA 4.60E-08 2.01E-07
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attached
Attached
Attached
Attached
Attached
Attached
Attach Additional Sheets As Necessary
Arsenic
Cadmium
Chromium (VI)
Manganese
Mercury
7.09E-06
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
Cadmium
Manganese
Mercury
Chromium (Total)
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
Arsenic
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)
(AFTER CONTROLS / LIMITS)
Mining operations
OPERATING SCENARIO 1 OF 1
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
LEAD
Quarry mining activities including drilling, blasting, marl/limestone and spoils/other ripping and loading, overburden removal and unloading
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: NA % OPACITY
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS
Beryllium 7.09E-06 1.70E-04 6.21E-02
1.70E-04 6.21E-02
Beryllium
6.91E-06 1.66E-04 6.05E-02
3.54E-07 8.51E-06 3.11E-03
5.06E-04 1.22E-02 4.44E+00
4.60E-08 1.10E-06 4.03E-04
REVISED 12/01/01 BEMISSION SOURCE ID NO: PLTRD
CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) X Other (Form B9)
START CONSTRUCTION DATE: Feb-09 OPERATION DATE: Oct-11 DATE MANUFACTURED: NA
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?):________
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 2.12 9.31 NA NA 2.12 9.31
PARTICULATE MATTER<10 MICRONS (PM10) Attached 0.41 1.81 NA NA 0.41 1.81
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.10 0.44 NA NA 0.10 0.44
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attach Additional Sheets As Necessary
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
LEAD
Vehicle traffic on paved roads
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: NA % OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)
Plant roads
OPERATING SCENARIO 1 OF 1
REVISED 12/01/01 BEMISSION SOURCE ID NO: QURD
CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAILTHE EMISSION SOURCE PROCESS (ATTACH FLOW DIAGRAM):
Coal,wood,oil, gas, other burner (Form B1) ! Woodworking (Form B4) ! Manufact. of chemicals/coatings/inks (Form B7)
Int.combustion engine/generator (Form B2) ! Coating/finishing/printing (Form! Incineration (Form B8)
Liquid storage tanks (Form B3) ! Storage silos/bins (Form B6) X Other (Form B9)
START CONSTRUCTION DATE: NA OPERATION DATE: Oct-11 DATE MANUFACTURED: NA
MANUFACTURER / MODEL NO. TBD
IS THIS SOURCE SUBJECT TO? NSPS (SUBPART?):________ NESHAP (SUBPART?):________ MACT (SUBPART?):________
EXPECTED ANNUAL HOURS OF OPERATIO 8760
SOURCE OF
EMISSION
AIR POLLUTANT EMITTED FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
PARTICULATE MATTER (PM) Attached 15.88 69.57 NA NA 15.88 69.57
PARTICULATE MATTER<10 MICRONS (PM10) Attached 4.52 19.78 NA NA 4.52 19.78
PARTICULATE MATTER<2.5 MICRONS (PM2.5) Attached 0.45 1.98 NA NA 0.45 1.98
SULFUR DIOXIDE (SO2)
NITROGEN OXIDES (NOx)
CARBON MONOXIDE (CO)
VOLATILE ORGANIC COMPOUNDS (VOC)
OTHER
SOURCE OF
EMISSION
HAZARDOUS AIR POLLUTANT AND CAS NO. FACTOR lb/hr tons/yr lb/hr tons/yr lb/hr tons/yr
TOXIC AIR POLLUTANT AND CAS NO. EF SOURCE
Attach Additional Sheets As Necessary
Attachments: (1) emissions calculations and supporting documentation; (2) indicate all requested state and federal enforceable permit limits (e.g. hours of operation,
emission rates) and describe how these are monitored and with what frequency; and (3) describe any monitoring devices, gauges, or test ports for this source.
PLETE THIS FORM AND COMPLETE AND ATTACH APPROPRIATE B1 THROUGH B9 FORM FOR EACH SOU
INDICATE EXPECTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS
lb/hr lb/day lb/yr
TOXIC AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS) BEFORE CONTROLS / LIMITS (AFTER CONTROLS / LIMITS)
LEAD
Vehcle traffic on unpaved roads in quarry
TYPE OF EMISSION SOURCE (CHECK AND COMPLETE APPROPRIATE FORM B1-B9 ON THE FOLLOWING PAGES):
EXPECTED OP. SCHEDULE: 24 HR/DAY 7 DAY/WK 52 WK/YR
PERCENTAGE ANNUAL THROUGHPUT (%): DEC-FEB 25 MAR-MAY 25 JUN-AUG 25 SEP-NOV 25
VISIBLE STACK EMISSIONS UNDER NORMAL OPERATION: NA % OPACITY
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION FOR THIS SOURCE
EXPECTED ACTUAL
FORM BSPECIFIC EMISSIONS SOURCE INFORMATION (REQUIRED FOR ALL SOURCES)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EMISSION SOURCE DESCRIPTION:
POTENTIAL EMSSIONS
(AFTER CONTROLS / LIMITS)
Quarry roads
OPERATING SCENARIO 1 OF 1
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: FQ
Quarry crushing and handling CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
Quantities shown are wet basis. Relative quantities of each material may vary.
Spoils quantity assumes that 50% of the crushed material will be wasted (e.g., remains in the quarry) and not conveyed to the plant.
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
LIMITATION(UNIT/HR)
MAX. DESIGN
TYPE CAPACITY (UNIT/HR)
Primary crushers (2) for marl/limestone and overburden/spoils, secondary crusher, and conveyor transfer points.
OPERATING SCENARIO 1 OF 1
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS
Marl/limestone -
Spoils/other -
Attach Additional Sheets as Necessary
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
3,411,152
434,183
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
REQUESTED CAPACITY
1500 tph
500 tph
None
None
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: RMHS
Raw material unloading, handling, and storage CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
tpy
tpy
tpy
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
Additives may consist of fly ash/bottom ash, mill scale, bauxite, sand, and/or other purchased raw materials.
Quarried raw materials may consist of marl, limestone, clay and/or spoils.
Quantities shown are wet basis. Relative quantities of each material may vary.
CAPACITY (UNIT/HR)
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Unloading, handling, and storage of quarried raw materials, additives, gypsum, and solid fuels (coal, coke) (fugitve transfer
points)
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
LIMITATION(UNIT/HR)
NA NoneAdditives - 425,102
TYPE
Attach Additional Sheets as Necessary
Gypsum -
Limestone -
283,824
127,549
102,040
None
None
3,628,243Quarried raw materials -
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
NA
NA
NA
NA None
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
Coal/coke -
None
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: RMKF
Raw mill and kiln feed CONTROL DEVICE ID NO(S): CD5-CD13
EMISSION POINT (STACK) ID NO(S): E5 - E13
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Raw mill feed storage and handling; kiln feed storage and handling; kiln dust bins
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Raw mill feed - 3,398,880 485 None
Virgin kiln feed - 3,376,980 386 None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: COAL
Coal/coke handling system and mill CONTROL DEVICE ID NO(S): CD1-4, CD14-18
EMISSION POINT (STACK) ID NO(S): E1-E4, E14-E18
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
Quantities shown are wet basis as received.
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Coal/coke unloading, conveying, and storage bins
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Coal/Coke - 283,824 30 None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: KS
Kiln system CONTROL DEVICE ID NO(S): CD44A, B, N, S
EMISSION POINT (STACK) ID NO(S): E44
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: Coal, coke, biomass, fuel oil, nat. gas TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE: NoneCOMMENTS:
* Request annual production limit of 2,190,000 tons clinker.
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO Combined (maximum) operations
Kiln with in-line raw mill, clinker cooler, and coal mill. The raw mill runs approximately 80% of the time and is off
(bypassed) approximately 20% of the time that the kiln is operating.
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Kiln feed with recycle - 3,677,010 420 None*
Attach Additional Sheets as Necessary
675
30 tph
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: CHS
Clinker handling and storage CONTROL DEVICE ID NO(S): CD19-21
EMISSION POINT (STACK) ID NO(S): E19 - E21
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Clinker discharge from clinker cooler, clinker dome, off-spec clinker bin
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Clinker - 2,190,000 250 None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: FM
Finish mills CONTROL DEVICE ID NO(S): CD22-31, CD45-47
EMISSION POINT (STACK) ID NO(S): E22-31, E45-47
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
tpy
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Finish mills 1 and 2, feed bins, and cement transfer
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Clinker - 2,190,000 150 tph cement each None
Gypsum - 127,549 NA None
Limestone - 102,040 NA None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: CHSL
Cement handling, storage, and loadout CONTROL DEVICE ID NO(S): CD32-34, 40-43
EMISSION POINT (STACK) ID NO(S): E32 - E43
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Cement dome; cement transport; truck and rail loadouts; and packing plant.
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Cement - 2,406,593 170 tph (packhouse) None
350 tph (truck) None
350 tph (rail) None
500 tph (barge) None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED 12/01/01 B2
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: GEN
Emergency generator CONTROL DEVICE ID NO(S): NA
OPERATING SCENARIO 1 OF 1 EMISSION POINT (STACK) ID NO(S): GEN
CHECK ALL THAT APPLY X EMERGENCY G SPACE HEAT G ELECTRICAL GENERATION
G PEAK SHAVER G OTHER (DESCRIBE): ___________________
GENERATOR OUTPUT (KW): 800 ANTICIPATED ACTUAL HOURS OF OPERATION AS PEAK SHAVER (HRS/YR): NA
ENGINE OUTPUT (HP):
TYPE ICE: G GASOLINE ENGINE G DIESEL ENGINE UP TO 600 H X DIESEL ENGINE GREATER THAN 600 HP G DUAL FUEL ENGINE
G OTHER (DESCRIBE): _________________________________________ (complete below)
ENGINE TYPE G RICH BURN X LEAN BURN
EMISSION REDUCTION MODIFICATIONS G INJECTION TIMING RETAR G PREIGNITION CHAMBER COMBUSTION G OTHER _________
OR G STATIONARY GAS TURBINE (complete below G NATURAL GAS PIPELINE COMPRESSOR OR TURBINE (complete below)
FUEL G NATURAL GAS G OIL ENGINE TYPE: G 2-CYCLE LEAN BURN G 4-CYCLE LEAN G TURBINE
G OTHER (DESCRIBE):____________ G 4-CYCLE RICH BURN G OTHER (DESCRIBE): _______________
CYCLE: G COGENERATION G SIMPLE CONTROLS: G COMBUSTION MODIFICATIONS (DESCRIBE): __________________
G REGENERATIVE G COMBINED G NONSELECTIVE CATALYTIC REDUCTIONG SELECTIVE CATALYTIC REDUCTION
CONTROLS: G WATER-STEAM INJECTION G CLEAN BURN AND PRECOMBUSTION CHAMBER G UNCONTROLLED
G UNCONTROLLED G LEAN-PREMIX
DESCRIBE METHODS TO MINIMIZE VISIBLE EMISSIONS DURING IDLING, OR LOW LOAD OPERATIONS:
COMMENTS:
FUEL TYPE
FORM B2EMISSION SOURCE (INTERNAL COMBUSTION ENGINES/GENERATORS)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
FUEL USAGE (INCLUDE STARTUP/BACKUP FUEL)
MAXIMUM DESIGN REQUESTED CAPACITY
UNITS CAPACITY (UNIT/HR) LIMITATION (UNIT/HR)
0.05
POLLUTANT NOX CO PM
Diesel 137,200 Btu/gal
UNITS (% BY WEIGHT)
SULFUR CONTENT
FUEL CHARACTERISTICS (COMPLETE ALL THAT ARE APPLICABLE)
FUEL TYPE BTU/UNIT
Diesel 57.2 gal/hr None
UNIT
OTHER
MANUFACTURER'S SPECIFIC EMISSION FACTORS (IF AVAILABLE)
0.2 0.164 0.1
VOC
EMISSION FACTOR LB/UNIT 6.3 3.5
PM10
Attach Additional Sheets As Necessary
g/KW*hrg/KW*hrg/KW*hrg/KW*hrg/KW*hr
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: SP
Storage piles CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
acres
acres
acres
acres
acres
Mill scale (Plant) - acres
Fly ash/Bottom ash (Plant) - acres
Coal/coke (Plant) - acres
Gypsum (Plant) - acres
Limestone (Plant) - acres
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
Material types and relative quantities may vary.
NA None
NA None
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Marl/limestone (Quarry) -
LIMITATION (UNIT/BATCH)
0.5
0.4
0.10
0.25
0.7
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
NA None
Wind erosion from storage piles in quarry and raw material piles in the plant
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
0.5 NA None
Spoils (Quarry) - 1.0 NA None
Spoils/other (Quarry) - 0.5 NA None
Marl/limestone/spoils (Plant) - 2.3 NA None
Overburden (Quarry) - 2.0 NA None
Attach Additional Sheets as Necessary
NA None
NA None
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: MINE
Mining operations CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
tpy
tpy
tpy
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
Quantities shown are wet basis. Relative quantities of each material may vary.
Overburden quantity assumes that 50% of the crushed material will be wasted (e.g., remains in the quarry) and not conveyed to the plant.
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Quarry mining activities including drilling, blasting, marl/limestone and spoils/other ripping and loading, overburden removal
and unloading
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
Marl/limestone - 3,411,152 NA None
Spoils/other - 434,183 NA None
Overburden - 3,177,255 NA None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: PLTRD
Plant roads CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Vehicle traffic on paved roads
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
NA NA None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED: 12/01/01 B9
EMISSION SOURCE DESCRIPTION: EMISSION SOURCE ID NO: QURD
Quarry roads CONTROL DEVICE ID NO(S): NA
EMISSION POINT (STACK) ID NO(S): NA
DESCRIBE IN DETAIL THE PROCESS (ATTACH FLOW DIAGRAM):
UNITS
UNITS
MAXIMUM DESIGN (BATCHES / HOUR):
REQUESTED LIMITATION (BATCHES / HOUR): (BATCHES/YR):
FUEL USED: None TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR):
MAX. CAPACITY HOURLY FUEL USE: REQUESTED CAPACITY ANNUAL FUEL USE:
COMMENTS:
FORM B9EMISSION SOURCE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO 1 OF 1
Vehcle traffic on unpaved roads in quarry
MATERIALS ENTERING PROCESS - CONTINUOUS PROCESS MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/HR) LIMITATION(UNIT/HR)
NA NA None
Attach Additional Sheets as Necessary
MATERIALS ENTERING PROCESS - BATCH OPERATION MAX. DESIGN REQUESTED CAPACITY
TYPE CAPACITY (UNIT/BATCH) LIMITATION (UNIT/BATCH)
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD5 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E5 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.72 0.60 0.32
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 8500 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Raw mill feed bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
TOTAL = 100
Attach Additional Sheets As Necessary
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
PARTICLE SIZE DISTRIBUTION
CUMULATIVE
(MICRONS)
50-100
SIZE
OF TOTAL %
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
DESCRIBE CONTROL SYSTEM:
25-50
X YES G NO WARNING ALARM? G YES X NO
1-10
WEIGHT %
10-25
0-1
1 OF 1
>100
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
OPERATING SCENARIO: Feb-09
Oct-11
P.E. SEAL REQUIRED (PER 2Q .0112)? YES
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD6 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E6 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.65 0.55 0.29
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 7750 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Raw mill feed transport
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD7 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E7 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.91 0.76 0.41
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 10800 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Raw mill feed
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD8 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E8 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.96 0.81 0.43
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 90
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 90
INLET AIR FLOW RATE (ACFM): 11700 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Raw mill reject
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD9 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E9 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.25 0.21 0.11
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 302
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 302
INLET AIR FLOW RATE (ACFM): 4200 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Kiln dust bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD10 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E10 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.30 0.25 0.13
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 150
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 150
INLET AIR FLOW RATE (ACFM): 4000 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Raw meal transport to silo
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD11 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E11 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.31 0.26 0.14
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 150
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 150
INLET AIR FLOW RATE (ACFM): 4200 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Raw meal silo
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD12 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E12 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.35 0.30 0.16
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 150
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 150
INLET AIR FLOW RATE (ACFM): 4760 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Raw meal silo extraction
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD13 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): RMKF
EMISSION POINT (STACK) ID NO(S): E13 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.32 0.27 0.14
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 150
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 150
INLET AIR FLOW RATE (ACFM): 4300 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Kiln feed
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD1 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E1 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.47 0.39 0.21
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 5535 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Coal rail unloading
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD2 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E2 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.47 0.39 0.21
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 5535 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Coal unloading by truck
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD3 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E3 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.58 0.49 0.26
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 6868 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Coal transport to storage
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD4 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E4 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.58 0.49 0.26
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 6868 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Coal transport from storage
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD14 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E14 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.13 0.11 0.06
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 90
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 90
INLET AIR FLOW RATE (ACFM): 1540 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Coal mill feed bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD15 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E15 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.13 0.11 0.06
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 90
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 90
INLET AIR FLOW RATE (ACFM): 1540 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Coal mill feed bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD16 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E16 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.50 0.42 0.23
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 90
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 90
INLET AIR FLOW RATE (ACFM): 6100 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Coal mill feed transport
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD17 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E17 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.01 0.01 0.01
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 140
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 140
INLET AIR FLOW RATE (ACFM): 175 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Fine coal bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD18 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): COAL
EMISSION POINT (STACK) ID NO(S): E18 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.01 0.01 0.01
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 140
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 140
INLET AIR FLOW RATE (ACFM): 175 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Fine coal bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD44A, B CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): KS
EMISSION POINT (STACK) ID NO(S): E44 POSITION IN SERIES OF CONTROL(Refers to kiln FF) NO. 3 OF 3 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filters for kiln system (kiln, in-line raw mill, and clinker cooler) and coal mill all venting through the main kiln stack.
Data below reflect combined outlet flow conditions at main stack.
Emissions include an estimate of condensible PM.
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 98.77 89.36 66.44
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN 193 MAX 435
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN 193 MAX 435
INLET AIR FLOW RATE (ACFM): 673804 @ 193 F (Mill On) FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
1) Kiln with in-line raw mill and clinker cooler (CD44A) (~645,000 acfm @ 194 F)
2) Coal mill exhaust (CD44B) (~30,000 acfm @ 180 F)
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD19 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHS
EMISSION POINT (STACK) ID NO(S): E19 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.29 0.24 0.13
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 257
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 257
INLET AIR FLOW RATE (ACFM): 4600 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Clinker discharge from cooler
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD20 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHS
EMISSION POINT (STACK) ID NO(S): E20 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.23 0.19 0.10
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 257
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 257
INLET AIR FLOW RATE (ACFM): 3672 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Clinker dome
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD21 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHS
EMISSION POINT (STACK) ID NO(S): E21 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.14 0.12 0.06
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 257
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 257
INLET AIR FLOW RATE (ACFM): 2260 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Off-spec bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD22 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E22 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.72 0.61 0.32
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 156
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 156
INLET AIR FLOW RATE (ACFM): 9820 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill feed bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD23 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E23 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.65 0.54 0.29
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 156
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 156
INLET AIR FLOW RATE (ACFM): 8830 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill feed bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD46 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E46 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.35 0.30 0.16
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 156
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 156
INLET AIR FLOW RATE (ACFM): 4810 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement additive bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
DESCRIBE CONTROL SYSTEM:
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD47 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E47 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.89 0.75 0.40
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 77
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 77
INLET AIR FLOW RATE (ACFM): 10587 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement additve intake
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
DESCRIBE CONTROL SYSTEM:
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD24 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E24 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.35 0.29 0.16
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 156
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 156
INLET AIR FLOW RATE (ACFM): 4697 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill feed
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD25 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E25 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.18 0.15 0.08
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 2719 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill recirculation bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD26 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E26 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.35 0.30 0.16
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 5262 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill reject
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD27 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E27 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.15 0.12 0.07
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 2154 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement transport
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD28 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E28 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.40 0.33 0.18
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 178
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 178
INLET AIR FLOW RATE (ACFM): 5580 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill feed
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD29 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E29 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.18 0.15 0.08
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 2719 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill recirculation bin
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD30 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E30 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.35 0.30 0.16
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 5262 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement mill reject
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD31 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E31 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.15 0.12 0.07
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 2154 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement transport
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD45A, B CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): FM
EMISSION POINT (STACK) ID NO(S): E45 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filters (2 identical units in parallel) venting through a common stack. Data below reflect combined outlet flow conditions.
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 8.47 7.12 3.81
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 210
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 210
INLET AIR FLOW RATE (ACFM): 125438 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Exhaust from Finish mill 1 (CD45A) and Finish mill 2 (CD45B)
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD32 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHSL
EMISSION POINT (STACK) ID NO(S): E32 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 1.81 1.52 0.82
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 26910 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement dome
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD33 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHSL
EMISSION POINT (STACK) ID NO(S): E33 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.12 0.10 0.05
PRESSURE DROP (IN. H20): MIN: MAX: TB GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 1800 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement dome extraction rail
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD34 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHSL
EMISSION POINT (STACK) ID NO(S): E34 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.12 0.10 0.05
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 1800 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement dome extraction truck
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
NOTE
PLEASE NOTE THAT THE FOLLOWING C1 FORMS IN THE ORIGINAL APPLICATION HAVE BEEN DELETED:
E35, E36, E37, E38, E39 (FORMERLY IN CHSL GROUP)
(October 2008)
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD40 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHSL
EMISSION POINT (STACK) ID NO(S): E40 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 1.53 1.29 0.69
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 22750 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement silo
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD41 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHSL
EMISSION POINT (STACK) ID NO(S): E41 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.09 0.07 0.04
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 1271 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement silo extration
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD42 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHSL
EMISSION POINT (STACK) ID NO(S): E42 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.17 0.15 0.08
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 2578 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Cement transport
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01 C1
CONTROL DEVICE ID NO: CD43 CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): CHSL
EMISSION POINT (STACK) ID NO(S): E43 POSITION IN SERIES OF CONTROLS NO. 1 OF 1 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE:
PROPOSED START CONSTRUCTION DATE:
Fabric filter
POLLUTANT(S) COLLECTED: PM PM10 PM2.5
BEFORE CONTROL EMISSION RATE (LB/HR): NA NA NA
CAPTURE EFFICIENCY: 100 % 100 % 100 % %
CONTROL DEVICE EFFICIENCY: 99.9 % 99.9 % 99+ % %
CORRESPONDING OVERALL EFFICIENCY: 99.9 % 99.9 % 99+ % %
EFFICIENCY DETERMINATION CODE: 4 4 4
TOTAL EMISSION RATE (LB/HR): 0.50 0.42 0.22
PRESSURE DROP (IN. H20): MIN: MAX: TBD GAUGE?
BULK PARTICLE DENSITY (LB/FT3): NA INLET TEMPERATURE (oF): MIN MAX 212
POLLUTANT LOADING RATE: NA G LB/HR G GR/FT3 OUTLET TEMPERATURE (oF): MIN MAX 212
INLET AIR FLOW RATE (ACFM): 7416 FILTER MAX OPERATING TEMP. (oF): TBD
NO. OF COMPARTMENTS: TBD NO. OF BAGS PER COMPARTMENT: TBD LENGTH OF BAG (IN.): TBD
DIAMETER OF BAG (IN.): TBD DRAFT: X INDUCED/NEG. G FORCED/POS. FILTER SURFACE AREA (FT2): TBD
AIR TO CLOTH RATIO: TBD FILTER MATERIAL: TBD G WOVEN G FELTED
DESCRIBE CLEANING PROCEDURES:
X AIR PULSE G SONIC
G REVERSE FLOW G SIMPLE BAG COLLAPSE
G MECHANICAL/SHAKER G RING BAG COLLAPSE
G OTHER
DESCRIBE INCOMING AIR STREAM:
Packing plant
METHOD FOR DETERMINING WHEN TO CLEAN:
G AUTOMATIC G TIMED G MANUAL
METHOD FOR DETERMINING WHEN TO REPLACE THE BAGS:
G ALARM G INTERNAL INSPECTION G VISIBLE EMISSION G OTHER
SPECIAL CONDITIONS:
G MOISTURE BLINDING G CHEMICAL RESISTIVITY G OTHER
EXPLAIN:
X YES G NO WARNING ALARM? G YES X NO
PARTICLE SIZE DISTRIBUTION
FORM C1CONTROL DEVICE (FABRIC FILTER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
Oct-11
OPERATING SCENARIO: Feb-09
1 OF 1 P.E. SEAL REQUIRED (PER 2Q .0112)? YES
DESCRIBE CONTROL SYSTEM:
>100
SIZE WEIGHT % CUMULATIVE
(MICRONS) OF TOTAL %
Attach Additional Sheets As Necessary
0-1
1-10
10-25
25-50
50-100
TOTAL = 100
DESCRIBE MAINTENANCE PROCEDURES: To be included in O&M plan required pursuant to 40 CFR 63.1350(a), including cleaning method and bag
replacement schedule. The only particle size information is PM 10 and PM2.5 fractions per AP-42.
ON A SEPARATE PAGE, ATTACH A DIAGRAM SHOWING THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
REVISED 12/01/01
CONTROL DEVICE ID NO: CD44N CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): KS
EMISSION POINT (STACK) ID NO(S)E44 POSITION IN SERIES OF CONTROLSNO. 1 OF 3 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE: Oct-11
PROPOSED START CONSTRUCTION DATE Feb-09
DESCRIBE CONTROL SYSTEM:
A selective non-catalytic reduction (SNCR) system will be installed in the preheater area of the kiln system to control NOx emissions.
The system will inject an ammonia-containing solution into the process where kiln feed and combustion gases mix in countercurrent flow.
The system may be operated at a variable input rate (TBD) to limit NOx emissions to 1.95 lb/ton clinker as BACT.
POLLUTANT(S) COLLECTED: NOxBEFORE CONTROL EMISSION RATE (LB/HR): ~700CAPTURE EFFICIENCY: 100 % % % %
CONTROL DEVICE EFFICIENCY: 30+ % % % %
CORRESPONDING OVERALL EFFICIENCY: 30 % % % %
EFFICIENCY DETERMINATION CODE: 4
TOTAL EMISSION RATE (LB/HR): 487.50
PRESSURE DROP (IN. H20): MIN NA MAX NA BULK PARTICLE DENSITY (LB/FT3) NA
INLET TEMPERATURE (oF): MIN MAX
INLET AIR FLOW RATE (ACFM): TBD OUTLET AIR FLOW RATE (ACFM): NA
INLET AIR FLOW VELOCITY (FT/SE TBD OUTLET AIR FLOW VELOCITY (FT/SEC): NA
INLET MOISTURE CONTENT (%): TBD FORCED AIR INDUCED AIR
COLLECTION SURFACE AREA (FT2NA FUEL USAGE RATE: NA
DESCRIBE STARTUP PROCEDURES:
To be included in the O&M plan required pursuant to 40 CFR 63.1350(a).
DESCRIBE MAINTENANCE PROCEDURES:
To be included in the O&M plan required pursuant to 40 CFR 63.1350(a).
DESCRIBE ANY AUXILIARY MATERIALS INTRODUCED INTO THE CONTROL SYSTEM:
Aqueous ammonia or equivalent
DESCRIBE ANY MONITORING DEVICES, GAUGES, TEST PORTS, ETC:
ATTACH A DIAGRAM OF THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
OUTLET TEMPERATURE (oF): MIN NA MAX NA
SNCR injection rate will be continuously monitored. NOx will be monitored by CERM at the stack.
OPERATING SCENARIO:
FUEL USED: None
The SNCR system is located at the Preheater Tower (E13) on the CCC overall plant process flow diagram.
Attach manufacturer's specifications, schematics, and all other drawings necessary to describe this control.
P.E. SEAL REQUIRED (PER 2Q .0112)? YES
FORM C9
C9
CONTROL DEVICE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
1 OF 1
Attach Additional Sheets As Necessary
REVISED 12/01/01
CONTROL DEVICE ID NO: CD44S CONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NO(S): KS
EMISSION POINT (STACK) ID NO(S)E44 POSITION IN SERIES OF CONTROLSNO. 2 OF 3 UNITS
MANUFACTURER: TBD MODEL NO: TBD
DATE MANUFACTURED: TBD PROPOSED OPERATION DATE: Oct-11
PROPOSED START CONSTRUCTION DATE Feb-09
DESCRIBE CONTROL SYSTEM:
A lime injection system will be installed on the kiln system to control SO2 emissions during both raw mill-on and raw mill-off operating conditions.
The system will inject wet lime (slurry) into the kiln gas stream at 2 different locations: 1) in the raw mill, during mill-on operating condition,
and 2) in the conditioning tower at the preheater exit, during mill-off operating condition.
The system may be operated at a variable input rate (TBD) to limit SO2 emissions to 1.33 & 1.80 lb/ton clinker (30-day & 24-hr averages) as BACT.
POLLUTANT(S) COLLECTED: SO2BEFORE CONTROL EMISSION RATE (LB/HR): ~1,075 (at preheater exit)
CAPTURE EFFICIENCY: 100 % % % %
CONTROL DEVICE EFFICIENCY: 65-75* % % % %
CORRESPONDING OVERALL EFFICIENCY: 65-75 % % % %
EFFICIENCY DETERMINATION CODE: 4 *Note 75% control includes inherent scrubbing effect of the raw mill.
TOTAL EMISSION RATE (LB/HR): 332.5 - 450 (30-day & 24-hr averages)
PRESSURE DROP (IN. H20): MIN NA MAX NA BULK PARTICLE DENSITY (LB/FT3) NA
INLET TEMPERATURE (oF): MIN MAX
INLET AIR FLOW RATE (ACFM): TBD OUTLET AIR FLOW RATE (ACFM): NA
INLET AIR FLOW VELOCITY (FT/SE TBD OUTLET AIR FLOW VELOCITY (FT/SEC): NA
INLET MOISTURE CONTENT (%): TBD FORCED AIR INDUCED AIR
COLLECTION SURFACE AREA (FT2NA FUEL USAGE RATE: NA
DESCRIBE STARTUP PROCEDURES:
To be included in the O&M plan required pursuant to 40 CFR 63.1350(a).
DESCRIBE MAINTENANCE PROCEDURES:
To be included in the O&M plan required pursuant to 40 CFR 63.1350(a).
DESCRIBE ANY AUXILIARY MATERIALS INTRODUCED INTO THE CONTROL SYSTEM:
Lime slurry
DESCRIBE ANY MONITORING DEVICES, GAUGES, TEST PORTS, ETC:
ATTACH A DIAGRAM OF THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S):
FORM C9
C9
CONTROL DEVICE (OTHER)
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
1 OF 1
OUTLET TEMPERATURE (oF): MIN NA MAX NA
Lime injection rate will be continuously monitored. SO2 will be monitored by CERM at the stack.
OPERATING SCENARIO:
FUEL USED: None
Lime injection points are located 1) at the Raw Mill (E7) and 2) at the Preheater Tower exit (E13) on the CCC overall plant process flow diagram.
Attach manufacturer's specifications, schematics, and all other drawings necessary to describe this control.
P.E. SEAL REQUIRED (PER 2Q .0112)? YES
Attach Additional Sheets As Necessary
REVISED 12/01/01 D1
AIR POLLUTANT EMITTED
HAZARDOUS AIR POLLUTANT EMITTED CAS NO.
ASC
71432
BEC
CDC
CRC
50000
7647010
MNC
HGC
TOXIC AIR POLLUTANT EMITTED CAS NO. lb/hr lb/day lb/year Yes No
7664417 2.50E+00 6.00E+01 2.19E+04 X
ASC 3.35E-03 8.05E-02 2.94E+01 X
71432 7.81E-01 1.87E+01 6.79E+03 X
BEC 2.09E-04 5.03E-03 1.84E+00 X
CDC 5.86E-04 1.41E-02 5.13E+00 X
NSCR6 2.85E-04 6.83E-03 2.49E+00 X
16984488 2.25E-01 5.40E+00 1.97E+03 X
50000 1.16E-01 2.77E+00 1.01E+03 X
7647010 7.18E+00 1.72E+02 6.29E+04 X
MNC 2.22E-01 5.33E+00 1.94E+03 X
HGC 3.00E-02 7.20E-01 2.63E+02 X
NA
0.086
175.24
1,456.45
2,138.03
POTENTIAL EMISSIONS
BEFORE CONTROLS /
527.44
3068.8
348.05
(AFTER CONTROLS /
LIMITATIONS)
Mercury
(AFTER CONTROLS /
LIMITATIONS)
(AFTER CONTROLS /
LIMITATIONS)
175.24
Beryllium
Cadmium
INDICATE REQUESTED ACTUAL EMISSIONS AFTER CONTROLS / LIMITATIONS. EMISSIONS ABOVE THE TOXIC PERMIT EMISSION RATE
(TPER) IN 15A NCAC 2Q .0711 MAY REQUIRE AIR DISPERSION MODELING. USE NETTING FORM D2 IF NECESSARY.
Hydrogen Chloride
Manganese
Fluorides
Modeling Required ?
Chromium (VI)
Benzene
LIMITATIONS)
NA
NA1.31E-01
1.61E-01
NITROGEN OXIDES (NOx)
NA
NA
OTHER
Formaldehyde
Hydrogen Chloride
Manganese
Formaldehyde
NA
Mercury
Attach Additional Sheets As Necessary
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
EXPECTED ACTUAL EMISSIONSPOTENTIAL EMISSIONPOTENTIAL EMISSIONS
EXPECTED ACTUAL EMISSIONS
LIMITATIONS)
(AFTER CONTROLS /
LIMITATIONS)
tons/yr
BEFORE CONTROLS /
9.18E-04
PARTICULATE MATTER < 10 MICRONS (PM10)
PARTICULATE MATTER < 2.5 MICRONS (PM2.5)
SULFUR DIOXIDE (SO2)
9.72E-01
3,067.54
LEAD 0.086
tons/yr
VOLATILE ORGANIC COMPOUNDS (VOC)
FORM D1
tons/yr
662.56
tons/yr tons/yr
NA 662.56
FACILITY-WIDE EMISSIONS SUMMARY
PARTICULATE MATTER (PM)
POTENTIAL EMISSION
527.44
348.05
1.47E-02
NA
NA
NA
NA
HAZARDOUS AIR POLLUTANT EMISSIONS INFORMATION - FACILITY-WIDE
tons/yr
1.47E-02
5.04E-01
9.72E-01
3.14E+01
CRITERIA AIR POLLUTANT EMISSIONS INFORMATION - FACILITY-WIDE
NA
1,456.45
3,067.54
2880.5
2,138.03
CARBON MONOXIDE (CO)
9.18E-04
Benzene
Beryllium
Arsenic
2.57E-03
1.61E-01
NA 3.40E+003.40E+00
NA
2.57E-03
Ammonia
5.04E-01
Chromium (Total)
Cadmium
TOXIC AIR POLLUTANT EMISSIONS INFORMATION - FACILITY-WIDE
NA
1.31E-01
3.14E+01
COMMENTS:
See attached spreadsheet for additional HAP and TAP emissions (those not requiring modeling).
Arsenic
REVISED: 12/01/0
1. Maintenance activities 2Q .0102 (c)(1)(A)
2. Air conditioning equipment 2Q .0102 (c)(1)(B)
3. Laboratory activities 2Q .0102 (c)(1)(C)
4. Storage tanks 2Q .0102 (c)(1)(D)
5. Space and hot water heaters 2Q .0102 (c)(1)(E)
6. Diesel, kerosene, etc. dispensing equipment 2Q .0102 (c)(1)(H)
7. Motor vehicles, non-road engines, and portable generators 2Q .0102 (c)(1)(L)(i)-(iii)
8. Storage tanks meeting listed criteria 2Q .0102 (c)(2)(A)
9. Emergency and portable generators and other internal 2Q .0102 (c)(2)(B)(v) and (vi)
combustion engines meeting listed criteria
10.
NA
< Applicable thresholds
Attach Additional Sheets As Necessary
DESCRIPTION OF EMISSION SOURCEBASIS FOR EXEMPTION OR
INSIGNIFICANT ACTIVITY
SIZE OR
PRODUCTION
RATE
< Applicable thresholds
NA
NA
NA
NA
NA
NA
FORM D4
INSIGNIFICANT ACTIVITIES PER 2Q .0503 FOR TITLE V SOURCESACTIVITIES EXEMPTED PER 2Q .0102 OR
EXEMPT AND INSIGNIFICANT ACTIVITIES SUMMARY
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate D4
REVISED: 12/01/01 D5 PROVIDE DETAILED TECHNICAL CALCULATIONS TO SUPPORT ALL EMISSION, CONTROL, AND REGULATORY
DEMONSTRATIONS MADE IN THIS APPLICATION. INCLUDE A COMPREHENSIVE PROCESS FLOW DIAGRAM AS
NECESSARY TO SUPPORT AND CLARIFY CALCULATIONS AND ASSUMPTIONS. ADDRESS THE FOLLOWING SPECIFIC ISSUES ON SEPARATE PAGES:
A
B
C
D
E PROFESSIONAL ENGINEERING SEAL -
NEW SOURCES AND MODIFICATIONS OF EXISTING SOURCES. (SEE INSTRUCTIONS FOR FURTHER APPLICABILITY).
I, John P. Carroll Jr., attest that this application for Carolinas Cement Company LLC
has been reviewed by me and is accurate, complete and consistent with the information supplied
in the engineering plans, calculations, and all other supporting documentation to the best of my knowledge. I further attest that to the best of my
knowledge the proposed design has been prepared in accordance with the applicable regulations. Although certain portions of this submittal
package may have been developed by other professionals, inclusion of these materials under my seal signifies that I have reviewed this material
and have judged it to be consistent with the proposed design. Note: In accordance with NC General Statutes 143-215.6A and 143-215.6B, any
person who knowingly makes any false statement, representation, or certification in any application shall be guilty of a Class 2 misdemeanor which
may include a fine not to exceed $10,000 as well as civil penalties up to $25,000 per violation.
(PLEASE USE BLUE INK TO COMPLETE THE FOLLOWING)
NAME:
DATE:
COMPANY:
ADDRESS:
TELEPHONE:
SIGNATURE:
PAGES CERTIFIED:
PURSUANT TO 15A NCAC 2Q .0112 "APPLICATION REQUIRING A PROFESSIONAL ENGINEERING SEAL,"
A PROFESSIONAL ENGINEER REGISTERED IN NORTH CAROLINA SHALL BE REQUIRED TO SEAL TECHNICAL PORTIONS OF THIS APPLICATION FOR
SPECIFIC EMISSIONS SOURCE (EMISSION INFORMATION) (FORM B) - SHOW CALCULATIONS USED, INCLUDING EMISSION FACTORS, MATERIAL
BALANCES, AND/OR OTHER METHODS FROM WHICH THE POLLUTANT EMISSION RATES IN THIS APPLICATION WERE DERIVED. INCLUDE CALCULATION
OF POTENTIAL BEFORE AND, WHERE APPLICABLE, AFTER CONTROLS. CLEARLY STATE ANY ASSUMPTIONS MADE AND PROVIDE ANY REFERENCES
AS NEEDED TO SUPPORT MATERIAL BALANCE CALCULATIONS.
SPECIFIC EMISSION SOURCE (REGULATORY INFORMATION)(FORM E2 - TITLE V ONLY) - PROVIDE AN ANALYSIS OF ANY REGULATIONS APPLICABLE TO
INDIVIDUAL SOURCES AND THE FACILITY AS A WHOLE. INCLUDE A DISCUSSION OUTING METHODS (e.g. FOR TESTING AND/OR MONITORING
REQUIREMENTS) FOR COMPLYING WITH APPLICABLE REGULATIONS, PARTICULARLY THOSE REGULATIONS LIMITING EMISSIONS BASED ON PROCESS
RATES OR OTHER OPERATIONAL PARAMETERS. PROVIDE JUSTIFICATION FOR AVOIDANCE OF ANY FEDERAL REGULATIONS (PREVENTION OF
SIGNIFICANT DETERIORATION (PSD), NEW SOURCE PERFORMANCE STANDARDS (NSPS), NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR
POLLUTANTS (NESHAPS), TITLE V), INCLUDING EXEMPTIONS FROM THE FEDERAL REGULATIONS WHICH WOULD OTHERWISE BE APPLICABLE TO THIS
FACILITY. SUBMIT ANY REQUIRED TO DOCUMENT COMPLIANCE WITH ANY REGULATIONS. INCLUDE EMISSION RATES CALCULATED IN ITEM "A"
ABOVE, DATES OF MANUFACTURE, CONTROL EQUIPMENT, ETC. TO SUPPORT THESE CALCULATIONS.
CONTROL DEVICE ANALYSIS (FORM C) - PROVIDE A TECHNICAL EVALUATION WITH SUPPORTING REFERENCES FOR ANY CONTROL EFFICIENCIES
LISTED ON SECTION C FORMS, OR USED TO REDUCE EMISSION RATES IN CALCULATIONS UNDER ITEM "A" ABOVE. INCLUDE PERTINENT OPERATING
PARAMETERS (e.g. OPERATING CONDITIONS, MANUFACTURING RECOMMENDATIONS, AND PARAMETERS AS APPLIED FOR IN THIS APPLICATION)
CRITICAL TO ENSURING PROPER PERFORMANCE OF THE CONTROL DEVICES). INCLUDE AND LIMITATIONS OR MALFUNCTION POTENTIAL FOR THE
PARTICULAR CONTROL DEVICES AS EMPLOYED AT THIS FACILITY. DETAIL PROCEDURES FOR ASSURING PROPER OPERATION OF THE CONTROL
DEVICE INCLUDING MONITORING SYSTEMS AND MAINTENANCE TO BE PERFORMED.
NCDENR/Division of Air Quality - Application for Air Permit to Construct/Operate
TECHNICAL ANALYSIS TO SUPPORT PERMIT APPLICATION
FORM D
Attach Additional Sheets As Necessary
PLACE NORTH CAROLINA SEAL HERE
(IDENTIFY ABOVE EACH PERMIT FORM AND ATTACHMENT
THAT IS BEING CERTIFIED BY THIS SEAL)
PROCESS AND OPERATIONAL COMPLIANCE ANALYSIS - (FORM E3 - TITLE V ONLY) - SHOWING HOW COMPLIANCE WILL BE ACHIEVED WHEN USING
PROCESS, OPERATIONAL, OR OTHER DATA TO DEMONSTRATE COMPLIANCE. REFER TO COMPLIANCE REQUIREMENTS IN THE REGULATORY
ANALYSIS IN ITEM "B" WHERE APPROPRIATE. LIST ANY CONDITIONS OR PARAMETERS THAT CAN BE MONITORED AND REPORTED TO DEMONSTRATE
COMPLIANCE WITH THE APPLICABLE REGULATIONS.
TAB C
PLANTWIDE POTENTIAL EMISSIONS INVENTORY – REVISED
Carolinas Cement PTE Emission Summary
Version 102008
Plantwide Emissions
EU DescriptionPM
tons/yr
PM10
tons/yr
PM2.5
tons/yr
SO2
tons/yr
NOX
tons/yr
CO
tons/yr
VOC
tons/yr
Pb
tons/yr
Fluorides
tons/yr
HCl
tons/yr
Total
HAPs
tons/yrPoint Sources
Kiln System 432.59 391.41 291.03 1456.35 2135.25 3066.00 175.20 0.082 0.99 31.43 41.001
Raw Mill & Kiln Feed 20.90 17.56 9.41 0.00 0.00 0.00 0.00 0.002 0.00 0.00 0.009
Coal/Coke System 12.58 10.57 5.66 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.001
Clinker Transfer & Storage 2.91 2.45 1.31 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.001
Finish Mills 57.79 48.55 26.01 0.00 0.00 0.00 0.00 0.001 0.00 0.00 0.021
Cement Transfer & Storage 19.03 15.99 8.57 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.007
Existing Terminal 2.25 1.89 1.01 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.001
Emergency Generator 0.09 0.07 0.07 0.10 2.78 1.54 0.04 0.000 0.00 0.00 0.003
Subtotal Point Sources 548.16 488.48 343.06 1456.45 2138.03 3067.54 175.24 0.085 0.99 31.43 41.044
Fugitive Sources
Quarry Equipment 6.99 3.20 0.55 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.002
Plant Process Equipment 4.62 2.18 0.33 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.002
Wind Erosion - Storage Piles 8.40 4.20 0.63 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.004
Mining Operations 15.53 7.78 1.05 0.00 0.00 0.00 0.00 0.000 0.00 0.00 0.004
Plant Roads 9.31 1.81 0.44 NA NA NA NA NA NA NA NA
Quarry Roads 69.57 19.78 1.98 NA NA NA NA NA NA NA NA
Subtotal Fugitive Sources 114.41 38.96 4.99 0.00 0.00 0.00 0.00 0.001 0.00 0.00 0.012
Total Emissions 662.56 527.44 348.05 1,456.45 2,138.03 3,067.54 175.24 0.086 0.99 31.43 41.056
Notes
Kiln system includes the preheater/precalciner kiln with in-line raw mill, coal mill, and clinker cooler venting through the main stack.
Kiln PM emissions include an estimate of condensible particulate matter. See "Kiln System" sheet for details.
W:\5000\050020\050020.0051\PSD Application Revision 10-08 (Final Documents)\Tab C - Plantwide Potential Emissions Inventory\Carolinas Cement PTE Page 1 of 53
Carolinas Cement PTE HAP-TAP Summary
CAS No. Pollutant TAP HAPKiln
System
Raw Mill &
Kiln Feed
Solid Fuel
System
Clinker
Transfer &
Storage
Finish
Mills
Cement
Transfer &
Storage
Existing
Terminal
Emergency
Generator
Quarry
Equip.
Process
Fugitive
Storage
Piles
Mining
Operation
Total
(ton/yr)
Total
(lbs/yr)
83329 Acenaphthene (Component of POM) X 9.17E-06 9.17E-06 0.018
208968 Acenaphthylene (Component of POM) X 1.31E-01 1.81E-05 1.31E-01 262.836
75070 Acetaldehyde X X 4.94E-05 4.94E-05 0.099
107028 Acrolein X X 1.54E-05 1.54E-05 0.031
7664417 Ammonia X 1.10E+01 1.10E+01 21900.000
120127 Anthracene (Component of POM) X 2.41E-06 2.41E-06 0.005
SBC Antimony & Compounds X 7.12E-03 5.39E-05 3.61E-05 6.46E-06 3.01E-05 6.38E-06 7.55E-07 1.80E-05 1.32E-05 5.43E-05 1.21E-04 7.46E-03 14.916
ASC Arsenic & Compounds X X 1.31E-02 6.69E-05 2.39E-06 2.24E-06 9.92E-04 3.60E-04 4.26E-05 1.40E-05 1.12E-05 2.50E-05 3.11E-05 1.47E-02 29.375
56553Benz(a)anthracene (Component of POM &
PAH)X 4.71E-05 1.22E-06 4.83E-05 0.097
71432 Benzene X X 3.39E+00 1.52E-03 3.40E+00 6792.041
50328Benzo(a)pyrene (Component of POMT &
PAH)X X 1.42E-04 5.03E-07 1.43E-04 0.286
205992Benzo(b)fluoranthene (Component of POM
& PAH)X 6.13E-04 2.17E-06 6.15E-04 1.231
191242 Benzo(ghi)perylene (Component of POM) X 8.54E-05 1.09E-06 8.65E-05 0.173
207089Benzo(k)fluoranthene (Component of POM
& PAH)X 1.64E-04 4.27E-07 1.65E-04 0.329
BEC Beryllium & Compounds X X 7.23E-04 3.93E-05 4.40E-06 4.37E-07 6.06E-05 2.19E-05 2.59E-06 1.40E-05 7.67E-06 1.28E-05 3.11E-05 9.18E-04 1.835
92524 Biphenyl (Component of POM) X 6.68E-03 6.68E-03 13.359
CDC Cadmium & Compounds X X 2.41E-03 6.16E-05 5.28E-06 1.28E-06 1.22E-05 3.48E-06 4.12E-07 1.33E-05 9.63E-06 2.00E-05 3.03E-05 2.57E-03 5.133
75150 Carbon disulfide X X 1.20E-01 1.20E-01 240.900
108907 Chlorobenzene X X 1.75E-02 1.75E-02 35.040
CRC Chromium & Compounds (Total Cr) X 1.53E-01 1.01E-03 6.29E-05 2.07E-04 3.39E-03 1.23E-03 1.45E-04 1.31E-04 2.72E-04 7.32E-04 3.62E-04 1.61E-01 321.669
NSCR6Chromium (VI) Non-Specific Compounds, as
Cr(VI)X X 4.38E-04 7.50E-06 6.29E-07 3.32E-05 5.39E-04 1.96E-04 2.32E-05 6.99E-07 2.06E-06 4.70E-06 1.55E-06 1.25E-03 2.494
218019 Chrysene (Component of POM & PAH) X 1.75E-04 3.00E-06 1.78E-04 0.356
COC Cobalt Compounds X 1.75E-02 3.62E-04 2.23E-05 5.56E-06 2.94E-04 1.06E-04 1.25E-05 7.89E-05 8.97E-05 2.78E-04 2.16E-04 1.90E-02 37.970
117817 Di(2-ethylhexyl)phthalate (DEHP) X 1.04E-01 1.04E-01 208.050
53703Dibenzo(a,h)anthracene (Component of
POM & PAH)X 6.90E-04 6.78E-07 6.91E-04 1.381
84742 Dibutylphthalate X 4.49E-02 4.49E-02 89.790
D/F Dioxin/Furan X 2.41E-07 2.41E-07 0.000
100414 Ethyl benzene X 2.08E-02 2.08E-02 41.610
206440 Fluoranthene (Component of POM) X 9.64E-03 7.90E-06 9.64E-03 19.288
86737 Fluorene (Component of POM) X 2.08E-02 2.51E-05 2.08E-02 41.660
16984488 Fluorides (sum of all fluoride compounds) X 9.86E-01 9.86E-01 1971.000
50000 Formaldehyde X X 5.04E-01 1.55E-04 5.04E-01 1007.709
7647010 Hydrogen chloride X X 3.14E+01 3.14E+01 62853.000
193395Indeno(1,2,3-cd)pyrene (Component of
POM & PAH)X 9.53E-05 8.11E-07 9.61E-05 0.192
PBC Lead & Compounds X 8.21E-02 1.76E-03 1.27E-05 2.33E-07 6.65E-04 2.36E-04 2.79E-05 2.10E-04 1.81E-04 4.13E-04 4.66E-04 8.61E-02 172.196
MNC Manganese Compounds X X 9.42E-01 4.77E-03 7.30E-06 3.00E-04 1.33E-02 4.80E-03 5.68E-04 1.32E-03 1.02E-03 1.99E-03 2.22E-03 9.72E-01 1944.088
HGC Mercury & Compounds X X 1.31E-01 1.37E-06 1.26E-06 2.62E-07 3.41E-06 7.23E-07 8.56E-08 7.69E-08 3.05E-07 9.71E-07 2.01E-07 1.31E-01 262.817
74873 Methyl chloride X 4.16E-01 4.16E-01 832.200
78933 Methyl ethyl ketone X 3.29E-02 3.29E-02 65.700
74873 Methylene chloride X X 5.37E-01 5.37E-01 1073.100
91203 Naphthalene (Component of POM) X 1.86E+00 2.55E-04 1.86E+00 3723.509
NIC Nickel & Compounds X X 1.53E-02 6.31E-04 7.89E-04 1.83E-05 1.78E-03 6.43E-04 7.61E-05 2.13E-04 1.43E-04 2.17E-04 3.08E-04 2.01E-02 40.291
85018 Phenanthrene (Component of POM) X 4.27E-01 7.99E-05 4.27E-01 854.260
108952 Phenol X X 1.20E-01 1.20E-01 240.900
POM Polycyclic Organic Matter (Total Inc PAH) X 2.46E+00 4.15E-04 2.46E+00 4928.633
129000 Pyrene (Component of POM) X 4.82E-03 7.27E-06 4.83E-03 9.651
SEC Selenium Compounds X 2.19E-01 3.24E-04 8.18E-06 4.95E-07 2.08E-04 6.47E-05 7.66E-06 1.07E-04 5.60E-05 6.35E-05 1.94E-04 2.20E-01 440.067
100425 Styrene X X 1.64E-03 1.64E-03 3.285
108883 Toluene X X 2.08E-01 5.51E-04 2.09E-01 417.201
76131Trichloro-1,2,2-trifluoroethane, 1,1,2- (CFC-
113)X 5.48E-02 5.48E-02 109.500
1330207 Xylene X X 1.42E-01 3.78E-04 1.43E-01 285.456
Total HAPs Only 4.10E+01 9.08E-03 9.52E-04 5.43E-04 2.08E-02 7.46E-03 8.83E-04 3.08E-03 2.12E-03 1.81E-03 3.81E-03 3.98E-03 4.11E+01 82111.349
HAP & TAP EMISSIONS (Ton/Year))
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Carolinas Cement PTE HAP-TAP Summary
CAS No. Pollutant TAP HAPKiln
System
Raw Mill &
Kiln Feed
Solid Fuel
System
Clinker
Transfer &
Storage
Finish
Mills
Cement
Transfer &
Storage
Existing
Terminal
Emergency
Generator
Quarry
Equip.
Process
Fugitive
Storage
Piles
Mining
Operation
Total
(lbs/hr)
Total
(lbs/hr)
83329 Acenaphthene (Component of POM) X 3.67E-05 3.67E-05 0.000
208968 Acenaphthylene (Component of POM) X 3.00E-02 7.23E-05 3.01E-02 0.030
75070 Acetaldehyde X X 1.97E-04 1.97E-04 0.000
107028 Acrolein X X 6.18E-05 6.18E-05 0.000
7664417 Ammonia X 2.50E+00 2.50E+00 2.500
120127 Anthracene (Component of POM) X 9.64E-06 9.64E-06 0.000
SBC Antimony & Compounds X 1.63E-03 1.23E-05 8.24E-06 1.48E-06 6.88E-06 1.46E-06 1.72E-07 4.12E-06 3.00E-06 1.24E-05 2.77E-05 1.70E-03 0.002
ASC Arsenic & Compounds X X 3.00E-03 1.53E-05 5.46E-07 5.12E-07 2.27E-04 8.21E-05 9.72E-06 3.19E-06 2.57E-06 5.72E-06 7.09E-06 3.35E-03 0.003
56553Benz(a)anthracene (Component of POM &
PAH)X 1.08E-05 4.87E-06 1.56E-05 0.000
71432 Benzene X X 7.75E-01 6.08E-03 7.81E-01 0.781
50328Benzo(a)pyrene (Component of POMT &
PAH)X X 3.25E-05 2.01E-06 3.45E-05 0.000
205992Benzo(b)fluoranthene (Component of POM
& PAH)X 1.40E-04 8.70E-06 1.49E-04 0.000
191242 Benzo(ghi)perylene (Component of POM) X 1.95E-05 4.36E-06 2.39E-05 0.000
207089Benzo(k)fluoranthene (Component of POM
& PAH)X 3.75E-05 1.71E-06 3.92E-05 0.000
BEC Beryllium & Compounds X X 1.65E-04 8.98E-06 1.01E-06 9.97E-08 1.38E-05 5.00E-06 5.91E-07 3.19E-06 1.75E-06 2.93E-06 7.09E-06 2.09E-04 0.000
92524 Biphenyl (Component of POM) X 1.53E-03 1.53E-03 0.002
CDC Cadmium & Compounds X X 5.50E-04 1.41E-05 1.21E-06 2.93E-07 2.78E-06 7.95E-07 9.41E-08 3.04E-06 2.20E-06 4.56E-06 6.91E-06 5.86E-04 0.001
75150 Carbon disulfide X X 2.75E-02 2.75E-02 0.028
108907 Chlorobenzene X X 4.00E-03 4.00E-03 0.004
CRC Chromium Compounds (Total Cr) X 3.50E-02 2.31E-04 1.44E-05 4.74E-05 7.73E-04 2.80E-04 3.31E-05 2.98E-05 6.22E-05 1.67E-04 8.27E-05 3.67E-02 0.037
NSCR6Chromium (VI) Non-Specific Compounds, as
Cr(VI)X X 1.00E-04 1.71E-06 1.44E-07 7.58E-06 1.23E-04 4.48E-05 5.30E-06 1.60E-07 4.70E-07 1.07E-06 3.54E-07 2.85E-04 0.000
218019 Chrysene (Component of POM & PAH) X 4.00E-05 1.20E-05 5.20E-05 0.000
COC Cobalt Compounds X 4.00E-03 8.26E-05 5.08E-06 1.27E-06 6.72E-05 2.42E-05 2.86E-06 1.80E-05 2.05E-05 6.34E-05 4.93E-05 4.33E-03 0.004
117817 Di(2-ethylhexyl)phthalate (DEHP) X 2.38E-02 2.38E-02 0.024
53703Dibenzo(a,h)anthracene (Component of
POM & PAH)X 1.58E-04 2.71E-06 1.60E-04 0.000
84742 Dibutylphthalate X 1.03E-02 1.03E-02 0.010
D/F Dioxin/Furan X 5.50E-08 5.50E-08 0.000
100414 Ethyl benzene X 4.75E-03 4.75E-03 0.005
206440 Fluoranthene (Component of POM) X 2.20E-03 3.16E-05 2.23E-03 0.002
86737 Fluorene (Component of POM) X 4.75E-03 1.00E-04 4.85E-03 0.005
16984488 Fluorides (sum of all fluoride compounds) X 2.25E-01 2.25E-01 0.225
50000 Formaldehyde X X 1.15E-01 6.18E-04 1.16E-01 0.116
7647010 Hydrogen chloride X X 7.18E+00 7.18E+00 7.175
193395Indeno(1,2,3-cd)pyrene (Component of
POM & PAH)X 2.18E-05 3.24E-06 2.50E-05 0.000
PBC Lead & Compounds X 1.88E-02 4.02E-04 2.90E-06 5.32E-08 1.52E-04 5.39E-05 6.38E-06 4.79E-05 4.14E-05 9.42E-05 1.06E-04 1.97E-02 0.020
MNC Manganese Compounds X X 2.15E-01 1.09E-03 1.67E-06 6.85E-05 3.05E-03 1.10E-03 1.30E-04 3.02E-04 2.34E-04 4.54E-04 5.06E-04 2.22E-01 0.222
HGC Mercury & Compounds X X 3.00E-02 3.14E-07 2.87E-07 5.98E-08 7.78E-07 1.65E-07 1.95E-08 1.76E-08 6.97E-08 2.22E-07 4.60E-08 3.00E-02 0.030
74873 Methyl chloride X 9.50E-02 9.50E-02 0.095
78933 Methyl ethyl ketone X 7.50E-03 7.50E-03 0.008
74873 Methylene chloride X X 1.23E-01 1.23E-01 0.123
91203 Naphthalene X 4.25E-01 1.02E-03 4.26E-01 0.426
NIC Nickel & Compounds X X 3.50E-03 1.44E-04 1.80E-04 4.18E-06 4.06E-04 1.47E-04 1.74E-05 4.87E-05 3.27E-05 4.95E-05 7.03E-05 4.60E-03 0.005
85018 Phenanthrene (Component of POM) X 9.75E-02 3.20E-04 9.78E-02 0.098
108952 Phenol X X 2.75E-02 2.75E-02 0.028
POM Polycyclic Organic Matter (Total Inc PAH) X 5.63E-01 1.66E-03 5.64E-01 0.564
129000 Pyrene (Component of POM) X 1.10E-03 2.91E-05 1.13E-03 0.001
SEC Selenium Compounds X 5.00E-02 7.40E-05 1.87E-06 1.13E-07 4.75E-05 1.48E-05 1.75E-06 2.45E-05 1.28E-05 1.45E-05 4.43E-05 5.02E-02 0.050
100425 Styrene X X 3.75E-04 3.75E-04 0.000
108883 Toluene X X 4.75E-02 2.20E-03 4.97E-02 0.050
76131Trichloro-1,2,2-trifluoroethane, 1,1,2- (CFC-
113)X 1.25E-02 1.25E-02 0.013
1330207 Xylene X X 3.25E-02 1.51E-03 3.40E-02 0.034
Total HAPs Only 9.36E+00 2.07E-03 2.17E-04 1.24E-04 4.74E-03 1.70E-03 2.02E-04 1.23E-02 4.85E-04 4.13E-04 8.69E-04 9.08E-04 9.39E+00 9.385
HAP & TAP EMISSIONS (Lbs/Hr))
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Carolinas Cement PTE Air Toxics
NC Toxic Air Pollutants Evaluation
Pollutant (CAS No.) CarcinogensChronic
Toxicants
Acute
Systemic
Toxicants
Acute
IrritantsAnnual PTE Max Daily Max Hourly
Modeling
Required?
lb/yr lb/day lb/hr lb/hr lb/yr lb/day lb/hr
acetaldehyde (75-07-0) 6.8 0.10 0.005 0.0002 No
acrolein (107-02-8) 0.02 0.03 0.001 0.0001 No
* ammonia (7664-41-7) 0.68 21900.00 60.000 2.5000 Yes
* arsenic and compounds 0.016 29.37 0.080 0.0034 Yes
* benzene (71-43-2) 8.1 6792.04 18.746 0.7811 Yes
benzo(a)pyrene (50-32-8) 2.2 0.29 0.001 0.0000 No
* beryllium and compounds 0.28 1.84 0.005 0.0002 Yes
* cadmium and compounds 0.37 5.13 0.014 0.0006 Yes
carbon disulfide (75-15-0) 3.9 240.90 0.660 0.0275 No
chlorobenzene (108-90-7) 46 35.04 0.096 0.0040 No
* chromium (VI) compounds 0.0056 2.49 0.007 0.0003 Yes
di(2-ethylhexyl)phthalate (DEHP)
(117-81-7)0.63 208.05 0.570 0.0238 No
* fluorides 0.34 0.064 1971.00 5.400 0.2250 Yes
* formaldehyde (50-00-0) 0.04 1007.71 2.775 0.1156 Yes
* hydrogen chloride (7647-01-0) 0.18 62853.00 172.200 7.1750 Yes
* manganese and compounds 0.63 1944.09 5.326 0.2219 Yes
*mercury, aryl and inorganic
compounds0.013 262.82 0.720 0.0300 Yes
methyl ethyl ketone (78-93-3) 78 22.4 65.70 0.180 0.0075 No
methylene chloride (75-09-2) 1600 0.39 1073.10 2.940 0.1225 No
nickel and compounds 0.13 40.29 0.110 0.0046 No
phenol (108-95-2) 0.24 240.90 0.660 0.0275 No
styrene (100-42-5) 2.7 3.29 0.009 0.0004 No
toluene (108-88-3) 98 14.4 417.20 1.193 0.0497 No
1,1,2-trichloro-1,2,2-
trifluoroethane (76-13-1)240 109.50 0.300 0.0125 No
xylene (1330-02-07) 57 16.4 285.46 0.816 0.0340 No
1 From 15A NCAC 2Q Section .0711 Toxic Air Pollutant Guidelines*Compound requires modeling
Emission Rates Requiring A Permit1 Plantwide Emissions
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Carolinas Cement PTE Throughput Data
Material
tons/hr tons/yr hrs/yr % Material Status
Clinker Produced (Kiln/Cooler)
Raw Mill on 1,752,000 7,008 80.00
Raw Mill off 438,000 1,752 20.00
Kiln total 250 2,190,000 8,760 100.00 Produced (6000 tons/day)
Raw Mill Feed (Dry) 485 3,398,880 7,008 Produced
Virgin Kiln Feed @ 1.542 386 3,376,980 Produced
Kiln Feed w/recycle @ 1.679 420 3,677,010 8,760 Produced
Kiln Fuels Used
Coal/Coke (as fired) 30 262,800 8,760 As fired
Alternative fuels Up to 50% heat input
Raw Material Throughput (Dry Basis)*
Limestone (62.9-64.4%) 1500 2,149,448 8,760 63.65 Mined onsite
Upper Marl (18.3-24.1%) 715,920 21.20 Mined onsite
Other Onsite Materials** (2.9-7.9%) 182,357 5.40 Mined onsite
Subtotal (Quarry Max.) 3,047,724
Mill Scale (0.9-1.0%) 32,081 0.95 Received by truck
Fly Ash/Bottom Ash (9.3-10.4%) 332,633 9.85 Received by truck
Bauxite (0%) 0 0.00 May be substituted
Subtotal (Purchased Max.) 364,714
Total (Dry) 3,412,438 101.05
Raw Mix Required 3,376,980 100.00
Raw Material Throughput (Wet Basis)*
Limestone @ 16% M 1500 2,558,866 8,760 63.13 Mined onsite
Upper Marl @ 16% M 852,285 21.03 Mined onsite
Other Onsite Materials** @ 16% M 217,092 5.36 Mined onsite
Subtotal (Quarry Max.) 3,628,243
Mill Scale @ 5% M 33,770 0.83 Received by truck
Fly Ash/Bottom Ash @ 15% M 391,332 9.65 Received by truck
Bauxite (0%) 0 0.00 May be substituted
Subtotal (Purchased Max.) 425,102
Total (Wet) 4,053,346 100.00
Average moisture content 15.81
Quarry Overburden removed 3,177,255 Mined onsite
Quarry Spoils to Stacker Pile 217,092 Mined onsite
Cement Production
Clinker Cooler 250 2,190,000 8,760 Produced
Clinker transfer to silos 2,190,000 8,760 Transferred
Clinker Silos (2) 2,190,000 8,760 Stored
Fringe Clinker Silo @ 1.0% 21,900 Stored
Gypsum required (5% of cement) 15 120,330
Gypsum @ 6% M 127,549 Received by truck
Limestone required (4% of cement) 96,264
Limestone @ 6% M 102,040 Onsite material
Finish Mills (Cement)
Throughput Capacity
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Carolinas Cement PTE Throughput Data
Material
tons/hr tons/yr hrs/yr % Material Status
Throughput Capacity
Finish Mill #1 150 1,203,297 8,760 Produced
Finish Mill #2 150 1,203,297 8,760 Produced
Total cement 300 2,406,593
Cement Silos 300 2,406,593 8,760 100.00 Stored
Cement Packhouse 170 481,319 8,760 20.00 Packaged
Bulk Cement 1,925,275 8,760 80.00 Loaded, bulk
Cement shipped by truck
Packaged cement 481,319 20.00 Shipped by truck (0-20%)
Bulk cement 350 433,187 18.00 Shipped by truck (18-30%)
Subtotal 914,505 38.00 Total trucked (30-38%)
Cement shipped by rail 350 1,010,769 42.00 Shipped by rail (42-70%)
Cement shipped by barge 500 481,319 20.00 Shipped by barge (0-20%)
Total cement shipped 2,406,593 100.00
Fuel Unloading
Coal/coke @ 8% M 283,824 8,760 100.00 Received by rail (60-100%)
113,530 40.00 Received by truck (0-40%)
Mining Operation
No. of holes drilled 15,200
Ave depth (ft) 5
Total feet of holes drilled 76,000
No. of blasts 76
Ave area of blast (sq ft) 20,000
* Individual quantities of the raw material components will vary.
** Other onsite materials may include spoils, lower marl, brown clay, or green clay.
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Carolinas Cement PTE Kiln System
Max. Average
Process Throughput Pollutant RM On RM Off lb/T basis EF Source RM On RM Off tons/yr7 lbs/yr lbs/hr8 lbs/hr9
PM (filterable) 0.1400 0.1400 kiln feed Note 1 205.91 51.48 257.39 58.77 58.77
PM10 (filterable) 0.1176 0.1176 kiln feed Note 2 172.97 43.24 216.21 49.36 49.36
PM2.5 (filterable) 0.0630 0.0630 kiln feed Note 2 92.66 23.17 115.83 26.44 26.44
RM On: 1,752,000 Condensible PM 0.16 0.16 clinker Note 3 140.16 35.04 175.20 40.00 40.00
RM Off: 438,000 Total PM NA NA NA Note 4 346.07 86.52 432.59 98.77 98.77
Total 2,190,000 Total PM10 NA NA NA Note 4 313.13 78.28 391.41 89.36 89.36
Total PM2.5 NA NA NA Note 4 232.82 58.21 291.03 66.44 66.44
SO2 1.21 1.80 clinker Note 1 1062.15 394.20 1456.35 450.00 332.50
NOx 1.95 1.95 clinker Note 1 1708.20 427.05 2135.25 487.50 487.50
RM On: 2,941,608 CO 2.80 2.80 clinker Note 1 2452.80 613.20 3066.00 700.00 700.00
RM Off: 735,402 VOC 0.16 0.16 clinker Note 1 140.16 35.04 175.20 40.00 40.00
Total 3,677,010 Lead 7.5E-05 7.5E-05 clinker Note 6 0.0657 0.0164 0.0821 164 0.0188 0.0188
Fluorides 9.0E-04 9.0E-04 clinker Note 6 0.7884 0.1971 0.9855 1,971 0.2250 0.2250
SO2 Ave = 1.33 HAPs/TAPs
lb/T clkr Ammonia 0.010 0.010 clinker Note 6 8.7600 2.1900 10.9500 21,900 2.5000 2.5000
Antimony 6.5E-06 6.5E-06 clinker Note 12 0.0057 0.0014 0.0071 14 0.0016 0.0016
Arsenic 1.2E-05 1.2E-05 clinker Note 6 0.0105 0.0026 0.0131 26 0.0030 0.0030
Benzene 3.1E-03 3.1E-03 clinker Note 6 2.7156 0.6789 3.3945 6,789 0.7750 0.7750
Beryllium 6.6E-07 6.6E-07 clinker Note 6 0.0006 0.0001 0.0007 1.4 0.0002 0.0002
Cadmium 2.2E-06 2.2E-06 clinker Note 6 0.0019 0.0005 0.0024 4.8 0.0006 0.0006
Carbon disulfide 1.1E-04 1.1E-04 clinker Note 6 0.0964 0.0241 0.1205 240.9 0.0275 0.0275
Chlorobenzene 1.6E-05 1.6E-05 clinker Note 6 0.0140 0.0035 0.0175 35.0 0.0040 0.0040
Chromium (Total) 1.4E-04 1.4E-04 clinker Note 6 0.1226 0.0307 0.1533 306.6 0.0350 0.0350
Chromium (VI) 4.0E-07 4.0E-07 clinker Note 11 0.0004 0.0001 0.0004 0.88 0.0001 0.0001
Cobalt 1.6E-05 1.6E-05 clinker Note 12 0.0140 0.0035 0.0175 35 0.0040 0.0040
Dibutylphthalate 4.1E-05 4.1E-05 clinker Note 6 0.0359 0.0090 0.0449 89.8 0.0103 0.0103
Di(2-ethylhexyl)
phthalate (DEHP)9.5E-05 9.5E-05 clinker Note 6 0.0832 0.0208 0.1040 208 0.0238 0.0238
Dioxin/Furan 2.2E-10 2.2E-10 clinker Note 6, 13 1.93E-07 4.82E-08 2.41E-07 4.82E-04 5.50E-08 5.50E-08
Ethylbenzene 1.9E-05 1.9E-05 clinker Note 6 1.66E-02 4.16E-03 2.08E-02 42 0.0048 0.0048
Formaldehyde 4.6E-04 4.6E-04 clinker Note 6 4.03E-01 1.01E-01 5.04E-01 1007 0.1150 0.1150
420
Kiln System (Main Stack) - Potential Emissions
Emission Factor tons/yr
AnnualThroughput
(tons clinker)
Annual
Throughput
(tons kiln
feed)
HourlyRate
(ton/hr
clinker)
HourlyRate
(ton/hrkiln feed)
250
Total
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Carolinas Cement PTE Kiln System
Max. Average
Process Throughput Pollutant RM On RM Off lb/T basis EF Source RM On RM Off tons/yr7 lbs/yr lbs/hr8 lbs/hr9
Kiln System (Main Stack) - Potential Emissions
Emission Factor tons/yr Total
HCl 0.0287 0.0287 clinker Note 5 25.14 6.29 31.43 62,853 7.1750 7.1750
Manganese 8.6E-04 8.6E-04 clinker Note 6 0.7534 0.1883 0.9417 1,883 0.2150 0.2150
Mercury 1.2E-04 1.2E-04 clinker Note 14 0.1051 0.0263 0.1314 263 0.0300 0.0300
Methyl chloride 3.8E-04 3.8E-04 clinker Note 6 0.3329 0.0832 0.4161 832 0.0950 0.0950
Methyl ethyl ketone 3.0E-05 3.0E-05 clinker Note 6 0.0263 0.0066 0.0329 66 0.0075 0.0075
Methylene chloride 4.9E-04 4.9E-04 clinker Note 6 0.4292 0.1073 0.5366 1,073 0.1225 0.1225
Nickel 1.4E-05 1.4E-05 clinker Note 12 0.0123 0.0031 0.0153 31 0.0035 0.0035
Phenol 1.1E-04 1.1E-04 clinker Note 6 0.0964 0.0241 0.1205 241 0.0275 0.0275
Selenium 2.0E-04 2.0E-04 clinker Note 6 0.1752 0.0438 0.2190 438 0.0500 0.0500
Styrene 1.5E-06 1.5E-06 clinker Note 6 0.0013 0.0003 0.0016 3 0.0004 0.0004
Toluene 1.9E-04 1.9E-04 clinker Note 6 0.1664 0.0416 0.2081 416 0.0475 0.0475
1,1,2-trichloro-1,2,2-
trifluoroethane5.0E-05 5.0E-05 clinker Note 6 0.0438 0.0110 0.0548 110 0.0125 0.0125
Xylenes 1.3E-04 1.3E-04 clinker Note 6 0.1139 0.0285 0.1424 285 0.0325 0.0325
POM
Acenaphthylene 1.2E-04 1.2E-04 clinker Note 6 0.1051 0.0263 0.1314 262.8 0.0300 0.0300
Benz(a)anthracene 4.3E-08 4.3E-08 clinker Note 6 0.0000 0.0000 0.0000 0.1 0.0000 0.0000
Benzo(a)pyrene 1.3E-07 1.3E-07 clinker Note 6 0.0001 0.0000 0.0001 0.3 0.0000 0.0000
Benzo(b)fluoranthene 5.6E-07 5.6E-07 clinker Note 6 0.0005 0.0001 0.0006 1.2 0.0001 0.0001
Benzo(g,h,l)perylene 7.8E-08 7.8E-08 clinker Note 6 0.0001 0.0000 0.0001 0.2 0.0000 0.0000
Benzo(k)fluoranthene 1.5E-07 1.5E-07 clinker Note 6 0.0001 0.0000 0.0002 0.3 0.0000 0.0000
Biphenyl 6.1E-06 6.1E-06 clinker Note 6 0.0053 0.0013 0.0067 13.4 0.0015 0.0015
Chrysene 1.6E-07 1.6E-07 clinker Note 6 0.0001 0.0000 0.0002 0.4 0.0000 0.0000
Dibenz(a,h)anthracene 6.3E-07 6.3E-07 clinker Note 6 0.0006 0.0001 0.0007 1.4 0.0002 0.0002
Fluoranthene 8.8E-06 8.8E-06 clinker Note 6 0.0077 0.0019 0.0096 19.3 0.0022 0.0022
Fluorene 1.9E-05 1.9E-05 clinker Note 6 0.0166 0.0042 0.0208 41.6 0.0048 0.0048
Indeno(1,2,3-cd)pyrene 8.7E-08 8.7E-08 clinker Note 6 0.0001 0.0000 0.0001 0.2 0.0000 0.0000
Naphthalene 1.7E-03 1.7E-03 clinker Note 6 1.4892 0.3723 1.8615 3,723.0 0.4250 0.4250
Phenanthrene 3.9E-04 3.9E-04 clinker Note 6 0.3416 0.0854 0.4271 854.1 0.0975 0.0975
Pyrene 4.4E-06 4.4E-06 clinker Note 6 0.0039 0.0010 0.0048 9.6 0.0011 0.0011
Total POM 1.9711 0.4928 2.4639 4,927.8 0.5625 0.5625
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Carolinas Cement PTE Kiln System
Max. Average
Process Throughput Pollutant RM On RM Off lb/T basis EF Source RM On RM Off tons/yr7 lbs/yr lbs/hr8 lbs/hr9
Kiln System (Main Stack) - Potential Emissions
Emission Factor tons/yr Total
Notes
1 Proposed BACT emission limits based on site-specific kiln design and materials.
2 PM10 estimated at 84% of PM emissions, and PM2.5 estimated at 45% of PM emissions, using AP-42 Table 11.6-5
3 Emission factor for condensible PM from AP-42 Table 11.6-2. There is considerable uncertainty with this factor.
4 Total PM is the sum of filterable and condensible PM.
5 HCl emission factor from Portland Cement Manufacturing Reporting Under Section 313 of EPCRA
(Toxic Release Inventory) , Portland Cement Association, 2003
6 Emission factors from EPA's AP-42 Table 11.6-9
7 Total tons/yr = annual throughput x emission factor / 2000 (sum of raw mill on & raw mill off)
8 Max lbs/yr = hourly throughput (see Throughput Data sheet) x max emission factor
9 Average lbs/yr = Total tons/yr x 2000 / 8760 hrs
11 Emission factor for chromium (VI) from June 2005 stack test, CEMEX, Victorville, California
12 Emission factor for nickel from November 1999 stack test, Roanoke Cement Company, Cloverdale, Virginia
13 Emissions for dioxin/furan estimated using emission factor for 1,2,3,4,6,7,8-HpCDD. Actual emissions will be limited under the
Portland Cement NESHAP.
14 Mercury EF estimated to limit emissions below NESHAP limit.
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Carolinas Cement PTE Baghouses-New
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Baghouse
ID
Control
Device IDFlow Rate Temp Flow Rate
Grain
Loading
Operating
Hours
PM
Emissions
PM
Emissions
PM10
Fraction
PM10
Emissions
PM10
Emissions
PM2.5
Fraction
PM2.5
Emissions
acfm deg F scfm gr/scf hrs/yr lb/hr TPY lb/hr TPY lb/hr
Raw Mill & KF E5 Raw mill feed bin 143.BF650 CD5 8,500 77 8,358 0.01 8760 0.72 3.14 0.84 0.60 2.64 0.45 0.32
Raw Mill & KF E6 Raw mill feed transport 311.BF750 CD6 7,750 77 7,620 0.01 8760 0.65 2.86 0.84 0.55 2.40 0.45 0.29
Raw Mill & KF E7 Raw mill feed 321.BF470 CD7 10,800 77 10,619 0.01 8760 0.91 3.99 0.84 0.76 3.35 0.45 0.41
Raw Mill & KF E8 Raw mill reject 321.BF950 CD8 11,700 90 11,232 0.01 8760 0.96 4.22 0.84 0.81 3.54 0.45 0.43
Raw Mill & KF E9 Kiln dust bin 331.BF400 CD9 4,200 302 2,910 0.01 8760 0.25 1.09 0.84 0.21 0.92 0.45 0.11
Raw Mill & KF E10 Raw meal transport to silo 341.BF410 CD10 4,000 150 3,462 0.01 8760 0.30 1.30 0.84 0.25 1.09 0.45 0.13
Raw Mill & KF E11 Raw meal silo 341.BF350 CD11 4,200 150 3,635 0.01 8760 0.31 1.36 0.84 0.26 1.15 0.45 0.14
Raw Mill & KF E12 Raw meal silo extraction 351.BF440 CD12 4,760 150 4,120 0.01 8760 0.35 1.55 0.84 0.30 1.30 0.45 0.16
Raw Mill & KF E13 Kiln feed 351.BF470 CD13 4,300 150 3,722 0.01 8760 0.32 1.40 0.84 0.27 1.17 0.45 0.14
RMKF Subtotal 4.77 20.90 4.01 17.56 2.15
Kiln System E44 Main stack - Raw mill On 673,804 193 544,822 0.0126 8760 58.77 257.39 0.84 49.36 216.21 0.45 26.44
Kiln System E44 Main stack - Raw mill Off 653,251 435 385,382
Kiln System Kiln/raw mill/cooler baghouse 331.BF200 CD44A
Kiln System Coal mill baghouse 461.BF500 CD44B
KS Subtotal 58.77 257.39 49.36 216.21 26.44
Coal System E1 Coal rail unloading 211.BF320 CD1 5,535 77 5,442 0.01 8760 0.47 2.04 0.84 0.39 1.72 0.45 0.21
Coal System E2 Coal unloading by truck 231.BF310 CD2 5,535 77 5,442 0.01 8760 0.47 2.04 0.84 0.39 1.72 0.45 0.21
Coal System E3 Coal transport to storage 231.BF330 CD3 6,868 77 6,753 0.01 8760 0.58 2.54 0.84 0.49 2.13 0.45 0.26
Coal System E4 Coal transport from storage 241.BF120 CD4 6,868 77 6,753 0.01 8760 0.58 2.54 0.84 0.49 2.13 0.45 0.26
Coal System E14 Coal mill feed bin 461.BF130 CD14 1,540 90 1,478 0.01 8760 0.13 0.56 0.84 0.11 0.47 0.45 0.06
Coal System E15 Coal mill feed bin 461.BF230 CD15 1,540 90 1,478 0.01 8760 0.13 0.56 0.84 0.11 0.47 0.45 0.06
Coal System E16 Coal mill feed transport 461.BF350 CD16 6,100 90 5,856 0.01 8760 0.50 2.20 0.84 0.42 1.85 0.45 0.23
Coal System E17 Fine coal bin 461.BF650 CD17 175 140 154 0.01 8760 0.01 0.06 0.84 0.01 0.05 0.45 0.01
Coal System E18 Fine coal bin 461.BF750 CD18 175 140 154 0.01 8760 0.01 0.06 0.84 0.01 0.05 0.45 0.01
COAL Subtotal 2.87 12.58 2.41 10.57 1.29
Clinker E19 Clinker discharge from cooler 441.BF540 CD19 4,600 257 3,387 0.01 8760 0.29 1.27 0.84 0.24 1.07 0.45 0.13
Clinker E20 Clinker dome 471.BF150 CD20 3,672 257 2,704 0.01 8760 0.23 1.02 0.84 0.19 0.85 0.45 0.10
Clinker E21 Off-spec bin 471.BF240 CD21 2,260 257 1,664 0.01 8760 0.14 0.62 0.84 0.12 0.52 0.45 0.06
CHS Subtotal 0.66 2.91 0.56 2.45 0.30
Finish Mills E22 Cement mill feed bin 511.BF090 CD22 9,820 156 8,417 0.01 8760 0.72 3.16 0.84 0.61 2.65 0.45 0.32
Finish Mills E23 Cement mill feed bin 512.BF050 CD23 8,830 156 7,569 0.01 8760 0.65 2.84 0.84 0.54 2.39 0.45 0.29
Finish Mills E46 Cement additive bin 511.BF300 CD46 4,810 156 4,123 0.01 8760 0.35 1.55 0.84 0.30 1.30 0.45 0.16
Finish Mills E47 Cement additve intake 232.BF150 CD47 10,587 77 10,410 0.01 8760 0.89 3.91 0.84 0.75 3.28 0.45 0.40
Finish Mills E24 Cement mill feed 531.BF290 CD24 4,697 156 4,026 0.01 8760 0.35 1.51 0.84 0.29 1.27 0.45 0.16
Finish Mills E25 Cement mill recirculation bin 531.BF020 CD25 2,719 212 2,136 0.01 8760 0.18 0.80 0.84 0.15 0.67 0.45 0.08
Finish Mills E26 Cement mill reject 531.BF215 CD26 5,262 212 4,134 0.01 8760 0.35 1.55 0.84 0.30 1.30 0.45 0.16
Finish Mills E27 Cement transport 531.BF615 CD27 2,154 212 1,692 0.01 8760 0.15 0.64 0.84 0.12 0.53 0.45 0.07
Finish Mills E28 Cement mill feed 532.BF290 CD28 5,580 178 4,618 0.01 8760 0.40 1.73 0.84 0.33 1.46 0.45 0.18
Finish Mills E29 Cement mill recirculation bin 532.BF020 CD29 2,719 212 2,136 0.01 8760 0.18 0.80 0.84 0.15 0.67 0.45 0.08
Finish Mills E30 Cement mill reject 532.BF215 CD30 5,262 212 4,134 0.01 8760 0.35 1.55 0.84 0.30 1.30 0.45 0.16
Finish Mills E31 Cement transport 532.BF615 CD31 2,154 212 1,692 0.01 8760 0.15 0.64 0.84 0.12 0.53 0.45 0.07
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Carolinas Cement PTE Baghouses-New
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Baghouse
ID
Control
Device IDFlow Rate Temp Flow Rate
Grain
Loading
Operating
Hours
PM
Emissions
PM
Emissions
PM10
Fraction
PM10
Emissions
PM10
Emissions
PM2.5
Fraction
PM2.5
Emissions
acfm deg F scfm gr/scf hrs/yr lb/hr TPY lb/hr TPY lb/hr
Finish Mills Cement mill 1 baghouse 531.BF500 CD45A
Finish Mills Cement mill 2 baghouse 532.BF500 CD45B
Finish Mills E45 Cement mill stack 125,438 210 98,853 0.01 8760 8.47 37.11 0.84 7.12 31.17 0.45 3.81
FM Subtotal 13.19 57.79 11.08 48.55 5.94
Cement E32 Cement dome 611.BF600 CD32 26,910 212 21,144 0.01 8760 1.81 7.94 0.84 1.52 6.67 0.45 0.82
Cement E33 Cement dome extraction rail 621.BF305 CD33 1,800 212 1,414 0.01 8760 0.12 0.53 0.84 0.10 0.45 0.45 0.05
Cement E34 Cement dome extraction truck 621.BF315 CD34 1,800 212 1,414 0.01 8760 0.12 0.53 0.84 0.10 0.45 0.45 0.05
Cement E40 Cement silo 612.BF600 CD40 22,750 212 17,875 0.01 8760 1.53 6.71 0.84 1.29 5.64 0.45 0.69
Cement E41 Cement silo extration 612.BF620 CD41 1,271 212 999 0.01 8760 0.09 0.37 0.84 0.07 0.31 0.45 0.04
Cement E42 Cement transport 622.BF410 CD42 2,578 212 2,026 0.01 8760 0.17 0.76 0.84 0.15 0.64 0.45 0.08
Cement E43 Packing plant 641.BF150 CD43 7,416 212 5,827 0.01 8760 0.50 2.19 0.84 0.42 1.84 0.45 0.22
CHSL Subtotal 4.35 19.03 3.65 15.99 1.96
Grand Total 84.62 370.61 71.08 311.32 38.08
NotesPM10 and PM2.5 fractions for Kiln and other baghouse emissions derived from AP-42 Table 11.6-5
Kiln PM emissions shown above are filterable only
Average ground elevation at plant site = 7 m (23 ft).
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Carolinas Cement PTE Baghouses-New
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Baghouse
ID
Raw Mill & KF E5 Raw mill feed bin 143.BF650
Raw Mill & KF E6 Raw mill feed transport 311.BF750
Raw Mill & KF E7 Raw mill feed 321.BF470
Raw Mill & KF E8 Raw mill reject 321.BF950
Raw Mill & KF E9 Kiln dust bin 331.BF400
Raw Mill & KF E10 Raw meal transport to silo 341.BF410
Raw Mill & KF E11 Raw meal silo 341.BF350
Raw Mill & KF E12 Raw meal silo extraction 351.BF440
Raw Mill & KF E13 Kiln feed 351.BF470
RMKF Subtotal
Kiln System E44 Main stack - Raw mill On
Kiln System E44 Main stack - Raw mill Off
Kiln System Kiln/raw mill/cooler baghouse 331.BF200
Kiln System Coal mill baghouse 461.BF500
KS Subtotal
Coal System E1 Coal rail unloading 211.BF320
Coal System E2 Coal unloading by truck 231.BF310
Coal System E3 Coal transport to storage 231.BF330
Coal System E4 Coal transport from storage 241.BF120
Coal System E14 Coal mill feed bin 461.BF130
Coal System E15 Coal mill feed bin 461.BF230
Coal System E16 Coal mill feed transport 461.BF350
Coal System E17 Fine coal bin 461.BF650
Coal System E18 Fine coal bin 461.BF750
COAL Subtotal
Clinker E19 Clinker discharge from cooler 441.BF540
Clinker E20 Clinker dome 471.BF150
Clinker E21 Off-spec bin 471.BF240
CHS Subtotal
Finish Mills E22 Cement mill feed bin 511.BF090
Finish Mills E23 Cement mill feed bin 512.BF050
Finish Mills E46 Cement additive bin 511.BF300
Finish Mills E47 Cement additve intake 232.BF150
Finish Mills E24 Cement mill feed 531.BF290
Finish Mills E25 Cement mill recirculation bin 531.BF020
Finish Mills E26 Cement mill reject 531.BF215
Finish Mills E27 Cement transport 531.BF615
Finish Mills E28 Cement mill feed 532.BF290
Finish Mills E29 Cement mill recirculation bin 532.BF020
Finish Mills E30 Cement mill reject 532.BF215
Finish Mills E31 Cement transport 532.BF615
PM2.5
Emissions
TPY
1.41
1.29
1.79
1.90
0.49
0.58
0.61
0.70
0.63
9.41
115.83
115.83
0.92
0.92
1.14
1.14
0.25
0.25
0.99
0.03
0.03
5.66
0.57
0.46
0.28
1.31
1.42
1.28
0.70
1.76
0.68
0.36
0.70
0.29
0.78
0.36
0.70
0.29
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Carolinas Cement PTE Baghouses-New
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Baghouse
ID
Finish Mills Cement mill 1 baghouse 531.BF500
Finish Mills Cement mill 2 baghouse 532.BF500
Finish Mills E45 Cement mill stack
FM Subtotal
Cement E32 Cement dome 611.BF600
Cement E33 Cement dome extraction rail 621.BF305
Cement E34 Cement dome extraction truck 621.BF315
Cement E40 Cement silo 612.BF600
Cement E41 Cement silo extration 612.BF620
Cement E42 Cement transport 622.BF410
Cement E43 Packing plant 641.BF150
CHSL Subtotal
Grand Total
PM2.5
Emissions
TPY
16.70
26.01
3.57
0.24
0.24
3.02
0.17
0.34
0.98
8.57
166.78
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Carolinas Cement PTE Baghouses-New
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Baghouse
ID
Raw Mill & KF E5 Raw mill feed bin 143.BF650
Raw Mill & KF E6 Raw mill feed transport 311.BF750
Raw Mill & KF E7 Raw mill feed 321.BF470
Raw Mill & KF E8 Raw mill reject 321.BF950
Raw Mill & KF E9 Kiln dust bin 331.BF400
Raw Mill & KF E10 Raw meal transport to silo 341.BF410
Raw Mill & KF E11 Raw meal silo 341.BF350
Raw Mill & KF E12 Raw meal silo extraction 351.BF440
Raw Mill & KF E13 Kiln feed 351.BF470
RMKF Subtotal
Kiln System E44 Main stack - Raw mill On
Kiln System E44 Main stack - Raw mill Off
Kiln System Kiln/raw mill/cooler baghouse 331.BF200
Kiln System Coal mill baghouse 461.BF500
KS Subtotal
Coal System E1 Coal rail unloading 211.BF320
Coal System E2 Coal unloading by truck 231.BF310
Coal System E3 Coal transport to storage 231.BF330
Coal System E4 Coal transport from storage 241.BF120
Coal System E14 Coal mill feed bin 461.BF130
Coal System E15 Coal mill feed bin 461.BF230
Coal System E16 Coal mill feed transport 461.BF350
Coal System E17 Fine coal bin 461.BF650
Coal System E18 Fine coal bin 461.BF750
COAL Subtotal
Clinker E19 Clinker discharge from cooler 441.BF540
Clinker E20 Clinker dome 471.BF150
Clinker E21 Off-spec bin 471.BF240
CHS Subtotal
Finish Mills E22 Cement mill feed bin 511.BF090
Finish Mills E23 Cement mill feed bin 512.BF050
Finish Mills E46 Cement additive bin 511.BF300
Finish Mills E47 Cement additve intake 232.BF150
Finish Mills E24 Cement mill feed 531.BF290
Finish Mills E25 Cement mill recirculation bin 531.BF020
Finish Mills E26 Cement mill reject 531.BF215
Finish Mills E27 Cement transport 531.BF615
Finish Mills E28 Cement mill feed 532.BF290
Finish Mills E29 Cement mill recirculation bin 532.BF020
Finish Mills E30 Cement mill reject 532.BF215
Finish Mills E31 Cement transport 532.BF615
Stack
Height
Stack
Height
Exit
Diameter
Exit
Velocity
m ft ft ft/s
35.0 114.8
35.0 114.835.0 114.823.0 75.538.0 124.718.0 59.174.0 242.815.0 49.2
115.0 377.3
125.0 410.1 14.76 65.60
7.5 24.69.7 31.88.5 27.99.5 31.2
41.0 134.541.0 134.523.0 75.520.0 65.620.0 65.6
16.0 52.556.0 183.751.0 167.3
19.0 62.3 2.00 52.1016.0 52.5 2.00 46.8418.0 59.1 1.50 45.3718.0 59.1 2.00 56.1732.0 105.0 1.50 44.3020.0 65.6 1.00 57.7013.0 42.7 1.50 49.6314.0 45.9 1.00 45.7132.0 105.0 1.50 52.6320.0 65.6 1.00 57.7032.0 105.0 1.50 49.6314.0 45.9 1.00 45.71
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Carolinas Cement PTE Baghouses-New
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Baghouse
ID
Finish Mills Cement mill 1 baghouse 531.BF500
Finish Mills Cement mill 2 baghouse 532.BF500
Finish Mills E45 Cement mill stack
FM Subtotal
Cement E32 Cement dome 611.BF600
Cement E33 Cement dome extraction rail 621.BF305
Cement E34 Cement dome extraction truck 621.BF315
Cement E40 Cement silo 612.BF600
Cement E41 Cement silo extration 612.BF620
Cement E42 Cement transport 622.BF410
Cement E43 Packing plant 641.BF150
CHSL Subtotal
Grand Total
Stack
Height
Stack
Height
Exit
Diameter
Exit
Velocity
m ft ft ft/s
41.1 135.0 6.56 61.83
44.0 144.4 3.00 63.458.5 27.98.5 27.9
68.0 223.019.0 62.310.0 32.8
17.0 55.8
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Carolinas Cement PTE Baghouses-Existing
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Control
Device IDFlow Rate Temp Flow Rate
Grain
Loading
Operating
Hours
PM
Emissions
PM
Emissions
PM10
Fraction
PM10
Emissions
PM10
Emissions
PM2.5
Fraction
PM2.5
Emissions
PM2.5
Emissions
acfm deg F scfm gr/scf hrs/yr lb/hr TPY lb/hr TPY lb/hr TPY
Cement ES-4 Cement silo CD-P43 1,500 68 1,500 0.02 8,760 0.26 1.13 0.84 0.22 0.95 0.45 0.12 0.51
Cement ES-R33 Screw conv/truck loadout CD-P30 1,500 68 1,500 0.02 8,760 0.26 1.13 0.84 0.22 0.95 0.45 0.12 0.51
ECT Subtotal 0.51 2.25 0.43 1.89 0.23 1.01
Grand Total 0.51 2.25 0.43 1.89 0.23 1.01
NotesPM10 and PM2.5 fractions for baghouse emissions derived from AP-42 Table 11.6-5
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Carolinas Cement PTE Baghouses-Existing
Point Sources (Controlled by Baghouses)
Equipment
Group
Emission
Point No.Process Unit
Control
Device ID
Cement ES-4 Cement silo CD-P43
Cement ES-R33 Screw conv/truck loadout CD-P30
ECT Subtotal
Grand Total
Stack
Height
Exit
DiameterOrientation
ft ft
80 1.25 Horizontal
20 1.0 Horizontal
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Carolinas Cement PTE Metals Data
Material Sb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Seppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm
Additives 5.4 6.2 1.3 4.1 309 2.5 72 116 540 0.22 40 3.6Bauxite 0.2 16.6 0.4 1 112 1.12 35 24 46 0.10 3 6Bottom ash 4.44 4.64 1.41 4 113 0.5 72 77 413 0.24 10.8 3.98Cement 0.335 18.9 1.15 0.183 64.4 10.3 5.57 12.4 252 0.038 33.8 3.4CKD 0.658 16.4 0.794 16.49 56.8 0.57 4.80 899 180 0.628 21.9 34.48Clinker 2.22 0.77 0.15 0.44 71.3 11.4 1.91 0.08 103 0.09 6.29 0.17Coal/Coke 2.87 0.19 0.35 0.42 5.0 0.05 1.77 1.01 0.58 0.10 62.7 0.65Gypsum 2.31 0.56 0.08 0.48 3.3 0.033 0.53 2.92 28.0 0.26 1.42 5.51Limestone/Marl 2 2 2 2 16 0.1 11 30 196 0.011 28 16Mill Scale 14.0 20.6 0.09 5 2,073 20.7 75 462 1,680 0.08 304 0.15Overburden 16 2 2 2 31 0.1 18 30 70 0.016 4 8Quarry Blend 2.36 2 2 1.94 18 0.1 11.2 30 192 0.011 30 15.6Raw Meal 2.68 2.47 1.94 2.20 47.8 0.35 18.0 39.3 231 0.035 30.6 14.4Sand 2.46 0.43 0.08 0.41 50 0.5 5.24 22.0 199 0.029 5.26 0.14Spoils/Other 8 2 2 1 44 0.1 14 30 127 0.011 54 9
Coal 2.5 0.19 0.35 0.42 5 0.05 0.98 1.01 0.48 0.06 1.25 0.65Coke 2.87 0.16 0.08 0.39 0.79 0.0079 1.77 0.08 0.58 0.10 62.7 0.17
Material Sb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Se
Additives 8 8 8 8 8 8 8 8 8 8 8 8Bauxite 1 1 1 12 12 9 12 12 12 12 1 1Bottom ash 3 3 3 12 12 11 12 12 12 2A 3 3Cement 4 4 4 4 13 13 3 4 3 4 4 4CKD 4 4 4 4 4 9 3 4 3 4 4 4Clinker 3 3 3 3 13 13 3 3 3 3 3 3Coal/Coke 6 6 6 6 6 9 6 6 6 6 6 6Gypsum 3 7 3 7 11 9 7 7 3 7 7 7Limestone/Marl 10 10 10 10 10 10 10 10 10 10 10 10Mill Scale 3 3 3 12 12 9 12 12 12 12 3 3Overburden 10 10 10 10 10 10 10 10 10 10 10 10Quarry Blend 8 8 8 8 8 8 8 8 8 8 8 8Raw Meal 8 8 8 8 8 8 8 8 8 8 8 8Sand 3 3 3 3 11 9 3 3 3 2 3 3Spoils/Other 10 10 10 10 10 10 10 10 10 10 10 10
Coal 3 3 3 3 11 9 3 3 3 5 3 3Coke 3 3 3 3 3 9 3 3 3 3 3 3
Metals Concentration References1 Emission Estimation Technique Manual for Alumina Refining , Environment Australia, March 1999.2 Mercury and Lead Content in Raw Materials , Portland Cement Association, R&D Serial No. 2888, 2006.
2A Estimated mercury concentration in ash consistent with NESHAP emission limit.
Metals Concentration Data
References
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Carolinas Cement PTE Metals Data
3 Laboratory Analyses for Roanoke Cement Co., ETS Analytical Services, Inc., December 9, 1992 and June 11, 1993. 4 Trace Metals in Cement and Kiln Dust From North American Cement Plants, Construction Technology Laboratories, Inc., 1991.5 Typical Analysis, West Virginia Coal, January 25, 2006. 6 Highest concentration for either coal or coke. 7 Gypsum for Agricultural Use in Ohio - Sources and Quality of Available Products, Ohio State University Extension Fact Sheet, 2005.8 Calculated concentrations using a typical mixture of component materials. 9 Assumes hexavalent chromium content is no more than 1 percent of total chromium for these materials.
10 Chemical analysis of Starfish quarry raw materials, September 2007. 11 Hexavalent Chromium in Cement Manufacturing: Literature Review , Portland Cement Association, R&D Serial No. 2983, 2007.12 Typical metals content for site-specific raw materials, January 2008. 13 Predicted chromium content for site-specific products, January 2008.
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Carolinas Cement PTE Baghouses-HAP-TAPs
Point Sources - HAP & TAP Emissions
Equipment
Group
Emission
Point No.Process Unit
Material
Processed
PM
Emissions
PM
EmissionsSb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Se
lb/hr TPY lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr
Raw Mill & KF E5 Raw mill feed bin Raw meal 0.7164 3.14 1.92E-06 1.77E-06 1.39E-06 1.58E-06 3.43E-05 2.49E-07 1.29E-05 2.82E-05 1.66E-04 2.49E-08 2.19E-05 1.04E-05
Raw Mill & KF E6 Raw mill feed transport Raw meal 0.6532 2.86 1.75E-06 1.61E-06 1.27E-06 1.44E-06 3.12E-05 2.27E-07 1.18E-05 2.57E-05 1.51E-04 2.27E-08 2.00E-05 9.44E-06
Raw Mill & KF E7 Raw mill feed Raw meal 0.9102 3.99 2.44E-06 2.25E-06 1.77E-06 2.00E-06 4.35E-05 3.16E-07 1.64E-05 3.58E-05 2.10E-04 3.16E-08 2.79E-05 1.32E-05
Raw Mill & KF E8 Raw mill reject Raw meal 0.9627 4.22 2.58E-06 2.38E-06 1.87E-06 2.12E-06 4.60E-05 3.34E-07 1.73E-05 3.79E-05 2.22E-04 3.34E-08 2.95E-05 1.39E-05
Raw Mill & KF E9 Kiln dust bin CKD 0.2494 1.09 1.64E-07 4.09E-06 1.98E-07 4.11E-06 1.42E-05 1.42E-07 1.20E-06 2.24E-04 4.49E-05 1.57E-07 5.46E-06 8.60E-06
Raw Mill & KF E10 Raw meal transport to silo Raw meal 0.2968 1.30 7.97E-07 7.33E-07 5.76E-07 6.53E-07 1.42E-05 1.03E-07 5.34E-06 1.17E-05 6.86E-05 1.03E-08 9.09E-06 4.29E-06
Raw Mill & KF E11 Raw meal silo Raw meal 0.3116 1.36 8.36E-07 7.70E-07 6.05E-07 6.86E-07 1.49E-05 1.08E-07 5.61E-06 1.23E-05 7.20E-05 1.08E-08 9.54E-06 4.50E-06
Raw Mill & KF E12 Raw meal silo extraction Raw meal 0.3532 1.55 9.48E-07 8.72E-07 6.86E-07 7.77E-07 1.69E-05 1.23E-07 6.36E-06 1.39E-05 8.16E-05 1.23E-08 1.08E-05 5.10E-06
Raw Mill & KF E13 Kiln feed Raw meal 0.3190 1.40 8.56E-07 7.88E-07 6.20E-07 7.02E-07 1.53E-05 1.11E-07 5.74E-06 1.25E-05 7.37E-05 1.11E-08 9.77E-06 4.61E-06
RMKF Subtotal 4.7725 20.90 1.23E-05 1.53E-05 8.98E-06 1.41E-05 2.31E-04 1.71E-06 8.26E-05 4.02E-04 1.09E-03 3.14E-07 1.44E-04 7.40E-05
Coal System E1 Coal rail unloading Coal/Coke 0.4665 2.04 1.34E-06 8.86E-08 1.63E-07 1.96E-07 2.33E-06 2.33E-08 8.26E-07 4.71E-07 2.71E-07 4.66E-08 2.92E-05 3.03E-07
Coal System E2 Coal unloading by truck Coal/Coke 0.4665 2.04 1.34E-06 8.86E-08 1.63E-07 1.96E-07 2.33E-06 2.33E-08 8.26E-07 4.71E-07 2.71E-07 4.66E-08 2.92E-05 3.03E-07
Coal System E3 Coal transport to storage Coal/Coke 0.5788 2.54 1.66E-06 1.10E-07 2.03E-07 2.43E-07 2.89E-06 2.89E-08 1.02E-06 5.85E-07 3.36E-07 5.79E-08 3.63E-05 3.76E-07
Coal System E4 Coal transport from storage Coal/Coke 0.5788 2.54 1.66E-06 1.10E-07 2.03E-07 2.43E-07 2.89E-06 2.89E-08 1.02E-06 5.85E-07 3.36E-07 5.79E-08 3.63E-05 3.76E-07
Coal System E14 Coal mill feed bin Coal/Coke 0.1267 0.56 3.64E-07 2.41E-08 4.44E-08 5.32E-08 6.34E-07 6.34E-09 2.24E-07 1.28E-07 7.35E-08 1.27E-08 7.95E-06 8.24E-08
Coal System E15 Coal mill feed bin Coal/Coke 0.1267 0.56 3.64E-07 2.41E-08 4.44E-08 5.32E-08 6.34E-07 6.34E-09 2.24E-07 1.28E-07 7.35E-08 1.27E-08 7.95E-06 8.24E-08
Coal System E16 Coal mill feed transport Coal/Coke 0.5019 2.20 1.44E-06 9.54E-08 1.76E-07 2.11E-07 2.51E-06 2.51E-08 8.88E-07 5.07E-07 2.91E-07 5.02E-08 3.15E-05 3.26E-07
Coal System E17 Fine coal bin Coal/Coke 0.0132 0.06 3.79E-08 2.51E-09 4.62E-09 5.54E-09 6.60E-08 6.60E-10 2.34E-08 1.33E-08 7.66E-09 1.32E-09 8.28E-07 8.58E-09
Coal System E18 Fine coal bin Coal/Coke 0.0132 0.06 3.79E-08 2.51E-09 4.62E-09 5.54E-09 6.60E-08 6.60E-10 2.34E-08 1.33E-08 7.66E-09 1.32E-09 8.28E-07 8.58E-09
COAL Subtotal 2.8724 12.58 8.24E-06 5.46E-07 1.01E-06 1.21E-06 1.44E-05 1.44E-07 5.08E-06 2.90E-06 1.67E-06 2.87E-07 1.80E-04 1.87E-06
Clinker E19 Clinker discharge from cooler Clinker 0.2904 1.27 6.45E-07 2.24E-07 4.36E-08 1.28E-07 2.07E-05 3.31E-06 5.55E-07 2.32E-08 2.99E-05 2.61E-08 1.83E-06 4.94E-08
Clinker E20 Clinker dome Clinker 0.2318 1.02 5.15E-07 1.78E-07 3.48E-08 1.02E-07 1.65E-05 2.64E-06 4.43E-07 1.85E-08 2.39E-05 2.09E-08 1.46E-06 3.94E-08
Clinker E21 Off-Spec Clinker 0.1427 0.62 3.17E-07 1.10E-07 2.14E-08 6.28E-08 1.02E-05 1.63E-06 2.72E-07 1.14E-08 1.47E-05 1.28E-08 8.97E-07 2.43E-08
CHS Subtotal 0.6648 2.91 1.48E-06 5.12E-07 9.97E-08 2.93E-07 4.74E-05 7.58E-06 1.27E-06 5.32E-08 6.85E-05 5.98E-08 4.18E-06 1.13E-07
Finish Mills E22 Cement mill feed bin Cement 0.7215 3.16 2.42E-07 1.36E-05 8.30E-07 1.32E-07 4.64E-05 7.43E-06 4.02E-06 8.95E-06 1.82E-04 2.74E-08 2.44E-05 2.45E-06
Finish Mills E23 Cement mill feed bin Cement 0.6487 2.84 2.17E-07 1.23E-05 7.46E-07 1.19E-07 4.18E-05 6.68E-06 3.61E-06 8.04E-06 1.63E-04 2.47E-08 2.19E-05 2.21E-06
Finish Mills E46 Cement additive bin Limestone 0.3534 1.55 8.16E-07 1.98E-07 2.83E-08 1.70E-07 1.17E-06 1.17E-08 1.87E-07 1.03E-06 9.89E-06 9.19E-08 5.02E-07 1.95E-06
Finish Mills E47 Cement additve intake Limestone 0.8922 3.91 2.06E-06 5.00E-07 7.14E-08 4.28E-07 2.94E-06 2.94E-08 4.73E-07 2.61E-06 2.50E-05 2.32E-07 1.27E-06 4.92E-06
Finish Mills E24 Cement mill feed Cement 0.3451 1.51 1.16E-07 6.52E-06 3.97E-07 6.32E-08 2.22E-05 3.55E-06 1.92E-06 4.28E-06 8.70E-05 1.31E-08 1.17E-05 1.17E-06
Finish Mills E25 Cement mill recirculation bin Cement 0.1831 0.80 6.13E-08 3.46E-06 2.11E-07 3.35E-08 1.18E-05 1.89E-06 1.02E-06 2.27E-06 4.61E-05 6.96E-09 6.19E-06 6.23E-07
Finish Mills E26 Cement mill reject Cement 0.3544 1.55 1.19E-07 6.70E-06 4.08E-07 6.49E-08 2.28E-05 3.65E-06 1.97E-06 4.39E-06 8.93E-05 1.35E-08 1.20E-05 1.20E-06
Finish Mills E27 Cement transport Cement 0.1451 0.64 4.86E-08 2.74E-06 1.67E-07 2.65E-08 9.34E-06 1.49E-06 8.08E-07 1.80E-06 3.66E-05 5.51E-09 4.90E-06 4.93E-07
Finish Mills E28 Cement mill feed Cement 0.3958 1.73 1.33E-07 7.48E-06 4.55E-07 7.24E-08 2.55E-05 4.08E-06 2.20E-06 4.91E-06 9.97E-05 1.50E-08 1.34E-05 1.35E-06
Finish Mills E29 Cement mill recirculation bin Cement 0.1831 0.80 6.13E-08 3.46E-06 2.11E-07 3.35E-08 1.18E-05 1.89E-06 1.02E-06 2.27E-06 4.61E-05 6.96E-09 6.19E-06 6.23E-07
Finish Mills E30 Cement mill reject Cement 0.3544 1.55 1.19E-07 6.70E-06 4.08E-07 6.49E-08 2.28E-05 3.65E-06 1.97E-06 4.39E-06 8.93E-05 1.35E-08 1.20E-05 1.20E-06
Finish Mills E31 Cement transport Cement 0.1451 0.64 4.86E-08 2.74E-06 1.67E-07 2.65E-08 9.34E-06 1.49E-06 8.08E-07 1.80E-06 3.66E-05 5.51E-09 4.90E-06 4.93E-07
Finish Mills E45 Cement mill stack Cement 8.4731 37.11 2.84E-06 1.60E-04 9.74E-06 1.55E-06 5.45E-04 8.73E-05 4.72E-05 1.05E-04 2.14E-03 3.22E-07 2.86E-04 2.88E-05
FM Subtotal 13.1950 57.79 6.88E-06 2.27E-04 1.38E-05 2.78E-06 7.73E-04 1.23E-04 6.72E-05 1.52E-04 3.05E-03 7.78E-07 4.06E-04 4.75E-05
Cement E32 Cement dome Cement 1.8123 7.94 6.07E-07 3.43E-05 2.08E-06 3.32E-07 1.17E-04 1.87E-05 1.01E-05 2.25E-05 4.57E-04 6.89E-08 6.13E-05 6.16E-06
Cement E33 Cement dome extraction rail Cement 0.1212 0.53 4.06E-08 2.29E-06 1.39E-07 2.22E-08 7.80E-06 1.25E-06 6.75E-07 1.50E-06 3.05E-05 4.61E-09 4.10E-06 4.12E-07
Cement E34 Cement dome extraction truck Cement 0.1212 0.53 4.06E-08 2.29E-06 1.39E-07 2.22E-08 7.80E-06 1.25E-06 6.75E-07 1.50E-06 3.05E-05 4.61E-09 4.10E-06 4.12E-07
Cement E35 Cement bin for barge loading Cement DELETED
Cement E36 Cement transport to barge Cement DELETED
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Carolinas Cement PTE Baghouses-HAP-TAPs
Point Sources - HAP & TAP Emissions
Equipment
Group
Emission
Point No.Process Unit
Material
Processed
PM
Emissions
PM
EmissionsSb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Se
lb/hr TPY lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr
Cement E37 Cement transport to barge Cement DELETED
Cement E38 Loading spout Cement DELETED
Cement E39 Loading spout Cement DELETED
Cement E40 Cement silo Cement 1.5321 6.71 5.13E-07 2.90E-05 1.76E-06 2.80E-07 9.86E-05 1.58E-05 8.53E-06 1.90E-05 3.86E-04 5.82E-08 5.18E-05 5.21E-06
Cement E41 Cement silo extration Cement 0.0856 0.37 2.87E-08 1.62E-06 9.84E-08 1.57E-08 5.51E-06 8.82E-07 4.77E-07 1.06E-06 2.16E-05 3.25E-09 2.89E-06 2.91E-07
Cement E42 Cement transport Cement 0.1736 0.76 5.82E-08 3.28E-06 2.00E-07 3.18E-08 1.12E-05 1.79E-06 9.67E-07 2.15E-06 4.38E-05 6.60E-09 5.87E-06 5.90E-07
Cement E43 Packing plant Cement 0.4994 2.19 1.67E-07 9.44E-06 5.74E-07 9.14E-08 3.22E-05 5.14E-06 2.78E-06 6.19E-06 1.26E-04 1.90E-08 1.69E-05 1.70E-06
CHSL Subtotal 4.3456 19.03 1.46E-06 8.21E-05 5.00E-06 7.95E-07 2.80E-04 4.48E-05 2.42E-05 5.39E-05 1.10E-03 1.65E-07 1.47E-04 1.48E-05
Grand Total, New Baghouses 25.8501 113.22 3.04E-05 3.25E-04 2.89E-05 1.91E-05 1.35E-03 1.77E-04 1.80E-04 6.11E-04 5.30E-03 1.60E-06 8.81E-04 1.38E-04
Cement ES-4 Cement silo Cement 0.2571 1.13 8.61E-08 4.86E-06 2.96E-07 4.71E-08 1.66E-05 2.65E-06 1.43E-06 3.19E-06 6.48E-05 9.77E-09 8.69E-06 8.74E-07
Cement ES-R33 Screw conv/truck loadout Cement 0.2571 1.13 8.61E-08 4.86E-06 2.96E-07 4.71E-08 1.66E-05 2.65E-06 1.43E-06 3.19E-06 6.48E-05 9.77E-09 8.69E-06 8.74E-07
Cement Total, Existing Baghouses 0.5143 2.25 1.72E-07 9.72E-06 5.91E-07 9.41E-08 3.31E-05 5.30E-06 2.86E-06 6.38E-06 1.30E-04 1.95E-08 1.74E-05 1.75E-06
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Carolinas Cement PTE Baghouses-HAP-TAPs
Point Sources - HAP & TAP Emissions
Equipment
Group
Emission
Point No.Process Unit
Material
Processed
Raw Mill & KF E5 Raw mill feed bin Raw meal
Raw Mill & KF E6 Raw mill feed transport Raw meal
Raw Mill & KF E7 Raw mill feed Raw meal
Raw Mill & KF E8 Raw mill reject Raw meal
Raw Mill & KF E9 Kiln dust bin CKD
Raw Mill & KF E10 Raw meal transport to silo Raw meal
Raw Mill & KF E11 Raw meal silo Raw meal
Raw Mill & KF E12 Raw meal silo extraction Raw meal
Raw Mill & KF E13 Kiln feed Raw meal
RMKF Subtotal
Coal System E1 Coal rail unloading Coal/Coke
Coal System E2 Coal unloading by truck Coal/Coke
Coal System E3 Coal transport to storage Coal/Coke
Coal System E4 Coal transport from storage Coal/Coke
Coal System E14 Coal mill feed bin Coal/Coke
Coal System E15 Coal mill feed bin Coal/Coke
Coal System E16 Coal mill feed transport Coal/Coke
Coal System E17 Fine coal bin Coal/Coke
Coal System E18 Fine coal bin Coal/Coke
COAL Subtotal
Clinker E19 Clinker discharge from cooler Clinker
Clinker E20 Clinker dome Clinker
Clinker E21 Off-Spec Clinker
CHS Subtotal
Finish Mills E22 Cement mill feed bin Cement
Finish Mills E23 Cement mill feed bin Cement
Finish Mills E46 Cement additive bin Limestone
Finish Mills E47 Cement additve intake Limestone
Finish Mills E24 Cement mill feed Cement
Finish Mills E25 Cement mill recirculation bin Cement
Finish Mills E26 Cement mill reject Cement
Finish Mills E27 Cement transport Cement
Finish Mills E28 Cement mill feed Cement
Finish Mills E29 Cement mill recirculation bin Cement
Finish Mills E30 Cement mill reject Cement
Finish Mills E31 Cement transport Cement
Finish Mills E45 Cement mill stack Cement
FM Subtotal
Cement E32 Cement dome Cement
Cement E33 Cement dome extraction rail Cement
Cement E34 Cement dome extraction truck Cement
Cement E35 Cement bin for barge loading Cement
Cement E36 Cement transport to barge Cement
Sb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Se
TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY
8.42E-06 7.75E-06 6.09E-06 6.90E-06 1.50E-04 1.09E-06 5.65E-05 1.23E-04 7.25E-04 1.09E-07 9.61E-05 4.53E-05
7.68E-06 7.07E-06 5.56E-06 6.29E-06 1.37E-04 9.94E-07 5.15E-05 1.12E-04 6.61E-04 9.93E-08 8.76E-05 4.13E-05
1.07E-05 9.85E-06 7.74E-06 8.77E-06 1.91E-04 1.38E-06 7.18E-05 1.57E-04 9.21E-04 1.38E-07 1.22E-04 5.76E-05
1.13E-05 1.04E-05 8.19E-06 9.28E-06 2.02E-04 1.46E-06 7.59E-05 1.66E-04 9.74E-04 1.46E-07 1.29E-04 6.09E-05
7.19E-07 1.79E-05 8.68E-07 1.80E-05 6.21E-05 6.21E-07 5.24E-06 9.82E-04 1.97E-04 6.86E-07 2.39E-05 3.77E-05
3.49E-06 3.21E-06 2.52E-06 2.86E-06 6.22E-05 4.51E-07 2.34E-05 5.11E-05 3.00E-04 4.51E-08 3.98E-05 1.88E-05
3.66E-06 3.37E-06 2.65E-06 3.00E-06 6.53E-05 4.74E-07 2.46E-05 5.37E-05 3.15E-04 4.74E-08 4.18E-05 1.97E-05
4.15E-06 3.82E-06 3.00E-06 3.40E-06 7.40E-05 5.37E-07 2.78E-05 6.08E-05 3.57E-04 5.37E-08 4.74E-05 2.24E-05
3.75E-06 3.45E-06 2.71E-06 3.07E-06 6.68E-05 4.85E-07 2.52E-05 5.49E-05 3.23E-04 4.85E-08 4.28E-05 2.02E-05
5.39E-05 6.69E-05 3.93E-05 6.16E-05 1.01E-03 7.50E-06 3.62E-04 1.76E-03 4.77E-03 1.37E-06 6.31E-04 3.24E-04
5.86E-06 3.88E-07 7.15E-07 8.58E-07 1.02E-05 1.02E-07 3.62E-06 2.06E-06 1.19E-06 2.04E-07 1.28E-04 1.33E-06
5.86E-06 3.88E-07 7.15E-07 8.58E-07 1.02E-05 1.02E-07 3.62E-06 2.06E-06 1.19E-06 2.04E-07 1.28E-04 1.33E-06
7.28E-06 4.82E-07 8.87E-07 1.06E-06 1.27E-05 1.27E-07 4.49E-06 2.56E-06 1.47E-06 2.54E-07 1.59E-04 1.65E-06
7.28E-06 4.82E-07 8.87E-07 1.06E-06 1.27E-05 1.27E-07 4.49E-06 2.56E-06 1.47E-06 2.54E-07 1.59E-04 1.65E-06
1.59E-06 1.05E-07 1.94E-07 2.33E-07 2.78E-06 2.78E-08 9.82E-07 5.61E-07 3.22E-07 5.55E-08 3.48E-05 3.61E-07
1.59E-06 1.05E-07 1.94E-07 2.33E-07 2.78E-06 2.78E-08 9.82E-07 5.61E-07 3.22E-07 5.55E-08 3.48E-05 3.61E-07
6.31E-06 4.18E-07 7.69E-07 9.23E-07 1.10E-05 1.10E-07 3.89E-06 2.22E-06 1.28E-06 2.20E-07 1.38E-04 1.43E-06
1.66E-07 1.10E-08 2.02E-08 2.43E-08 2.89E-07 2.89E-09 1.02E-07 5.84E-08 3.35E-08 5.78E-09 3.63E-06 3.76E-08
1.66E-07 1.10E-08 2.02E-08 2.43E-08 2.89E-07 2.89E-09 1.02E-07 5.84E-08 3.35E-08 5.78E-09 3.63E-06 3.76E-08
3.61E-05 2.39E-06 4.40E-06 5.28E-06 6.29E-05 6.29E-07 2.23E-05 1.27E-05 7.30E-06 1.26E-06 7.89E-04 8.18E-06
2.82E-06 9.79E-07 1.91E-07 5.60E-07 9.06E-05 1.45E-05 2.43E-06 1.02E-07 1.31E-04 1.14E-07 8.00E-06 2.16E-07
2.25E-06 7.82E-07 1.52E-07 4.47E-07 7.23E-05 1.16E-05 1.94E-06 8.12E-08 1.05E-04 9.14E-08 6.39E-06 1.73E-07
1.39E-06 4.81E-07 9.37E-08 2.75E-07 4.45E-05 7.12E-06 1.19E-06 5.00E-08 6.44E-05 5.62E-08 3.93E-06 1.06E-07
6.46E-06 2.24E-06 4.37E-07 1.28E-06 2.07E-04 3.32E-05 5.56E-06 2.33E-07 3.00E-04 2.62E-07 1.83E-05 4.95E-07
1.06E-06 5.97E-05 3.63E-06 5.78E-07 2.03E-04 3.25E-05 1.76E-05 3.92E-05 7.96E-04 1.20E-07 1.07E-04 1.07E-05
9.52E-07 5.37E-05 3.27E-06 5.20E-07 1.83E-04 2.93E-05 1.58E-05 3.52E-05 7.16E-04 1.08E-07 9.60E-05 9.66E-06
3.58E-06 8.67E-07 1.24E-07 7.43E-07 5.11E-06 5.11E-08 8.20E-07 4.52E-06 4.33E-05 4.02E-07 2.20E-06 8.53E-06
9.03E-06 2.19E-06 3.13E-07 1.88E-06 1.29E-05 1.29E-07 2.07E-06 1.14E-05 1.09E-04 1.02E-06 5.55E-06 2.15E-05
5.06E-07 2.86E-05 1.74E-06 2.77E-07 9.73E-05 1.56E-05 8.42E-06 1.87E-05 3.81E-04 5.74E-08 5.11E-05 5.14E-06
2.69E-07 1.52E-05 9.22E-07 1.47E-07 5.16E-05 8.26E-06 4.47E-06 9.95E-06 2.02E-04 3.05E-08 2.71E-05 2.73E-06
5.20E-07 2.93E-05 1.79E-06 2.84E-07 9.99E-05 1.60E-05 8.65E-06 1.92E-05 3.91E-04 5.90E-08 5.25E-05 5.28E-06
2.13E-07 1.20E-05 7.31E-07 1.16E-07 4.09E-05 6.54E-06 3.54E-06 7.88E-06 1.60E-04 2.41E-08 2.15E-05 2.16E-06
5.81E-07 3.28E-05 1.99E-06 3.17E-07 1.12E-04 1.79E-05 9.66E-06 2.15E-05 4.37E-04 6.59E-08 5.86E-05 5.89E-06
2.69E-07 1.52E-05 9.22E-07 1.47E-07 5.16E-05 8.26E-06 4.47E-06 9.95E-06 2.02E-04 3.05E-08 2.71E-05 2.73E-06
5.20E-07 2.93E-05 1.79E-06 2.84E-07 9.99E-05 1.60E-05 8.65E-06 1.92E-05 3.91E-04 5.90E-08 5.25E-05 5.28E-06
2.13E-07 1.20E-05 7.31E-07 1.16E-07 4.09E-05 6.54E-06 3.54E-06 7.88E-06 1.60E-04 2.41E-08 2.15E-05 2.16E-06
1.24E-05 7.01E-04 4.27E-05 6.79E-06 2.39E-03 3.82E-04 2.07E-04 4.60E-04 9.35E-03 1.41E-06 1.25E-03 1.26E-04
3.01E-05 9.92E-04 6.06E-05 1.22E-05 3.39E-03 5.39E-04 2.94E-04 6.65E-04 1.33E-02 3.41E-06 1.78E-03 2.08E-04
2.66E-06 1.50E-04 9.13E-06 1.45E-06 5.11E-04 8.18E-05 4.42E-05 9.84E-05 2.00E-03 3.02E-07 2.68E-04 2.70E-05
1.78E-07 1.00E-05 6.11E-07 9.72E-08 3.42E-05 5.47E-06 2.96E-06 6.58E-06 1.34E-04 2.02E-08 1.79E-05 1.81E-06
1.78E-07 1.00E-05 6.11E-07 9.72E-08 3.42E-05 5.47E-06 2.96E-06 6.58E-06 1.34E-04 2.02E-08 1.79E-05 1.81E-06
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Carolinas Cement PTE Baghouses-HAP-TAPs
Point Sources - HAP & TAP Emissions
Equipment
Group
Emission
Point No.Process Unit
Material
Processed
Cement E37 Cement transport to barge Cement
Cement E38 Loading spout Cement
Cement E39 Loading spout Cement
Cement E40 Cement silo Cement
Cement E41 Cement silo extration Cement
Cement E42 Cement transport Cement
Cement E43 Packing plant Cement
CHSL Subtotal
Grand Total, New Baghouses
Cement ES-4 Cement silo Cement
Cement ES-R33 Screw conv/truck loadout Cement
Cement Total, Existing Baghouses
Sb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Se
TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY
2.25E-06 1.27E-04 7.72E-06 1.23E-06 4.32E-04 6.91E-05 3.74E-05 8.32E-05 1.69E-03 2.55E-07 2.27E-04 2.28E-05
1.26E-07 7.09E-06 4.31E-07 6.86E-08 2.41E-05 3.86E-06 2.09E-06 4.65E-06 9.45E-05 1.42E-08 1.27E-05 1.27E-06
2.55E-07 1.44E-05 8.75E-07 1.39E-07 4.90E-05 7.83E-06 4.24E-06 9.43E-06 1.92E-04 2.89E-08 2.57E-05 2.59E-06
7.33E-07 4.13E-05 2.52E-06 4.00E-07 1.41E-04 2.25E-05 1.22E-05 2.71E-05 5.51E-04 8.31E-08 7.39E-05 7.44E-06
6.38E-06 3.60E-04 2.19E-05 3.48E-06 1.23E-03 1.96E-04 1.06E-04 2.36E-04 4.80E-03 7.23E-07 6.43E-04 6.47E-05
1.33E-04 1.42E-03 1.27E-04 8.38E-05 5.89E-03 7.77E-04 7.90E-04 2.68E-03 2.32E-02 7.02E-06 3.86E-03 6.05E-04
3.77E-07 2.13E-05 1.30E-06 2.06E-07 7.25E-05 1.16E-05 6.27E-06 1.40E-05 2.84E-04 4.28E-08 3.81E-05 3.83E-06
3.77E-07 2.13E-05 1.30E-06 2.06E-07 7.25E-05 1.16E-05 6.27E-06 1.40E-05 2.84E-04 4.28E-08 3.81E-05 3.83E-06
7.55E-07 4.26E-05 2.59E-06 4.12E-07 1.45E-04 2.32E-05 1.25E-05 2.79E-05 5.68E-04 8.56E-08 7.61E-05 7.66E-06
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Carolinas Cement PTE Generator
Emergency Generator Emissions
Maximum Hourly Emissions:
Unit ID EU Description Size
Fuel Rate
gal/hr
Heat Input
MMBtu/hr
Output
kW-hr
PM
lbs/hr
PM10
lbs/hr
PM2.5
lbs/hr
SO2
lbs/hr
NOX
lbs/hr
CO
lbs/hr
VOC
lbs/hrGEN Generator 800 kW 57.2 7.84 800 0.3527 0.2892 0.2822 0.3957 11.1111 6.1728 0.1764
Annual Average Hourly Emissions:
Unit ID EU Description Size
Fuel Rate
gal/hr
Heat Input
MMBtu/hr
Output
kW-hr
PM
lbs/hr
PM10
lbs/hr
PM2.5
lbs/hr
SO2
lbs/hr
NOX
lbs/hr
CO
lbs/hr
VOC
lbs/hrGEN Generator 800 kW NA NA NA 0.0201 0.0165 0.0161 0.0226 0.6342 0.3523 0.0101
Annual Emissions:
Unit ID EU Description
Operating
Hours
Fuel Rate
gal/yr
Heat Input
MMBtu/yr
Output
kW-hr/yr
PM
tons/yr
PM10
tons/yr
PM2.5
tons/yr
SO2
tons/yr
NOX
tons/yr
CO
tons/yr
VOC
tons/yrGEN Generator 500 28,600 3,918 400,000 0.09 0.07 0.07 0.10 2.78 1.54 0.04
Notes: The emergency generator operates during testing and power outages. Potential emissions based on maximum of 500 hrs/yr of operation.Generator is diesel fuel-fired. Assume 137,000 Btu/gal heat value of fuel. Sulfur limit is 0.05 percent.Emission factors from NSPS Subpart IIII Standards of Performance for Stationary Compression Ignition Internal Combustion Enginesand AP-42 Chapter 3.4.
Emissions Basis: Pollutant
Emission
Factor EF UnitsPM 0.20 g/kW-hr Exhaust flow rate 6046 acfm
PM100.164 g/kW-hr Exhaust temperature 955 deg F
PM2.50.16 g/kW-hr Exhaust vent diameter 8 in.
SO2 0.0505 lb/MMBtu
NOX 6.3 g/kW-hr
CO 3.5 g/kW-hr
VOC 0.1 g/kW-hr
Source of EF
NSPS Limit
Emission LimitLimit: NOx + HC = 6.4
82% of PM: Table 3.4-2
80% of PM: Table 3.4-2
AP-42 Table 3.4-1
Limit: NOx + HC = 6.4
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Carolinas Cement PTE Generator
Generator HAP & TAP Emissions
Pollutant TAP HAP
EF (lb/
MMBtu)
AP-42
Table lbs/hr tons/yrAcetaldehyde X X 2.52E-05 3.4-3 1.97E-04 4.94E-05Acrolein X X 7.88E-06 3.4-3 6.18E-05 1.54E-05Benzene X X 7.76E-04 3.4-3 6.08E-03 1.52E-03Formaldehyde X X 7.89E-05 3.4-3 6.18E-04 1.55E-04Toluene X X 2.81E-04 3.4-3 2.20E-03 5.51E-04Xylenes X X 1.93E-04 3.4-3 1.51E-03 3.78E-04PAH'sAcenaphthene X 4.68E-06 3.4-4 3.67E-05 9.17E-06Acenaphthylene X 9.23E-06 3.4-4 7.23E-05 1.81E-05Anthracene X 1.23E-06 3.4-4 9.64E-06 2.41E-06Benz(a)anthracene X 6.22E-07 3.4-4 4.87E-06 1.22E-06Benzo(a)pyrene X X 2.57E-07 3.4-4 2.01E-06 5.03E-07Benzo(b)fluoranthene X 1.11E-06 3.4-4 8.70E-06 2.17E-06Benzo(g,h,l)perylene X 5.56E-07 3.4-4 4.36E-06 1.09E-06Benzo(k)fluoranthene X 2.18E-07 3.4-4 1.71E-06 4.27E-07Chrysene X 1.53E-06 3.4-4 1.20E-05 3.00E-06Dibenz(a,h)anthracene X 3.46E-07 3.4-4 2.71E-06 6.78E-07Fluoranthene X 4.03E-06 3.4-4 3.16E-05 7.90E-06Fluorene X 1.28E-05 3.4-4 1.00E-04 2.51E-05Indeno(1,2,3-cd)pyrene X 4.14E-07 3.4-4 3.24E-06 8.11E-07Naphthalene X 1.30E-04 3.4-4 1.02E-03 2.55E-04Phenanthrene X 4.08E-05 3.4-4 3.20E-04 7.99E-05Pyrene X 3.71E-06 3.4-4 2.91E-05 7.27E-06POM (Total PAH) X 2.12E-04 3.4-4 1.66E-03 4.15E-04
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Carolinas Cement PTE Fugitive EF's
Emission Factor Calculation Sheet (Fugitives)
Material Transfer Operations PM PM-10 PM-2.5
k (particle size multiplier) 0.74 0.35 0.053
Mean Wind Speed (mph) Wilmington, NC 8.6 PM EF PM-10 EF PM-2.5 EF
(Source: EPA TANKS2 MET DATA) (lb/ton handled) (lb/ton handled) (lb/ton handled)
Marl Average Moisture Content (%) 16 2.61E-04 1.23E-04 1.87E-05
Bauxite Average Moisture Content (%) 5 1.33E-03 6.28E-04 9.52E-05
Coal/Coke Average Moisture Content (%) 8 6.88E-04 3.25E-04 4.93E-05
Dried Material Avg. Moisture Content (%) 1 1.26E-02 5.98E-03 9.06E-04
Sand Average Moisture Content (%) 5 1.33E-03 6.28E-04 9.52E-05
Ash Average Moisture Content (%) 15 2.85E-04 1.35E-04 2.04E-05
Gypsum Average Moisture Content (%) 6 1.03E-03 4.87E-04 7.37E-05
Mill Scale Average Moisture Content (%) 5 1.33E-03 6.28E-04 9.52E-05
Clinker Average Moisture Content (%) 0.1 3.18E-01 1.50E-01 2.28E-02
Additives Average Moisture Content (%) 12 3.90E-04 1.84E-04 2.79E-05
Raw Mix Average Moisture Content (%) 15.81 2.65E-04 1.25E-04 1.90E-05
Material transfer factors from AP-42 Section 13.2.4.3 (Aggregate Handling and Storage Piles, 11/06)
E = k * 0.0032 * (U/5)^1.3 / (M/2)^1.4
E = transfer emission factor (lb/ton)
k = particle size multiplier
U = mean wind speed (mph)
M = material moisture content (%)
Miscellaneous Operations Reference PM EF PM-10 EF PM-2.5 EF
(lb/ton) (lb/ton) (lb/ton)
Primary & secondary crushers 1 0.0012 0.00054 0.00010
Cement transfer (uncontrolled) 2 0.72 0.46 0.11
1) AP-42 Table 11.19.2-2 (Crushed Stone Processing, 8/04) (wet crushing = controlled)
2) AP-42 Table 11.12.2-2 (PM & PM10). Assume PM2.5 = 15% of PM.
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Carolinas Cement PTE Material Transfer
Fugitive Emissions From Material Transfer Points
TSP PM10
Area Equipment Description Material
Factor
lbs/ton tons/yr
Factor
lbs/ton tons/yr
Factor
lbs/ton tons/yr lbs/hr lbs/hr
Quarry Hopper/Feeder 1 Limestone/Marl FQ1 None 8,760 3,411,152 NA 2.61E-04 0.44 1.23E-04 0.21 1.87E-05 0.03 0.1015 0.0480
Quarry Primary Crusher 1 Limestone/Marl FQ1 None 8,760 3,411,152 NA 0.0012 2.05 0.00054 0.92 0.0001 0.17 0.4673 0.2103
Quarry Mining Conveyor 2 Transfer Limestone/Marl FQ1 None 8,760 3,411,152 NA 2.61E-04 0.44 1.23E-04 0.21 1.87E-05 0.03 0.1015 0.0480
Subtotal FQ1 2.94 1.34 0.23 0.6704 0.3063
Quarry Mining Conveyor 1 Transfer Limestone/Marl FQ2 None 8,760 3,411,152 NA 2.61E-04 0.44 1.23E-04 0.21 1.87E-05 0.03 0.1015 0.0480
Quarry Hopper/Feeder 2 Spoils/Other FQ3 None 8,760 434,183 NA 2.61E-04 0.06 1.23E-04 0.03 1.87E-05 0.00 0.0129 0.0061
Quarry Primary Crusher 2 Spoils/Other FQ3 None 8,760 434,183 NA 0.0012 0.26 0.00054 0.12 0.0001 0.02 0.0595 0.0268
Quarry Spoils Conveyor 2 Transfer Spoils/Other FQ3 None 8,760 434,183 NA 2.61E-04 0.06 1.23E-04 0.03 1.87E-05 0.00 0.0129 0.0061
Subtotal FQ3 0.37 0.17 0.03 0.0853 0.0390
Quarry Spoils Conveyor 3 Transfer Spoils/Other FQ4 None 8,760 217,092 NA 2.61E-04 0.03 1.23E-04 0.01 1.87E-05 0.00 0.0065 0.0031
Quarry Radial Stacker Transfer Spoils/Other FQ5 None 8,760 217,092 NA 2.61E-04 0.03 1.23E-04 0.01 1.87E-05 0.00 0.0065 0.0031
Quarry Stacker to Pile Spoils/Other FQ6 None 8,760 217,092 NA 2.61E-04 0.03 1.23E-04 0.01 1.87E-05 0.00 0.0065 0.0031
Quarry Spoils Conveyor 1 Transfer Spoils/Other FQ7 None 8,760 217,092 NA 2.61E-04 0.03 1.23E-04 0.01 1.87E-05 0.00 0.0065 0.0031
Quarry/Plant Secondary Crusher Feeder Quarry Blend FQ8 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Quarry/Plant Secondary Crusher Quarry Blend FQ8 None 8,760 3,628,243 NA 0.0012 2.18 0.00054 0.98 0.0001 0.18 0.4970 0.2237
Quarry/Plant Belt Conveyor Transfer Quarry Blend FQ8 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Subtotal FQ8 3.12 1.43 0.25 0.7130 0.3258
Quarry Total FQ 6.99 3.20 0.55 1.5961 0.7314
Plant-Unloading Hopper Hopper/Feeder 1 Additives F1 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Plant-Unloading Hopper Belt Conveyor Transfer Additives F1 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Plant-Unloading Hopper Hopper/Feeder 2 Coal/Coke F1 None 8,760 113,530 NA 6.88E-04 0.04 3.25E-04 0.02 4.93E-05 0.00 0.0089 0.0042
Plant-Unloading Hopper Belt Conveyor Transfer Coal/Coke F1 None 8,760 113,530 NA 6.88E-04 0.04 3.25E-04 0.02 4.93E-05 0.00 0.0089 0.0042
Subtotal F1 0.24 0.12 0.02 0.0557 0.0263
Plant-Rail Unloading Enclosed Hopper w/Dust
Suppression
Coal/Coke F2 None 8,760 283,824 50 6.88E-04 0.05 3.25E-04 0.02 4.93E-05 0.00 0.0111 0.0053
Plant-Raw Storage Bldg Belt to Tripper Belt Quarry Blend F3 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Plant-Raw Storage Bldg Tripper Belt to Piles Quarry Blend F3 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Plant-Raw Storage Bldg Pile Reclaimer Quarry Blend F3 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Plant-Raw Storage Bldg Reclaimer to Belt Quarry Blend F3 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Location
Control
Efficiency
%
Control
Device
ID
Operating
Hours
Annual
Throughput
(tons)
Hourly Emission
TSP PM10 PM2.5
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Carolinas Cement PTE Material Transfer
Fugitive Emissions From Material Transfer Points
TSP PM10
Area Equipment Description Material
Factor
lbs/ton tons/yr
Factor
lbs/ton tons/yr
Factor
lbs/ton tons/yr lbs/hr lbs/hrLocation
Control
Efficiency
%
Control
Device
ID
Operating
Hours
Annual
Throughput
(tons)
Hourly Emission
TSP PM10 PM2.5
Plant-Raw Storage Bldg Belt to Tripper Belt Additives F3 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Plant-Raw Storage Bldg Tripper Belt to Piles Additives F3 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Plant-Raw Storage Bldg Pile Reclaimer Additives F3 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Plant-Raw Storage Bldg Reclaimer to Belt Additives F3 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Plant-Raw Storage Bldg Belt to Tripper Belt Coal/Coke F3 None 8,760 113,530 NA 6.88E-04 0.04 3.25E-04 0.02 4.93E-05 0.00 0.0089 0.0042
Plant-Raw Storage Bldg Tripper Belt to Piles Coal/Coke F3 None 8,760 113,530 NA 6.88E-04 0.04 3.25E-04 0.02 4.93E-05 0.00 0.0089 0.0042
Plant-Raw Storage Bldg Pile Reclaimer Coal/Coke F3 None 8,760 113,530 NA 6.88E-04 0.04 3.25E-04 0.02 4.93E-05 0.00 0.0089 0.0042
Plant-Raw Storage Bldg Reclaimer to Belt Coal/Coke F3 None 8,760 113,530 NA 6.88E-04 0.04 3.25E-04 0.02 4.93E-05 0.00 0.0089 0.0042
Subtotal F3 2.38 1.13 0.17 0.5434 0.2570
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F4 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Plant-Additives Transfer Belt Conveyor Transfer Additives F5 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F6 None 8,760 3,628,243 NA 2.61E-04 0.47 1.23E-04 0.22 1.87E-05 0.03 0.1080 0.0511
Plant-Additives Transfer Belt Conveyor Transfer Additives F7 None 8,760 425,102 NA 3.90E-04 0.08 1.84E-04 0.04 2.79E-05 0.01 0.0189 0.0090
Subtotal 0.56 0.26 0.04 0.1269 0.0600
Plant-Marl Transfer Conveyor to Silo Quarry Blend F7A None 8,760 3,628,243 50 2.61E-04 0.24 1.23E-04 0.11 1.87E-05 0.02 0.0540 0.0255
Plant-Marl Transfer Silo to Enclosed Belt Quarry Blend F7B None 8,760 3,628,243 50 2.61E-04 0.24 1.23E-04 0.11 1.87E-05 0.02 0.0540 0.0255
Plant-Additives Transfer Conveyor to Silo Bottom Ash F7C None 8,760 391,332 50 2.85E-04 0.03 1.35E-04 0.01 2.04E-05 0.00 0.0064 0.0030
Plant-Additives Transfer Silo to Enclosed Belt Bottom Ash F7D None 8,760 391,332 50 2.85E-04 0.03 1.35E-04 0.01 2.04E-05 0.00 0.0064 0.0030
Subtotal 0.53 0.25 0.04 0.1208 0.0571
Plant-Cement Additives Truck Unloading Gypsum F8 None 8,760 127,549 NA 1.03E-03 0.07 4.87E-04 0.03 7.37E-05 0.00 0.0150 0.0071
Plant-Cement Additives Hopper/Feeder Gypsum F8 None 8,760 127,549 NA 1.03E-03 0.07 4.87E-04 0.03 7.37E-05 0.00 0.0150 0.0071
Plant-Cement Additives Belt Conveyor Transfer Gypsum F8 None 8,760 127,549 NA 1.03E-03 0.07 4.87E-04 0.03 7.37E-05 0.00 0.0150 0.0071
Plant-Cement Additives Truck Unloading Limestone F8 None 8,760 102,040 NA 1.03E-03 0.05 4.87E-04 0.02 7.37E-05 0.00 0.0120 0.0057
Plant-Cement Additives Hopper/Feeder Limestone F8 None 8,760 102,040 NA 1.03E-03 0.05 4.87E-04 0.02 7.37E-05 0.00 0.0120 0.0057
Subtotal F8 0.30 0.14 0.02 0.0689 0.0326
Plant Subtotal RMHS 4.62 2.18 0.33 1.0538 0.4984
Notes:
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Carolinas Cement PTE Material Transfer
Fugitive Emissions From Material Transfer Points
Area Equipment Description Material
Quarry Hopper/Feeder 1 Limestone/Marl FQ1
Quarry Primary Crusher 1 Limestone/Marl FQ1
Quarry Mining Conveyor 2 Transfer Limestone/Marl FQ1
Subtotal FQ1
Quarry Mining Conveyor 1 Transfer Limestone/Marl FQ2
Quarry Hopper/Feeder 2 Spoils/Other FQ3
Quarry Primary Crusher 2 Spoils/Other FQ3
Quarry Spoils Conveyor 2 Transfer Spoils/Other FQ3
Subtotal FQ3
Quarry Spoils Conveyor 3 Transfer Spoils/Other FQ4
Quarry Radial Stacker Transfer Spoils/Other FQ5
Quarry Stacker to Pile Spoils/Other FQ6
Quarry Spoils Conveyor 1 Transfer Spoils/Other FQ7
Quarry/Plant Secondary Crusher Feeder Quarry Blend FQ8
Quarry/Plant Secondary Crusher Quarry Blend FQ8
Quarry/Plant Belt Conveyor Transfer Quarry Blend FQ8
Subtotal FQ8
Quarry Total FQ
Plant-Unloading Hopper Hopper/Feeder 1 Additives F1
Plant-Unloading Hopper Belt Conveyor Transfer Additives F1
Plant-Unloading Hopper Hopper/Feeder 2 Coal/Coke F1
Plant-Unloading Hopper Belt Conveyor Transfer Coal/Coke F1
Subtotal F1
Plant-Rail Unloading Enclosed Hopper w/Dust
Suppression
Coal/Coke F2
Plant-Raw Storage Bldg Belt to Tripper Belt Quarry Blend F3
Plant-Raw Storage Bldg Tripper Belt to Piles Quarry Blend F3
Plant-Raw Storage Bldg Pile Reclaimer Quarry Blend F3
Plant-Raw Storage Bldg Reclaimer to Belt Quarry Blend F3
Location
PM2.5
lbs/hr
0.0073
0.0389
0.0073
0.0535
0.0073
0.0009
0.0050
0.0009
0.0068
0.0005
0.0005
0.0005
0.0005
0.0077
0.0414
0.0077
0.0569
0.1263
0.0014
0.0014
0.0006
0.0006
0.0040
0.0008
0.0077
0.0077
0.0077
0.0077
Rates
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Carolinas Cement PTE Material Transfer
Fugitive Emissions From Material Transfer Points
Area Equipment Description Material Location
Plant-Raw Storage Bldg Belt to Tripper Belt Additives F3
Plant-Raw Storage Bldg Tripper Belt to Piles Additives F3
Plant-Raw Storage Bldg Pile Reclaimer Additives F3
Plant-Raw Storage Bldg Reclaimer to Belt Additives F3
Plant-Raw Storage Bldg Belt to Tripper Belt Coal/Coke F3
Plant-Raw Storage Bldg Tripper Belt to Piles Coal/Coke F3
Plant-Raw Storage Bldg Pile Reclaimer Coal/Coke F3
Plant-Raw Storage Bldg Reclaimer to Belt Coal/Coke F3
Subtotal F3
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F4
Plant-Additives Transfer Belt Conveyor Transfer Additives F5
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F6
Plant-Additives Transfer Belt Conveyor Transfer Additives F7
Subtotal
Plant-Marl Transfer Conveyor to Silo Quarry Blend F7A
Plant-Marl Transfer Silo to Enclosed Belt Quarry Blend F7B
Plant-Additives Transfer Conveyor to Silo Bottom Ash F7C
Plant-Additives Transfer Silo to Enclosed Belt Bottom Ash F7D
Subtotal
Plant-Cement Additives Truck Unloading Gypsum F8
Plant-Cement Additives Hopper/Feeder Gypsum F8
Plant-Cement Additives Belt Conveyor Transfer Gypsum F8
Plant-Cement Additives Truck Unloading Limestone F8
Plant-Cement Additives Hopper/Feeder Limestone F8
Subtotal F8
Plant Subtotal RMHS
Notes:
PM2.5
lbs/hr
Rates
0.0014
0.0014
0.0014
0.0014
0.0006
0.0006
0.0006
0.0006
0.0389
0.0077
0.0014
0.0077
0.0014
0.0091
0.0039
0.0039
0.0005
0.0005
0.0086
0.0011
0.0011
0.0011
0.0009
0.0009
0.0049
0.0755
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Carolinas Cement PTE Fugitives-HAP-TAPs
Fugitive HAP & TAP Emissions
Area Equipment Description Material LocationPM
Emissions
PM
EmissionsSb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Se
lb/hr TPY lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr
Quarry Primary Crusher 1 & Equip. Limestone/Marl FQ1 0.6704 2.94 1.34E-06 1.34E-06 1.34E-06 1.34E-06 1.07E-05 6.70E-08 7.37E-06 2.01E-05 1.31E-04 7.37E-09 1.88E-05 1.07E-05
Quarry Mining Conveyor 1 Transfer Limestone/Marl FQ2 0.1015 0.44 2.03E-07 2.03E-07 2.03E-07 2.03E-07 1.62E-06 1.02E-08 1.12E-06 3.05E-06 1.99E-05 1.12E-09 2.84E-06 1.62E-06
Quarry Primary Crusher 2 & Equip. Spoils/Other FQ3 0.0853 0.37 6.83E-07 1.71E-07 1.71E-07 8.53E-08 3.75E-06 8.53E-09 1.19E-06 2.56E-06 1.08E-05 9.39E-10 4.61E-06 7.68E-07
Quarry Spoils Conveyor 3 Transfer Spoils/Other FQ4 0.0065 0.03 5.17E-08 1.29E-08 1.29E-08 6.46E-09 2.84E-07 6.46E-10 9.05E-08 1.94E-07 8.21E-07 7.11E-11 3.49E-07 5.82E-08
Quarry Radial Stacker Transfer Spoils/Other FQ5 0.0065 0.03 5.17E-08 1.29E-08 1.29E-08 6.46E-09 2.84E-07 6.46E-10 9.05E-08 1.94E-07 8.21E-07 7.11E-11 3.49E-07 5.82E-08
Quarry Stacker to Pile Spoils/Other FQ6 0.0065 0.03 5.17E-08 1.29E-08 1.29E-08 6.46E-09 2.84E-07 6.46E-10 9.05E-08 1.94E-07 8.21E-07 7.11E-11 3.49E-07 5.82E-08
Quarry Spoils Conveyor 1 Transfer Spoils/Other FQ7 0.0065 0.03 5.17E-08 1.29E-08 1.29E-08 6.46E-09 2.84E-07 6.46E-10 9.05E-08 1.94E-07 8.21E-07 7.11E-11 3.49E-07 5.82E-08
Quarry/Plant Secondary Crusher & Equip. Quarry Blend FQ8 0.7130 3.12 1.68E-06 1.43E-06 1.43E-06 1.38E-06 1.26E-05 7.13E-08 7.97E-06 2.14E-05 1.37E-04 7.84E-09 2.11E-05 1.11E-05
Quarry Subtotal FQ 1.5961 6.99 4.12E-06 3.19E-06 3.19E-06 3.04E-06 2.98E-05 1.60E-07 1.80E-05 4.79E-05 3.02E-04 1.76E-08 4.87E-05 2.45E-05
Plant-Unloading Hopper Hopper/Feeder 1 Additives F1a 0.0379 0.17 2.04E-07 2.36E-07 4.84E-08 1.55E-07 1.17E-05 9.55E-08 2.74E-06 4.37E-06 2.04E-05 8.48E-09 1.52E-06 1.36E-07
Plant-Unloading Hopper Hopper/Feeder 2 Coal/Coke F1b 0.0178 0.08 5.12E-08 3.39E-09 6.24E-09 7.49E-09 8.92E-08 8.92E-10 3.16E-08 1.80E-08 1.03E-08 1.78E-09 1.12E-06 1.16E-08
Plant-Rail Unloading Enclosed Hopper Coal/Coke F2 0.0111 0.05 3.20E-08 2.12E-09 3.90E-09 4.68E-09 5.57E-08 5.57E-10 1.97E-08 1.13E-08 6.47E-09 1.11E-09 6.99E-07 7.25E-09
Plant-Raw Storage Bldg Raw Storage Bldg Quarry Blend F3a 0.4320 1.89 1.02E-06 8.64E-07 8.64E-07 8.38E-07 7.64E-06 4.32E-08 4.83E-06 1.30E-05 8.29E-05 4.75E-09 1.28E-05 6.73E-06
Plant-Raw Storage Bldg Raw Storage Bldg Additives F3b 0.0757 0.33 4.09E-07 4.72E-07 9.68E-08 3.10E-07 2.34E-05 1.91E-07 5.47E-06 8.75E-06 4.09E-05 1.70E-08 3.04E-06 2.72E-07
Plant-Raw Storage Bldg Raw Storage Bldg Coal/Coke F3c 0.0357 0.16 1.02E-07 6.78E-09 1.25E-08 1.50E-08 1.78E-07 1.78E-09 6.31E-08 3.60E-08 2.07E-08 3.57E-09 2.24E-06 2.32E-08
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F4 0.1080 0.47 2.55E-07 2.16E-07 2.16E-07 2.10E-07 1.91E-06 1.08E-08 1.21E-06 3.24E-06 2.07E-05 1.19E-09 3.19E-06 1.68E-06
Plant-Additives Transfer Belt Conveyor Transfer Additives F5 0.0189 0.08 1.02E-07 1.18E-07 2.42E-08 7.76E-08 5.85E-06 4.78E-08 1.37E-06 2.19E-06 1.02E-05 4.24E-09 7.59E-07 6.81E-08
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F6 0.1080 0.47 2.55E-07 2.16E-07 2.16E-07 2.10E-07 1.91E-06 1.08E-08 1.21E-06 3.24E-06 2.07E-05 1.19E-09 3.19E-06 1.68E-06
Plant-Additives Transfer Belt Conveyor Transfer Additives F7 0.0189 0.08 1.02E-07 1.18E-07 2.42E-08 7.76E-08 5.85E-06 4.78E-08 1.37E-06 2.19E-06 1.02E-05 4.24E-09 7.59E-07 6.81E-08
Plant-Marl Transfer Conveyor to Silo Quarry Blend F7A 0.0540 0.24 1.27E-07 1.08E-07 1.08E-07 1.05E-07 9.55E-07 5.40E-09 6.04E-07 1.62E-06 1.04E-05 5.94E-10 1.60E-06 8.41E-07
Plant-Marl Transfer Silo to Enclosed Belt Quarry Blend F7B 0.0540 0.24 1.27E-07 1.08E-07 1.08E-07 1.05E-07 9.55E-07 5.40E-09 6.04E-07 1.62E-06 1.04E-05 5.94E-10 1.60E-06 8.41E-07
Plant-Additives Transfer Conveyor to Silo Bottom Ash F7C 0.0064 0.03 2.83E-08 2.96E-08 8.99E-09 2.55E-08 7.20E-07 3.19E-09 4.59E-07 4.91E-07 2.63E-06 1.53E-09 6.89E-08 2.54E-08
Plant-Additives Transfer Silo to Enclosed Belt Bottom Ash F7D 0.0064 0.03 2.83E-08 2.96E-08 8.99E-09 2.55E-08 7.20E-07 3.19E-09 4.59E-07 4.91E-07 2.63E-06 1.53E-09 6.89E-08 2.54E-08
Plant-Cement Additives Gypsum/LS Handling Gypsum/LS F8 0.0689 0.30 1.59E-07 3.86E-08 5.52E-09 3.31E-08 2.28E-07 2.28E-09 3.65E-08 2.01E-07 1.93E-06 1.79E-08 9.79E-08 3.80E-07
Plant Subtotal RMHS 1.0538 4.62 3.00E-06 2.57E-06 1.75E-06 2.20E-06 6.22E-05 4.70E-07 2.05E-05 4.14E-05 2.34E-04 6.97E-08 3.27E-05 1.28E-05
Quarry-Storage Piles Limestone/Marl Limestone/Marl PQ1 0.0858 0.38 1.72E-07 1.72E-07 1.72E-07 1.72E-07 1.37E-06 8.58E-09 9.44E-07 2.57E-06 1.68E-05 9.44E-10 2.40E-06 1.37E-06
Quarry-Storage Piles Spoils/Other Spoils/Other PQ2 0.0858 0.38 6.87E-07 1.72E-07 1.72E-07 8.58E-08 3.78E-06 8.58E-09 1.20E-06 2.57E-06 1.09E-05 9.44E-10 4.63E-06 7.72E-07
Quarry-Storage Piles Spoils Spoils/Other PQ3 0.1716 0.75 1.37E-06 3.43E-07 3.43E-07 1.72E-07 7.55E-06 1.72E-08 2.40E-06 5.15E-06 2.18E-05 1.89E-09 9.27E-06 1.54E-06
Quarry-Storage Piles Overburden Overburden PQ4 0.3433 1.50 5.49E-06 6.87E-07 6.87E-07 6.87E-07 1.06E-05 3.43E-08 6.18E-06 1.03E-05 2.40E-05 5.49E-09 1.37E-06 2.75E-06
Plant-Storage Piles Raw Storage Bldg Quarry Blend PB1 0.2917 1.28 6.88E-07 5.83E-07 5.83E-07 5.66E-07 5.16E-06 2.92E-08 3.26E-06 8.75E-06 5.60E-05 3.21E-09 8.62E-06 4.54E-06
Plant-Storage Piles Raw Storage Bldg Bauxite PB1 0.0000 0.00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00
Plant-Storage Piles Raw Storage Bldg Mill Scale PB1 0.0309 0.14 4.32E-07 6.36E-07 2.78E-09 1.54E-07 6.40E-05 6.40E-07 2.32E-06 1.43E-05 5.19E-05 2.47E-09 9.39E-06 4.63E-09
Plant-Storage Piles Raw Storage Bldg Bottom Ash PB1 0.6503 2.85 2.89E-06 3.02E-06 9.17E-07 2.60E-06 7.35E-05 3.25E-07 4.68E-05 5.01E-05 2.69E-04 1.56E-07 7.02E-06 2.59E-06
Plant-Storage Piles Raw Storage Bldg Coal/Coke PB1 0.1047 0.46 3.00E-07 1.99E-08 3.66E-08 4.40E-08 5.24E-07 5.24E-09 1.85E-07 1.06E-07 6.07E-08 1.05E-08 6.56E-06 6.81E-08
Plant-Storage Piles Gypsum Gypsum PB2 0.0858 0.38 1.98E-07 4.81E-08 6.87E-09 4.12E-08 2.83E-07 2.83E-09 4.55E-08 2.51E-07 2.40E-06 2.23E-08 1.22E-07 4.73E-07
Plant-Storage Piles Limestone Limestone PB3 0.0687 0.30 1.59E-07 3.84E-08 5.49E-09 3.30E-08 2.27E-07 2.27E-09 3.64E-08 2.00E-07 1.92E-06 1.78E-08 9.75E-08 3.78E-07
Storage Piles Subtotal SP 1.9186 8.40 1.24E-05 5.72E-06 2.93E-06 4.56E-06 1.67E-04 1.07E-06 6.34E-05 9.42E-05 4.54E-04 2.22E-07 4.95E-05 1.45E-05
Mining Operation Drilling Limestone/Marl M1 0.2256 0.99 4.51E-07 4.51E-07 4.51E-07 4.51E-07 3.61E-06 2.26E-08 2.48E-06 6.77E-06 4.42E-05 2.48E-09 6.32E-06 3.61E-06
Mining Operation Blasting Limestone/Marl M1 0.3435 1.50 6.87E-07 6.87E-07 6.87E-07 6.87E-07 5.50E-06 3.44E-08 3.78E-06 1.03E-05 6.73E-05 3.78E-09 9.62E-06 5.50E-06
Mining Operation LS/Marl Ripping/Loading Limestone/Marl M1 1.3995 6.13 2.80E-06 2.80E-06 2.80E-06 2.80E-06 2.24E-05 1.40E-07 1.54E-05 4.20E-05 2.74E-04 1.54E-08 3.92E-05 2.24E-05
Mining Operation Spoils Removal/Loading Spoils/Other M2 0.1781 0.78 1.43E-06 3.56E-07 3.56E-07 1.78E-07 7.84E-06 1.78E-08 2.49E-06 5.34E-06 2.26E-05 1.96E-09 9.62E-06 1.60E-06
Mining Operation Overburden Removal/Loading Overburden M3 1.3036 5.71 2.09E-05 2.61E-06 2.61E-06 2.61E-06 4.04E-05 1.30E-07 2.35E-05 3.91E-05 9.13E-05 2.09E-08 5.21E-06 1.04E-05
Mining Operation Overburden Unoading Overburden M4 0.0946 0.41 1.51E-06 1.89E-07 1.89E-07 1.89E-07 2.93E-06 9.46E-09 1.70E-06 2.84E-06 6.62E-06 1.51E-09 3.78E-07 7.57E-07
Mining Operation Subtotal MINE 3.5450 15.53 2.77E-05 7.09E-06 7.09E-06 6.91E-06 8.27E-05 3.54E-07 4.93E-05 1.06E-04 5.06E-04 4.60E-08 7.03E-05 4.43E-05
Grand Total 8.1135 35.54 4.72E-05 1.86E-05 1.50E-05 1.67E-05 3.42E-04 2.06E-06 1.51E-04 2.90E-04 1.50E-03 3.55E-07 2.01E-04 9.60E-05
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Carolinas Cement PTE Fugitives-HAP-TAPs
Fugitive HAP & TAP Emissions
Area Equipment Description Material Location
Quarry Primary Crusher 1 & Equip. Limestone/Marl FQ1
Quarry Mining Conveyor 1 Transfer Limestone/Marl FQ2
Quarry Primary Crusher 2 & Equip. Spoils/Other FQ3
Quarry Spoils Conveyor 3 Transfer Spoils/Other FQ4
Quarry Radial Stacker Transfer Spoils/Other FQ5
Quarry Stacker to Pile Spoils/Other FQ6
Quarry Spoils Conveyor 1 Transfer Spoils/Other FQ7
Quarry/Plant Secondary Crusher & Equip. Quarry Blend FQ8
Quarry Subtotal FQ
Plant-Unloading Hopper Hopper/Feeder 1 Additives F1a
Plant-Unloading Hopper Hopper/Feeder 2 Coal/Coke F1b
Plant-Rail Unloading Enclosed Hopper Coal/Coke F2
Plant-Raw Storage Bldg Raw Storage Bldg Quarry Blend F3a
Plant-Raw Storage Bldg Raw Storage Bldg Additives F3b
Plant-Raw Storage Bldg Raw Storage Bldg Coal/Coke F3c
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F4
Plant-Additives Transfer Belt Conveyor Transfer Additives F5
Plant-Marl Transfer Belt Conveyor Transfer Quarry Blend F6
Plant-Additives Transfer Belt Conveyor Transfer Additives F7
Plant-Marl Transfer Conveyor to Silo Quarry Blend F7A
Plant-Marl Transfer Silo to Enclosed Belt Quarry Blend F7B
Plant-Additives Transfer Conveyor to Silo Bottom Ash F7C
Plant-Additives Transfer Silo to Enclosed Belt Bottom Ash F7D
Plant-Cement Additives Gypsum/LS Handling Gypsum/LS F8
Plant Subtotal RMHS
Quarry-Storage Piles Limestone/Marl Limestone/Marl PQ1
Quarry-Storage Piles Spoils/Other Spoils/Other PQ2
Quarry-Storage Piles Spoils Spoils/Other PQ3
Quarry-Storage Piles Overburden Overburden PQ4
Plant-Storage Piles Raw Storage Bldg Quarry Blend PB1
Plant-Storage Piles Raw Storage Bldg Bauxite PB1
Plant-Storage Piles Raw Storage Bldg Mill Scale PB1
Plant-Storage Piles Raw Storage Bldg Bottom Ash PB1
Plant-Storage Piles Raw Storage Bldg Coal/Coke PB1
Plant-Storage Piles Gypsum Gypsum PB2
Plant-Storage Piles Limestone Limestone PB3
Storage Piles Subtotal SP
Mining Operation Drilling Limestone/Marl M1
Mining Operation Blasting Limestone/Marl M1
Mining Operation LS/Marl Ripping/Loading Limestone/Marl M1
Mining Operation Spoils Removal/Loading Spoils/Other M2
Mining Operation Overburden Removal/Loading Overburden M3
Mining Operation Overburden Unoading Overburden M4
Mining Operation Subtotal MINE
Grand Total
Sb As Be Cd Cr Cr(VI) Co Pb Mn Hg Ni Se
TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY TPY
5.87E-06 5.87E-06 5.87E-06 5.87E-06 4.70E-05 2.94E-07 3.23E-05 8.81E-05 5.75E-04 3.23E-08 8.22E-05 4.70E-05
8.89E-07 8.89E-07 8.89E-07 8.89E-07 7.12E-06 4.45E-08 4.89E-06 1.33E-05 8.72E-05 4.89E-09 1.25E-05 7.12E-06
2.99E-06 7.47E-07 7.47E-07 3.74E-07 1.64E-05 3.74E-08 5.23E-06 1.12E-05 4.75E-05 4.11E-09 2.02E-05 3.36E-06
2.26E-07 5.66E-08 5.66E-08 2.83E-08 1.25E-06 2.83E-09 3.96E-07 8.49E-07 3.59E-06 3.11E-10 1.53E-06 2.55E-07
2.26E-07 5.66E-08 5.66E-08 2.83E-08 1.25E-06 2.83E-09 3.96E-07 8.49E-07 3.59E-06 3.11E-10 1.53E-06 2.55E-07
2.26E-07 5.66E-08 5.66E-08 2.83E-08 1.25E-06 2.83E-09 3.96E-07 8.49E-07 3.59E-06 3.11E-10 1.53E-06 2.55E-07
2.26E-07 5.66E-08 5.66E-08 2.83E-08 1.25E-06 2.83E-09 3.96E-07 8.49E-07 3.59E-06 3.11E-10 1.53E-06 2.55E-07
7.37E-06 6.25E-06 6.25E-06 6.06E-06 5.52E-05 3.12E-07 3.49E-05 9.37E-05 5.99E-04 3.44E-08 9.23E-05 4.87E-05
1.80E-05 1.40E-05 1.40E-05 1.33E-05 1.31E-04 6.99E-07 7.89E-05 2.10E-04 1.32E-03 7.69E-08 2.13E-04 1.07E-04
8.95E-07 1.03E-06 2.12E-07 6.80E-07 5.12E-05 4.18E-07 1.20E-05 1.92E-05 8.95E-05 3.71E-08 6.65E-06 5.96E-07
2.24E-07 1.48E-08 2.73E-08 3.28E-08 3.91E-07 3.91E-09 1.38E-07 7.89E-08 4.53E-08 7.81E-09 4.90E-06 5.08E-08
1.40E-07 9.28E-09 1.71E-08 2.05E-08 2.44E-07 2.44E-09 8.64E-08 4.93E-08 2.83E-08 4.88E-09 3.06E-06 3.17E-08
4.47E-06 3.78E-06 3.78E-06 3.67E-06 3.35E-05 1.89E-07 2.12E-05 5.68E-05 3.63E-04 2.08E-08 5.59E-05 2.95E-05
1.79E-06 2.07E-06 4.24E-07 1.36E-06 1.02E-04 8.37E-07 2.40E-05 3.83E-05 1.79E-04 7.43E-08 1.33E-05 1.19E-06
4.48E-07 2.97E-08 5.47E-08 6.56E-08 7.81E-07 7.81E-09 2.77E-07 1.58E-07 9.06E-08 1.56E-08 9.80E-06 1.02E-07
1.12E-06 9.46E-07 9.46E-07 9.18E-07 8.36E-06 4.73E-08 5.29E-06 1.42E-05 9.08E-05 5.20E-09 1.40E-05 7.37E-06
4.47E-07 5.17E-07 1.06E-07 3.40E-07 2.56E-05 2.09E-07 5.99E-06 9.58E-06 4.47E-05 1.86E-08 3.33E-06 2.98E-07
1.12E-06 9.46E-07 9.46E-07 9.18E-07 8.36E-06 4.73E-08 5.29E-06 1.42E-05 9.08E-05 5.20E-09 1.40E-05 7.37E-06
4.47E-07 5.17E-07 1.06E-07 3.40E-07 2.56E-05 2.09E-07 5.99E-06 9.58E-06 4.47E-05 1.86E-08 3.33E-06 2.98E-07
5.58E-07 4.73E-07 4.73E-07 4.59E-07 4.18E-06 2.37E-08 2.64E-06 7.10E-06 4.54E-05 2.60E-09 6.99E-06 3.69E-06
5.58E-07 4.73E-07 4.73E-07 4.59E-07 4.18E-06 2.37E-08 2.64E-06 7.10E-06 4.54E-05 2.60E-09 6.99E-06 3.69E-06
1.24E-07 1.30E-07 3.94E-08 1.12E-07 3.16E-06 1.40E-08 2.01E-06 2.15E-06 1.15E-05 6.70E-09 3.02E-07 1.11E-07
1.24E-07 1.30E-07 3.94E-08 1.12E-07 3.16E-06 1.40E-08 2.01E-06 2.15E-06 1.15E-05 6.70E-09 3.02E-07 1.11E-07
6.98E-07 1.69E-07 2.42E-08 1.45E-07 9.97E-07 9.97E-09 1.60E-07 8.82E-07 8.46E-06 7.85E-08 4.29E-07 1.66E-06
1.32E-05 1.12E-05 7.67E-06 9.63E-06 2.72E-04 2.06E-06 8.97E-05 1.81E-04 1.02E-03 3.05E-07 1.43E-04 5.60E-05
7.52E-07 7.52E-07 7.52E-07 7.52E-07 6.01E-06 3.76E-08 4.13E-06 1.13E-05 7.37E-05 4.13E-09 1.05E-05 6.01E-06
3.01E-06 7.52E-07 7.52E-07 3.76E-07 1.65E-05 3.76E-08 5.26E-06 1.13E-05 4.77E-05 4.13E-09 2.03E-05 3.38E-06
6.01E-06 1.50E-06 1.50E-06 7.52E-07 3.31E-05 7.52E-08 1.05E-05 2.26E-05 9.55E-05 8.27E-09 4.06E-05 6.77E-06
2.41E-05 3.01E-06 3.01E-06 3.01E-06 4.66E-05 1.50E-07 2.71E-05 4.51E-05 1.05E-04 2.41E-08 6.01E-06 1.20E-05
3.01E-06 2.56E-06 2.56E-06 2.48E-06 2.26E-05 1.28E-07 1.43E-05 3.83E-05 2.45E-04 1.41E-08 3.78E-05 1.99E-05
0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00
1.89E-06 2.79E-06 1.22E-08 6.77E-07 2.80E-04 2.80E-06 1.01E-05 6.25E-05 2.27E-04 1.08E-08 4.11E-05 2.03E-08
1.26E-05 1.32E-05 4.02E-06 1.14E-05 3.22E-04 1.42E-06 2.05E-04 2.19E-04 1.18E-03 6.84E-07 3.08E-05 1.13E-05
1.32E-06 8.71E-08 1.61E-07 1.93E-07 2.29E-06 2.29E-08 8.12E-07 4.63E-07 2.66E-07 4.59E-08 2.88E-05 2.98E-07
8.68E-07 2.10E-07 3.01E-08 1.80E-07 1.24E-06 1.24E-08 1.99E-07 1.10E-06 1.05E-05 9.77E-08 5.34E-07 2.07E-06
6.95E-07 1.68E-07 2.41E-08 1.44E-07 9.92E-07 9.92E-09 1.59E-07 8.78E-07 8.42E-06 7.82E-08 4.27E-07 1.66E-06
5.43E-05 2.50E-05 1.28E-05 2.00E-05 7.32E-04 4.70E-06 2.78E-04 4.13E-04 1.99E-03 9.71E-07 2.17E-04 6.35E-05
1.98E-06 1.98E-06 1.98E-06 1.98E-06 1.58E-05 9.88E-08 1.09E-05 2.96E-05 1.94E-04 1.09E-08 2.77E-05 1.58E-05
3.01E-06 3.01E-06 3.01E-06 3.01E-06 2.41E-05 1.50E-07 1.66E-05 4.51E-05 2.95E-04 1.66E-08 4.21E-05 2.41E-05
1.23E-05 1.23E-05 1.23E-05 1.23E-05 9.81E-05 6.13E-07 6.74E-05 1.84E-04 1.20E-03 6.74E-08 1.72E-04 9.81E-05
6.24E-06 1.56E-06 1.56E-06 7.80E-07 3.43E-05 7.80E-08 1.09E-05 2.34E-05 9.91E-05 8.58E-09 4.21E-05 7.02E-06
9.14E-05 1.14E-05 1.14E-05 1.14E-05 1.77E-04 5.71E-07 1.03E-04 1.71E-04 4.00E-04 9.14E-08 2.28E-05 4.57E-05
6.63E-06 8.29E-07 8.29E-07 8.29E-07 1.28E-05 4.14E-08 7.46E-06 1.24E-05 2.90E-05 6.63E-09 1.66E-06 3.31E-06
1.21E-04 3.11E-05 3.11E-05 3.03E-05 3.62E-04 1.55E-06 2.16E-04 4.66E-04 2.22E-03 2.01E-07 3.08E-04 1.94E-04
2.07E-04 8.13E-05 6.55E-05 7.32E-05 1.50E-03 9.01E-06 6.62E-04 1.27E-03 6.56E-03 1.55E-06 8.81E-04 4.21E-04
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Carolinas Cement PTE Storage Piles
AREA PILE PILE ID Active Silt Material AVG Wind Speed Rain Control TSP PM10 PM2.5 TSP PM10 PM2.5
MATERIAL AREA No. Days Content Throughput WIND > 12 mph Days Efficiency Wind Wind Wind Hourly Hourly Hourly
(n) (s) SPEED (f) (p) Emissions Emissions Emissions Emissions Emissions Emissions
(Acres) (days/yr) percent (T/yr) (mph) percent (days/yr) (%) (T/yr) (T/yr) (T/yr) (lb/hr) (lb/hr) (lb/hr)
Quarry Limestone/Marl (Crusher Feed) 0.5 PQ1 365 3.9 3,411,152 8.6 13.3 118 0 0.38 0.19 0.03 0.0858 0.0429 0.0064
Quarry Spoils/other (Crusher Feed) 0.5 PQ2 365 3.9 434,183 8.6 13.3 118 0 0.38 0.19 0.03 0.0858 0.0429 0.0064
Quarry Spoils (Stacker Pile) 1.0 PQ3 365 3.9 217,092 8.6 13.3 118 0 0.75 0.38 0.06 0.1716 0.0858 0.0129
Quarry Overburden (Active Pile) 2.0 PQ4 365 3.9 3,177,255 8.6 13.3 118 0 1.50 0.75 0.11 0.3433 0.1716 0.0257
Plant Limestone/Marl/Spoils (Bldg) 2.3 PB1 365 3.9 3,628,243 8.6 13.3 0 50 1.28 0.64 0.10 0.2917 0.1458 0.0219
Plant Bauxite 0.0 PB1 365 6.0 0 8.6 13.3 0 50 0.00 0.00 0.00 0.0000 0.0000 0.0000
Plant Mill Scale 0.10 PB1 365 9.5 33,770 8.6 13.3 0 50 0.14 0.07 0.01 0.0309 0.0154 0.0023
Plant Bottom Ash 0.25 PB1 365 80 391,332 8.6 13.3 0 50 2.85 1.42 0.21 0.6503 0.3252 0.0488
Plant Coal/Coke 0.7 PB1 365 4.6 283,824 8.6 13.3 0 50 0.46 0.23 0.03 0.1047 0.0524 0.0079
Subtotal (Raw Storage Bldg) 4.72 2.36 0.35 1.0776 0.5388 0.0808
Plant Gypsum 0.5 PB2 365 3.9 127,549 8.6 13.3 118 0 0.38 0.19 0.03 0.0858 0.0429 0.0064
Plant Limestone 0.4 PB3 365 3.9 102,040 8.6 13.3 118 0 0.30 0.15 0.02 0.0687 0.0343 0.0051
SP Total All Piles 8.40 4.20 0.63 1.9186 0.9593 0.1439
Equation for Wind Erosion:
References: Control of Open Fugitive Dust Sources, EPA-450/3-88-008, p. 4-17
Ef = 1.7*(s/1.5)*(f/15)*((365-p)/235)*(1-(C/100)) TSP (lbs/acre/day) PM10 fraction = 0.5
E = A*n*Ef/2000 TSP (tons/yr) PM2.5 fraction (AP-42 0.075
s = Silt content of the aggregate (%) Typical silt contents of materials from AP-42 Table 13.2.4-1
f = Percent of time that the unobstructed wind speed exceeds 12 mph at the mean pile height
p = Number of days with >= 0.01 in. of precipitation per year
C = Overall control efficiency (%) Estimated 50% control efficiency for piles in raw material storage building due to wind reduction
A = Size of the pile (acres)
n = Number of days per year the pile is continuously active
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Carolinas Cement PTE Mining
Quarry Drilling
Source AREA Drill Average Number TSP PM10 PM10 PM2.5 PM2.5 Control TSP PM10 PM2.5 TSP PM10
Location Footage Depth of Holes Emission Fraction Factor Fraction Factor Efficiency Emissions Emissions Emissions Hourly Hourly
Factor Emissions Emissions
(ft/yr) (ft/hole) (holes/yr) (lb/hole) (lb/hole) (lb/hole) (%) (T/yr) (T/yr) (T/yr) (lb/hr) (lb/hr)
M1 Quarry 76,000 5 15,200 1.3 0.52 0.68 0.03 0.04 90 0.99 0.51 0.03 0.2256 0.1173
Notes
TSP emission factor from AP-42 Table 11.9-4
Assume PM10 and PM2.5 fractions are similar to blasting, from Table 11.9-1
Control efficiency based on drill rigs using either fabric filters or wet suppression
Quarry Blasting
Source AREA Number Average TSP PM10 PM10 PM2.5 PM2.5 Control TSP PM10 PM2.5 TSP PM10
Location of Blasts Blast Emission Fraction Factor Fraction Factor Efficiency Emissions Emissions Emissions Hourly Hourly
Area, A Factor Emissions Emissions
(blasts/yr) (sq ft) (lb/blast) (lb/hole) (lb/hole) (%) (T/yr) (T/yr) (T/yr) (lb/hr) (lb/hr)
M1 Quarry 76 20,000 39.60 0.52 20.59 0.03 1.19 0 1.50 0.78 0.05 0.3435 0.1786
Notes
TSP emission factor (lb/blast) from AP-42 Table 11.9-1
0.000014 x (A)^1.5
PM10 and PM2.5 fractions from AP-42 Table 11.9-1
Quarry Ripping/Loading/Unloading
Source AREA OPERATION MATERIAL Volume TSP PM10 PM10 Units PM2.5 PM2.5 Note Control TSP PM10 PM2.5 TSP PM10
Location Throughput Basis Factor Fraction Factor Fraction Factor Efficiency Emissions Emissions Emissions Hourly Hourly
Emissions Emissions
(T/yr) (CY/yr) (lb/Unit) (lb/Unit) (lb/Unit) (%) (T/yr) (T/yr) (T/yr) (lb/hr) (lb/hr)
M1 Quarry LS/Marl Ripping 3,411,152 2,526,779 1.80E-02 0.50 9.00E-03 CY 0.075 1.35E-03 1 75% 5.69 2.84 0.43 1.2980 0.6490
M1 Quarry LS/Marl Loading 3,411,152 2.61E-04 0.47 1.23E-04 ton 0.072 1.87E-05 2 0.44 0.21 0.03 0.1015 0.0480
Subtotal 6.13 3.05 0.46 1.3995 0.6970
M2 Quarry Spoils/Other Removal 434,183 321,617 1.80E-02 0.50 9.00E-03 CY 0.075 1.35E-03 1 75% 0.72 0.36 0.05 0.1652 0.0826
M2 Quarry Spoils/Other Loading 434,183 2.61E-04 0.47 1.23E-04 ton 0.072 1.87E-05 2 0.06 0.03 0.00 0.0129 0.0061
Subtotal 0.78 0.39 0.06 0.1781 0.0887
M3 Quarry Overburden Removal 3,177,255 2,353,522 1.80E-02 0.50 9.00E-03 CY 0.075 1.35E-03 1 75% 5.30 2.65 0.40 1.2090 0.6045
M3 Quarry Overburden Loading 3,177,255 2.61E-04 0.47 1.23E-04 ton 0.072 1.87E-05 2 0.41 0.20 0.03 0.0946 0.0447
Subtotal 5.71 2.84 0.43 1.3036 0.6492
M4 Quarry Overburden Unloading 3,177,255 2.61E-04 0.47 1.23E-04 ton 0.072 1.87E-05 2 0.41 0.20 0.03 0.0946 0.0447
Subtotal Group 13.03 6.48 0.97 2.9758 1.4797
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Carolinas Cement PTE Mining
MINE (All Operations) GRAND TOTAL 15.53 7.78 1.05 3.5450 1.7757
Notes
1 PM-10 emission factor for ripping/removal from FIRE database SCC 30501036
1 cubic yard marl or overburden = 1.35 tons as excavated
Assume TSP = 2 x PM-10 (PM-10 fraction = 0.5)
Assume PM2.5 fraction of TSP = 0.075
Control efficiency for material mining operations estimated at a minimum of 75% due to high moisture content.
2 Controlled emission factors are used for material loading operations (include moisture).
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Carolinas Cement PTE Mining
Quarry Drilling
Source AREA Drill
Location Footage
(ft/yr)
M1 Quarry 76,000
Notes
TSP emission factor from AP-42 T
Assume PM10 and PM2.5 fraction
Control efficiency based on drill rig
Quarry Blasting
Source AREA Number
Location of Blasts
(blasts/yr)
M1 Quarry 76
Notes
TSP emission factor (lb/blast) from
0.000014 x (A)^1.5
PM10 and PM2.5 fractions from A
Quarry Ripping/Loading/Unloading
Source AREA OPERATION
Location
M1 Quarry LS/Marl Ripping
M1 Quarry LS/Marl Loading
M2 Quarry Spoils/Other Removal
M2 Quarry Spoils/Other Loading
M3 Quarry Overburden Removal
M3 Quarry Overburden Loading
M4 Quarry Overburden Unloading
PM2.5
Hourly
Emissions
(lb/hr)
0.0068
PM2.5
Hourly
Emissions
(lb/hr)
0.0103
PM2.5
Hourly
Emissions
(lb/hr)
0.0974
0.0073
0.1046
0.0124
0.0009
0.0133
0.0907
0.0068
0.0974
0.0068
0.2222
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Carolinas Cement PTE Mining
MINE (All Operations)
Notes
1 PM-10 emission factor for
1 cubic yard marl or overb
Assume TSP = 2 x PM-10
Assume PM2.5 fraction of
Control efficiency for mate
2 Controlled emission facto
0.2392
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Carolinas Cement PTE Traffic Inputs
Bauxite Plant 0 tons/year Truck 15 tons 25 tons 0
Bottom Ash Plant 391,332 tons/year Truck 15 tons 25 tons 15,653
Mill Scale Plant 33,770 tons/year Truck 15 tons 25 tons 1,351
Coal/Coke/Fuels Plant 113,530 tons/year Truck 15 tons 25 tons 4,541
Gypsum Plant 127,549 tons/year Truck 15 tons 25 tons 5,102
Cement bulk Plant 433,187 tons/year Truck 15 tons 25 tons 17,327
Cement bags Plant 481,319 tons/year Truck 15 tons 25 tons 19,253
Limestone Plant 102,040 tons/year Truck 15 tons 25 tons 4,082
Employees Plant 100 employees/day Auto/Pickup 1.75 tons 1 employee 36,500
Marl/Limestone Quarry 3,411,152 tons/year Truck 77.9 tons 100 tons 34,112
Spoils/Other Quarry 434,183 tons/year Truck 77.9 tons 100 tons 4,342
Overburden Quarry 3,177,255 tons/year Truck 77.9 tons 100 tons 31,773
Total TripsMaterial Quantity TransportedVehicle Weight
(Empty)Load CapacityVehicle TypeLocation
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Carolinas Cement PTE All Roads
Unit Road Type Vehicle Total Total TSP PM10 PM2.5ID Type Length Mileage Emissions Emissions Emissions
(mi) (Mi/yr) (Ton/yr) (Ton/yr) (Ton/yr)
PLTRD Paved Trucks/Autos 1.06 43,533 9.31 1.81 0.44QURD Unpaved Trucks 1.45 40,141 69.57 19.78 1.98
Total 78.87 21.59 2.42
Annual Emissions
All Roads Emission Summary
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Carolinas Cement PTE Paved Summary
Paved Road Emission Summary
Segment Segment Segment Description Direction Silt Material Total TSP PM10 PM2.5 TSP PM10 PM2.5 TSP PM10 PM2.5
No. Length Length -Way Loading Trips Mileage E Factor E Factor E Factor Emissions Emissions Emissions Emissions Emissions Emissions
(ft) (mi) (g/m2) (#/yr) (Mi/yr) lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr) (lb/hr) (lb/hr) (lb/hr)
PR1 635 0.120 South entrance 1 0.20 43,975 5,289 0.54 0.10 0.03 1.420 0.276 0.068 0.3243 0.0631 0.0156
PR2 2127 0.403 Additives truck route 2 0.20 25,627 20,647 0.47 0.09 0.02 4.830 0.939 0.231 1.1028 0.2144 0.0528
PR3 114 0.022 Entrance connector 1 0.20 30,729 752 0.33 0.06 0.02 0.122 0.024 0.006 0.0279 0.0054 0.0013
PR4 603 0.114 Gyp truck route 2 0.20 9,184 2,098 0.47 0.09 0.02 0.491 0.095 0.024 0.1120 0.0218 0.0054
PR5 305 0.058 Internal connector 1 0.20 26,647 1,539 0.19 0.04 0.01 0.145 0.028 0.007 0.0331 0.0064 0.0015
PR6 95 0.018 Exit connector 1 0.20 26,647 479 0.19 0.04 0.01 0.045 0.009 0.002 0.0103 0.0020 0.0005
PR7 95 0.018 Cement silo entrance 1 0.20 17,327 312 0.19 0.04 0.01 0.029 0.006 0.001 0.0067 0.0013 0.0003
PR8 76 0.014 Cement silo exit 1 0.20 17,327 249 0.82 0.16 0.04 0.102 0.020 0.005 0.0234 0.0046 0.0011
PR9 502 0.095 South exit 1 0.20 43,975 4,181 0.40 0.08 0.02 0.840 0.163 0.040 0.1918 0.0373 0.0092
PR10 225 0.043 Employee parking 2 0.20 36,500 3,111 0.01 0.00 0.00 0.011 0.002 0.000 0.0025 0.0004 0.0000
PR11 420 0.080 Packing entrance 1 0.20 17,327 1,378 0.82 0.16 0.04 0.566 0.110 0.027 0.1292 0.0252 0.0062
PR12 420 0.080 Packing exit 1 0.20 43,975 3,498 0.40 0.08 0.02 0.703 0.137 0.034 0.1605 0.0312 0.0077
TOTAL 1.064 43,533 9.305 1.808 0.445 2.1244 0.4128 0.1016
Annual Emissions Hourly Emissions
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Carolinas Cement PTE Paved Roads
Paved Roads Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR1 0.120 Raw Additives 0.20 15 25 40 27.5 X 40.0 25 425,102 17,004 0 2,045 2,045 81,800
PR1 0.120 Coal/coke 0.20 15 25 40 27.5 X 40.0 25 113,530 4,541 0 546 546 21,846
PR1 0.120 Gypsum 0.20 15 25 40 27.5 X 40.0 25 127,549 5,102 0 614 614 24,544
PR1 0.120 Cement bulk 0.20 15 25 40 27.5 X 15.0 25 433,187 17,327 2,084 0 2,084 31,258
PR1 0.120 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR1 0.120 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR1 0.120 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR1 0.120 SUBTOTAL 0.20 30.1 43,975 2,084 3,205 5,289 159,448
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR2 0.403 Raw Additives 0.20 15 25 40 27.5 X X 27.5 25 425,102 17,004 6,850 6,850 13,700 376,747
PR2 0.403 Coal/coke 0.20 15 25 40 27.5 X X 27.5 25 113,530 4,541 1,829 1,829 3,659 100,616
PR2 0.403 Gypsum 0.20 15 25 40 27.5 127,549 0 0 0 0
PR2 0.403 Cement bulk 0.20 15 25 40 27.5 433,187 0 0 0 0
PR2 0.403 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR2 0.403 Limestone 0.20 15 25 40 27.5 X X 27.5 25 102,040 4,082 1,644 1,644 3,288 90,433
PR2 0.403 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR2 0.403 SUBTOTAL 0.20 27.5 25,627 10,324 10,324 20,647 567,795
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR3 0.022 Raw Additives 0.20 15 25 40 27.5 X 15.0 25 425,102 17,004 367 0 367 5,507
PR3 0.022 Coal/coke 0.20 15 25 40 27.5 X 15.0 25 113,530 4,541 98 0 98 1,471
PR3 0.022 Gypsum 0.20 15 25 40 27.5 X 40.0 25 127,549 5,102 0 110 110 4,406
PR3 0.022 Cement bulk 0.20 15 25 40 27.5 433,187 0 0 0 0
PR3 0.022 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR3 0.022 Limestone 0.20 15 25 40 27.5 X X 27.5 25 102,040 4,082 88 88 176 4,847
PR3 0.022 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR3 0.022 SUBTOTAL 0.20 21.6 30,729 553 198 752 16,231
Truck Weights
Truck Weights
Truck Weights
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Carolinas Cement PTE Paved Roads
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR4 0.114 Raw Additives 0.20 15 25 40 27.5 425,102 0 0 0 0
PR4 0.114 Coal/coke 0.20 15 25 40 27.5 113,530 0 0 0 0
PR4 0.114 Gypsum 0.20 15 25 40 27.5 X X 27.5 25 127,549 5,102 583 583 1,165 32,047
PR4 0.114 Cement bulk 0.20 15 25 40 27.5 433,187 0 0 0 0
PR4 0.114 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR4 0.114 Limestone 0.20 15 25 40 27.5 X X 27.5 25 102,040 4,082 466 466 932 25,637
PR4 0.114 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR4 0.114 SUBTOTAL 0.20 27.5 9,184 1,049 1,049 2,098 57,684
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR5 0.058 Raw Additives 0.20 15 25 40 27.5 X 15.0 25 425,102 17,004 982 0 982 14,734
PR5 0.058 Coal/coke 0.20 15 25 40 27.5 X 15.0 25 113,530 4,541 262 0 262 3,935
PR5 0.058 Gypsum 0.20 15 25 40 27.5 X 15.0 25 127,549 5,102 295 0 295 4,421
PR5 0.058 Cement bulk 0.20 15 25 40 27.5 433,187 0 0 0 0
PR5 0.058 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR5 0.058 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR5 0.058 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR5 0.058 SUBTOTAL 0.20 15.0 26,647 1,539 0 1,539 23,089
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR6 0.018 Raw Additives 0.20 15 25 40 27.5 X 15.0 25 425,102 17,004 306 0 306 4,589
PR6 0.018 Coal/coke 0.20 15 25 40 27.5 X 15.0 25 113,530 4,541 82 0 82 1,226
PR6 0.018 Gypsum 0.20 15 25 40 27.5 X 15.0 25 127,549 5,102 92 0 92 1,377
PR6 0.018 Cement bulk 0.20 15 25 40 27.5 433,187 0 0 0 0
PR6 0.018 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR6 0.018 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR6 0.018 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
Truck Weights
Truck Weights
Truck Weights
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Carolinas Cement PTE Paved Roads
PR6 0.018 SUBTOTAL 0.20 15.0 26,647 479 0 479 7,192
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR7 0.018 Raw Additives 0.20 15 25 40 27.5 425,102 0 0 0 0
PR7 0.018 Coal/coke 0.20 15 25 40 27.5 113,530 0 0 0 0
PR7 0.018 Gypsum 0.20 15 25 40 27.5 127,549 0 0 0 0
PR7 0.018 Cement bulk 0.20 15 25 40 27.5 X 15.0 25 433,187 17,327 312 0 312 4,676
PR7 0.018 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR7 0.018 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR7 0.018 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR7 0.018 SUBTOTAL 0.20 15.0 17,327 312 0 312 4,676
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR8 0.014 Raw Additives 0.20 15 25 40 27.5 425,102 0 0 0 0
PR8 0.014 Coal/coke 0.20 15 25 40 27.5 113,530 0 0 0 0
PR8 0.014 Gypsum 0.20 15 25 40 27.5 127,549 0 0 0 0
PR8 0.014 Cement bulk 0.20 15 25 40 27.5 X 40.0 25 433,187 17,327 0 249 249 9,976
PR8 0.014 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR8 0.014 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR8 0.014 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR8 0.014 SUBTOTAL 0.20 40.0 17,327 0 249 249 9,976
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR9 0.095 Raw Additives 0.20 15 25 40 27.5 X 15.0 25 425,102 17,004 1,617 0 1,617 24,250
PR9 0.095 Coal/coke 0.20 15 25 40 27.5 X 15.0 25 113,530 4,541 432 0 432 6,476
PR9 0.095 Gypsum 0.20 15 25 40 27.5 X 15.0 25 127,549 5,102 485 0 485 7,276
PR9 0.095 Cement bulk 0.20 15 25 40 27.5 X 40.0 25 433,187 17,327 0 1,647 1,647 65,897
PR9 0.095 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR9 0.095 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
Truck Weights
Truck Weights
Truck Weights
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Carolinas Cement PTE Paved Roads
PR9 0.095 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR9 0.095 SUBTOTAL 0.20 24.9 43,975 2,534 1,647 4,181 103,900
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR10 0.043 Raw Additives 0.20 15 25 40 27.5 425,102 0 0 0 0
PR10 0.043 Coal/coke 0.20 15 25 40 27.5 113,530 0 0 0 0
PR10 0.043 Gypsum 0.20 15 25 40 27.5 127,549 0 0 0 0
PR10 0.043 Cement bulk 0.20 15 25 40 27.5 433,187 0 0 0 0
PR10 0.043 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR10 0.043 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR10 0.043 Employees 0.20 1.75 0 1.75 1.75 X X 1.8 0 100 36,500 1,555 1,555 3,111 5,444
PR10 0.043 SUBTOTAL 0.20 1.8 36,500 1,555 1,555 3,111 5,444
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR11 0.080 Raw Additives 0.20 15 25 40 27.5 425,102 0 0 0 0
PR11 0.080 Coal/coke 0.20 15 25 40 27.5 113,530 0 0 0 0
PR11 0.080 Gypsum 0.20 15 25 40 27.5 127,549 0 0 0 0
PR11 0.080 Cement bulk 0.20 15 25 40 27.5 X 40.0 25 433,187 17,327 0 1,378 1,378 55,133
PR11 0.080 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
PR11 0.080 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR11 0.080 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR11 0.080 SUBTOTAL 0.20 40.0 17,327 0 1,378 1,378 55,133
Truck Trips
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Loading Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (g/m2) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
PR12 0.080 Raw Additives 0.20 15 25 40 27.5 X 15.0 25 425,102 17,004 1,353 0 1,353 20,289
PR12 0.080 Coal/coke 0.20 15 25 40 27.5 X 15.0 25 113,530 4,541 361 0 361 5,418
PR12 0.080 Gypsum 0.20 15 25 40 27.5 X 15.0 25 127,549 5,102 406 0 406 6,088
PR12 0.080 Cement bulk 0.20 15 25 40 27.5 X 40.0 25 433,187 17,327 0 1,378 1,378 55,133
PR12 0.080 Cement bags 0.20 15 25 40 27.5 481,319 0 0 0 0
Truck Weights
Truck Weights
Truck Weights
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Carolinas Cement PTE Paved Roads
PR12 0.080 Limestone 0.20 15 25 40 27.5 102,040 0 0 0 0
PR12 0.080 Employees 0.20 1.75 0 1.75 1.75 100 0 0 0 0
PR12 0.080 SUBTOTAL 0.20 24.9 43,975 2,120 1,378 3,498 86,928
GRAND TOTAL 43,533
Notes: Emissions based on AP-42 Section 13.2.1 (11/06), Equation (2).
E = [k * (sL/2)^0.65 * (W/3)^1.5 - C] * (1 - P/4N)
where E = emission factor, lb/VMT k (PM-30) = 0.082 lb/VMT
k = particle size multiplier k (PM-10) = 0.016 lb/VMT
sL = road surface silt loading, g/m^2 k (PM-2.5) = 0.0024 lb/VMT
W = average vehicle weight, tons C (PM-30) = 0.00047 lb/VMT
C = 1980's vehicle exhaust, brake & tire wear, lb/VMT C (PM-10) = 0.00047 lb/VMT
P = number of days with >= 0.01 in precipitation C (PM-2.5) = 0.00036 lb/VMT
N = number of days in the averaging period (365) P = 118 days (Wilmington average)
Silt loading will be minimized by use of vacuum sweeping and/or water flushing
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Carolinas Cement PTE Paved Roads
Paved Roads
Segment Segment Material
No. Length
(mi)
PR1 0.120 Raw Additives
PR1 0.120 Coal/coke
PR1 0.120 Gypsum
PR1 0.120 Cement bulk
PR1 0.120 Cement bags
PR1 0.120 Limestone
PR1 0.120 Employees
PR1 0.120 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR2 0.403 Raw Additives
PR2 0.403 Coal/coke
PR2 0.403 Gypsum
PR2 0.403 Cement bulk
PR2 0.403 Cement bags
PR2 0.403 Limestone
PR2 0.403 Employees
PR2 0.403 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR3 0.022 Raw Additives
PR3 0.022 Coal/coke
PR3 0.022 Gypsum
PR3 0.022 Cement bulk
PR3 0.022 Cement bags
PR3 0.022 Limestone
PR3 0.022 Employees
PR3 0.022 SUBTOTAL
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.54 0.10 0.03 1.420 0.276 0.068
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.47 0.09 0.02 4.830 0.939 0.231
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.33 0.06 0.02 0.122 0.024 0.006
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Carolinas Cement PTE Paved Roads
Segment Segment Material
No. Length
(mi)
PR4 0.114 Raw Additives
PR4 0.114 Coal/coke
PR4 0.114 Gypsum
PR4 0.114 Cement bulk
PR4 0.114 Cement bags
PR4 0.114 Limestone
PR4 0.114 Employees
PR4 0.114 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR5 0.058 Raw Additives
PR5 0.058 Coal/coke
PR5 0.058 Gypsum
PR5 0.058 Cement bulk
PR5 0.058 Cement bags
PR5 0.058 Limestone
PR5 0.058 Employees
PR5 0.058 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR6 0.018 Raw Additives
PR6 0.018 Coal/coke
PR6 0.018 Gypsum
PR6 0.018 Cement bulk
PR6 0.018 Cement bags
PR6 0.018 Limestone
PR6 0.018 Employees
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.47 0.09 0.02 0.491 0.095 0.024
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.19 0.04 0.01 0.145 0.028 0.007
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
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Carolinas Cement PTE Paved Roads
PR6 0.018 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR7 0.018 Raw Additives
PR7 0.018 Coal/coke
PR7 0.018 Gypsum
PR7 0.018 Cement bulk
PR7 0.018 Cement bags
PR7 0.018 Limestone
PR7 0.018 Employees
PR7 0.018 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR8 0.014 Raw Additives
PR8 0.014 Coal/coke
PR8 0.014 Gypsum
PR8 0.014 Cement bulk
PR8 0.014 Cement bags
PR8 0.014 Limestone
PR8 0.014 Employees
PR8 0.014 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR9 0.095 Raw Additives
PR9 0.095 Coal/coke
PR9 0.095 Gypsum
PR9 0.095 Cement bulk
PR9 0.095 Cement bags
PR9 0.095 Limestone
0.19 0.04 0.01 0.045 0.009 0.002
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.19 0.04 0.01 0.029 0.006 0.001
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.82 0.16 0.04 0.102 0.020 0.005
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
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Carolinas Cement PTE Paved Roads
PR9 0.095 Employees
PR9 0.095 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR10 0.043 Raw Additives
PR10 0.043 Coal/coke
PR10 0.043 Gypsum
PR10 0.043 Cement bulk
PR10 0.043 Cement bags
PR10 0.043 Limestone
PR10 0.043 Employees
PR10 0.043 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR11 0.080 Raw Additives
PR11 0.080 Coal/coke
PR11 0.080 Gypsum
PR11 0.080 Cement bulk
PR11 0.080 Cement bags
PR11 0.080 Limestone
PR11 0.080 Employees
PR11 0.080 SUBTOTAL
Segment Segment Material
No. Length
(mi)
PR12 0.080 Raw Additives
PR12 0.080 Coal/coke
PR12 0.080 Gypsum
PR12 0.080 Cement bulk
PR12 0.080 Cement bags
0.40 0.08 0.02 0.840 0.163 0.040
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.01 0.00 0.00 0.011 0.002 0.000
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
0.82 0.16 0.04 0.566 0.110 0.027
TSP PM10 PM2.5 TSP PM10 PM2.5
E Factor E Factor E Factor Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr)
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Carolinas Cement PTE Paved Roads
PR12 0.080 Limestone
PR12 0.080 Employees
PR12 0.080 SUBTOTAL
GRAND TOTAL
Notes:
0.40 0.08 0.02 0.703 0.137 0.034
9.305 1.808 0.445
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Carolinas Cement PTE Unpaved Summary
Unpaved Road Emission Summary
Segment Segment Segment Description Direction Silt Material Total TSP PM10 PM2.5 TSP PM10 PM2.5 TSP PM10 PM2.5
No. Length Length -Way Content Trips Mileage E Factor E Factor E Factor Emissions Emissions Emissions Emissions Emissions Emissions
(ft) (mi) (%) (#/yr) (Mi/yr) lb/VMT lb/VMT lb/VMT (Ton/yr) (Ton/yr) (Ton/yr) (lb/hr) (lb/hr) (lb/hr)
UR1 1500 0.284 Limestone/Marl haul 2 8.3 34,112 19,382 13.86 3.94 0.39 33.589 9.552 0.955 7.6688 2.1807 0.2181
UR2 3750 0.710 Spoils/Other haul 2 8.3 4,342 6,167 13.86 3.94 0.39 10.688 3.039 0.304 2.4403 0.6939 0.0694
UR3 2425 0.459 Overburden loop 1 8.3 31,773 14,593 13.86 3.94 0.39 25.290 7.191 0.719 5.7739 1.6419 0.1642
TOTAL 1.454 40,141 69.568 19.782 1.978 15.883 4.517 0.452
Annual Emissions Hourly Emissions
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Carolinas Cement PTE Unpaved Roads
Unpaved RoadsSurface
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Content Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (%) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
UR1 0.284 Marl/limestone 8.3 78 100 178 127.893 X X 127.9 100 3,411,152 34,112 9,691 9,691 19,382 2,478,754
UR1 0.284 Spoils 8.3 78 100 178 127.893 434,183 0 0 0 0
UR1 0.284 Overburden 8.3 78 100 178 127.893 3,177,255 0 0 0 0
UR1 0.284 SUBTOTAL 8.3 127.9 34,112 9,691 9,691 19,382 2,478,754
Surface
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Content Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (%) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
UR2 0.710 Marl/limestone 8.3 78 100 178 127.893 3,411,152 0 0 0 0
UR2 0.710 Spoils 8.3 78 100 178 127.893 X X 127.9 100 434,183 4,342 3,084 3,084 6,167 788,761
UR2 0.710 Overburden 8.3 78 100 178 127.893 3,177,255 0 0 0 0
UR2 0.710 SUBTOTAL 8.3 127.9 4,342 3,084 3,084 6,167 788,761
Surface
Segment Segment Material Silt Empty Capacity Loaded Avg Empty Loaded Truck Material Material Material Empty Loaded Total Weight x
No. Length Content Weight Net Thruput Trips Mileage Mileage Mileage Mileage
(mi) (%) (Tons) (Tons) (Tons) (Tons) (T/yr) (#/yr) (Mi/yr) (Mi/yr) (Mi/yr)
UR3 0.459 Marl/limestone 8.3 78 100 178 127.893 3,411,152 0 0 0 0
UR3 0.459 Spoils 8.3 78 100 178 127.893 434,183 0 0 0 0
UR3 0.459 Overburden 8.3 78 100 178 127.893 X X 127.9 100 3,177,255 31,773 7,296 7,296 14,593 1,866,272
UR3 0.459 SUBTOTAL 8.3 127.9 31,773 7,296 7,296 14,593 1,866,272
GRAND TOTAL 40,141
Notes: E = k * (s/12)^a * (W/3)^b * (365 - P)/365 for industrial unpaved roads
where E = emission factor, lb/VMT Constant PM-30 PM-10 PM-2.5
k = particle size multiplier k 4.9 1.5 0.15
s = surface material silt content, % a 0.7 0.9 0.9
W = average vehicle weight, tons b 0.45 0.45 0.45
P = number of days with >= 0.01 in precipitation
a, b = constants for specific partical size P = 118 days (Wilmington average)
Emission factors from AP-42 Section 13.2.2 (11/06), Equations (1a) & (2). Silt content based on stone quarrying haul road (Table 13.2.2-1).
A control efficiency of 75% was used to account for natural surface moisure or watering as needed at an equivalent surface moisture ratio of 2
(Figure 13.2.2-2).
Truck Weights Truck Trips
Truck Weights Truck Trips
Truck Weights Truck Trips
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Carolinas Cement PTE Unpaved Roads
Unpaved Roads
Segment Segment Material
No. Length
(mi)
UR1 0.284 Marl/limestone
UR1 0.284 Spoils
UR1 0.284 Overburden
UR1 0.284 SUBTOTAL
Segment Segment Material
No. Length
(mi)
UR2 0.710 Marl/limestone
UR2 0.710 Spoils
UR2 0.710 Overburden
UR2 0.710 SUBTOTAL
Segment Segment Material
No. Length
(mi)
UR3 0.459 Marl/limestone
UR3 0.459 Spoils
UR3 0.459 Overburden
UR3 0.459 SUBTOTAL
GRAND TOTAL
Notes:
where
TSP PM10 PM2.5 Control TSP PM10 PM2.5
E Factor E Factor E Factor Efficiency Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (%) (Ton/yr) (Ton/yr) (Ton/yr)
13.86 3.94 0.39 75% 33.589 9.552 0.955
TSP PM10 PM2.5 Control TSP PM10 PM2.5
E Factor E Factor E Factor Efficiency Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (%) (Ton/yr) (Ton/yr) (Ton/yr)
13.86 3.94 0.39 75% 10.688 3.039 0.304
TSP PM10 PM2.5 Control TSP PM10 PM2.5
E Factor E Factor E Factor Efficiency Emissions Emissions Emissions
lb/VMT lb/VMT lb/VMT (%) (Ton/yr) (Ton/yr) (Ton/yr)
13.86 3.94 0.39 75% 25.290 7.191 0.719
69.57 19.78 1.98
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Carolinas Cement PM10-SO2-NOX Emissions Summary
Version 102008
Plantwide Emissions
EU DescriptionPM10
tons/yr
SO2
tons/yr
NOX
tons/yr
PM10
lb/hr
SO2
lb/hr
NOX
lb/hr
PM10
lb/hr
SO2
lb/hr
NOX
lb/hrPoint Sources
Kiln System 391.41 1456.35 2135.25 89.36 450.00 487.50 89.36 332.50 487.50
Raw Mill & Kiln Feed 17.56 0.00 0.00 4.01 0.00 0.00 4.01 0.00 0.00
Coal/Coke System 10.57 0.00 0.00 2.41 0.00 0.00 2.41 0.00 0.00
Clinker Transfer & Storage 2.45 0.00 0.00 0.56 0.00 0.00 0.56 0.00 0.00
Finish Mills 48.55 0.00 0.00 11.08 0.00 0.00 11.08 0.00 0.00
Cement Transfer & Storage 15.99 0.00 0.00 3.65 0.00 0.00 3.65 0.00 0.00
Existing Terminal 1.89 0.00 0.00 0.43 0.00 0.00 0.43 0.00 0.00
Emergency Generator 0.07 0.10 2.78 0.29 0.40 11.11 0.02 0.02 0.63
Subtotal Point Sources 488.48 1456.45 2138.03 111.80 450.40 498.61 111.53 332.52 488.13
Fugitive Sources
Quarry Equipment 3.20 0.00 0.00 0.73 0.00 0.00 0.73 0.00 0.00
Plant Process Equipment 2.18 0.00 0.00 0.50 0.00 0.00 0.50 0.00 0.00
Wind Erosion - Storage Piles 4.20 0.00 0.00 0.96 0.00 0.00 0.96 0.00 0.00
Mining Operations 7.78 0.00 0.00 1.78 0.00 0.00 1.78 0.00 0.00
Plant Roads 1.81 0.00 0.00 0.41 0.00 0.00 0.41 0.00 0.00
Quarry Roads 19.78 0.00 0.00 4.52 0.00 0.00 4.52 0.00 0.00
Subtotal Fugitive Sources 38.96 0.00 0.00 8.89 0.00 0.00 8.89 0.00 0.00
Total Emissions 527.44 1,456.45 2,138.03 120.69 450.40 498.61 120.42 332.52 488.13
Notes
Kiln PM10 emissions include an estimate of condensible particulate matter.
Normal Operation (Mill On & Long-term) Mill Off Condition (Short-term SO2)
Kiln Stack Parameters: Flow 673,804 acfm Flow 653,251 acfm
Temp 193 deg F Temp 435 deg F
Height 410.1 ft Height 410.1 ft
Diameter 14.76 ft Diameter 14.76 ft
Maximum Annual Maximum Hourly Average Hourly
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Carolinas Cement PM10-SO2-NOX PM Emissions
Plantwide Emissions
EU Description
PM
Filterable
lb/hr
PM
Condensible
lb/hr
PM Total
lb/hr
PM10
Filterable
lb/hr
PM10
Condensible
lb/hr
PM10
Total
lb/hr
PM2.5
Filterable
lb/hr
PM2.5
Condensible
lb/hr
PM2.5
Total
lb/hr
Point Sources
Kiln System 49.36 40.00 89.36 49.36 40.00 89.36 26.44 40.00 66.44
Raw Mill & Kiln Feed 4.77 0.00 4.77 4.01 0.00 4.01 2.15 0.00 2.15
Coal/Coke System 2.87 0.00 2.87 2.41 0.00 2.41 1.29 0.00 1.29
Clinker Transfer & Storage 0.66 0.00 0.66 0.56 0.00 0.56 0.30 0.00 0.30
Finish Mills 13.19 0.00 13.19 11.08 0.00 11.08 5.94 0.00 5.94
Cement Transfer & Storage 4.35 0.00 4.35 3.65 0.00 3.65 1.96 0.00 1.96
Existing Terminal 0.51 0.00 0.51 0.43 0.00 0.43 0.23 0.00 0.23
Emergency Generator 0.35 0.00 0.35 0.29 0.00 0.29 0.28 0.00 0.28
Subtotal Point Sources 76.08 40.00 116.08 71.80 40.00 111.80 38.59 40.00 78.59
Fugitive Sources
Quarry Equipment 1.60 0.00 1.60 0.73 0.00 0.73 0.13 0.00 0.13
Plant Process Equipment 1.05 0.00 1.05 0.50 0.00 0.50 0.08 0.00 0.08
Wind Erosion - Storage Piles 1.92 0.00 1.92 0.96 0.00 0.96 0.14 0.00 0.14
Mining Operations 3.54 0.00 3.54 1.78 0.00 1.78 0.24 0.00 0.24
Plant Roads 2.12 0.00 2.12 0.41 0.00 0.41 0.10 0.00 0.10
Quarry Roads 15.88 0.00 15.88 4.52 0.00 4.52 0.45 0.00 0.45
Subtotal Fugitive Sources 26.12 0.00 26.12 8.89 0.00 8.89 1.14 0.00 1.14
Total Emissions 102.20 40.00 142.20 80.69 40.00 120.69 39.73 40.00 79.73
Notes
Maximum hourly emissions are shown
PM2.5 HourlyPM Hourly PM10 Hourly
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Carolinas Cement PM10-SO2-NOX PM Size Distribution
PM, fraction
Plantwide
emissions,
lb/hr
Percent
less than
or equal to
AP-42 Table
11.6-5
(reference only)
PM, range
Plantwide
emissions,
lb/hr
Percent in
range
PM10
Only, lb/hr
Percent in
range
PM
CondensiblePM10 Total
Percent in
range
PM(TSP) 102.20 100
PM20 102.20 100 100 PM15-PM20 14.79 14.5
PM15 87.41 85.5 89 PM10-PM15 6.72 6.6
PM10 80.69 79.0 84 PM5-PM10 7.35 7.2 7.35 9.1 7.35 6.1
PM5 73.34 71.8 77 PM2.5-PM5 33.61 32.9 33.61 41.7 33.61 27.8
PM2.5 39.73 38.9 45 PM0.5-PM2.5 39.73 38.9 39.73 49.2 40.00 79.73 66.1
Total 102.20 100.0 80.69 100.0 40.00 120.69 100.0
Notes
PM, PM10, and PM2.5 are calculated plantwide hourly emissions from Carolinas Cement potential emission inventory
PM15 and PM5 emissions are interpolated values adjusted using data in AP-42 Table 11.6-5 (Average Particle Size Distribution for
Portland Cement Kilns)
Filterable Emissions Filterable Emissions Filterable + Condensible
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TAB D
CONTROL TECHNOLOGY ANALYSIS – REVISED
CONTROL TECHNOLOGY ANALYSIS
Prepared for
Carolinas Cement Company LLC Castle Hayne, North Carolina Plant
PN 050020.0051
Prepared by
Environmental Quality Management, Inc. Cedar Terrace Office Park, Suite 250 3325 Durham-Chapel Hill Boulevard
Durham, North Carolina 27707
February 25, 2008 (Revised April 8, 2008)
(Revised October 20, 2008)
ii
CONTENTS Section Page Tables............................................................................................................................................. iv
1 Introduction.............................................................................................................................. 1
1.1 Project Description ...................................................................................................... 1 1.2 Cement Manufacturing and Control Technology Requirements ................................ 1 1.3 Control Technology Requirements ..............................................................................2
2 BACT Analysis for PM and PM10 ........................................................................................... 4
2.1 Sources of PM/PM10.................................................................................................... 4 2.2 Identification of Control Options for PM.................................................................... 4 2.3 Elimination of Technically Infeasible Options for PM ............................................... 8 2.4 Ranking of Technically Feasible PM Control Options ............................................. 10 2.5 Evaluation of Technically Feasible PM Control Options ......................................... 13 2.6 Review of Recent Permit Limits ............................................................................... 14 2.7 Selection of BACT for PM........................................................................................ 14
3 BACT Analysis for SO2......................................................................................................... 18
3.1 Description of SO2 Reaction Processes..................................................................... 18 3.2 Identification of SO2 Control Options ...................................................................... 19 3.3 Elimination of Technically Infeasible SO2 Control Options..................................... 30 3.4 Ranking of Technically Feasible SO2 Control Options............................................. 32 3.5 Evaluation of Technically Feasible SO2 Control Options......................................... 33 3.6 Review of Recent Permit Limits ............................................................................... 33 3.7 Selection of BACT for SO2 ....................................................................................... 35
4 BACT Analysis for NOx ........................................................................................................ 36
4.1 NOx Formation and Control Mechanisms ................................................................. 36 4.2 Identification of NOx Control Options ...................................................................... 39 4.3 Elimination of Technically Infeasible NOx Control Options .................................... 49 4.4 Ranking of Technically Feasible NOx Control Options............................................ 50 4.5 Evaluation of Technically Feasible NOx Control Options ........................................ 51 4.6 Review of Recent Permit Limits ............................................................................... 51 4.7 Selection of BACT for NOx ...................................................................................... 53
iii
CONTENTS (continued) Section Page 5 BACT Analysis for CO and VOC ......................................................................................... 54
5.1 CO and VOC Formation Processes ........................................................................... 54 5.2 Identification of CO/VOC Control Options .............................................................. 56 5.3 Elimination of Technically Infeasible CO/VOC Control Options ............................ 58 5.4 Ranking of Technically Feasible CO/VOC Control Options.................................... 60 5.5 Evaluation of Technically Feasible CO/VOC Control Options ................................ 60 5.6 Review of Kiln Permit Limits ................................................................................... 60 5.7 Selection of BACT for CO and VOC........................................................................ 63
6 Summary of Proposed BACT Emission Limits..................................................................... 64
Appendices A SO2 Emissions Diagram
B Cost Calculations for SO2
C Cost Calculations for NOx
iv
TABLES
Number Page
1 Ranking of Technically Feasible Control Options Non-Fugitive Process Sources - PM... 10
2 Ranking of Technically Feasible Control Options Paved Roads - PM10 ............................ 12
3 Ranking of Technically Feasible Control Options Unpaved Roads - PM10 ....................... 13
4 Summary of PM BACT Determinations for Cement Kilns and Coolers Since 2000......... 15
5 SO2 Reaction Processes ...................................................................................................... 18
6 Ranking of Technically Feasible Control Options Preheater/Precalciner Kiln
System - SO2 .................................................................................................................... 333
7 Summary of Impact Analysis for SO2 ................................................................................ 33
8 Summary of Recent SO2 Permit Determinations for Cement Kilns (2000-Present) .......... 34
9 Ranking of Technically Feasible Control Options Preheater/Precalciner Kiln
Systems - NOx .................................................................................................................... 51
10 Summary of Impact Analysis for NOx................................................................................ 51
11 Summary of Recent NOx Permit Determinations for Cement Kilns (2000-Present).......... 52
12 Summary of Recent CO Permit Determinations for Cement Kilns (2000-Present) ........... 61
13 Summary of Recent VOC Permit Determinations for Cement Kilns (2000-Present) ........ 62
14 Proposed BACT Limits....................................................................................................... 64
1
SECTION 1
INTRODUCTION
1.1 Project Description
Carolinas Cement Company LLC (CCC) is proposing to construct a modern Portland
cement manufacturing facility at the site of an existing cement storage terminal operated by
Roanoke Cement Company near Castle Hayne, North Carolina. The plant will include a multi-
stage preheater-precalciner kiln with an in-line raw mill, coal mill, and clinker cooler venting
through the main stack. Production is expected to be 6000 tons per day (tons/day) and 2,190,000
tons per year (tons/yr) of clinker and approximately 2,400,000 tons/yr of cement. Fuels may
include coal, petroleum coke, fuel oil, biomass fuels, and natural gas. The raw materials for
clinker production may include limestone/marl, clay, quarry spoils, bauxite, slag, fly ash/bottom
ash, sand, and/or mill scale. Synthetic gypsum or natural gypsum will be milled with the clinker
to produce cement. Associated processes will include mining, crushing, blending, grinding,
material handling and storage for raw materials, fuels, clinker, and finished cement. Cement will
be shipped by rail and truck. The project will also include a diesel emergency generator set.
1.2 Cement Manufacturing
Portland cement is used in almost all construction applications including homes, public
buildings, roads, industrial plants, dams, bridges, and many other structures. Therefore, the
quality of Portland cement must meet very demanding standards. The manufacture of a high
quality Portland cement begins with the use of a high quality calcium carbonate material (i.e.,
marl or limestone) and the production of a high quality cement clinker.
In the Portland cement manufacturing process, raw materials such as limestone, marl,
clay, sand, and iron ore are heated to their fusion temperature, typically 1,400º to 1,500ºC
(2,550º to 2,750ºF), in a refractory lined kiln by burning various fuels such as coal, coke, and
other fuels mentioned above. Burning an appropriately proportioned mixture of raw materials at
a suitable temperature produces hard fused nodules called "clinker," which are cooled and then
2
mixed with calcium sulfate (gypsum) and ground to a desired fineness. Different types of
cements are produced by using appropriate kiln feed composition, blending the clinker with the
desired amount of gypsum, and grinding the product mixture to appropriate fineness.
Manufacture of cements of all types involves the same basic high temperature fusion, clinkering
and fine grinding process.
There are four primary types of refractory lined kilns used in the Portland cement
industry: long wet kilns, long dry kilns, preheater kilns, and preheater/precalciner kilns. The long
wet, long dry, and most preheater kilns have only one fuel combustion zone, whereas the newer
preheater kilns with a riser duct and the preheater/precalciner kilns have two or more fuel
combustion zones. These newer designs of dry pyroprocessing systems increase the overall
energy efficiency of the cement plant. The energy efficiency of the cement making process is
important as it determines the amount of heat input needed to produce a unit quantity of cement
clinker. A high thermal efficiency leads to less consumption of heat and fuel, with
correspondingly lower emissions.
1.3 Control Technology Requirements
As discussed in Section 2.4 of the Regulatory Analysis Report, under the Prevention of
Significant Deterioration (PSD) rules applicable to this project, Best Available Control
Technology (BACT) must be used to control emissions of the following pollutants: particulate
matter (PM); PM less than 10 microns in diameter (PM10); sulfur dioxide (SO2), nitrogen oxides
(NOx); carbon monoxide (CO); and volatile organic compounds (VOC).
BACT is defined as an emission limitation, including a visible emission standard, based
on the maximum degree of reduction of each pollutant subject to Prevention of Significant
Deterioration (PSD) review which the North Carolina Department of Environment and Natural
Resources (DENR) on a case-by-case basis, taking into account energy, environmental, and
economic impacts, and other costs, determines is achievable through application of production
processes and available methods, systems, and techniques (including fuel cleaning or treatment
or innovative fuel combustion techniques) for control of such pollutant. If the DENR determines
that technological or economic limitations on the application of measurement methodology to a
particular part of a source or facility would make the imposition of an emission standard
infeasible, a design, equipment, work practice, operational standard or combination thereof, may
3
be prescribed instead to satisfy the requirement for the application of BACT. Such standard
shall, to the degree possible, set forth the emissions reductions achievable by implementation of
such design, equipment, work practice or operation. Each BACT determination shall include
applicable test methods or shall provide for determining compliance with the standard(s) by
means that achieve equivalent results.
The EPA has consistently interpreted the statutory and regulatory BACT definitions as
containing two core requirements that the agency believes must be met by any BACT
determination. First, the BACT analysis must include consideration of the most stringent
available technologies, i.e., those which provide the "maximum degree of emissions reduction."
Second, any decision to require a lesser degree of emissions reduction must be justified by an
objective analysis of "energy, environmental, and economic impacts" contained in the record of
the permit decision.
The minimum control efficiency to be considered in a BACT analysis must result in an
emission rate less than or equal to any applicable new source performance standards (NSPS)
emission rate or National Emission Standards for Hazardous Air Pollutants (NESHAP). The
applicable NSPS/NESHAP represents the maximum allowable emission limits from the source.
On June 16, 2008, EPA proposed major changes to the NSPS for Portland Cement (PC)
plants (Subpart F) which, when finalized, will apply to this project. Currently, the PC NSPS
regulates only PM. The proposed NSPS changes would reduce the PM emission limits for new
or modified kilns and clinker coolers commencing construction after June 16, 2008. In addition,
new or modified cement kilns would be subject to new limits for NOx and SO2 emissions. CCC
will comply with the emission limits resulting from final revised NSPS or NESHAP rules, if
those emission limits are more stringent than the proposed BACT limits proposed herein.
In this BACT analysis, the most effective technically feasible controls were evaluated
based on an analysis of energy, environmental, and economic impacts. As part of the analysis,
several control options for potential reductions in criteria pollutant emissions were identified.
The control options were identified by:
(1) Researching the RACT/BACT/LAER Clearinghouse (2) Drawing from previous engineering experience
(3) Surveying available literature (4) Review of PSD permits for Portland cement plants.
4
SECTION 2
BACT ANALYSIS FOR PM AND PM10
2.1 Sources of PM/PM10
PM and PM10 (hereafter referred to as PM but also applies to the PM10 fraction) at a
cement plant is emitted from process sources (i.e., kilns, coolers, mills, transfer points) and
fugitive dust sources (i.e., paved roads, unpaved roads, and quarrying operations).
Process sources of PM from the proposed project include: (1) Raw material handling and storage (2) Solid fuel handling and storage (3) Raw material milling and blending (4) Pyroprocessing (kiln and clinker cooler) (5) Clinker and gypsum handling and storage (6) Cement finish grinding (7) Cement handling and loadout.
Fugitive sources of PM from the proposed project include:
(1) Quarrying operations (drilling, blasting, marl ripping, and truck loading) (2) Truck and loader traffic on unpaved roads (3) Truck traffic on paved roads (4) Material transfer points (5) Wind erosion from storage piles.
2.2 Identification of Control Options for PM
The first step in the BACT determination for PM is the identification of available control
technologies. This section reviews the available PM control technologies that apply to the
proposed project. In preparing this section, a review of EPA's emission standard determination
methods for the Portland cement industry was made. EPA evaluated several types of control
technologies in developing the particulate matter NSPS and NESHAP for Portland cement
plants. In establishing and promulgating the particulate matter NSPS and NESHAP emission
limits, EPA focused on fabric filter and electrostatic precipitator (ESP) technologies as a basis
for control of PM from kilns and clinker coolers. EPA's evaluation on raw material processing
5
(including crushers, mills, and transfer points) was limited to measures needed to ensure opacity
levels of 10 percent or less. No specific control technologies were evaluated for these processes.
Furthermore, no evaluation was made for fugitive dust PM emissions.
This BACT determination will focus its evaluation on fabric filter and ESP control
technologies for the kilns and clinker coolers. A larger range of control options will be reviewed
for material handling and fugitive emission activities.
2.2.1 Fabric Filter Systems
Fabric filter (baghouse) systems consist of a structure containing tubular bags made of a
woven fabric. A baghouse removes PM from the flue gas by drawing the dust laden air through
a bank of filter tubes suspended in a housing. PM is collected on the upstream side of the fabric.
Dust on the bags is periodically removed, collected in a hopper, and reintroduced to the process.
PM removal efficiencies of 99 to greater than 99.9 percent are typical for baghouses at
varying operational conditions. The typical air-to-cloth ratio of a standard baghouse ranges from
approximately 1.2:1 to 2:1 for reverse air, and from 3:1 to 4:1 for pulse-jet systems. The bags in
baghouses used in the Portland cement industry are made from a variety of materials including
Nomex®, Gore-tex®, polyester, Teflon®, and fiberglass.
The technical feasibility of using baghouses is primarily dependent on exhaust gas
temperatures and moisture content. Gas temperatures must be less than 260°C (500°F) to
preclude damage to the bags. For the application of baghouse systems on cement kilns, this
condition is usually achieved by cooling exhaust gases prior to passing them through the
baghouse. Moisture contents must also be minimized to avoid condensation and possible
blinding of the bags.
Cooling gases from cement kilns can be accomplished in a variety of ways. At plants
using preheater/precalciner systems, kiln exhaust gases are often ducted to an in-line raw mill (or
raw material dryer) to dry the raw feed material, and used to preheat combustion air for the kiln.
When exhaust gases are not ducted to the raw mill (either by design or when the in-line raw mill
is offline), water sprays and/or bleed-in air is needed. These procedures increase the moisture
content of exhaust gases entering the baghouse. When either approach is used, the temperature
of gases entering the baghouse must be maintained above the dew point of the gas to prevent
condensation, which leads to blinding of the filter bags.
6
The primary advantages of baghouses include: high removal efficiencies, simplicity in
their operation, reliability, and the ease of maintenance, as compartments within the baghouse
system can be isolated for repairs without shutting down the entire system.
The primary disadvantages of baghouses include the need for relatively high pressure
drops (necessitating high energy consumption), limitation of temperatures to less than 260ºC
(500ºF), and the relatively high maintenance requirements (frequent replacement of bags).
2.2.2 Electrostatic Precipitator (ESP) Systems
Cleaning of exhaust gases using ESPs involves three steps: (a) passing the suspended
particles through a direct current corona to charge them electrically, (b) collecting the charged
particles on a grounded plate, and (c) removing the collected particulate from the plate by a
mechanical process (i.e., rapping).
The specific collection area (SCA) is the parameter used to ensure proper design control
efficiency of an ESP. The SCA is defined as the ratio of the total plate area to the gas flow rate.
As the SCA of an ESP increases, collection efficiency improves. The high resistivity of particles
in exhaust gases from preheater/precalciner kilns requires that they be conditioned prior to
entering the ESP.
The primary advantages of using an ESP for PM control are the high PM collection
efficiency, low pressure drop, relatively low operating costs, and its ability to operate effectively
at relatively high temperature and flow rates.
The primary disadvantages to using an ESP are the high resistivity of the PM in cement
process exhaust gases (especially from preheater/precalciner kilns), its sensitivity to fluctuations
in exhaust gas conditions, and the high initial capital cost. The relatively large space
requirements make using ESPs infeasible for sources other than kilns and clinker coolers.
2.2.3 Wet Scrubbing Systems
Wet scrubbers remove PM from exhaust gases by capturing the particles in/on liquid
droplets and separating the droplets from the gas stream. Wet scrubbers can be grouped into the
following major categories:
(1) Venturi scrubbers (2) Mechanically aided scrubbers (3) Pump aided scrubbers (4) Wetted filter-type scrubbers
7
(5) Tray or sieve-type scrubbers.
The differences between these scrubbers are the manner in which the liquid is introduced
to the gas stream, the methods which the particles are captured by the liquid droplets, and the
manner in which the liquid droplets are removed. Wet scrubbers are capable of removing 80 to
99 percent of the PM from exhaust gas streams when properly designed and operated.
The primary advantages of a wet scrubber include its ease of maintenance and known
technology with specific design parameters for specific applications. The primary disadvantages
of a wet scrubber are their lower PM control efficiencies, a requirement to treat and/or dispose of
effluent, and the possibility of solids buildup at the wet-dry interface. An additional
disadvantage for this project is the water supply requirement to operate these systems.
2.2.4 Cyclone Collectors and Inertial Separator Systems
Cyclone collectors and inertial separators provide a low cost, low maintenance method of
removing larger diameter PM (> 30 µm) from gas streams. On their own, they are not usually
sufficient to meet BACT or NSPS emission standards, but they serve well as precleaners for
other more efficient control devices and as dry product recovery devices.
Cyclone systems consist of one or more conically shaped vessels in which the gas stream
follows a circular motion prior to outlet (typically near the top of the cone). Particles enter the
cyclone suspended in the gas stream, which is forced into a vortex by the shape of the cyclone.
The inertia of the particles resists the change in direction of the gas and they move outward
under the influence of centrifugal force until they strike the walls of the cyclone. At this point,
the particles are caught in a thin laminar layer of air next to the cyclone wall and are carried
downward by gravity where they are collected in hoppers. Cyclones are capable of removing in
excess of 90 percent of the larger diameter (> 30 µm) PM. However, their efficiency decreases
significantly for small diameter (< 30 µm) PM. The overall average control efficiency ranges
from 50 to 95 percent based on a range of particle sizes in the gas stream.
Cyclones vary in dimensions and inlet and outlet conditions. Collection efficiency is a
function of (a) size of particles in the gas stream, (b) particle density, (c) inlet gas velocity, (d)
dimensions of the cyclone, and (e) smoothness of the cyclone wall. In the cement industry
cyclone type collection systems are typically used for product recovery or as pre-collection
systems in combination with baghouses or ESPs.
8
2.2.5 Water Sprays, Enclosures and Other PM Control Systems
PM controls in use for a variety of material handling processes and fugitive dust sources
at Portland cement plants and quarries include water sprays and enclosures for crushers and
conveyor transfer points, wind screens and enclosures for storage piles, watering and chemical
stabilizers (emulsions) used on unpaved roads, and flushing and vacuum sweeping on paved
roads. The efficiencies for these controls range from 50 to 97 percent individually, but in some
instances, combining controls can achieve higher overall control levels.
Many of the efficiencies assigned to these types of control measures are based on
empirical models that take into account the quantity of water used, the frequency of application,
the time between applications, and the meteorological conditions present at the time of
application. In addition, the natural high moisture content of certain raw materials may make the
use of water sprays or other control measures unnecessary.
2.3 Elimination of Technically Infeasible Options for PM
The second step in the BACT determination for PM is to eliminate any technically
infeasible control technologies. Each available control technology is considered, and those that
are infeasible based on physical, chemical, and engineering principles are eliminated.
2.3.1 Fabric Filter Systems
Fabric filter (baghouse) systems have been proven to be technically feasible control
technologies for preheater/precalciner kilns, clinker coolers, and other process sources.
Therefore, this technology must be considered further for these types of sources.
2.3.2 ESP Systems
ESP control systems have been proven to be technically feasible control technologies for
preheater/precalciner kilns and clinker coolers. Therefore, this technology must be considered
further for these types of sources.
Because of the large space requirements necessary for ESP systems, they are technically
infeasible for other process sources (finish mills, transfer points, etc.). Further, ducting
emissions from other process sources to a single ESP system would also be technically infeasible
due to the area of coverage and variation of gas stream conditions that would result.
9
2.3.3 Wet Scrubbing Systems
Wet scrubbing systems are not considered technically feasible PM control technologies
for preheater/precalciner kilns and clinker coolers because wet scrubbing systems are not capable
of reducing PM emissions from these sources to levels that meet the NSPS emission levels.
Wet scrubbers have been proven to be a technically feasible control option for process
sources in other industries. Therefore, this technology must be considered further for these types
of sources.
2.3.4 Cyclone Collector and Inertial Separator Systems
Cyclone collector and inertial separator systems can be used to control PM emitted from
preheater/precalciner kiln systems and clinker coolers. However, because these systems are not
capable of reducing particulate matter emissions from these sources to levels that meet the NSPS
emission levels, these control options are considered technically infeasible for
preheater/precalciner kilns and clinker coolers, unless combined with another control technology.
Cyclone collector and inertial separator systems have been proven to be technically
feasible control options for process sources. Therefore, these technologies must be considered
further for these types of sources.
2.3.5 Water Sprays, Enclosures, and Other PM Control Options
Water sprays, enclosures, and other PM control systems cannot be used to control PM
emitted from preheater/precalciner kiln systems and clinker coolers because these systems are
not capable of reducing PM emissions from these sources to levels that meet the NSPS emission
levels. Therefore, they are considered a technically infeasible option for preheater/precalciner
kilns and clinker coolers. In addition, water sprays cannot be used on sources handling hot
clinker or cement due to obvious problems with product damage/solidification and equipment
pluggage.
Water sprays, enclosures, and other PM control systems have been proven to be
technically feasible control options for other process and fugitive dust sources. Therefore, these
technologies must be considered further for these types of sources.
10
2.4 Ranking of Technically Feasible PM Control Options
The third step in the BACT determination for PM is to rank the technically feasible
control technologies by control effectiveness. The control efficiencies listed are typical values
for the indicated technology.
2.4.1 Preheater/Precalciner Kiln and Clinker Cooler System
Two technologies are considered to be technically feasible for controlling PM emissions
from the preheater/precalciner kiln and clinker cooler system to levels below the NSPS or
NESHAP standards. The maximum control efficiency for a fabric filter baghouse system on a
PH/PC kiln system is in excess of 99.9 percent. The maximum control efficiency for an ESP
system on a PH/PC kiln system is also in excess of 99.9 percent. Because the two technologies
have similar control efficiencies and because they are both the maximum control technology
options available, CCC has the option to choose either technology as BACT. Because CCC has
selected a fabric filter, representing the maximum control level possible for this system, a fabric
filter is the only control option considered for these sources.
2.4.2 Other Process Sources
The control technologies that are technically feasible for controlling PM emissions from
other process sources are ranked in Table 1 (in order of descending efficiency). The control
efficiencies listed are typical values for the indicated technology.
TABLE 1. RANKING OF TECHNICALLY FEASIBLE CONTROL OPTIONS NON-
FUGITIVE PROCESS SOURCES - PM
Control Technology Control Efficiency
Fabric Filter Baghouses 99-99.9+%
Wet Scrubbers 80-99%
Cyclones and Inertial Separators 50-95%
Water Sprays, Partial Enclosures, and Other PM Control Methods
50-90+%
No Control 0%
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2.4.3 Fugitive Dust Sources
The control technologies that are technically feasible for controlling PM emissions from
fugitive dust sources are discussed in the following subsections:
2.4.3.1 Quarrying Operations
Quarrying operations include drilling, blasting, ripping, and loading of limestone rock
and marl into loaders for transport to the primary crusher hopper. The control technologies that
are technically feasible for controlling PM emissions from quarrying operations include
baghouses or water applications to drilling equipment, and best management practices for
blasting and material loading. It should be noted that the quarry materials at the CCC plant are
naturally wet (typically > 15% moisture) and as such additional controls may not be very
effective or necessary.
2.4.3.2 Paved Roads
The control technologies that are technically feasible for controlling PM emissions from
paved roads include watering (flushing with water), vacuum sweeping, or a combination of these
methods. Primary roadways into and throughout the cement plant will be paved. All paved
roadways will remain paved throughout the life of the project.
The use of water flushing followed by vacuum sweeping provides an estimated control
efficiency of between 46 to 96 percent. Individually, water flushing and vacuum sweeping have
control efficiencies of less than 70 percent. Because of the volume of traffic on most paved plant
roads, the efficiency of water flushing in addition to sweeping is essentially the same as
sweeping alone, as determined by the formulas in Table 2.
Table 2 summarizes the rankings for control options for paved roads.
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TABLE 2. RANKING OF TECHNICALLY FEASIBLE CONTROL OPTIONS PAVED
ROADS - PM10
Operation Control Technology Control Efficiency Source/Notes
Paved Roads Water Flushing & Vacuum Sweeping
96-0.2363V* Air Pollution Engineering Manual Chpt. 4, p 146, Paved Surface Cleaning
Water Flushing 69-0.231V* Air Pollution Engineering Manual- Chpt. 4, p 146, Paved Surface Cleaning
Vacuum Sweeping 46-58 Air Pollution Engineering Manual- Chpt. 4, p 146, Paved Surface Cleaning
No Control 0% Assumes all Federal and State regulations could be met.
*Where V = number of vehicle passes since application.
2.4.3.3 Unpaved Roads
The control technologies that are technically feasible for controlling PM emissions from
unpaved roads include paving, watering, and application of chemical dust suppressants. Due to
the constant changes in quarrying activities, travel routes in a quarry are routinely changing.
Therefore, paving roads in an active quarry is technically infeasible. The roads within the quarry
area will remain unpaved. Vehicle traffic on these roads will be limited to haul trucks and
loaders carrying limestone to the primary crusher and vehicles transporting overburden.
PM emissions from unpaved roads can be controlled by watering or chemical dust
suppression methods. Studies have shown that on heavily traveled unpaved roads, chemical
suppression methods are as effective as watering at regular intervals.
The use of chemical suppression (such as an emulsion) is expected to provide a 62-90+
percent control efficiency for the unpaved roads. Watering (or natural surface moisture)
provides control efficiencies ranging from 0 to 90+ percent, depending on the ability to maintain
soil moisture content in the range of 2 to 8 percent. As noted above, soil conditions in the quarry
are naturally wet, therefore eliminating the need to water these roads under normal conditions.
Table 3 summarizes the rankings for control options for unpaved roads:
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TABLE 3. RANKING OF TECHNICALLY FEASIBLE CONTROL OPTIONS
UNPAVED ROADS - PM10
Operation Control Technology Control Efficiency Source/Notes
Unpaved Roads
Chemical stabilization
62-90+%* Air Pollution Engineering Manual- Chpt. 4, Fig. 6, Chemical Stabilization of Unpaved Surfaces
Watering/natural moisture
0-90+%* Air Pollution Engineering Manual - Chpt. 4, Fig. 5, Watering of Unpaved Roads
No Control 0% Assumes all Federal and State regulations could be met.
*Depends on frequency of application. 2.5 Evaluation of Technically Feasible PM Control Options
The fourth step in a BACT determination for PM is to complete the analysis of the
feasible control technologies and document the results. The control technologies are evaluated
on the basis of the most effective technology taking into account economic, energy, and
environmental considerations. The evaluation of the most effective control technologies for PM
emissions for the proposed modification is presented below.
2.5.1 Preheater/Precalciner Kilns and Clinker Coolers
Baghouses are the most effective control technology available for PM emissions from
preheater/precalciner kilns and clinker coolers. Because CCC has selected the maximum
available technology to control PM10 emissions from the preheater/precalciner kiln and cooler,
no further evaluation is necessary.
2.5.2 Other Process Sources
Baghouses are the most effective PM control technology for the other process sources.
Except for the quarry, raw material handling, and raw coal handling sources, CCC is proposing
to use fabric filter baghouses on all process sources associated with the proposed project (e.g.,
closed conveying systems; clinker and cement silos; coal mill; finish mill; and cement loadout).
Because CCC is choosing the most effective technology, no further evaluation is necessary.
14
2.5.3 Fugitive Dust Sources
CCC will incorporate best management practices to minimize fugitive dust emissions
from drilling, blasting, stone removal, and loading operations. Best management practices
include wet suppression or fabric filters for drills and limiting drop heights between loaders and
truck beds. No other methods are available to control these sources.
Vacuum sweeping and/or water flushing for paved roadways, and watering/natural
surface moisture or chemical emulsions for unpaved roadways are the maximum feasible control
methods for PM emissions from fugitive dust sources. CCC has selected the maximum feasible
methods available to control PM emissions from its fugitive dust sources. Therefore, no further
evaluations are necessary.
Materials from the quarry are naturally wet and no additional measures would reduce
emissions from material handling and storage operations. Emissions from crushers will be
minimized by partial enclosure and natural or added moisture. Other raw materials and fuels will
be stored in bins or under roof to minimize surface drying and wind erosion. These represent the
top control option and no further evaluation is necessary.
2.6 Review of Recent Permit Limits
Table 4 summarizes the PM permit determinations made for cement kilns and coolers
since 2000.
2.7 Selection of BACT for PM
The BACT determination for PM emissions considers a comprehensive list of control
options available for the criteria pollutant. Energy, environmental, and economic factors are
used, as necessary to support the various BACT determinations.
2.7.1 Process Sources
CCC has selected the top option of baghouses designed to achieve at least 99.9 percent
control efficiency for all process sources. These will be used on the kiln, clinker cooler, and
other sources as specified in Section 2.5.2.
15
TABLE 4. SUMMARY OF PM BACT DETERMINATIONS FOR CEMENT KILNS AND COOLERS SINCE 2000
Company Location
New/
Mod
Permit
Date
Technology
Applied
In
Operation Kiln Limit Units
Cooler
Limit Units Test Method
American Cement
Sumter Co., FL
N 2/06 FF N PM/PM10 – 0.09
Lb/ton KF
Included in kiln limit
M5
GCC Dacotah Rapid City, SD
N 4/10/03 FF Y PM – 0.01 gr/dscf PM-0.01 gr/dscf M5
Florida Rock Industries – Kiln 2
Newberry, FL N 7/22/05 ESP’s N PM – 0.136 PM10 – 0.118
Lb/ton KF lb/ton KF
PM – 0.06 PM10 – 0.05
lb/ton KF lb/ton KF
M5 M5, PM = PM10
GCC Rio Grande
Pueblo, CO N 3/5/04 FF’s N PM – 0.01 gr/dscf PM – 0.01 gr/dscf Not specified
Giant Cement Harleyville, SC
N 5/29/03 No PSD BACT Limit
Y PM – 0.3 lb/ton KF
PM – 0.1 lb/ton KF
M5
Holcim Holly Hill, SC
N 12/22/99 No PSD BACT Limit
Y PM – 0.3 lb/ton KF
PM – 0.1 lb/ton KF
M5
Holcim Lee Island, MO
N 6/8/04 FF’s N PM10 – 0.28 lb/ton clinker
PM10 – 0.07 lb/ton clinker
Not specified
Lafarge – Kiln 1
Harleyville, SC
M 8/18/06 FF Y PM – 0.15 lb/ton KF
0.06 lb/ton KF
M5
Lafarge – Kiln 2
Harleyville, SC
N 8/18/06 FF N PM – 0.2 lb/ton KF
Included in kiln limit – cooler not separately vented
M5
Lehigh Portland Cement
Mason City, IA
M 12/1/03 ESP’s Y PM – 0.516 lb/ton clinker
PM – 0.015 gr/dscf M5 (incl. condensibles)
Sumter Cement Sumter Co., FL
N 2/6/06 FF N PM/PM10 – 0.09
lb/ton KF
Included in kiln limit – cooler not separately vented
M5
16
Suwannee American Cement – Kiln 1
Branford, FL N 6/1/00 FF’s Y PM – 0.13 PM10 – 0.11
lb/ton KF lb/ton KF
PM – 0.07 PM10 – 0.06
lb/ton KF lb/ton KF
M5 None specified
Suwannee American Cement – Kiln 2
Branford, FL N 2/15/06 FF N PM – 0.1 PM10 – 0.1
lb/ton KF lb/ton KF
Included in kiln limit – cooler not separately vented
M5
Rinker/Florida Crushed Stone – Kiln 2
Brooksville, FL
N 5/29/03 FF N PM – 0.136 PM10 – 0.118
lb/ton KF lb/ton KF
Included in kiln limit – cooler not separately vented
M5 M5, PM = PM10
Continental Cement
Hannibal, MO
N 7/24/07 FF N(?) PM10-0.516 lb/ton clinker
PM10 - 0.01 gr/dscf Not specified
17
The emission limits proposed as BACT are summarized in Section 6 and discussed in
more detail in Regulatory Analysis Report.
2.7.2 Fugitive Emissions from Unpaved Roads
For new high-traffic roads at the cement plant, the top option (paving) was selected. For
other unpaved roads, CCC proposes to use watering, natural surface moisture, or chemical
suppression as necessary to minimize fugitive emissions. It is not practical to pave roads in the
quarry due to the broad and changing area on which the trucks and front end loaders move.
Also, watering in the quarry is not necessary under normal conditions because of natural surface
moisture.
2.7.3 Fugitive Dust from Paved Roads
CCC proposes as BACT vacuum sweeping and/or water flushing at a frequency as
necessary to minimize silt loading on paved road surfaces.
2.7.4 Fugitive Dust from Quarrying Operations
CCC proposes as BACT utilizing best management practices for drilling, blasting, stone
removal and truck loading operations.
2.7.5 Fugitive Dust from Storage Piles
All clinker storage will be fully enclosed. Emissions from storage of limestone, marl,
and other high moisture quarried raw materials are very low and do not need additional control
measures. Fugitive emissions from lower moisture raw materials and solid fuels will be
minimized by storage under roof, in a partial enclosure, or behind wind screens.
18
SECTION 3
BACT ANALYSIS FOR SO2
3.1 Description of SO2 Reaction Processes
The only sources of sulfur oxides (SOx) associated with the proposed project are the
preheater/precalciner kiln system, and the emergency diesel generator. Sulfur oxides, mainly
SO2, are generated from the sulfur compounds in the raw materials and, to a lesser extent, from
sulfur in fuels used to fire the preheater/precalciner kiln system. The sulfur content of the raw
materials and fuels is expected to vary over time. SO2 emissions from the emergency generator
are very minor and are directly related to the diesel sulfur content.
SO2 is both liberated and absorbed throughout the pyroprocessing system, starting at the
raw mill, continuing through the preheating/precalcining and burning zones, and ending with
clinker production according to the reactions listed in Table 5. Sulfides from the raw material
(limestone rock) are the predominant source of SO2. A smaller quantity of SO2 is liberated from
sulfates in fuel, and this SO2 is more readily absorbed into the kiln feed material and product
(clinker) matrix.
TABLE 5. SO2 REACTION PROCESSES
Process SO2 Formation SO2 Absorption
Raw Mill Sulfides + O2 Oxides + SO2 CaCO3 + SO2 CaSO3 + CO2 Organic S + O2 SO2
Preheating zone Sulfides + O2 Oxides + SO2 CaCO3 + SO2 CaSO3 + CO2 Organic S + O2 SO2
Calcining zone Fuel S + O2 SO2 CaO + SO2 CaSO3 CaSO4 + C CaO + SO2 + CO CaSO3 + ½ O2 CaSO4
Burning zone Fuel S + O2 SO2 NaO + SO2 + ½ O2 NaSO4 Sulfates Oxides + SO2 + ½ O2 K2O + SO2 + ½ O2 K2SO4 CaO + SO2 + ½ O2 CaSO4
The raw mill and preheater/precalciner use kiln exhaust gases to heat and calcine the raw
feed before it enters the kiln. The counter flow of raw materials and exhaust gases in the raw
19
mill and preheater and precalciner, in effect, act as an inherent dry scrubber to control SO2
emissions creating CaSO3 and CaSO4, which either pass directly with the raw materials to the
burning zone or are collected by the main baghouse and recirculated back into the raw material
stream. Depending on the process and the source and concentration of sulfur, SO2 absorption in
preheater/precalciner kiln systems has been estimated to range from approximately 70 percent to
more than 95 percent.
3.2 Identification of SO2 Control Options
This section reviews the available SOx control technologies that were considered for the
proposed project.
A nationwide SO2 plant survey sponsored by the Portland Cement Association (PCA)
reported that dry process kilns (including preheater/precalciner systems) emit approximately half
as much SO2 per ton of clinker as wet process kilns. In a dry process plant, much less heat input
is needed to manufacture one ton of clinker versus a wet process kiln. The increased energy
efficiency of the dry process results in substantially lower fuel costs. Because of this energy cost
savings, the dry production process has become the predominant process in the Portland cement
industry for new plants.
SO2 emissions from preheater/precalciner kiln systems with in-line raw mills are
controlled within the process itself (inherent dry scrubbing) by absorbing SO2 primarily with
calcium carbonate (CaCO3) in the raw feed material. The absorption takes place in the kiln,
precalciner, preheater, and raw mill. Additional methods of reducing SO2 include process
modifications and add-on flue gas desulfurization systems. The degree to which each of these
methods affect SO2 reduction can vary considerably depending on several process parameters
that will be discussed in the following sections.
3.2.1 Inherent Dry Scrubbing
Total potential SO2 emissions from a cement kiln include oxidization of sulfur during
fuel combustion and raw feed preheating and calcination. The emissions and projected control
efficiency achieved by the inherent dry scrubbing of the preheater/precalciner kiln system can be
roughly estimated using sulfur content and projected operating data.
20
Sulfur liberation and absorption processes take place in the rotary kiln, in the precalciner,
and in the lower sections of the preheater tower. Using raw material sulfur sampling and mix
design data, CCC estimates that the worst-case uncontrolled SO2 emissions from the raw
materials, prior to the preheater, will be 10.75 lb/ton clinker. A portion of the SO2 from the kiln
gases is absorbed into the kiln feed in the preheater tower. The SO2 removal efficiency of the
preheater has been estimated at 60 percent. Therefore the SO2 emissions at the preheater exit are
approximately 4.30 lb/ton clinker. Appendix A contains a diagram illustrating the path of gas
flow and uncontrolled SO2 emissions from the preheater to the main stack.
A small portion of the preheater gases (approximately 7.8 percent) are diverted to the
coal mill to aid in the coal drying process. Subtracting the SO2 that is vented to the coal mill
leaves 3.96 lb/ton clinker. When the raw mill is not running (up to 20 percent of the time), these
emissions are vented through the main stack to the atmosphere. A small amount of SO2
absorption occurs in the coal mill system. The coal mill exhaust, containing an estimated 0.25 lb
SO2/ton clinker is also vented to the main stack. Therefore the total SO2 emissions when the raw
mill is not running will be 3.96 + 0.25 = 4.22 lb/ton clinker.
Kiln gases pass through the raw grinding mill when it is running, where additional SO2 is
absorbed into the raw material. The SO2 removal efficiency of the raw mill has been estimated
at 50 percent. Therefore the SO2 emissions at the raw mill exit will be approximately 1.98 lb/ton
clinker. The SO2 emissions at the stack will be 1.98 + 0.25 = 2.23 lb/ton clinker when the raw
mill is on. The raw mill is expected to run at least 80 percent of the time. Factoring in 20
percent mill-off time, the average long-term SO2 emissions are estimated at 2.63 lb/ton clinker.
It should be noted that fuel sulfur is neglected in the above estimates because the
uncontrolled contribution is smaller, and more than 99 percent of the SO2 from fuels is typically
absorbed into the process based on cement industry experience. To evaluate total SO2 removal
by the system, however, fuel sulfur inputs must be included. The average sulfur input from fuels
(as SO2) is estimated to be 3.84 lb/ton clinker. Therefore the total uncontrolled SO2 from raw
materials and fuels is 10.75 + 3.84 = 14.59 lb/ton clinker. The average system removal
efficiency based on the SO2 emission estimate is (14.59 – 2.63) / 14.59 x 100 = 82.0 percent.
The controlled SO2 is absorbed into the clinker matrix and kiln dust as calcium or alkali
sulfates and eventually becomes part of the finished cement product. The overall predicted SO2
removal efficiency of this system is lower than some other preheater-precalciner kilns because of
21
the higher levels of sulfur found in the onsite raw materials in combination with the conservative
assumptions used.
The above uncontrolled emissions and inherent SO2 removal efficiencies are best
estimates based on the expected raw material chemistry, modern kiln design, and site specific
conditions. There are uncertainties associated with these estimates because variability in the raw
materials is expected and because every kiln is different. The 60 percent SO2 capture in the
preheater and 50 percent SO2 capture in the raw mill are estimates based on manufacturers
experience and existing data. However, no specific guarantees of performance will be provided
by the equipment vendors for inherent dry scrubbing. In addition to inherent dry scrubbing,
CCC recognizes the need for additional controls to ensure that SO2 emissions are reduced
consistent with the BACT analysis and proposed emission limits presented herein.
3.2.2 Process Modifications
Process modifications that can affect SO2 emission levels include:
1. A reduction of the sulfur content in the raw feed material
2. Increasing the oxygen level in the kiln.
3.2.2.1 Raw Feed Sulfur Reduction
Switching from raw feed materials with high sulfur contents to those with low sulfur
contents could reduce potential SO2 emissions. Limestone always contains sulfates, and often
contains sulfur-rich pyrite (FeS2). Pyrite has been identified as the cause of high SO2 emissions
at several plants throughout the US. High pyrite limestone could be replaced either by pyrite-
free limestone or other calcium-rich products. However, because of the huge volume of
limestone used, it is not feasible to ship lower sulfur, cement-quality limestone from other
locations.
Sulfur is also present in other raw materials and fuels used in the cement making process.
Limiting the sulfur contents in these materials would have little effect on the reduction of
potential SO2 emissions.
22
3.2.2.2 Increased Oxygen Levels
Several studies have shown that increased oxygen levels at certain locations in the kiln
system will reduce SO2 emissions. It is theorized that the SO2 reacts with the increased oxygen
to form SO3, which reacts better with the alkali dust from the raw materials, and is absorbed by
the clinker or the dust cake on a fabric filter. Advantages are the ease of implementing the
technology. Disadvantages include the impact on clinker formation, kiln stability, and increased
NOx and PM10 emissions.
3.2.3 Flue Gas Desulfurization Systems
Five types of Flue Gas Desulfurization (FGD) systems are available that could provide
control of SO2 emissions from Portland cement kilns:
1. Wet scrubbing 2. Wet absorbent addition 3. Dry absorbent addition 4. D-SOX cyclone 5. Lime hydrator.
3.2.3.1 Wet Scrubbing
Wet scrubbing can be an effective add-on control technology for SO2 removal using an
aqueous alkaline solution. SO2 is removed from the exhaust gases by scrubbing because it can
be readily neutralized by alkaline solution and is highly soluble in aqueous solutions. Wet
scrubbers have been shown to provide SO2 control in the range of 20 to 95 percent under various
operating conditions. Cyclonic spray towers generally achieve control efficiencies at the higher
end of the range. Wet scrubbing can also remove some particulate matter, VOCs, and acid gases.
As applied to cement plants, the scrubber is located after the primary PM control device and
minimal additional particulate is removed. The solids in mist carryover from the scrubber can in
some cases be greater than the inlet particulate loading from the fabric filter. In theory, wet
scrubbing produces a calcium sulfate (CaSO4) byproduct, typically referred to as synthetic
gypsum. However, in practice, not all cement plants that have used wet scrubbing have been
successful in obtaining useable synthetic gypsum. If the cement plant can reclaim the scrubber
sludge as synthetic gypsum and reincorporate it in the finish grinding process as synthetic
gypsum, the overall environmental benefits associated with a wet scrubber can be considerable.
23
Wet scrubbing increases the water demand for the plant and introduces a new water
pollution source. Wastewater generated by the scrubber must be properly treated and disposed.
Application of a wet scrubber requires passing the exhaust gases through a particulate
control device to reduce the dust load and recover product. Next, the exhaust gas is cooled by
spraying quench water or a slurried reagent (such as slaked lime or finely ground limestone) in
an absorption chamber. SO2 is scrubbed from the exhaust gas by the reaction with the slurried
lime [Ca(OH)2] or limestone (calcium carbonate). The Ca(OH)2 or calcium carbonate reacts
with the SO2 to form synthetic gypsum (CaSO4 – 2H2O). In theory, the synthetic gypsum
precipitates into small crystals that are dewatered. The dewatered synthetic gypsum can then be
used to supplement purchased gypsum in the production of cement and represents a potential
beneficial reuse of byproduct materials. However, if the gypsum cannot be effectively
crystallized, as has been the experienced by some cement plants utilizing wet scrubbing systems,
the scrubber sludge must be disposed of at considerable cost.
At the present time there have been only a small number of cement kilns in North
America that have employed wet scrubbing technology for abatement of SO2. There are,
however, several kilns, which have permits to install wet scrubbers. The following describes the
operations of four of these plants.
ESSROC, Nazareth, Pennsylvania – A wet scrubber was installed on a preheater kiln to
reduce SO2 by 20 to 25 percent to comply with a State SO2 emission limit. The scrubber was an
early design with two units in parallel, and only had an availability of 65 percent of kiln
operating hours. Chronic fouling of demisters, piping, and nozzles occurred and the scrubbers
were discontinued with conversion of the kiln to a precalciner design during an expansion
project.
Holcim, Midlothian, Texas – Scrubbers were installed on two kiln lines in an effort to
increase production and avoid PSD permitting. The units are a more advanced design and have
removal efficiencies of between 70 to 90 percent. Recent SO2 emissions are in the range of 2 to
3 lb/ton clinker.
TXI, Midlothian, Texas – A scrubber was installed as part of an upgrade of the plant from
wet kiln operation (4 units) to a new precalciner line. The kiln system has high uncontrolled SO2
and controlled emissions are limited to approximately 0.95 lb/ton clinker. This scrubber is
24
located between the kiln fabric filter and a regenerative thermal oxidizer (RTO) used for
CO/VOC control.
Holcim, Dundee, Michigan – Two scrubbers were installed on the two wet kilns for
removal of SO2 prior to control of hydrocarbon emissions using an RTO. The SO2 is converted
to sulfur trioxide (SO3) in the RTO, causing corrosion and a visible condensing aerosol in the
combustion process. The plant installed the RTO to meet stack opacity and odor limitations and
the scrubbers were required for the RTO to function properly.
There are two other wet scrubbers that have been permitted at cement plants in the US as
part of recent expansion projects. These are at Lehigh Cement, Mason City, Iowa, and North
Texas Cement, Whitewright, Texas. Controlled SO2 emissions at the Lehigh plant are limited to
approximately 1.0 lb/ton clinker. The Texas Cement plant has not been constructed.
Environmental Impacts
The use of wet scrubbers can have an adverse environmental impact by generating solid
waste requiring landfill disposal (if a usable synthetic gypsum cannot be produced), and require
treatment and disposal of liquid blowdown containing dissolved solids (alkali salts).
In addition, saturation of the gas stream results in evaporation of large quantities of fresh
water that can have an impact on the water supply in the area.
Wet scrubbers produce an exhaust gas stream that is lower in temperature than otherwise
would be the case. Reheating of the gas stream may be necessary in some situations to reduce
ambient impacts of other pollutants. If the gas is reheated, additional NOx and CO would be
generated by the additional fuel combustion.
Energy Impacts
The static pressure drop through the wet scrubber and demister increases the electrical
energy demand for the project and has an adverse impact on energy usage at the site. In addition
the need to reheat stack gases for dispersion and corrosion prevention has a significant energy
impact.
Product Impacts
The wet scrubber does not have an adverse process impact if the waste is landfilled, but
can have an impact if synthetic gypsum is returned to the process. Changes in process quality
cannot be predicted until after scrubber startup in that the quality of synthetic gypsum is site
specific.
25
3.2.3.2 Wet Absorbent Addition
Wet absorbent addition (WAA) to the process gas stream can reduce high levels of SO2
emissions in dry cement kiln systems. Lime and hydrated lime can be used for this purpose.
Various types of wet absorbent systems have been used on dry kilns, with lime slurry addition
being the most effective.
Wet absorbent addition is limited to kiln systems where the lime slurry droplet can
evaporate to dryness before entering the particulate control device. This eliminates use on wet
kilns where flue gas temperatures are too low for rapid evaporation and flue gas moisture is near
moisture saturation levels.
It should be noted that the limestone in the kiln feed and calcium oxide in kiln dust act as
natural absorbents of some of the SO2 emissions produced from fuel combustion and pyritic
sulfur in the feed. Further, good burner design and proper operation of the kiln will chemically
absorb sulfur into the clinker. Additional SO2 reduction can be achieved by absorbent addition
into the process gas stream.
With wet absorbent addition, calcium oxide (CaO) or calcium hydroxide [Ca(OH)2]
slurry is injected into the process gas stream. Solid particles of calcium sulfite (CaSO3) or
calcium sulfate (CaSO4) are produced, which are removed from the gas stream along with excess
reagent by a particulate matter control device. The SO2 removal efficiency varies widely
depending on the point of introduction into the process according to the temperature, degree of
mixing, properties of the absorbent (size, surface area, etc.), and retention time.
In a dry process cement kiln system, the gases contain a low concentration of water vapor
at an elevated temperature and must be cooled and humidified prior to entering the baghouse or
ESP. Lime or calcium hydrate slurry can be introduced with the spray cooling water. Flue gas
temperatures are reduced through the heat absorbed as sensible heat from evaporation of water.
These temperatures are defined by the system design, kiln heat balance, amount of air inleakage,
and radiant and convective heat losses. The conditions present are optimal for proper operation
of the kiln.
For lime slurry injection to succeed as an SO2 absorption control method several
conditions must occur. These include:
1. Generation of spray droplets of sufficient surface area to adsorb SO2 (typically
150 to 250 m).
26
2. Droplets exist for sufficient duration to allow absorption and reaction (typically 3 to 5 s).
3. Sufficient reagent present in the droplet to maintain excess absorbent during droplet life.
4. Activity of hydrate particle in the droplet sufficient to replenish dissolved solids in the liquid as SO2 consumes reagent (i.e., particle size, reactivity, etc.).
5. When used in conjunction with a dry particulate collection device, the droplet must evaporate to dryness prior to entering the device.
An analysis of the heat balance for the dry process kiln determines if there is sufficient
sensible heat available in the gas streams to allow evaporation of injected water containing
hydrate slurry.
Hydrate solids may be introduced in the conditioning water as suspended/dissolved
solids. Normal solids content in the water can be as high as 5 percent solids by weight using air
atomizing spray nozzles. The generation of small droplets and fine hydrate particle size allows
effective absorption of SO2 and reaction to form sulfates. SO2 removal effectiveness can vary
between 50 and 70 percent depending on residence time and hydrate surface area.
The lower SO2 removal estimates have been documented in applications where the
conditioning towers, duct arrangement, and particulate control devices are not adequate for
injection of lime slurry. The constraints of the system result in wet bottoms in the conditioning
towers and build up on ducts and baghouse walls. These conditions limit the hydrate slurry
injection rates and the removal efficiency.
The higher SO2 removal estimates have been documented at new greenfield installations
in which optimum designs can be implemented. In these designs larger conditioning towers and
longer straight runs of ductwork are used along with control device gas distribution systems.
The major issues in applying this type of control system to preheater/precalciner kiln
system are the impacts on the thermal efficiency of the system and the effects moisture will have
on the PM10 control system.
The heat exchange processes that take place in the precalciner, preheater, and raw mill
are critical to the overall thermal efficiency of the process. Gases from the preheater are routed
to the raw mill to aid in the grinding and drying process. If the WAA system is installed prior to
the raw mill, the reduction in gas temperatures from the spray drying process would decrease the
ability of the gases to dry the materials in the raw mill. To adjust for the temperature decrease,
additional heat energy would be necessary in the raw mill. The additional heat input requirement
27
at CCC would be 73.5 MMbtu/hr. The cost to provide additional heat for drying material in the
raw mill using natural gas would be approximately $7,200,000 per year (see Appendix B). The
additional air flow would require a larger baghouse and additional fan horsepower. This would
be cost-prohibitive as well as imposing additional energy and environmental impacts.
If the WAA system were installed after the raw mill, it is unlikely that the system could
sufficiently dry the gases prior to exhausting them to the baghouse. Therefore, additional heat
energy would again be necessary to ensure that the added moisture in the exhaust gases did not
condense in the baghouse.
A hybrid system is also possible to optimize the SO2 reduction effects of a WAA system.
In this hybrid system, wet lime slurry is injected into the conditioning/spray tower to reduce SO2
emissions when the raw mill is not operating. When the raw mill is operating, wet lime is
introduced into the raw mill, enhancing SO2 adsorption as this material is ground with the raw
material while kiln gases pass through the mill. CCC proposes to use this type of hybrid system
for SO2 control.
Environmental Impacts
No adverse environmental impacts are expected from the use of wet absorption (hybrid
system) at this location. However, if gas reheating is used for a continuous spray tower system,
additional products of combustion would be emitted through fuel burning.
Energy Impacts
The change in energy required to implement wet slurry injection (hybrid system) is
minimal and does not result in an adverse energy impact. However, if gas reheating is used for a
continuous spray tower system, additional energy would be required in the form of fuel burning
and additional fan horsepower.
Process Impacts
The injection of wet slurry is not expected to have significant process impacts except in
applications with high uncontrolled SO2 emissions and high dosage rates, when excess sulfate
could affect product quality. The addition of Ca(OH)2 at the expected rates should not adversely
affect cement quality.
28
3.2.3.3 Dry Absorbent Addition
Dry absorbent addition to the process gas stream or in an add-on control device (dry
scrubber) can reduce high levels of SO2 emissions. Lime, calcium hydrate, limestone, or soda
ash could be used for this purpose. Various types of dry absorbent systems have been used on
wet and dry cement kilns, and one end-of-pipe dry scrubber has been installed on a kiln in
Switzerland.
It should be noted that the calcium oxide and limestone in the kiln feed acts as a natural
absorbent of some of the SO2 emissions produced from fuel combustion and pyrite
decomposition. Further, good burner design and proper operations of the kiln will chemically
bond sulfur into the clinker. Additional SO2 reduction can be achieved by dry absorbent addition
into the process gas stream.
With absorbent addition, dry CaO or Ca(OH)2 is injected into the process gas stream.
Solid particles of CaSO3 or CaSO4 are produced, which are removed from the gas stream along
with excess reagent by a particulate matter control device in the process flow. The SO2 removal
efficiency varies widely depending on the point of introduction into the process according to the
temperature, degree of mixing, and retention time.
The single known application of an add-on dry scrubber uses a venturi reactor column to
produce a fluidized bed of dry slaked lime and raw meal. As a result of contact between the
exhaust gas and the absorbent, as well as the long residence time and low temperature
characteristic of the system, SO2 is efficiently absorbed by this system. An additional
application injects Ca(OH)2 in the gas stream after the preheater first stage cyclone.
The addition of dry absorbent to flue gas streams has been used at Roanoke Cement in
Troutville, Virginia and at several other new cement plants. Effectiveness and cost are specific
to each application and depend on the gas stream conditions and residence time available for
reaction.
Typically the molar ratio (Ca/S) for absorption is on the order of 3.0 to 15 and requires
approximately 2 seconds for completion. Initial surface reactions occur in the first 0.1 s and the
coating retards reaction with the bulk of the particle. For increased effectiveness a very fine
particle is required or a high Ca/S ratio. Typical removal efficiency is between 20 and 50
percent depending on gas stream conditions.
29
For the process to be implemented, hydrate would be received by truck, pneumatically
conveyed to a storage silo, and then injected through nozzles into the gas stream. Complete and
uniform distribution and mixing in the gas stream are necessary. The best location for injection
is at the preheater exhaust, which allows adequate residence time for reaction.
Environmental Impacts
No adverse environmental impacts are expected from the use of dry absorption at this
location.
Energy Impacts
The change in energy required to implement dry adsorption is minimal and does not
result in adverse energy impact.
Process Impacts
The injection of dry absorbent is not generally expected to have a significant process
impact. However, high injection rates of Ca(OH)2 can impact the calcium to silica ratio and
upset the kiln chemistry.
3.2.3.4 D-SOx Cyclone
The D-SOx cyclone system is designed to use some of the free lime (CaO) that is created
in the calciner to reduce SO2 emissions. A portion of the calciner exit gas (about 5% for plants
with significant pyritic sulfur) is taken off of the calciner exit duct and goes up to a collection
cyclone at the top of the preheater tower which separates most of the entrained dust from the gas.
The captured dust is then fed to the cyclone exit duct where the pyritic sulfur is converted to
SO2. The free lime in the calciner dust absorbs some of the SO2 to give a 25 to 30 percent
reduction. This has been proven in two plants in the U.S. according to FLSmidth. The exit gas
from the D-SOx cyclone is returned to the outlet of the second stage preheater cyclone. A natural
draft is created in the system thereby eliminating the need for an extra fan. Since no outside
reagent is required, the system has much lower operating costs than the control systems based on
purchased lime addition.
3.2.3.5 Lime Hydrator
An on-line lime hydrator system has been developed at a pilot test plant in Denmark.
The system extracts calcined raw material from the bottom stage cyclone, hydrates the surface of
30
the lime particles in a separate vessel, and returns the material to the top of the preheater where it
is mixed with preheater feed to absorb SO2. FLSmidth indicates that a 44 percent SO2 reduction
could be expected with this system. A relatively small amount of additional heat and energy are
required for the system. This system has advantages over wet lime injection systems in that the
hydrated lime is made on-line, thus saving the costs of added lime, transportation, and storage.
However, there have not yet been any full-scale commercial applications of this system.
3.3 Elimination of Technically Infeasible SO2 Control Options
The second step in the BACT analysis is to eliminate any technically infeasible control
technologies. Each control technology is considered and those that are infeasible based on
physical, chemical, and engineering principles are eliminated.
3.3.1 Inherent Dry Scrubbing
This technology has been demonstrated as technically feasible and is estimated to result
in a potential SO2 absorption efficiency of 82 percent based on a sulfur balance (see Section
3.2.1). As an inherent process technology, the underlying reduction efficiency is not comparable
to other add-on SO2 control options.
3.3.2 Process Modifications
The technical feasibility of process modifications is dependent on several factors that
cannot be directly quantified, and factors that impact the emissions of other pollutants. The
following subsections discuss the relative feasibility of the identified process modifications.
3.3.2.1 Raw Material Sulfur Reduction
The raw materials to be used by CCC have a medium sulfur content. As noted above, a
high percentage of the sulfur winds up in the clinker. In order to produce cement with good
rheological properties (workability and plastic shrinkage) and strength development, it is
necessary to produce clinker with an acceptable SO3/alkali molar ratio. The raw materials and
coal to be used by CCC are adequate for this purpose; reducing sulfur content below current
levels may be detrimental to clinker product quality.
Absorption of fuel sulfur throughout the calciner, preheater, and raw mill is expected to
be very high (exceeding 99%). This has been demonstrated at another precalciner kiln (Roanoke
31
Cement Company in Troutville, Virginia) where increasing the fuel sulfur content by 39 percent
produced no increase in SO2 emissions. Based on the foregoing discussion, lowering fuel sulfur
content would have little effect on emissions and may adversely affect product quality. Because
most of the raw materials are mined onsite and are required for cement clinker production, the
sulfur content of these materials cannot effectively be reduced. Consequently, this control
technique is not considered a feasible option and is not considered further in this BACT analysis.
3.3.2.2 Increased O2 Levels
Cement kiln operators strive for an oxygen level in the kiln exhaust gases of
approximately 3 percent (approximately 10 to 15% excess air) to guarantee the desired oxidizing
conditions in the kiln burning zone. Increasing oxygen levels in the kiln through the use of
excess air alters the flame characteristics and adversely affects clinker quality. Testing has
shown that increasing or decreasing the oxygen level even one percent can result in a clinker
product that does not meet industry standards.
Because of the potential adverse impact to clinker quality resulting from increasing O2
levels to reduce SOx emissions, this technology is not considered a feasible option and is not
considered further in this BACT analysis.
3.3.3 Flue Gas Desulfurization Systems
Five different FGD systems were evaluated for technical feasibility. The additional
control efficiency of a FGD system may be difficult to quantify because of the inherent
scrubbing efficiency of the preheater/precalciner kiln system.
3.3.3.1 Wet Scrubbing
There are several disadvantages to a wet lime scrubbing system. A wet scrubber would
require up to 500 gallons of water per minute. A large amount of the water would be vaporized
and emitted as a steam plume from the stack. The steam plume that would occur may be visually
unappealing to neighbors in the area. The sludge byproduct from the wet scrubber would require
treatment and disposal if it does not meet quality standards for use as a cement additive.
Because a scrubber would be located downstream of the PM10 control device, aerosols
from the scrubber could be emitted from the kiln stack. These aerosols would increase the PM10
loading from the source, and would tend to build up on equipment used in the exhaust gas
32
processing system (ID fans, etc.). Nonetheless, this technology may be technically feasible and
will be reviewed further.
3.3.3.2 Dry Absorbent Addition (DAA)
Because this has been employed in other cement plants, this technology is considered
technically feasible and will be reviewed further.
3.3.3.3 Wet Absorbent Addition (WAA)
Because WAA has been employed at several cement plants, this technology is considered
technically feasible and will be reviewed further.
3.3.3.4 D-SOX Cyclone
This technology has been employed at two cement plants in the U.S., is considered
technically feasible, and will be reviewed further.
3.3.3.4 Lime Hydrator
This technology has been proposed by FLSmidth but a full-scale commercial system has
not yet been employed at a cement plant. However, the technology is considered technically
feasible and will be reviewed further.
3.4 Ranking of Technically Feasible SO2 Control Options
The third step in the BACT analysis is to rank remaining SO2 control technologies by
control effectiveness. All of the technologies determined to be technically feasible are added to
the base case condition of inherent dry scrubbing. The SO2 control technologies determined to
be technically feasible are a wet scrubbing system, WAA, and DAA.
Because the coal mill will use preheater gases for coal grinding and drying, a portion of
the gases would not be treated by a WAA system.
For WAA, a hybrid system is being evaluated that would add wet lime to the raw mill
during mill-on operating conditions and to the conditioning tower during mill-off conditions
(approximately 20% of the time).
Table 6 shows the ranking and the estimated control efficiency of each control option.
33
TABLE 6. RANKING OF TECHNICALLY FEASIBLE CONTROL OPTIONS
PREHEATER/PRECALCINER KILN SYSTEM - SO2
Control Technology Control Efficiency1
Wet Scrubbing System (Post-baghouse) 90
DAA (Preheater Gases) 50
WAA (Conditioning Tower/Raw Mill) 55
D-SOX Cyclone (Preheater Gases) 30
Lime Hydrator (Preheater Gases) 44
Inherent Dry Scrubbing (Base Case) NA 1The optimum control efficiency listed is at the control point only; this is in addition to the control provided by inherent dry scrubbing.
3.5 Evaluation of Technically Feasible SO2 Control Options
The fourth step in a BACT analysis for SO2 is to complete the analysis of the applicable
control technologies and document the results. The control technologies are evaluated on the
basis of economic, energy, and environmental considerations.
The D-SOX cyclone and the lime hydrator can be eliminated from further consideration at
this point because their SO2 removal efficiencies are lower than the top three available options.
Table 7 presents a summary of the impact analysis for each of the above control options. The
detailed cost calculations for all options are presented in Appendix B.
TABLE 7. SUMMARY OF IMPACT ANALYSIS FOR SO2
Impacts
Method
System
removal,
%
SO2
Removed,
tons/yr
Capital
Costs,
MM$
Annualized
Cost, 1000
$
Cost
Effectiveness
$/ton SO2 Environmental Product Energy
Wet Scrubbing1
90 2,592 35.8 8,793 3,392 Yes No Yes
Dry Absorbent
50 1,440 1.8 3,803 2,641 No No No
Wet Absorbent2
50 1,435 3.0 1,965 1,371 No No No
1Costs are shown for wet scrubbing alone. Reheating of stack gases if necessary would result in significant additional cost. 2System removal is lower than in Table 6 because coal mill gases are not controlled by WAA.
3.6 Review of Recent Permit Limits
Table 8 summarizes the SO2 permit determinations made for cement kilns since 2000.
34
TABLE 8. SUMMARY OF RECENT SO2 PERMIT DETERMINATIONS FOR CEMENT KILNS (2000-PRESENT)
Company Location Kiln Type PermitDate
Technology Applied Removal
(%)
InOperation (Yes/No)
Limit(lb/ton clinker)
Rejected Technology and $/Ton
Lafarge – Kiln 1 Harleyville, SC PC (mod) 8/18/06 Process (inherent dry
scrubbing)94 Yes
0.90 – 30 day 1.6 – 24 h
WS – 27,300 DAA – 8.480
WAA – 42.600
Lafarge – Kiln 2 Harleyville, SC PC (new) 8/18/06 Process (inherent dry
scrubbing)94 No
0.90 – 30 day 1.6 – 24 h
WS – 25,900 DAA – 7,340
WAA – 33,400
Suwannee American Cement – Kiln 2
Branford, FL PC (new) 2/15/06 Process & hydrated lime
injection for mill off 4 No 0.27 – 24 h
WS - $86,900 DAA - $7,271
Sumter Cement Sumter Co., Fl PC (new) 2/6/06 Low S materials No 0.2 – 24 h
American Cement Sumter Co., FL PC (new) 2/06 Low S. materials No 0.20 – 24 h WS
Florida Rock Industries – Kiln 2
Newberry, FL PC (new) 7/22/05 Process (inherent dry
scrubbing)NA No 0.28 – 24 h WS - $20,453
Rinker/Florida Crushed Stone – Kiln 2
Brooksville, FL PC (new) 7/6/05 Process (inherent dry
scrubbing)NA No 0.23 – 24 h
Holcim Lee Island, MO PC (new) 06/08/04 Lime spray drying - mill off 93 No 1.26 WS - $13,225
GCC Rio Grande Pueblo, CO PC (new) 3/5/04 Process; low S coal NA No 1.99
Lehigh Portland Cement Mason City, IA PC (mod) 12/11/03 Wet Scrubbing 90 Yes 1.01
GCC Dacotah Rapid City, SD PC (mod) 04/10/03 Process (inherent dry
scrubbing)NA Yes 2.16 Fuel or raw mix S limits
Holcim Theodore, AL PC (mod) 02/04/03 Limit not based on BACT NA Yes 0.13
CEMEX Demopolis, AL PC (mod) 09/13/02 Low S coal NA Yes 1.14 WS - $10,327
Suwannee American Cement – Kiln 1
Branford, FL PC (new) 06/01/00 Process (inherent dry
scrubbing)NA Yes 0.27 – 24 h
WS - $29,700 DAA - $7,400
Monarch Cement Humboldt, KS 2PC
(mod)01/27/00
Process (inherent dry scrubbing)
NA Yes 1.10 WS - $10,345
Lo S Fuel, WAA, DAA
Lafarge Davenport, IA PC
(mod)11/09/99
Process (inherent dry scrubbing)
NA Yes 7.62
North Texas Cement Whitewright, TX PC (new) 03/04/99 Wet Scrubbing 85 No2 2.75
Continental Cement Hannibla, MO PC (New) 7/24/07 Lime spray drying-mill off 50-90 No(?) 1.93 WS - > $6,800
Notes: 2. May never be built
PC = Precalciner NA = Not applicable WS = Wet scrubber S = Sulfur DAA = Dry absorbent addition WAA = Wet absorbent addition
35
3.7 Selection of BACT for SO2
CCC proposes as BACT for SO2 from the kiln system the inherently low-emitting
process coupled with wet adsorbent addition. The requested BACT emission limits are 1.33
lb/ton of clinker, 30-day rolling average and 1.80 lb/ton of clinker, maximum 24-hour rolling
average) as measured by Continuous Emission Monitor (CEM).
For the emergency diesel generator set, CCC proposes a fuel sulfur limit consistent with
the NSPS Subpart IIII Standards of Performance for Stationary Compression Ignition Internal
Combustion Engines.
36
SECTION 4
BACT ANALYSIS FOR NOX
The only sources of NOx emissions associated with the proposed project are the
preheater/precalciner kiln system and the new emergency diesel generator set.
4.1 NOx Formation and Control Mechanisms
NOx is formed as a result of reactions occurring during combustion of fuels in the main
kiln and precalciner vessel of a traditional preheater/precalciner cement kiln. NOx is produced
through three mechanisms during combustion 1) fuel NOx, 2) thermal NOx, and 3) “prompt”
NOx.
Fuel NOx is the NOx that is formed by the oxidation of nitrogen and nitrogen complexes
in fuel. In general, approximately 60 percent of fuel nitrogen is converted to NOx. The resulting
emissions are primarily affected by the nitrogen content of fuel and excess O2 in the flame.
Nitrogen in the kiln feed may also contribute to NOx formation although to a much smaller
extent.
Thermal NOx is the most significant NOx mechanism in kiln combustion. The rate of
conversion is controlled by both excess O2 in the flame and the temperature of the flame. In
general, NOx levels increase with higher flame temperatures that are typical in the kiln burning
zone.
“Prompt NOx” is a term applied to the formation of NOx in the flame surface during
luminous oxidation. The formation is instantaneous and does not depend on flame temperature
or excess air. This formation may be considered the baseline NOx level that is present during
combustion and is relatively small compared to the other two mechanisms.
Thermal NOx formation can be expressed by two important reactions of the extended
Zeldovich mechanism:
)(2 slowNNONO !"!
37
)(2 fastONOON !"!
At high temperature and excess O2, a higher concentration of O radicals (or H radicals) is
present and therefore NOx forms more rapidly. At lower temperatures, an equilibrium reaction
of NO with O2 further results in NO2 formation. Fuel NOx is formed by the reaction of nitrogen
in the fuel with available oxygen.
In a precalciner kiln, fuel combustion occurs at two locations and each follows a separate
mechanism in the formation of NOx (i.e., thermal NOx dominates in the kiln burning zone and
fuel NOx dominates in the precalciner). For this reason, the effects of process operation on final
NOx levels are complex and do not necessarily conform to conventional understanding of
combustion as defined through steam generation technology. Experience with various cement
kilns also has shown that actual NOx emissions are highly site specific.
4.1.1 Fuel Effects
Fuel type has an effect on NOx emissions. For example, data from combustion
simulations and field trials indicate combustion of coal produces significantly lower NOx than
natural gas combustion in a main kiln burner. In general, substituting fuels with higher Btu
content will reduce NOx emissions in part because fuel efficiency is increased and less total fuel
is consumed.
The use of alternative fuels such as tires and plastics can reduce NOx emissions when
fired at intermediate locations within the kiln system. This concept is further discussed in
Sections 4.2.6 (Mid-Kiln Firing) and 4.2.7 (Staged Combustion).
4.1.2 Main Kiln Firing
In the rotary kiln section, the purpose of combustion is to increase material temperature
to a level that will allow calcined meal to become viscous (liquid) and form calcium silicates.
The temperature required for “burning” depends on cement type and meal properties and is in
excess of 1400ºC (2550#F). Some meal types require a higher flame temperature than others to
achieve the material temperature required to initiate fusion.
Cement kilns are distinct from conventional combustion sources such as steam generation
in that the combustion chamber is a confined space that is refractory lined. This radiates energy
38
back into the flame, thereby increasing the flame temperature. At given excess air levels, a
confined flame will usually produce higher NOx emissions than an open flame such as a boiler
fire box.
NOx levels from kiln firing are also strongly related to fuel type, flame shape, and peak
flame temperature. At higher peak flame temperatures, more thermal NOx is formed. Flame
shape is also related to the percentage of primary air used in combustion in the kiln. High levels
of primary air increase NOx formation by providing excess O2 in the hottest portion of the flame.
Experience has indicated that a long flame and low primary air volume can minimize NOx
formation in the main kiln. However, in order to obtain high quality clinker with the best
microstructure, a relatively short, strong, and steady flame is necessary. In addition, too long of
a flame may also cause kiln rings and lead to incomplete fuel combustion.
4.1.3 Precalciner Firing
A secondary firing zone is the precalciner vessel. Fuel is introduced and burned in situ
with the preheated raw meal. Under these conditions, heat released by fuel oxidation is extracted
by meal decarbonization. The efficient use and transfer of energy reduces the peak temperature
in the vessel. Normal temperatures are between 900º and 980ºC (1650# and 1800#F). This lower
temperature and operation at reduced excess air levels reduces the formation of NOx. Thermal
NOx is small and fuel NOx predominates.
NOx formed in the main kiln combustion passes through the precalciner and the gases are
cooled slowly in the preheater cyclones. NOx formation is an endothermic process and as gases
cool, NOx tends to revert to N2 and O2. This decomposition process is rapid at elevated
temperatures but decreases at temperatures below approximately 700ºC (1300#F). In effect, if
the flue gases can be slowly cooled to 700#C over an extended period, a progressive decrease in
NOx concentration occurs. This process occurs in the preheater after other combustion radicals
(OH-, H+, O-, etc.) have been eliminated.
39
4.2 Identification of NOx Control Options
4.2.1 Selective Non-Catalytic Reduction
Selective non-catalytic reduction (SNCR) involves the injection of an ammonia-
containing solution into the preheater tower to reduce NOx within the optimum temperature
range of 870# to 1090#C (1600º to 2000ºF). Because the optimum temperature range must be
present for a sufficient time period to allow the reaction to occur, SNCR is only a viable
technology on some preheater or precalciner kiln designs. The ammonia-containing solution
may be supplied in the form of anhydrous ammonia, aqueous ammonia, or urea.
SNCR involves the following primary reactions:
OHNHOHNH 223 !"!
2 23
2
2 2NH O NH H O! " !$
NH H NH H3 2 2! " !!
Following NH2 formation by any of the above mechanisms, reduction of NO occurs:
NH NO N H O2 2 2! " !
At temperatures lower than 870#C, reaction rates are slow, and there is potential for
significant amounts of ammonia to exit or “slip” through the system. This ammonia slip may
result in a detached visible plume at the main stack, as the ammonia will combine with sulfates
and chlorides in the exhaust gases to form inorganic condensable salts. The condensable salts
can become a significant source of condensable PM emissions that cannot be controlled with a
baghouse or ESP. Ammonium sulfate aerosols would be a concern under upcoming programs to
deal with PM2.5 and regional haze. In addition, there may be health and safety issues with on-site
ammonia generation.
At temperatures within the optimal temperature range, the above reactions proceed at
normal rates. However, as noted in the literature as well as by vendors, a minimum of 5 ppm
ammonia slip may still occur as a side effect of the SNCR process.
At temperatures above 1090#C, the necessary reactions do not occur. In this case, the
ammonia or urea reagent will oxidize and result in even greater NOx emissions. In addition,
SNCR secondary reactions can form a precipitate, resulting in preheater fouling and kiln upset.
40
Ammonia reagent may react with sulfur in kiln gases to form ammonium sulfate. Ammonium
sulfate in the preheater can create a solids buildup. Ammonium sulfate in the kiln dust recycle
stream may adversely affect the kiln operation.
The optimal temperature window for application of the SNCR process occurs somewhere
in the preheater system. Fluctuations in the temperature at various points in the preheater are
common during normal cement kiln operation. Therefore, selecting one zone for SNCR
application in the preheater cannot reliably assure consistent results. Alternatively, selecting
multiple zones of injection creates significantly increased complexity to an already complex
chemical process.
SNCR has been employed at a significant number of European cement plants for NOx
reduction and recently at several new cement plants in the U.S. The European systems include
two precalciner plants (Sweden) and at least 17 preheater plants primarily in Germany. The
principal vendor has been Polysius. In Europe the chemical of choice for ammonia reagent is
photowater. Photowater is a waste produced during development of film, which contains
approximately 5.0 percent ammonia and is classified as a hazardous waste in the U.S. The
availability and classification of the waste make it a low cost alternative to other ammonia or
urea reagents for NOx control in Europe.
Full-scale SNCR systems have now been installed on at least 6 preheater-precalciner
plants in the U.S. The reagent used in these systems is ammonia water or urea solution.
The requirements for SNCR include an optimum temperature range (i.e., 870# to 1090#C)
and the presence of an oxidizing atmosphere. At the low flue gas temperature the reaction rate is
slow and ineffective. Ammonia introduced will not react and will be lost as gas. Some of the
ammonia will react with SO2 in the conditioning tower forming ammonium sulfate (NH4)2SO4
which is a submicron aerosol. This aerosol may form a visible emission at the stack.
Because the raw materials at the plant site contain naturally occurring carbon (i.e.,
bitumen and kerogens), pyrolysis of organics occurs in the preheater tower producing CO. This
results in a reducing atmosphere. The current control practice is to limit oxygen at the calciner
exit to reduce NOx. SNCR requires an oxidizing atmosphere and the two conditions are opposed
in theory. CO is expected to increase as NOx is reduced.
In addition, ammonia emitted as gas in the plume will react with SO2 or HCl in the
condensed water vapor plume forming a highly visible plume under certain weather conditions.
41
A similar plume has been noted at Glens Falls, New York; Permanente, California; Redding,
California; Ravena, New York; Midlothian, Texas; Mississauga, Ontario; Edmonton, Alberta;
and Exshaw, Alberta as result of naturally occurring ammonia in the kiln feed.
Direct mixing of urea with feed would not be effective in system designs where the feed
is injected into the gas stream at the inlet of the first stage preheater for meal preheating. At this
location flue gas temperatures are too low for the reaction to affect NOx but sufficiently high to
decompose the urea to ammonia, CO2, and water vapor.
SNCR will be investigated as an additional NOx control option. The kiln will also
employ indirect firing and low NOx burners and staged combustion calciner design.
4.2.2 Selective Catalytic Reduction
Selective catalytic reduction (SCR) is a process that uses ammonia in the presence of a
catalyst to reduce NOx. The catalyst is typically vanadium pentoxide, zeolite, or titanium
dioxide. The SCR process has been proven to reduce NOx emissions from combustion sources
such as incinerators and boilers used in electric power generation plants. No full-scale
application of SCR on a Portland cement plant exists anywhere in North America but there has
been one long-term pilot project (Kirchdorf, Austria) and three industrial applications
(Solnhofen, Germany, Monselice, Italy, and Sarche di Calavino, Italy) in Europe. The Solnhofen
and Monselice kilns are small preheater kilns with relatively high uncontrolled NOx levels (up to
1800 mg/Nm3 at Monselice). The Sarche di Calavino kiln is a small semi-dry type kiln (no
operating experience is yet available). The Monselice kiln has high ammonia and low sulfur in
the feed and has experienced very high ammonia slip (120 mg/Nm3). The Kirchdorf system
operated in 1996-1998 on only a slipstream (approximately 10%) of the kiln gases.
In the SCR process, the NOx-containing exhaust gas is injected with anhydrous ammonia
and passed through a catalyst bed to initiate the catalytic reaction. As the catalytic reaction is
completed, NOx is reduced to nitrogen and water. The critical temperature range required for the
completion of this reaction is 300# to 450#C, which is higher than the typical cement kiln ESP or
fabric filter inlet gas temperature.
Technical application of SCR requires the catalyst to be placed either 1) after the
preheater tower and before the PM control device (dirty side) or 2) after the particulate control
device (clean side). Placement at the preheater tower satisfies the temperature requirements, but
42
subjects the catalyst to the recirculating dust load and potential fouling. Location at the fabric
filter exit requires reheating of the gases to the required temperature for catalyst activation.
Dirty Side
The most prohibitive disadvantage of the SCR process in this location is fouling of the
SCR catalyst. The high dust loading and recirculating sulfate and ammonium species in cement
kiln gases are likely to plug the catalyst and render it ineffective. Minor impurities in the gas
stream, such as compounds or salts of sulfur, arsenic, calcium, and alkalis, may deactivate the
catalyst very rapidly, strongly affecting the efficiency and system availability as well as
increasing the waste catalyst disposal volume.
Continual fouling of the SCR catalyst would render it inoperative as a NOx control
option. Ammonia injected to an SCR system with a fouled catalyst would pass unreacted
through the system (i.e., ammonia slip). The unreacted ammonia would combine with sulfates
and chlorides in the exit gases, forming inorganic condensable salts, which result in a detached
visible plume and a significant increase in condensable PM10 emissions. In addition, SCR on
power plants has been shown to convert SO2 to SO3 as a secondary reaction. SO3 will react with
CaO between preheater stages forming gypsum (CaSO4), which can plug the tower and cause
kiln shutdown.
Two options for dirty side application exist: 1) after the preheater tower and before the
raw mill; or 2) after the raw mill and before the particulate control device. Gases exiting the
preheater tower are within the optimal temperature range for SCR catalyst activation. However,
the dust loading along with the recirculating feed in this region is very high and would render the
catalyst useless in a very short timeframe. Gases exiting the raw mill system are much cooler
(100º to 120ºC) and would require supplemental reheat prior to the SCR catalyst followed by gas
cooling to protect the baghouse. The reheat of gases from the raw mill system would be cost
prohibitive (see discussion on Clean Side applications).
Clean Side
Installation of the catalyst after the pollution control device reduces the potential for
fouling from meal/recirculating dust load, but requires significant reheating of the gas stream to
obtain the required catalyst temperature. This can be more significant if combined with wet
scrubbing prior to the NOx control. SO2 removal may be required to prevent conversion of SO2
to SO3 in the catalyst bed which would increase SO3 emissions if the NOx control were the last
43
system in the gas train. In addition, reheating of the gas stream results in increased emissions of
CO, VOC, and other pollutants and significant additional cost.
It should be noted that no full-scale clean side SCR systems exist on a cement kiln. The
three full-scale SCR systems that have been operated in Europe are dirty side applications. The
SCR system at Solnhofen is not currently operating.
An additional concern to clean side applications is the formation of SO3 (H2SO4). SCR
catalysts have been shown to convert SO2 to SO3. SO3 readily combines with water vapor to
form H2SO4 (sulfuric acid mist), or with ammonia or chlorides to form aerosol particulates.
These pollutants are highly visible and would not meet opacity limits. Installation of a wet gas
scrubbing system would not be effective in removing H2SO4 aerosols (i.e., 0.5 micron) and the
cost would be prohibitive.
The optimum temperature for reaction is 300# to 450#C. In the presence of the catalyst,
the NOx is reduced to N2 by reaction with ammonia. For the reaction to occur the ammonia must
be present in excess molar ratio. Typical usage in utility applications is 1.05 - 1.10 to 1.0
(NH3/NOx). The excess ammonia required produces “ammonia slip” of between 10 and 15 ppm
in the flue gases.
Recent studies of the use of SCR at major utilities have indicated that some SO2 present
in the flue gases is oxidized to SO3 during the process. The rate of conversion can increase SO3
by 15 to 100 ppm depending on catalyst composition, temperature, and SO2 concentration. It has
also been noted that the catalyst life is greatly reduced by the presence of SO3 in the gas stream.
The slippage of ammonia and formation of SO3 has resulted in an intense visible plume as
ammonia reacts with SO2 in the flue gases and when SO3 condenses forming acid aerosols
(H2SO4 % 2H2O).
Using technology transfer, it has been suggested that heat recovery could be used to
reduce the high cost of reheating the gas stream for a clean side SCR application on a cement
kiln (additional heating would still be required to raise the exhaust temperature to an optimum
level for SCR performance). Both regenerative and recuperative systems could be available for
this purpose. These systems have been proposed for applications such as industrial boilers in
which the residual PM passing the final control device is fly ash. In these cases the deposits
which may occur on the heat exchange surface can be removed by air on steam blowers.
44
In a cement kiln, the CaCO3 and CaO in the PM react with the SO3 formed in the SCR
bed producing CaSO4 · 2H2O which is a hard crystalline deposit. Allowing the deposits to build
up would reduce the heat recovery, increase the fuel burning requirement, and reduce the
efficiency of the system. The PM which would be deposited on the heat exchanger surfaces in a
cement kiln application could not be removed without outage of the equipment and
hydroblasting. This would be a serious recurring, if not continuous, maintenance problem.
An RTO with multiple heat exchanger units has been installed at TXI in Middlothian,
Texas, for CO and VOC control. This unit has experienced, severe heat exchanger fouling
requiring continuous cleaning (off-line), which resulted in the Texas agency allowing the unit to
be repermitted for use only during ozone season due to high maintenance costs and down time.
Thus, SCR with heat recovery is not considered technically feasible and will not be evaluated
further.
EPA’s Alternative Control Techniques (ACT) Document Update NOx Emissions from
New Cement Kilns dated November 2007, while acknowledging that there are no installations of
SCR technology in cement plants in the United States, concludes that SCR technology is
technically feasible based on technology transfer from utility boiler and gas turbine applications.
The ACT document indicates a NOx conversion rate of 80 to 90 percent for SCR is possible,
however, this removal efficiency is unproven in preheater-precalciner cement kilns.
The application of SCR on cement kilns is fundamentally different than utility boilers due
to their differences in gas composition, dust loading, and chemistry, which accounts for the
preference for SNCR rather than SCR in cement kilns in both the US and abroad. Because of
operational problems and the ability of SNCR to achieve the target NOx level of 500 mg/Nm3,
the SCR system at the Solnhofen plant has been replaced by SNCR. The most serious issues yet
to be resolved with SCR in cement kilns are catalyst life, poisoning of the catalyst, fouling of the
bed, system resistance, ability to correctly inject ammonia at proper molar ratio under non-steady
state conditions, and creation of detached plume.
4.2.3 Indirect Firing and Low NOx Burners
Indirect firing systems (a low NOx technology) can be used on the precalciner and rotary
kiln burner systems. This technology functions by grinding the fuel and collecting the
pulverized fuel with a fabric filter and receiving bin. The fuel is then fired using a dense phase
45
conveying system that limits the volume of air necessary to transport fuel to the burner. This
design reduces primary air injected with fuel.
The indirect-firing process allows the flame to be fuel rich, which reduces the oxygen
available for NOx formation. In some cases it can also result in higher flame temperatures
because the heat release occurs with less combustion gases (i.e., excess air).
Low NOx burners in general are not as effective when used on the rotary kiln section of a
preheater-precalciner kiln system because gases containing the thermal NOx formed in the main
kiln section are gradually cooled as they move through the system resulting in NOx reduction (as
previously discussed), and subsequently the gases pass through the precalciner burning zone and
preheater cyclones where they are further reduced. NOx contained in the alkali bypass gases,
however, would not be subject to this reduction.
The indirect-firing process allows the flame to be fuel rich, which reduces the oxygen
available for NOx formation. In some cases it can also result in higher flame temperatures
because the heat release occurs with less combustion gases (i.e., excess air).
Indirect firing with a low NOx burner attempts to create two combustion zones, primary
and secondary, at the end of the main burner pipe. In the high-temperature primary zone,
combustion is initiated in a fuel-rich environment in the presence of a less than stoichiometric
oxygen level. The submolar level of oxygen at the primary combustion site minimizes NOx
formation. The presence of CO in this portion of the flame also chemically reduces some of the
NOx that is formed.
In the secondary zone, combustion is completed in an oxygen-rich environment. The
temperature in the secondary zone is much lower than in the first; therefore, lower NOx
formation is achieved as combustion is completed.
Indirect-firing and a low-NOx main kiln burner will be used on the CCC kiln. The
emission levels achieved with indirect firing are defined by the burnability of the mix, amount of
conveying air required, and design of the burner. In kiln systems where the mix is difficult to
burn (crystalline silica, quartz, high lime/silica ratio, etc.) or where high excess air is required,
the NOx levels are generally higher and this technology is more effective in such situations. In
general, the expected NOx reduction ranges from 0 to 30 percent from baseline levels at the same
mix design and excess air levels.
46
4.2.4 Semi-Direct Firing and Low NOx Burners
Semi-direct firing practice involves the separation of pulverized fuel from the mill sweep
air using a cyclone separator. The fuel is placed in a small feeder bin from which it is metered to
the kiln burner pipe. The exhaust gases of the cyclone are used to transport the fuel from the bin
discharge. Advantages in the design are that a portion of the sweep air can be returned to the
mill or exhausted to the atmosphere and that minor variations in fuel delivery rate are eliminated.
The major advantage for NOx abatement is that the volume of primary air can be marginally
reduced (i.e., 20 to 25% of combustion air). The system is similar to mill recirculation but can
include partial sweep air discharge. The level of NOx reduction would be less than that provided
by indirect firing and low NOx burners.
4.2.5 Mill Air Recirculation
A method to reduce primary air usage involves returning a portion of the coal mill sweep
air (30 to 50%) to the coal mill inlet. By returning sweep air, the volume of air used to convey
pulverized fuel to the burner pipe is reduced. The amount of the return air possible depends on
the mill grinding rate (i.e., percent of utilization), volatile content of fuel, moisture in the fuel,
grindability of the fuel, and the final conveying air temperature achieved. The reduction in
primary air allows the use of low NOx burner technology that further reduces NOx formation.
The use of mill air recirculation can achieve primary combustion air between 15 and 25
percent but is highly variable. Kilns operating with a hard burning mix do not typically achieve
high NOx reductions. Also, recirculation is not possible for fuels containing high free moisture
(i.e., fuels stored outdoors exposed to weather). The level of NOx reduction would be less than
that provided by indirect firing and low NOx burners.
4.2.6 Mid-Kiln Firing
Mid-kiln firing (MKF) is a potential NOx reduction technology that involves injecting
solid fuel into the calcining zone of a rotating long kiln using a specially designed feed injection
mechanism. The technology is applicable to conventional wet process and long dry kilns. The
fuel used is generally whole tires, although containerized waste fuels have also been used at
some plants. Fuel is injected near the mid-point of the kiln, once per kiln revolution, using a
system consisting of a “feed fork,” pivoting doors, and a drop tube extending through the kiln
wall.
47
Another form of mid-kiln firing has been used for certain preheater and
preheater/precalciner kiln systems. Whole tires are introduced into the riser duct using a
specially designed feed mechanism (drop chute with air lock). This creates an additional
secondary firing zone in which the solid fuel is burned in contact with the partially calcined
meal. Combustion is initiated in the riser duct (located midway between the calciner and rotary
kiln sections of the kiln system) and is completed within the rotary kiln section in a reducing
atmosphere away from the elevated temperatures of the main kiln burner. NOx formation is
inherently lower in this area, and NOx formation may be further reduced due to improvements in
fuel efficiency and the shifting of fuel burning requirements (e.g., less fuel must be burned at the
main kiln burner).
MKF is a staged combustion technology that allows part of the fuel to be burned at a
material calcination temperature of 600# to 900#C, which is much lower than the clinker burning
temperature of 1200# to 1480#C, thus reducing the potential for thermal NOx formation. By
adding fuel in the main flame at mid-kiln, MKF changes both the flame temperature and flame
length. These changes may reduce thermal NOx formation by burning part of the fuel at a lower
temperature and by creating reducing conditions at the solid waste injection point that may
destroy some of the NOx formed upstream in the kiln burning zone. MKF may also produce
additional fuel NOx depending upon the nitrogen content of the fuel. The additional fuel NOx,
however, is typically insignificant relative to thermal NOx formation. The discontinuous fuel
feed from MKF can also result in increased CO. To control CO emissions, the kiln may require
an increase in combustion air, which can decrease production capacity.
Test data showing NOx reduction levels for long dry and wet kilns were compiled for the
EPA in the report “NOx Control Technology for the Cement Industry” (EC/R Inc., 2000). Tests
conducted on three wet process kilns using MKF technology showed an average reduction in
NOx emissions of 40 percent, with a range from 28 to 59 percent.
MKF in the form of riser duct firing is applicable at CCC. The general concerns in
applying this combustion practice include community acceptance of tire burning; reduced sulfur
retention in the clinker, and potential product quality impacts. These issues have been
successfully managed at many cement plants such that they pose no significant adverse impacts
on current or future operations. Because an adequate supply of tires is uncertain in the area,
MKF is not planned at the current time.
48
4.2.7 Staged Combustion (SC)/Calciner Modification
SC is a combustion technology that is currently used with preheater/precalciner kilns to
reduce NOx generation by all major kiln vendors. Multi-staged combustion (MSC) which
includes the use of two or more low NOx burning zones, is supplied by two or more vendors as
NOx control technology on modern preheater/precalciner cement kilns. MSC is also considered
a common technology as it has been used for many years throughout the cement industry.
Another form of SC combines high temperature combustion and reburning without staging air or
fuel in the calciner. This technology creates one high temperature reducing zone by injection of
all of the calciner fuel into one reducing zone at the bottom of the calciner. The reducing zone is
followed immediately by an oxidizing zone where all the tertiary air is introduced into the
calciner. Splitting of feed or staged feed is used to control the temperatures and help in creating
and controlling the high temperature reducing zone. However, this form of staged combustion
does not utilize splitting of tertiary air to stage air flow.
Staged combustion takes place in and around the precalciner and is accomplished in
several ways depending on the system design. The purpose of staged combustion is to burn fuel
in two stages, i.e., primary and secondary. Staged air combustion suppresses the formation of
NOx by operating under fuel-rich, reducing conditions (less than stoichiometric oxygen) in the
flame or primary zone where most of the NOx is potentially formed. This zone is followed by
oxygen-rich conditions in a downstream, secondary zone where CO is oxidized at a lower
temperature with minimal NOx formation.
To delineate the NOx control mechanisms of SC, the combustion chemistry of NOx
formation by virtue of fuel nitrogen should be examined. Fuels introduced to the primary
combustion zone undergo a pyrolysis that liberates nitrogen originally bound in the fuel.
Nitrogen-bearing products that are gaseous will again pyrolize to form HCN and NHi radicals.
With NO and oxygen radicals (OX) already present in the gas stream, the NHi will react as such:
NHi + OX " NO + …
NHi + NO " N2 + …
Because the primary stage of SC is a high-temperature (1150# to 1200#C) reducing environment
where CO is prevalent and oxygen radicals are relatively scarce, NHi radicals can scavenge
49
oxygen from NO as shown in the second equation. This phenomenon is the basis for successful
NOx reduction in SC kilns.
Research and actual emission monitoring on preheater/precalciner cement kilns have
shown that SC technology applied to the area of the precalciner works to effectively lower NOx
emissions per unit clinker produced. Although potential disadvantages to SC may exist,
experience has shown that when included as part of the kiln system design, it will produce a
reduction in NOx emissions with minimal process problems. The SC control option is capable of
reducing NOx emissions by 10 to 50 percent, depending on the site-specific kiln operating
parameters (i.e., kiln feed burnability).
SC can have limitations under specific conditions which affect the potential NOx control
effectiveness. In kiln systems employing a mix that has a high sulfur to alkali molar ratio, the
volatility of sulfur is increased due to the strong reducing conditions in SC and the relatively low
O2 content in the system. This causes severe preheater plugging. The required conditions for
optimum SC operation (low excess oxygen), conflict with preventing sulfur deposition. In order
to operate the preheater a higher oxygen content at the calciner exit can be required. These
problems have been documented in Europe and U.S. facilities. A high S/alkali molar feed ratio
prevents the achievement of maximum NOx reduction using SC.
4.3 Elimination of Technically Infeasible NOx Control Options
The second step in the BACT analysis for NOx is to eliminate any technically infeasible
or undemonstrated control technologies. Each control technology was considered and those that
were infeasible based on physical, chemical, and engineering principles or undemonstrated in the
Portland cement industry were eliminated.
Indirect firing, a low-NOx main kiln burner, a SC calciner, and SNCR will be used.
These are technically feasible options for NOx control. The feasibility of the other NOx control
options are discussed below.
4.3.1 SCR
Because of the serious operational problems concerning catalyst plugging and
deactivation and the fact that no cement kilns anywhere in the world that have applied SCR in a
dirty side application have been successful in operating SCR on a sustained long-term basis, the
50
application of SCR to dirty side kiln gases is not considered technically feasible. The applicable
of SCR to clean side kiln gases with heat recovery is also not considered technically feasible due
to heat exchanger pluggage problems as discussed in Section 4.2.2. Although clean side
applications without heat recovery have not been installed in cement kilns in either the US or
Europe, SCR is theoretically applicable for this case and will be evaluated further in this report.
4.3.2 Semi-Direct Firing and Low NOx Burners
Semi-direct firing would not reduce NOx emissions below the base-case design.
Therefore it is not applicable and will not be evaluated further.
4.3.3 Mill Air Recirculation
This technology applies to coal/coke direct-fired kilns not currently using a fuel-rich
primary combustion technology. Because the CCC kiln will be indirect-fired, this technology is
not applicable.
4.3.4 Mid-Kiln (Riser Duct) Firing
The CCC kiln system will be designed to employ this technology as an option, however,
MKF is not expected to reduce emissions below the levels achieved by other selected NOx
control technologies. Therefore, no further evaluation of MKF will be conducted.
4.3.5 Staged Combustion (SC)/Calciner Modification
SC will be employed on the CCC kiln. No further evaluation is needed for the new kiln.
4.4 Ranking of Technically Feasible NOx Control Options
The third step in the BACT analysis is to rank remaining NOx control technologies by
control effectiveness. The remaining NOx control technologies evaluated are SNCR, SCR (clean
side) and a combination of indirect firing, low-NOx main kiln burner, and SC. Table 9 shows the
ranking and the estimated control efficiency.
51
TABLE 9. RANKING OF TECHNICALLY FEASIBLE CONTROL OPTIONS
PREHEATER/PRECALCINER KILN SYSTEMS – NOX
Control Technology Control Efficiency Notes
SCR (clean side) 60% 1.16 lb/ton clinker
SNCR 30% 1.95 lb/ton clinker
Indirect firing, low-NOx main burner, SC
NA Base Case = 2.8 lb/ton clinker
4.5 Evaluation of Technically Feasible NOx Control Options
The fourth step in a BACT analysis for NOx is to complete the analysis of the applicable
control technologies and to document the results. The feasible control technologies are evaluated
on the basis of economic, energy, and environmental considerations.
CCC is proposing to employ indirect firing, low NOx burners, SC, and SNCR. Therefore,
the evaluation was limited to the incremental effectiveness of installing SCR rather than SNCR.
Table 10 presents a summary of the impact of the technically feasible control options. The
detailed cost calculations are presented in Appendix C.
TABLE 10. SUMMARY OF IMPACT ANALYSIS FOR NOx
Impacts
Method
%
removal
NOx,
removed
tons/yr
Capital
Costs,
MM$
Annualized
Cost MM$
Cost
Effectiveness
$/ton NOx Environmental Product Energy
SNCR 30 931 2.71 2.04 2,191 Yes No No
SCR* 60 1,840 4.60 29.7 16,139 Yes No Yes
*Clean side without heat recovery.
4.6 Review of Recent Permit Limits
Table 11 summarizes the NOx BACT determinations made for cement kilns since 2000.
52
TABLE 11. SUMMARY OF RECENT NOX PERMIT DETERMINATIONS FOR CEMENT KILNS (2000-PRESENT)
Company Location
Kiln
Type Permit Date Technology Applied Removal
In
OperationLimit Rejected Technology
and $/Ton (%) (Yes/No) (lb/ton clinker) and $/Ton
Drake Cement Drake, AZ PC (new) Draft Lo NOx, MSC, SNCR NA No 2.3 first 6 months, 1.95 thereafter2 (1.2 beyond
BACT)
Lafarge – Kiln 1 Harleyville, SC PC (mod) 8/18/06 Lo NOx, MSC, SNCR 29%
(SNCR) Yes
2.652 (3.5 for 1st year)
Lafarge – Kiln 2 Harleyville, SC PC (new) 8/18/06 Lo NOx, MSC, SNCR 29%
(SNCR) No
1.952 (3.0 for 1st year)
Suwannee American Cement - Kiln 2
Branford, FL PC (new) 2/15/06 Lo NOx, MSC, SNCR 20%
(SNCR) No
1.952 2.4 for first 6 months
SCR - $21,600
Sumter Cement Sumter Co., FL PC (new) 2/6/06 Lo NOx, MSC, SNCR No 1.952
(3.0 for 1st year) SCR – 10,200
American Cement Sumter Co., FL PC (new) 2/06 Lo-NOx, MSC, SNCR No 1.952
(3.0 for 1st year)
Florida Rock Industries – Kiln 2 Newberry, FL PC(new) 7/22/05 Lo NOx, MSC, SNCR No 1.952
2.4 for first 6 months SCR
Rinker/Florida Crushed Stone - Kiln 2
Brooksville, FL PC(new) 7/6/05 Lo NOx, MSC, SNCR 28%
(SNCR) No
1.952 2.4 for first 6 months
SCR - $16,712
Holcim Lee Island, MO PC (new) 06/08/04 Lo NOx, MSC 1 30 No 3.00 (year 1 & 2) 2.80
(after year 2) SCR
GCC Rio Grande Pueblo, CO PC (new) 3/5/04 Low NOx, MSC NA Yes 2.32
Lehigh Portland Cement Mason City, IA PC (mod) 12/11/03 Lo NOx, SNCR NA Yes 2.85
GCC Dacotah Rapid City, SD PC (mod) 04/10/03 Lo NOx, MSC NA Yes 5.52 (not BACT) FGR, MKF, Lo NOx,
TDF, SCR, SNCR
Holcim Theodore, AL PC (mod) 02/04/03 Limit not based on BACT NA Yes 3.33 (not BACT)
Holcim (Devil's Slide) Morgan, UT PC (mod) 11/20/02 Lo NOx, MSC NA Yes 4.55 (not BACT) FGR, Lo NOx, staged
combustion, SNCR, SCR
Suwannee American Cement - Kiln 1
Branford, FL PC (mod) 4/01 MSC, SNCR NA Yes 2.9 – 24 h
2.42
Monarch Cement Humboldt, KS 2PC
(mod) 01/27/00 Good combustion practices NA Yes 4.21
FGR, Lo NOx, staged combustion, SNCR, SCR
Holcim Holly Hill, SC PC (new) 12/22/99 Lo NOx, MSC NA Yes 4.33
Lafarge Davenport, IA PC (mod) 11/09/99 Yes 4.00
North Texas Cement Whitewright, TX PC (new) 03/04/99 Lo NOx, MSC NA No 3.87 SNCR
Continental Cement Hannibal, MO PC (new) 7/24/07 Lo NOx, MSC NA No(?) Not specified (not
BACT)
Notes: 1. SNCR required as Innovative Control Technology after year 2 – 1.8 lb/ton summer season limit. 2. Rolling 30-day average.
53
4.7 Selection of BACT for NOx
CCC proposes as BACT the use of indirect firing, low-NOx burners, SC, and SNCR. Use
of SCR can be rejected on a cost basis, which exceeds $16,000 per ton of NOx removed. It
should be noted that EPA also rejected SCR as the basis for its recent NOx NSPS proposal
stating:
“Considering these potential technical operating difficulties with SCR in this industry, somewhat high cost effectiveness, the uncertainty of the costs estimates, and adverse non-air and energy implications, EPA is not proposing SCR as BDT for Portland cement kilns.” The requested emission limit is 1.95 lb/ton of clinker, 30-day rolling average, as
measured by CEM. This averaging time is appropriate to account for the variability in NOx
emissions from cement kilns and is consistent with EPA’s NOx State Implementation Plan (SIP)
call guidance for cement kilns. This emission limit is equivalent to the lowest emission level
currently established as BACT in the U.S. for cement kilns.
For the new diesel emergency generator set, CCC proposes to install a unit that complies
with the NOx emission standards given in NSPS Subpart IIII.
54
SECTION 5
BACT ANALYSIS FOR CO AND VOC
The only sources of CO and VOC associated with the project are the
preheater/precalciner kiln system and the new emergency diesel generator set.
5.1 CO and VOC Formation Processes
CO and VOC emissions from cement kiln pyroprocessing systems generally occur from
two separate and distinct processes in the system: 1) products of incomplete combustion of fuel
and 2) decomposition of organic material in the kiln feed. Each CO and VOC formation process
occurs under uniquely different conditions and is defined by the process technology and feed
materials.
5.1.1 CO and VOC from Kiln Feed
For the purpose of this discussion, the pyroprocessing technology is confined to the
preheater/precalciner design. In this design, raw meal is introduced to the exhaust gas stream
from the preheater and preheated through a series of cyclones (stages) in a countercurrent flow
design. In the process of heating, organic materials naturally occurring in the feed (kerogen and
bitumin) are progressively heated and they begin to thermally degrade. The heating at relatively
low temperature and at a low oxygen atmosphere results in complex organic molecules to be
cracked, recombined, and re-ordered until the species are reduced to short-chain VOC’s, CO,
and/or carbon dioxide (CO2). During the pyrolytic process, a significant fraction of the organic
carbon is fully oxidized to CO2.
Depending on the nature of the organics present in the feed materials, the location of the
thermal decomposition in the preheater varies along with the degree of complete oxidation. The
presence of light hydrocarbon species in the meal typically results in VOC and condensible
hydrocarbons in the kiln preheater gases, but the CO concentrations are low. Conversely,
55
complex hydrocarbons generally produce CO during decomposition, but low concentrations of
VOC.
Depending on the geological deposit of the feed materials, the composition and
concentration of organic materials in the kiln feed (meal) may vary significantly. The spatial
distribution within the deposit is both lateral and vertical, and cannot be mitigated by selective
mining or material substitution. The level of contaminants in the kiln feed is unique to each site
and results in site-specific CO and VOC emission rates.
The rate of conversion of meal carbon to CO2 is influenced by the temperature profile of
the preheater, the organic content of the kiln feed, and the composition of the organics in the kiln
feed. Recent studies do not indicate that the oxygen content of the flue gases influences the CO
emission rate. Papers published in Zement-Kalk-Gips also support the same conclusion. The
temperature of the preheater stages is defined by the kiln and mix designs (C3S, silica, etc.) and
cannot be modified sufficiently to complete oxidation of CO and VOC in the preheater.
5.1.2 CO and VOC from Incomplete Combustion
CO and VOC may also be produced as a product of incomplete combustion of fuel in the
precalciner vessel. Modern precalciners burn fuel in suspension with meal. The precalciner
vessel is designed to decarbonize (or calcine) the raw feed simultaneously with the combustion
of fuel in suspension. This design allows use of liquid, gaseous, and solid fuels over a range of
heat values and qualities (ash, moisture, etc.). Because of the continuous generation of thermal
energy (combustion) and consumption of thermal energy due to the decarbonization, the
temperatures are stabilized and the thermal variation is minimized. This process results in
reduced thermal NOx and promotes de-NOx of kiln gases entering the precalciner. With this
design, however, it is impossible to eliminate all CO that is normally associated with fuel
combustion in a conventional combustion device such as a boiler. Typical CO concentrations
after the precalciner and lowest preheater cyclone exit are between 250 and 1500 ppm and VOC
is low (i.e., 5 to 10 ppm).
The MSC design for NOx control generates a reducing atmosphere zone to enhance NOx
reduction. CO generation will also be increased in this zone. The design functions in a similar
manner to SC in boilers. Theoretically, CO is not directly involved in the chemical reactions to
56
reduce NOx. An oxygen deficiency zone is needed to create more NHi radicals to reduce NOx.
CO is the result of this reducing atmosphere.
5.2 Identification of CO/VOC Control Options
This section reviews the available CO/VOC control technologies that were considered for
the CCC Cement Plant.
5.2.1 Thermal Oxidation
Thermal oxidation is performed with devices that use a flame, sometimes combined
within an enclosed chamber, to convert CO and VOC to carbon dioxide (CO2). Thermal
oxidizers operate most effectively at temperatures between 1,200º to 2,000ºF, with a residence
time of 0.2 to 2.0 seconds. By raising the temperature, the residence time for complete
combustion can be reduced and vice versa. However, temperature is the more important process
variable.
Two types of thermal oxidizers are commonly used in industrial plants. The most
common thermal oxidizer is an afterburner. Afterburners can be either direct-fired with no heat
recovery, or with recuperative heat recovery. A second type of thermal oxidizer is a regenerative
thermal oxidizer (RTO). A regenerative thermal oxidizer operates in an enclosed chamber and
recovers up to 85 percent of the heat energy input. For the purposes of this analysis, a
regenerative thermal oxidizer was evaluated.
There are no cement plants currently operating using direct-fired afterburner or a
recuperative type afterburner. Afterburners are not desirable for cement kiln applications
because of limited residence time resulting in poor CO combustion efficiency, an increase in
NOx emissions, and significant additional fuel burning requirements. There are, however, two
plants which have employed an RTO. These are at TXI, Midlothian, Texas and Holcim, Inc.,
Dundee, Michigan. The TXI operation is a precalciner and the Dundee operation involves two
wet process kilns.
TXI, Midlothian, Texas
The system was installed during a plant expansion and was used to reduce CO and VOC
emissions below a de minimus increase and therefore avoid PSD review. No BACT analysis
was conducted and the Texas Commission on Environmental Quality (TCEQ) does not consider
57
the use of an RTO as BACT under State or Federal requirements. The unit has experienced
significant operational difficulties including higher than anticipated heat exchanger fouling and
pressure drop. This has increased afterburner fuel costs and decreased kiln capacity. It is also
important that the plant operates a fabric filter for primary particulate control and a sulfur
dioxide (SO2) scrubber for SO2 removal prior to the RTO.
Holcim, Dundee, Michigan
Historically the Dundee kilns have emitted condensable hydrocarbons, which formed
visible plumes and an objectionable odor. In an effort to control these problems, the plant
installed an RTO. The design was modified from the TXI configuration to include an open type
(checker) heat exchanger that was expected to have less potential for fouling. The unit has been
effective in control of visible emissions (VE) and odor but has experienced poor heat recovery,
high fuel costs, and significant maintenance problems. In some cases under high hydrocarbon
loads, the unit has experienced over temperature due to uncontrolled self-fueling. The units were
installed to replace existing carbon injection systems for hydrocarbons and did not go through
PSD or a BACT analysis. As a result of the failure of the mechanical system, they have been
decommissioned.
5.2.2 Catalytic Oxidation
Catalytic oxidation is performed with devices that use a flame within an enclosed
chamber to convert CO and VOC to CO2. Catalytic oxidizers operate effectively at lower
temperatures than thermal oxidizers (between 600º to 900ºF) because of the use of catalysts to
drive the reaction. The catalysts (typically platinum based) are placed on an alumina pellet or
honeycomb support and the exhaust gases pass over or through the catalyst within the enclosed
chamber. The temperature in the oxidizer is maintained either by the exothermic reaction or with
supplemental fuel firing.
The presence of particulate matter in an exhaust gas stream inhibits the operation of the
unit and creates problems with catalyst poisoning.
Advantages of a catalytic oxidizer over a thermal oxidizer include:
1. Lower fuel requirements 2. Lower operating temperatures 3. Little or no insulation required 4. Reduced fire hazards 5. Reduced flashback problems.
58
Disadvantages of this system include: 1. Initial capital cost is higher 2. Catalyst poisoning (fouling) is possible 3. PM10 must be removed first 4. Disposal of spent catalyst, which may be hazardous. No catalytic oxidation units are currently being used on any cement kilns in the U.S. or
abroad.
5.2.3 Excess Air
Excess air introduced into the combustion zones tends to reduce the amount of CO and
VOC formed by oxidizing them to CO2. This reaction is limited to areas in the combustion zone
where the CO concentration is greater than 50 ppm. The advantages of the use of excess air are
the ease of implementing the technology and the potential for lower SO2 emissions. The major
disadvantage is that increasing excess air in the combustion zone increases NOx formation and
can adversely affect clinker quality.
5.2.4 Good Combustion Practices
Because CO and VOC formation can result from incomplete combustion of fuels and the
oxidation of uncombusted carbon in those fuels, the better the combustion practices, the lower
the CO and VOC formation. Good combustion practices require the following elements:
1. Proper mixing
2. High temperature.
Good combustion practice is the inherently lowest emitting method of controlling CO and VOC
emissions from combustion sources.
5.3 Elimination of Technically Infeasible CO/VOC Control Options
The second step in the BACT analysis for CO and VOC is to eliminate any technically
infeasible or undemonstrated control technologies. Each control technology is considered and
those that are infeasible based on physical, chemical, and engineering principles or are
undemonstrated in the Portland cement industry were eliminated.
59
5.3.1 Thermal Oxidation
Because PM present in the uncleaned flue gases would routinely plug and foul thermal
oxidation equipment, a thermal oxidation unit would have to be placed downstream of the
baghouse to be technically feasible. Placing the oxidizer at this location would require
supplemental fuel firing to maintain the optimal operating temperature range of 1,200º to
2,000ºF. The additional fuel firing would result in an undesirable increase in NOx emissions,
thus negating the NOx control technology employed upstream. Although it appears to be
technically feasible to install a regenerative thermal oxidization unit downstream of the
preheater/precalciner system baghouse from a theoretical standpoint, in practice these systems
have failed to perform successfully. Therefore, the use of thermal oxidation (RTO) is considered
to be infeasible from a practical standpoint and will not be considered further in this BACT
analysis.
5.3.2 Catalytic Oxidation
PM present in Portland cement kiln flue gases poisons the catalysts used in catalytic
oxidation units and would routinely plug and foul catalytic oxidation equipment. The presence
of PM in the catalytic oxidation unit will result in poor CO/CO2 conversion and an increase in
operational interruptions. Therefore, the use of a catalytic oxidation unit is an infeasible option
and is not considered further in this BACT analysis.
In addition to the technical issues, two environmental issues result from the catalytic
oxidation control option. Spent catalyst is often classified as a “hazardous waste.” Disposal of a
hazardous waste represents a significant environmental concern.
5.3.3 Excess Air
As outlined in the NOx BACT determination (Section 4), excess air results in an
alteration of the flame characteristics in the kiln and precalciner. This change in the flame will
have a detrimental affect on the clinker quality. Therefore, the use of excess air is not a
technically feasible control alternative and will not be considered further in this BACT analysis.
In addition to the technical argument, the effectiveness of this control method is limited
by the carbonation process equilibrium and the CO and VOC concentration. Adding excess air
to either the kiln or precalciner combustion zones would result in an increase in NOx and PM10
60
emissions from the system. Creating more NOx and PM10 to reduce CO and VOC emissions
does not represent a viable environmental benefit.
5.3.4 Good Combustion Practices
This is a technically feasible option and will be further considered in the BACT analysis.
5.4 Ranking of Technically Feasible CO/VOC Control Options
The third step in the BACT analysis for CO/VOC is to rank remaining control
technologies by control effectiveness. The only control technology option that is considered
technically feasible is good combustion practices.
5.5 Evaluation of Technically Feasible CO/VOC Control Options
The fourth step in a BACT analysis for CO and VOC is to complete the analysis of the
feasible control technologies and document the results. The feasible control technologies are
evaluated on the basis of economic, environmental, and energy considerations. The only
technically and practically feasible option appears to be good combustion practices. There are
no significant negative environmental, product, or energy impacts associated with this
technology.
5.6 Review of Kiln Permit Limits
A review of plants identified in the BACT/LAER Clearinghouse indicated that the
documentation is incomplete and that several facilities have been constructed under the Federal
PSD program or State-only BACT requirements. Considering the incompleteness of the data, a
State-by-State review of recently permitted precalciner facilities was conducted. Tables 12 and
13 summarize recent permit determinations for CO and VOC.
The range of CO emissions for good combustion practice is site-specific and is between
1.56 and 10.6 lb/ton of clinker. The range of VOC emissions for good combustion practices is
also site-specific and ranges between 0.12 and 5.31 lb/ton of clinker.
The one plant identified as using post-control technology is TXI Operations, Midlothian,
Texas, which listed an RTO for CO and VOC abatement. Post-control was voluntarily
implemented to avoid PSD review during plant expansion. The uncontrolled CO emission rate
61
TABLE 12. SUMMARY OF RECENT CO PERMIT DETERMINATIONS FOR CEMENT KILNS (2000-PRESENT)
Company Location Kiln Type Permit Date Technology Applied Removal
In
OperationLimit Rejected Technology
and $/Ton (%) (Yes/No) (lb/ton clinker) and $/Ton
Lafarge – Kiln 1 Harleyville, SC PC (mod) 8/18/06 GC NA Yes 10.51
Lafarge – Kiln 2 Harleyville, SC PC (new) 8/18/06 GC NA No 6.81
Suwannee American Cement - Kiln 2
Branford, FL PC (new) 2/15/06 GC No 2.901 RTO
Sumter Cement Sumter Co., FL PC (new) 2/6/06 GC No
2.91 RTO
American Cement Sumter Co., FL PC (new) 2/06 GC No 2.91 RTO
Florida Rock Industries – Kiln 2 Newberry, FL PC (new) 7/22/05 GC No 3.6 – 24 h RTO
Rinker/Florida Crushed Stone – Kiln 2
Brooksville, FL PC (new) 7/6/05 GC No 3.6 – 24 h RTO
Holcim Lee Island, MO PC (new) 06/08/04 GC NA No 6.01
GCC Rio Grande Pueblo, CO PC (new) 3/5/04 GC NA Yes 2.11
Lehigh Portland Cement Mason City, IA PC (mod) 12/11/03 GC NA Yes 3.7 – 3 h RTO - $5900
Roanoke Cement Co. Troutville, VA PC (mod) 6/12/03 GC NA Yes 3.0 – 24 h RTO
GCC Dacotah Rapid City, SD PC (mod) 04/10/03 GC NA Yes 4.88
Holcim Theodore, AL PC (mod) 02/04/03 GC NA Yes 10.6 – annual
Holcim (Devil's Slide) Morgan, UT PC (mod) 11/20/02 GC NA Yes 4.56
Suwannee American Cement - Kiln 1
Branford, FL PC (new) 06/01/00 GC NA Yes 3.60 – 3 h RTO
Monarch Cement Humboldt, KS 2PC (mod) 01/27/00 GC NA Yes 3.7 – annual RTO - $2713
Holcim Holly Hill, SC PC (new) 12/22/99 GC NA Yes 6.8
Lafarge Davenport, IA PC (mod) 11/09/99 GC Yes 1.64
North Texas Cement Whitewright, TX PC (new) 03/04/99 GC NA No 2.91 RTO
TXI Midlothian, TX PC (mod) 11/98 RTO (Based on PSD
avoidance, not BACT) 75 Yes 1.56
Titan America Medley, FL PC (new) 12/02/05 GC NA Yes 2.0 RTO
Continental Cement Hannibal, MO PC (new) 7/24/07 GC NA No(?) 3.6 RTO > $5600
Notes: GC – Good combustion RTO – Regenerative Thermal Oxidizer 130-day rolling average
62
TABLE 13. SUMMARY OF RECENT VOC PERMIT DETERMINATIONS FOR CEMENT KILNS (2000-PRESENT)
Company Location Kiln Type Permit Date Technology Applied Removal
In
OperationLimit Rejected Technology
and $/Ton (%) (Yes/No) (lb/ton clinker) and $/Ton
Lafarge – Kiln 1 Harleyville, SC PC (mod) 8/18/06 GC Yes 0.55 – 3 h
Lafarge – Kiln 2 Harleyville, SC PC (new) 8/18/06 GC No 0.55 – 3 h
Suwannee American Cement - Kiln 2
Branford, FL PC (new) 2/15/06 GC No 0.121 RTO
Sumter Cement Sumter Co., FL PC (new) 2/6/06 GC No 0.1151 RTO
American Cement Sumter Co., FL PC (new) 2/06 GC No 0.121 RTO
Florida Rock Industries – Kiln 2 Newberry, FL PC (new) 7/22/05 GC No 0.121 RTO
Rinker/Florida Crushed Stone - Kiln 2
Brooksville, FL PC (new) 7/6/05 GC No 0.121
Holcim Lee Island, MO PC (new) 06/08/04 GC No 0.332
GCC Rio Grande Pueblo, CO PC (new) 3/5/04 GC Yes No limit
Lehigh Portland Cement Mason City, IA PC (mod) 12/11/03 GC Yes No limit
GCC Dacotah Rapid City, SD PC (mod) 04/10/03 GC Yes No limit
Holcim Theodore, AL PC (mod) 02/04/03 GC Yes 2.35 (not BACT)
Holcim (Devil's Slide) Morgan, UT PC (mod) 11/20/02 GC Yes 0.33
Suwannee American Cement - Kiln 1
Branford, FL PC (new) 06/01/00 GC Yes 0.191
Monarch Cement Humboldt, KS 2PC (mod) 01/27/00 GC Yes
Holcim Holly Hill, SC PC (new) 12/22/99 GC Yes 0.27 – 3 h
Lafarge Davenport, IA PC (mod) 11/09/99 GC Yes
North Texas Cement Whitewright, TX PC (new) 03/04/99 GC No 5.31
TXI Midlothian, TX PC (mod) 11/98 RTO (Based on PSD
avoidance, not BACT) 85 Yes 0.34
Continental Cement Hannibal, MO PC (new) 7/24/07 GC No(?) 0.12 RTO >$58,000
Notes: 130-day block average. 230-day rolling average.
63
was estimated to be 6.8 lb/ton. No estimate of the uncontrolled VOC emission rate is available. This
unit has experienced significant technical difficulties in maintaining continuous operation of the RTO.
An RTO was installed at Holcim Dundee, Michigan for odor and visible emission (con-
(condensable hydrocarbon) control but has been discontinued due to high maintenance and system
failure. This system was installed on two wet cement kilns.
5.7 Selection of BACT for CO and VOC
The addition of an RTO to reduce CO and VOC can be rejected on the basis of practical
applicability. CCC proposes as BACT the use of good combustion practices for these pollutants. The
requested BACT emission limits are: CO – 2.80 lb/ton clinker and VOC – 0.16 lb/ton clinker.
Compliance with both emission limits will be determined by CEMS on a 30-day rolling average basis.
For the new diesel emergency generator set, CCC proposes to install a unit that complies with
the emission standards for CO and hydrocarbons (HC) given in NSPS Subpart IIII.
64
SECTION 6
SUMMARY OF PROPOSED BACT EMISSION LIMITS
The proposed BACT controls and limits are summarized in Table 14.
TABLE 14. PROPOSED BACT LIMITS
Pollutant Operation Emission Limit VE, % Control Kiln/raw mill/clinker cooler/coal mill
0.14 lb/ton dry preheater feed* 10 Baghouse Particulate Matter
Finish mills and other process sources
0.01 gr/scf 10 Baghouse
Sulfur Dioxide (SO2) Kiln/raw mill (main stack)
1.33 lb/ton clinker, 30-day rolling average and 1.80 lb/ton clinker, 24-h rolling average
NA
Lime injection
Nitrogen Oxides (NOx)
Kiln/raw mill (main stack)
1.95 lb/ton clinker, 30-day rolling average
NA
Low-NOx burner, indirect firing, SC, SNCR
Carbon Monoxide (CO)
Kiln/raw mill (main stack)
2.80 lb/ton clinker, 30-day rolling average
NA
Good combustion
Volatile Organic Compounds
Kiln/raw mill (main stack)
0.16 lb/ton clinker, 30-day rolling average
NA Good combustion
*Filterable PM only – see discussion in Regulatory Analysis Report, Section 3.
APPENDIX A
SO2 EMISSIONS DIAGRAMS
APPENDIX B
COST CALCULATIONS FOR SO2
10/20/2008
Parameter Inherent Control Dry Lime Wet Lime Wet Lime CT D-SOx Cyclone Lime Hydrator Wet Scrubber Wet Scrubber Units
Base Case (1) Injection (2) Hybrid (3) & Reheat (3a) (4) (5) No Reheat (6) With Reheat (7)
SO2 Emis Factor, Mill On 2.23 1.12 1.20 1.02 1.56 1.25 0.22 0.22 lb/ton clinker
SO2 Emis Factor, Mill Off 4.22 2.11 1.80 1.80 2.95 2.36 0.42 0.42 lb/ton clinker
Average SO2 Emis Factor 2.63 1.32 1.32 1.18 1.84 1.47 0.26 0.26 lb/ton clinker
Meets 1.33 lb/ton Limit? No Yes Yes Yes No No Yes Yes
SO2 Base Case 2880.4 2880.4 2880.4 2880.4 2880.4 2880.4 2880.4 2880.4 tons/yr
SO2 Removed 0.0 1440.2 1435.0 1591.4 864.1 1267.4 2592.4 2592.4 tons/yr
SO2 Final Emissions 2880.4 1440.2 1445.4 1289.0 2016.3 1613.0 288.0 288.0 tons/yr
Average Control Efficiency 0% 50% 50% 55% 30% 44% 90% 90% %
Capital Cost N/A $1,833,600 $2,979,600 $5,730,000 $1,100,000 $4,500,000 $35,755,631 $40,255,631 $
Direct Operating Cost N/A $3,512,259 $1,509,465 $9,426,082 $602,209 $297,710 $3,591,139 $11,265,290 $/yr
Indirect Operating Cost N/A $290,729 $455,746 $851,789 $185,094 $674,676 $5,202,019 $5,849,994 $/yr
Total Annualized Cost N/A $3,802,988 $1,965,211 $10,277,871 $787,303 $972,386 $8,793,157 $17,115,284 $/yr
Control Cost Effectiveness N/A $2,641 $1,370 $6,458 $911 $767 $3,392 $6,602 $/ton SO2
Cost, Product Basis N/A $1.74 $0.90 $4.69 $0.36 $0.44 $4.02 $7.82 $/ton clinker
Clinker Production = 2,190,000 ton/yr
Notes: 1 Base case SO2 emissions without add-on controls
2 Dry lime injection used in preheater tower. Assume 4:1 molar ratio. Equipment cost from Envirocare.
3 Wet lime injection used in conditioning tower when the raw mill is off and in the raw mill when it is on. Equipment cost from Envirocare.
3a Wet lime injection used in conditioning tower (continuous) with gas reheat when the raw mill is on.
4 Costs for D-Sox system from FLS.
5 Costs for Lime Hydrator system from FLS.
6 Cost for wet scrubber with no reheating of exhaust gases (EPA cost estimate scaled up for CCC production).
7 Cost for wet scrubber with stack gas reheat if needed for ambient compliance.
8 Indirect operating costs include 7% interest & 15-year equipment life assumptions.
Control Technology
CASTLE HAYNE PLANT
SUMMARY OF SO2 CONTROL OPTIONS
CCC-SO2-BACT OPTIONS 1 OF 38
10/20/2008
PRODUCTION 5,443 MT/D 6,000 ST/D
250 ST/HR
365.0 Days/yr 365.0 Days/yr
1,986,755 Tonnes/yr 2,190,000 ST/YR
PLANT CAPACITY 100.0 %
SO2 FACTOR MILL-ON 1.01 Kg/Tonne 2.23 LB/TON
SO2 FACTOR MILL-OFF 1.91 Kg/Tonne 4.22 LB/TON
AVERAGE SO2 1.19 Kg/Tonne 2.63 LB/TON
RAW MILL SO2 REMOVAL 50.0 % 50.0 %
ADD-ON CONTROL FACTOR 0 % 0 %
SO2 EMISSIONS UNCONTROLLED
RAW MILL-ON 1775.50 Tonnes/yr 1957.14 TON/YR
202.68 Kg/HR 446.83 LB/HR
RAW MILL-OFF 837.58 Tonnes/yr 923.27 TON/YR
478.07 Kg/HR 1053.96 LB/HR
ANNUAL SO2 2613.08 Tonnes/yr 2880.40 TON/YR
OPERATING HOURS 8,760 HRS/YR At Potential Capacity
MILL-ON 7,008 HRS/YR 80%
MILL-OFF 1,752 HRS/YR 20%
100%
CASTLE HAYNE PLANT
KILN DESIGN DATA
CCC-SO2-BACT CURRENT 2 OF 38
10/20/2008
SO2 EMISSION ESTIMATES (lb/ton clinker)
Notes
Uncontrolled
so2 lb/ston 10.75 100% Uncontrolled SO2 before preheater
preheater exit 4.30 0.60 60% preheater capture
stack % 40 40% SO2 passing preheater
coal mill diversion 0.34 7.83% gases to coal mill
coal mill exit 0.25 0.25 25% coal mill circuit capture
so2 passing (mill off) 3.96
mill on 1.98 0.50 50% raw mill capture
50% SO2 passing mill
total so2, mill on 2.23 raw mill + coal mill
total so2, mill off 4.22 mill off + coal mill
stack % 24.47 24% of raw material SO2 goes to stack
30-day average 2.63 0.8 mill-on 80% raw mill in operation
0.2 mill-off 20% raw mill down
CONTROL OPTIONS
Dry lime injection 0.50 loss 50% Control
Location: Preheater
so2 mill down 2.11
so2 mill-in 1.12
30-day average 1.32
Wet lime injection (Hybrid) 0.50 loss 50% Control
so2 mill down 1.80 Location: Conditoning Tower
so2 mill-in 1.20 Location: Raw Mill
30-day average 1.32
Wet lime injection (CT only) 0.45 loss 55% Control
so2 mill down 1.80 Location: Conditoning Tower
so2 mill-in 1.02 Location: Conditoning Tower
30-day average 1.18
CCC-SO2-BACT Control Options 3 OF 38
10/20/2008
D-SOx cyclone 0.70 loss 30% Control
Location: Preheater
so2 mill down 2.95
so2 mill-in 1.56
30-day average 1.84
Lime hydrator 0.56 loss 44% Control
Location: Preheater
so2 mill down 2.36
so2 mill-in 1.25
30-day average 1.47
Wet scrubber 0.10 loss 90% Control
Location: Stack
so2 mill down 0.42
so2 mill-in 0.22
30-day average 0.26
CCC-SO2-BACT Control Options 4 OF 38
10/20/2008
OPERATION 8760 HR/YR
PRODUCTION 5,443 TONNES/DAY
226.80 TONNES/HR
SO2 UNCONTROLLED 2.15 KG/TONNE
PREHEATER EXIT 487.62 KG/HR
PREHEATER EXIT 1075.0 LB/HR 4.30 LB/TON
16.8 MOLES SO2
ANNUAL (AVE) 4708.50 T/YR
TEMP
SO2 REMOVED 50.0 % AVE 315.6 C
100 % LOW CONCENTRATION ADJUSTMENT
50.0 % ANNUAL
ANNUAL (AVE) 2354.25 T/YR
NET SO2 2354.25 T/YR 2.15 LB/TON
COAL MILL 184.34 T/YR 7.83% 0.17 LB/TON
NET SO2 2169.91 T/YR 1.98 LB/TON
495.41 LB/HR
CONTROLLED SO2 MILL-IN 224.7 KG/HR PRE-MILL UNCONTROLLED 2880.4 T/YR495.4 LB/HR PRE-MILL CONTROLLED 1440.2 T/YR
247.7 LB/HR POST-MILL REMOVED 1440.2 T/YR
868.0 T/YR POST-MILL
CONTROLLED SO2 MILL-OUT 495.4 LB/HR POST-MILL
434.0 T/YR POST-MILL
ANNUAL CONTROLLED SO2 1301.9 T/YR POST-MILL
COAL MILL 138.3 T/YR
TOTAL 1440.2 T/YR STACK
LIME INJECTION RATE 4 Ca(OH)2 / SO2 molar ratio
67 MOLES Ca(OH)2
4972 LB/HR Ca(OH)2
GYPSUM FORMATION 527 LB/HR
LIME REACTED 290 LB/HR
UNREACTED LIME -222 LB/HR
LOADING TO CYCLONE 304 LB/HR
CYCLONE REMOVAL 100 %
COLLECTED DUST 304.3 LB/HR
WASTE DUST 0 T/YR RETURNED TO PROCESS
LIME USED 21777 T/YR
946.8 LOADS/YR
TRUCKS 0.39 DAYS
DRY LIME INJECTION SYSTEM
(DRY SCRUBBING)
CCC-SO2-BACT DRYCa(OH)2 5 OF 38
10/20/2008
COST ESTIMATEDRY LIME INJECTION (DRY SCRUBBING)
PLANT SIZE CAPACITY 2,190,000 TON/YR
FACTOR COSTCAPITAL COSTS
DIRECT COSTDRY SYSTEM SILO/FILTER
BLOWERSDUCTWORKCYCLONE,BINSELECTRICALPIPINGMISCELLANEOUS EQUIPMENT
EQUIPMENT TOTAL 800,000OTHER INSTRUMENTS 0.10 80,000
TAXES 0.05 40,000FREIGHT 0.05 40,000
PEC TOTAL 960,000
INSTALLATION FOUNDATIONS 0.10 96,000ERECTION 0.20 192,000ELECTRICAL 0.05 48,000DUCTING 0.10 96,000INSULATION 0.05 48,000SITE PREPARATION 0.10 96,000TOTAL 576,000
DIRECT COSTS TOTAL 1,536,000
INDIRECT COSTS ENGINEERING/DESIGN 0.10 96,000CONST/FIELD EXPENSE 0.05 48,000CONTR.FEE 0.10 96,000START-UP 0.02 19,200PERFORMANCE TEST 0.01 9,600CONTINGENCIES 0.03 28,800TOTAL 297,600
RETROFIT PREMIUM (20% OF DIRECT & INDIRECT COST) 0.0
TOTAL CAPITAL COST 1,833,600
CCC-SO2-BACT COST-DRYLIME 6 OF 38
10/20/2008
COST ESTIMATEDRY LIME INJECTION (DRY SCRUBBING)
OPERATING COST(DIRECT)
UTILITIES BH FAN STATIC PRESSURE 8.00 IN H2OFAN VOLUME 1000 ACFMFAN POWER 15.00 BHPFK PUMP STATIC PRESSURE 40.00 IN H2OBLOWER VOLUME 500 ACFMFAN POWER 50.00 BHPCONNECTED LOAD 65.00 BHPPOWER 48.47 KWHrHOURS OPERATED 8760 HRSELECTRICAL COST 0.0550 $/KWHrANNUAL COST 23,353 $/YR
REAGENT REAGENT USAGE 21,777 TON/YRCOST 155.00 $/TONANNUAL COST 3,375,406 $/YR
WASTE DISPOSAL CKD 0 TON/YR8.00 $/TON
COST 0 $/YR
MAINTENANCE LABOR & MATERIALSREPLACEMENT PARTS 5% OF PEC 48,000 $/YRMATERIALS 21000 $/YR
MAINTENANCE LABOR HR/YR 1000
COST $/HR 21.00
COST $/YR 21,000
LABOR LABOR HR/YR 1000COST $/HR 19.00COST $/YR 19,000
SUPERVISOR LABOR HR/YR 150COST $/HR 30.00COST $/YR 4,500
FUEL SAVINGS $/YR $0
TOTAL DIRECT OPERATING COST $/YR $3,512,259
CCC-SO2-BACT COST-DRYLIME 7 OF 38
10/20/2008
COST ESTIMATEDRY LIME INJECTION (DRY SCRUBBING)
OPERATING COST(INDIRECT) OVERHEAD % 60.00$/YR 26,700
PROPERTY TAX % 0.42$/YR 7,701
INSURANCE % 1.00$/YR 18,336
ADMINISTRATION % 2.00$/YR 36,672
CAPITAL RECOVERY %-INTEREST 7.00LIFE-YEARS 15.00FACTOR 0.109795$/YR 201,319
TOTAL INDIRECT OPERATING COST $/YR 290,729
TOTAL ANNUALIZED COST $/YR 3,802,988
ANNUAL EMISSIONS REDUCTION TON/YR 1440.20% 50.00
COST BENEFIT $/TON 2,641
CCC-SO2-BACT COST-DRYLIME 8 OF 38
10/20/2008
OPERATION 8760 HR/YR
MILL ON 7008 HR/YR
MILL OFF 1752 HR/YR
PRODUCTION 5,443 TONNES/DAY
226.80 TONNES/HR
SO2 UNCONTROLLED 2.15 KG/TONNE
PREHEATER EXIT 487.62 KG/HR
PREHEATER EXIT 1075.0 LB/HR 4.30 LB/TON
COAL MILL GASES
CM INLET 82.9 LB/HR 0.33 LB/TON
SO2 REMOVED 25.0 %
20.71 LB/HR
SO2 COAL MILL EXHAUST 62.14 LB/HR 0.25 LB/TON
CONDITIONING TOWER (MILL-OFF)
CT INLET 992.1 LB/HR 3.97 LB/TON
15.50 MOLES SO2
SO2 REMOVED 61.0 % AVE
274.51 KG/HR
605.18 LB/HR
SO2 MILL MILL-OFF 386.92 LB/HR 1.55 LB/TON
LIME INJECTION RATE 2.5 Ca(OH)2 / SO2 molar ratio
38.8 MOLES Ca(OH)2
2868 LB/HR Ca(OH)2 2512 T/YR
GYPSUM FORMATION 1287 LB/HR
LIME REACTED 708 LB/HR
UNREACTED LIME -669 LB/HR
LOADING TO CYCLONE 618 LB/HR
CYCLONE REMOVAL 100 %
COLLECTED DUST 618.0 LB/HR
WASTE DUST 0 T/YR RETURNED TO PROCESS
WATER RATE 117.07 GPM
976.37 LB/MIN
443.21 L/MIN
58,582 LB/HR
12,306,494 GAL/YR
WET LIME INJECTION SYSTEM
LIME SLURRY TO CT (MILL-OFF) & RAW MILL (MILL-ON)
CCC-SO2-BACT WETCa(OH)2 (Hybrid) 9 OF 38
10/20/2008
TOTAL SLURRY 61,450 LB/HR
SLURRY SOLIDS 4.67 %
PARTICLE SIZE 25 um
RAW MILL (MILL-ON)
MILL INLET 992.1 LB/HR 3.97 LB/TON
15.50 MOLES SO2
SO2 REMOVED 76.0 % AVE
342.01 KG/HR
754.00 LB/HR
SO2 MILL MILL-ON 238.11 LB/HR 0.95 LB/TON
LIME INJECTION RATE 1.5 Ca(OH)2 / SO2 molar ratio
23 MOLES Ca(OH)2
1721 LB/HR Ca(OH)2 6029 T/YR
TOTAL LIME USED 8541 T/YR
LOADS 342
TRUCKS/DAY 0.9
SO2 ANNUAL EMISSIONS
COAL MILL 272.2 T/YR
STACK MILL-ON 834.3 T/YR
STACK MILL-OFF 338.9 T/YR
TOTAL 1445.4 T/YR 1.32 LB/TON
UNCONTROLLED 2880.4 T/YR 2.63 LB/TON
SO2 REMOVED 1435.0 T/YR 49.8 %
CCC-SO2-BACT WETCa(OH)2 (Hybrid) 10 OF 38
10/20/2008
COST ESTIMATE
SPRAY DRYING IN CT & RAW MILL ADDITION (LIME SLURRY ABSORBENT)
PLANT SIZE CAPACITY 2,190,000 TON/YR
FACTOR COST
CAPITAL COSTS
DIRECT COST
REAGENT SYSTEM LANCES,NOZZLES
VALVES,PUMPS
DUCTWORK
CYCLONE,BINS
ELECTRICAL
PIPING
MISCELLANEOUS EQUIPMENT
1,300,000
EQUIPMENT TOTAL 1,300,000
OTHER INSTRUMENTS 0.10 130,000
TAXES 0.05 65,000
FREIGHT 0.05 65,000
PEC TOTAL 1,560,000
INSTALLATION FOUNDATIONS 0.10 156,000
ERECTION 0.20 312,000
ELECTRICAL 0.05 78,000
DUCTING 0.10 156,000
INSULATION 0.05 78,000
SITE PREPARATION 0.10 156,000
TOTAL 936,000
DIRECT COSTS TOTAL 2,496,000
INDIRECT COSTS ENGINEERING/DESIGN 0.10 156,000
CONST/FIELD EXPENSE 0.05 78,000
CONTR.FEE 0.10 156,000
START-UP 0.02 31,200
PERFORMANCE TEST 0.01 15,600
CONTINGENCIES 0.03 46,800
TOTAL 483,600
RETROFIT PREMIUM (20% OF DIRECT & INDIRECT COST) 0.0
TOTAL CAPITAL COST 2,979,600
CCC-SO2-BACT COST-WETLIME (Hybrid) 11 OF 38
10/20/2008
COST ESTIMATE
SPRAY DRYING IN CT & RAW MILL ADDITION (LIME SLURRY ABSORBENT)
OPERATING COST(DIRECT)
UTILITIES
TRANSFER PUMP 5.00 BHP
REAGENT PUMP 2.00 BHP
AGGITATOR MOTOR 10.00 BHP
BLOWER COMPRESSOR 100.00 BHP
CONNECTED LOAD 117.00 BHP
POWER 87.25 KWHr
HOURS OPERATED 8760 HRS
ELECTRICAL COST 0.0550 $/KWHr
ANNUAL COST 42,036 $/YR
REAGENT REAGENT USAGE 8,541 T/YR
COST 155.00 $/TON
ANNUAL COST 1,323,929 $/YR
WASTE DISPOSAL CKD 0 TON/YR
8.00 $/TON
COST 0 $/YR
WATER USAGE SUPPLY 12,306,494 GAL/YR
COST 0.00 $/MMGAL
ANNUAL COST 0 $/YR
MAINTENANCE LABOR & MATERIALS
REPLACEMENT PARTS 5% OF PEC 78,000 $/YR
MATERIALS 21000 $/YRMAINTENANCE LABOR HR/YR 1000
COST $/HR 21.00
COST $/YR 21,000
LABOR LABOR HR/YR 1000
COST $/HR 19.00
COST $/YR 19,000
SUPERVISOR LABOR HR/YR 150
COST $/HR 30.00
COST $/YR 4,500
FUEL SAVINGS $/YR $0
TOTAL DIRECT OPERATING COST $/YR $1,509,465
CCC-SO2-BACT COST-WETLIME (Hybrid) 12 OF 38
10/20/2008
COST ESTIMATE
SPRAY DRYING IN CT & RAW MILL ADDITION (LIME SLURRY ABSORBENT)
OPERATING COST(INDIRECT) OVERHEAD % 60.00
$/YR 26,700
PROPERTY TAX % 0.42
$/YR 12,514
INSURANCE % 1.00
$/YR 29,796
ADMINISTRATION % 2.00
$/YR 59,592
CAPITAL RECOVERY %-INTEREST 7.00
LIFE-YEARS 15.00
FACTOR 0.109795
$/YR 327,144
TOTAL INDIRECT OPERATING COST $/YR 455,746
TOTAL ANNUALIZED COST $/YR 1,965,211
ANNUAL EMISSIONS REDUCTION TON/YR 1434.96
% 49.82
COST BENEFIT $/TON 1,370
CCC-SO2-BACT COST-WETLIME (Hybrid) 13 OF 38
10/20/2008
OPERATION 8760 HR/YR
MILL ON 7008 HR/YR
MILL OFF 1752 HR/YR
PRODUCTION 5,443 TONNES/DAY
226.80 TONNES/HR
SO2 UNCONTROLLED 2.15 KG/TONNE
PREHEATER EXIT 487.62 KG/HR
PREHEATER EXIT 1075.0 LB/HR 4.30 LB/TON
COAL MILL GASES
CM INLET 82.9 LB/HR 0.33 LB/TON
SO2 REMOVED 25.0 %
20.71 LB/HR
SO2 COAL MILL EXHAUST 62.14 LB/HR 0.25 LB/TON
CONDITIONING TOWER (MILL-OFF & MILL-ON)
CT INLET 992.1 LB/HR 3.97 LB/TON
15.50 MOLES SO2
SO2 REMOVED 61.0 % AVE
274.51 KG/HR
605.18 LB/HR
SO2 MILL MILL-OFF 386.92 LB/HR 1.55 LB/TON
LIME INJECTION RATE 2.5 Ca(OH)2 / SO2 molar ratio
39 MOLES Ca(OH)2
2868 LB/HR Ca(OH)2 12,561 T/YR
GYPSUM FORMATION 1287 LB/HR
LIME REACTED 708 LB/HR
UNREACTED LIME -669 LB/HR
LOADING TO CYCLONE 618 LB/HR
CYCLONE REMOVAL 100 %
COLLECTED DUST 618.0 LB/HR
WASTE DUST 0 T/YR RETURNED TO PROCESS
WATER RATE 117.07 GPM
976.37 LB/MIN
443.21 L/MIN
58,582 LB/HR
61,532,472 GAL/YR
WET LIME INJECTION SYSTEM
LIME SLURRY TO CT WITH MILL GAS REHEAT
CCC-SO2-BACT WETCa(OH)2 (CT) 14 OF 38
10/20/2008
TOTAL SLURRY 61,450 LB/HR
SLURRY SOLIDS 4.67 %
PARTICLE SIZE 25 um
RAW MILL (MILL-ON)
MILL INLET 386.9 LB/HR 1.55 LB/TON
6.05 MOLES SO2
SO2 REMOVED 50.0 % AVE
87.75 KG/HR
193.46 LB/HR
SO2 MILL MILL-ON 193.46 LB/HR 0.77 LB/TON
LIME INJECTION RATE 0 Ca(OH)2 / SO2 molar ratio
0 MOLES Ca(OH)2
0 LB/HR Ca(OH)2 0 T/YR
TOTAL LIME USED 12,561 T/YR
LOADS 502
TRUCKS/DAY 1.4
SO2 ANNUAL EMISSIONS
COAL MILL 272.2 T/YR
STACK MILL-ON 677.9 T/YR
STACK MILL-OFF 338.9 T/YR
TOTAL 1289.0 T/YR 1.18 LB/TON
UNCONTROLLED 2880.4 T/YR 2.63 LB/TON
SO2 REMOVED 1591.4 T/YR 55.2 %
CCC-SO2-BACT WETCa(OH)2 (CT) 15 OF 38
10/20/2008
COST ESTIMATE
SPRAY DRYING IN CT ONLY (LIME SLURRY ABSORBENT) WITH MILL GAS REHEAT
PLANT SIZE CAPACITY 2,190,000 TON/YR
FACTOR COST
CAPITAL COSTS
DIRECT COST
REAGENT SYSTEM LANCES,NOZZLES
VALVES,PUMPS
DUCTWORK
CYCLONE,BINS
ELECTRICAL
PIPING & MISCELLANEOUS
SUBBOTAL 1,300,000
INCREASE KILN BAGHOUSE & ID FAN SIZE 1,200,000
EQUIPMENT TOTAL 2,500,000
OTHER INSTRUMENTS 0.10 250,000
TAXES 0.05 125,000
FREIGHT 0.05 125,000
PEC TOTAL 3,000,000
INSTALLATION FOUNDATIONS 0.10 300,000
ERECTION 0.20 600,000
ELECTRICAL 0.05 150,000
DUCTING 0.10 300,000
INSULATION 0.05 150,000
SITE PREPARATION 0.10 300,000
TOTAL 1,800,000
DIRECT COSTS TOTAL 4,800,000
INDIRECT COSTS ENGINEERING/DESIGN 0.10 300,000
CONST/FIELD EXPENSE 0.05 150,000
CONTR.FEE 0.10 300,000
START-UP 0.02 60,000
PERFORMANCE TEST 0.01 30,000
CONTINGENCIES 0.03 90,000
TOTAL 930,000
RETROFIT PREMIUM (20% OF DIRECT & INDIRECT COST) 0.0
TOTAL CAPITAL COST 5,730,000
CCC-SO2-BACT COST-WETLIME (CT) 16 OF 38
10/20/2008
COST ESTIMATE
SPRAY DRYING IN CT ONLY (LIME SLURRY ABSORBENT) WITH MILL GAS REHEAT
OPERATING COST(DIRECT)
UTILITIES
TRANSFER PUMP 5.00 BHP
REAGENT PUMP 2.00 BHP
AGGITATOR MOTOR 10.00 BHP
BLOWER COMPRESSOR 100.00 BHP
CONNECTED LOAD 117.00 BHP
POWER 87.25 KWHr
HOURS OPERATED 8760 HRS
ELECTRICAL COST 0.0550 $/KWHr
ANNUAL COST 42,036 $/YR
REAGENT REAGENT USAGE 12,561 T/YR
COST 155.00 $/TON
ANNUAL COST 1,946,955 $/YR
NATURAL GAS REHEAT RATE 73.5 MMBTU/HR
COST 14.02 $/MMBTU
ANNUAL COST 7,221,592 $/YR
WATER USAGE SUPPLY 61,532,472 GAL/YR
COST 0.00 $/MMGAL
ANNUAL COST 0 $/YR
MAINTENANCE LABOR & MATERIALS
REPLACEMENT PARTS 5% OF PEC 150,000 $/YR
MATERIALS 21000 $/YRMAINTENANCE LABOR HR/YR 1000
COST $/HR 21.00
COST $/YR 21,000
LABOR LABOR HR/YR 1000
COST $/HR 19.00
COST $/YR 19,000
SUPERVISOR LABOR HR/YR 150
COST $/HR 30.00
COST $/YR 4,500
FUEL SAVINGS $/YR $0
TOTAL DIRECT OPERATING COST $/YR $9,426,082
CCC-SO2-BACT COST-WETLIME (CT) 17 OF 38
10/20/2008
COST ESTIMATE
SPRAY DRYING IN CT ONLY (LIME SLURRY ABSORBENT) WITH MILL GAS REHEAT
OPERATING COST(INDIRECT) OVERHEAD % 60.00
$/YR 26,700
PROPERTY TAX % 0.42
$/YR 24,066
INSURANCE % 1.00
$/YR 57,300
ADMINISTRATION % 2.00
$/YR 114,600
CAPITAL RECOVERY %-INTEREST 7.00
LIFE-YEARS 15.00
FACTOR 0.109795
$/YR 629,123
TOTAL INDIRECT OPERATING COST $/YR 851,789
TOTAL ANNUALIZED COST $/YR 10,277,871
ANNUAL EMISSIONS REDUCTION TON/YR 1591.40
% 55.25
COST BENEFIT $/TON 6,458
CCC-SO2-BACT COST-WETLIME (CT) 18 OF 38
10/20/2008
COST ESTIMATED-SOX CYCLONE
PLANT SIZE CAPACITY 2,190,000 TON/YR
FACTOR COSTCAPITAL COSTS
DIRECT COSTEQUIPMENT D-SOX CYCLONE SYSTEM (FLS QUOTE) 1,100,000
TOTAL CAPITAL COST 1,100,000
OPERATING COST(DIRECT)
UTILITIES BH FAN STATIC PRESSUREFAN VOLUMEFAN POWERFK PUMP STATIC PRESSUREBLOWER VOLUMEFAN POWERCONNECTED LOADPOWER (TOTAL) 794702 KWHrHOURS OPERATED HRSELECTRICAL COST 0.0550 $/KWHrANNUAL COST 43,709 $/YR
REAGENT REAGENT USAGE TON/YRCOST 155.00 $/TONANNUAL COST 0 $/YR
WASTE DISPOSAL CKD 0 TON/YR8.00 $/TON
COST 0 $/YR
MAINTENANCE LABOR & MATERIALSREPLACEMENT PARTS 5% OF PEC $/YR 55,000MATERIALS $/YR 21000
MAINTENANCE LABOR HR/YR 1000
COST $/HR 21.00
COST $/YR 21,000
LABOR LABOR HR/YR 1000COST $/HR 19.00COST $/YR 19,000
SUPERVISOR LABOR HR/YR 150COST $/HR 30.00COST $/YR 4,500
ADDITIONAL FUEL COST 0.20 $/TON CLINKER $/YR $438,000
TOTAL DIRECT OPERATING COST $/YR $602,209
CCC-SO2-BACT COST-D-SOx Cyclone 19 OF 38
10/20/2008
COST ESTIMATED-SOX CYCLONE
OPERATING COST(INDIRECT) OVERHEAD % 60.00$/YR 26,700
PROPERTY TAX % 0.42$/YR 4,620
INSURANCE % 1.00$/YR 11,000
ADMINISTRATION % 2.00$/YR 22,000
CAPITAL RECOVERY %-INTEREST 7.00LIFE-YEARS 15.00FACTOR 0.109795$/YR 120,774
TOTAL INDIRECT OPERATING COST $/YR 185,094
TOTAL ANNUALIZED COST $/YR 787,303
ANNUAL EMISSIONS REDUCTION TON/YR 864.12% 30.00
COST BENEFIT $/TON 911
CCC-SO2-BACT COST-D-SOx Cyclone 20 OF 38
10/20/2008
COST ESTIMATE
LIME HYDRATOR
PLANT SIZE CURRENT CAPACITY 2,190,000 TON/YR
FACTOR COST
CAPITAL COSTS
E-String, lime hydrator, ductwork, ID fan (FLS QUOTE) 4,500,000
TOTAL CAPITAL COST 4,500,000
OPERATING COST(DIRECT)
ADDITIONAL FUEL COST EST 0.17 $/TON CLINKER $/YR $372,300
ADDITIONAL POWER COST EST 0.02 $/TON CLINKER $/YR $43,800
MAINTENANCE LABOR & MATERIALS
REPLACEMENT PARTS 5% OF PEC $/YR 225,000
MATERIALS $/YR 21000MAINTENANCE LABOR HR/YR 1000
COST $/HR 21.00
COST $/YR 21,000
LABOR LABOR HR/YR 1000
COST $/HR 19.00
COST $/YR 19,000
SUPERVISOR LABOR HR/YR 150
COST $/HR 30.00
COST $/YR 4,500
TOTAL DIRECT OPERATING COST $/YR $706,600
OPERATING COST(INDIRECT) OVERHEAD % 60.00
$/YR 26,700
PROPERTY TAX % 0.42
$/YR 18,900
INSURANCE % 1.00
$/YR 45,000
ADMINISTRATION % 2.00
$/YR 90,000
CAPITAL RECOVERY %-INTEREST 7.00
LIFE-YEARS 15.00
FACTOR 0.109795
$/YR 494,076
TOTAL INDIRECT OPERATING COST $/YR 674,676
TOTAL ANNUALIZED COST $/YR 1,381,276
ANNUAL EMISSIONS REDUCTION TON/YR 1267.38
% 44.00
COST BENEFIT $/TON 1,090
CCC-SO2-BACT COST-Lime Hydrator 21 OF 38
10/20/2008
DESIGN BASIS FOR WET SCRUBBER SYSTEM
INLET GASES FROM KILN (MILL-IN)
861,328 NM3/HR 544053 SCFM
1,139,443 M3/HR 670651 ACFM
H2O 141,488 NM3/HR 89370 WSCFM
DRY GAS 719,840 NM3/HR 454683 DSCFM
TEMPERATURE 88.3 C 191 F MILL IN WORST CASE
SPECIES % NM3/HR SCFM LB/MIN KG/MIN Cp BTU/LB-F Cp KJ/Kg-K h BTU/MIN h KJ/MIN
H2O 16.43 141487.7 88943.1 4154.3 1888.3 1094.7 524.4 4,547,567 4315
CO2 10.94 94223.7 59231.6 6769.3 3077.0 0.2031 0.0540 77,330 73
O2 11.65 100326.8 63068.2 5233.9 2379.0 0.2149 0.0572 63,271 60
N2 60.93 524795.1 329900.7 23975.3 10897.9 0.2470 0.0657 333,110 316
SO2 0.01 88.6658 56.1 9.3 4.229 0.2031 0.0540 106 0
NO 0.02 151.6 95.3 7.7 3.5 0.2031 0.0540 88 0CO 0.03 254.0 159.7 11.6 5.3 0.2031 0.0540 132 0
TOTAL 100 861328 541454 40161 18255 5,021,604 4764
SATURATION 0.109 LB/LB-DA
TEMPERATURE 123.9 F
51.0 C
524.2 K
SO2 REMOVAL 90 % AVERAGE
100 % AVAILABILITY
90 % ANNUAL
SPECIES % NM3/HR SCFM LB/MIN KG/MIN Cp BTU/LB-F Cp KJ/Kg-K h BTU/MIN h KJ/MIN
H2O 15.61 133181 83721.3 3910.4 1777.4 1110.9 532.2 4,344,159 4122
CO2 13.09 94224 59231.6 6769.3 3077.0 0.2047 0.054 127,325 121
O2 13.94 100327 63068.2 5233.9 2379.0 0.2152 0.057 103,513 98
N2 72.91 524795 329900.7 23975.3 10897.9 0.2474 0.066 544,944 517
SO2 0.00 9 5.6 0.9 0.4 0.2047 0.054 17 0
NO 0.02 152 95.3 7.7 3.5 0.2047 0.054 145 0CO 0.04 254 159.7 11.6 5.3 0.2047 0.054 218 0
TOTAL 100 852941 536182 39909 18141 5,120,321 4858
DIFFERENCE 98718
CCC-SO2-BACT WET-SCRUBBER 22 OF 38
10/20/2008
INLET GAS VOLUME 16872 AM3/MIN
595386 ACFM
SCRUBBER DIAMETER 9.8 M
SCRUBBER AREA 75.3 M2
VELOCITY 224.0 M/MIN
HEIGHT/DIAMETER 4.0
HEIGHT 39.2 M
LIQUID GAS RATIO 7.13 M3/KM3
RECIRCULATION 120.3 M3/MIN
31626.0 GAL/MIN
HEAD 21.3 M
DENSITY 1.15
OXIDATION BLOWER 3 M3/M3
360.90 NM3/MIN
HEAD 6.63 M
261.0 IN WC
REAGENT FEED 0.5 M3/MIN
131.4 GAL/MIN
HEAD 29.8 M
DENSITY 1.25
GYPSUM SLURRY 1.7 M3/MIN
436.4 GAL/MIN
29.8 M
1.25
SLURRY DISCHARGE 0.75 M3/MIN
197.0 GAL/MIN
16.2 M
1.15
WATER MAKEUP
GYPSUM PRODUCTION
CCC-SO2-BACT WET-SCRUBBER 23 OF 38
10/20/2008
SO2 REMOVED 228.4 KG/HR
SULFUR 114.2 KG/HR
GYPSUM 487.0 KG/HR ANHYDRATE
615.5 KG/HR HYDRATED
WATER 128.4 KG/HR HYDRATED
PRODUCTION 5,443 TONNE/DAY
226.8 TONNE/HR
GYPSUM 2.71 KG/TONNE
2,696 TONNE/YR
FREE MOISTURE 10 %
REAGENT USAGE CaCO3 358.6 KG/HR
1.6 KG/TONNE
1570.6 TONNE/YR
WATER LOSS FREE 61.5 KG/HR
HYDRATE 128.4 KG/HR
STACK WATER LOSS -6651.7 KG/HR
BLOWDOWN TOTAL 0.63 %
(RECIRCULATION) TOTAL 0.8 M3/MIN
WATER 42.7 M3/HR
42,520 KG/HR
SOLIDS(WEIGHT) 6.2 %
WATER MAKE-UP 36,059 KG/HR
0.60 M3/MIN
158.86 GPM
SO2 REMOVAL BASELINE 1.32 KG/TONNE
PRODUCTION 1,986,755 TONNE/YR
2613 TONNE/YR
1957 T/YR MILL-IN
923 T/YR MILL-OUT
2880 T/YR ANNUAL
CONTROLLED 261 TONNE/YR
CCC-SO2-BACT WET-SCRUBBER 24 OF 38
10/20/2008
288 T/YR ANNUAL
REDUCTION 2352 TONNE/YR
2592 T/YR ANNUAL
B. STEAM ENTHALPY AT ATMOSPHERIC PRESSURE
A0 A1 A2 C
H2O 4.5630E-01 1.6660E-05 2.2320E-07 1.0690E+03
CCC-SO2-BACT WET-SCRUBBER 25 OF 38
10/20/2008
COST ESTIMATE
WET SCRUBBER
PLANT SIZE CURRENT CAPACITY 2,190,000 TON/YR
FACTOR COST
CAPITAL COSTS
DIRECT COST
SCRUBBER COMPOMENTS SCRUBBER BODY
VALVES,PUMPS
DUCTWORK
CIVIL
ELECTRICAL
N.GAS SERVICE
ID FAN
SLUDGE TREATMENT
MISCELLANEOUS EQUIPMENT
STACK/REHEAT
EQUIPMENT TOTAL 11,918,544
OTHER INSTRUMENTS 0.10 1,191,854
TAXES 0.05 595,927
FREIGHT 0.05 595,927
PEC TOTAL 14,302,252
INSTALLATION FOUNDATIONS 0.12 1,716,270
ERECTION 0.60 8,581,351
ELECTRICAL 0.10 1,430,225
DUCTING 0.30 4,290,676
INSULATION 0.02 286,045
SITE PREPARATION 0.01 143,023
TOTAL 1.15 16,447,590
DIRECT COSTS TOTAL 30,749,842
INDIRECT COSTS ENGINEERING/DESIGN 0.20 2,860,450
CONST/FIELD EXPENSE 0.05 715,113
CONTR.FEE 0.05 715,113
START-UP 0.01 143,023
PERFORMANCE TEST 0.01 143,023
CONTINGENCIES 0.03 429,068
TOTAL 5,005,788
RETROFIT PREMIUM (20% OF DIRECT & INDIRECT COST) 0.0
TOTAL CAPITAL COST 35,755,631
CCC-SO2-BACT COST-WET-SCRUBBER 26 OF 38
10/20/2008
COST ESTIMATE
WET SCRUBBER
OPERATING COST(DIRECT)
UTILITIES ID FAN STATIC PRESSURE 8.00 IN H2O
FAN VOLUME 670651 ACFM
FAN POWER 1211.00 BHP
FAN STATIC PRESSURE 5.00 IN H2O
COMBUSTION FAN VOLUME 7120 ACFM
FAN POWER 8.04 BHP
SATURATED GASES 595386.17 ACFM
GPM 67065.10 GPM
RECIRCULATION PUMPS(4) 3027 BHP
REAGENT PUMP 71.50 BHP
AGGITATOR MOTOR 185.00 BHP
PULSE PUMP 285.00 BHP
BLOWER COMPRESSOR 285.00 BHP
CONNECTED LOAD 5064.75 BHP
POWER 3776.78 KWHr
HOURS OPERATED 8760 HRS
ELECTRICAL COST 0.0550 $/KWHr
ANNUAL COST 1,819,654 $/YR
N.GAS(FLUE GAS REHEAT) 0.00 GJ/HR
COST 14.777 $/GJ
ANNUAL COST 0 $/YR
REAGENT REAGENT USAGE 1731.26 TON/YR
COST 25.00 $/TON
ANNUAL COST 43,282 $/YR
WASTE DISPOSAL GYPSUM 2696 TON/YR
50.00 $/TON
COST 134790 $/YR
WATER TREATMENT DISCHARGE 373650 M3/YR
COST 2.00 $/M3
ANNUAL COST 747301 $/YR
MAINTENANCE LABOR & MATERIALS
REPLACEMENT PARTS 5% OF PEC 715,113 $/YR
MATERIALS 42000 $/YRMAINTENANCE LABOR HR/YR 2000
COST $/HR 21.00
COST $/YR 42,000
LABOR LABOR HR/YR 2000
COST $/HR 19.00
COST $/YR 38,000
SUPERVISOR LABOR HR/YR 300
COST $/HR 30.00
COST $/YR 9,000
FUEL SAVINGS $/YR $0
TOTAL DIRECT OPERATING COST $/YR $3,591,139
CCC-SO2-BACT COST-WET-SCRUBBER 27 OF 38
10/20/2008
COST ESTIMATE
WET SCRUBBER
OPERATING COST(INDIRECT) OVERHEAD % 60.00
$/YR 53,400
PROPERTY TAX % 0.42
$/YR 150,174
INSURANCE % 1.00
$/YR 357,556
ADMINISTRATION % 2.00
$/YR 715,113
CAPITAL RECOVERY %-INTEREST 7.00
LIFE-YEARS 15.00
FACTOR 0.109795
$/YR 3,925,776
TOTAL INDIRECT OPERATING COST $/YR 5,202,019
TOTAL ANNUALIZED COST $/YR 8,793,157
ANNUAL EMISSIONS REDUCTION TON/YR 2592.36
% 90.00
COST BENEFIT $/TON 3,392
CCC-SO2-BACT COST-WET-SCRUBBER 28 OF 38
10/20/2008
INPUTS FLUE GAS STREAM
LB/MIN KG/MIN LB/HR SCFM NM3/HR % PPM(WET) PPM(DRY)
CO 11.60 5.27 695.84 159.58 253.9 0.03 297.5 352.5
O2 5233.87 2379.03 314032.41 63068.18 100326.8 11.76
N2 23975.34 10897.88 1438520.56 330140.47 525176.5 61.55
SO2 0.93 0.42 55.82 5.61 8.9 0.00 10.4
NO 7.69 3.49 461.28 63.96 101.8 0.01 119.2
H2O 3910.38 1777.45 234622.93 83721.28 133181.0 15.61CO2 6769.33 3076.97 406159.55 59231.60 94223.7 11.04
TOTAL(WET) 39909.14 18140.52 2394548.38 536390.67 853272.5 100.00
TOTAL(DRY) 35998.76 16363.07 2159925.46 452669.39 720091.5
INLET 593165.54 ACFM
1012738.04 AM3/HR
123.89 oF
51.05 C
BURNER COMBUSTION AIR
LB/MIN KG/MIN
DRY AIR 514.79 234.00
O2 119.43 54.29
N2 395.36 179.71
H2O 11.23 5.11WET AIR 526.02 239.10
MOISTURE 0.0218 lb/lb DA
0.0218 KG/KG DA
T= 70 oF
21 C
RH 50 %
HEAT BALANCE FOR REHEAT FLUE GASES (WET SCRUBBER)
CCC-SO2-BACT RHEAT 29 OF 38
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (WET SCRUBBER)
LB/MIN KG/MIN LB/HR SCFM NM3/HR
O2 119.43 54.29 7165.87 1439.60 2290.1
N2 395.36 179.71 23721.51 5440.13 8654.0
DRY GAS 514.79 234.00 30887.38 6879.74 10944.1H2O 11.2343 5.11 674.06 240.53 382.6
TOTAL 526.02 239.10 31561.44 7120.26 11326.7
TOTAL HEATER INPUTS
LB/MIN KG/MIN LB/HR SCFM NM3/HR %WET %DRY
CO 11.60 5.271 695.84 159.58 253.9 0.03 0.03
O2 5353.30 2433.320 321198.28 64507.78 102616.8 11.87 14.04
N2 24370.70 11077.591 1462242.06 335580.60 533830.5 61.74 73.02
SO2 0.93 0.423 55.82 5.61 8.9 0.00 0.00
NO 7.69 3.495 461.28 63.96 101.8 0.01 0.01
CO2 6769.33 3076.966 406159.55 59231.60 94223.7 10.90 12.89
TOTAL 36513.55 16597.067 2190812.83 459549.13 731035.5H2O 3921.62 1782.553 235296.99 83961.81 133563.7 15.45
TOTAL 40435.16 18379.620 2426109.82 543510.94 864599.2 100.00 100.00
HHV FUELS
CO 4339 BTU/LB
0.0101 GJ/KG
N.G. 22077 BTU/LB
0.0512 GJ/KG
AUXILIARY FUEL RATE
N.G. 41.96 LB/MIN
19.07 KG/MIN
HEAT INPUTS
CO 50,321 BTU/MIN 5.15 %
0.053 GJ/MIN
3,019,240 BTU/HR
3.1823 GJ/HR
COMBUSTION AIR
CCC-SO2-BACT RHEAT 30 OF 38
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (WET SCRUBBER)
N.G. 926,451 BTU/MIN 94.85 %
0.976 GJ/HR
55,587,054 BTU/HR
58.589 GJ/HR
TOTAL 976,772 BTU/MIN
1.030 GJ/HR
58,606,294 BTU/HR
61.771 GJ/HR
FUEL ANALYSIS
CO % N.G.%
C 42.85 69.12
H 0.00 23.20
O 57.15 1.58
N 0.00 5.76S 0.00 0.34
TOTAL 100.00 100.00
LB/MIN KG/MIN LB/MIN KG/MIN LB/MIN KG/MIN
C-CO2 0.00 0 77.16 35.07 77.16 35.071
CO-CO2 6.61 3.00 0.00 0 6.61 3.005
H2-H2O 0.00 0 77.30 35.14 77.30 35.137
S-SO2 0.00 0 0.14 0.06 0.14 0.065N-NO 0.00 0 5.52 2.51 5.52 2.511
NET 6.61 3.00 160.12 72.78 166.73 75.788
O2 BOUND 6.63 3.01 0.66 0.30 7.29 3.314
O2 EXCESS -159.44 -72.474
COMBUSTION AIR 5353.30 2433.320
NET O2 EXCESS 5193.86 2360.846
OXYGEN REQUIRED
GASES N.G. TOTAL
CCC-SO2-BACT RHEAT 31 OF 38
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (WET SCRUBBER)
FLUE GASES NG INPUT TOTAL TOTALLB/MIN LB/MIN LB/MIN LB/MIN KG/MIN SCFM NM3/HR %DRY %WET PPM DRY
CO2 18.19 106.16 6769.33 6893.68 3133.49 60398.94 96080.6 13.17 11.09
CO 0.00 0.00 11.60 11.60 5.27 159.58 253.9 0.03 0.03 347.9
H2O 0.00 87.04 3921.62 4008.65 1822.12 85825.29 136528.0 15.76
N2 0.00 0.00 24370.70 24366.87 11075.85 335561.10 533799.5 73.15 61.62
O2 EXCES 0.00 0.00 5193.86 5193.86 2360.85 62560.06 99518.5 13.64 11.49
SO2 0.00 0.29 0.93 1.22 0.55 7.32 11.6 0.00 0.00 16.0NO 0.00 0.51 7.69 8.20 3.73 68.72 109.3 0.01 0.01 149.8
TOTAL 18.19 194.00 40275.72 40484.08 18401.85 544581.00 100.00
TOTAL(DRY) 458755.72 100.00
MASS BALANCE 229.7 PPM NOX
LB/MIN KG/MIN
SOURCE GASES 39909.14 18140.51806
COMBUSTION AIR 526.02 239.1017988
N.GAS 41.96 19.07478561
TOTAL 40477.13 18398.69465
COMBUSTION PRODUCTS 40484.08 18401.85401
DIFFERENCE -0.02 -0.02 %
Cp-BTU/LB-oF Cp KJ/Kg-K T-oF LB/MIN KG/MIN h-BTU/MIN h KJ/MIN
N2 0.2474 0.066 123.89 23975.34 10897.883 544944.13 517
O2 0.2152 0.057 123.89 5233.87 2379.03341 103513.45 98
CO 0.2047 0.054 123.89 11.60 5.27149861 218.13 0
CO2 0.2047 0.054 123.89 6769.33 3076.96632 127324.96 121
SO2 0.1306 0.035 123.89 0.93 0.42287279 11.16 0
NO 0.2047 0.054 123.89 7.69 3.49451736 144.60 0H2O 1110.9 532.2362 123.89 3910.38 1777.44643 4344158.76 4122
TOTAL 39909.14 18140.5181 5,120,315 4858
FLUE GAS PRODUCTS
INPUT ENTHALPY FLUE GASES
FLOW
CCC-SO2-BACT RHEAT 32 OF 38
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (WET SCRUBBER)
Cp-BTU/LB-oF Cp KJ/Kg-K T-oF LB/MIN KG/MIN h-BTU/MIN h KJ/MIN
N2 0.2468 0.066 70.00 395.36 179.708373 3707.38 4
O2 0.2147 0.057 70.00 119.43 54.2869042 974.39 1H2O 1086.3 520.5 70.00 11.23 5.10652205 12204.32 12
TOTAL 526.02 239.101799 16886 16
TOTAL GASES 5137201 4874
BTU/LB GJ/KG LB/MIN KG/MIN h-BTU/MIN h KJ/MIN
CO 4339.0 0.01 0.00 0 0 0NAT. GAS 22077 0.05 41.96 19.07478561 926451 879
FUEL TOTAL 926451 879
TOTAL 6,063,652
RADIATION LOSSES 2.00 121,273
NET ENTHALPY FLUE GASES 5,942,379
Cp-BTU/LB-oF Cp KJ/Kg-K T-oF LB/MIN KG/MIN h-BTU/MIN h KJ/MIN % wt SCFM NM3/HR PPM(WET)
N2 0.2481 0.066 190.86 24366.87 11075.9 960391 911 60.19 335531.9 533753.0
O2 0.2159 0.057 190.86 5193.86 2360.8 178149 169 12.83 62586.0 99559.8
CO2 0.2078 0.055 190.86 6893.68 3133.5 227550 216 17.03 60319.7 95954.5
CO 0.2078 0.055 190.86 11.60 5.3 383 0 0.03 159.6 253.9 293.08
SO2 0.1361 0.036 190.86 1.22 0.6 26 0 0.00 7.3 11.7
NO 0.2078 0.055 190.86 8.20 3.7 271 0 0.02 68.2 108.5H2O 1141.49 546.9 190.86 4008.65 1822.1 4575846 4341 9.90 85825.3 136528.0
TOTAL 40484.08 18401.9 5942614 5638 100 544498.0 866169.3
NET DIFFERENCE 235
REHEAT TEMPERATURE 190.9oF NOX EF= 83.00 LB/MMFT3
88.3OC NOX 19.43 T/YR
41.96 LB/MIN
N.GAS USAGE 19.07 KG/MIN CO EF= 61.00 LB/MMFT3
N.GAS USAGE 55.59 MMBTU/HR CO 14.28 T/YR
58.59 GJ/HR
SO2 EF= 0.60 LB/MMFT3
FLUE GAS OXYGEN 13.64 % SO2 0.14 T/YR
INLET FUEL CONCENTRATION 1.70 BTU/SCF
OUTPUT ENTHALPY
INPUT ENTHALPY PRIMARY AIR
CCC-SO2-BACT RHEAT 33 OF 38
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (WET SCRUBBER)
DSCFM NM3/HR WSCFM NM3/HR ACFM AM3/HR
INLET 452669 720091 536391 853272 661206 1128787OUTLET 458756 729773 544581 866301 671302 1146023
STEAM ENTHALPY AT ATMOSHERIC PRESSURE
A0 A1 A2 C
H2O 4.563E-01 1.666E-05 2.232E-07 1.069E+03
FLUE GAS VOLUME SUMMARY @ COMBUSTOR
CCC-SO2-BACT RHEAT 34 OF 38
10/20/2008
COST ESTIMATE
WET SCRUBBER
PLANT SIZE CURRENT CAPACITY 2,190,000 TON/YR
FACTOR COST
CAPITAL COSTS
DIRECT COST
SCRUBBER COMPOMENTS SCRUBBER BODY
VALVES,PUMPS
DUCTWORK
CIVIL
ELECTRICAL
N.GAS SERVICE
ID FAN
SLUDGE TREATMENT
MISCELLANEOUS EQUIPMENT
STACK/REHEAT 1,500,000
EQUIPMENT TOTAL 13,418,544
OTHER INSTRUMENTS 0.10 1,341,854
TAXES 0.05 670,927
FREIGHT 0.05 670,927
PEC TOTAL 16,102,252
INSTALLATION FOUNDATIONS 0.12 1,932,270
ERECTION 0.60 9,661,351
ELECTRICAL 0.10 1,610,225
DUCTING 0.30 4,830,676
INSULATION 0.02 322,045
SITE PREPARATION 0.01 161,023
TOTAL 1.15 18,517,590
DIRECT COSTS TOTAL 34,619,842
INDIRECT COSTS ENGINEERING/DESIGN 0.20 3,220,450
CONST/FIELD EXPENSE 0.05 805,113
CONTR.FEE 0.05 805,113
START-UP 0.01 161,023
PERFORMANCE TEST 0.01 161,023
CONTINGENCIES 0.03 483,068
TOTAL 5,635,788
RETROFIT PREMIUM (20% OF DIRECT & INDIRECT COST) 0.0
TOTAL CAPITAL COST 40,255,631
CCC-SO2-BACT COST-WET-SCRUBBER W-REHEAT 35 OF 38
10/20/2008
COST ESTIMATE
WET SCRUBBER
OPERATING COST(DIRECT)
UTILITIES ID FAN STATIC PRESSURE 8.00 IN H2O
FAN VOLUME 670651 ACFM
FAN POWER 1211.00 BHP
FAN STATIC PRESSURE 5.00 IN H2O
COMBUSTION FAN VOLUME 7120 ACFM
FAN POWER 8.04 BHP
SATURATED GASES 595386.17 ACFM
GPM 67065.10 GPM
RECIRCULATION PUMPS(4) 3027 BHP
REAGENT PUMP 71.50 BHP
AGGITATOR MOTOR 185.00 BHP
PULSE PUMP 285.00 BHP
BLOWER COMPRESSOR 285.00 BHP
CONNECTED LOAD 5064.75 BHP
POWER 3776.78 KWHr
HOURS OPERATED 8760 HRS
ELECTRICAL COST 0.0550 $/KWHr
ANNUAL COST 1,819,654 $/YR
N.GAS(FLUE GAS REHEAT) 58.59 GJ/HR
COST 14.777 $/GJ
ANNUAL COST 7,584,151 $/YR
REAGENT REAGENT USAGE 1731.26 TON/YR
COST 25.00 $/TON
ANNUAL COST 43,282 $/YR
WASTE DISPOSAL GYPSUM 2696 TON/YR
50.00 $/TON
COST 134790 $/YR
WATER TREATMENT DISCHARGE 373650 M3/YR
COST 2.00 $/M3
ANNUAL COST 747301 $/YR
MAINTENANCE LABOR & MATERIALS
REPLACEMENT PARTS 5% OF PEC 805,113 $/YR
MATERIALS 42000 $/YRMAINTENANCE LABOR HR/YR 2000
COST $/HR 21.00
COST $/YR 42,000
LABOR LABOR HR/YR 2000
COST $/HR 19.00
COST $/YR 38,000
SUPERVISOR LABOR HR/YR 300
COST $/HR 30.00
COST $/YR 9,000
FUEL SAVINGS $/YR $0
TOTAL DIRECT OPERATING COST $/YR $11,265,290
CCC-SO2-BACT COST-WET-SCRUBBER W-REHEAT 36 OF 38
10/20/2008
COST ESTIMATE
WET SCRUBBER
OPERATING COST(INDIRECT) OVERHEAD % 60.00
$/YR 53,400
PROPERTY TAX % 0.42
$/YR 169,074
INSURANCE % 1.00
$/YR 402,556
ADMINISTRATION % 2.00
$/YR 805,113
CAPITAL RECOVERY %-INTEREST 7.00
LIFE-YEARS 15.00
FACTOR 0.109795
$/YR 4,419,852
TOTAL INDIRECT OPERATING COST $/YR 5,849,994
TOTAL ANNUALIZED COST $/YR 17,115,284
ANNUAL EMISSIONS REDUCTION TON/YR 2592.36
% 90.00
COST BENEFIT $/TON 6,602
CCC-SO2-BACT COST-WET-SCRUBBER W-REHEAT 37 OF 38
10/20/2008
POWER COST 0.055 $/KWH
PROPERTY TAX RATE 0.42 $/100 New Hanover
0.4200 %
CAPITAL RECOVERY RATE 7 %
LABOR COSTS
SUPERVISOR 30.00 $/HR
OPERATOR 25.00 $/HR
1ST CLASS MAINTENANCE 21.00 $/HR
1ST CLASS ELECTRICIAN 21.00 $/HR
1ST CLASS WELDER 21.00 $/HR
GENERAL LABOR 19.00 $/HR
NATURAL GAS 14.78 $/GJ 14.02 $/MMBTU PSNC
FUEL OIL 5.41 $/GJ 5.13 $/MMBTU
COAL 3.73 $/GJ 3.54 $/MMBTU =$85/TON
COKE 0 $/GJ 0 $/MMBTU
CKD DISPOSAL 7.27 $/TONNE 8.00 $/TON
GYPSUM WASTE DISPOSAL 45.45 $/TONNE 50.00 $/TON
MICROFINE LIME 140.91 $/TONNE 155 $/TON
LIMESTONE REAGENT 22.73 $/TONNE 25 $/TON
WATER COST 0.0000 $/M3 0 $/MM gal
WATER TREATMENT 2.0000 $/M3 7571 $/MM gal
PLANT COSTS
CCC-SO2-BACT PLANT COSTS 38 OF 38
APPENDIX C
COST CALCULATIONS FOR NOX
10/20/2008
PRODUCTION 5,443 MT/D 6,000 ST/D
365.0 Days/yr 365.0 Days/yr
1,986,755 Tonnes/yr 2,190,000 ST/YR
PLANT CAPACITY 100.0 %
NOX FACTOR (BASELINE) 1.27 Kg/Tonne 2.80 LB/TON
CONTROL FACTOR 0 % 0 %
NOX EMISSIONS UNCONTROLLED
ANNUAL NOX 2781.46 Tonnes/yr 3066.00 TON/YR
317.52 Kg/HR 700.00 LB/HR
OPERATING HOURS 8,760 HRS/YR AT 100% CAPACITY
MILL-IN 7,884 HRS/YR 90.00%
MILL-DOWN 876 HRS/YR 10.00%
NOTE: Reformatted to separate SO2 calculations 10/20/08.
NOx calculations have not been changed.
CASTLE HAYNE PLANT
KILN DESIGN DATA
CCC-NOX-BACT CURRENT 1 OF 13
10/20/2008
COST ESTIMATE
SNCR NOX CONTROL OPTION
FACTOR COST
CAPITAL COSTS
DIRECT COST
BASIC UREA UNIT 1,200,000
EQUIPMENT TOTAL 1,200,000
OTHER INSTRUMENTS 0.10 120,000
TAXES 0.05 60,000
FREIGHT 0.05 60,000
TOTAL 1,440,000
INSTALLATION FOUNDATIONS 0.10 144,000
ERECTION 0.20 288,000
ELECTRICAL 0.05 72,000
PIPING 0.10 144,000
INSULATION 0.05 72,000
SITE PREPARATION 0.10 144,000
TOTAL 0.60 864,000
DIRECT COSTS TOTAL 2,304,000
INDIRECT COSTS ENGINEERING/DESIGN 0.05 72,000
CONST/FIELD EXPENSE 0.05 72,000
CONTR.FEE 0.05 72,000
START-UP 0.02 28,800
PERFORMANCE TEST 0.01 14,400
CONTINGENCIES 0.10 144,000
TOTAL 403,200
RETROFIT PREMIUM (20% OF DIRECT & INDIRECT COST) 0
TOTAL CAPITAL COST 2,707,200
CCC-NOX-BACT COST-SNCR 2 OF 13
10/20/2008
COST ESTIMATE
SNCR NOX CONTROL OPTION
OPERATING COST(DIRECT)
UTILITIES PUMP PRESSURE 80.00 PSIG
LIQUOR DENSITY 11.00 LB/GAL
1.32 SG
0.0122 FT3/LB
PUMP VOLUME 20 GPM
13200 LB/HR
PUMP HORSEPOWER 124.00 BHP
CONNECTED LOAD 124.00 BHP
POWER 92.47 KWHr
HOURS OPERATED 8760 HRS
ELECTRICAL COST 0.0370 $/KWHr
ANNUAL COST 29,971 $/YR
NATURAL GAS 0.00 MMBTU/HR
COST 7.097 $/MMBTU
ANNUAL COST 0 $/YR
REAGENTS UTILIZATION 0.70
MOLAR RATIO 1.00
USAGE 5713 T/YR
UNIT COST 0.12 $/LB
COST $1,371,130
MAINTENANCE LABOR & MATERIALS
5% OF DIRECT CAPITAL COST 115,200 $/YR
MAINTENANCE LABOR HR/YR 500
COST $/HR 21.00
COST $/YR 10,500
OPERATOR LABOR HR/YR 500
COST $/HR 25.00
COST $/YR 12,500
SUPERVISOR LABOR HR/YR 200
COST $/HR 30.00
COST $/YR 6,000
TOTAL DIRECT OPERATING COST 1,545,301
CCC-NOX-BACT COST-SNCR 3 OF 13
10/20/2008
COST ESTIMATE
SNCR NOX CONTROL OPTION
OPERATING COST(INDIRECT) OVERHEAD % 60.00
$/YR 17,400
PROPERTY TAX % 1.46
$/YR 39,497
INSURANCE % 1.00
$/YR 27,072
ADMINISTRATION % 2.00
$/YR 54,144
CAPITAL RECOVERY %-INTEREST 10.00
LIFE-YEARS 15.00
FACTOR 0.131474
$/YR 355,926
TOTAL INDIRECT OPERATING COST 494,039
TOTAL ANNUAL COST $/YR $2,039,340
EXPECTED NOx(PRE-SNCR) LB/TON 2.80
T/YR 3066
EXPECTED NOx(POST-SNCR) LB/TON 1.95
REDUCTION T/YR 931
% 30
$/TON $2,191
$/TON-CLK $0.93
CCC-NOX-BACT COST-SNCR 4 OF 13
10/20/2008
INPUTS FLUE GAS STREAM
LB/MIN KG/MIN LB/HR SCFM NM3/HR % PPM(WET) PPM(DRY)
CO 11.65 5.30 699.18 160.34 255.1 0.03 294.1 353.2
O2 5020.57 2282.08 301234.38 60497.90 96238.1 11.10
N2 24090.40 10950.18 1445424.06 331724.82 527696.8 60.84
SO2 3.75 1.71 225.30 22.62 36.0 0.00 41.5
NO 7.61 3.46 456.51 63.30 100.7 0.01 116.1
H2O 4263.82 1938.10 255828.90 91288.28 145218.4 16.74CO2 7028.33 3194.70 421700.06 61497.93 97828.9 11.28
TOTAL(WET) 40426.14 18375.52 2425568.39 545255.20 867373.9 100.00
TOTAL(DRY) 36162.32 16437.42 2169739.49 453966.92 722155.5
INLET 672133.18 ACFM
1147629.82 AM3/HR
190.86 oF
88.26 C
BURNER COMBUSTION AIR
LB/MIN KG/MIN
DRY AIR 5832.1 2650.95
O2 1353.04 615.02 424.15 MMBTU/HR
N2 4479.04 2035.93 8.3 LB/1000BTU
H2O 63.64 28.93 5832.1 LB/MINWET AIR 5895.72 2679.87
MOISTURE 0.0109 lb/lb DA
0.0109 KG/KG DA
T= 70 oF
21 C
RH 50 %
LB/MIN KG/MIN LB/HR SCFM NM3/HR
O2 1353.04 615.02 81182.61 16309.37 25944.4
N2 4479.04 2035.93 268742.43 61631.60 98041.5
DRY GAS 5832.08 2650.95 349925.04 77940.97 123985.9H2O 63.6373 28.93 3818.24 1362.48 2167.4
TOTAL 5895.72 2679.87 353743.28 79303.44 126153.3
HEAT BALANCE FOR REHEAT FLUE GASES (SCR)
COMBUSTION AIR
CCC-NOX-BACT RHEAT-SCR 5 OF 13
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (SCR)
TOTAL HEATER INPUTS
LB/MIN KG/MIN LB/HR SCFM NM3/HR %WET %DRY
CO 11.65 5.297 699.18 160.34 255.1 0.03 0.03
O2 6373.62 2897.098 382416.99 76807.27 122182.5 12.30 14.44
N2 28569.44 12986.110 1714166.49 393356.42 625738.3 62.98 73.95
SO2 3.75 1.707 225.30 22.62 36.0 0.00 0.00
NO 7.61 3.458 456.51 63.30 100.7 0.01 0.01
CO2 7028.33 3194.697 421700.06 61497.93 97828.9 9.85 11.56
TOTAL 41994.41 19088.368 2519664.52 531907.89 846141.4H2O 4327.45 1967.024 259647.14 92650.75 147385.7 14.83
TOTAL 46321.86 21055.391 2779311.66 624558.64 993527.2 100.00 100.00
HHV FUELS
CO 4339 BTU/LB
0.0101 GJ/KG
N.G. 22077 BTU/LB
0.0512 GJ/KG
AUXILIARY FUEL RATE
N.G. 320.21 LB/MIN
145.55 KG/MIN
HEAT INPUTS
CO 0 BTU/MIN 0.00 %
0.000 GJ/MIN
3,033,730 BTU/HR
3.1976 GJ/HR
N.G. 7,069,193 BTU/MIN 100.00 %
7.451 GJ/HR
424,151,559 BTU/HR
447.056 GJ/HR
TOTAL 7,069,193 BTU/MIN
7.451 GJ/HR
427,185,289 BTU/HR
450.253 GJ/HR
CCC-NOX-BACT RHEAT-SCR 6 OF 13
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (SCR)
FUEL ANALYSIS
CO % N.G.%
C 42.85 69.12
H 0.00 23.20
O 57.15 1.58
N 0.00 5.76S 0.00 0.34
TOTAL 100.00 100.00
LB/MIN KG/MIN LB/MIN KG/MIN LB/MIN KG/MIN
C-CO2 0.00 0 588.73 267.60 588.73 267.604
CO-CO2 0.00 0.00 0.00 0 0.00 0.000
H2-H2O 0.00 0 589.85 268.11 589.85 268.112
S-SO2 0.00 0 1.09 0.49 1.09 0.495N-NO 0.00 0 42.14 19.16 42.14 19.156
NET 0.00 0.00 1221.81 555.37 1221.81 555.367
O2 BOUND 6.66 3.03 5.06 2.30 11.72 5.327
O2 EXCESS -1210.09 -550.040
COMBUSTION AIR 6373.62 2897.098
NET O2 EXCESS 5163.53 2347.058
CO REMOVAL 0.00 %
FLUE GASES NG INPUT TOTAL TOTALLB/MIN LB/MIN LB/MIN LB/MIN KG/MIN SCFM NM3/HR %DRY %WET PPM DRY
CO2 0.00 810.06 7028.33 7838.39 3562.90 68676.05 109247.6 13.09 10.88
CO 0.00 0.00 11.65 11.65 5.30 160.34 255.1 0.03 0.03 305.7
H2O 0.00 664.13 4327.45 4991.59 2268.90 106869.85 170005.0 16.93
N2 0.00 0.00 28569.44 28565.65 12984.39 393383.31 625781.1 75.00 62.30
O2 EXCESS 0.00 0.00 5163.53 5163.53 2347.06 62194.70 98937.3 11.86 9.85
SO2 0.00 2.18 3.75 5.93 2.70 35.71 56.8 0.01 0.01 68.1NO 0.00 0.51 7.61 8.12 3.69 68.05 108.3 0.01 0.01 129.7
TOTAL 0.00 1476.88 45111.77 46584.86 21174.94 631388.01 100.00
TOTAL(DRY) 524518.16 100.00
TOTAL
FLOW
OXYGEN REQUIRED
FLUE GAS PRODUCTS
GASES N.G.
CCC-NOX-BACT RHEAT-SCR 7 OF 13
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (SCR)
MASS BALANCE 198.9 PPM NOX
LB/MIN KG/MIN
SOURCE GASES 40426.14 18375.51807
COMBUSTION AIR 5895.72 2679.873302
N.GAS 320.21 145.5482806
TOTAL 46642.07 21200.93966
COMBUSTION PRODUCTS 46584.86 21174.93693
DIFFERENCE 0.12 0.12 %
Cp-BTU/LB-oF Cp KJ/Kg-K T-oF LB/MIN KG/MIN h-BTU/MIN h KJ/MIN
N2 0.2481 0.066 190.86 24090.40 10950.18229 949493.68 901
O2 0.2159 0.057 190.86 5020.57 2282.078624 172204.88 163
CO 0.2078 0.055 190.86 11.65 5.296796695 384.65 0
CO2 0.2078 0.055 190.86 7028.33 3194.697445 231994.50 220
SO2 0.1361 0.036 190.86 3.75 1.7067954 81.19 0
NO 0.2078 0.055 190.86 7.61 3.458393635 251.14 0H2O 1141.5 546.8783 190.86 4263.82 1938.09773 4867109.74 4618
TOTAL 40426.14 18375.51807 6,221,520 5903
Cp-BTU/LB-oF Cp KJ/Kg-K T-oF LB/MIN KG/MIN h-BTU/MIN h KJ/MIN
N2 0.2468 0.066 70.00 4479.04 2035.927486 42001.13 40
O2 0.2147 0.057 70.00 1353.04 615.0197612 11038.94 10H2O 1086.3 520.5 70.00 63.64 28.92605517 69131.77 66
TOTAL 5895.72 2679.873302 122172 116
TOTAL GASES 6343692 6019
BTU/LB GJ/KG LB/MIN KG/MIN h-BTU/MIN h KJ/MIN
CO 4339.0 0.01 0.00 0 0 0NAT. GAS 22077 0.05 320.21 145.5482806 7069193 6707
FUEL TOTAL 7069193 6707
TOTAL 13,412,884
RADIATION LOSSES 2.00 268,258
NET ENTHALPY FLUE GASES 13,144,627
INPUT ENTHALPY PRIMARY AIR
INPUT ENTHALPY FLUE GASES
CCC-NOX-BACT RHEAT-SCR 8 OF 13
10/20/2008
HEAT BALANCE FOR REHEAT FLUE GASES (SCR)
Cp-BTU/LB-oF Cp KJ/Kg-K T-oF LB/MIN KG/MIN h-BTU/MIN h KJ/MIN % wt SCFM NM3/HR PPM(WET)
N2 0.2531 0.067 644.00 28565.65 12984.4 4424460 4198 61.32 393349.0 625726.6
O2 0.2204 0.059 644.00 5163.53 2347.1 696608 661 11.08 62220.5 98978.3
CO2 0.2286 0.061 644.00 7838.39 3562.9 1096731 1041 16.83 68585.9 109104.2
CO 0.2286 0.061 644.00 11.65 5.3 1630 2 0.03 160.3 255.1 254.00
SO2 0.1736 0.046 644.00 5.93 2.7 630 1 0.01 35.7 56.9
NO 0.2286 0.061 644.00 8.12 3.7 1136 1 0.02 67.6 107.5H2O 1348.27 645.9 644.00 4991.59 2268.9 6729985 6385 10.72 106869.8 170005.0
TOTAL 46584.86 21174.9 12951180 12288 100 631289.0 1004233.5
NET DIFFERENCE -193446
REHEAT TEMPERATURE 644.0oF NOX EF= 83.00 LB/MMFT3
340.0OC NOX T/YR
N.GAS USAGE 320.21 LB/MIN
N.GAS USAGE 145.55 KG/MIN CO EF= 61.00 LB/MMFT3
N.GAS USAGE 424.15 MMBTU/HR CO T/YR
447.06 GJ/HR
SO2 EF= 0.60 LB/MMFT3
FLUE GAS OXYGEN 11.86 % SO2 T/YR
INLET FUEL CONCENTRATION 11.32 BTU/SCF
DSCFM NM3/HR WSCFM NM3/HR ACFM AM3/HR
INLET 453967 722156 545255 867374 1140079 1946302OUTLET 524518 834386 631388 1004391 1320175 2253756
STEAM ENTHALPY AT ATMOSHERIC PRESSURE
A0 A1 A2 C
H2O 4.563E-01 1.666E-05 2.232E-07 1.069E+03
FLUE GAS VOLUME SUMMARY @ COMBUSTOR
OUTPUT ENTHALPY
CCC-NOX-BACT RHEAT-SCR 9 OF 13
10/20/2008
COST ESTIMATE
SCR NOX CONTROL OPTION
FACTOR COST
CAPITAL COSTS
DIRECT COST
BASIC SCR UNIT 2,000,000
EQUIPMENT TOTAL 2,000,000
OTHER INSTRUMENTS 100,000
TAXES 0.06 120,000
FREIGHT 0.10 200,000
TOTAL 2,420,000
INSTALLATION FOUNDATIONS 0.08 193,600
ERECTION 0.14 338,800
ELECTRICAL 0.10 242,000
PIPING 0.15 363,000
INSULATION 0.01 24,200
SITE PREPARATION 0.02 48,400
TOTAL 0.50 1,210,000
DIRECT COSTS TOTAL 3,630,000
INDIRECT COSTS ENGINEERING/DESIGN 0.10 242,000
CONST/FIELD EXPENSE 0.05 121,000
CONTR.FEE 0.03 72,600
START-UP 0.01 24,200
PERFORMANCE TEST 0.01 24,200
CONTINGENCIES 0.20 484,000
TOTAL 968,000
RETROFIT PREMIUM (N/A) 0
TOTAL CAPITAL COST 4,598,000
CCC-NOX-BACT COST-SCR 10 OF 13
10/20/2008
COST ESTIMATE
SCR NOX CONTROL OPTION
OPERATING COST(DIRECT)
UTILITIES PUMP PRESSURE 80.00 PSIG
LIQUOR DENSITY 11.00 LB/GAL
1.32 SG
0.0122 FT3/LB
PUMP VOLUME 20 GPM
13200 LB/HR
PUMP HORSEPOWER 124.00 BHP
CONNECTED LOAD 124.00 BHP
POWER 92.47 KWHr
HOURS OPERATED 8760 HRS
ELECTRICAL COST 0.0370 $/KWHr
ANNUAL COST 29,971 $/YR
NATURAL GAS 424.15 MMBTU/HR
COST 7.097 $/MMBTU
ANNUAL COST 26,368,545 $/YR
REAGENTS UTILIZATION 0.70
MOLAR RATIO 1.00
USAGE 5713 T/YR
UNIT COST 0.12 $/LB
COST $1,371,130
MAINTENANCE LABOR & MATERIALS
15% OF DIRECT CAPITAL COST 689,700 $/YR
(INCLUDES CATALYST REPLACEMENT EVERY 3 YEARS)
MAINTENANCE LABOR HR/YR 1000
COST $/HR 21.00
COST $/YR 21,000
OPERATOR LABOR HR/YR 8760
COST $/HR 25.00
COST $/YR 219,000
SUPERVISOR LABOR HR/YR 1752
COST $/HR 30.00
COST $/YR 52,560
TOTAL DIRECT OPERATING COST 28,751,906
CCC-NOX-BACT COST-SCR 11 OF 13
10/20/2008
COST ESTIMATE
SCR NOX CONTROL OPTION
OPERATING COST(INDIRECT) OVERHEAD % 44.00
$/YR 128,726
PROPERTY TAX % 1.46
$/YR 67,083
INSURANCE % 1.00
$/YR 45,980
ADMINISTRATION % 2.00
$/YR 91,960
CAPITAL RECOVERY %-INTEREST 10.00
LIFE-YEARS 15.00
FACTOR 0.131474
$/YR 604,516
TOTAL INDIRECT OPERATING COST 938,266
TOTAL ANNUAL COST $/YR $29,690,172
EXPECTED NOx(PRE-SCR) LB/TON 2.80
T/YR 3066
EXPECTED NOx(PRE-SCR) LB/TON 1.120
REDUCTION T/YR 1,840
% 60
$/TON $16,139
$/TON-CLK $13.56
CCC-NOX-BACT COST-SCR 12 OF 13
10/20/2008
POWER COST 0.037 $/KWH
PROPERTY TAX RATE 2.4316 $/100 @ 60%
1.4590 %
CAPITAL RECOVERY RATE 10 %
LABOR COSTS
SUPERVISOR 30.00 $/HR
OPERATOR 25.00 $/HR
1ST CLASS MAINTENANCE 21.00 $/HR
1ST CLASS ELECTRICIAN 21.00 $/HR
1ST CLASS WELDER 21.00 $/HR
GENERAL LABOR 19.00 $/HR
NATURAL GAS 7.48 $/GJ 7.10 $/MMBTU
FUEL OIL 5.40702 $/GJ 5.13 $/MMBTU
COAL 2.2661 $/GJ 2.15 $/MMBTU
COKE 0 $/GJ 0 $/MMBTU
CKD DISPOSAL 7.27 $/TONNE 8 $/TON
GYPSUM WASTE DISPOSAL 45.53 $/TONNE 50.08 $/TON ASSUME 30 MILES
MICROFINE LIME 54.55 $/TONNE 60 $/TON
LIMESTONE REAGENT 22.73 $/TONNE 25 $/TON
WATER COST 0.0000 $/M3 0 $/MM gal
WATER TREATMENT 2.0000 $/M3 7571 $/MM gal
PLANT COSTS
CCC-NOX-BACT PLANT COSTS1 13 OF 13
TAB G
PLOT PLANS, SURVEY MAPS, AND PROCESS FLOW DIAGRAMS –
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