title v permit renewal application carmeuse lime & stone ... · the coal handling operations at...

February 26, 2019 Mr. Julian Breckenridge Minerals Section Supervisor Kentucky Division of Air Quality 300 Sower Boulevard, 2nd Floor Frankfort, Kentucky 40601 RE: Title V Permit Renewal Application Carmeuse Lime & Stone, Inc. – Black River Plant (AI – 3400) Dear Mr. Breckenridge: Carmeuse Lime & Stone (Carmeuse) owns and operates a limestone mine, limestone processing, and lime manufacturing plant in Pendleton County, Kentucky (Black River Plant). The plant is classified as a major source under the Title V operating permit program. The current Title V permit (V-14-002 R6) for the Black River Plant expires on August 26, 2019. Pursuant to Condition G.2.a of the permit, a renewal application must be submitted to the Kentucky Division for Air Quality (the Division) 6 months prior to permit expiration (February 26, 2019). Accordingly, Carmeuse is submitting the enclosed permit renewal application. If you have any questions or comments in regard to this submittal, please do not hesitate to call Mr. Paul Smith of Trinity Consultants at (859) 341-8100 or me at (859) 479-6715. Sincerely, Kris Milner, P.E. Environmental Area Manager Carmeuse Lime & Stone, Inc. [email protected] Enclosure cc: Mr. Michael R. Klenda, Carmeuse

Mr. Paul Smith, P.E., Trinity Consultants

Environmental solutions delivered uncommonly well

TITLE V AIR PERMIT RENEWAL APPLICATION

Carmeuse Lime & Stone, Inc. 9043 Highway 154

Butler, Kentucky 41006

PreparedBy:

TRINITYCONSULTANTS1717DixieHighway,Suite900

Covington,Kentucky41011(859)341‐8100

www.trinityconsultants.com

Project191801.0026

February26,2019

Carmeuse Lime & Stone – Black River Plant | Title V Permit Renewal Application Trinity Consultants i

TABLE OF CONTENTS

1. APPLICATION SUMMARY 1-1

1.1PurposeofApplication..........................................................................................................................................1‐1

1.2SummaryofApplicationContents.....................................................................................................................1‐1

2. FACILITY AND OPERATIONS DESCRIPTION 2-1

2.1FacilityLocation......................................................................................................................................................2‐1

2.2FacilityOperationsSummary..............................................................................................................................2‐1

2.3LimestoneHandling...............................................................................................................................................2‐1 2.3.1MinetoStockpileTransfer(LS01)................................................................................................................................2‐1 2.3.2LimestoneStockpiles(LS02)andLimestoneScreeningandCrushing(LS03).........................................2‐2 2.3.3KilnLimestoneFeedSystem(LS04)............................................................................................................................2‐2 2.3.4LimestoneLoadoutOperations(LS05)......................................................................................................................2‐2 2.3.5SinterProcess(LS06).........................................................................................................................................................2‐2

2.4CoalReceivingandStorage(CL01)....................................................................................................................2‐2

2.5RotaryKilns..............................................................................................................................................................2‐3

2.6LimeHandling..........................................................................................................................................................2‐3 2.6.1LimeDustCollectionSystems(PSD)(LM01)andLimeSystemBuildings(LM02).................................2‐3 2.6.2LimeStoragetoHydrate(LM03)..................................................................................................................................2‐4 2.6.3LimeDustCollectionSystems(Non‐PSD)(LM04).................................................................................................2‐4 2.6.4RejectLimeStockpiles(LM05),RejectLimeProcessing(LM06),andClinkerReclaim(LM07).......2‐4 2.6.5LimeLoadout(LM08)........................................................................................................................................................2‐5

2.7HydratePlant...........................................................................................................................................................2‐5 2.7.1HydrationPlant(HY01),HydrateBinstoLoadout(HY02),andPulverizationSystem(HY03)........2‐5

2.8SouthHyDratePlant(UnderConstruction)....................................................................................................2‐6 2.8.1LimeScreeningandTransfer..........................................................................................................................................2‐6 2.8.2LimeStorageandProcessing..........................................................................................................................................2‐6 2.8.3HydrationandDrying.........................................................................................................................................................2‐7 2.8.4HydrateStorageandLoadouttoTrucks....................................................................................................................2‐7

2.9FugitiveEmissionsFromRoads..........................................................................................................................2‐7

2.10StationaryEngines...............................................................................................................................................2‐7

3. BLACK RIVER PLANT EMISSION INVENTORY 3-1

3.1FrameworkforEmissionUnitInventory.........................................................................................................3‐1 3.1.1GroupingofEmissionUnits.............................................................................................................................................3‐1 3.1.2NomenclatureforIndividualEmissionUnits...........................................................................................................3‐1

3.2ChangestoRotaryKilnEmissionFactors........................................................................................................3‐3

4. APPLICABLE REQUIREMENTS SUMMARY 4-1

4.1SourceClassification..............................................................................................................................................4‐1 4.1.1PreventionofSignificantDeterioration.....................................................................................................................4‐1 4.1.2TitleVPermittingProgram..............................................................................................................................................4‐1

Carmeuse Lime & Stone – Black River Plant | Title V Permit Renewal Application Trinity Consultants ii

4.1.3HazardousAirPollutants..................................................................................................................................................4‐2

4.2NewSourcePerformanceStandards................................................................................................................4‐2 4.2.1NSPSSubpartY–CoalPreparationandProcessingPlants...............................................................................4‐2 4.2.2NSPSSubpartHH–LimeManufacturingPlants.....................................................................................................4‐2 4.2.3NSPSSubpartOOO–NonmetallicMineralProcessingPlants..........................................................................4‐3 4.2.4NSPSSubpartUUU–CalcinersandDryers(NotApplicable)............................................................................4‐3 4.2.5NSPSSubpartIIII–StationaryCompressionIgnitionInternalCombustionEngines.............................4‐3 4.2.6NSPSSubpartJJJJ–StationarySparkIgnitionInternalCombustionEngines............................................4‐4

4.3NationalEmissionStandardsforHazardousAirPollutants.....................................................................4‐4 4.3.1NESHAPSubpartAAAAA–LimeManufacturingPlants......................................................................................4‐4 4.3.2NESHAPSubpartZZZZ–ReciprocatingInternalCombustionEngines........................................................4‐4 4.3.3NESHAPSubpartDDDDD–BoilersandProcessHeaters....................................................................................4‐5

4.4KentuckySIPRegulations.....................................................................................................................................4‐5 4.4.1401KAR51:017–PreventionofSignificantDeteriorationofAirQuality..................................................4‐5 4.4.2401KAR59:010–NewProcessOperations............................................................................................................4‐6 4.4.3401KAR59:015–NewIndirectHeatExchangers................................................................................................4‐6 4.4.4401KAR61:020–ExistingProcessOperations.....................................................................................................4‐6 4.4.5401KAR63:010–FugitiveEmissions........................................................................................................................4‐6 4.4.6401KAR63:020–PotentiallyHazardousMatterorToxicSubstances........................................................4‐7

4.5ComplianceAssuranceMonitoring...................................................................................................................4‐7 4.5.1CAMApplicabilityAnalysis..............................................................................................................................................4‐7 4.5.2CAMPlanSubmittalTimeframe.....................................................................................................................................4‐9

5. REQUESTED CHANGES TO TITLE V PERMIT 5-11

5.1VEMonitoringProvisionsforLimestoneandCoalHandlingOperations..........................................5‐11

5.2DifferentialPressureExcursionsforRotaryKilns#1to#5...................................................................5‐11

5.3DifferentialPressureExcursionsforLimeHandlingSystemBaghousesSubjecttoPSDLimits.5‐12

5.4StandardizeVisibleEmissionsFollow‐UpRequirements.......................................................................5‐13

5.5LimeHandlingSystemProcessRatesDuringTests..................................................................................5‐14

5.6CoalHeatingValueandSulfurContentLimitations..................................................................................5‐14

APPENDIX A: AREA MAP AND SITE PLAN A

APPENDIX B: EMISSION UNIT INVENTORY B

APPENDIX C: PROCESS FLOW DIAGRAMS C

APPENDIX D: DEP7007 APPLICATION FORMS D

APPENDIX E: SUGGESTED TITLE V PERMIT REVISIONS E

Carmeuse Lime & Stone – Black River Plant | Title V Permit Renewal Application Trinity Consultants 1-1

1. APPLICATION SUMMARY

1.1 PURPOSE OF APPLICATION

CarmeuseLime&Stone(Carmeuse)ownsandoperatesalimestonemine,limestoneprocessing,andlimemanufacturingplantinPendletonCounty,Kentucky(BlackRiverPlant).TheplantisclassifiedasamajorsourceundertheTitleVoperatingpermitprogram.ThecurrentTitleVpermit(V‐14‐002R6)wasissuedtotheplantonAugust26,2014andwasmostrecentlyrevisedonOctober28.2018.PursuanttoConditionG.2.aofthepermit,arenewalapplicationmustbesubmittedtotheKentuckyDivisionforAirQuality(Division)atleast6monthspriortopermitexpiration(i.e.,byFebruary26,2019).Accordingly,Carmeuseissubmittingthisrenewalapplication.

1.2 SUMMARY OF APPLICATION CONTENTS

ThisapplicationreportandassociatedappendicesconstitutethecompleteTitleVpermitapplicationfortheBlackRiverPlant.Pursuantto401KAR52:020,Section4(2)(c),applicationsforpermitrenewalsshallprovideonlytheinformationthatisnewordifferentfromthemostrecentsource‐widepermitapplicationandcertificationbyaresponsibleofficial.AsmostoftheinformationfromthelastTitleVrenewalapplicationcorrectlyreflectstheemissionunitsandapplicablerequirementsoftheplant,thecontentsofthisrenewalapplicationarelimited.Forreadabilityandcompleteness,adescriptionofthecoreprocessesispresentedinSection2alongwithsitemapsinAppendixA,anemissionunitindexinAppendixB,andprocessflowdiagramsinAppendixC.InSection3,abriefexplanationoftheorganizationandnomenclatureforemissionunitsisprovided.Section4providesareviewofapplicablerequirementsunderstateandfederalairregulatoryprogramsandfrompastpermitactions.InSection5,thechangestotheexistingpermitbeingsoughtthroughtherenewalactionarelistedalongwiththebackgroundandjustificationforeach.Forexample,Carmeuseisseekingsomechangestoexistingmonitoringandrecordkeepingrequirementsbasedonemissionsandmonitoringdatacollectedduringthecurrentpermitterm,withtheaimofimprovingthemethodsofcomplianceassuranceandminimizingunnecessaryadministrativeburdens.Supportingthediscussionofpermitconditionchanges,aredline/strike‐outversionofthecurrentTitleVpermitshowingpermitconditionchangesbeingsoughtthroughthisrenewalisprovidedinAppendixE.RequiredDEP7007seriesapplicationformsareprovidedinAppendixD.Withtheexceptionofsomeemissionfactorinformationfortherotarykilns,therearenoupdatesneededtotheapplicationformscurrentlyonfilewiththeDivisionfromthelastTitleVpermitrenewalapplicationandsubsequentrevisions.Thus,theonlyDEP7007formsprovidedforthisrenewalarethe7007AIandthe7007Nforthefiverotarykilns.Carmeuseisawarethat401KAR52:050wasrecentlypromulgatedthatincorporatesanewlyrevisedsetofDEP7007seriesforms.However,Section2of401KAR52:050allowsapplicantstocontinueusingpreviousversionsoftheformsuntilJuly1,2019.1Sincetheupdatedformswerenotavailableatthetimeofdraftingthisapplication,Carmeusehaselectedtousethecurrentlyapprovedversionsoftheformsuntilthenextpermitapplication.

1DivisionforAirQuality,ProposedRegulationChanges,401KAR52:050.Permitapplication,registrationapplication,andcomplianceforms,November,15,2018http://air.ky.gov/SiteCollectionDocuments/401%20KAR%2052.050%20AAC%20filed%2011‐15‐18.pdf


2. FACILITY AND OPERATIONS DESCRIPTION

2.1 FACILITY LOCATION

TheBlackRiverPlantislocatedapproximately26milessoutheastofCincinnatiinPendletonCounty,Kentucky,onastripoflandbetweentheOhioRiverandU.S.Highway8.Thepropertyencompassesanareaofapproximately1,200surfaceacres.FigureA‐1inAppendixAshowsthefacilitylocationandthesurroundingareaonatopographicalmap.TheUniversalTransverseMercator(UTM)coordinatesofthefacilityare(approximately)218.8kilometers(km)Eastand4,303.5kmNorth(Zone17,NAD83).FigureA‐2isanaerialimageofthefacility.Colored shading has been added to this image denoting the physical location of the major emission unit groupings. Figure A-3 provides a plan view of the facility showing the location of regulated point sources.

2.2 FACILITY OPERATIONS SUMMARY

HighcalciumlimeismanufacturedattheBlackRiverPlantthroughthecalcinationoflimestone,representedbythefollowingreaction:2 CaCO3+heat→CO2+CaO(highcalciumlime)Thecoreprocessoperationsare:(1)miningrawlimestone;(2)preparinglimestonebycrushingandsizing;(3)calcininglimestoneinkilns;and(4)transfer,storage,andloadoutoflimeandlimestone.Aportionofthelimeproducedisalsoconveyedtoahydrateplantatthesitetoproducehydratedlimeproducts.Adetaileddescriptionofthesecoreprocessoperationsaredescribedinthefollowingsections.TheorganizationandnomenclatureisconsistentwiththatrepresentedontheemissionunitindextableinAppendixB.Toaidinreviewingthedescriptions,thecorrespondingprocessflowdiagramsprovidedinAppendixCcanalsobereferenced.

2.3 LIMESTONE HANDLING

Thelimestonehandlingandprocessingareaissubdividedintosixfunctionalsubgroups:(1)minetostockpile;(2)stockpiles;(3)screeningandcrushingoperations;(4)kilnfeed;(5)loadout;and(6)sinteroperations.TheselimestoneprocessesarerepresentedonFigureC‐1inAppendixC.

2.3.1 Mine to Stockpile Transfer (LS01)

Limestoneissuppliedfromanundergroundminelocatedadjacenttoandundertheplant.Limestoneisminedbytheroomandpillarbenchingmethodusingdrillingandblasting.Limestoneiscrushedinaprimaryjawcrusherundergroundintheminebeforeitistransportedbyaseriesofbeltconveyorstoarun‐of‐minestockpileatthesurface.Thefugitiveemissionsfromtheconveyingandtransferoperationsarecontrolledbyavailablewatersprays(asneededtomaintainmoistmaterial)locatedatvariouspointsbetweenthemineportalexitandthestockpile.

2Limestonerockusedinlimeproductionistypicallyeitherpredominantlycalciumcarbonate,whichisthecaseforrockquarriedattheBlackRiverPlantor,itmaycontainahighmagnesiumcarbonateconcentration(termeddolomiticlimestone).


2.3.2 Limestone Stockpiles (LS02) and Limestone Screening and Crushing (LS03)

Twoundergroundbeltconveyorsreceivelimestoneviavibratingfeedersfromtherun‐of‐minestockpileandtransferitabovegroundtothescreeningbuilding.Insidethescreeningbuilding,twotripledecklimestonescreensseparatethestoneintolargekilnfeed(roughly2½"×1"),smallkilnfeed(roughly½"×1"),oversized,andundersizedstone.Thelargekilnfeedstonesaretransferredtoastockpileviatripperconveyors.Smallkilnfeedstonesaresenttoaseparatepileviatwobeltconveyors.Oversizedstonesarepassedthroughtwosecondaryconecrushers,whichbreakdownoversizedlimestoneintosmallerpieces.Thesecrushersoperateinaclosedcircuitwithscreenstorecyclethelimestonetokilnfeed.Undersizedstonefromthescreensistransferredtoadualscrewclassifier.Aradialstackerthentransfersstonetoastockpile(½×150Mesh)ortoasinterprocess(LS06).Thescreensinsidethescreeningbuildinghavetheabilitytobefloodedwithwatertoaidintheseparationofthebrokenlimestoneandminimizedustgeneration.Thesecondarycrushers,spiralclassifier,andconveyortransferpoints,whichalloperateinsidebuildingsandareenclosed,arenotadirectsourceofemissionstotheatmosphere.Fugitiveemissionsgeneratedinsidethebuildingsarecontrolledbyenclosureandarerepresentedintheemissioninventorybythescreening,crushing,andtransferhousebuildings.

2.3.3 Kiln Limestone Feed System (LS04)

Thekilnfeedlimestoneisrecoveredfromthestockpilesviaanundergroundbeltconveyor,whichisfedbymultiplevibratingfeederslocatedinareclaimtunnelunderthelimestonestockpiles.ThestoneisthentransferredbybeltconveyorstoeitherthestonebinsforKilns#1,#2,and#3ortothepreheatersforKilns#4and#5.ThreesetsofindoorandoutdoorbeltconveyorsfeedlimestonefromthestonebinstoKilns#1,#2,and#3.Fugitiveemissionsgeneratedfromlimestonefeedarecontrolledbymoistmaterialand/orenclosureinbuildings.

2.3.4 Limestone Loadout Operations (LS05)

Dependingonmarketdemand,limestonefromthestockpilescanbeloadedintotrucksusingfrontendloadersforoffsitedelivery.Alternately,limestonefromthestockpilescanbefedintostonedumphoppers,whichconveythestonetothelimestonebargeloadoutstation.Fugitiveemissionsfromthestonedumphoppersandtransferpointstothebargeloadoutstationarecontrolledbyenclosureandmoistmaterial.

2.3.5 Sinter Process (LS06)

Stonesfromthedualscrewclassifierinthescreeningbuildingaretransferredtoadoubledecklimestonescreeninthesinterprocessarea.Thescreenseparatesstoneinto8’sandsinter.Separatedstoneisthentransferredtorespectivestockpilesviatwofixedstackers.Thismaterialcanbefedintotrucksviafrontendloaders.Emissionsfromscreenandtransferpointsarecontrolledbyavailablewetsuppression(moistmaterial).

2.4 COAL RECEIVING AND STORAGE (CL01)

Coal,usedasthemainfuelintherotarykilns,isreceivedattheplantprimarilyviabarge,butitcanalsobereceivedviatruck.Coalreceivedviatrucksisfirstunloadedintotwodumphoppersandisthentransferredbybeltconveyorintothreeofthefourcoalsilos.Coalreceivedviabargeisunloadedintoacoalreceivinghopperlocatedonthebargeplatform.Coalisthentransferredtothefourcoalsilosviaaseriesofbeltconveyors.Vibratingfeederslocatedinsidethecoalsilosfeedcoaltoabeltconveyorthattransferscoalto5smallercoalsurgebinseachofwhichservesoneofthekilns.The5smallercoalbinsareusedtoholdtheshort‐termsupplyofcoalneededineachkiln.Allthecoalconveyorsareshroudedandfugitiveemissionsarecontrolledby


enclosureandmoistmaterial.ThecoalreceivingandstorageprocessesarerepresentedonFigureC‐2inAppendixC.

2.5 ROTARY KILNS

Therearefiverotarylimekilnscurrentlyinoperationattheplant.Inalimekiln,limestone(CaCO3)iscalcinedtoproducelime(CaO)andcarbondioxide(CO2).Calcinationisaccomplishedinthekilnbyexposingtheappropriatelysizedlimestonetohotexhaustgasesgeneratedfromtheburningoffuel.CoalistheprimaryfuelusedinKilns#1‐#4,althoughthefiringofcoalcanalsobesupplementedwithglycerinandnaturalgas.Naturalgasisalsousedasthestartupfuelforallofthekilns.CarmeusesubmittedaminorpermitrevisionapplicationinJanuary2017totheDivisioncoveringtheinstallationofnewmultichannelburnersinKilns#4and#5thatwillprovidetheabilitytoco‐firenaturalgaswithcoal.CarmeusehassincecompletedtheburnerchangeinKiln#5,allowingthekilntooperateinaco‐firingmode.Thus,theprimaryfuelforKiln#5isnowamixofnaturalgasandcoal,althoughtheKilnretainstheabilitytooperateon100%coal.AsdetailedinarequestforextensionofconstructionauthorityforKiln#4burnersubmittedtotheDivisioninNovember2018,theKiln#4burnerchangehasbeendelayedandisexpectedtooccursometimein2019.Thelimestoneisfedintothecolderendofthekilnandmovescountercurrenttothehotexhaustgasasthekilnrotatestowardsthehotendofthekilnswherethefuelburnerislocated.ThenewerKilns#4and#5areequippedwithpreheaters,whichutilizeexcessheatfromthekilntopre‐heatthelimestoneinpreheatingchamber.Thecalcinedlimeproductisdischargedfromthehotendofthekiln.Theexhaustgasesfromthekilnsareroutedthroughbaghousesbeforedischargingtotheatmosphere.TheexhaustgasesfromKilns#2,#4,and#5eachdischargethroughasinglestack.TheexhaustgasfromKiln#1issplitbetweentwostacks.TheexhaustgasfromKiln#3isdischargedtotheatmosphereoutofventsofthebaghouse.

2.6 LIME HANDLING

Thelimehandling,storage,andloadoutprocessesaresubdividedinto8groupsbasedonapplicableregulationsandfunctions,asdetailedineachofthefollowingsections.TheseprocessesarerepresentedonFiguresC‐1,C‐3,C‐4,andC‐5inAppendixC.

2.6.1 Lime Dust Collection Systems (PSD) (LM01) and Lime System Buildings (LM02)

Afterthelimeproductleavesthekilns,itpassesthroughcoolerssituatedinthetwokilndischargebuildingstoreduceitstemperature.Thelimeisthenconveyedfromthekilndischargebuildingstotheproducthandlingandstorageareabymeansofaseriesofconveyorsystems.AconveyorsystemtransferslimefromthedischargebuildingservingKilns#1,#2,and#3(33‐01)totheProductStorageBuilding(33‐05)viaTransferHouse1(33‐03).(RefertoFigureA‐2inAppendixAandFigureC‐3inAppendixC.)AseparateconveyorsystemtransferslimefromthedischargebuildingservingKilns#4and#5(33‐02)totheProductStorageBuildingviaTransferHouse2(33‐04).OnceintheProductStorageBuilding,thelimeisscreenedandsizedintosmall,medium,granular,andothergradesofproduct.Theproductisthenconveyedtoasetofstoragebinsorstoragesilos(33‐06).Therejectproductfromthekilnsystemisstoredinaseparatebinandissenttoadedicatedloadout.ThetransfersfromkilndischargetotheProductStorageBuilding,tostoragebins,andontotheloadoutstationsalloccurinsidethebuildingstructures.Alltransferpointsfromscrewconveyorstoscrewconveyors,screwconveyorstobucketelevators,andstoragebinstoscrewconveyorsinthelimehandlingareaarecompletelyenclosedwithnoemissionstotheinsidebuildingatmosphere.However,therearealsosomeopenbeltconveyor


toconveyortransfersthanmaybeasourceofindoordust.Multipledustcollectionsystemsprovidepickupductsattheseopenconveyortransferpointsandotherstrategicpointsinsidethebuilding.Theseairstreamsareductedanddirectedtofabricfilterswherethelimeisrecovered.Thedustcollectionsystemsthatwereinstalled,upgraded,ormodifiedin1995(orthataretiedtoconveyorsystemsthatwereinstalled,upgradedormodifiedin1995)areorganizedtogetherintoemissiongroupingLM01,sinceallthesesystemsarecoveredbyapplicablerequirementsfromthe1993PSDpermitaction.Becausethebuildingsenclosingtheseoperationsarealsosubjecttoopacityrestrictionsestablishedinthe1993PSDpermitaction,theyareorganizedtogetherintoemissiongroupingLM02.

2.6.2 Lime Storage to Hydrate (LM03)

SomeofthelimeproducedatthefacilitycanbetransferredfromtheProductStorageBuildingtotheHydratePlantviaaseriesofcoveredbeltconveyors.Smalldustcollectorsaresituatedatthetwoconveyortransferpointsbetweentheselocationstocaptureandminimizeemissions.PartofthebeltconveyorsystemusedtotransportlimetotheHydratePlantissharedforlimestonetransferfromthedumphopperstobargeloadout.Fugitiveemissionsfromthebeltconveyorareminimizedbyshroudingandenclosure.

2.6.3 Lime Dust Collection Systems (Non-PSD) (LM04)

PMinthekilnexhaustgasiscapturedbydedicatedbaghousesservingeachkiln.Thekilndustcapturedateachbaghouseiscollectedinthreedustbins.Aseriesofenclosedscrewconveyorstransportthekilndustfrombaghousestothesedustbins.Displacementairemissionstiedtoenclosedtransfersintothedustbinsarecontrolledbydedicatedbinventfiltersforeachdustbin.DustfromtheKiln#1and#2DustBinandfromtheKiln#3DustBinisloadedintotrucksattwotruckloadouts.Theemissionsfromthisloadingprocessarecapturedbydedicateddustcollectorsoneachloadoutspout.Inaddition,dustaccumulatedinallthekilndustbinscanbesenttoaslurrymixtank,whereitismixedwithwaterandsenttoundergroundinactiveareasofthemine.ThedustcollectionsystemsassociatedwiththedustbinsforKilns#1,#2,and#3werenotassociatedwiththe1993PSDpermitactionfortheplantexpansion.Therefore,becausetheyhaveamorelimitedsetofapplicablerequirements,theyareorganizedtogetherintoemissiongroupingLM04.ThedustcollectionsystemfortheKiln#4and#5dustbinwasapartoftheplantexpansionprojectcoveredbythe1993PSDpermit,andthusitisincludedinLM01.

2.6.4 Reject Lime Stockpiles (LM05), Reject Lime Processing (LM06), and Clinker Reclaim (LM07)

Duetovariousprocessinstabilitiesorothercauses,limethatisnotsuitabletouseasproductmaybegeneratedatboththehotandcoldendofeachkiln.Atthehotend,thisrejectlimeisseparatedwhentheproductlimeistransferredfromthecoolers.Alargechamberatthefeedend(coldend)ofeachkilnallowsforlargerdustparticlestodropoutbeforetheexhaustgasistreated.Rejectlime,dust,andyardmaterialgeneratedintheprocessiscollectedintooneoffourauthorizedlimecontainingmaterialstockpiles(LM05)whereitisstoredforfurtherdisposal.Aseparateemissionunitisdefinedforeachoftheserejectlimestockpiles,sincetheyhavethepotentialtobeasourceoffugitivedust.Therejectlimefromthesestockpilesisreclaimedusingfrontendloaders.Thelimeistransferredintoareceivinghopperthatislocatedwithinapartiallyenclosedshed.Thereceivinghopperfeedsawetscrewsystemthatisusedtoseparatefinesfromrejectlime.Dustgeneratedfromthetransferintothereceivinghopperisminimizedthroughuseofasmalldustcollectionsystem.Rejectlimeisthenhydraulicallytransferredtoaholdingtankandthen


undergroundfordisposal.SeparatedfinesmayalsobecollectedbyfrontendloadersandtransferredintoahighpHpondonsite,wheretheyaremixedwithwaterandsentundergroundfordisposal.ThisrejectlimeprocessingoperationisorganizedintoemissiongroupingLM06.Intheclinkerreclaimprocess(LM07),clinkerandlimematerialrecoveredatvariousstagesoftheprocessispickedupinfrontendloadersandistransferredtoareceivinghopper.Fromthishopper,thematerialistransferredtothelimeconveyersystemservingKilns#4and#5.Fromhere,itisconveyedtodownstreamlimescreening,crushing,andstoragesystemoperationsencompassedbyLM01andLM02.

2.6.5 Lime Loadout (LM08)

Differentgradesofproductstoredinsilosandproductbinsareshippedoffsiteforsalebymeansofrailcarloadout,truckloadout,andbargeloadoutoperations.Therejectsfromtheprocessarealsotransferredfromtherejectbintotrucksattherejecttruckloadoutstation.Fugitiveemissionsassociatedwitheachoftheseloadoutstationoperationsareminimizedthroughuseofdustcollectorsconfiguredtotheloadoutspouts.AllthelimeloadoutoperationsareorganizedintoemissiongroupLM08.

2.7 HYDRATE PLANT

2.7.1 Hydration Plant (HY01), Hydrate Bins to Loadout (HY02), and Pulverization System (HY03)

Aportionoftheproductstreamfromlimestoragemaybedirectedtothehydrateplantviaseriesofbeltconveyors(LM03).Thelimetobeprocessedinthehydrateplantisfirststoredintwohydratorfeedbins.Binventcollectorssittingonthetopofeachhydratorfeedbincontroltheemissionassociatedwiththetransferfromthebeltconveyorintothebin.Asetofcompletelyenclosedscrewconveyorsandabucketelevatorthentransferlimefromthefeedbinstothehydratorsysteminsidethehydrateplantbuilding.Emissionsfromtheenclosedhydratorsystem,whichincludesaclassifier,aseasoner,andamixer,arecontrolledbyadustcollector.Hydratedlimeisclassifiedintothepropersizerangeandisdirectedtohydrateproductbinsviascrewconveyorsystems.Thetransferpointsonthestoragebinsarecontrolledbyintegratedbinventfiltersystems.Thehydratedlimeproductcanbeshippedoffsiteviatrucksorrailcarsinbulkform.Alternately,theproductcanfirstbebaggedinabaggingoperation.Rejectsfromthehydrateplantarestoredinaseparaterejectbinandaretransferredbacktothelimestorageareaviatrucks.Emissionsfromloadoutoperationsatthehydrateplantareaarecontrolledbydustcollectorsontheloadingspouts.Therearenoemissionsassociatedwiththeconveyingandshipmentofbaggedproductsincethematerialisencasedinsealedbags.Thehydrateplantbuildingalsohousesapulverizersystemthatcanbeusedtogeneratedifferentsizegradesoflime.ThemainunitoperationsareaRaymondmillandwhizzer.Themillpulverizesthematerialand,aftersizing,theproductistransferredintoProductStorageBin#3andisshippedoffsiteviatruckinbulkform.TwodustcollectorscontrolemissionsfromtheRaymondmillandwhizzersinthepulverizationoperation.ThehydrateareaprocessesarerepresentedonFigureC‐6inAppendixC.


2.8 SOUTH HYDRATE PLANT (UNDER CONSTRUCTION)

CarmeusesubmittedasignificantpermitrevisionapplicationonMarch3,2016fortheconstructionofanewhydrateplant(termedtheSouthHydratePlant)onacurrentlyundevelopedsectionoftheexistingBlackRiverPlantproperty.ConstructionoftheSouthHydratePlantwasfirstauthorizedinV‐14‐002R3.TheprojectwasoriginallyintendedtobeginconstructioninMarch2018.However,asdetailedinarequestforextensionofconstructionauthoritysubmittedtotheDivisioninMarch2018,significantchangeshavetakenplaceinthelimeandhydratemarketsservedbytheBlackRiverPlantaftertheprojectwasoriginallyconceivedandplanned,andthesechangesnecessitatedthatCarmeusedelaythecommencementofconstructionfortheproject.3TherequestforextensionofconstructionauthoritywasapprovedbytheDivisioninMay2018,permittingtheconstructioncommencementauthoritytoextendtoSeptember30,2019.

2.8.1 Lime Screening and Transfer

AnexistingsmallbuildingattheBlackRiverPlantdesignatedasTransferHouse1enclosesthetransfersoflimefromconveyorsemanatingfromtheKilnDischargeBuildingtoconveyorsthattransportthelimetotheLimeProcessingandStorageBuildings.AspartoftheSouthHydratePlantproject,TransferHouse1willbeexpandedtocontainnewconveyingandscreeningequipmentassociatedwiththeSouthHydratePlant.Anewdivertergatewillbeinstalledtoprovidetheoptiontodivertlimefeedstockfromthecurrentlimetransferpointandredirectittothenewoperations.Thedivertedlimewillfirstbecarriedbyabucketelevatoruptoanewscreeningsystem,whichwillremovebothoversizedmaterialandfinesfromthelimefeedleavingamixof“pebblelime”.Thefinersizelimematerialwillbesentbacktotheexistinglimetransferpointusinganenclosedscrewconveyor.OversizedmaterialwillbecollectedinabunkerlocatedonthegroundleveloftheTransferHouse1,whereitcanbeperiodicallypickedupandremovedusingmobileequipment.Fromthescreen,thepebblelimewillbetransferredontoacoveredconveyorthatwillexitTransferHouse1.AllnewmaterialtransferandscreeningoperationswillbelocatedinsideTransferHouse1.Dustthatmaybegeneratedinsidethebuildingspaceattheequipmenttransferpointswillbepickedupinhoodswithadraftinducedfromanewdustcollector(DC‐06108)whichwilldischargethecleanedairstreamtotheatmosphere.

2.8.2 Lime Storage and Processing

Anewcoveredconveyorwilltransportthepebblelimeapproximately100feetfromTransferHouse1overtotheareaoftheplantwherethenewSouthHydratePlantwillbeconstructed.Theconveyorwilltransferthelimeintoanenclosedbucketelevator,whichwillraisethematerialupandintofullyenclosedchutesconnectedtotwostoragebins(QuickLimeBins#1and#2).Acartridgefiltersystem(DC‐06116)attheheadofthetransportconveyorwillbeusedtopulladraftonandcapturedustthatmaybegeneratedatthematerialtransferpoints.AirfromtheQuickLimeBinsdisplacedduringloadingofthebinswillexhaustthroughintegratedpassivebinventfiltersonthetopofthebins.FromtheQuickLimeBins,thepebblelimewillbetransferredonanenclosedconveyorrunningunderthebinsintotheSouthHydratePlantbuildingtoacrusherthatisusedtoachievethedesiredparticlesizedistributioninthelimestreamforthehydrationprocess.LimeexitingthecrusheristhentransferredtoaSurgeBinviaanenclosedbucketelevatorandscrewconveyor.PickuphoodsatthetransferpointontheconveyorundertheQuickLimeBins,atthetransferpointsinsidetheSouthHydrateBuilding,andfromtheSurgeBinwillcapturedustthatmaybegeneratedusingadraftinducedbyanewdustcollector(DC‐21105),whichwillexhausttoatmosphere.

3RefertoemailcommunicationfromMr.KrisMilner(Carmeuse)toMr.SeanAlteri(theDivision)onMarch21,2018containingtheConstructionAuthorizationExtensionRequestinPDFformat.


2.8.3 Hydration and Drying

FromtheSurgeBin,thelimewillbetransferredtothehydratorequipmentusingasetofenclosedscrewconveyors.IntheHydrator,thelimewillbemixedwithwatertoformhydrate.ThehydratorisequippedwithanintegratedprocessfilterthatcapturesandrecovershydratedustintherelativelysmallvolumeofexhaustgasgeneratedbytheHydratoritself.ThehydratewilldischargeintoascrewconveyorthatconveysittoaMillDryerthatwillbeusedtoremovefreemoisture.Hotairforthedryingprocesswillbesuppliedbyanewindirectnaturalgas‐firedheater.Combustiongasfromtheheaterwillexhaustoutadedicatedstacktotheatmosphere.ThedriedhydrateinthecarrierhotairstreamfromtheMillDryerwillbepneumaticallyconveyedtoalargeprocessfiltersystemtoseparatethedryingairfromthehydrateproduct.Theairstreamwillexhaustoutadedicatedstacktotheatmosphere.

2.8.4 Hydrate Storage and Loadout to Trucks

FromtheMillDryerProcessFilter,thehydratewillbetransferredbyscrewconveyorandbucketelevatortooneoftwostoragebins(HydrateBin#1and#2).Eachhydratebinwillbeequippedwithasmallblowertoinjectairintothebottomofthebintoenhancetheflowpropertiesofthehydrate.Anintegrateddustcollectoroneachhydratebinwillcaptureandrecoverentrainedhydrateandreturnittothebins.Thehydrateproductwillbeshippedoffsiteviatrucksinbulkform.Duetothephysicalspacingofthehydratebins,onlyonetruckwillbeabletobeloadedatanyonetime.Dustthatmaybegeneratedfromloadoutoperationswillbecontrolledbyringtypefabricfiltersystemsintegratedwiththeloadingspouts.TherewillbenoquantifiableincreaseintrucktrafficattheplantasaresultoftheSouthHydratePlantsincethetrucktrafficassociatedwiththenewhydrateplantwillbedisplacingexistingtrucktrafficassociatedwitheithertheexistinghydrateplantorlimearea.

2.9 FUGITIVE EMISSIONS FROM ROADS

ThemovementoftrucksandotherequipmentinandaroundthepropertyisasmallsourceoffugitivePMemissions.Aportionoftheroadsinthecentralpartofthefacilityarepaved.Rawmaterialdelivery,limestone,andlimeproducttrucksprimarilytravelinareasoftheplantthatarepaved.Limestonetruckmovementsalsotraverseareasofthepropertythatareunpaved.Fugitiveemissionsassociatedwithtruckmovementsonpavedandunpavedroadsegmentsareencompassedbyemissionunits23‐01and25‐01,respectively.Inadditiontotherawmaterial,limestone,andlimeproducttrucktrafficatthesite,trucksarealsooccasionallyusedtohaulmaterialstotheon‐sitelandfilllocatedwestofthecentralplantoperations.Mostoff‐specorunusablematerialsaccumulatedatthesitearedisposedtotheundergroundmineviatheRejectLimeProcessingoperation(LM06).However,sometypesofoversizematerialsuchaskilnbrickscannotbedisposedunderground.Previously,fugitiveemissionsassociatedwithhaultrucksandotherequipmenttiedtothelandfilloperationswerecoveredunderemissionunit24‐01.However,trucktraffictoandfromthelandfillisverysmallrelativetotrafficfromallothertypesofrawmaterialandproducttrucksattheproperty.Tosimplifyhowemissionsfromthesetypesofoperationsaretalliedandtrackedannuallyforfeepurposes,fugitivesassociatedwithlandfilltruckshavebeenincorporatedintoemissionunits23‐01and25‐01forpavedandunpavedroads.

2.10 STATIONARY ENGINES

TheBlackRiverplanthassix(6)stationarycompression‐ignitionenginesusingdieselfuel.Fiveoftheengines(includedinemissiongroupEN01)areusedtomaintaintherotationontherotarykilnsintheeventofpoweroutagesandonalimitedbasistoturnthekilnsduringplannedstartups,shutdowns,andmaintenanceevents.


Thesixthengine(initsownemissiongroupEN02)isusedformineshaftoperationsincaseofthepoweroutages.TheBlackRiverplantalsohasone(1)sparkignitionengineusingnaturalgas(includedinemissiongroupEN03),thatisintegraltoanemergencygeneratorinstalledin2017.Theemergencygeneratorhelpstoensurethesafeoperationofthekilnsbysupportingtheburnermanagementsystem(BMS)intheeventofapoweroutage.


3. BLACK RIVER PLANT EMISSION INVENTORY

AspresentedinSection2,theheartoftheoperationsattheBlackRiverPlantarethe5existingrotarykilns.Thekilns,whicharealsotheprimaryemissionunits,accountfornearlyallemissionsofregulatedpollutants,exceptforparticulatematter.Theothercorefunctionalareasoftheplantcanbelogicallysegregatedbetweenthosethatoccurupstreamofthekilns(limestoneprocessing)andthosethatoccurdownstreamofthekilns(limehandlingandhydrateplant).Alsosupportingthekilnsarethecoalreceivingandhandlingoperations.Thematerialhandling,storage,andloadoutoperationsassociatedwiththeprocessesupstreamanddownstreamofthekilnsareonlyasourceofparticulatematteremissions.ThesePMemissionscanbelargelyattributedtothereleaseoffugitivedustatconveyortoconveyortransferpointsandfromstoragepiles.Duetothephysicalcharacteristicsofthelimestonerockanditsmoisturecontent,thegenerationoffugitivedustfromlimestoneconveyingandstorageoperationsisrelativelylow.Similarly,thefugitivedustattributabletoconveyingandstorageofcoalisrelativelylow.Downstreamofthekilns,limeisconveyedtocrushingandscreeningprocessesandtostorage.Fromstorage,thelimeisdistributedtoloadoutsviabarge,railcarortruck.Withafewexceptions,allthelimeconveyingprocessesoccurindoors,eitherwithinbuildings,conveyortubes,orstoragesilos.Dustcollectionsystemscaptureandcollectemissionsgeneratedinsidethesestructuresattransferpointsandroutethemtofabricfiltersforcontrol.Thus,theprimaryemissionunitsinthelimehandlingpartoftheplantarethedustcollectionsystems.

3.1 FRAMEWORK FOR EMISSION UNIT INVENTORY

3.1.1 Grouping of Emission Units

TheBlackRiverPlantemissionunitinventoryisorganizedinto8categories,correspondingtothefunctionalprocessareasattheplant.Theemissionunitswithineachfunctionalareaarethenfurtherorganizedintologicalgroupingsbasedonthestageoftheprocesstheyencompassand/orcommonapplicablerequirements.Theemissiongroupingsgenerallyfollowtheflowofmaterialfromtheminethroughthelimestonescreeningandcrushingprocess,throughthekilns,andthenultimatelytoloadoutsviabarge,rail,ortruck.AlistingofthefunctionalareacategoriesandemissionunitgroupingsisprovidedinTable3‐1.EachSectionBoftheTitleVpermitcoverstheemissionunitsassociatedwitheachemissiongrouping.

3.1.2 Nomenclature for Individual Emission Units

3.1.2.1 Emission Unit ID Numbers

IndividualemissionunitsattheBlackRiverPlanthavealreadybeenassignedEquipmentIDs,SourceIDs,andProcessIDswithintheKentuckyEmissionInventorySystem(KyEIS).Bydesign,boththeEquipmentIDsandSourceIDsareuniqueforeachindividualemissionunit.TheSourceIDsdefinedintheKyEISsystemforemissionunitsattheBlackRiverPlantare4digitnumbers,withthefirsttwodigitslooselycorrespondingtoalegacybreakdownofthefunctionalareaoftheplantandthesecondtwodigitsbeingasequentialnumberinthatgrouping.WithregardtotheProcessIDnumberswithinKyEIS,theonlyemissionunitsattheBlackRiverPlantforwhichseparateProcessIDsaredefinedaretherotarykilns.ProcessID1foreachkilncoversemissionsfromtherotarykilnprocessthataretiedtolimeproduction,ProcessIDs2coversemissionsofcertainairtoxiccompoundsthataretiedtocoalcombustion,andProcessID3coverstheemissionsassociatedfiringofnaturalgasduringstartup.


3.1.2.2 Emission Unit Names and Descriptions

EachoftheemissionunitnamesareprefixedwiththeinternalequipmentidentificationnumberusedwithinCarmeuse’smasterequipmentinventorysystem.Forconveyortoconveyortransfers,thedescriptionindicatesthenameoftheconveyorcoveredandthenameoftheconveyorbeingtransferredto.Forexample,inemissiongroupingLS01–MinetoStockpileTransfers,thefirstemissionunitisaconveyortransferpointwithSourceID01‐01.Thisemissionunit,named“14‐101BeltConveyorTransferto14‐102BeltConveyor”encompassesfugitiveemissionsthatmayoccurfromthe14‐101BeltConveyoraswellasthosetiedtotheopentransfertothe14‐102BeltConveyor.Othertypesofequipment(e.g.,screens,storagebins,bucketelevators,dustcollectionsystems)aresimilarlynamedstartingwiththeequipmentnumberprefixandthenasuitablydetailedidentificationoftheequipment.EmissionunitsforactivitiesthatdonothaveanassignedequipmentnumberinCarmeuse’sinternalinventorysystem(e.g.,stockpiles,buildings)aresimplygivenasuitabledetailedtextdescription.

Table3‐1.FunctionalAreaCategoriesandEmissionGroupingsforEmissionUnitsattheBlackRiverPlant

FunctionalAreaEmissionGroupID

EmissionGroupName

1. LimestoneProcessing LS01 MinetoStockpileTransfers LS02 LimestoneStockpiles LS03 LimestoneScreening&Crushing LS04 KilnLimestoneFeedSystem LS05 LimestoneLoadoutOperations2. CoalReceiving&Storage CL01 CoalReceiving,StorageandConveying3. RotaryKilns KL01 RotaryKiln#1 KL02 RotaryKiln#2 KL03 RotaryKiln#3 KL04 RotaryKiln#4 KL05 RotaryKiln#54. LimeHandling&Storage LM01 LimeDustCollectionSystems(PSD) LM02 LimeSystemBuildings LM03 LimeStoragetoHydratePlant LM04 LimeDustCollectionSystems(Non‐PSD) LM05 RejectLimeStockpiles LM06 RejectLimeProcessing LM07 LimeClinkerReclaim LM08 LimeLoadout5. HydrationPlant HY01 HydratePlant HY02 HydrateBinstoLoadout HY03 LimePulverizerSystem6. Roads RD01 HaulRoads7. Engines EN01 StationaryEngines EN02 StationaryEmergency‐UseCIEngines EN03 StationaryEmergency‐UseSIEngines8.SouthHydratePlant SH01 SouthHydratePlant SH02 HotAirHeater


3.2 CHANGES TO ROTARY KILN EMISSION FACTORS

CarmeuseisseekingtoupdatetheemissionfactorsrepresentedintheKyEISforeachoftherotarykilnstoreflectrecentperformancetestscompletedinthepermitterm.Accordingly,updatedfactorsandcalculatedemissionsareprovidedonanupdatedsetof7007NapplicationformsforthekilnsinAppendixD.Foreachofthekilns,emissionsareestimatedusinganemissionfactorappliedtoadesignprocessrateorfuelfiringrate.Theemissionfactorsutilizedarederivedfromsite‐specifictestdataorareobtainedfrompublishedemissionfactorsforsimilarprocesses.Todefinetheemissionrateslistedonthe7007Napplicationform,theserepresentativeactualemissionfactorsareappliedtoprocessratesandfueluseratesthatcorrespondtothemaximumkilncapacities.Thesetalliedemissionsthusrepresentamaximumemissionratethatwouldoccurifakilnoperatedcontinuouslyatitsdesignrate.Thetalliedemissionsshouldnotbeconstruedaseitherthepotentialemissionratesorexpectedactualannualemissionrates.Thisisbecausethepotentialemissionratewouldbebasedonemissionlimitsallowedunderregulationratherthanrepresentativeemissionfactorsshownontheapplicationforms.Forannualemissioninventoriescompletedforfeepurposes,actualemissionswouldbelessthantalliedontheformssincetherepresentativeemissionfactorswouldbeappliedtoactualannualprocessratesandfuelfiringrates,ratherthandesignrates.

Carmeuse Lime & Stone – Black River Plant | Title V Permit Application Trinity Consultants 4-1

4. APPLICABLE REQUIREMENTS SUMMARY

ThissectionofthepermitapplicationsummarizestheairqualityregulationsthatapplytooperationsattheBlackRiverPlant.Specifically,applicablerequirementsunderNewSourcePerformanceStandards(NSPS),NationalEmissionStandardsofHazardousPollutants(NESHAP),andKentuckyStateImplementationPlan(SIP)regulationsarecovered.AcopyoftheexistingTitleVpermitshowingmarkupsforchangesbeingsoughtthroughthisrenewalalsodelineatesallapplicablerequirementsfromtheseregulations.

4.1 SOURCE CLASSIFICATION

4.1.1 Prevention of Significant Deterioration

TheBlackRiverPlantislocatedinPendletonCounty,Kentucky,whichhasbeendesignatedbyU.S.EPAasunclassified/attainmentforallcriteriapollutants.4Therefore,withrespecttothefederalNewSourceReviewpermittingprogram,onlythePreventionofSignificantDeterioration(PSD)programrequirementsarerelevanttothefacility.KentuckyhasincorporatedtherequirementsofthePSDpermittingprogramintoitsStateImplementationPlan(SIP)at401KAR51:017.5ThesePSDregulationsspecificallydefine28industrialsourcecategoriesforwhichthemajorsourcethresholdis100tpyofanyregulatedpollutant.6Themajorsourcethresholdforfacilitiesnotonthis“Listof28”is250tpy.AspresentedinSection2.2,theprimaryfunctionofBlackRiverPlantistoproducelimefromlimestone.Assuch,theBlackRiverPlantisclassifiedunderSIC3274(Lime).Thisfacilityclassificationisincludedonthe“Listof28”sourcecategories.Thus,themajorsourcethresholdunderthePSDprogramforthefacilityis100tpyofaregulatedNSRpollutant.SincethepotentialemissionsofatleastoneregulatedNSRpollutant(e.g.,SO2)currentlyexceeds100tpy,theBlackRiverPlantisclassifiedasanexistingmajorsourceunderthePSDprogram.

4.1.2 Title V Permitting Program

40CFRPart70containstheregulationsimplementingtheTitleVoperatingpermitprogrammandatedbytheCleanAirAct.KentuckyhasincorporatedtheprovisionsofthisfederaloperatingpermitprograminitsSIPregulationsat401KAR52:020.Asspecifiedin401KAR52:001,Section1(46),amajorsourcewithrespecttotheTitleVregulationsencompassesfacilitieswithpotentialemissionsof100tpyofanyregulatedpollutant,10tpyofanysingleHAPand/or25tpyofanycombinationofHAPs.TheBlackRiverPlantisanexistingmajorsourceandiscurrentlyoperatingundertheTitleVoperatingpermitV‐14‐002R6,issuedAugust26,2014,andmostrecentlyrevisedonOctober28,2018.

4401KAR51:010.

540CFR52.931.

6401KAR51:001,Section1(118)(a)(2)(a)


4.1.3 Hazardous Air Pollutants

AmajorsourceofHAPisonewithpotentialemissionsinexcessof25tpyfortotalcombinedHAPsand/orpotentialemissionsinexcessof10tpyforanyindividualHAP.AsexistingpotentialemissionsofcombinedHAPsexceed25tpy,theBlackRiverPlantisclassifiedasanexistingmajorsourceofHAPs.

4.2 NEW SOURCE PERFORMANCE STANDARDS

NSPSrequirenew,modified,orreconstructedsourcesinapplicablesourcecategoriestocontrolemissionstothelevelsachievablebythebestdemonstratedtechnologyasspecifiedintheapplicableprovisions.AnysourcesubjecttoanNSPSisalsosubjecttothegeneralprovisionsofNSPSsubpartA,exceptasnoted.ThefollowingNSPSsubpartsarepotentiallyapplicabletotheemissionunitsattheBlackRiverPlant:> SubpartY–CoalPreparationandProcessingPlants> SubpartHH–LimeManufacturingPlants> SubpartOOO–NonmetallicMineralProcessingPlants> SubpartUUU–CalcinersandDryersinMineralIndustries> SubpartIIII–StationaryCompressionIgnitionInternalCombustionEngines> SubpartJJJJ–StationarySparkIgnitionInternalCombustionEnginesAnanalysisofapplicabilityforeachoftheserulesisprovidedinthefollowingsubsections.TherearenootherNSPSregulationsthatareapplicableorpotentiallyapplicabletoemissionunitsattheplant.TheemissionunitssubjecttoeachregulationandtheapplicablerequirementstiedtoeachareaddressedintheSuggestedPermitinAppendixE.

4.2.1 NSPS Subpart Y – Coal Preparation and Processing Plants

NSPSSubpartYappliestoaffectedfacilitiesincoalpreparationandprocessingplantsconstructedormodifiedafterOctober27,1974,thatprocessmorethan200tonsofcoalperday.A“coalpreparationandprocessingplant”isdefinedundertheruleasanyfacility(excludingundergroundminingoperations)whichpreparescoalbyoneormoreofthefollowingprocesses:breaking,crushing,screening,wetordrycleaning,andthermaldrying.ThecoalhandlingoperationsattheBlackRiverfacilityhavethecapacitytoprocessmorethan200tonsperdayofcoalandthecoalispulverizedpriortobeingdeliveredtothekilns.ThroughtheinitialTitleVpermitaction,theDivisionpreviouslydeterminedthatNSPSSubpartYappliestothecoalhandlingoperations.NSPSSubpartYlimitstheopacityfromcoalprocessingandconveyingequipmentto20%.Sincenoneoftheexistingcoalhandlingequipmentatthefacilityhasbeenconstructed,reconstructed,ormodifiedafterApril28,2008,newerprovisionsinSubpartYpromulgatedonOctober8,2009donotapply.

4.2.2 NSPS Subpart HH – Lime Manufacturing Plants

NSPSSubpartHHappliestorotarylimekilnsconstructedormodifiedafterMay3,1977.Kiln#1,Kiln#2,andKiln#3attheBlackRiverfacilitywereconstructedin1970,1970and1974,respectively,andhavenotsincebeenmodified(asdefinedin40CFR60SubpartA).7Therefore,thesekilnsarenotcurrentlysubjecttothe

7CapitalimprovementsweremadetoKiln#2followinganunplannedshutdownin1998duetoequipmentfailure.Theseimprovements,intheinterimperioduntilthekilnrestartedin2005,includedreplacementofthestoneandcoalbinsservingKiln#2,anupgradeofthebaghousesystem,andotherminorstructuralandequipmentchanges.However,noneof


requirementsofthisSubpart.Kiln#4andKiln#5,whichwereconstructedin1995,aresubjecttotherequirementsofthissubpart.

4.2.3 NSPS Subpart OOO – Nonmetallic Mineral Processing Plants

NSPSSubpartOOOregulatesPMemissionsfromeachcrusher,grindingmill,screeningoperation,bucketelevator,beltconveyor,baggingoperation,storagebin,andenclosedtruckorrailcarloadingoperationatanonmetallicmineralprocessingplantconstructed,reconstructed,ormodifiedafterAugust31,1983.Pursuantto40CFR§60.671,anonmetallicmineralprocessingplantmeansanycombinationofequipmentthatisusedtocrushorgrindanynonmetallicmineralwhereverlocatedexceptasprovidedin40CFR§60.670(b)and(c).Limestoneisincludedinthelistofnonmetallicmineralscoveredbytherule.Therefore,limestonehandlingequipmentattheBlackRiverPlantconstructedormodifiedafterAugust31,1983,issubjecttotherequirementsofSubpartOOO.Theboundaryofthenonmetallicmineralprocessingplantbeginsattheconveyorfromtherun‐of‐minestonestockpile(01‐03)andcoverslimestoneprocessingoperationsuptothepointthatprocessedstoneistransferredtothetwokilnfeedstockpiles.AttheBlackRiverplant,thematerialhandlingoperationswithinthenonmetallicmineralprocessingplantincludecrushers,screeningoperations,andbeltconveyors,whicharegroupedtogetherunderemissiongroupLS03–LimestoneScreeningandCrushing.TheseemissionunitsaresubjecttotherequirementsofSubpartOOOastheunderlyingequipmentwasconstructedormodifiedin1995.Thescreeningoperationsinthesinterprocessarea(LS06)arealsosubjecttoSubpartOOO.Thelimestoneconveyingoperationsbetweenthekilnfeedpilesandthekilns(LS04)arenotsubjecttoSubpartOOOsincetheyarenotpartofthenonmetallicmineralprocessingplantasdefinedundertherule.Theyare,however,regulatedunderNESHAPSubpartAAAAAasaprocessedstonehandlingsystem,asdetailedfurtherbelow.

4.2.4 NSPS Subpart UUU – Calciners and Dryers (Not Applicable)

NSPSSubpartUUUappliestocalcinersanddryersatmineralprocessingplants.Theexistingrotarykilnsmeetthedefinitionofcalcinerin§60.731.However,limestoneisnotoneofthenamedmineralsinthedefinitionofmineralprocessingplant.Therefore,therotarykilnsattheBlackRiverPlantarenotsubjecttotherequirementsofthissubpart.

4.2.5 NSPS Subpart IIII – Stationary Compression Ignition Internal Combustion Engines

NSPSSubpartIIII,whichwasoriginallypromulgatedonJuly11,2006,establishedstandardsforownersandoperatorsofstationarycompressionignition(CI)internalcombustionengines(ICE)constructed,reconstructed,ormodifiedafterJuly11,2005andmanufacturedafterApril1,2006.8AsnotedinSection2.9andshownintheemissionunitinventorytableprovidedinAppendixB,therearesevenstationaryenginescurrentlyattheBlackRiverplant,sixofwhicharecompression‐ignitionenginesusingdieselfuel.Fiveoftheengines,whichareusedtoturnthekilnsintheeventofapoweroutage(34‐01,34‐02,34‐03,34‐04,and34‐05),wereallconstructedbetween2015and2018andaretherebysubjecttoSubpartIIII.Additionally,the166hpMineEscapeShaftEmergencyGenerator(34‐06)wasinstalledin2006.Thisengine,whichwasorderedafterJuly11,2005,wasmanufacturedbyJohnDeereonMay2,2006,justaftertheApril1,

thesechangesresultedinanincreaseinshort‐termpotentialemissions(lb/hr)ofanypollutantregulatedunderSubpartHH(i.e.,PM)andthusKiln#2remainsgrandfatheredwithrespecttothisregulation.

8Per40CFR60.4200(a),forthepurposesofNSPSSubpartIIII,thedatethatconstructioncommencesisthedatetheenginewasorderedbytheowneroroperator.


2006applicabilitydate.Therefore,thisengineisalsosubjecttoSubpartIIII.Thecurrentpermit(V‐14‐002R6)adequatelycapturesalloftheapplicablerequirementsforthecompressionignitionenginesunderSubpartIIII.

4.2.6 NSPS Subpart JJJJ – Stationary Spark Ignition Internal Combustion Engines

NSPSJJJJisapplicabletoownersandoperatorsofstationarysparkignition(SI)internalcombustionengines(ICE)thatcommencedconstructionafterJune12,2006andweremanufacturedafterJanuary1,2009foremergencyengineswithamaximumenginepowergreaterthan25hp.Becausethenaturalgas‐firedemergencygeneratorengine(34‐07)wasorderedafterJune12,2006andmanufacturedafterJanuary1,2009,pursuantto40CFR60.4230(a)(4)(iv),theSIICEissubjecttorequirementsinSubpartJJJJ.Astheenginemeetstherequirementsof40CFR60.4243(d),theengineisalsoclassifiedasanemergencystationaryICE.Becausethegeneratorenginehasamaximumenginepowerbetween25bhpand100bhp,pursuantto40CFR60.4233(d),theenginemustmeettheemissionrequirementslistedinTable1of40CFR60,SubpartJJJJ.TheKohlerengineiscertifiedtomeettheseemissionstandardsandcomplieswithallapplicablerequirementsinSubpartJJJJ.

4.3 NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS

NationalEmissionStandardsforHazardousAirPollutants(NESHAP)areemissionstandardsformajorandareasourcesofHAP.Part63NESHAPallowableemissionstandardsand/orworkpracticeformajorHAPsourcesindesignatedsourcecategoriesareestablishedonthebasisofaMaximumAchievableControlTechnology(MACT)determination.TheBlackRiverPlantisclassifiedasamajorsourceofHAPssincecombinedHAPemissionsexceed25tpy.InreviewingthesourcecategoriesforwhichNESHAPareestablishedformajorHAPsources,thereareonlytwothatarepotentiallyapplicabletotheemissionunitsattheBlackRiverPlant.Thesearediscussedinthefollowingsections.TheemissionunitssubjecttoeachregulationandtheapplicablerequirementstiedtoeachareaddressedintheSuggestedPermitinAppendixE.

4.3.1 NESHAP Subpart AAAAA – Lime Manufacturing Plants

NESHAPSubpartAAAAAappliestoeachlimekiln,theirassociatedcoolers,andprocessedstonehandlingoperationslocatedatlimemanufacturingplantslocatedatamajorsourceofHAP.AlloftheexistingrotarykilnsattheBlackRiverfacilityaresubjecttotherequirementsofthissubpart.Allfivekilnseachmeetthedefinitionofanexistinglimekilnin§63.7082(e)sincetheywereallconstructedpriortoDecember20,2002,thedatetheregulationwasinitiallyproposed..Processedstonehandlingisdefinedin§63.7143asequipmentortransferpointsbetweenequipmentusedtotransportprocessedstone(limestoneprocessedtoasizesuitableforfeedingtoalimekiln),andincludes:storagebins,conveyingsystemtransferpoints,bulkloadingorunloadingsystems,screeningoperations,bucketelevators,andbeltconveyors,endingwheretheprocessedmaterialisfedtothekiln.AttheBlackRiverPlant,thelimestonehandlingequipmentusedtotransferprocessedlimestonefromthekilnfeedstockpiletostonebins,andfromstonebinstothekilnsaregroupedunderLS04–KilnLimestoneFeedSystem.EmissionunitsinthisgroupingaresubjecttotherequirementsSubpartAAAAA.Inaddition,becausetheKiln1,2&3DischargeBuilding(33‐01)enclosessomeofthebeltconveyorsmovinglimestonebetweenthe#1,#2,and#3StoneBinsandKiln#1,#2,and#3,thisbuildingisalsosubjecttotheopacitystandardsofSubpartAAAAA.

4.3.2 NESHAP Subpart ZZZZ – Reciprocating Internal Combustion Engines

SubpartZZZZregulatesHAPsemittedfromstationaryreciprocatinginternalcombustionengines(RICE)locatedatmajorandareasourcesofHAPemissions.WhenSubpartZZZZwasoriginallypromulgated(June15,2004),theaffectedsourcewaslimitedonlytostationaryRICElocatedatmajorsourcesofHAPsthathadacapacity


greaterthan500hp.However,EPApromulgatedrevisionstoSubpartZZZZonJanuary18,2008,that,amongotherchanges,broadenedtheapplicabilityoftheruletocovernewstationaryRICEwithcapacitieslessthanorequalto500hpatamajororareasourceofHAPswithfewexceptions.Then,onMarch3,2012,therulewasagainrevisedtopullinexistingstationaryRICEofanysizeatbothmajorandareaHAPsources.9AffectedsourcesunderSubpartZZZZareclassifiedaseitherexistingstationaryRICEornewstationaryRICE.ForRICEwitharatinglessthanorequalto500hp(whichisallenginesattheBlackRiverPlant),existingRICEarethosethatwereconstructedorreconstructedbeforeJune12,2006.10SincealltheenginesatthefacilitywereconstructedafterJune12,2006,theyareallnewstationaryRICEunderSubpartZZZZ.Pursuantto§63.6590(c),alltheenginesattheBlackRiverPlantmeettherequirementsofSubpartZZZZbymeetingtherequirementsofSubpartIIIIorSubpartJJJJasapplicable.

4.3.3 NESHAP Subpart DDDDD –Boilers and Process Heaters

40CFR63SubpartDDDDDappliestoownersandoperatorsofindustrial,commercial,orinstitutionalboilersorprocessheatersasdefinedin40CFR63.7575thatarelocatedat,orarepartof,amajorsourceofHAP.Thenewgas‐firedairheater(EU35‐21)servingtheMillDryer(EU35‐20)thatwillbeinstalledaspartoftheSouthHydratePlantprojectwillbeconsideredaprocessheaterasdefinedin40CFR63.7575.Asspecifiedin40CFR63.7490(b),theheaterwillbeclassifiedasanewaffectedfacilitysinceitwillcommenceconstructionafterJune4,2010.Astheheaterwillbedesignedtoonlyburnnaturalgas,theheaterwillbeinthe“unitsdesignedtoburngas1fuels”subcategoryasspecifiedin40CFR63.7499.Assuch,thenewheaterwillnotbesubjecttoanyemissionlimitsinTables1and2or11through13ofSubpartDDDDD,ortheoperatinglimitsinTable4ofSubpartDDDDD.Instead,thenewheaterwillonlybesubjecttotheworkpracticestandardsasdetailedinTable3ofSubpartDDDDDandassociatedrequirements.

4.4 KENTUCKY SIP REGULATIONS

4.4.1 401 KAR 51:017 – Prevention of Significant Deterioration of Air Quality

AsindicatedintheSection4.1,theBlackRiverPlantisclassifiedasanexistingmajorsourceunderthePSDprogram.KentuckyhasincorporatedtherequirementsofthePSDpermittingprogramintoitsStateImplementationPlan(SIP)at401KAR51:017.RotaryKiln#4,Kiln#5,downstreamlimeconveyingequipment(groupedunderLM01)andtheirassociatedbuildings(groupedunderLM02)wereallpartofaproject(authorizedbyPermitC‐93‐032onAugust12,1993)thattriggeredPSDpermittingrequirements.Fromthatproject,eachoftheseemissionunits/groupshaveBestAvailableControlTechnology(BACT)emissionlimitsinthecurrentTitleVpermitalongwithassociatedoperatinglimitsandworkpracticestandards.CarmeusehasalsotakenoperatingandemissionlimitationsoncertainemissionunitsassociatedwiththeSouthHydratePlantproject(authorizedbyV‐14‐002R3)toprecludetriggeringPSDpermittingrequirements.Eachoftheselimitationsarerepresentedinthecurrentpermit(V‐14‐002R6).

969Fed.Reg.33474,June15,2004;73Fed.Reg.3568,January18,2008;75Fed.Reg.9648,March3,2010.

1040CFR63.6590(a)(1)(ii).


4.4.2 401 KAR 59:010 – New Process Operations

Particulateemissionsfromnewprocessoperations(commencedonorafterJuly2,1975)notsubjecttoothernewsourcestandardsareregulatedby401KAR59:010.Theaffectedfacilitiesregulatedbythisstandardincludeany“method,form,action,operation,ortreatmentofmanufacturingorprocessing,andshallincludeanystorageorhandlingofmaterialsorproducts,before,during,oraftermanufacturingorprocessing.”Dustcollectionsystemsandotherpointsourcesinthelimehandlingarea,hydrateplant,andsouthhydrateplantthatwereconstructedafterJuly2,1975,aresubjecttothisregulation.ThesearenotedontheemissionunitindextableprovidedinAppendixB.Section3oftheruleestablishesopacityandPMmassemissionsstandards.Opacityofcontinuousemissions(visibleemissionsofparticulatematterpersistingformorethanthreeminutes)shallnotequalorexceed20percentfromacontroldeviceorstackassociatedwithanaffectedfacility.Themassemissionstandardforparticulateemissionsintotheopenairfromacontroldeviceorstackislimitedbasedontheprocessweightrate.Adifferentprocessweightbasedallowableemissionratealgorithmappliesdependingoniftheprocessweightfortheoperationisaboveorbelow60,000lb/hr.

4.4.3 401 KAR 59:015 – New Indirect Heat Exchangers

Theprovisionsof401KAR59:015applytoeachindirectheatexchangerhavinganinputcapacitygreaterthanone(1)millionBTUperhour(MMBtu/hr)andcommencedonorafterApril9,1972.401KAR59:015containsstandardsforPMandsulfurdioxide(SO2).Forsourceswithatotalheatinputcapacitytotalingten(10)MMBtu/hrorlessforallaffectedfacilitiesatthesource,emissionsofPMshallnotbeinexcessof0.56lb/MMBtuandemissionsofSO2shallnotbeinexcessof3.0lb/MMBtuforcombustionofgaseousfuels.Inaddition,affectedfacilitiesshallnotcauseemissionsofPMinexcessoftwenty(20)percentopacity.Thenewnaturalgas‐firedairheatertobeinstalledaspartattheSouthHydratePlantwillhaveaninputcapacitygreaterthanoneMMBtu/hrandwillcommenceafterApril9,1972.Therefore,theprovisionsof401KAR59:015willapplytothenewheater.Asthenewheaterwillbenaturalgas‐firedonly,itwillbeincompliancewithallprovisionsof401KAR59:015bydesign.

4.4.4 401 KAR 61:020 – Existing Process Operations

Particulateemissionsfromexistingprocessoperations(commencedpriortoJuly2,1975)areregulatedby401KAR61:020.Asin401KAR59:010,Section3oftheruleestablishesopacityandPMmassemissionsstandardsbasedontheprocessweightrate.Kiln#1,Kiln#2,andKiln#3aretheonlyprocessoperationsattheBlackRiverfacilitythatarecoveredunderthisrulesincetheywereconstructedpriortoJuly2,1975.ThepotentialPMemissionratefromeachofthesekilnsisbelowtheallowableemissionlimitunder401KAR61:020.

4.4.5 401 KAR 63:010 – Fugitive Emissions

FugitiveemissionsgeneratedfromvariousactivitiesattheBlackRiverfacilityareregulatedby401KAR63:010.401KAR63:010isagenerallyapplicablestandardthatrequiresreasonableprecautionstopreventairbornePMemissions.Operationsthatareregulatedunder401KAR63:010arenotedontheemissionunittableinAppendixB.Inaccordancewith401KAR63:010,Carmeusetakesreasonableprecautionsasdescribedintheregulationtopreventfugitiveemissionsandtoensurenovisiblefugitivedustemissionsaredischargedbeyondthepropertyline.


4.4.6 401 KAR 63:020 – Potentially Hazardous Matter or Toxic Substances

Kentuckyregulatestheemissionsoftoxicairpollutantemissionsthrough401KAR63:020.TheDivisioncanrequirethatdispersionmodelingorotheranalysesbecompletedbyfacilitiesatpermitrenewalorwhenconstructingormodifyingequipmentwhenthereisanincreaseinairtoxicpollutantemissions,asdefinedin401KAR63:020Section2(2),deemedtobesignificant.Thisisdonesothatthereisadocumentedbasisforaffirmingthatafacilitydoesnotcauseanadverseimpact.However,pursuantto401KAR63:020,Section1,therequirementsofthisruleareapplicableonlytotheextentthatsuchemissionsarenotelsewheresubjecttotheprovisionsoftheKentuckyAdministrativeRegulations.BecausethetoxicairpollutantemissionsfromemissionunitsatBlackRiverfacilityarealreadyregulatedunderNESHAP,whichareincorporatedbyreferenceintheKAR,noadditionalrequirementsunder401KAR63:020applytothisfacility.

4.5 COMPLIANCE ASSURANCE MONITORING

4.5.1 CAM Applicability Analysis

Under40CFRPart64,theComplianceAssuranceMonitoring(CAM)regulations,facilitiesarerequiredtoprepareandsubmitmonitoringplansforcertainemissionunitswithaTitleVapplication.TheCAMplansareintendedtodocumentmethodsthatwillprovideon‐goingandreasonableassuranceofcompliancewithemissionlimits.Pursuantto§64.2(a),theCAMregulationsapplytoapollutant‐specificemissionsunit(PSEU),asdefinedin§64.1,atamajorTitleVsourceifthefollowingcriteriaaremet:

1. thePSEUissubjecttoanemissionlimitationorstandardfortheregulatedpollutant,otherthananemissionlimitationorstandardthatisexemptunder§64.2(b),

2. thePSEUusesacontroldeviceasdefinedin§64.1toachievecompliancewiththeemissionlimitation,and

3. thePSEUhaspotentialpre‐controlledemissionsoftheapplicableregulatedairpollutantthatareequaltoorgreaterthanTitleVmajorsourcethresholds.

AnanalysisofapplicabilitytoCAMforeachunitthatissubjecttoanemissionlimitationorstandardattheBlackRiverPlantisprovidedinthissection.Emissionunitsnotsubjecttoanyemissionstandards,whicharethereforenotaddressedherein,includethefugitiveemissionsourcesinthelimestoneprocessingarea,whichareonlysubjectto401KAR63:010.Thisregulationdoesnotprescribeanyunit‐specificemissionstandards,onlygeneralworkpractices.

4.5.1.1 Rotary Kilns

AllfiverotarykilnsattheBlackRiverplantaresubjecttoPMemissionstandards.EachkilnisequippedwithadedicatedbaghousewhichisusedtoachievecompliancewiththesePMemissionlimitsandpre‐controlledemissionsexceed100tpy.However,CAMrequirementsdonotapplytoemissionlimitsproposedbyEPAafterNovember15,1990,pursuanttoSection111or112oftheCleanAirAct.11ThelowestapplicablePMemissionlimitapplicabletothekilnsisfrom40CFR63SubpartAAAAA,theNESHAPforLimePlants,whichwasproposedonDecember20,2002.Accordingly,therotarykilnsarenotsubjecttoCAMrequirementsforPM.12

1140CFR64.2(b)(1)(i).

12AlthoughKilns#1,#2,and#3arealsosubjecttoPMemissionstandardsunder401KAR61:020,theNESHAPSubpartAAAAAPMlimitismorestringentandsubsumestheseSIP‐basedPMstandards.


RotaryKilns#4and#5arealsosubjecttoBACTemissionlimitsforSO2,NOX,andCOestablishedaspartofthe1993PSDpermitaction.However,thereisnocontroldeviceusedtoachievecompliancewiththeseemissionstandards.Therefore,CAMdoesnotapplytoKiln#4and#5forSO2,NOX,orCO.

4.5.1.2 Dust Collection Systems in Lime Handling Area

MultipledustcollectionsystemsareusedtocapturePMemissionsgeneratedinthematerialhandlingandtransferoperationsinthelimeareaoftheplant.MostofthedustcollectionsystemsconsistofductingtopickuphoodsthatroutecapturedPMemissionstoafiltersystemforcontrolofPMpriortodischargetotheatmosphere.Thevariousbarge,railcar,andtruckloadoutstationsalsousefiltersystemsontheloadingchutestocontrolPMemissions.ThesedustcollectionsystemsarewithinemissiongroupingsLM01–LimeDustCollectionSystems(PSD),LM03–LimeStoragetoHydrate,LM04–LimeDustCollectionSystem(non‐PSD),andLM06–RejectLimeProcessing.DustcollectionsystemsunderLM01aresubjecttoPMemissionstandardsestablishedaspartofthe1993PSDpermitaction,aswellas401KAR59:010.DustcollectionsystemsunderLM03,LM04,andLM06aresubjecttoprocessweightbasedPMstandardsunder401KAR59:010only.Whilethepost‐controlledPMemissionratesforallthelimehandlingdustcollectionsystemsarelessthan100tpy,basedonthemassemissionratesattheexitofthedustcollectionsystemsandthenominalcontrolefficienciesthebaghouseswouldbeexpectedtoachieve,itisreasonabletoassumethatpotentialpre‐controlledemissionsexceed100tpy.13Therefore,pursuantto40CFR64.2(a),becausethefabricfiltersareusedtoachievecompliancewithPMemissionlimits,CAMappliestotheseemissionunitsforPM.ACAMplanforPMthatcanbeappliedforallthedustcollectionsystemswaspreparedandsubmittedwiththelastTitleVpermitrenewalapplicationin2012andtherehavebeennochangessincethatwarrantarevision.

4.5.1.3 Bin Vent Filters and Dust Collection Systems in Hydrate Area

Thehydratorfeedbinsandhydrateproductstoragebins,whicharesubjecttoprocessweightbasedPMemissionstandardsunder401KAR59:010,areequippedwithbinventfiltersystemstominimizetheamountofPMreleasedwithdisplacementair.ThesebinventfiltersystemsmayormaynotbeclassifiedasairpollutioncontrolequipmentunderCAMsincetheyareintegratedcomponentsofthestoragebins.Regardless,thepost‐controlledemissionsfromeachofthebinventfiltersystemarelowanditisreasonabletopresumebasedonfeasibleoperatingtimesandnominalcontrolefficienciesprovidedbythefiltersystemsthatpre‐controlledemissionsarelessthan100tpy.Thus,CAMdoesnotapplytothebinventfiltersystemsinthehydratearea.Similartothelimehandlingarea,thetruckandrailcarloadoutstationsforthehydrateplantemployfabricfiltertocontrolPMemissions.Theestimatedpre‐controlledemissionsfromeachoftheseoperationshoweverarelessthan100tpy.Thepre‐controlledemissionsfromtheotherpointsourcesinthehydrateareaequippedwithdustcollectorsarealsolessthan100tpy.Thus,CAMdoesnotapplytothedustcollectionsystemsinthehydratearea.

4.5.1.4 Hydrator/Scrubber System in Hydrate Area

Thehydrator/scrubbersystem(21‐12inemissiongroupHY01)isasmallsourceofPMemissionsthatisentrainedinthesteamplumereleasedfromthehydrator.Thesteamisproducedfromheatgeneratedintheexothermicreactioncausedbythemixingoflimeandwaterinthehydratorunit.Awaterscrubberinherenttothehydratorunitisusedtointroducewatertotheprocessandcoolthesteam.Indirectly,thehydratorscrubberprovidesincidentalcontrolofPMentrainedinthesteam.However,becausethehydratorscrubberisaninherent

13Basedonthelowexhaustflowandintermittentoperationofcertaindustcollectionsystems(e.g.,atthebarge,rail,andtruckloadoutstations),theirpre‐controlledemissionsmaybelessthan100tpyofPM,inwhichcaseCAMwouldnotbeapplicable.However,intheabsenceofspecificdataavailabletoaccuratelydefinetheinletloadingconcentrationstothebaghouses,aconservativepresumptionhasbeenmadethattheyareallsubjecttoCAM.


partofthehydrationprocess,itwouldnotbeclassifiedasanairpollutioncontroldeviceunderCAM.Therefore,CAMdoesnotapplytothisemissionunit.

4.5.1.5 Stationary Internal Combustion Engines

Noneofthestationaryenginesatthefacilityuseacontroldevicetoachievecompliancewithanapplicablestandard.Inaddition,theemissionstandardsapplicableunderNSPSSubpartIIIIandNSPSSubpartJJJJareexemptfromCAMpursuantto40CFR64.2(b)(1)(i)and,sincethisregulationwaspromulgatedafterNovember15,1990.Therefore,CAMdoesnotapplytothestationaryengines.

4.5.1.6 South Hydrate Plant

1. MaterialHandlingandTruckLoadoutDustCollectionSystems

TherearethreedustcollectionsystemstobeinstalledattheSouthHydratePlantthatwillbeusedtominimizedustemissionsfrommaterialhandlingandtransferoperations.TheseareDC‐06108(EU35‐01to35‐04),DC‐06116(EU35‐05to35‐07)andDC‐21105(EU35‐10to35‐18).Inaddition,thetruckloadoutstationsforthehydrateplantemployfabricfiltersintegratedwiththeloadingspouttocontrolPMemissions(EU35‐24and35‐25).Eachofthesesystemsandtheunderlyingoperationsbeingcontrolled,aresubjecttoprocessweightbasedPMemissionstandardsunder401KAR59:010.However,theestimatedpre‐controlledemissionsfromeachoftheseoperationsarewellbelow100tpy.Thus,CAMdoesnotapplytothedustcollectionsystemsinthehydratearea.

2. BinVentFiltersThenewSouthHydratePlantQuickLimeBins(EU35‐08and35‐09)feedbinsandHydrateBins(EU35‐22and35‐23),whicharesubjecttoprocessweightbasedPMemissionstandardsunder401KAR59:010,willbeequippedwithbinventfiltersystemsordustcollectionsystemstominimizetheamountofPMreleasedwithdisplacementair.ThesebinventfiltersystemsarenotconsideredtobeairpollutioncontrolequipmentunderCAMsincetheyareintegratedcomponentsofthestoragebins.Regardless,thepost‐controlledemissionsfromeachofthebinventfiltersystemarelowanditisreasonabletopresumebasedonfeasibleoperatingtimesandnominalcontrolefficienciesprovidedbythefiltersystemsthatpre‐controlledemissionsarelessthan100tpy.Thus,CAMwillnotapplytothebinventfiltersystems.

3. HydratorDustCollectorSystemandProcessFilterSystem

TheHydratorSystem(EU35‐19)isasmallsourceofPMemissions.Adustcollectorinherenttotheoperationofthehydratorunitisusedtocapturehydratematerialfromtheexhaustofthehydratorandreturnthematerialbackintothehydrator.Becausethehydratordustcollectorisaninherentpartofthehydrationprocess,itisnotclassifiedasanairpollutioncontroldeviceunderCAM.Therefore,CAMdoesnotapplytothisemissionunit.TheprocessfiltersystemassociatedwiththeMillDryer(EU35‐20)isdesignedtoseparatethedriedhydratefromthehotaircarrierstreamthatispneumaticallyconveyedfromtheMillDryer,andtotransferittotwohydrateproductbins.Thisprocessfilterisanecessarypieceofequipmentandthemanufacturingprocesscouldnotfunctionproperlywithoutit.Assuch,itisnotclassifiedasanairpollutioncontroldeviceunderCAM.Therefore,CAMdoesnotapplytothisemissionunit.

4.5.2 CAM Plan Submittal Timeframe

AllthedustcollectionsystemsinthelimehandlingareaforwhichCAMrequirementsapply(forPM)aresmallpollutant‐specificemissionunitssincepost‐controlledPMemissionsforeachfiltersystemarelessthan100tpy.


Pursuantto§64.5(b),theinitialproposedCAMplansareduetobesubmittedaspartoftheapplicationforrenewalofaTitleVpermit.However,therequiredCAMPlanwasdevelopedandsubmittedwiththepriorTitleVrenewalapplicationandtherehavebeennochangessincethatwarrantanupdateorrevision.TheCAMPlanrequirementsforthelimehandlingoperationsarealreadyincorporatedintothecurrentTitleVpermit.


5. REQUESTED CHANGES TO TITLE V PERMIT

Carmeuseisseekingtohavecertainexistingpermitconditionsreplacedorrewordedaspartofthispermitaction.Insomecases,experiencesinthecurrentpermittermhaverevealedchangesthatcouldmakethecurrentcompliancemethodsmoreeffectiveorthatcouldreducedatacollectionandmanagementchallengeswithoutaffectingthecomplianceassuranceprovided.Inothercases,changesareneededsimplytoaddmoreclarityandconsistencytopermitconditions.Afewerrorsandtyposhavealsobeennoted.AllthechangesbeingproposedareintendedtoimprovetheeffectivenessofthemonitoringmethodsandbetterallowCarmeusetodemonstratecompliancewiththeapplicableoperatingandemissionstandardsofthepermit.ThefollowingsectionsdiscussthechangesbeingsoughtbyCarmeusetotheexistingpermitprovisionsalongwiththerationaleforthechanges.SpecificwordingchangestoexistingconditionsofthepermitarenotedintheSuggestedPermitRevisionsprovidedinAppendixE.

5.1 VE MONITORING PROVISIONS FOR LIMESTONE AND COAL HANDLING OPERATIONS

Condition4inSectionB,EmissionGroupLS03–LimestoneScreeningandCrushing,(Page7of125)EmissionGroupCL01–CoalReceivingandStorage,(Page17of125)Thecurrentpermit(V‐14‐002R6)includesarequirementforCarmeusetoconductweeklyvisibleemissions(VE)monitoringforthelimestoneandcoalmaterialhandlingoperationslistedabove.However,duetothepropertiesofthelimestoneandcoalmaterialhandled,theseoperationsareveryunlikelytobeasourceofvisiblefugitivedustandamonthlyrecordthatthereisnoobservedvisibleemissionsshouldbesufficientfordemonstratingcompliancewith401KAR63:010.Therefore,CarmeuseisrequestingthattherequiredVEmonitoringfrequencybechangedtomonthly.TheDivisionhasalreadyestablishedthatamonthlyVEmonitoringrequirementisappropriateforessentiallyidenticallimestoneandcoalhandlingoperationsatthesisterCarmeuseplantinMaysville,Kentucky.14TheDivisionhasalsoestablishedthatmonthlyVEmonitoringissufficientfortheprocessedstonehandlingsystemsattheBlackRiverPlant(EmissionGroupLS04),whicharesubjecttomorestringentemissionstandardsundertheLimeMACT(40CFR63,SubpartAAAAA)thantheotherlimestonehandlingoperations.Forthesereasons,andsothereisconsistencybetweenallthelimestonehandlingoperationswithintheBlackRiverPlant,andconsistencybetweentheBlackRiverPlantandMaysvillePlantTitleVpermitsforsimilaremissionunits,CarmeuserequeststhattheVEmonitoringfrequencyforthelistedsystemsberevisedtomonthly.

5.2 DIFFERENTIAL PRESSURE EXCURSIONS FOR ROTARY KILNS #1 TO #5

SectionB,RotaryKiln#1,Condition4.b(Page20of125)RotaryKiln#3,Condition4.b(Page32of125)

14Forexample,inPermitV‐16‐014R1fortheMaysvillePlant(AI3003),refertoCondition4forEmissionGroup1:LS01–MinetoStockpileTransfers;Condition4.aand4.bforEmissionGroup3:LS03–LimestoneScreeningandCrushing;andCondition4forEmissionGroup7:CL01–CoalReceiving&Storage.


Forthebaghousecontrolsystemsoneachofthefiverotarykilns,uponobservingadifferentialpressurereadingoutsidethenormaloperatingrangedocumentedintheOM&MPlan,thecurrentpermitrequiresthatCarmeuseconductanimmediateMethod9opacityreadingfollowingthecompletionofthecorrectiveactionforanyreadingoutsideofthepressuredroprange,or,forthekilnsequippedwithContinuousOpacityMonitors(COMS)toverifycompliancewiththeopacitylimitviatheCOMSreading.CarmeusehaspreviouslyanalyzedoverlappingcontinuousdifferentialpressureandopacitymonitoringdataforRotaryKilns#2,#4,and#5andconfirmedthatthereisnocorrelationbetweenopacityatakilnbaghousestackandchangesinbaghousedifferentialpressure,evenchangeswherethepressureextendsoutsidethenormalrange.Therefore,thesignificantadministrativecostandeffortofconductingMethod9opacityreadingsinresponsetoeachandeverydifferentialpressureexcursionyieldsnoadditionalcomplianceassurancebenefits.AlthoughCarmeuserecognizesthattheremustbesomeadditionalcomplianceassurancemeasuretakeninresponsetobaghousedifferentialpressureexcursions,theDivisionhasalreadyestablishedwhatitconsiderstobeappropriatemonitoringandcorrectiveactionprovisionsforequivalentlimekilnssubjecttothesameLimeMACTemissionlimitsinthepermitfortheCarmeuseMaysvillePlant(V‐16‐014R1).15 ForRotaryKilns#1and#3,whicharenotequippedwithCOMS,Carmeuseisproposingthatimmediateanddocumentedcorrectiveactionandaverificationthatthedifferentialpressurehasreturnedtonormalrangeissufficienttoensurethebaghousesareoperatingasdesigned.ThisapproachavoidstheunnecessarycompletionofaMethod9procedureinsituationswhentherearenovisibleemissionsandnoimpactonopacityduetothedifferentialpressureexcursions.ThesuggestedstrikeoutofCondition4.bisprovidedbelow.b. FollowingareadingoutsideofthepressuredroprangespecifiedintheOM&M:

1) Maintenancepersonnelshallinspectthemonitoringsystem,baghouse,andoperationsimmediately;andtakecorrectionactionassoonaspracticable.

2) Uponcompletedcorrectiveaction,thepermitteeshallimmediatelyconductanEPAReferenceMethod9opacityreadingonthedustcollectionsystemservicedensurepressuredrophasreturnedtonormalrange.[401KAR52:020,Section10]

5.3 DIFFERENTIAL PRESSURE EXCURSIONS FOR LIME HANDLING SYSTEM BAGHOUSES SUBJECT TO PSD LIMITS

EmissionGroupLM01encompassesallthelimehandlingsystembaghousesattheBlackRiverPlantthataresubjecttoPMemissionandopacitylimitsestablishedinapriorPSDpermitaction.Asisthecasefortherotarykilnbaghouses,uponobservingadifferentialpressurereadingoutsidetheexcursionrangespecified,thecurrentpermitrequiresthatCarmeuseconductanimmediateMethod9opacityreadingfollowingthecompletionofcorrectiveaction.Aswiththerotarykilns,CarmeusemaintainsthatconductingaMethod9opacityreadingisnotanappropriateorusefulcomplianceassurancemeasureinresponsetoabaghousedifferentialpressurereading.FortheCarmeuseMaysvillePlanttheDivisionhasestablishedwhatitconsiderstobeappropriatemonitoringandcorrectiveactionprovisionsforequivalentlimehandlingbaghouses,someofwhicharealsosubjecttothesamePSDemissionlimitsasthoseattheBlackRiverPlant.16Carmeusemaintainsthatdocumentedcorrectiveactionbymaintenancepersonnelandaverificationthatthepressurehadreturnedtothenormalrangeshould

15Forexample,refertoCondition4.binSectionBforRotaryKilns#1‐#3ofPermitV‐16‐014R1(page25of74)fortheMaysvillePlant.

16Forexample,refertoCondition4.cinSectionBforEmissionGroup10:LM01–LimeDustCollectionSystems,ofPermitV‐16‐014R1(page41of74)fortheMaysvillePlant.


besufficientandappropriate,aswiththekilns,sincetheDivisionhaspreviouslydeterminedthatadditionalfollow‐upmeasuresintheformofaMethod9readingarenecessary.CarmeuserequeststhattheconditionberewordedtoremovetheMethod9readingrequirement. b. FollowingareadingoutsideofthepressuredroprangespecifiedintheOM&M:

1) Maintenancepersonnelshallinspectthemonitoringsystem,baghouse,andoperationsimmediately;andtakecorrectionactionassoonaspracticable.

2) Uponcompletedcorrectiveaction,thepermitteeshallimmediatelyconductanEPAReferenceMethod9opacityreadingonthedustcollectionsystemservicedensurepressuredrophasreturnedtonormalrange.[401KAR52:020,Section10]

5.4 STANDARDIZE VISIBLE EMISSIONS FOLLOW-UP REQUIREMENTS

SectionB,EmissionGroupLS03–LimestoneScreeningandCrushing,(Page7of125)EmissionGroupCL01–CoalReceivingandStorage,(Page17of125)EmissionGroupLM01–LimeDustCollectionSystems(PSD),(Page58of125)EmissionGroupLM02–LimeSystemBuildings,(Page60of125)EmissionGroupHY01–HydrationPlant(Page83of125)EmissionGroupHY02–HydrateBinstoLoadout(Page87of125)EmissionGroupHY03–LimePulverizerSystem(Page89of125)EmissionGroupSH01–SouthHydratePlant(Page95of125)Thecurrentpermit(V‐14‐002R6)includesrequirementsforCarmeusetoconductVEmonitoringforthelimestone,lime,andcoalmaterialhandlingoperationslistedabove.However,thecurrentVEmonitoringrequirementsforeachemissiongroupcontaininconsistentphrasingandverboseorduplicativelanguage.Therefore,CarmeuseisrequestingthattheVEmonitoringrequirementlanguagebemadeconsistentthroughouttheTitleVpermit.Additionally,eachoftheVEmonitoringrequirementsfortheemissiongroupsindicatedaboverequirethatMethod9testingbeconductedimmediatelyifanyvisibleemissionsareobservedduringavisualobservation.CarmeuseconsidersthisrequirementoverlyburdensomeandunnecessaryfortheBlackRiverPlant.WhenvisibleemissionsareobservedfromanemissionunitattheBlackRiverPlant,itcanmostoftenbequicklyresolvedthroughcorrectiveaction.ByrequiringimmediateMethod9readingsthecorrectiveactionisdelayedandinduecourseresultsinhigherparticulateemissions.CarmeuseisrequestingthattheDivisionremovetherequirementforimmediateMethod9readingswhenvisibleemissionsaredetectedduringaVEreadingandinsteadprovideopportunityforimmediatecorrectiveaction.Theproposedlanguagetoallowforimmediatecorrectiveactionisprovidedbelow.Importantly,CarmeuseisrequestingthatthissamelanguagebeusedforallcoveredemissionunitsotheVErequirementsareconsistentthroughoutthepermit.

Conductvisualobservations(daily,weekly,ormonthly)duringdaylighthours.Ifvisibleemissionsareobserved,takecorrectiveactionandconductafollow‐upvisualobservation.Ifvisibleemissionsareobservedafterthecorrectiveaction,conductanEPAReferenceMethod9reading.


5.5 LIME HANDLING SYSTEM PROCESS RATES DURING TESTS

SectionB,EmissionGroupLM01–LimeDustCollectionSystems(PSD),(Page56of125)PursuanttoConditionG.5.b,anyrequiredperformancetestshallbeconductedundernormalconditionsthatarerepresentativeofthesource’soperationsandcreatethehighestrateofemissions.Ifthemaximumproductionraterepresentsasource’shighestemissionsrateandaperformancetestisconductedatlessthanthemaximumproductionrate,asourceshallbelimitedtoaproductionrateofnogreaterthan110percentoftheaverageproductionrateduringtheperformancetests.ThisgeneralrequirementisreasonableformostemissionunitsregulatedbytheDivision,howeverthebaghousescontrollinglimehandlingemissionsareanexception.AfterlimeleavestheKilns,itistransferredtoaseriesofindoorconveyanceequipment.Manyofthetheseconveyorshandlethelimeproducedfrommultiplekilnsconcurrently(refertoAppendixC,FigureC‐3).TofullysatisfytherequirementsinConditionG.5.b,duringperformancetesting,CarmeusewouldneedtooperatealloftheKilnsthatcouldpotentiallyuseeachconveyancesystemduringtheperformancetesting.Duetomarketvolatility,certainkilnsmaybeidledforperiodsoftimeandschedulingperformancetestingaroundlimeproductionoperationsisimpractical.ItisnotpracticallyoreconomicallyfeasibleforCarmeusetostartupanykilnsnotalreadyinoperationsolelytoconductaperformancetest.Inaddition,theamountoflimedustgeneratedattheinteriortransferpointsthatarecontrolledbythebaghousesisrelativelyconsistentregardlessofhowmanykilnsareinoperation.401KAR50:045,Section5,allowstheDivisiontowaivethe110percentproductionrateperformancetestingrequirementonacase‐by‐casebasisifthesourcedemonstratestotheDivision'ssatisfactionthatthesourceisincompliancewithallapplicablerequirements.ThelastsetofperformancetestingofthelimehandlingbaghouseswasconductedonFebruary24‐26,2015.Thistestingdemonstratedthattheopacityfromeachoftherepresentativedustcollectorswaszeropercentandthemeasuredparticulatematteremissionswerewellbeloweachoftheirrespectiveemissionlimitations.Carmeusebelievesthatthetestingconductedinthecurrentpermitterm,coupledwithon‐goingcontroldevicemonitoring,providessufficientassuranceofcompliancemovingforwardforthelimehandlingbaghouses.However,shouldtheDivisionincludeanynewtestingrequirementsforthelimehandlingsystemsfortheupcomingpermitterm,CarmeuseisrequestingthataprovisionbeaddedtotheStatementofBasisclarifyingthatthegenerallyapplicableprocessraterequirementsforperformancetestsonthelimehandlingsystemsareconsideredmetsolongasallcurrentkilnsinoperationareoperatingwithin90%oftheirstatedcapacity.

5.6 COAL HEATING VALUE AND SULFUR CONTENT LIMITATIONS

SectionB,EmissionRotaryKiln#4,Condition1.b(Page36of125)RotaryKiln#5,Condition1.b(Page45of125)Aspartofthe1995PSDpermitaction,operatinglimitsonthesulfurcontentandheatingvalueofthecoalburnedasfuelinRotaryKilns#4and#5wereestablished.Thecurrentoperatinglimitationrequiresthattheminimumaverageheatingvalueofthecoalbe12,900Btu/lbandthattheaveragesulfurcontentofthefuelbenomorethan0.9%unlesstheNOX,CO,PM,andSO2emissionlimitsarenotexceeded.Theaverageisfurtherdefinedastheaverageofshipmentsreceivedineachmonth.CarmeusebelievestheintentoftheexistingoperatinglimitscanberetainedwhileprovidingmoreclaritybyslightlyrewordingtheselimitsasshownbelowandinthesuggestedpermitprovidedinAppendixE.


b. Theonlysolidfuelpermissibleinthekilniscoal.[401KAR51:017,C‐93‐032]

1) Coalwithlessthananaverageheatingvalueofeither12,900Btu/lbortheaverageforthecoalburnedduring a prior passing compliance demonstration for nitrogen oxide (NOx), carbonmonoxide (CO),particulate(PM),andsulfurdioxide(SO2),whicheverislower,shallnotbeburned.Forthepurposesofthiscondition,averageheatingvalueisdefinedastheweightedaverageheatingvalueinthecoalfromallshipmentsreceived ineachmonthonadryweightbasis.Coalwith less thanaminimumaverageheatingvalueof12,900Btu/lbforeachshipmentshallnotbeburnedasfuelunlessthenitrogenoxide(NOx), carbon monoxide (CO), particulate (PM), and sulfur dioxide (SO2) emission limits are notexceeded.Averageisdefinedastheaverageheatingvalueofshipmentsreceivedineachmonth.

2) Coalwithmorethananaveragesulfurcontentofeither0.9%ortheaverageforthecoalburnedduringapriorpassingcompliancedemonstrationforNOx,CO,PM,andSO2,whicheverishigher,shallnotbeburned.Forthepurposesofthiscondition,averagesulfurcontent isdefinedastheweightedaveragesulfurcontent inthecoalfromallshipmentsreceived ineachmonthonadryweightbasis.Coalwithmorethananaveragesulfurcontentof0.9%foreachshipmentshallnotbeburnedasfuelunlesstheNOx,CO,PM,andSO2emissionlimitsarenotexceeded.Averageisdefinedastheaveragesulfurcontentofshipmentsreceivedineachmonth.

Carmeuse Lime & Stone – Black River Plant | Title V Permit Application Trinity Consultants

APPENDIX A: AREA MAP AND SITE PLAN

FigureA‐1:AreaMap

FigureA‐2:AerialImageSitePlan

FigureA‐3:EmissionPointLocation

_̂

190,000 200,000 210,000 220,000 230,000 240,000 250,000

4,275

,000

4,285

,000

4,295

,000

4,305

,000

4,315

,000

4,325

,000

4,335

,000

4,345

,000

Appendix A-1. Area Map

UTM Easting (m)

UTM

North

ing (m

)

All Coordinates shown in UTM Coordinates,Zone 17, NAD 83 Datum

Area Map Extent

Carmeuse Lime & StoneBlack River Plant

Black River Plant

LM-03

LS - 01LS-02 LS-03

LS-05

LS-06CL-01

KL 01 - KL 03

KL04 - KL 05LM-02

LM-02LM-02

LM-02

LM-02

LM-02LM-02

LM-06

LM-06

LM-08

LM-08

HY01 - HY 03

218,6

0021

8,700

218,8

0021

8,900

219,0

0021

9,100

4,303,300 4,303,400 4,303,500 4,303,600 4,303,700 4,303,800 4,303,900 4,304,000 4,304,100 4,304,200

±

LegendColored shaded denotes locationof major emission groupings and their ID

Appendix A-2. Site PlanBlack River Plant

UTM

North

ing (m

)

UTM Easting (m)All Coordinates shown in UTM Coordinates,

Zone 17, NAD 83 Datum

21 0821 05

21 35

22 0921 31

21 23

27 02

21 1820 2120 20

32 0632 1032 14

32 13

32 15

32 08

21 01

29 0429 03

18 3018 27

18 2418 22

18 16

18 09

18 0618 01

17 4117 3217 27

17 17 17 13 17 10

17 05

16 11

11 0110 01

09 01 08 0107 01

218,6

0021

8,700

218,8

0021

8,900

219,0

00

4,303,300 4,303,400 4,303,500 4,303,600 4,303,700 4,303,800 4,303,900 4,304,000 4,304,100 4,304,200

±

UTM Easting (m)

UTM

North

ing (m

)

All Coordinates shown in UTM Coordinates,Zone 17, NAD 83 Datum

Appendix A-3. Emission Point LocationBlack River Plant


APPENDIX B: EMISSION UNIT INVENTORY

EmissionUnitIndexTable

APPENDIX BEmission Unit Inventory

CarmeuseBlack River Plant

Page: 1 of 7Printed: 2/22/2019

1. Emission Unit IndexEmis

GroupID

Title V Section B,Emission Group Name

Title V Section B,Emission Subgroup

Dwg#

KyEIS Equipment

ID

KyEIS Source

ID

KyEIS Process

IDEmission Unit and KyEIS Equipment/SourceDescription

Constr/ModifcDate

ApplicableRegulations Control Description

Emission Type

LS01 Mine to Stockpile Transfers 001 EQPT00030 01 01 1 14-101 Belt Conveyor Transfer to 14-102 Belt Conveyor 1969 63:010 Moist Material Fugitive

LS01 Mine to Stockpile Transfers 001 EQPT00031 01 02 1 14-102 Belt Conveyor Transfer to 14-200 Reversing Belt Conveyor

1969 63:010 Moist Material Fugitive

LS01 Mine to Stockpile Transfers 001 EQPT00032 01 04 1 14-200 Reversing Belt Conveyor Transfer to Stockpiles 1995 63:010 Moist Material Fugitive

LS02 Limestone Stockpiles 001 AREA00001 01 03 1 Limestone Stockpile (42,000 tons) (8x0 ROM) 1995 63:010 Moist Material Fugitive

LS02 Limestone Stockpiles 001 AREA00003 01 08 1 Small Kiln Feed Stockpile (1/2 x 1) 1995 63:010 Moist Material Fugitive

LS02 Limestone Stockpiles 001 AREA00005 01 12 1 Large Kiln Feed Stockpile (2 1/2 x 1) 1995 63:010 Moist Material Fugitive

LS02 Limestone Stockpiles 001 AREA00008 01 16 1 1/2 x 150 Mesh Stockpiles 1995 63:010 Moist Material Fugitive

LS02 Limestone Stockpiles 001 AREA00017 31 01 1 Riverside Stone Stockpile #1 2001 63:010 Moist Material Fugitive



LS03 Limestone Screening & Crushing

Limestone Conveyor Transfers

001 EQPT00033 01 06 1 51-100 Belt Conveyor Transfer to 51-201 Belt Conveyor 1969 NSPS OOO Moist Material Fugitive



001 EQPT00035 01 09 1 51-206 Belt Conveyor Transfer to Small Kiln Feed Stockpile 1995 NSPS OOO Moist Material Fugitive



001 EQPT00036 01 11 1 51-208 Tripper Conveyor Transfer to Large Kiln Feed Stockpile

1995 NSPS OOO Moist Material Fugitive



001 EQPT00037 01 15 1 51-204 Radial Stacker Transfer to 1/2x150 Mesh Stockpile or 51-221 Limestone Screen




001 EQPT00079 02 01 1 51-200 Belt Conveyor Transfer to 51-201 Belt Conveyor 1995 NSPS OOO Moist Material Fugitive



001 EQPT00084 02 07 1 51-304 Secondary Cone Crusher Transfer to 51-201 Belt Conveyor




001 EQPT00085 02 08 1 51-305 Secondary Cone Crusher Transfer to 51-201 Belt Conveyor




001 EQPT00089 02 12 1 51-203 Belt Conveyor Transfer to 51-204 Radial Stacker 1995 NSPS OOO Moist Material Fugitive


Limestone Processing Buildings

001 EQPT00080 02 02 1 Screening Building Operations 1995 NSPS OOO Moist Material Inside Building

Fugitive



001 EQPT00083 02 05 1 Crusher Building Operations 1995 NSPS OOO Moist Material Inside Building

Fugitive



001 EQPT00087 02 10 1 Transfer House from Screening Building to Stockpiles 1995 NSPS OOO Moist Material Inside Building

Fugitive

LS04 Kiln Limestone Feed System Feed Piles to Stone Bins

001 EQPT00049 01 32 1 52-215 Belt Conveyor Transfer to #3 Stone Bin 1976 NESHAP 5A Moist Material Fugitive


001 EQPT00092 02 15 1 52-301 Belt Conveyor Transfer to 52-302 Belt Conveyor 1995 NESHAP 5A Moist Material Fugitive


001 EQPT00093 02 16 1 52-302 Belt Conveyor Transfer to 52-303 Belt Conveyor or 52-215 Belt Conveyor or #1 Stone Bin or #2 Stone Bin

1995 NESHAP 5A Moist Material Fugitive




EmisGroup

IDTitle V Section B,Emission Group Name


Dwg#

KyEIS Equipment

ID

KyEIS Source

ID

KyEIS Process


Constr/ModifcDate


Emission Type


001 EQPT00095 02 18 1 52-303 Belt Conveyor Transfer to 52-304 Belt Conveyor or #4 Preheater

1995 NESHAP 5A Moist Material Fugitive


001 EQPT00234 02 20 1 52-304 Belt Conveyor Transfer to #5 Preheater 1995 NESHAP 5A Moist Material Fugitive

LS04 Kiln Limestone Feed System Stone Bins to Kilns 001 EQPT00044 01 26 1 81-121 Belt Conveyor Transfer to 81-131 Belt Conveyor 1970 NESHAP 5A Moist Material Fugitive

LS04 Kiln Limestone Feed System Stone Bins to Kilns 001 EQPT00045 01 27 1 81-131 Belt Conveyor Transfer to Kiln # 1 1970 NESHAP 5A Moist Material Fugitive

LS04 Kiln Limestone Feed System Stone Bins to Kilns 001 EQPT00047 01 30 1 82-122 Belt Conveyor Transfer to 82-132 Belt Conveyor 1970 NESHAP 5A Moist Material Fugitive



LS04 Kiln Limestone Feed System Lime Storage Building 003 33 01 1 Kilns 1, 2, & 3 Discharge Building - Burner Building 1 1970 63:010, 51:017; NESHAP 5A

DC + Enclosure Fugitive

LS05 Limestone Loadout Operations 001 EQPT00098 03 01 1 93-102 Belt Conveyor and Barge Loadout 2007 63:010 Moist Material Fugitive

LS05 Limestone Loadout Operations 001 EQPT00264 04 01 1 93-110 Stone Dump Hoppers Transfer to 93-100 Belt Conveyor


LS05 Limestone Loadout Operations 001 EQPT00096 05 02 1 93-100 Belt Conveyor Transfer to 93-101 Belt Conveyor (When in Limestone Service)


LS05 Limestone Loadout Operations 001 EQPT00259 31 02 1 Limestone Transfers via Front End Loader to 93-110 Stone Dump Hoppers


LS05 Limestone Loadout Operations 001 EQPT00260 31 03 1 Limestone Transfers via Front End Loader to Trucks 2007 63:010 Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Truck Receiving 002 EQPT00137 06 01 1 Coal Receiving Hoppers at Truck Dump 1995 NSPS Y Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Truck Receiving 002 EQPT00281 06 03 1 54-801 Belt Conveyor Transfer to 54-802 Reversing Belt Conveyor or #2 Silo

1995 NSPS Y Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Truck Receiving 002 EQPT00149 06 05 1 54-802 Reversing Belt Conveyor Transfer to #1 Silo, #2 Silo, or #3 Silo


CL01 Coal Receiving & Storage Coal Barge Receiving 002 EQPT00254 28 01 1 Barge Receiving Hopper 2006 NSPS Y Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Barge Receiving 002 EQPT00255 28 02 1 54-101 Belt Conveyor Transfer to 54-102 Belt Conveyor 2006 NSPS Y Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Barge Receiving 002 EQPT00256 28 03 1 54-102 Belt Conveyor Transfer to 54-103 Belt Conveyor 2006 NSPS Y Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Barge Receiving 002 EQPT00257 28 05 1 54-103 Belt Conveyor Transfer to 54-802 Reversing Belt Conveyor or #4 Silo


CL01 Coal Receiving & Storage Coal Silos to Bins 002 EQPT00282 06 07 1 54-803 Belt Conveyor Transfer to 54-804 Belt Conveyor 1995 NSPS Y Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Silos to Bins 002 EQPT00283 06 09 1 54-804 Belt Conveyor Transfer to 54-805 or 54-806 Belt Conveyors or #2 Coal Bin


CL01 Coal Receiving & Storage Coal Silos to Bins 002 EQPT00284 06 11 1 54-806 Belt Conveyor Transfer to 54-807 Belt Conveyor or #3 Coal Bin


CL01 Coal Receiving & Storage Coal Silos to Bins 002 EQPT00285 06 12 1 54-807 Belt Conveyor Transfer to 54-808 Belt Conveyor or #4 Coal Bin


CL01 Coal Receiving & Storage Coal Silos to Bins 002 EQPT00286 06 16 1 54-808 Belt Conveyor Transfer to #5 Coal Bin 1995 NSPS Y Moist Material Fugitive




EmisGroup



Dwg#

KyEIS Equipment

ID

KyEIS Source

ID

KyEIS Process


Constr/ModifcDate


Emission Type

CL01 Coal Receiving & Storage Coal Silos to Bins 002 EQPT00287 06 18 1 54-805 Belt Conveyor Transfer to #1 Coal Bin 1995 NSPS Y Moist Material Fugitive

CL01 Coal Receiving & Storage Coal Silos to Bins 002 EQPT00288 28 07 1 54-821 Belt Conveyor Transfer to 54-803 Belt Conveyor 1995 NSPS Y Moist Material Fugitive

KL01 Rotary Kiln #1 003 COMB00001 07 01 1 Rotary Kiln #1 1970 61:020, NESHAP 5A, CAM

Baghouse Point

KL01 Rotary Kiln #1 003 COMB00001 07 01 2 Pulverized Coal Burner 1970 61:020, NESHAP 5A, CAM

Baghouse Point

KL01 Rotary Kiln #1 003 COMB00001 07 01 3 Natural Gas - Startup 1970 61:020, NESHAP 5A, CAM

Baghouse Point


Baghouse Point


Baghouse Point


Baghouse Point


Baghouse Point


Baghouse Point


Baghouse Point

KL04 Rotary Kiln #4 003 COMB00009 10 01 1 Rotary Kiln #4 1995 51:017, NSPS HH, NESHAP 5A

Baghouse Point

KL04 Rotary Kiln #4 003 COMB00009 10 01 2 Pulverized Coal Burner 1995 51:017, NSPS HH, NESHAP 5A

Baghouse Point

KL04 Rotary Kiln #4 003 COMB00009 10 01 3 Natural Gas - Startup 1995 51:017, NSPS HH, NESHAP 5A

Baghouse Point

KL05 Rotary Kiln #5 003 COMB00010 11 01 1 Rotary Kiln #5 1995 51:017, NSPS HH, NESHAP 5A

Baghouse Point

KL05 Rotary Kiln #5 003 COMB00010 11 01 2 Pulverized Coal Burner 1995 51:017, NSPS HH, NESHAP 5A

Baghouse Point

KL05 Rotary Kiln #5 003 COMB00010 11 01 3 Natural Gas - Startup 1995 51:017, NSPS HH, NESHAP 5A

Baghouse Point

LM01 Lime Dust Collection Systems (PSD)

Kiln Discharge to Lime Storage

003 EQPT00289 16 11 1 84-018 Dust Collection System for Kiln 4 & 5 Discharge Conveyors

1995 59:010, 51:017, CAM

na Point



003 EQPT00175 17 05 1 89-858 Dust Collection System for Lime Bins and Truck Loadout

1998 59:010, 51:017, CAM

na Point



003 EQPT00177 17 10 1 89-855 Dust Collection System for Silo #11 Feed Conveyors 1995 59:010, 51:017, CAM

na Point




na Point




na Point



003 EQPT00188 17 27 1 89-850 Dust Collection System for Lime Screening Area 1995 59:010, 51:017, CAM

na Point



003 EQPT00193 17 32 1 89-861 Dust Collection System for Lime Bins and Screens 1998 59:010, 51:017, CAM

na Point



003 EQPT00199 17 41 1 89-851 Dust Collection System for Lime Screening and Bucket Elevator

1995 59:010, 51:017, CAM

na Point




EmisGroup



Dwg#

KyEIS Equipment

ID

KyEIS Source

ID

KyEIS Process


Constr/ModifcDate


Emission Type


Lime Storage to Loadout

004 EQPT00202 18 01 1 94-835 Dust Collection System for #13 & #14 Kiln Run Silo Transfer to 94-801

1995 59:010, 51:017, CAM

na Point



004 EQPT00207 18 06 1 94-834 Dust Collection System for #11 & # 12 Kiln Run Silo Transfer to 94-803

1995 59:010, 51:017, CAM

na Point



004 EQPT00210 18 09 1 94-836 Dust Collection System for Kiln Silo Discharge Conveyors

1995 59:010, 51:017, CAM

na Point



004 EQPT00217 18 16 1 94-832 Dust Collection System for Product Bin Discharge Conveyors and Screens

1995 59:010, 51:017, CAM

na Point



003 EQPT00224 18 22 1 94-831 Dust Collection System for Product Bin Discharge Conveyors

1995 59:010, 51:017, CAM

na Point



004 EQPT00225 18 24 1 94-829 Dust Collection System for Lime Railcar Loadout 1995 59:010, 51:017, CAM

na Point



004 EQPT00226 18 27 1 94-837 Dust Collection System for Lime Barge Loadout 1995 59:010, 51:017, CAM

na Point



004 EQPT00232 18 30 1 94-833 Dust Collection System for Lime Truck Loadout 1995 59:010, 51:017, CAM

na Point


Kiln 4 & 5 Dust Bin 005 EQPT00290 32 08 1 63-270 Bin Vent Collector System for Kiln 4 & 5 1995 59:010, 51:017, CAM

na Point

LM02 Lime System Buildings 003 EQPT00292 33 02 1 Kilns 4 & 5 Discharge Building - Burner Building 2 1995 63:010; 51:017 DC + Enclosure Fugitive

LM02 Lime System Buildings 003 EQPT00293 33 03 1 Transfer Tower 1 from Kiln to Storage and/or to South Hydrate Plant

1970 63:010; 51:017 DC + Enclosure Fugitive

LM02 Lime System Buildings 003 EQPT00294 33 04 1 Transfer Tower 2 from Kiln to Storage 1970 63:010; 51:017 DC + Enclosure Fugitive

LM02 Lime System Buildings 004 EQPT00295 33 05 1 Product Storage Building 1995 63:010; 51:017 DC + Enclosure Fugitive

LM02 Lime System Buildings 004 EQPT00296 33 06 1 Product Storage Silos 1995 63:010; 51:017 DC + Enclosure Fugitive

LM02 Lime System Buildings 001 EQPT00297 33 07 1 Transfer House 3 Deg Tower 1980 63:010; 51:017 DC + Enclosure Fugitive

LM03 Lime Storage to Hydrate Conveyor Transfers 001 EQPT00058 20 01 1 94-550 Belt Conveyor Transfer to 93-100 Belt Conveyor 1980 63:010 93-111 (DC) Fugitive

LM03 Lime Storage to Hydrate Conveyor Transfers 001 EQPT00101 29 01 1 93-100 Belt Conveyor (In Lime Service) Transfer to 93-101 Belt Conveyor

1980 63:010 93-112 (DC) Fugitive

LM03 Lime Storage to Hydrate Dust Collection Systems

001 EQPT00102 21 01 1 90-014 Dust Collection System for DEG Tower Conveyors 1980 59:010; CAM na Point


004 EQPT00298 29 03 1 93-111 Dust Collection System for 94-550 Belt Conveyor Transfer

2009 59:010; CAM na Point


004 EQPT00299 29 04 1 93-112 Dust Collection System for 93-100 Belt Conveyor Transfer (When in Lime Service)


LM04 Lime Dust Collection Systems (Non PSD)

Loading Spouts 005 EQPT00302 32 11 1 63-261LS Kiln 1 & 2 Dust Bin Loading Spout 1970 63:010 63-271 (DC) Fugitive


Loading Spouts 005 EQPT00303 32 12 1 63-353LS Kiln 3 Dust Bin Loading Spout 1974 63:010 63-272 (DC) Fugitive


Dust Collection Systems

005 EQPT00300 32 09 1 63-400 Dust Collection System for Kiln 1 & 2 Dust Bin and Transfers




005 EQPT00301 32 10 1 63-264 Dust Collection System for Kiln 1 & 2 Dust Bin and Transfers




005 EQPT00304 32 13 1 63-271 Dust Collection System for Kiln 1 & 2 Dust Bin Loading Spout





EmisGroup



Dwg#

KyEIS Equipment

ID

KyEIS Source

ID

KyEIS Process


Constr/ModifcDate


Emission Type



005 EQPT00305 32 14 1 63-272 Dust Collection System for Kiln 3 Dust Bin Loading Spouts




005 32 15 1 63-354 Dust Collection System for Kiln 3 Dust Bin and Transfers




005 EQPT00326 32 16 1 89-848 Dust Collection System for Lime Transfers 2014 59:010; CAM na Point

LM05 Reject Lime Stockpiles 005 AREA00020 32 01 1 Reject Lime Stockpile 2007 63:010 Wet Suppression Point

LM05 Reject Lime Stockpiles 005 AREA00021 32 02 1 Reject Lime Stockpile (Reject Bunker) 2007 63:010 Wet Suppression Point

LM05 Reject Lime Stockpiles 005 AREA00022 32 03 1 Reject Lime Stockpile (South of Hydrate Plant) 2007 63:010 Wet Suppression Point

LM05 Reject Lime Stockpiles 005 AREA00023 32 04 1 Reject Lime Stockpile (South of Kiln #5) 2007 63:010 Wet Suppression Point

LM06 Reject Lime Processing 005 EQPT00307 32 05 1 89-005 CM Screw Receiving Hopper 2007 63:010 89-004 (DC) Fugitive

LM06 Reject Lime Processing 005 EQPT00308 32 06 1 89-004 Dust Collection System for CM Screw Receiving 2007 59:010; CAM na Point

LM06 Reject Lime Processing 005 EQPT00309 32 07 1 Front End Loader Dump to High pH Pond 2007 63:010 Wet Suppression Fugitive

LM07 Clinker Reclaim 003 EQPT00055 12 01 1 89-800H Clinker Receiving Hopper to 89-800 Belt Conveyor 1997 63:010 84-018 (DC) Fugitive

LM07 Clinker Reclaim 003 EQPT00310 12 03 1 Front End Loader to Clinker Hopper 1997 63:010 84-018 (DC) Fugitive

LM08 Lime Loadout 004 EQPT00100 13 01 1 94-540 Railcar Loadout Spout (Lime) 1974 63:010 89-829 (DC) Fugitive

LM08 Lime Loadout 004 EQPT00104 14 01 1 89-045 Truck Loadout for Lime Rejects 1995 63:010 89-858 (DC) Fugitive

LM08 Lime Loadout 004 EQPT00105 14 02 1 94-002 Barge Loadout 1995 63:010 94-837 (DC) Fugitive

LM08 Lime Loadout 004 EQPT00106 14 03 1 94-003 Truck Loadout 1995 63:010 94-833 (DC) Fugitive

HY01 Hydration Plant Conveyor Transfers 006 EQPT00060 21 02 1 90-050 Belt Conveyor Transfer to Hydrate Feed Bins #1 & #2 1980 63:010 Shrouded Fugitive

HY01 Hydration Plant Filter Systems 006 EQPT00311 20 20 1 90-138A Bin Vent Collector on 90-135 (Hydrator #1 Feed Bin) 1980 59:010 na Point

HY01 Hydration Plant Filter Systems 006 EQPT00312 20 21 1 90-138B Bin Vent Collector on 90-133 (Hydrator #2 Feed Bin) 1980 59:010 na Point

HY01 Hydration Plant Filter Systems 006 EQPT00125 21 18 1 90-128 Dust Collection System for Classifier Operations 1980 59:010 na Point

HY01 Hydration Plant Hydrator System 006 EQPT00116 21 12 1 Hydrator/Scrubber System 1980 59:010 na Point

HY02 Hydrate Bins to Loadout Loadout Transfers 006 EQPT00134 21 25 1 90-172 Truck Loadout 1980 63:010 90-170 (DC) Fugitive

HY02 Hydrate Bins to Loadout Loadout Transfers 006 EQPT00135 21 27 1 90-124LS Reject Truck Loadout 1980 63:010 90-303 (DC) Fugitive

HY02 Hydrate Bins to Loadout Loadout Transfers 006 EQPT00313 21 28 1 90-307 Truck Loadout 1980 63:010 90-215 (DC) Fugitive

HY02 Hydrate Bins to Loadout Loadout Transfers 006 EQPT00136 27 01 1 90-221LS Railcar Loadout 2002 63:010 90-221 (DC) Fugitive




EmisGroup



Dwg#

KyEIS Equipment

ID

KyEIS Source

ID

KyEIS Process


Constr/ModifcDate


Emission Type

HY02 Hydrate Bins to Loadout Storage Bin Vent Filter Systems

006 EQPT00314 21 32 1 90-139A Bin Vent Collector on 90-222 (#3 Product Storage Bin)

1980 59:010 na Point


006 EQPT00315 21 33 1 90-139B Bin Vent Collector on 90-223 (#2 Product Storage Bin)

1980 59:010 na Point


006 EQPT00316 21 34 1 90-139C Bin Vent Collector on 90-224 (#1 Product Storage Bin)

1980 59:010 na Point

HY02 Hydrate Bins to Loadout Dust Collection Systems

006 EQPT00132 21 23 1 90-215 Dust Collection System for #3 Product Bin Truck Loadout

1980 59:010 na Point


006 EQPT00317 21 31 1 90-170 Dust Collection System for #1 & #2 Product Bin Truck Loadout

1980 59:010 na Point


006 EQPT00318 21 35 1 90-303 Dust Collection System for Hydrate Reject Loadout 1980 59:010 na Point


006 EQPT00253 22 09 1 91-209 Dust Collection System for Hydrate Bagging Operation 1980 59:010 na Point


006 EQPT00319 27 02 1 90-221 Dust Collection System for 90-221LS Railcar Loadout 2002 59:010 na Point

HY03 Lime Pulverizer System 006 EQPT00109 21 05 1 90-137 Dust Collection System for Mill Feed Bin 1980 59:010 na Point

HY03 Lime Pulverizer System 006 EQPT00112 21 08 1 90-142 Dust Collection System for Mill 1980 59:010 na Point

RD01 Haul Roads AREA00012 23 01 1 Haul Roads (Paved) 1995 63:010 Wet Suppression Fugitive

RD01 Haul Roads AREA00015 25 01 1 Haul Roads (Unpaved) 2003 63:010 Wet Suppression Fugitive

EN01 Stationary Engines EQPT00332 34 06 1 Kiln 1 Pony Motor Engine 2018 NESHAP ZZZZ;NSPS IIII

na Point


na Point


na Point


na Point


na Point

EN02 Stationary Emergency-Use Engines (NSPS IIII Applicable)

34 11 1 Mine Escape Shaft Emergency Generator 2006 NESHAP ZZZZ;NSPS IIII

na Point

EN03 Stationary Emergency-Use Engines (NSPS JJJJ

34 12 1 Kiln BMS Emergency Generator 2017 NESHAP ZZZZ;NSPS JJJJ

na Point

SH01 South Hydrate Plant Quick Lime Handling and Storage

C-3 EQPT00333 35 01 1 Transfer to BE-06103 Bucket Elevator 2016 59:010 DC-06108 Point


C-3 EQPT00334 35 02 1 Upper Section of BE-06103 Bucket Elevator 2016 59:010 DC-06108 Point


C-3 EQPT00335 35 03 1 SN-06104 Screen 2016 59:010 DC-06108 Point


C-3 EQPT00336 35 04 1 Transfer from SN-06104 Screen to BC-06113 Belt Conveyor 2016 59:010 DC-06108 Point


C-3 EQPT00338 35 05 1 Transfer from BC-06113 Belt Conveyor to BE-06118 Bucket Elevator

2016 59:010 DC-06116 Point


C-7 EQPT00339 35 06 1 Lower Section of BE-06118 Bucket Elevator 2016 59:010 DC-06116 Point




EmisGroup



Dwg#

KyEIS Equipment

ID

KyEIS Source

ID

KyEIS Process


Constr/ModifcDate


Emission Type




C-7 STOR00042 35 08 1 BN-06120 Quick Lime Bin #1 with Integrated Passive Bin Vent Filter (DC-06121)

2016 59:010 na Vent


C-7 STOR00043 35 09 1 BN-06125 Quick Lime Bin #2 with Integrated Passive Bin Vent Filter (DC-06126)

2016 59:010 na Vent


C-7 EQPT00341 35 10 1 Transfer from BN-06120 Quick Lime Bin #1 to BC-22101 Belt Conveyor

2016 59:010 DC-21105 Point


C-7 EQPT00342 35 11 1 Transfer from BN-06125 Quick Lime Bin #2 to BC-22101 Belt Conveyor

2016 59:010 DC-21105 Point


C-7 EQPT00343 35 12 1 Transfer from BC-22101 Belt Conveyor to CR-22102 Crusher 2016 59:010 DC-21105 Point


C-7 EQPT00344 35 13 1 Transfer from CR-22102 Crusher to BE-21101 Bucket Elevator 2016 59:010 DC-21105 Point


C-7 EQPT00345 35 14 1 Lower Section of BE-21101 Bucket Elevator 2016 59:010 DC-21105 Point




C-7 EQPT00347 35 16 1 Transfer to BN-21103 Crushed Lime Surge Bin 2016 59:010 DC-21105 Point


C-7 EQPT00348 35 17 1 Transfer to BN-25104 Rejects Bin 2016 59:010 DC-21105 Point



SH01 South Hydrate Plant Hydrator and Drying C-7 EQPT00352 35 19 1 HY-23101 Hydrator System with Integrated Process Filter (DC-23103)

2016 59:010 na Point

SH01 South Hydrate Plant Hydrator and Drying C-7 COMB00012 35 20 1 ML-23116 Mill Dryer with Integrated Process Filter (DC-23119) 2016 59:010 na Point

SH01 South Hydrate Plant Hydrate Storage and Loadout

C-7 STOR00045 35 22 1 BN-25111 Hydrate Bin #1 with Integrated Bin Vent Filter (DC-25112)

2016 59:010 na Vent


C-7 STOR00046 35 23 1 BN-25123 Hydrate Bin #2 with Integrated Bin Vent Filter (DC-25124)

2016 59:010 na Vent


C-7 EQPT00357 35 24 1 Truck Loadout from Hydrate Bin #1 with Spout Filter (DC-25120)

2016 59:010 DC-25120 Vent


C-7 EQPT00358 35 25 1 Truck Loadout from Hydrate Bin #2 with Spout Filter (DC-25132)

2016 59:010 DC-25132 Vent

SH02 South Hydrate Hot Air Heater Hot Air Heater for Hydrator System

C-7 COMB00011 35 21 1 HU-23128 Gas-Fired Hot Air Heater for Hydrator System 2016 59:015;NESHAP DDDDD

na Point


APPENDIX C: PROCESS FLOW DIAGRAMS

FigureC‐1:LimestoneSystem

FigureC‐2:CoalReceivingSystem

FigureC‐3:LimeHandling–KilnstoStorage

FigureC‐4:LimeHandling–StoragetoLoadout

FigureC‐5:KilnDustSystems

FigureC‐6:HydratePlant

FigureC‐7:SouthHydratePlant

To trucks

Black River Plant | Butler, KY

Figure C-1 Limestone System

1717 Dixie Hwy, Ste. 900Covington, KY 41011

File:Carmeuse Black River PFDs (Permit Renewal) 2019-0222 1124 PS.vsdx

Project No: 191801.0026

BARGE

STONE DUMP HOPPERS

Lime Barge Loadout

93-102LS

30" BC-52-301

SMALL KILN FEED

LARGE KILN FEED

KILN #3 KILN #2 KILN #1

24" BC-81-12124" BC-82-12224" BC-83-228

01-35

01-31

01-30

01-27

01-26

24" BC-83-224 24" BC-82-112

24" BC-81-111

#5PREHEATER

#3STONE BIN

#1STONE BIN

#4PREHEATER

#2STONE BIN

30" BC-52-30201-01 01-02

01-04

01-03100 PILE

200 PILE

42" BC-51-100

RIVERSIDE STOCKPILE

RIVERSIDE STOCKPILE

RIVERSIDE STOCKPILE

CONE CRUSHER

CONE CRUSHER

SURGE BIN

02-16

33-01

01-11

01-32

31-01 31-04 31-07

01-0602-01

02-07 02-08

01-08

01-09

03-01

29-0105-02

31-02

Dump Hoppers

20-01 04-01

33-07

02-10

02-02

02-05

Lime Storage to HydrateLM03

Mine to Stockpile TransfersLS01

30" TC-51-208

30" BC-52-302

02-15

02-18

02-20

Lime System BuildingsLM02

31-03

Limestone Screening and CrushingLS03

Limestone StockpilesLS02

29-03

29-04

Kiln Limestone Feed SystemLS04

36" BC-51-202

30" BC-51-207

24" BC-51-205

24" BC-51-206

24" TC-51-203

Dual Screw Classifier51-303

Transfer House 3Deg Tower

KILN #5 KILN #4

24" BC-82 13224" BC-82-131

30" BC-52-30430" BC-52-125

30" BC-52-303

42" BC-51-200

42" BC-51-201

36" BC-51-202

Transfer House from Screening Building to Stockpiles

Screening Building

Crusher Building

Kilns 1, 2 & 3Discharge Building

DC 93-11142" BC-93-101

DC 93-112

DC 90-014

42"BC-93-10242" BC-93-100

42" BC‐14‐102

42" BC‐14‐200

DC 90-014

DC 90-014

21-01

Limestone Loadout OperationsLS05

Lime to Existing

Hydrate Plant (Figure C-6)

Lime from 94-808on DWG. 002

01-12

01-16

01-15

1/2x150 MESH


Figure C-2 Coal System



Project No: 191801.0026

#3COAL BIN

#2COAL BIN

#1COAL BIN

#4COAL BIN

#5COAL BIN

TRUCK DUMP HOPPER

06-01

#1COAL SILO

#2COAL SILO

#3COAL SILO

#4COAL SILO

06-03

06-05

28-05

28-0328-02

28-01

28-0706-07

06-09

06-1806-11

06-12

06-1630" BC‐54‐808

30" BC‐54‐807

30" BC‐54‐806 30" BC‐54‐805

36" BC‐54‐821

36" BC‐54‐803

30" BC‐54‐804

Coal Receiving and StorageCL01

ON LAND ON RIVERWORK BARGE/PLATFORM BARGE

BARGEUNLOADER

BARGEHOPPER

30" BC‐54‐802

KILN #3 KILN #2 KILN #1

24" BC-89-811

24" BC-89-812

24" BC-89-813

24" BC-89-815

24" BC-89-816

24" BC-89-814

DC 89-021

DC89-848

DC89-848

DC89-021

KILN #5

KILN #4

SCREEN SCREEN

SCREENSCREEN

SCREENROLL CRUSHER

SCREEN

FOR SILO WITHDRAWLS, SEE FIGURE C-4

FOR SILO WITHDRAWLS, SEE FIGURE C-4

94-863

24" BC-89-801

24" BC-89-802

DC 84-018

26" BC-89-800

24" BC-89-805

24" BC-89-806

24" BC-89-804 24" BC-89-818

24" BC-89-817

24" BC-89-809(57-809)

24" BC-89-810(57-810)

24" BC-89-821

ROLLCRUSHER

BE-8

9-83

0

18" SC-89-833

18" SC-89-831

18" SC-89-877

18" SC-89-832

18" SC-89-834

DC84-018

DC84-018

DC84-018

DC84-018 DC

84-018

DC84-018

DC 89-848

89-82589-824

DC89-850

DC89-850

89-823

DC89-851

89-826

DC 89-851

89-828

DC89-850

DC 89-850

DC 89-850

DC89-851

DC89-858

DC 89-861 DC 89-85089-827 DC 89-858

DC 89-858DC 89-861

89-839

89-829DC 89-857 DC 89-856 DC 89-855

DC89-857

DC89-857

DC89-856

DC89-855

FORCONTINUATIONSEE FIGURE C-4

24" BC-94-804

DC84-018

DC 89-846

DC 89-847

DC89-850

DC89-851

DC89-850

DC89-858

DC89-858

DC89-858

DC89-858

DC89-861

DC89-861

DC89-861

12" SC-89-863

DC89-857

DC89-856

DC89-855

DC89-857

DC89-857

DC89-855

DC89-856

DC89-857

DC89-857

DC89-851

DC89-846

DC89-021

DC89-021

DC89-858

FROMSCREW CNVR.

(ON C-4)

BE-8

9-83

5

10" SC-84-018C

24" RC-89-820

24" BC-89-822

17-41

17-32 17-27

17-1017-1317-17

07-0108-01

11-01

10-01

09-01

16-11

12-01

ClinkerReclaimLM-07

12-03

#14 SILO

#13 SILO

#12 SILO

#11 SILO

#7 BIN#8 BIN#9 BIN#10 BIN

#5 BIN#4 BIN #6 BIN#3 BIN#2 BIN#1 BINREJECTS

BIN89-045

32-16

24" BC-83-303

DC84-018

24" BC-89-803

12" SC-89-860

DC89-848

(On Enclosure)

DC89-848

(On Enclosure)

DC89-848

(On Enclosure)

DC89-848

(On Enclosure)

17-05

BC-06113


Figure C-3Kilns to Storage



Project No: 161801.0040

Transfer House 1(expanded as part of South

Hydrate Plant Project)

SCREENSN-06104

SC-06106

BE-0

6103

Continues onFigure B-3

(South Hydrate Plant)

DC-06108

E-1(7,200 cfm)

33-03


Kilns 1, 2 & 3Discharge Building

33-01

Kilns 4 & 5Discharge Building

33-02

ProductStorage SIlos

33-06

ProductStorage Buildings

33-05

Transfer House 233-04

Lime Dust CollectionSystems (PSD)

LM01

Lime Dust CollectionSystems (Non-PSD)

LM04

South Hydrate PlantSH01

(Construction TBD)

Oversize(+2½)

Overs BinBN-06105

Fines(under 1/8)

PebbleLime

35-01

35-02

35-03

35-04

Black River Plant | Butler, KYFigure C-4

Storage to Loadouts



Project No: 191801.0026

#14 SLO #13 SLO #12 SLO

18–0118–06

94–83494–834 94–83494–834 94–834

94–835 94–835 94–835

94–834

94–835 94–83594–835DC

33-06

DC DC DCDC

DC

DC

DCDC DC DC DC

#11 SLO

1 2 3 1 1 12 2 23 3 3

18-09

x

42" BC-94-801DC

94–836

42" BC-94-805

DC94–855

DC94-835

94-835DC

DC

DC

DC DC DC

DC DC DC DC

DCDC

DC DC

DC

DC DC

DC DC

DC

DCDC

DC

DC

DC DC

DC94-832

DC94-832

DC94-832

DC94-838

DC

DC94-837

DC94-837

DC

DC

DC94-832

DC

DC94-832

33-05

94-832

94-83294-836

94-836

DC94-836

DC94-836

24 BC-94-804(OUT OF SERVICE)

FOR CONTINUATIONSEE DWG. 001

DC94-832

8" SC-94-836-3

18-24 18-30DC

94-832

94-828SCREEN

30" BC-94-806

18" SC-94-86494-832

18-27

DC94-838

DC94-838

94-838DC

94-837

DC94-83714-02

42" BC-94-802

30" BC-94-550

LOADING SPOUT94-002

BARGE LOADING

RAIL LOADING

RAIL LOADSPOUT (LIME)

04-540

FOR CONTINUATIONSEE DWG. 004

DC94-828

94-852DC

13-01

DC94-832

DC94-832

94-832

20" SC-94-853

20" SC-94-855

20" PC-94-505

3D” BC-94-807

TO FINES BINSVIA BUCKET ELEVATOR 89-835

(ON DWG. 001)

SCREEN94-827

20" SC-94-832-1

DC94-832

18-16

94-831 94-831

94-83194-831 94-831 94-831 94-831 94-831

94-831

94-83294-832

94-83294-832 94-832 94-832

94-832DC

16“ SC-94-825

DC94-832

24" BC‐94‐811 24" BC‐94‐810

30" BC‐94‐805

94-83216" SC‐94‐826

16" SC‐94‐820

16" SC‐94‐819

16" SC‐94‐81816" SC‐94‐817

18-22

#10 BIN #9 BIN #1 BIN#8 BIN #7 BIN #3 BIN#2 BIN #4 BIN #5 BIN

TO FINES BINSVIA BUCKET

ELEVATOR 89‐835(ON DWG. 001)

94-831

94-832

94-831

#6 BIN

REJECTBIN

89-045

TRUCK LOADOUT

LOADING SPOUT

DC89-858

14-01

LOADING SPOUT

89-832 94-833

DC94-83314-0394-003

TRUCK HATCHOPENING AREA

ENCLOSEDTRUCK LOADINGSINGLE STATION

30" BC-94-809

DC94-829

DC94-833

24" BC-94-813

94-837

x x x


Lime Loadout OperationsLM08

TRUCK HATCHCLOSING AREA


LM01

DC94-833


Figure C-5 Dust Systems



Project No: 191801.0026

KILN #4BAGHOUSEB4‐001

KILN #5BAGHOUSEB5‐001

KILN #4BAGHOUSE

84-001

KILN #5BAGHOUSE

85-001

63-266BLOWER

DC 63-270

32-08

KILN#1 BAGHOUSE

81–221

KILN #1& #2

DUST BIN63 - 261

DC63-400

DC63-264

32-09 32-10

32-13

32-11LOADINGSPOUT

63-261LS

TOUNDERGROUND

SLURRYMIX TANK

63-358

DC63-271

REJECT LIME STOCKPILE




32-01

32-02

32-03

32-04

32-07

WATER FROMUNDERGROUND

HIGH pH POND

TO UNDERGROUND

SLURRY MIX TANK

32-0532-06

ENCLOSEDHOPPER

DC89-004

38" SC-89-005

TO UNDERGROUND

FINES

DUST FROM K5 DUST TRAP

LOADINGSPOUT63-353LS

32-12

32-14

KILN #3DUST BIN

B3-353

DC63-354 32-15

KILN#2 BAGHOUSE

83–322

KILN#3 BAGHOUSE

83–342

KILN#4 & #5 DUST BIN

63–269

Reject Lime StockpilesLM05

Reject Lime ProcessingLM06


LM01Lime Dust CollectionSystems (Non-PSD)

LM04

DC63-272

TRUCK LOADOUT

TRUCK LOADOUT


Figure C-6 Hydrate Plant



Project No: 191801.0026

#3 PRODUCT STORAGE

#2 PRODUCT STORAGE

DC90-139A

DC90–139B

21-28LOADING SPOUT

90-307

TRUCK LOADOUT

DC90-215

DC90-215

21-23

20" SC-90-21922-09

HYDRATEOPERATION

DC90-128

LIME

LIME

PULVERIZEDOPERATION

DC90-137

21-05

21-08

DC90-142

PULVERIZED LIME

21-32 21-33

#1 PRODUCT STORAGE

21-31

DC90-170

14" SC-90-203

20" SC-90-219A

21-25

DC

91-209

DC90-170

SHIPPINGHYDRATEBAGGING

OPERATION

TRUCK LOADOUT

LOADING SPOUT90-172LS

LOADING SPOUTDUST COLLECTOR

90-221 LOADING SPOUT90-221LS

RAIL LOADOUT

27-01

DC90-221

27-02

20" SC-90-220

21-34DC90-139C

21-12SCRUBBER

21-18

HYDRATOR#2 FEED BIN

HYDRATOR#1 FEED BIN

DCDC90-138A 90-138B

20-2120-20

21-02

21-35

DC

90-303

REJECTS BIN90-124

14" SC-90-124

DC90-303

TRUCK LOADOUT

LOADING SPOUT90-124LS

21-27

Hydration PlantHY01

Lime Pulverizer SystemHY03

Hydrate Bins to LoadoutHY02

CrusherCR-22102

SC-21110

SC-21111

HydratorHY-23101

Mill Dryer

ML-23116

DC-21105

SC-25102

SC-25110

SC-25109

Rejects ContainerBN-23110

DC-23103(2,800 cfm) Loadout

spout with filter

DC-25120(1,500 cfm)

Air Blower

DC-25112(2,000 cfm)

DC-25124(2,000 cfm)

DC-23119(20,500 cfm)

DC-06126DC-06121

DC-06116Cartridge Filter

(2,100 cfm)

Clean Ambient Air

Natural Gas

Clean Hot Air

Water

South Hydrate PlantSH01

(Construction TBD)

SC-21102

SC-23107

Air HeaterHU-23128


Figure C-7South Hydrate Plant 1



Project No: 161801.0040

Passive Bin Vent Filters

Pebble Lime

Crushed Quicklime

Emergency Relief Vent

Clean Hot Air(No Emissions)

Process Filter

Loadout spout with

filterDC-25132(1,500 cfm)

E-2

E-4E-3

E-6

E-5

E-9

E-10

E-12 E-13

BC-22101

BE-0

6118

Rejects BinBN-25104

CombustionAir

CombustionGas

Quick LimeBin 1

BN-06120

Quick LimeBin 2

BN-06125

Quicklime

E-8

Wet Hydrate

Dried HydrateIn Hot Air Stream

Crushed Quicklime Surge BinBN-21103

Quicklime

RejectHydrate

Hydrate

Hydrate Bin 1

BN-25111

Air Blower

E-11

Hydrate Bin 2

BN-25123Hydrate

Hydrate Hydrate

(5,500 cfm)

35-05

35-07

35-06

35-08 35-09

35-10 35-11 35-12

35-13

35-14

35-15

35-16

35-17

35-18

35-19

35-2035-21

35-22 35-23

35-24 35-25

Wet Reject Hydrate


APPENDIX D: DEP7007 APPLICATION FORMS

7007AI–AdministrativeInformation

7007N–EmissionsandStackInformation

Page _1_ AI of _4_ AI

(Revised 11/08)

Commonwealth of Kentucky

Energy and Environment Cabinet

Department for Environmental Protection

Division for Air Quality 300 Sower Blvd, 2nd Floor

Frankfort, Kentucky 40601

(502) 564-3999

http://www.air.ky.gov/

PERMIT APPLICATION

The completion of this form is required under Regulations 401 KAR 52:020, 52:030, and 52:040 pursuant

to KRS 224. Applications are incomplete unless accompanied by copies of all plans, specifications, and

drawings requested herein. Failure to supply information required or deemed necessary by the division to

enable it to act upon the application shall result in denial of the permit and ensuing administrative and

legal action. Applications shall be submitted in triplicate.

DEP7007AI

Administrative

Information

Enter if known

AFS Plant ID#

21-191-00002 (AI 3400)

Agency Use Only

Date Received

Log#

Permit#

1) APPLICATION INFORMATION

Note: The applicant must be the owner or operator. (The owner/operator may be individual(s) or a corporation.)

Name: Carmeuse Lime & Stone, Inc.

Title: NA Phone:

(If applicant is an individual)

Mailing Address: Carmeuse Lime & Stone

Company

Street or P.O. Box: 9043 Highway 154

City: Butler State: KY Zip Code: 41006

Is the applicant (check one): Owner Operator Owner & Operator Corporation/LLC* LP**

* If the applicant is a Corporation or a Limited Liability Corporation, submit a copy of the current Certificate of Authority from the

Kentucky Secretary of State.

** If the applicant is a Limited Partnership, submit a copy of the current Certificate of Limited Partnership from the Kentucky Secretary

of State.

Person to contact for technical information relating to application:

Name: Kris Milner, P.E.

Title: Environmental Area Manager Phone: 859-472-8100

2) OPERATOR INFORMATION

Note: The applicant must be the owner or operator. (The owner/operator may be individual(s) or a corporation.)

Name: Michael Klenda

Title: Surface Site Operations Manager Phone: 859-472-8223

Mailing Address: Carmeuse Lime & Stone

Company

Street or P.O. Box: 9043 Highway 154

City: Butler State: KY Zip Code: 41006


(Revised 11/08)

DEP7007AI

(Continued)

3) TYPE OF PERMIT APPLICATION

For new sources that currently do not hold any air quality permits in Kentucky and are required to obtain a permit prior to construction

pursuant to 401 KAR 52:020, 52:030, or 52:040.

Initial Operating Permit (the permit will authorize both construction and operation of the new source)

Type of Source (Check all that apply): Major Conditional Major Synthetic Minor Minor

For existing sources that do not have a source-wide Operating Permit required by 401 KAR 52:020, 52:030, or 52:040.


(Check one only)

Initial Source-wide Operating Permit Modification of Existing Facilities at Existing Plant

Construction of New Facilities at Existing Plant

Other (explain)

For existing sources that currently have a source-wide Operating Permit.


Current Operating Permit # V-14-002 R6

Administrative Revision (describe type of revision requested, e.g. name change):

Permit Renewal Significant Revision Minor Revision Off-Permit Change

Addition of New Facilities Modification of Existing Facilities

For all construction and modification requiring a permit pursuant to 401 KAR 52:020, 52:030, or 52:040.

Proposed Date for Start Proposed date for

of Construction or Modification: na Operation Start-up: na

4) SOURCE INFORMATION

Source Name: Carmeuse Lime & Stone Black River Operation

Source Street Address: 9043 Highway 154

City: Butler Zip Code: 41006 County: Pendleton

Primary Standard Industrial

Classification (SIC) Category: Lime Primary SIC #: 3274

Property Area Number of

(Acres or Square Feet): 1,200 Acres (Surface) Employees: ≈ 200

Description of Area Surrounding Source (check one):

Commercial Area Residential Area Industrial Area Industrial Park Rural Area Urban Area

Approximate Distance to Nearest

Residence or Commercial Property: < 0.5 miles

UTM or Standard Location Coordinates: (Include topographical map showing property boundaries)

UTM Coordinates: Zone 16 Horizontal (km) 739.6 Vertical (km) 4302.2

Standard Coordinates: Latitude Degrees Minutes Seconds

Longitude Degrees Minutes Seconds


(Revised 11/08)

DEP7007AI

(Continued)

4) SOURCE INFROMATION (CONTINUED)

Is any part of the source located on federal land? Yes No

What other environmental permits or registrations does this source currently hold in Kentucky?

Water Withdrawal Permit 0886; Water Quality Certification WQ401

DOWWRB- Floodplain Management 19671

KPDES Permit KY0045284

What other environmental permits or registrations does this source need to obtain in Kentucky?

5) OTHER REQUIRED INFORMATION

Indicate the type(s) and number of forms attached as part of this application.

DEP7007A Indirect Heat Exchanger, Turbine, Internal DEP7007R Emission Reduction Credit

Combustion Engine DEP7007S Service Stations

DEP7007B Manufacturing or Processing Operations DEP7007T Metal Plating & Surface Treatment Operations

DEP7007C Incinerators & Waste Burners DEP7007V Applicable Requirements & Compliance

DEP7007F Episode Standby Plan Activities

DEP7007J Volatile Liquid Storage DEP7007Y Good Engineering Practice (GEP) Stack Height

DEP7007K Surface Coating or Printing Operations Determination

DEP7007L Concrete, Asphalt, Coal, Aggregate, Feed, DEP7007AA Compliance Schedule for Noncomplying

Corn, Flour, Grain, & Fertilizer Emission Units

DEP7007M Metal Cleaning Degreasers DEP7007BB Certified Progress Report

1 DEP7007N Emissions, Stacks, and Controls Information DEP7007CC Compliance Certification* Refer to CY2018 Submittal DEP7007P Perchloroethylene Dry Cleaning Systems DEP7007DD Insignificant Activities

Check other attachments that are part of this application.

Required Data Supplemental Data

Map or Drawing Showing Location – Refer to Appendix A Stack Test Report

Process Flow Diagram and Description – Refer to Appendix C Certificate of Authority from the Secretary of State

(for Corporations and Limited Liability Companies)

Site Plan Showing Stack Data and Locations – Refer to Appendix A Certificate of Limited Partnership from the Secretary

of State (for Limited Partnerships)

Emission Calculation Sheets – Refer to N Form (Appendix D) Claim of Confidentiality (See 400 KAR 1:060)

Material Safety Data Sheets (MSDS) – Not Applicable Other (Specify)

Indicate if you expect to emit, in any amount, hazardous or toxic materials or compounds or such materials into the atmosphere from any

operation or process at this location.

Pollutants regulated under 401 KAR 57:002 (NESHAP) Pollutants listed in 401 KAR 63:060 (HAPS)

Pollutants listed in 40 CFR 68 Subpart F [112(r) pollutants] Other

Has your company filed an emergency response plan with local and/or state and federal officials outlining the measures that would be

implemented to mitigate an emergency release?

Yes No

Check whether your company is seeking coverage under a permit shield. If “Yes” is checked, applicable requirements must be identified on

Form DEP7007V. Identify any non-applicable requirements for which you are seeking permit shield coverage on a separate attachment to

the application.

Yes No A list of non-applicable requirements is attached


(Revised 11/08)

DEP7007AI

(Continued)

6) OWNER INFORMATION

Note: If the applicant is the owner, write “same as applicant” on the name line.

Name: Same as applicant

Title: Phone:

Mailing Address:

Company

Street or P.O. Box:

City: State: Zip Code:

List names of owners and officers of your company who have an interest in the company of 5% or more.

Name Position (owner, partner, president, CEO, treasurer, etc.)

None

(attach another sheet if necessary)

7) SIGNATURE BLOCK

I, the undersigned, hereby certify under penalty of law, that I am a responsible official, and that I have personally

examined, and am familiar with, the information submitted in this document and all its attachments. Based on my inquiry

of those individuals with primary responsibility for obtaining the information, I certify that the information is on knowledge

and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false or incomplete

information, including the possibility of fine or imprisonment.

BY:

(Authorized Signature) (Date)

Michael Klenda Surface Site Operations Manager (Typed or Printed Name of Signatory) (Title of Signatory)

2/26/2019

KyEISSource

ID#

KyEISProcess

ID# Emission Source DescriptionDate

Construct

HAPpresent

?SCCCode

SCCUnits

Fuel Ash

Content

FuelSulfur

Content

FuelHeat

ContentRatio

ApplicableRegulations

HourlyOperating

Rate(SCC

Units/hr)

AnnualOperating

Hours(hrs/yr)

HourlyOperating

Rate(SCC

Units/hr)

AnnualOperating

Rate(SCC

Units/yr)

AnnualOperating

Hours(hrs/yr)

KL01 - Rotary Kiln #107 01 1 Rotary Kiln #1 1970 Y 30501604 Tons Lime 61:020,

NESHAP 5A, CAM

30.5 8760 na na na

07 01 2 Pulverized Coal Burner 1970 Y 39000289 Tons Coal 7.6% 0.8% 12,935 Btu/lb 61:020, NESHAP 5A,

CAM

8.9 8760 na na na

07 01 3 Natural Gas - Startup 1970 Y 39000603 MMscf Natural Gas

neg. neg. 1,030 Btu/scf 61:020, NESHAP 5A,

CAM

0.2 8760 na na na


NESHAP 5A, CAM

30.5 8760 na na na


CAM

8.9 8760 na na na



CAM

0.3 8760 na na na

MaximumOperating Parameters Permitted Operating Parameters

SECTION I. Emissions Unit and Emission Point Information

Commonwealth of KentuckyEnergy & Environmental Cabinet

Department for Environmental Protection

DIVISION FOR AIR QUALITY

DEP7007N

Emissions, Stacks, and Controls Information

Applicant Name: Log #Carmeuse Lime & Stone - Black River Plant

Division Use Only: F___ Reviewer __________ Supervisor __________ Page _1__ N of _13__ N Revision 6/00

KyEISSource

ID#

KyEISProcess

ID# Emission Source DescriptionDate

Construct

HAPpresent

?SCCCode

SCCUnits

Fuel Ash

Content

FuelSulfur

Content

FuelHeat

ContentRatio

ApplicableRegulations

HourlyOperating

Rate(SCC

Units/hr)

AnnualOperating

Hours(hrs/yr)

HourlyOperating

Rate(SCC

Units/hr)

AnnualOperating

Rate(SCC

Units/yr)

AnnualOperating

Hours(hrs/yr)

MaximumOperating Parameters Permitted Operating Parameters

SECTION I. Emissions Unit and Emission Point Information


NESHAP 5A, CAM

65.0 8760 na na na


CAM

15.5 8760 na na na



CAM

0.4 8760 na na na

KL04 - Rotary Kiln #410 01 1 Rotary Kiln #4 1995 Y 30501604 Tons Lime 51:017, NSPS

HH, NESHAP 5A

46.0 8760 46 na na

10 01 2 Pulverized Coal Burner 1995 Y 39000289 Tons Coal 7.6% 0.8% 12,935 Btu/lb 51:017, NSPS HH, NESHAP

5A

9.6 8760 na na na


neg. neg. 1,030 Btu/scf 51:017, NSPS HH, NESHAP

5A

0.2 8760 na na na

KL05 - Rotary Kiln #511 01 1 Rotary Kiln #5 1995 Y 30501604 Tons Lime 51:017, NSPS

HH, NESHAP 5A

46.0 8760 46 na na

11 01 2 Pulverized Coal Burner 1995 Y 39000289 TonsCoal

7.6% 0.8% 12,935 Btu/lb 51:017, NSPS HH, NESHAP

5A

9.6 8760 na na na


neg. neg. 1,030 Btu/scf 51:017, NSPS HH, NESHAP

5A

0.3 8760 na na na


KyEISSource

ID #Process

ID(s) Pollutant CAS#

EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency

UncontrolledUnlimitedPotential

ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable

KL01 - Rotary Kiln #107 01 1 Rotary Kiln #1

PM na 0.239 lb/ton lime 2/7/2017 Stack Test- Method 5 na Baghouse 30.5 7.30 7.30 40.1 32.0 31.98 naPM10 na 0.276 lb/ton lime Assume 100% PM + Condensable na Baghouse 30.5 8.43 8.43 na 36.9 36.92 naPM2.5 na 0.252 lb/ton lime Assume 90% PM + Condensable na Baghouse 30.5 7.70 7.70 na 33.7 33.73 naCondensable PM na 0.037 lb/ton lime NPS Methodology na Baghouse 30.5 1.13 1.13 na 4.9 4.94 naSO2 07446-09-5 8.675 lb/ton lime 10/3/11-10/6/11 CEM Data na 30.5 264.59 na na 1,158.9 na naNOx 10102-44-0 6.515 lb/ton lime 10/3/11-10/6/11 CEM Data na 30.5 198.71 na na 870.3 na naCO 00630-08-0 5.495 lb/ton lime 10/3/11-10/6/11 CEM Data na 30.5 167.60 na na 734.1 na naVOC na 0.100 lb/ton lime Engineering Estimate na 30.5 3.05 na na 13.4 na na

CO2 124-38-9 3123.83 lb/ton lime 40 CFR 98 Table C-1 na 30.5 95,277 na na 417,313 na naCH4 74-82-8 0.183 lb/ton lime 40 CFR 98 Table C-2 na 30.5 5.58 na na 24.5 na naN2O na 0.027 lb/ton lime 40 CFR 98 Table C-3 na 30.5 0.81 na na 3.6 na naCO2e na 3135.93 lb/ton lime 40 CFR 98 Table A-2 na 30.5 95,646 na na 418,929 na naNote - Emission factors for PM, PM10, PM2.5, and SO2 are controlled emission factors. Therefore no control efficiency is used in calculating the controlled limited potential value shown for Process ID 1.

07 01 2 Pulverized Coal BurnerAntimony 07440-36-0 0.018 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 1.60E-01 1.60E-04 na 7.02E-01 7.02E-04 naArsenic 07740-38-2 0.410 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 3.65E+00 3.65E-03 na 1.60E+01 1.60E-02 naBeryllium 07440-41-7 0.021 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 1.87E-01 1.87E-04 na 8.19E-01 8.19E-04 naCadmium 07440-43-9 0.051 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 4.54E-01 4.54E-04 na 1.99E+00 1.99E-03 naChromium 07440-47-3 0.260 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 2.31E+00 2.31E-03 na 1.01E+01 1.01E-02 naFormaldehyde 00050-00-0 0.000 lb/ton Coal AP 42 Table 1.1-17 na 8.9 2.14E-03 2.14E-03 na 9.36E-03 na naHCl 07647-01-0 2.056 lb/ton Coal 11/07 stack test (K2) na 8.9 1.83E+01 1.83E+01 na 8.02E+01 na naLead 07439-92-1 0.004 lb/ton Coal NLA Test na Baghouse 99.9% 8.9 3.51E-02 3.51E-05 na 1.54E-01 1.54E-04 naManganese 07439-96-5 0.490 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 4.36E+00 4.36E-03 na 1.91E+01 1.91E-02 naMercury 07439-97-6 0.051 lb/ton Coal NLA Test na Baghouse 99.9% 8.9 4.58E-01 4.58E-04 na 2.00E+00 2.00E-03 naNickel 07440-02-0 0.280 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 2.49E+00 2.49E-03 na 1.09E+01 1.09E-02 naSelenium 07782-49-2 1.300 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 1.16E+01 1.16E-02 na 5.07E+01 5.07E-02 na

SECTION I. Emission Units and Emission Point Information (continued)

Emission Factors Control Equipment HourlyOperating

Rate(SCC

Units/hr)

Hourly (lb/hr) Emissions Annual (tons/yr) Emissions

UncontrolledEmission Factor(lb/SCC Units)

DEP7007N(continued)


KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)

07 01 3 Natural Gas - StartupCO 00630-08-0 84.0 lb/MMscf AP-42 Table 1.4-1, 07/98 na 0.2 18.90 na na 82.8 na naNOx 10102-44-0 100.0 lb/MMscf AP-42 Table 1.4-1, 07/98 na 0.2 22.50 na na 98.6 na naPM na 7.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na Baghouse 99.9% 0.2 1.71 na na 7.5 na naPM10 na 7.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na Baghouse 99.9% 0.2 1.71 na na 7.5 na naPM2.5 na 7.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na Baghouse 99.9% 0.2 1.71 na na 7.5 na naSO2 07446-09-5 0.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na 0.2 0.14 na na 0.6 na naVOC na 5.5 lb/MMscf AP-42 Table 1.4-2, 07/98 na 0.2 1.24 na na 5.4 na naHexane na 1.8 lb/MMscf AP-42 Table 1.4-3 na 0.2 0.41 na na 1.8 na naToluene na 0.00340 lb/MMscf AP-42 Table 1.4-3 na 0.2 7.65E-04 na na 3.35E-03 na naFormaldehyde na 0.07500 lb/MMscf AP-42 Table 1.4-3 na 0.2 0.02 na na 0.1 na na

CO2 00124-38-9 120,396 lb/MMscf 40 CFR 98, Subpart C, Table C-1 na 0.2 27,089.01 na na 118,650 na naCH4 00074-82-8 2.27076 lb/MMscf 40 CFR 98, Subpart C, Table C-2 na 0.2 0.51 na na 2.24 na naN2O 10024-97-2 0.22708 lb/MMscf 40 CFR 98, Subpart C, Table C-2 na 0.2 0.05 na na 0.22 na na


KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)


PM na 0.066 lb/ton lime 8/2016 Stack Test (100% coal) na Baghouse 30.5 2.02 2.02 40.1 8.8 8.83 naPM10 na 0.108 lb/ton lime Assume 100% Filterable PM + Condensable na Baghouse 30.5 3.30 3.30 na 14.5 14.47 naPM2.5 na 0.098 lb/ton lime Assume 90% of PM10 na Baghouse 30.5 2.97 2.97 na 13.0 13.03 naCondensable PM na 0.042 lb/ton lime 8/2016 Stack Test (100% coal) na Baghouse 30.5 1.29 1.29 na 5.6 5.64 naSO2 07446-09-5 8.163 lb/ton lime 8/2016 Stack Test (100% coal) na 30.5 248.97 na na 1,090.5 na naNOx 10102-44-0 3.275 lb/ton lime 8/2016 Stack Test (100% coal) na 30.5 99.90 na na 437.6 na naCO 00630-08-0 3.176 lb/ton lime 8/2016 Stack Test (100% coal) na 30.5 96.87 na na 424.3 na naVOC na 0.054 lb/ton lime 8/2016 Stack Test (100% coal) na 30.5 1.64 na na 7.2 na na


08 01 2 Pulverized Fuel BurnerAntimony 07440-36-0 0.018 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 1.60E-01 1.60E-04 na 7.02E-01 7.02E-04 naArsenic 07740-38-2 0.410 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 3.65E+00 3.65E-03 na 1.60E+01 1.60E-02 naBeryllium 07440-41-7 0.021 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 1.87E-01 1.87E-04 na 8.19E-01 8.19E-04 naCadmium 07440-43-9 0.051 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 4.54E-01 4.54E-04 na 1.99E+00 1.99E-03 naChromium 07440-47-3 0.260 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 2.31E+00 2.31E-03 na 1.01E+01 1.01E-02 naFormaldehyde 00050-00-0 0.000 lb/ton Coal AP 42 Table 1.1-17 na 8.9 2.14E-03 2.14E-03 na 9.36E-03 na naHCl 07647-01-0 2.056 lb/ton Coal 11/07 stack test (K2) na 8.9 1.83E+01 1.83E+01 na 8.02E+01 na naLead 07439-92-1 0.004 lb/ton Coal NLA Test na Baghouse 99.9% 8.9 3.51E-02 3.51E-05 na 1.54E-01 1.54E-04 naManganese 07439-96-5 0.490 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 4.36E+00 4.36E-03 na 1.91E+01 1.91E-02 naMercury 07439-97-6 0.051 lb/ton Coal NLA Test na Baghouse 99.9% 8.9 4.58E-01 4.58E-04 na 2.00E+00 2.00E-03 naNickel 07440-02-0 0.280 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 2.49E+00 2.49E-03 na 1.09E+01 1.09E-02 naSelenium 07782-49-2 1.300 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 8.9 1.16E+01 1.16E-02 na 5.07E+01 5.07E-02 na


KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)

08 01 3 Natural Gas - StartupCO 00630-08-0 84.0 lb/MMscf AP-42 Table 1.4-1, 07/98 na 0.2 18.90 na na 82.8 na naNOx 10102-44-0 100.0 lb/MMscf AP-42 Table 1.4-1, 07/98 na 0.2 22.50 na na 98.6 na naPM na 7.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na 0.2 1.71 na na 7.5 na naPM10 na 7.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na 0.2 1.71 na na 7.5 na naPM2.5 na 7.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na 0.2 1.71 na na 7.5 na naSO2 07446-09-5 0.6 lb/MMscf AP-42 Table 1.4-2, 07/98 na 0.2 0.14 na na 0.6 na naVOC na 5.5 lb/MMscf AP-42 Table 1.4-2, 07/98 na 0.2 1.24 na na 5.4 na naHexane na 1.8 lb/MMscf AP-42 Table 1.4-3 na 0.2 0.41 na na 1.8 na naToluene na 0.00340 lb/MMscf AP-42 Table 1.4-3 na 0.2 7.65E-04 na na 3.35E-03 na naFormaldehyde na 0.07500 lb/MMscf AP-42 Table 1.4-3 na 0.2 0.02 na na 0.1 na na

CO2 00124-38-9 120,396 lb/MMscf 40 CFR 98, Subpart C, Table C-1 na 0.2 27,089.01 na na 118,649.9 na naCH4 00074-82-8 2.27076 lb/MMscf 40 CFR 98, Subpart C, Table C-2 na 0.2 0.51 na na 2.24 na naN2O 10024-97-2 0.22708 lb/MMscf 40 CFR 98, Subpart C, Table C-2 na 0.2 0.05 na na 0.22 na na


KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)


PM na 0.073 lb/ton lime 9/27/2016 Stack Test na Baghouse 65.0 4.71 4.71 33.8 20.6 20.64 naPM10 na 0.110 lb/ton lime Assume 100% PM + Condensable na Baghouse 65.0 7.12 7.12 na 31.2 31.17 naPM2.5 na 0.102 lb/ton lime Assume 90% PM + Condensable na Baghouse 65.0 6.65 6.65 na 29.1 29.11 naCondensable PM na 0.037 lb/ton lime NPS Methodology na Baghouse 65.0 2.41 2.41 na 10.5 10.53 naSO2 07446-09-5 3.010 lb/ton lime 10/22-30/11 CEM data na 65.0 195.65 na na 856.9 na naNOx 10102-44-0 3.210 lb/ton lime 10/22-30/11 CEM data na 65.0 208.65 na na 913.9 na naCO 00630-08-0 6.060 lb/ton lime 10/22-30/11 CEM data na 65.0 393.90 na na 1,725.3 na naVOC na 0.100 lb/ton lime Engineering Estimate na 65.0 6.50 na na 28.5 na na


09 01 2 Pulverized Fuel BurnerAntimony 07440-36-0 0.018 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 2.79E-01 2.79E-04 na 1.22E+00 1.22E-03 naArsenic 07740-38-2 0.410 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 6.35E+00 6.36E-03 na 2.78E+01 2.78E-02 naBeryllium 07440-41-7 0.021 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 3.26E-01 3.26E-04 na 1.43E+00 1.43E-03 naCadmium 07440-43-9 0.051 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 7.90E-01 7.91E-04 na 3.46E+00 3.46E-03 naChromium 07440-47-3 0.260 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 4.03E+00 4.03E-03 na 1.77E+01 1.77E-02 naFormaldehyde 00050-00-0 0.000 lb/ton Coal AP 42 Table 1.1-17 na 15.5 3.72E-03 3.72E-03 na 1.63E-02 na naHCl 07647-01-0 2.516 lb/ton Coal 11/07 stack test (K2) na 15.5 3.90E+01 3.90E+01 na 1.71E+02 na naLead 07439-92-1 0.005 lb/ton Coal NLA Test na Baghouse 99.9% 15.5 7.47E-02 7.48E-05 na 3.27E-01 3.27E-04 naManganese 07439-96-5 0.490 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 7.59E+00 7.60E-03 na 3.33E+01 3.33E-02 naMercury 07439-97-6 0.063 lb/ton Coal NLA Test na Baghouse 99.9% 15.5 9.75E-01 9.75E-04 na 4.27E+00 4.27E-03 naNickel 07440-02-0 0.280 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 4.34E+00 4.34E-03 na 1.90E+01 1.90E-02 naSelenium 07782-49-2 1.300 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 15.5 2.02E+01 2.02E-02 na 8.83E+01 8.83E-02 na


KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)




KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)


PM na 0.030 lb/ton lime 7/2015 Stack Test na Baghouse 46.0 1.38 1.38 13.20 6.0 6.03 naPM10 na 0.170 lb/ton lime Assume 100% Filterable PM + Condensable na Baghouse 46.0 7.82 7.82 na 34.2 34.24 naPM2.5 na 0.153 lb/ton lime Assume 90% of PM10 na Baghouse 46.0 7.03 7.03 na 30.8 30.81 naCondensable PM na 0.140 lb/ton lime 6/2016 Stack Test on Kiln #5; 100% Coal Scenario na Baghouse 46.0 6.44 6.44 na 28.2 28.20 naSO2 07446-09-5 0.291 lb/ton lime 7/2015 Stack Test na 46.0 13.40 na 22.97 58.7 na naNOx 10102-44-0 2.021 lb/ton lime 7/2015 Stack Test na 46.0 92.95 na 128.33 407.1 na naCO 00630-08-0 0.598 lb/ton lime 7/2015 Stack Test na 46.0 27.50 na 91.67 120.4 na naVOC na 0.091 lb/ton lime 6/2016 Stack Test on Kiln #5; 100% Coal Scenario na 46.0 4.16 na na 18.2 na na

CO2 124-38-9 2,682 lb/ton lime 40 CFR 98 Table C-1 na 46.0 123,358 na na 540,308 na naCH4 74-82-8 0.131 lb/ton lime 40 CFR 98 Table C-2 na 46.0 6.02 na na 26.4 na naN2O na 0.019 lb/ton lime 40 CFR 98 Table C-3 na 46.0 0.88 na na 3.8 na naCO2e na 2,690 lb/ton lime 40 CFR 98 Table A-2 na 46.0 123,756 na na 542,052 na naNote - Emission factors for PM, PM10, PM2.5, and SO2 are controlled emission factors. Therefore no control efficiency is used in calculating the controlled limited potential value shown for Process ID 1.

10 01 2 Pulverized Fuel BurnerAntimony 07440-36-0 0.018 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 1.73E-01 1.73E-04 na 7.57E-01 7.57E-04 naArsenic 07740-38-2 0.410 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 3.94E+00 3.94E-03 na 1.72E+01 1.72E-02 naBeryllium 07440-41-7 0.021 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 2.02E-01 2.02E-04 na 8.83E-01 8.83E-04 naCadmium 07440-43-9 0.051 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 4.90E-01 4.90E-04 na 2.14E+00 2.14E-03 naChromium 07440-47-3 0.260 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 2.50E+00 2.50E-03 na 1.09E+01 1.09E-02 naFormaldehyde 00050-00-0 0.000 lb/ton Coal AP 42 Table 1.1-17 na 9.6 2.30E-03 na na 1.01E-02 na naHCl 07647-01-0 1.438 lb/ton Coal 11/07 stack test (K2) na 9.6 1.38E+01 na na 6.04E+01 na naLead 07439-92-1 0.006 lb/ton Coal NLA Test na Baghouse 99.9% 9.6 5.29E-02 5.29E-05 na 2.32E-01 2.32E-04 naManganese 07439-96-5 0.490 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 4.70E+00 4.70E-03 na 2.06E+01 2.06E-02 naMercury 07439-97-6 0.072 lb/ton Coal NLA Test na Baghouse 99.9% 9.6 6.90E-01 6.90E-04 na 3.02E+00 3.02E-03 naNickel 07440-02-0 0.280 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 2.69E+00 2.69E-03 na 1.18E+01 1.18E-02 naSelenium 07782-49-2 1.300 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 1.25E+01 1.25E-02 na 5.47E+01 5.47E-02 na


KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)




KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)


PM na 0.023 lb/ton lime 6/2018 Stack Test; Cofire Scenario (Assume PM = F na Baghouse 46.0 1.04 1.04 13.20 4.6 4.57 naPM10 na 0.170 lb/ton lime 6/2018 Stack Test; 82% Gas Scenario na Baghouse 46.0 7.80 7.80 na 34.2 34.17 naPM2.5 na 0.153 lb/ton lime Assume 90% of PM10 na Baghouse 46.0 7.02 7.02 na 30.8 30.75 naCondensable PM na 0.147 lb/ton lime 6/2018 Stack Test; Cofire Scenario na Baghouse 46.0 6.76 6.76 na 29.6 29.59 naSO2 07446-09-5 0.182 lb/ton lime 6/2018 Stack Test; Cofire Scenario na 46.0 8.35 na 22.97 36.6 na naNOx 10102-44-0 1.929 lb/ton lime 6/2018 Stack Test; Cofire Scenario na 46.0 88.74 na 128.33 388.7 na naCO 00630-08-0 0.688 lb/ton lime 6/2018 Stack Test; Cofire Scenario na 46.0 31.66 na 91.67 138.7 na naVOC na 0.160 lb/ton lime 6/2018 Stack Test; Cofire Scenario na 46.0 7.34 na na 32.2 na na

CO2 124-38-9 2,682 lb/ton lime 40 CFR 98 Table C-1 na 46.0 123,358 na na 540,308 na naCH4 74-82-8 0.131 lb/ton lime 40 CFR 98 Table C-2 na 46.0 6.02 na na 26.4 na naN2O na 0.019 lb/ton lime 40 CFR 98 Table C-3 na 46.0 0.88 na na 3.8 na naCO2e na 2,690 lb/ton lime 40 CFR 98 Table A-2 na 46.0 123,756 na na 542,052 na naNotes1. Emission factors for PM, PM10, PM2.5, and SO2 are controlled emission factors. Therefore no control efficiency is used in calculating the controlled limited potential value shown for Process ID 1.

11 01 2 Pulverized Fuel BurnerAntimony 07440-36-0 0.018 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 1.73E-01 1.73E-04 na 7.57E-01 7.57E-04 naArsenic 07740-38-2 0.410 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 3.94E+00 3.94E-03 na 1.72E+01 1.72E-02 naBeryllium 07440-41-7 0.021 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 2.02E-01 2.02E-04 na 8.83E-01 8.83E-04 naCadmium 07440-43-9 0.051 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 4.90E-01 4.90E-04 na 2.14E+00 2.14E-03 naChromium 07440-47-3 0.260 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 2.50E+00 2.50E-03 na 1.09E+01 1.09E-02 naFormaldehyde 00050-00-0 0.000 lb/ton Coal AP 42 Table 1.1-17 na 9.6 2.30E-03 na na 1.01E-02 na naHCl 07647-01-0 1.438 lb/ton Coal 11/07 stack test (K2) na 9.6 1.38E+01 na na 6.04E+01 na naLead 07439-92-1 0.006 lb/ton Coal NLA Test na Baghouse 99.9% 9.6 5.29E-02 5.29E-05 na 2.32E-01 2.32E-04 naManganese 07439-96-5 0.490 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 4.70E+00 4.70E-03 na 2.06E+01 2.06E-02 naMercury 07439-97-6 0.072 lb/ton Coal NLA Test na Baghouse 99.9% 9.6 6.90E-01 6.90E-04 na 3.02E+00 3.02E-03 naNickel 07440-02-0 0.280 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 2.69E+00 2.69E-03 na 1.18E+01 1.18E-02 naSelenium 07782-49-2 1.300 lb/ton Coal AP 42 Table 1.1-18 na Baghouse 99.9% 9.6 1.25E+01 1.25E-02 na 5.47E+01 5.47E-02 na

2. Emission factors provided for Kiln #5 criteria pollutant emissions are based on June 5, 2018 performance test, during which Kiln #5 was operated in cofiring mode. This is currently the primary operating mode for the kiln, however, during a small portion of the year the kiln is fired at 100% coal. To account for the varied emissions profile of the kiln during different operating modes, a weighted average emission factor will be submitted in each subsequent KDAQ Emission Survey.


KyEISSource

ID #Process


EmissionFactorBasis

Cont.Equip. #

ControlDevice

ControlEfficiency


ControlledLimited

Potential Allowable


ControlledLimited

Potential Allowable



Rate(SCC

Units/hr)



DEP7007N(continued)




KyEISSource

ID # Stack DescriptionHeight

(ft)Diameter

(ft)

VentHeight

(ft)Vertical

CoordinateHorizontalCoordinate

CollectionMethod Code

Flowrate(acfm)

Temperature(F)

ExitVelocity(ft/sec)

07 01 Rotary Kiln #1 102 8.00 4,302,092.88 739,511.96 IMI 68,500 349 22.7208 01 Rotary Kiln #2 150 5.79 4,302,081.01 739,512.13 IMI 108,200 322 68.5009 01 Rotary Kiln #3 77 44.8 4,302,047.83 739,517.76 IMI 246,000 306 2.6010 01 Rotary Kiln #4 120 7.50 4,302,042.48 739,576.41 IMI 153,800 341 58.0211 01 Rotary Kiln #5 120 7.50 4,302,028.66 739,588.29 IMI 181,900 423 68.61

Stack Physical Data Stack Geographic Data Stack Gas Stream Data

SECTION II. Stack Information

DEP7007N(continued)



APPENDIX E: SUGGESTED TITLE V PERMIT REVISIONS

TextofSuggestedTitleVPermitRevisions

Version: 3-8-18

TABLE OF CONTENTS SECTION ISSUANCE PAGE A. PERMIT AUTHORIZATION Revision 6 1 B. EMISSION POINTS, EMISSIONS UNITS, APPLICABLE Revision 6 2

REGULATIONS, AND OPERATING CONDITIONS C. INSIGNIFICANT ACTIVITIES Revision 6 113 D. SOURCE EMISSION LIMITATIONS AND TESTING Renewal 114

REQUIREMENTS E. SOURCE CONTROL EQUIPMENT REQUIREMENTS Renewal 115 F. MONITORING, RECORDKEEPING, AND REPORTING Revision 6 116

REQUIREMENTS G. GENERAL PROVISIONS Revision 6 119

Permit Permit Type

Activity# Complete Date

Issuance Date

Summary of Action

V-14-002 Renewal APE20120003 10/27/2012 8/26/2014 Renewal V-14-002

R1 Minor

revision APE20140002 11/26/2014 2/25/2015 Construction of new

baghouse LM04, EU 32-16V-14-002

R2 Minor

revision APE20150001 4/14/2015 8/14/2015 Replace Five Diesel-fired

generators V-14-002

R3 Significant Revision

APE20160001 APE20150002 APE20150003

4/12/2016 11/23/2016 Construction of a New Hydrate Plant, Duct Change

for Kiln #4, New Storage Pile, and the Replacement of Bin Vent Filter on Kiln #4 &

#5 Dust BinV-14-002

R4 Minor

Revision APE20170001 2/22/2017 6/1/2017 Construction of Multichannel

Burners for Rotary Kiln #4 and Rotary Kiln #5

V-14-002 R5

Minor Revision

APE20170002 5/31/2017 8/21/2017 Addition of a New Emergency Generator for

Multichannel Burners V-14-002

R6 Minor

Revision APE20180002 6/6/2018 10/28/2018 Modification of Existing

Testing Requirement

Permit Number: V-14-002 R6 Page: 1 of 124 SECTION A - PERMIT AUTHORIZATION

Pursuant to a duly submitted application the Kentucky Energy and Environment Cabinet (Cabinet) hereby authorizes the operation of the equipment described herein in accordance with the terms and conditions of this permit. This permit has been issued under the provisions of Kentucky Revised Statutes (KRS) Chapter 224 and regulations promulgated pursuant thereto. The permittee shall not construct, reconstruct, or modify any affected facilities without first submitting a complete application and receiving a permit for the planned activity from the permitting authority, except as provided in this permit or in 401 KAR 52:020, Title V Permits. Issuance of this permit does not relieve the permittee from the responsibility of obtaining any other permits, licenses, or approvals required by the Cabinet or any other federal, state, or local agency.

Permit Number: V-14-002 R6 Page: 2 of 124 SECTION B- EMISSIONS UNITS, EMISSION POINTS, APPLICABLE REGULATIONS AND OPERATING CONDITIONS

LIMESTONE: LS01 – Mine to Stockpile Transfers

EU # Description Design

Capacity(ton/hr)

Date Constructed or Last Modified

Controls

01-01 14-101 Belt Conveyor Transfer to 14-

102 Belt Conveyor 1,250 1974 Water Spray


200 Reversing Belt Conveyor 1,250 1974

Moist Material

01-04 14-200 Reversing Belt Conveyor

Transfer to Stockpiles 1,250 1995

Moist Material

APPLICABLE REGULATIONS: 401 KAR 63:010, Fugitive emissions 1. Operating Limitations:

a. Reasonable precautions shall be taken to prevent particulate matter from becoming airborne. Such reasonable precautions shall include, when applicable, but not be limited to the following [401 KAR 63:010, Section 3]: 1) Application and maintenance of asphalt, water, or suitable chemicals on roads, material

stockpiles, and other surfaces which can create airborne dusts. 2) Installation and use of hoods, fans, and fabric filters to enclose and vent the handling

of dusty materials, or the use of water sprays or other measures to suppress the dust emissions during handling;

3) Maintenance of paved roadways in a clean condition; 4) The prompt removal of earth or other material from a paved street which earth or other

material has been transported thereto by trucking or other earth moving equipment or erosion by water;

5) Installation and use of compaction or other measures to suppress the dust emissions during handling

b. No one shall allow earth or other material being transported by truck or earth moving

equipment to be deposited onto a paved street or roadway [401 KAR 63:010, Section 4]. 2. Emission Limitations:

No person shall cause or permit the discharge of visible fugitive dust emissions beyond the lot line of the property on which the emissions originate. [401 KAR 63:010, Section 3(2)]

Compliance Demonstration Method: Compliance shall be demonstrated with the 1. Operating Limitations above.

3. Testing Requirements: Not applicable.

Permit Number: V-14-002 R6 Page: 3 of 124 SECTION B- EMISSIONS UNITS, EMISSION POINTS, APPLICABLE REGULATIONS AND OPERATING CONDITIONS (CONTINUED)

4. Specific Monitoring Requirements: Conduct visual observations monthly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]

5. Specific Recordkeeping Requirements: a. Maintain a log of visual observations as required under 4. Specific Monitoring

Requirements, indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, corrective actions taken to mitigate any emissions observed and the results of the follow-up visual observations. [401 KAR 52:020, Section 10]

b. Maintain a log of routine and non-routine maintenance activities performed on the water spray system associated with EU 01-01. These records shall include, at a minimum, the date, the name(s) of the person or organization performing the maintenance, and a description of the maintenance completed. [401 KAR 52:020, Section 10]

6. Specific Reporting Requirements:

See Section F - Monitoring, Recordkeeping, and Reporting Requirements. 7. Specific Control Equipment Operating Conditions:

Water sprays shall be applied on EU 01-01 when applicable; to ensure that limestone material being conveyed is sufficiently moist to control fugitive emissions. [401 KAR 50:055, Section 2]


LIMESTONE: LS02 – Limestone Stockpiles

EU # Description Date Constructed or Last Modified

Controls

01-03 Limestone Stockpile (42,000 tons) (8 × x0

ROM) (Encompassing both the 100 Pile and 200 Pile Combined)

1995 Moist Material

01-08 Small Kiln Feed Stockpile (½ ×1)

(All Sections) 1995 Moist Material

01-12 Large Kiln Feed Stockpile (2½ × 1)

(All Sections) 1995 Moist Material

01-16 ½ × 150 Mesh Stockpiles 1995 Moist Material

31-01 Riverside Stone Stockpile #1 2001 Moist Material











equipment to be deposited onto a paved street or roadway. [401 KAR 63:010, Section 4]

2. Emission Limitations: No person shall cause or permit the discharge of visible fugitive dust emissions beyond the lot line of the property on which the emissions originate. [401 KAR 63:010, Section 3(2)]


Compliance Demonstration Method: Compliance shall be demonstrated with 1. Operating Limitations and 4. Specific Monitoring Requirements.

3. Testing Requirements:

Not Applicable 4. Specific Monitoring Requirements:

Inspect each stockpile and conduct visual observations at least once per month during daylight hours. If the stockpile is determined to have the potential to generate fugitive emissions (e.g. stockpiles are very dry, with no crust and wind speed is substantial enough to disturb the material) or visible emissions observed, take preventative actions to mitigate the potential for fugitive emissions (e.g. misting the stockpile) and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]

5. Specific Recordkeeping Requirements:

Maintain a log of stockpile inspections and visual observations as required under 4. Specific Monitoring Requirements indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, corrective actions taken to mitigate any emissions observed and the results of the follow-up visual observations. [401 KAR 52:020, Section 10]


See Section F - Monitoring, Recordkeeping, and Reporting Requirements.


LIMESTONE: LS03 – Limestone Screening and Crushing


Capacity(ton/hr)


Controls


01-06 51-100 Belt Conveyor Transfer to

51-201 Belt Conveyor 1,250 1974 Moist Material


Small Kiln Feed Stockpile 240 1995 Moist Material

01-11 51-208 Tripper Conveyor Transfer

to Large Kiln Feed Stockpile 775 1995 Moist Material

01-15 51-204 Radial Stacker Transfer to 1/2 × x150 Mesh Stockpile or 51-

221 Limestone Screen 210 1995 Moist Material


51-201 Belt Conveyor 1,250 1995 Moist Material

02-07 51-304 Cone Crusher Transfer to

51-201 Belt Conveyor 500 1995 Moist Material

02-08 51-305 Cone Crusher Transfer to



51-204 Radial Stacker 210 1995 Moist Material


02-02 Screening Building Operations 1,790 1995 Moist Material Inside Building

02-05 Crusher Building Operations 540 1995 Moist Material Inside Building

02-10 Transfer House from Screening

Building to Stockpiles 1,015 1995

Moist Material Inside Building

APPLICABLE REGULATIONS: 401 KAR 60:005, Section 2(2)(qqq) 40 C.F.R. 60.670 to 60.676, Tables 1 to 3 (Subpart OOO), Standards of Performance for Nonmetallic Mineral Processing Plants 1. Operating Limitations:

Not applicable


2. Emission Limitations:

a. Fugitive emissions from the exterior conveyor transfer points shall not exceed 10% opacity. [40 CFR 60.672(b)]

b. Fugitive emissions from the openings of the Limestone Processing Buildings listed shall not exceed 7% opacity. [40 CFR 60.672(e)(1)] Compliance Demonstration Method: Compliance shall be demonstrated by with 3. Testing Requirements and 4. Specific Monitoring Requirements.


a. In determining compliance with the particulate matter standards in 40 CFR 60.672(b) or 40 CFR 60.672(e)(1), the owner or operator shall use EPA Reference Method 9 of Appendix A-4 of this part and the procedures in 40 CFR 60.11, with the following additions [40 CFR 60.675 (c)(1)]: 1) The minimum distance between the observer and the emission source shall be 4.57

meters (15 feet). 2) The observer shall, when possible, select a position that minimizes interference from

other fugitive emission sources (e.g., road dust). The required observer position relative to the sun (EPA Reference Method 9 of Appendix A-4 of this part, Section 2.1) must be followed.

b. When determining compliance with the fugitive emissions standard, the duration of the

EPA Reference Method 9 (40 CFR part 60, Appendix A-4) observations must be 30 minutes (five 6-minute averages). Compliance with the applicable fugitive emission limits in Table 3 of 40 CFR 60, Subpart OOO must be based on the average of the five 6-minute averages. [40 CFR 60.675(e)(3)]

c. If the building encloses only affected facilities that commenced construction, modification, or reconstruction before April 22, 2008, and the owner or operator has previously conducted an initial EPA Reference Method 22 (40 CFR part 60, Appendix A-7) performance test showing zero visible emissions, then the owner or operator has demonstrated compliance with the opacity limit in 40 CFR 60.672(e)(1). If the owner or operator has not conducted an initial performance test for the building before April 22, 2008, then the owner or operator must conduct an initial EPA Reference Method 9 (40 CFR part 60, Appendix A-4) performance test according to this section and 40 CFR 60.11 to show compliance with the opacity limit in 40 CFR 60.672(e)(1). This test shall be conducted within 180 days following the issuance of permit V-14-002. [40 CFR 60.675(d)(2)]

4. Specific Monitoring Requirements:

Conduct visual observations weekly monthly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference

Commented [A1]: Carmeuse is proposing to change the monitoring frequency from weekly to monthly to be consistent with Lime MACT provisions for Processed Stone Handling systems and the other limestone material handling operations at the plant. Carmeuse is requesting the visible emissions monitoring language in the permit be standardized and immediate Method 9 readings be removed. Refer to application report for additional discussion.


Method 9 reading. If visible emissions are observed, conduct an EPA Reference Method 9 (40 CFR 60, Appendix A) reading immediately, then take corrective action and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]

5. Specific Recordkeeping Requirements: Maintain records of visual emission observations and EPA Reference Method 9 readings required under 4. Specific Monitoring Requirements indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed and the results of the follow-up visual observation. [401 KAR 52:020, Section 10]




LIMESTONE: LS04 – Kiln Limestone Feed System


Capacity(ton/hr)


Controls

Feed Piles to Stone Bins/Preheaters:

01-32 52-215 Belt Conveyor Transfer to #3

Stone Bin 875 1995 Moist Material



02-16

52-302 Belt Conveyor Transfer to 52-303 Belt Conveyor or 52-215 Belt

Conveyor or #1 Stone Bin or #2 Stone Bin

875 1995 Moist Material


52-304 Belt Conveyor or #4 Preheater

875 1995 Moist Material


Preheater 875 1995 Moist Material

Stone Bins/Preheaters to Kilns:




Kiln # 1 50 1974 Moist Material







Lime Storage Building:

33-01 Kilns 1, 2 & 3 Discharge Building enclosing Belt Conveyor Transfers

83-224, 82-112 and 81-111 NA 1974 Moist Material


APPLICABLE REGULATIONS: 401 KAR 63:002, Section 2(4)(ffff) 40 C.F.R. 63.7080 to 63.7143, Tables 1 to 8 (Subpart AAAAA), National Emission Standards for Hazardous Air Pollutants for Lime Manufacturing Plants 1. Operating Limitations:

a. Prepare and follow a written operations, maintenance, and monitoring (OM&M) plan. The plan must include items listed in 40 CFR 63.7100(d) and the corrective actions to be taken when required in Table 5 of 40 CFR 63, Subpart AAAAA. [40 CFR 63.7090(b)]

b. The unit must be in compliance with the operating limits of 40 CFR 63, Subpart AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)]

c. The units must be in compliance with the opacity and visible emission (VE) limits of 40 CFR 63, Subpart AAAAA during the times specified in 40 CFR 63.6(h)(1). [40 CFR 63.7100(b)]

d. While the conveyers are in operation, maintain the affected source according to the provisions in 40 CFR 63.6(e)(1)(i). [40 CFR 63.7100 (c)]

e. The permittee must develop a written startup, shutdown, and malfunction plan (SSMP) according to the provisions in 40 CFR 63.6(e)(3). [40 CFR 63.7100(e)]

2. Emission Limitations: a. There must be no VE from each building (EU 33-01). [40 CFR 63.7090(a), Table 1]

Compliance Demonstration Method: Compliance with the visible emissions limit shall be demonstrated through 4. Specific Monitoring Requirements b.

b. Fugitive emissions from the conveyor transfer points outside the buildings shall not exceed

10% opacity. [40 CFR 63.7090(a)]

Compliance Demonstration Method: Compliance shall be demonstrated through 3. Testing Requirements a. and 4. Specific Monitoring Requirements a.

3. Testing Requirements: a. Conduct a performance test within 5 years following the initial performance test and within

5 years following each subsequent performance test thereafter from each listed emission unit and the building using EPA Reference Methods 5, 9 or 17. [40 CFR 63.7111].

b. Testing must be conducted in accordance with the following [40 CFR 63.7112]: 1) The EPA Reference Method 9 (Appendix A to part 60 of this chapter) test duration for

each emission unit must be for at least 3 hours, but the 3-hour test may be reduced to 1 hour if, during the first 1-hour period, there are no individual readings greater than 10


percent opacity and there are no more than three readings of 10 percent during the first 1-hour period.

2) The performance test for a building must be conducted according to the specifications below, while all affected Processed Stone Handling (PSH) operations within the building are operating; the performance test for each affected building must be at least 75 minutes, with each side of the building and roof being observed for at least 15 minutes. i. The minimum distance between the observer and the emission source shall be

4.57 meters (15 feet). ii. The observer shall, when possible, select a position that minimizes interference

from other fugitive emission sources (e.g., road dust). The required observer position relative to the sun must be followed.

iii. If wet suppression is used to control Particulate Matter (PM) from PSH operations, a visible mist is sometimes generated by the spray. The water mist must not be confused with particulate matter emissions and is not considered VE. When a water mist of this nature is present, emissions must be observed at a point in the plume where the mist is no longer visible.

c. Performance tests shall not be conducted during periods of startup, shutdown, or

malfunction. [40 CFR 63.7112(c)]

4. Specific Monitoring Requirements: a. For each PSH operation subject to an opacity limitation as required in Table 1 of

40 CFR 63, Subpart AAAAA, or any vents from buildings subject to an opacity limitation [40 CFR 63.7121(e)]: 1) Conduct a monthly 1-minute VE check of each emission unit in accordance with 40

CFR 63.7121(e); the check must be conducted while the affected source is in operation; 2) If no VE are observed in 6 consecutive monthly checks for any emission unit, the

frequency of VE checking may decrease from monthly to semi-annually for that emission unit; if VE are observed during any semiannual check, resume VE checking of that emission unit on a monthly basis and maintain that schedule until no VE are observed in 6 consecutive monthly checks;

3) If no VE are observed during the semiannual check for any emission unit, the frequency of VE checking may decrease from semi-annually to annually for that emission unit; if VE are observed during any annual check, resume VE checking of that emission unit on a monthly basis and maintain that schedule until no VE are observed in 6 consecutive monthly checks; and

4) If VE are observed during any VE check, conduct a 6-minute test of opacity in accordance with EPA Reference Method 9 of appendix A to part 60 of this chapter; begin the EPA Reference Method 9 test within 1 hour of any observation of VE and the 6-minute opacity reading must not exceed the applicable opacity limit.

b. For any building subject to a VE limit, according to item 8 of Table 1 of 40 CFR 63.7121(e)]:


1) Conducting a monthly VE check of the building, in accordance with the specifications in 40 CFR 63.7112(k); the check must be conducted while all the enclosed PSH operations are operating;

2) The check for each affected building must be at least 5 minutes, with each side of the building and roof being observed for at least 1 minute;

3) If no VE are observed in 6 consecutive monthly checks of the building, the frequency of checking may decrease from monthly to semi-annually for that affected source; if VE are observed during any semi-annual check, resume checking on a monthly basis and maintain that schedule until no VE are observed in 6 consecutive monthly checks; and

4) If no VE are observed during the semi-annual check, the frequency of checking may decrease from semi-annually to annually for that affected source; and if VE are observed during any annual check, resume checking of that emission unit on a monthly basis and maintain that schedule until no VE are observed in 6 consecutive monthly checks (the source is in compliance if no VE are observed during any of these checks).


a. Records shall be kept as required under 40 CFR 63.7132: 1) A copy of each notification and report submitted to comply with 40 CFR 63,

Subpart AAAAA, including all documentation supporting any Initial Notification or Notification Compliance Status submitted in accordance with the requirements in 40 CFR 63.10(b)(2)(xiv). [40 CFR 63.7132(a)(1)]

2) The records in 40 CFR 63.6(e)(3)(iii) through (v) related to startup, shutdown and malfunction. [40 CFR 63.7132(a)(2)]

3) Records of performance tests, performance evaluations, and opacity and VE observations as required in 40 CFR 63.10(b)(2)(viii). [40 CFR 63.7132(a)(3)]

4) Records in 40 CFR 63.6(h)(6) must be kept for VE observations. [40 CFR 63.7132 (b)] 5) Records required by Tables 5 and 6 of 40 CFR 63, Subpart AAAAA, must be kept to

show continuous compliance with each emission limitation that applies to the facility. [40 CFR 63.7132(c)]

6) Records must be kept which document the basis for the initial applicability determination as required under 40 CFR 63.7081. [40 CFR 63.7132(d)]

b. Keep a log of all visual observations, any EPA Reference Method 9 and 22 tests performed, and any corrective actions taken. [401 KAR 52:020, Section 10]




LIMESTONE: LS05 – Limestone Loadout Operations


Controls

03-01 93-102 Belt Conveyor and Barge Loadout 2007 Moist Material

04-01 93-110 Stone Dump Hoppers Transfer to 93-

100 Belt Conveyor 2007 Moist Material

05-02 93-100 Belt Conveyor Transfer to 93-101

Belt Conveyor (When in Limestone Service)1995 Moist Material

31-02 Limestone Transfers via Front End Loader to

93-110 Stone Dump Hoppers 2007 Moist Material

31-03 Limestone Transfers via Front End Loader to

Trucks 2007 Moist Material









equipment to be deposited onto a paved street or roadway. [401 KAR 63:010, Section 4] 2. Emission Limitations:


Compliance Demonstration Method: Compliance shall be demonstrated with the 4. Specific Monitoring Requirements.


3. Testing Requirements: Not Applicable 4. Specific Monitoring Requirements: Conduct visual observations monthly during daylight hours. If visible emissions are observed,

take corrective action and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]

5. Specific Recordkeeping Requirements: Maintain a log of visual observations as required under 4. Specific Monitoring Requirements, indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, corrective actions taken to mitigate any emissions observed and the results of the follow-up visual observation. [401 KAR 52:020, Section 10]

6. Specific Reporting Requirements: See Section F - Monitoring, Recordkeeping, and Reporting Requirements.


COAL SYSTEM: CL01 – Coal Receiving and Storage


Capacity(ton/hr)

Date Constructed

or Last Modified

Controls

Receiving of Coal From Trucks

06-01 Coal Receiving Hoppers at Truck Dump 900 1995 Moist Material


802 Reversing Belt Conveyor or #2 Silo 450 1995 Moist Material

06-05 54-802 Reversing Belt Conveyor

Transfer to #1 Silo, #2 Silo, or #3 Silo 450 1995 Moist Material

Receiving of Coal From Barges

28-01 Barge Receiving Hopper 700 2006 Moist Material


102 Belt Conveyor 700 2006 Moist Material




802 Reversing Belt Conveyor or #4 Silo 700 2006 Moist Material

Conveying of Coal from Storage Silos to Bins



06-09 54-804 Belt Conveyor Transfer to 54-805 or 54-806 Belt Conveyors or #2

Coal Bin 450 1995 Moist Material


807 Belt Conveyor or #3 Coal Bin 450 1995 Moist Material


808 Belt Conveyor or #4 Coal Bin 450 1995 Moist Material








APPLICABLE REGULATIONS: 401 KAR 60:005, Section 2(2)(gg) 40 C.F.R. 60.250 to 60.258 (Subpart Y), Standards of Performance for Coal Preparation and Processing Plants 1. Operating Limitations:

Not applicable 2. Emission Limitations:

An owner or operator shall not cause to be discharged into the atmosphere from any coal processing and conveying equipment, coal storage system, or coal transfer and loading system processing coal constructed, reconstructed, or modified on or before April 28, 2008, gases which exhibit 20% opacity or greater. [40 CFR 60.254(a)] Compliance Demonstration Method: Compliance shall be demonstrated with 3. Testing Requirements and 4. Specific Monitoring Requirements.

3. Testing Requirements: a. The owner or operator must determine compliance with the applicable opacity standards as specified below. [40 CFR 60.257(a)]

1) EPA Reference Method 9 of appendix A-4 of this part and the procedures in 40 CFR 60.11 must be used to determine opacity, with the exceptions specified in paragraphs 40 CFR 60.257 (a)(1)(i) and (ii). i. The duration of the EPA Reference Method 9 of appendix A-4 of this part

performance test shall be 1 hour (ten 6-minute averages). ii. If, during the initial 30 minutes of the observation of an EPA Reference Method 9

of appendix A-4 of this part performance test, all of the 6-minute average opacity readings are less than or equal to half the applicable opacity limit, then the observation period may be reduced from 1 hour to 30 minutes.

2) To determine opacity for fugitive coal dust emissions sources, the additional requirements specified in paragraphs 40 CFR 60.257(a)(2)(i) through (iii) must be used. i. The minimum distance between the observer and the emission source shall be 5.0

meters (16 feet), and the sun shall be oriented in the 140-degree sector of the back. ii. The observer shall select a position that minimizes interference from other fugitive

coal dust emissions sources and make observations such that the line of vision is approximately perpendicular to the plume and wind direction.

iii. The observer shall make opacity observations at the point of greatest opacity in that portion of the plume where condensed water vapor is not present. Water vapor is not considered a visible emission.

3) A visible emissions observer may conduct visible emission observations for up to three fugitive, stack, or vent emission points within a 15-second interval if the following conditions specified in paragraphs (a)(3)(i) through (iii) of this section are met. i. No more than three emissions points may be read concurrently. ii. All three emissions points must be within a 70 degree viewing sector or angle in

front of the observer such that the proper sun position can be maintained for all three points.


iii. If an opacity reading for any one of the three emissions points is within 5 percent opacity from the applicable standard (excluding readings of zero opacity), then the observer must stop taking readings for the other two points and continue reading just that single point.

4. Specific Monitoring Requirements: Conduct visual observations monthly during daylight hours. If visible emissions are

observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference Method 9 reading. Perform a qualitative visual observation of the opacity of emissions from each transfer point on a weekly basis and maintain a log of the observations. If visible emissions from any transfer point are observed, then an EPA Reference Method 9 (40 CFR 60, Appendix A) reading shall be conducted immediately and take corrective action. After corrective actions have been complete, conduct a follow-up visual observation. [401 KAR 52:020, Section 10]


Maintain a log of visual emission observations and EPA Reference Method 9 readings required under 4. Specific Monitoring Requirements indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed and the results of the follow-up visual observations. [401 KAR 52:020, Section 10]



Commented [A2]: Carmeuse is proposing to change the monitoring frequency from weekly to monthly to be consistent with the limestone material handling operations at the plant, which also have a low potential for visible emissions. Carmeuse is requesting the visible emissions monitoring language in the permit be standardized and immediate Method 9 readings be removed. Refer to application report for additional discussion.


ROTARY LIME KILNS: KL01 - Rotary Kiln #1 Emission Unit 07-01 Rotary Kiln #1 Description: Fuller Kiln – 10'6" × 300' Construction Commenced: 1970 Maximum Rated Input Capacity: 61 tons/hour of limestone Primary Fuel: Pulverized Coal; Maximum Firing Rate: 8.9 tons/hr Secondary Fuels: Natural Gas, Glycerin Startup Fuels: Natural Gas Controls: Reverse-Air Baghouse (Wheelabrator No. 613, Model 360 Series 11.5) APPLICABLE REGULATIONS: 401 KAR 61:020, Existing process operations. 401 KAR 63:002, Section 2(4)(ffff) 40 C.F.R. 63.7080 to 63.7143, Tables 1 to 8 (Subpart AAAAA), National Emission Standards for Hazardous Air Pollutants for Lime Manufacturing Plants 40 CFR 64, Compliance Assurance Monitoring (CAM) for particulate matter. Requirements of this subpart are satisfied by applicability of 40 CFR 63, Subpart AAAAA. 1. Operating Limitations:

a. Maintain and operate the FF such that the BLDS or PM detector alarm condition does not exist for more than 5 percent of the total operating time in a 6-month period; and comply with the requirements in 40 CFR 63.7113(d) through (f) and Table 5 of Subpart AAAAA. In lieu of a BLDS or PM detector, maintain the FF such that the 6-minute average opacity for any 6-minute block period does not exceed 15 percent; and comply with the requirements in 40 CFR 63.7113(f) and (g) and Table 5 to Subpart AAAAA. [40 CFR 63.7090(b)]

b. Prepare and implement a written OM&M plan. The plan must include items listed in 40 CFR 63.7100(d) and the corrective actions to be taken when required in Table 5 of 40 CFR 63, Subpart AAAAA. [40 CFR 63.7090(b)]

c. The unit must be in compliance with the operating limits of 40 CFR 63, Subpart AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)]

d. The permittee must develop a written startup, shutdown, and malfunction plan (SSMP)

according to the provisions in 40 CFR 63.6(e)(3). [40 CFR 63.7100(e)]

e. Always operate and maintain the affected source, including air pollution control and monitoring equipment, according to the provisions in 40 CFR 63.6(e)(1)(i). [40 CFR 63.7100 (c)]


2. Emission Limitations: a. Emissions of particulate matter shall not exceed 0.12 lb/ton of stone feed (lb/tsf). Weighted

average PM emissions may be determined according to Equation 2 in 40 CFR 63.7112 and must not exceed 0.12 lb/tsf. [40 CFR 63.7090(a)]

Compliance Demonstration Method: Compliance shall be demonstrated through performance testing required under 3 Testing Requirements.

b. Emissions of particulate matter shall not exceed the emission rate calculated by the

following equations: [401 KAR 61:020 Section 3(2)(a)]

For process weight rates in excess of 30 ton/hr, E = 55.0P0.11 - 40 Where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr. Compliance Demonstration Method: Compliance shall be demonstrated through performance testing required under 3. Testing Requirements.

c. No person shall cause, suffer, allow or permit any continuous emission into the open air from a control device or stack associated with any affected facility which is equal to or greater than forty (40) percent opacity. [401 KAR 61:020, Section 3(1)(a)]

Compliance Demonstration Method: Compliance shall be demonstrated through the 4. Specific Monitoring Requirements.

d. The unit must be in compliance with the emission limitations of 40 CFR 63,

Subpart AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)].

3. Testing Requirements: a. Conduct a performance test in accordance with EPA Reference Method 5 for particulate

matter within 5 years following the initial performance test and within 5 years following each subsequent performance test thereafter. [40 CFR 63.7111 and 401 KAR 50:045] 1) Performance tests may not be conducted during periods of startup, shutdown, or malfunction, as specified in 40 CFR 63.7(e)(1). [40 CFR 63.7112(c)] 2) Three separate test runs must be conducted for each required performance test, as

specified in 40 CFR 63.7(e)(3). Each test run must last at least one hour. [40 CFR 63.7112(d)]

3) Calculate PM emissions from performance tests in accordance with the provisions in 40 CFR 63.7112(e), (f) and (g). 4) Performance test results must be documented in complete test reports that contain the information required by 40 CFR 63.7112 paragraphs (h)(1) through (10) of this section, as well as all other relevant information. The plan to be followed during testing must be made available to the Administrator at least 60 days prior to testing. [40 CFR 63.7112(h)]


5) The permittee must establish any applicable 3-hour block average operating limit indicated in Table 2 of 40 CFR 63, Subpart AAAAA according to the applicable requirements in Table 3 of 40 CFR 63, Subpart AAAAA and 40 CFR 63.7112 paragraphs (j)(1) through (4) of this section. [40 CFR 63.7112(j)]


a. Install, calibrate, maintain, and operate a monitoring device to continuously monitor the differential pressure across the kiln baghouse to ensure that pressure does not drop outside the pressure drop range documented in the OM&M Plan. Personnel will monitor the differential pressure reading across the baghouse once per shift and at least once every twelve hours of operation, except when the unit is not in operation. [401 KAR 61:005, Section 3(6)]

b. Following a reading outside of the pressure drop range specified in the OM&M: 1) Maintenance personnel shall inspect the monitoring system, baghouse, and operations

immediately; and take correction action as soon as practicable. 2) Upon completed corrective action, the permittee shall immediately conduct an EPA

Reference Method 9 opacity reading on the dust collection system serviced and ensure pressure drop has returned to normal range. [401 KAR 52:020, Section 10]

c. If a bag leak detection system or PM detector is not utilized, conduct a VE check daily

(minimum of 6-minutes) in accordance with EPA Reference Method 9 of Appendix A to 40 CFR Part 60. Record the opacity observed in an observation log. The reading shall be performed by a representative of the permittee certified in Visible Emissions Evaluation. Maintain a list of all individuals who are certified EPA Reference Method 9 Visible Emissions Evaluators. [40 CFR 63.7121(f)]

d. If the opacity reading is greater than fifteen (15) percent from the stack during the daily VE check, then initiate an inspection of the equipment and make repairs if necessary. [401 KAR 52:020, Section 10]

e. For each emission unit equipped with an add-on air pollution control device, inspect each capture/collection and closed vent system at least once each calendar year to ensure that each system is operating in accordance with the operating requirements in Item 6 of Table 2 of 40 CFR 63 Subpart AAAAA and record the results of each inspection. [40 CFR 63.7113 (f)]

f. Except for monitor malfunctions, associated repairs, required quality assurance or control

activities (including, as applicable, calibration checks and required zero adjustments), the permittee must monitor continuously (or collect data at all required intervals) at all times that the emission unit is operating. [40 CFR 63.7120(b)]

g. Data recorded during system breakdowns, repairs, preventive maintenance, calibration checks, and zero (low-level) and high-level adjustments, periods of non-operation of the process unit (or portion thereof), resulting in cessation of the emissions to which the monitoring applies; and start-ups, shutdowns, and malfunctions may not be used either in

Commented [A3]: Carmeuse is proposing to remove the requirement to conduct an immediate Method 9 reading due to a differential pressure excursion. Refer to rationale provided in the application report.


data averages or calculations of emission or operating limits; or in fulfilling a minimum data availability requirement. The permittee must use all the data collected during all other periods in assessing the operation of the control device and associated control system. [40 CFR 63.7120(c)]

h. The amount of material placed in the kiln (ton), amount of lime produced from the kiln

(tons), amount of coal and glycerin, source-wide natural gas consumed and hours of operation shall be monitored and recorded on a monthly basis. [401 KAR 52:020, Section 10].


a. Maintain records of inspection of each capture/collection and closed vent system as required by 40 CFR 63.7113(f).

b. Maintain records of all routine and non-routine maintenance activities performed on the dust collection system. These records shall include, at a minimum, the date, the name(s) of the person or organization performing the maintenance, and a description of the maintenance completed. [401 KAR 52:020, Section 10]

c. Keep records of performance tests and performance evaluation. [40 CFR 63.7132(a)(3)]

d. Keep visual observation records and EPA Reference Method 9 observation records, and

any inspections and repair records in a designated paper or electronic logbook. Records shall be maintained for five years. [401 KAR 52:020, Section 10]

e. Performance test results must be documented in complete test reports that contain the

information below, as well as all other relevant information. The plan to be followed during testing must be made available to the Division at least 60 days prior to testing. [40 CFR 63.7112(h)] 1) A brief description of the process and the air pollution control system; 2) Sampling location description(s); 3) A description of sampling and analytical procedures and any modifications to standard

procedures; 4) Test results, including opacity; 5) Quality assurance procedures and results; 6) Records of operating conditions during the test, preparation of standards, and

calibration procedures; 7) Raw data sheets for field sampling and field and laboratory analyses; 8) Documentation of calculations; 9) All data recorded and used to establish operating limits; and

10) Any other information required by the test method.

f. Maintain records of the differential pressure readings on the kiln baghouse taken once per shift in an electronic format. Records shall, at a minimum, include the date and time of the reading, and the reading value. Records shall also include information on any corrective


actions taken when readings outside the appropriate range are recorded. [401 KAR 52:020, Section 10]

g. Maintain records of the amount of material placed in the kiln (ton), amount of lime produced from the kiln (ton) processed, amount of coal and glycerin, source-wide natural gas consumed and hours of operation on a monthly basis. [401 KAR 52:020, Section 10].


a. The prepared and implemented written OM&M plan must be submitted to the Division for review and approval as part of the application for a 40 CFR part 70 or 40 CFR part 71 permit. Any subsequent changes to the plan must be submitted to the applicable permitting authority for review and approval. Pending approval by the field office of an initial or amended plan, the facility shall comply with the provisions of the submitted plan. Each plan must contain the following information: [40 CFR 63.7100(d)] 1) Process and control device parameters to be monitored to determine compliance, along

with established operating limits or ranges, as applicable, for each emission unit. 2) A monitoring schedule for each emission unit. 3) Procedures for the proper operation and maintenance of each emission unit and each

air pollution control device used to meet the applicable emission limitations and operating limits in Tables 1 and 2 of 40 CFR 63, Subpart AAAAA, respectively.

4) Procedures for the proper installation, operation, and maintenance of monitoring devices or systems used to determine compliance, including: i. Calibration and certification of accuracy of each monitoring device; ii. Performance and equipment specifications for the sample interface, parametric

signal analyzer, and the data collection and reduction systems; iii. Ongoing operation and maintenance procedures in accordance with the general

requirements of 40 CFR 63.8(c)(1), (3), and (4)(ii); and iv. Ongoing data quality assurance procedures in accordance with the general

requirements of 40 CFR 63.8(d). 5) Procedures for monitoring process and control device parameters. 6) Corrective actions to be taken when process or operating parameters or add-on control

device parameters deviate from the operating limits specified in Table 2 of 40 CFR 63, Subpart AAAAA, including: i. Procedures to determine and record the cause of a deviation or excursion, and the

time the deviation or excursion began and ended; and ii. Procedures for recording the corrective action taken, the time corrective action was

initiated, and the time and date the corrective action was completed. 7) A maintenance schedule for each emission unit and control device that is consistent

with the manufacturer's instructions and recommendations for routine and long-term maintenance.

b. The permittee must report each instance in which the unit did not meet each operating limit, opacity limit, and VE limit in Tables 2 and 6 of 40 CFR 63, Subpart AAAAA that applies. This includes periods of startup, shutdown, and malfunction. These instances are deviations from the emission limitations of 40 CFR 63, Subpart AAAAA. These deviations must be reported according to the requirements in 40 CFR 63.7131.[40 CFR 63.7121(b)]


c. The permittee must submit the Notification of Compliance Status containing the results of the initial compliance demonstration according to the requirements in 40 CFR 63.7130(e). [40 CFR 63.7114(c)]

7. Specific Control Equipment Operating Conditions:

a. The baghouse shall be operated to maintain compliance with permitted emission limitations, consistent with manufacturer’s specifications and standard operating practices. [401 KAR 50:055, Section 2]

b. Records regarding the maintenance of the dust collection system shall be maintained. [401 KAR 52:020, Section 10]


ROTARY LIME KILNS: KL02 - Rotary Kiln #2 Emission Unit 08-01 Rotary Kiln #2 Description: Fuller Kiln – 10'6" × 300' Construction Commenced: 1970 Maximum Rated Input Capacity: 61 tons/hour of Limestone Primary Fuel: Pulverized Coal; Maximum Firing Rate: 8.9 tons/hr Secondary Fuels: Natural Gas, Glycerin Startup Fuels: Natural Gas Controls: Pulse Jet Baghouse (Redi-Cam) 2003 APPLICABLE REGULATIONS: 401 KAR 61:020, Existing process operations. 401 KAR 63:002, Section 2(4)(ffff) 40 C.F.R. 63.7080 to 63.7143, Tables 1 to 8 (Subpart AAAAA), National Emission Standards for Hazardous Air Pollutants for Lime Manufacturing Plants 40 CFR 64, Compliance Assurance Monitoring (CAM) for particulate matter. Requirements of this subpart are satisfied by applicability of 40 CFR 63, Subpart AAAAA. 1. Operating Limitations:


Compliance Demonstration Method: Demonstrate continuous compliance by installing, maintaining, calibrating and operating a continuous opacity monitoring system (COMS) as required by 40 CFR part 63, subpart A, General Provisions and according to PS-1 of appendix B to part 60 of this chapter, except as specified in 40 CFR 63.7113(g)(2); and collecting the COMS data at a frequency of at least once every 15 seconds, determining block averages for each 6-minute period and demonstrating for each 6-minute block period the average opacity does not exceed 15 percent.

b. Prepare and implement a written OM&M plan. The plan must include items listed in 40

CFR 63.7100(d) and the corrective actions to be taken when required in Table 5 of 40 CFR 63, Subpart AAAAA. [40 CFR 63.7090(b)]




according to the provisions in 40 CFR 63.6(e)(3). [40 CFR 63.7100(e)] e. Always operate and maintain the affected source, including air pollution control and

monitoring equipment, according to the provisions in 40 CFR 63.6(e)(1)(i). [40 CFR 63.7100 (c)]


a. Emissions of particulate matter shall not exceed 0.12 lb/ton of stone feed (lb/tsf). Weighted average PM emissions may be determined according to Equation 2 in 40 CFR 63.7112 and must not exceed 0.12 lb/tsf. [40 CFR 63.7090(a)]

Compliance Demonstration Method: Compliance shall be demonstrated through performance testing required under 3. Testing Requirements.






d. The unit must be in compliance with the emission limitations of 40 CFR 63, Subpart

AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)]


matter within 5 years following the initial performance test and within 5 years following each subsequent performance test thereafter. [40 CFR 63.7111 and 401 KAR 50:045]


1) Performance tests may not be conducted during periods of startup, shutdown, or malfunction, as specified in 40 CFR 63.7(e)(1). [40 CFR 63.7112(c)]

2) Three separate test runs must be conducted for each required performance test, as specified in 40 CFR 63.7(e)(3). Each test run must last at least one hour. [40 CFR 63.7112(d)]

3) Calculate PM emissions from performance tests in accordance with the provisions in 40 CFR 63.7112(e), (f) and (g).

4) Performance test results must be documented in complete test reports that contain the information required by 40 CFR 63.7112 paragraphs (h)(1) through (10) of this section, as well as all other relevant information. The plan to be followed during testing must be made available to the Administrator at least 60 days prior to testing. [40 CFR 63.7112(h)]

5) The permittee must establish any applicable 3-hour block average operating limit indicated in Table 2 of 40 CFR 63 Subpart AAAAA according to the applicable requirements in Table 3 of 40 CFR 63 Subpart AAAAA and 40 CFR 63.7112 paragraphs (j)(1) through (4) of this section. [40 CFR 63.7112(j)]

4. Specific Monitoring Requirements: a. Install, calibrate, maintain, and operate a monitoring device to continuously monitor the

differential pressure across the kiln baghouse to ensure that pressure does not drop outside the pressure drop range documented in the OM&M Plan. Personnel will monitor the differential pressure reading across the baghouse once per shift and at least once every twelve hours of operation, except when the unit is not in operation. [401 KAR 61:005, Section 3(6)]

b. Following a reading outside of the pressure drop range specified in the OM&M:

1) Maintenance personnel shall inspect the monitoring system, baghouse, and operations immediately; and take correction action as soon as practicable.

2) Upon completed corrective action, the permittee shall immediately verify compliance with the opacity limit via COMS on the dust collection system serviced and ensure pressure drop has returned to normal range. [401 KAR 52:020, Section 10]

c. For each COMS used to monitor an add-on air pollution control device, the facility must meet the requirements in paragraphs (g)(1) and (2) of this section. [40 CFR 63.7113(g)]

1) Install the COMS at the outlet of the control device. 2) Install, maintain, calibrate, and operate the COMS as required by 40 CFR part 63,

subpart A, General Provisions and according to Performance Specification (PS)-1 of appendix B to part 60 of this chapter. Facilities that operate COMS installed on or before February 6, 2001, may continue to meet the requirements in effect at the time of COMS installation unless specifically required to re-certify the COMS by their permitting authority.


d. For each emission unit equipped with an add-on air pollution control device, inspect each capture/collection and closed vent system at least once each calendar year to ensure that each system is operating in accordance with the operating requirements in Item 6 of Table 2 of 40 CFR 63 Subpart AAAAA and record the results of each inspection. [40 CFR 63.7113 (f)]

e. Except for monitor malfunctions, associated repairs, required quality assurance or control activities (including, as applicable, calibration checks and required zero adjustments), the permittee must monitor continuously (or collect data at all required intervals) at all times that the emission unit is operating. [40 CFR 63.7120(b)]

f. Data recorded during system breakdowns, repairs, preventive maintenance, calibration checks, and zero (low-level) and high-level adjustments, periods of non-operation of the process unit (or portion thereof), resulting in cessation of the emissions to which the monitoring applies; and start-ups, shutdowns, and malfunctions may not be used either in data averages or calculations of emission or operating limits; or in fulfilling a minimum data availability requirement. The permittee must use all the data collected during all other periods in assessing the operation of the control device and associated control system. [40 CFR 63.7120(c)]

g. The amount of material placed in the kiln (ton), amount of lime produced from the kiln (ton)

processed, amount of coal and glycerin consumed, source-wide natural gas fuel usage and hours of operation shall be monitored and recorded on a monthly basis. [401 KAR 52:020, Section 10].








information below, as well as all other relevant information. The plan to be followed during testing must be made available to the Division at least 60 days prior to testing. [40 CFR 63.7112(h)] 1) A brief description of the process and the air pollution control system; 2) Sampling location description(s);


3) A description of sampling and analytical procedures and any modifications to standard procedures;

4) Test results, including opacity; 5) Quality assurance procedures and results; 6) Records of operating conditions during the test, preparation of standards, and

calibration procedures; 7) Raw data sheets for field sampling and field and laboratory analyses; 8) Documentation of calculations; 9) All data recorded and used to establish operating limits; and 10) Any other information required by the test method.

f. Maintain records of the COM data on the kiln baghouse. Records shall, at a minimum,

include the date and time of the reading and the opacity reading value. Records shall also include information on any corrective actions taken when the opacity exceeded the opacity trigger level. [401 KAR 52:020, Section 10]

g. Maintain records of the differential pressure readings on the kiln baghouse taken once per shift in an electronic format. Records shall, at a minimum, include the date and time of the reading, and the reading value. Records shall also include information on any corrective actions taken when readings outside the appropriate range are recorded. [401 KAR 52:020, Section 10]

h. Maintain records of the amount of material placed in the kiln (ton), amount of lime

produced from the kiln (tons), amount of coal, glycerin, source-wide natural gas consumed and hours of operation shall be monitored and recorded on a monthly basis. [401 KAR 52:020, Section 10]






signal analyzer, and the data collection and reduction systems;


iii. Ongoing operation and maintenance procedures in accordance with the general requirements of 40 CFR 63.8(c)(1), (3), and (4)(ii); and

iv. Ongoing data quality assurance procedures in accordance with the general requirements of 40 CFR 63.8(d).

5) Procedures for monitoring process and control device parameters. 6) Corrective actions to be taken when process or operating parameters or add-on control





b. The permittee must report each instance in which the unit did not meet each operating limit,

opacity limit, and VE limit in Tables 2 and 6 of 40 CFR 63, Subpart AAAAA that applies. This includes periods of startup, shutdown, and malfunction. These instances are deviations from the emission limitations of 40 CFR 63, Subpart AAAAA. These deviations must be reported according to the requirements in 40 CFR 63.7131.[40 CFR 63.7121(b)]






ROTARY LIME KILNS: KL03 - Rotary Kiln #3 Emission Unit 09-01 Rotary Kiln #3 Description: Allis-Chalmers Kiln – 14'6" × 400'6" Construction Commenced: 1974 Maximum Rated Input Capacity: 130 tons/hour of limestone Primary Fuel: Pulverized Coal; Maximum Firing Rate: 15.5 tons/hr Secondary Fuels: Natural Gas, Glycerin Startup Fuels: Natural Gas Controls: Reverse-Air Baghouse (American Air) APPLICABLE REGULATIONS: 401 KAR 61:020, Existing process operations. 401 KAR 63:002, Section 2(4)(ffff) 40 C.F.R. 63.7080 to 63.7143, Tables 1 to 8 (Subpart AAAAA), National Emission Standards for Hazardous Air Pollutants for Lime Manufacturing Plants 40 CFR 64, Compliance Assurance Monitoring (CAM) for particulate matter. Requirements of this subpart are satisfied by applicability of 40 CFR 63, Subpart AAAAA. 1. Operating Limitations:


b. Prepare and implement a written OM&M plan. The plan must include items listed in 40




according to the provisions in 40 CFR 63.6(e)(3). [40 CFR 63.7100(e)] e. Always operate and maintain the affected source, including air pollution control and



2. Emission Limitations: a. Emissions of particulate matter shall not exceed 0.12 lb/ton of stone feed (lb/tsf). Weighted

average PM emissions may be determined according to Equation 2 in 40 CFR 63.7112 and must not exceed 0.12 lb/tsf. [40 CFR 63.7090(a)]

Compliance Demonstration Method: Compliance shall be demonstrated through performance testing required under 3. Testing Requirements.






d. The unit must be in compliance with the emission limitations of 40 CFR 63, Subpart

AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)].


matter within 5 years following the initial performance test and within 5 years following each subsequent performance test thereafter. [40 CFR 63.7111 and 401 KAR 50:045] 1) Performance tests may not be conducted during periods of startup, shutdown, or

malfunction, as specified in 40 CFR 63.7(e)(1). [40 CFR 63.7112(c)] 2) Three separate test runs must be conducted for each required performance test, as





5) The permittee must establish any applicable 3-hour block average operating limit indicated in Table of 40 CFR 63, Subpart AAAAA according to the applicable requirements in Table 3 of 40 CFR 63, Subpart AAAAA and 40 CFR 63.7112 paragraphs (j)(1) through (4) of this section. [40 CFR 63.7112(j)]

4. Specific Monitoring Requirements: a. Install, calibrate, maintain, and operate a monitoring device to continuously monitor the


b. Following a reading outside of the pressure drop range specified in the OM&M:

1) Maintenance personnel shall inspect the monitoring system, baghouse, and operations immediately; and make needed repairs as soon as practicable.

2) Upon completed corrective action, the permittee shall immediately conduct EPA Reference Method 9 opacity reading on the dust collection system serviced and ensure pressure drop has returned to normal range. [401 KAR 52:020, Section 10]

c. If a bag leak detection system or PM detector is not utilized, conduct a VE check daily


d. If the opacity reading is greater than fifteen (15) percent from the stack during the daily VE check, then initiate an inspection of the equipment and make repairs if necessary. [401 KAR 52:020, Section 10]

e. For each emission unit equipped with an add-on air pollution control device, inspect each

capture/collection and closed vent system at least once each calendar year to ensure that each system is operating in accordance with the operating requirements in Item 6 of Table 2 of 40 CFR 63 Subpart AAAAA and record the results of each inspection. [40 CFR 63.7113(f)]

f. Except for monitor malfunctions, associated repairs, required quality assurance or control

activities (including, as applicable, calibration checks and required zero adjustments), the permittee must monitor continuously (or collect data at all required intervals) at all times that the emission unit is operating. [40 CFR 63.7120(b)]

g. Data recorded during system breakdowns, repairs, preventive maintenance, calibration checks, and zero (low-level) and high-level adjustments, periods of non-operation of the process unit (or portion thereof), resulting in cessation of the emissions to which the monitoring applies; and start-ups, shutdowns, and malfunctions may not be used either in



data averages or calculations of emission or operating limits; or in fulfilling a minimum data availability requirement. The permittee must use all the data collected during all other periods in assessing the operation of the control device and associated control system. [40 CFR 63.7120(c)]

h. The amount of material placed in the kiln (ton), amount of lime produced from the kiln (tons), amount of coal and glycerin, source-wide natural gas consumed and hours of operation shall be monitored and recorded on a monthly basis. [401 KAR 52:020, Section 10]












f. Maintain records of the differential pressure readings on the kiln baghouse taken once per shift in an electronic format. Records shall, at a minimum, include the date and time of the reading, and the reading value. Records shall also include information on any corrective


actions taken when readings outside the appropriate range are recorded. [401 KAR 52:020, Section 10]

g. Maintain records of the amount of material placed in the kiln (ton), amount of lime produced from the kiln (ton) processed, amount of coal and glycerin, source-wide natural gas consumed and hours of operation on a monthly basis. [401 KAR 52:020, Section 10].













b. The permittee must report each instance in which the unit did not meet each operating limit, opacity limit, and VE limit in Tables 2 and 6 of 40 CFR 63, Subpart AAAAA that applies. This includes periods of startup, shutdown, and malfunction. These instances are deviations from the emission limitations of 40 CFR 63, Subpart AAAAA. These deviations must be reported according to the requirements in 40 CFR 63.7131. [40 CFR 63.7121(b)]


ROTARY LIME KILNS: KL04 - Rotary Kiln #4 Emission Unit 10-01 Rotary Kiln #4 Description: KVS Kiln – 17' × 200' Construction Commenced: 1995 Maximum Rated Input Capacity: 110 tons/hour of Limestone Primary Fuels: Pulverized Coal; (Maximum Firing Rate: 9.6 tons/hr); Natural Gas (Maximum Firing Rate: 0.24 MMscf/hr) Secondary Fuel: Glycerin Startup Fuels: Natural Gas Controls: Pulse-Jet Baghouse [Model: Amerex (7) Module RP-14-304 D6 (16 × 9)] APPLICABLE REGULATIONS: 401 KAR 60:005, Section 2(2)(qq) 40 C.F.R. 60.340 to 60.344 (Subpart HH), Standards of Performance for Lime Manufacturing Plants 401 KAR 63:002, Section 2(4)(ffff) 40 C.F.R. 63.7080 to 63.7143, Tables 1 to 8 (Subpart AAAAA), National Emission Standards for Hazardous Air Pollutants for Lime Manufacturing Plants 401 KAR 51:017, Prevention of significant deterioration, (C-93-032). 1. Operating Limitations:

a. Lime production from Rotary Kiln #4 shall not exceed 46 tons per hour. [401 KAR 51:017, C-93-032] Compliance Demonstration Method: Compliance shall be demonstrated through 4. Specific Monitoring Requirements i.

b. The only solid fuel permissible in the kiln is coal. [401 KAR 51:017, C-93-032]

1) Coal with less than an average heating value of either 12,900 Btu/lb or the average for the coal burned during a prior passing compliance demonstration for nitrogen oxide (NOx), carbon monoxide (CO), particulate (PM), and sulfur dioxide (SO2), whichever is lower, shall not be burned. For the purposes of this condition, average heating value is defined as the weighted average heating value in the coal from all shipments received in each month on a dry weight basis. Coal with less than a minimum average heating value of 12,900 Btu/lb for each shipment shall not be burned as fuel unless the nitrogen oxide (NOx), carbon monoxide (CO), particulate (PM), and sulfur dioxide (SO2) emission limits are not exceeded. Average is defined as the average heating value of shipments received in each month.

2) Coal with more than an average sulfur content of either 0.9% or the average for the coal burned during a prior passing compliance demonstration for NOx, CO, PM, and SO2, whichever is higher, shall not be burned. For the purposes of this condition, average sulfur content is defined as the weighted average sulfur content

Commented [A5]: Carmeuse is proposing a clarification on the heating value and sulfur content averaging methodology for coal shipments. Refer to application report for additional discussion. Carmeuse is also requesting the PSD language from the prior permit (V-05-003 R1) be brought forward to the renewed permit for clarification.


in the coal from all shipments received in each month on a dry weight basis. Coal with more than an average sulfur content of 0.9% for each shipment shall not be burned as fuel unless the NOx, CO, PM, and SO2 emission limits are not exceeded. Average is defined as the average sulfur content of shipments received in each month.

Compliance Demonstration Method: In determining compliance with the sulfur content limitation and heating value of the coal, the permittee may obtain certification from the supplier or test one sample of coal as received or shipped in. When the facility combusts coal with an average heating value less than allowed12,900 Btu/lb or a sulfur content more than 0.9% sulfurallowed, the facility shall submit a protocol within 30 days of fuel receiptthe end of the month the excursion occurs to conduct performance testing to demonstrate compliance with nitrogen oxide, carbon monoxide, particulate, and sulfur dioxide emission limits are not exceeded.

c. Maintain and operate the FF such that the BLDS or PM detector alarm condition does not exist for more than 5 percent of the total operating time in a 6-month period; and comply with the requirements in 40 CFR 63.7113(d) through (f) and Table 5 of Subpart AAAAA. In lieu of a BLDS or PM detector maintain the FF such that the 6-minute average opacity for any 6-minute block period does not exceed 15 percent; and comply with the requirements in 40 CFR 63.7113(f) and (g) and Table 5 to Subpart AAAAA. [40 CFR 63.7090(b)]

Compliance Demonstration Method: Demonstrate continuous compliance by installing, maintaining, calibrating and operating a COMS as required by 40 CFR part 63, subpart A, General Provisions and according to PS-1 of appendix B to part 60 of this chapter, except as specified in 40 CFR 63.7113(g)(2); and collecting the COMS data at a frequency of at least once every 15 seconds, determining block averages for each 6-minute period and demonstrating for each 6-minute block period the average opacity does not exceed 15 percent.

d. Prepare and implement a written OM&M plan. The plan must include items listed in 40


e. The unit must be in compliance with the operating limits of 40 CFR 63, Subpart AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)]

f. The permittee must develop a written startup, shutdown, and malfunction plan (SSMP)

according to the provisions in 40 CFR 63.6(e)(3). [40 CFR 63.7100(e)] g. Always operate and maintain the affected source, including air pollution control and




a. Particulate Matter Emissions: 1) Shall not exceed 0.12 lb/ton of stone feed (lb/tsf). Weighted average PM emissions may

be determined according to Equation 2 in 40 CFR 63.7112 and must not exceed 0.12 lb/tsf. [40 CFR 63.7090(a) and 401 KAR 51:017]

Compliance Demonstration Method: Compliance shall be demonstrated through 3. Testing Requirements c.

2) The permittee shall not exceed 0.60 lb/ton of stone feed (lb/tsf). [40 CFR 60.342]

Compliance Demonstration Method: Compliance shall be demonstrated by meeting the requirements of 2. Emission Limitations a.(1).

b. Sulfur dioxide emissions shall not exceed 22.97 lb/hr. [401 KAR 51:017, C-93-032]

c. Nitrogen dioxide emissions shall not exceed 128.33 lb/hr. [401 KAR 51:017, C-93-032] d. Carbon monoxide emissions shall not exceed 91.67 lb/hr. [401 KAR 51:017, C-93-032]

Compliance Demonstration Method: 1. Compliance with 2. Emission Limitations b., c., and d. shall be demonstrated through

performance testing required under 3. Testing Requirements d. and e.

2. When required for comparison with the particulate matter emission limit, emission rates shall be calculated using the following equation:

E = (csQsd) / PK, where E = emission rate of particulate matter, lb/ton of stone feed cs = concentration of particulate matter, g/dscf Qsd = volumetric flow rate of effluent gas, dscf/hr P = stone feed rate, ton/hr K = conversion factor, 7000gr/lb

In determining the particulate matter concentration (cs) and the volumetric flow rate

(Qsd) of the effluent gas: a) EPA Reference Method 5 shall be used at negative-pressure fabric filters

and other types of control devices and b) EPA Reference Method 5 D shall be used at positive-pressure fabric filters.

The sampling time and sample volume for each run shall be at least 60 minutes and 31.8 dscf. The stone feed rate for each run shall be determined using the monitoring device specified in 3. Testing Requirements b.


e. Visible emissions discharged into the atmosphere shall not exceed 15% opacity when exiting from a dry emission control device. [40 CFR 60.342(a)(2), 401 KAR 51:017, C-93-032]

Compliance Demonstration Method: Compliance shall be demonstrated through monitoring required under 4. Specific Monitoring Requirements b.

f. The unit must be in compliance with the emission limitations of 40 CFR 63, Subpart AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)]


a. Testing shall be conducted in accordance with 401 KAR 50:045, Performance Tests, the testing shall be conducted under conditions representative of maximum emissions potential under anticipated operating conditions at the pollutant-specific emissions unit.

b. For the purpose of conducting a performance test, install, calibrate, maintain, and operate

a device for measuring the mass rate of stone feed to each rotary lime kiln. The measuring device used must be accurate to within 5 percent of the mass rate over its operating range. [40 CFR 60.343(d)] The mass rate of stone feed may be calculated for each 24-hour block period based on the lime production, multiplied by a suitable factor to arrive at the equivalent stone feed rate. The methodology for defining the stone feed to lime production factor shall be established during particulate matter performance tests.

c. Conduct a performance test in accordance with EPA Reference Method 5 for particulate






5) The permittee must establish any applicable 3-hour block average operating limit indicated in Table 2 to this 40 CFR 63, Subpart AAAAA t according to the applicable requirements in Table 3 of 40 CFR 63, Subpart AAAAA and 40 CFR 63.112 paragraphs (j)(1) through (4) of this section. [40 CFR 63.112(j)]


d. Performance testing in accordance with EPA Reference Method 6C for sulfur dioxide, EPA Reference Method 7E for nitrogen oxide, and EPA Reference Method 10 for carbon monoxide as specified in 401 KAR 50:015 shall be conducted once per permit life (or once every five years) and as required by the Division. [401 KAR 50:045, Section 1]

e. During Performance performance testing, the facility shall obtain one representative fuel

sample per hour. These samples collectively shall be analyzed for the percent sulfur content and heating value (Btu/lb) on a dry basis. [401 KAR 50:045, Section 1]


a. The owner or operator shall install, calibrate, maintain and operate a continuous monitoring system to monitor and record the opacity of a representative portion of the gases discharged into the atmosphere from each kiln. The span of this system shall be set at 40 percent (40%) opacity. [40 CFR 60.343(a)]

b. For each COMS used to monitor an add-on air pollution control device, meet the requirements in paragraphs (g)(1) and (2) of this section. [40 CFR 63.7003(g)] 1) Install the COMS at the outlet of the control device. 2) Install, maintain, calibrate, and operate the COMS as required by 40 CFR part 63,

subpart A, General Provisions and according to Performance Specification (PS)-1 of appendix B to part 60 of this chapter. Facilities that operate COMS installed on or before February 6, 2001, may continue to meet the requirements in effect at the time of COMS installation unless specifically required to re-certify the COMS by their permitting authority.

c. Install, calibrate, maintain, and operate a monitoring device to continuously monitor the


d. Following a reading outside of the pressure drop range specified in the OM&M:



e. If a bag leak detection system or PM detector is not utilized, conduct a VE check daily



f. For each emission unit equipped with an add-on air pollution control device, inspect each capture/collection and closed vent system at least once each calendar year to ensure that each system is operating in accordance with the operating requirements in Item 6 of Table 2 of 40 CFR 63 Subpart AAAAA and record the results of each inspection. [40 CFR 63.7113(f)]

g. Except for monitor malfunctions, associated repairs, required quality assurance or control activities (including, as applicable, calibration checks and required zero adjustments), the permittee must monitor continuously (or collect data at all required intervals) at all times that the emission unit is operating. [40 CFR 63.7120(b)]

h. Data recorded during system breakdowns, repairs, preventive maintenance, calibration checks, and zero (low-level) and high-level adjustments, periods of non-operation of the process unit (or portion thereof), resulting in cessation of the emissions to which the monitoring applies; and start-ups, shutdowns, and malfunctions may not be used either in data averages or calculations of emission or operating limits; or in fulfilling a minimum data availability requirement. The permittee must use all the data collected during all other periods in assessing the operation of the control device and associated control system. [40 CFR 63.7120(c)]

i. The amount of material placed in the kiln (ton), amount of lime produced from the kiln (tons), amount of coal and glycerin, natural gas consumed and hours of operation shall be monitored and recorded on a monthly basis. [401 KAR 52:020, Section 10]

j. In the absence of certification of the sulfur content of the coal from the supplier, the owner or operator shall obtain representative samples from each delivery of coal. These samples collectively shall be analyzed for the percent sulfur content and heating value (Btu/lb). [401 KAR 51:017, C-93-032]

k. The permittee shall monitor and calculate annual NOx, PM/PM10 and PM2.5 emissions from

emission unitsRotary Kiln #4 and #5 and maintain a record of the annual emissions, in tons per year on a calendar year basis for Five five (5) years following resumption of regular operations after the modification authorized by V-14-002 R4 (i.e., installation of multichannel burners). The source shall submit a report to the Division if: [401 KAR 51:017, Section 16(5). Source Obligation]

1) The annual NOx, PM/PM10 and PM2.5 emissions, in tons per year, from this the proposed projectmodification exceeds the baseline actual emissions for the project by a significant amount for NOx, PM/PM10 and PM2.5; and

2) The NOx, PM/PM10 and PM2.5 emissions differ from the projected actual emissions as submitted in the application for Kiln #4 and #5 respectively.



b. Keep records of performance tests and performance evaluation. [40 CFR 63.7132(a)(3)]

Commented [A6]: Carmeuse requests that this clause be added so that it is clear what modification is being referred to in the permit condition.


c. Keep visual observation records and EPA Reference Method 9 observation records, and


d. Performance test results must be documented in complete test reports that contain the information below, as well as all other relevant information. The plan to be followed during testing must be made available to the Division at least 60 days prior to testing. [40 CFR 63.7112(h)] 1) A brief description of the process and the air pollution control system; 2) Sampling location description(s); 3) A description of sampling and analytical procedures and any modifications to standard




e. Maintain records of the differential pressure readings on the kiln baghouse taken in an electronic format. Records shall, at a minimum, include the date and time of the reading, and the reading value. Records shall also include information on any corrective actions taken when readings outside the appropriate range are recorded. [401 KAR 52:020, Section 10]

f. Maintain records of all routine and non-routine maintenance activities performed on the

baghouse. These records shall include, at a minimum, the date, the name(s) of the person or organization performing the maintenance, and a description of the maintenance completed. [401 KAR 52:020, Section 10]

g. During all periods of startup, shutdown, or malfunction of the baghouse, keep a record of

any days when any air emissions were visible from the stack associated with the baghouse. [401 KAR 52:020, Section 10]


produced from the kiln (ton) processed, amount of coal and glycerin, natural gas consumed and hours of operation on a monthly basis. [401 KAR 52:020, Section 10].

i. Records of the heat content (Btu/lb) and sulfur content (percent) of coal sampled each

month shall be maintained. [401 KAR 51:017, C-93-032]

j. In accordance with the requirements of 401 KAR 51:017, Section 16 (5)(a), for the Kiln #4 and #5 Burner Change Project covered by Permit V-14-002 R4, the permittee shall:


1) Maintain a copy of the permit application covering the project that includes: [401 KAR 51:017 Section 16 (5)(b)]

i. A description of the project. ii. Identification of the emission units for which emissions of a regulated NSR

pollutant could be affected by the project; and iii. A description of the applicability test used to determine that the project is not a

major modification for any regulated NSR pollutant. The description should include baseline actual emissions, projected actual emissions, the amount of emissions exclude in calculating projected actual emissions and an explanations for why that amount was excluded, and any applicable netting calculations.

2) Calculate and maintain record of the annual NOx, PM/PM10 and PM2.5 emissions, in tons per year, on a calendar year basis for five years following commencement of operation of multichannel burners on both Kiln #4 and #5. [401 KAR 51:017 Section 16 (5) (c) (2)]

i. The Permittee shall report to the Division if the annual NOx, PM/PM10 orPM2.5 emissions, in tons per year, from Kiln #4 and #5, exceeds the baseline actual emissions by a significant amount and the emissions differ from the preconstruction projection as documented and maintained pursuant to Condition 5.j.1. [401 KAR 51:017 Section 16 (5) (e) (1)]

ii. The report shall be submitted to the Division with 60 days after the end of the year and shall contain the name, address, and telephone number of the major stationary source; the annual NOx emissions calculated; and any other information the Permittee wishes to include in the report. [401 KAR 51:017 Section 16 (5) (e) (2)]








requirements of 40 CFR 63.8(d).


5) Procedures for monitoring process and control device parameters. 6) Corrective actions to be taken when process or operating parameters or add-on control





b. The permittee must report each instance in which the unit did not meet each operating

limit, opacity limit, and VE limit in Tables 2 and 6 of 40 CFR 63, Subpart AAAAA that applies. This includes periods of startup, shutdown, and malfunction. These instances are deviations from the emission limitations of 40 CFR 63, Subpart AAAAA. These deviations must be reported according to the requirements in 40 CFR 63.7131.[40 CFR 63.7121(b)]

c. The permittee must submit the Notification of Compliance Status containing the results

of the initial compliance demonstration according to the requirements in 40 CFR 63.7130(e). [40 CFR 63.7114(c)]

d. Submit reports of excess emissions of all 6-minute periods during which the average

opacity of the visible emissions from any lime kiln utilizing a continuous monitoring system is greater than 15 percent. [40 CFR 60.343(e)]


a. The baghouse shall be operated to maintain compliance with permitted emission limitations, consistent with manufacturer’s specifications and/or standard operating practices. [401 KAR 50:055, Section 2]

b. Records regarding the maintenance of the dust collection systems shall be maintained. [401

KAR 52:020, Section 10]


ROTARY LIME KILNS: KL05 – Rotary Kiln #5 Emission Unit 11-01 Rotary Kiln #5 Description: KVS Kiln – 17' × 200' Construction Commenced: 1995 Maximum Rated Capacity: 110 tons/hour of stone Primary Fuels: Pulverized Coal- (Maximum Firing Rate: 9.6 tons/hr); Natural Gas (Maximum Firing Rate: 0.24 MMscf/hr) Secondary Fuel: Glycerin Startup Fuel: Natural Gas Controls: Pulse-Jet Baghouse [Model: Amerex (7) Module RP-14-304 D6 (16 × 9)] APPLICABLE REGULATIONS: 401 KAR 60:005, Section 2(2)(qq) 40 C.F.R. 60.340 to 60.344 (Subpart HH), Standards of Performance for Lime Manufacturing Plants 401 KAR 63:002, Section 2(4)(ffff) 40 C.F.R. 63.7080 to 63.7143, Tables 1 to 8 (Subpart AAAAA), National Emission Standards for Hazardous Air Pollutants for Lime Manufacturing Plants 401 KAR 51:017, Prevention of significant deterioration, (C-93-032). 1. Operating Limitations:

a. Lime production from Rotary Kiln #5 shall not exceed 46 tons per hour. [401 KAR 51:017, C-93-032] Compliance Demonstration Method: Compliance shall be demonstrated through 4. Specific Monitoring Requirements g.

b. The only solid fuel permissible in the kiln is coal. [401 KAR 51:017, C-93-032]

1) Coal with less than an average heating value of either 12,900 Btu/lb or the average for the coal burned during a prior passing compliance demonstration for nitrogen oxide (NOx), carbon monoxide (CO), particulate (PM), and sulfur dioxide (SO2), whichever is lower, shall not be burned. For the purposes of this condition, average heating value is defined as the weighted average heating value in the coal from all shipments received in each month on a dry weight basis. Coal with less than a minimum average heating value of 12,900 Btu/lb for each shipment shall not be burned as fuel unless the nitrogen oxide, carbon monoxide, particulate, and sulfur dioxide emission limits are not exceeded. Average is defined as the average heating value per shipment. Average is defined as the average of shipments received in each month.

2) Coal with more than an average sulfur content of either 0.9% or the average for the coal burned during a prior passing compliance demonstration for NOx, CO,

Commented [A7]: Carmeuse is proposing a clarification on the heating value and sulfur content averaging methodology for coal shipments. Refer to application report for additional discussion. Carmeuse is also requesting the PSD language from the prior permit (V-05-003 R1) be brought forward to the renewed permit for clarification.


PM, and SO2, whichever is higher, shall not be burned. For the purposes of this condition, average sulfur content is defined as the weighted average sulfur content in the coal from all shipments received in each month on a dry weight basis. Coal with more than an average sulfur content of 0.9% for each shipment shall not be burned as fuel unless the nitrogen oxide, carbon monoxide, particulate, and sulfur dioxide emission limits are not exceeded. Average is defined as the average of shipments received in each month.

Compliance Demonstration Method: In determining compliance with the sulfur content limitation and heating value of the coal, the permittee may obtain certification from the supplier or test one sample of coal as received or shipped in. When the facility combusts coal with an average heating value less than 12,900 Btu/lballowed or a sulfur content more than 0.9% sulfurallowed, the facility shall submit a protocol within 30 days of fuel receiptthe end of the month the excursion occurs to conduct performance testing to demonstrate compliance with nitrogen oxide, carbon monoxide, particulate, and sulfur dioxide emission limits are not exceeded.

c. Maintain and operate the FF such that the BLDS or PM detector alarm condition does not exist for more than 5 percent of the total operating time in a 6-month period; and comply with the requirements in 40 CFR 63.7113(d) through (f) and Table 5 of Subpart AAAAA. In lieu of a BLDS or PM detector maintain the FF such that the 6-minute average opacity for any 6-minute block period does not exceed 15 percent; and comply with the requirements in 40 CFR 63.7113(f) and (g) and Table 5 to Subpart AAAAA. [40 CFR 63.7090(b)]

Compliance Demonstration Method: Demonstrate continuous compliance by installing, maintaining, calibrating and operating a COMS as required by 40 CFR part 63, subpart A, General Provisions and according to PS-1 of appendix B to part 60 of this chapter, except as specified in 40 CFR 63.7113(g)(2); and collecting the COMS data at a frequency of at least once every 15 seconds, determining block averages for each 6-minute period and demonstrating for each 6-minute block period the average opacity does not exceed 15 percent.

d. Prepare and implement a written OM&M plan. The plan must include items listed in 40


e. The unit must be in compliance with the operating limits of 40 CFR 63, Subpart AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)]

f. The permittee must develop a written startup, shutdown, and malfunction plan (SSMP)

according to the provisions in 40 CFR 63.6(e)(3). [40 CFR 63.7100(e)] g. Always operate and maintain the affected source, including air pollution control and

monitoring equipment, according to the provisions in 40 CFR 63.6(e)(1)(i). [40 CFR


63.7100 (c)]

2. Emission Limitations: a. Particulate Matter Emissions:

1) Shall not exceed 0.12 lb/ton of stone feed (lb/tsf). Weighted average PM emissions may be determined according to Equation 2 in 40 CFR 63.7112 and must not exceed 0.12 lb/tsf. [40 CFR 63.7090(a) and 401 KAR 51:017] Compliance Demonstration Method: Compliance shall be demonstrated through performance testing required under 3. Testing Requirements c.

2) The permittee shall not exceed 0.60 lb/ton of stone feed (lb/tsf). [40 CFR 60.342]

Compliance Demonstration Method: Compliance shall be demonstrated by meeting the requirements of 2. Emission Limitations a. (1).

b. Sulfur dioxide emissions shall not exceed 22.97 lb/hr. [401 KAR 51:017, C-93-032]

c. Nitrogen dioxide emissions shall not exceed 128.33 lb/hr. [401 KAR 51:017, C-93-032]

d. Carbon monoxide emissions shall not exceed 91.67 lb/hr. [401 KAR 51:017, C-93-032]

Compliance Demonstration Method: 1. Compliance with 2. Emission Limitations b., c., and d shall be demonstrated through

performance testing required under 3. Testing Requirements d. and e.

2. When required for comparison with the particulate matter emission limit, emission rates shall be calculated using the following equation:

E = (csQsd) / PK, where E = emission rate of particulate matter, lb/ton of stone feed cs = concentration of particulate matter, g/dscf Qsd = volumetric flow rate of effluent gas, dscf/hr P = stone feed rate, ton/hr K = conversion factor, 7000gr/lb

In determining the particulate matter concentration (cs) and the volumetric flow rate

(Qsd) of the effluent gas: a) EPA Reference Method 5 shall be used at negative-pressure fabric filters and other

types of control devices and b) EPA Reference Method 5 D shall be used at positive-pressure fabric filters.

The sampling time and sample volume for each run shall be at least 60 minutes and


31.8 dscf. The stone feed rate for each run shall be determined using the monitoring device specified in 3. Testing Requirements b.

e. Visible emissions discharged into the atmosphere shall not exceed 15% opacity when

exiting from a dry emission control device. [40 CFR 60.342(a)(2), 401 KAR 51:017, C-93-032]

Compliance Demonstration Method: Compliance shall be demonstrated through 4. Specific Monitoring Requirements b.

f. The unit must be in compliance with the emission limitations of 40 CFR 63, Subpart AAAAA at all times, except during periods of startup, shutdown, and malfunction. [40 CFR 63.7100(a)]

3. Testing Requirements: a. Within 180 days of installing a multichannel burner in either Kiln #4 or Kiln #5 (whichever

is completed first), the permittee shall conduct a performance tests to validate the emissions information provided in the permit application for Permit V-14-002 R4. The performance tests shall be conducted while co-firing coal and natural gas at the highest gas substitution rate achievable during the test. [Permit V-14-002 R4; 401 KAR 50:045]

b. Testing shall be conducted in accordance with 401 KAR 50:045, Performance Tests, the

testing shall be conducted under conditions representative of maximum emissions potential under anticipated operating conditions at the pollutant-specific emissions unit.

c. For the purpose of conducting a performance test, install, calibrate, maintain, and operate

a device for measuring the mass rate of stone feed to each rotary lime kiln. The measuring device used must be accurate to within 5 percent of the mass rate over its operating range. [40 CFR 60.343(d)] The mass rate of stone feed may be calculated for each 24-hour block period based on the lime production, multiplied by a suitable factor to arrive at the equivalent stone feed rate. The methodology for defining the stone feed to lime production factor shall be established during particulate matter performance tests.

d. Conduct a performance test in accordance with EPA Reference Method 5 for particulate







5) The permittee must establish any applicable 3-hour block average operating limit indicated in Table 2 of 40 CFR 63, Subpart AAAAA according to the applicable requirements in Table 3 of 40 CFR 63, Subpart AAAAA and 40 CFR 63.112 paragraphs (j)(1) through (4) of this section. [40 CFR 63.112(j)]

e. Performance testing in accordance with EPA Reference Method 6C for sulfur dioxide, EPA

Reference Method 7E for nitrogen oxide, and EPA Reference Method 10 for carbon monoxide as specified in 401 KAR 50:015 shall be conducted once per permit life (or once every five years) and as required by the Division. [401 KAR 50:045, Section 1]

f. During Performance performance testing, the facility shall obtain one representative fuel sample per hour. These samples collectively shall be analyzed for the percent sulfur content and heating value (Btu/lb) on a dry basis. [401 KAR 50:045, Section 1]


a. The owner or operator shall install, calibrate, maintain and operate a continuous monitoring system to monitor and record the opacity of a representative portion of the gases discharged into the atmosphere from each kiln. The span of this system shall be set at 40 percent (40%) opacity. [40 CFR 60.343(a)]

b. For each COMS used to monitor an add-on air pollution control device, meet the

requirements in paragraphs (g)(1) and (2) of this section. [40 CFR 63.7003(g)] 1) Install the COMS at the outlet of the control device. 2) Install, maintain, calibrate, and operate the COMS as required by 40 CFR part 63, subpart A, General Provisions and according to Performance Specification (PS)-1 of appendix B to part 60 of this chapter. Facilities that operate COMS installed on or before February 6, 2001, may continue to meet the requirements in effect at the time of COMS installation unless specifically required to re-certify the COMS by their permitting authority.

c. Install, calibrate, maintain, and operate a monitoring device to continuously monitor the


d. Following a reading outside of the pressure drop range specified in the OM&M:




e. If a bag leak detection system or PM detector is not utilized, conduct a VE check daily


f. For each emission unit equipped with an add-on air pollution control device, inspect each capture/collection and closed vent system at least once each calendar year to ensure that each system is operating in accordance with the operating requirements in Item 6 of Table 2 of 40 CFR 63 Subpart AAAAA and record the results of each inspection. [40 CFR 63.7113(f)]

g. Except for monitor malfunctions, associated repairs, required quality assurance or control activities (including, as applicable, calibration checks and required zero adjustments), the permittee must monitor continuously (or collect data at all required intervals) at all times that the emission unit is operating. [40 CFR 63.7120(b)]

h. Data recorded during system breakdowns, repairs, preventive maintenance, calibration

checks, and zero (low-level) and high-level adjustments, periods of non-operation of the process unit (or portion thereof), resulting in cessation of the emissions to which the monitoring applies; and start-ups, shutdowns, and malfunctions may not be used either in data averages or calculations of emission or operating limits; or in fulfilling a minimum data availability requirement. The permittee must use all the data collected during all other periods in assessing the operation of the control device and associated control system. [40 CFR 63.7120(c)]

i. The amount of material placed in the kiln (ton), amount of lime produced from the kiln

(tons), amount of coal and glycerin, natural gas consumed and hours of operation shall be monitored and recorded on a monthly basis. [401 KAR 52:020, Section 10]

j. In the absence of certification of the sulfur content of the coal from the supplier, the

owner or operator shall obtain representative samples from each delivery of coal. These samples collectively shall be analyzed for the percent sulfur content and heating value (Btu/lb). [401 KAR 51:017, C-93-032]

k. The permittee shall monitor and calculate annual NOx, PM/PM10 and PM2.5 emissions from

emission unitsRotary Kiln #4 and #5 and maintain a record of the annual emissions, in tons per year on a calendar year basis for Five five (5) years following resumption of regular operations after the modification authorized by V-14-002 R4 (i.e., the installation of multichannel burners). The source shall submit a report to the Division if: [401 KAR 51:017, Section 16(5). Source Obligation]

Commented [A8]: Carmeuse requests that this clause be added so that it is clear what modification is being referred to in the permit condition.


1) The annual NOx, PM/PM10 and PM2.5 emissions, in tons per year, from this the modificationproposed project exceeds the baseline actual emissions for the project by a significant amount for NOx, PM/PM10 and PM2.5; and

2) The NOx, PM/PM10 and PM2.5 emissions differ from the projected actual emissions as submitted in the application for Kiln #4 and #5 respectively.

5. Specific Recordkeeping Requirements: a. Maintain records of inspection of each capture/collection and closed vent system as

required by 40 CFR 63.7113(f).

b. Keep records of performance tests and performance evaluation. [40 CFR 63.7132(a)(3)]

c. Keep visual observation records and EPA Reference Method 9 observations, any inspections and repair records in a designated logbook. Records shall be maintained for five years. [401 KAR 52:020, Section 10]

d. Performance test results must be documented in complete test reports that contain the





e. Maintain records of the differential pressure readings on the kiln baghouse taken once per shift in an electronic format. Records shall, at a minimum, include the date and time of the reading, and the reading value. Records shall also include information on any corrective actions taken when readings outside the appropriate range are recorded. [401 KAR 52:020, Section 10]

f. Maintain records of all routine and non-routine maintenance activities performed on the baghouse. These records shall include, at a minimum, the date, the name(s) of the person or organization performing the maintenance, and a description of the maintenance completed. [401 KAR 52:020, Section 10]

g. During all periods of startup, shutdown, or malfunction of the baghouse, keep a record of

any days when any air emissions were visible from the stack associated with the baghouse. [401 KAR 52:020, Section 10]



produced from the kiln (tons), amount of coal, glycerin, natural gas consumed and hours of operation on a monthly basis. [401 KAR 52:020, Section 10].

i. Maintain records of the heat content (Btu/lb) and sulfur content (percent) of coal sampled each month shall be maintained. [401 KAR 51:017, C-93-032]

j. In accordance with the requirements of 401 KAR 51:017, Section 16 (5)(a), for the Kiln #4 and #5 Burner Change Project covered by Permit V-14-002 R4, the permittee shall: 1) Maintain a copy of the permit application covering the project that includes:

[401 KAR 51:017, Section 16 (5)(b)] i. A description of the project. ii. Identification of the emission units for which emissions of a regulated NSR

pollutant could be affected by the project; and iii. A description of the applicability test used to determine that the project is not a

major modification for any regulated NSR pollutant. The description should include baseline actual emissions, projected actual emissions, the amount of emissions exclude in calculating projected actual emissions and an explanations for why that amount was excluded, and any applicable netting calculations.

2) Calculate and maintain record of the annual NOx, PM/PM10 and PM2.5 emissions, in tons per year, on a calendar year basis for five years following commencement of operation of multichannel burners on both Kiln #4 and #5. [401 KAR 51:017 Section 16 (5) (c) (2)]

i. The Permittee shall report to the Division if the annual NOx, PM/PM10 orPM2.5 emissions, in tons per year, from Kiln #4 and #5, exceeds the baseline actual emissions by a significant amount and the emissions differ from the preconstruction projection as documented and maintained pursuant to Condition 5.j.1. [401 KAR 51:017 Section 16 (5) (e) (1)]

ii. The report shall be submitted to the Division with 60 days after the end of the year and shall contain the name, address, and telephone number of the major stationary source; the annual NOx emissions calculated; and any other information the Permittee wishes to include in the report. [401 KAR 51:017 Section 16 (5) (e) (2)]




air pollution control device used to meet the applicable emission limitations and


operating limits in Tables 1 and 2 of 40 CFR 63, Subpart AAAAA, respectively. 4) Procedures for the proper installation, operation, and maintenance of monitoring

devices or systems used to determine compliance, including: i. Calibration and certification of accuracy of each monitoring device; ii. Performance and equipment specifications for the sample interface, parametric








b. Submit reports of excess emissions of all 6-minute periods during which the average opacity of the visible emissions from any lime kiln utilizing a continuous monitoring system is greater than 15 percent. [40 CFR 60.343(e)]


d. The permittee must report each instance in which the unit did not meet each operating limit,

opacity limit, and VE limit in Tables 2 and 6 of 40 CFR 63, Subpart AAAAA that applies. This includes periods of startup, shutdown, and malfunction. These instances are deviations from the emission limitations of 40 CFR 63, Subpart AAAAA. These deviations must be reported according to the requirements in 40 CFR 63.7131.[40 CFR 63.7121(b)]



b. Records regarding the maintenance of the dust collection systems shall be maintained.

[401 KAR 52:020, Section 10]


LIME: LM01 – Lime Dust Collection Systems (PSD)

EU # Description Date Constructed or

Last Modified


16-11 84-018 Dust Collection System for Kiln 4 & 5 Discharge Conveyors

1995

17-05 89-858 Dust Collection System for Lime Bins and Truck Loadout

1998, replaced 2014

17-10 89-855 Dust Collection System for Silo #11 Feed Conveyors 1995



17-27 89-850 Dust Collection System for Lime Screening Area 1995

17-32 89-861 Dust Collection System for Lime Bins and Screens 1998, replaced 2014

17-41 89-851 Dust Collection System for Lime Screening and Bucket Elevator

1995


18-01 94-835 Dust Collection System for #13 & #14 Kiln Run Silo Transfer to 94-801

1995

18-06 94-834 Dust Collection System for #11 & # 12 Kiln Run Silo Transfer to 94-803

1995

18-09 94-836 Dust Collection System for Kiln Silo Discharge Conveyors

1995

18-16 94-832 Dust Collection System for Product Bin Discharge Conveyors and Screens

1995

18-22 94-831 Dust Collection System for Product Bin Discharge Conveyors

1995

18-24 94-829 Dust Collection System for Lime Railcar Loadout 1995

18-27 94-837 Dust Collection System for Lime Barge Loadout 1995

18-30 94-833 Dust Collection System for Lime Truck Loadout 1995

Kiln 4 and 5 Dust Bin

32-08 63-270 Bin Vent Collector System for Kiln 4 & 5 Dust Bin 1995

APPLICABLE REGULATIONS: 401 KAR 59:010, New process operations


401 KAR 51:017, Prevention of significant deterioration, (C-93-032). 40 CFR 64, Compliance Assurance Monitoring (CAM) for particulate matter 1. Operating Limitations:

a. Except as provided in 1. Operating Limitations b, processes may not operate without corresponding control device also in operation. [401 KAR 52:020, Section 10]

b. During periods of maintenance on a dust collection system (either planned or taken in response to a malfunction) when its associated conveyor systems inside a building must remain in operation, the following provisions apply: 1) For any set of dust collection systems serving a given lime handling building (that is

defined in LM02), only one of those systems can be taken offline at a time for maintenance if an associated conveyor system inside the building remains in operation. This restriction does not apply if actions are being taken in response to a malfunction.

2) During a malfunction of any dust collection system that is part of a set of dust collection systems serving a given lime handling building, all scheduled maintenance for that set shall be postponed until the malfunctioned system is repaired and operating as intended.

3) Periods of maintenance shall be conducted as expeditiously as possible. The time during which a dust collection system serving an active conveyor is offline for a discrete maintenance event shall not exceed 24 hours.

4) During times of maintenance when a dust collection system must be temporarily shut down while an associated conveyer system inside a building remains in operation, the facility shall: i. Continuously perform visual emissions evaluations consistent with procedures

specified in EPA Reference Method 9 from varying vantage points covering the building in which the operating conveyor system is located. If any visible emissions are observed, take appropriate action to mitigate emissions and initiate a formal EPA Reference Method 9 opacity test. These tests shall continue until there are again no visible emissions observed. Any readings recorded above the 7% opacity standard shall be documented in the semiannual report. Begin visual observations prior to the dust collector being taken offline and before maintenance activities commence. Continue the observations until the dust collector has returned to normal operation.

ii. If any EPA Reference Method 9 reading exceeds 7% opacity, the dust collector shall be brought back online immediately if possible, or all operations that emit PM captured by that baghouse (conveyers, bins, loadouts, screening area, screens, bucket elevators, and silo transfers) shall be immediately shutdown.

iii. The Division may waive the requirement to shutdown upon a demonstration that the cause(s) of the opacity has been identified and corrected immediately. [401 KAR 52:020, Section 10]

2. Emission Limitations: a. Emissions from each listed emission unit except 18-27 shall not exceed 7% opacity.


Emissions from 18-27 (94-937 Dust Collection System for Lime Barge Loadout) shall not exceed 15% opacity. [401 KAR 51:017, C-93-032]

Compliance Demonstration Method: Compliance with the opacity limit is demonstrated through performance testing required under 3. Testing Requirements.

b. The opacity of emissions from the Dust Collection Systems shall not exceed twenty percent (20%). [401 KAR 59:010, Section 3 (1)]

Compliance Demonstration Method: Compliance with 1. Operating Limitations and 2. Emissions Limitations a.

c. Emissions of particulate matter from each dust collection system shall not exceed 0.02 gr/acfm. [401 KAR 51:017, C-93-032]

Compliance Demonstration Method: See 3. Testing Requirements.

d. Emissions of particulate matter from each listed emission unit shall not exceed the rate

calculated by the following equations: [401 KAR 59:010, Section 3 (2)]

For process weight rates up to 30 ton/hr, E = 3.59P0.62 For process weight rates in excess of 30 ton/hr, E = 17.31P0.16

where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr. For the purposes of this calculation, the process rate of conveyor systems served by the dust collection system should be used. Compliance Demonstration Method: Compliance with 2. Emission Limitation c.

3. Testing Requirements: a. Except as provided in 3. Testing Requirements b, within 180 days of issuance of permit

V-14-002, conduct initial performance tests using EPA Reference Method 5 to measure the particulate matter and EPA Reference Method 9 to determine opacity from each of the dust collection systems. [401 KAR 50:045]

b. In lieu of conducting performance testing on all listed emission units, the facility has the option of conducting representative testing. Representative determinations shall be based on the material to be captured, design flowrate (acfm), fabric filter material, cleaning method, cleaning frequency, and air-to-cloth ratio. The proposed limited set of representative units shall be documented in the test protocol submitted to the Division for approval in accordance with 401 KAR 50:045.

The selected limited set of representative units shall not be tested as the representative unit for performance testing conducted during the next permit lifetime.

Commented [A9]: Carmeuse requests that Conditions 3.a to 3.c be removed as these conditions covered a one-time testing obligation that was satisfied in the prior permit term.



a. Monitor the overall processing rate (tons/hour) for conveying systems served by the dust collections systems between the kiln discharge and lime storage, as defined by total combined kiln production rate on a monthly basis. [401 KAR 52:020, Section 10]

b. Monitor the overall process rate (tons/hour) for the conveying systems served by the dust

collection systems between lime storage and load out, as defined by amount of combined mass of lime loaded out by truck, rail, and barge. [401 KAR 52:020, Section 10]

c. Install, calibrate, maintain, and operate a monitoring device to continuously monitor the differential pressure across the dust collection system baghouses to ensure that pressure does not drop outside the pressure drop range listed in the table below. Personnel will monitor the differential pressure reading across the baghouse once per shift and at least once every twelve hours of operation, except when the unit is not in operation. [401 KAR 61:005, Section 3(6)]

EU # Indicator Ranges

16-11 1.5”-7.5”

17-05 0.6”-7.5”

17-10 1.5”-7.5”

17-13 1.5”-7.5”

17-17 1.5”-7.5”

17-27 1.5”-7.5”

17-32 0.6”-7.5”

17-41 1.5”-7.5”

18-01 1.5”-7.5”

18-06 1.5”-7.5”

18-09 1.5”-7.5”

18-16 1.5”-7.5”

18-22 1.5”-7.5”

18-24 1.5”-7.5”

18-27 1.5”-7.5”

18-30 1.5”-7.5”

32-08 1.5”-7.5”

d. Following a reading outside of the pressure drop range:


1) Maintenance personnel shall inspect the baghouse and operations immediately; and make needed repairs as soon as practicable.

2) Upon completed corrective action, the permittee shall immediately conduct an EPA Reference Method 9 opacity reading on the dust collection system serviced and ensure pressure drop has returned to normal range. [401 KAR 52:020, Section 10]

e. Conduct a daily visual observation of the exhaust point of each dust collection system. If

visible emissions are observed, take corrective action and conduct visual observation using EPA Reference Method 9.Conduct visual observations daily during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference Method 9 reading. [401 KAR 52:020, Section 10]

f. For emission units 17-05, 18-24, 18-27, and 18-30, at least once per day prior to loading truck, barge or rail (if any are loaded any time that day), the person(s) responsible for the loading operations shall inspect and document that the curtains are present, the loading sock has no holes or tears, and the dust collection system is operational. If the curtain is damaged, loading shall be delayed until the curtain is repaired or temporary measures to control emission are taken. On days when the loadout system is not operated, no inspection is required

5. Specific Recordkeeping Requirements: a. Maintain records of the differential pressure readings on the dust collection systems taken

in an electronic format. Records shall, at a minimum, include the date and time of the reading, and the reading value. Records shall also include information on any corrective actions taken when readings outside the appropriate range are recorded. [40 CFR Part 64, 401 KAR 52:020, Section 10]

b. Maintain records of all dust collection systems inspections, repair activities or corrective

actions performed on the dust collection systems due to malfunction. These records shall include, at a minimum, the date, and the name of the person or organization performing the repair or corrective action, and a description of the repair or corrective action completed. [401 KAR 52:020, Section 10]

c. Maintain records of visible emission observations required under Conditions 4.e indicating

for each observation the date and time, name of observer, standing position in location to the emission point, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed and corrective actions taken to mitigate any visible emissions observed. [40 CFR Part 64, 401 KAR 52:020, Section 10]

d. Maintain records of EPA Reference Method 9 readings required under Conditions 4.e

indicating for each reading the date and time, name of observer, standing position in location to the building, weather conditions, result of the EPA Reference Method 9 reading, suspected or known cause of opacity and corrective actions taken to mitigate the emissions observed. [40 CFR Part 64, 401 KAR 52:020, Section 10]


Commented [A11]: Carmeuse is requesting the visible emissions monitoring language in the permit be standardized and immediate Method 9 readings be removed. Refer to application report for additional discussion.


e. Maintain records of the total combined kiln production rate and the amount of combined mass of lime loaded out by truck, rail, and barge (tons/month) on a monthly. [401 KAR 52:020, Section 10]

6. Specific Reporting Requirements: a. Within thirty (30) days of the final date of issuance of permit V-14-002, the permittee shall

submit operation maintenance, and malfunction plan for the dust collection systems and bin vent collector system to the Florence Field Office. The plan shall include as a minimum: 1) Facility's written instructions for the operation and maintenance of the dust collection

systems and bin vent collector system. 2) A schedule and methods to maintain the dust collection systems and bin vent collector

system. 3) A schedule and methods to detect needed repair of the dust collection systems and bin

vent collector system. 4) A schedule and methods to detect malfunctions in the dust collection systems and bin

vent collector system. 5) Method of keeping records of Items (1-4).

[401 KAR 52:020, Section 10] b. See Section F - Monitoring, Recordkeeping, and Reporting Requirements

7. Specific Control Equipment Operating Conditions: a. The dust collection systems shall be operated to maintain compliance with permitted

emission limitations, consistent with operation maintenance, and malfunction plan required. [401 KAR 50:055, Section 2]



LIME: LM02 – Lime System Buildings


33-02 Kilns 4 & 5 Discharge Building 1995

33-03 Transfer House 1 from Kiln to Storage 1995

33-04 Transfer House 2 from Kiln to Storage 1995

33-05 Product Storage Building 1995

33-06 Product Storage Silos 1995

33-07 Transfer House 3 Deg Tower 1995

APPLICABLE REGULATIONS: 401 KAR 63:010, Fugitive emissions 401 KAR 51:017, Prevention of significant deterioration, (C-93-032). 1. Operating Limitations:






5) Installation and use of compaction or other measures to suppress the dust emissions during handling.



a. No person shall cause or permit the discharge of visible fugitive dust emissions beyond the lot line of the property on which the emissions originate. [401 KAR 63:010, Section 3(2)]

Compliance Demonstration Method: Compliance shall be demonstrated with 1. Operating Limitations.


b. Fugitive emissions from the openings of the Lime System Buildings listed shall not exceed 7% opacity. [401 KAR 51:017; C-93-032]

Compliance Demonstration Method: Compliance shall be demonstrated through 4. Specific Monitoring Requirements.

3. Testing Requirements: Not applicable

4. Specific Monitoring Requirements: Conduct visual observations daily during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference Method 9 reading. Conduct visible emissions observations of the entire exterior of the building daily. Visible emissions shall be observed during daylight hours. If visible emissions are observed, conduct EPA Reference Method 9 immediately and take corrective action. After corrective actions have been complete, conduct a follow-up visual observation. [401 KAR 52:020, Section 10]

5. Specific Recordkeeping Requirements: a. Maintain records of visible emission observations required under 4. Specific Monitoring

Requirements indicating for each observation the date and time, name of observer, standing position in location to the building, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, and corrective actions taken to mitigate any visible emissions observed. [401 KAR 52:020, Section 10]

b. Maintain records of EPA Reference Method 9 readings required under 4. Specific Monitoring Requirements indicating for each reading the date and time, name of observer, standing position in location to the building, weather conditions, the EPA Reference Method 9 reading, suspected or known cause of opacity and corrective actions taken to mitigate the emissions observed. [401 KAR 52:020, Section 10]

c. Maintain records of all inspections of the lime conveyor systems inside the listed buildings indicating the date and time, name of inspector, a description of any repairs needed and the date when such repairs were completed. [401 KAR 52:020, Section 10]


Report any visible emissions, the date and time of visible emissions, and opacity values of all EPA Reference Method 9 tests completed in semiannual monitoring reports.

7. Specific Control Equipment Operating Conditions: Openings in the lime system buildings shall be kept closed at all times except for entry and exit or for conducting maintenance activities. [401 KAR 50:055, Section 2]



LIME: LM03 – Lime Storage to Hydrate


Controls

Belt Conveyor Transfers (Partially Enclosed):

20-01 94-550 Belt Conveyor Transfer to 93-100 Belt Conveyor

1980 93-111 Dust Collection System

29-01 93-100 Belt Conveyor (In Lime Service) Transfer to 93-101 Belt Conveyor


Dust Collection Systems:

21-01 90-014 Dust Collection System for DEG Tower Conveyors

1980

29-03 93-111 Dust Collection System for 94-550 Belt Conveyor Transfer

2006

29-04 93-112 Dust Collection System for 93-100 Belt Conveyor Transfer (When in Lime Service)

2006

APPLICABLE REGULATIONS: 401 KAR 63:010, Fugitive emissions, applies to EU 20-01 and 29-01 401 KAR 59:010, New process operations, applies to EU 21-01, 29-03 and 29-04 40 CFR 64, Compliance Assurance Monitoring (CAM) for particulate matter. 1. Operating Limitations:








b. No one shall allow earth or other material being transported by truck or earth moving equipment to be deposited onto a paved street or roadway. [401 KAR 63:010, Section 4]

2. Emission Limitations: a. No person shall cause or permit the discharge of visible fugitive dust emissions beyond the

lot line of the property on which the emissions originate. [401 KAR 63:010, Section 3(2)] Compliance Demonstration Method: Compliance shall be demonstrated with 1. Operating Limitations.

b. Emissions of particulate matter from the Dust Collection Systems listed shall not exceed

the rate calculated by the following equations: [401 KAR 59:010, Section 3 (2)] For process weight rates in excess of 30 ton/hr, E = 17.31P0.16 where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process

Weight Rates (tons/hr)

21-01, 29-03, 29-04 300

c. The opacity of emissions from the Dust Collection Systems shall not exceed twenty

percent. [401 KAR 59:010, Section 3 (1)]

Compliance Demonstration Method: The emission units are considered to be in compliance with process weight rule limits and opacity limit when the Dust Collection Systems are operating and properly maintained.


Testing shall be conducted at such times as may be requested by the Cabinet in accordance with 401 KAR 50:045, Section 4.


a. Monitor the amount of lime conveyed (tons/month) to the hydrate plant on a monthly basis. [401 KAR 52:020, Section 10]

b. Comply with the requirements specified below for the listed dust collection systems to

meet applicable particulate matter Compliance Assurance Monitoring Requirements. [40 CFR 64]


Particulate Matter CAM Approach for LM 03:

Differential Pressure: Visible Emissions:Indicator: Measurement of the resistance of

flow across the fabric filter as the gas passes through the filter and filter cake.

Opacity of emissions are related to the size and concentration of particles in the exhaust gas.

Measurement Approach:

Personnel will monitor the differential pressure across the fabric filter. Alternatively, the permittee may install, calibrate, maintain and operate a monitoring device to continuously monitor the differential pressure across the fabric filter.

A qualitative visual observation (QVO) is conducted daily by knowledgeable observers.

Indicator Range:

While the unit is operating, the indicator range is 1.5”to 9.0”.

While operating, a daily QVO will be completed. Presence of visible emissions will trigger an immediate determination of opacity using EPA Reference Method 9

Excursion defined:

An excursion is defined as a manually recorded differential pressure reading outside the indicator range.

An excursion is defined as visible emissions equal to or greater than 20 percent opacity for any fifteen (15) second interval using the procedures of EPA Reference Method 9.

Excursion Follow-up:

Following an excursion, the permittee shall conduct a physical inspection of the fabric filter to determine and immediately correct any revealed performance issues.

Following an excursion, the permittee will implement corrective measures. Any maintenance and repairs will be performed on the control device to restore the dust collection systems to operate consistent with good engineering practices.

QA/QC Procedures:

Differential pressure across the fabric filter is read using a manometer or similar type gauge. If necessary, the gauge shall be recalibrated to zero when the dust collection system is shut down for maintenance.

The person responsible for making QVO and Reference EPA Reference Method 9 observations will be certified in accordance with EPA Reference Method 9.

Monitoring Frequency:

Personnel will monitor the differential pressure across the fabric filter once per shift or at least once every twelve hours of operation, except when the unit is not in operation.

Daily


Differential Pressure: Visible Emissions: Data

Collection Procedures:

The source data from each monitoring device shall record a data point every minute from each control device during operation. The 15-minute average will not include periods of startup or shutdown.

Daily QVOs shall be maintained and shall include the time and date of the assessment, an indication of any visible emissions and the name of the person conducting the QVO.


a. Maintain records of visible emission observations required under 4. Specific Monitoring Requirements b indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed, and the results of the EPA Reference Method 9 readings. [40 CFR Part 64, 401 KAR 52:020, Section 10]

b. Maintain records of belt conveyor inspections indicating for each inspection the date and

time, name of inspector, a description of any repairs needed and the date when such repairs were completed. [401 KAR 52:020, Section 10]

c. Maintain records of the differential pressure readings on the dust collection systems.

Records shall, at a minimum include the date and time of the reading, the data collection method, the differential pressure range, the reading value, and, for direct observations, the person collecting the reading. Records shall also include information on any corrective actions taken when readings outside the appropriate range are recorded. [40 CFR Part 64, 401 KAR 52:020, Section 10]

d. Maintain records of all routine and non-routine maintenance activities performed on the

dust collection systems. These records shall include, at a minimum, the date, the name(s) of the person or organization performing the maintenance, and a description of the maintenance completed. [401 KAR 52:020, Section 10]

e. Maintain records of amount of lime conveyed (tons/month) to the hydrate plant on a

monthly basis. [401 KAR 52:020, Section 10]. 6. Specific Reporting Requirements:

See Section F - Monitoring, Recordkeeping, and Reporting Requirements 7. Specific Control Equipment Operating Conditions:

a. The dust collection systems shall be operated to maintain compliance with permitted emission limitations, consistent with good engineering practices. [401 KAR 50:055, Section 2]


[401 KAR 52:020, Section 10]


LIME: LM04 – Lime Dust Collection Systems (Non-PSD)


Controls

Loading Spouts:

32-11 63-261LS Kiln 1 & 2 Dust Bin Loading Spout


32-12 63-353LS Kiln 3 Dust Bin Loading Spout 1974 63-272 Dust Collection System


32-09 63-400 Dust Collection System for Kiln 1 & 2 Dust Bin and Transfers

2011

32-10 63-264 Dust Collection System for Kiln 1 & 2 Dust Bin and Transfers

1974

32-13 63-271 Dust Collection System for Kiln 1 & 2 Dust Bin Loading Spout

2004

32-14 63-272 Dust Collection System for Kiln 3 Dust Bin Loading Spouts

2004

32-15 63-354 Dust Collection System for Kiln 3 Dust Bin and Transfers

2004

32-16 89-848 Dust Collection System for Lime Transfers

2015

APPLICABLE REGULATIONS: 401 KAR 63:010, Fugitive emissions; applies to EU 32-11 and 32-12 401 KAR 59:010, New process operations; applies to EU 32-09, 32-13, 32-14, 32-15 and 32-16 401 KAR 61:020, Existing process operations; applies to EU 32-10 40 CFR 64, Compliance Assurance Monitoring (CAM) for particulate matter 1. Operating Limitations:


stockpiles, and other surfaces which can create airborne dusts.


2) Installation and use of hoods, fans, and fabric filters to enclose and vent the handling of dusty materials, or the use of water sprays or other measures to suppress the dust emissions during handling;






a. No person shall cause or permit the discharge of visible fugitive dust emissions beyond the lot line of the property on which the emissions originate. [401 KAR 63:010, Section 3(2)] Compliance Demonstration Method: Compliance shall be demonstrated with 1. Operating Limitations.

b. Emissions of particulate matter from the Dust Collection Systems (EU 32-09, 32-13, 32-

14, 32-15 and 32-16) shall not exceed the rate calculated by the following equations: [401 KAR 59:010, Section 3 (2)] For process weight rates in excess of 30 ton/hr, E = 17.31P0.16 where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process


32-13, 32-14 80

32-09 46.5

32-15 48

32-16 218

c. The opacity of emissions from the Dust Collection Systems shall not exceed twenty

percent. [401 KAR 59:010, Section 3 (1)]

Compliance Demonstration Method: The dust collection systems are considered to be in compliance with process weight rule limits and opacity limit when they are operating and properly maintained.

d. Emissions of particulate matter from EU 32-10, shall not exceed the rate calculated by the following equations: [401 KAR 61:020, Section 3] For process weight rates in excess of 30 ton/hr, E = 55.0P0.11-40


where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process


32-10 46.5

e. The opacity of emissions from the Loading Spouts and one Dust Collection system

(EU 32-11, 32-12 and 32-10) shall not exceed 40 percent (40%) based on a 6-minute average.

Compliance Demonstration Method: These emission units are considered to be in compliance with process weight rule limits and opacity limit when the filter systems of the dust collection system or the systems associated with the loading spouts are operating and properly maintained.

3. Testing Requirements: a. Testing shall be conducted at such times as may be requested by the Cabinet in accordance

with 401 KAR 50:045, Section 4.

b. Conduct a performance test in accordance with EPA Reference Method 5 for particulate matter within 6 months of operation EU 32-16. During the performance testing, the facility shall verify accuracy of the suggested indicator pressure drop range of 1.5”-10.5” for 40 CFR 64, CAM in 4. Specific Monitoring Requirements b. Testing shall be conducted in accordance with 401 KAR 50:045, Performance Tests, and shall be conducted under conditions representative of maximum emissions potential under anticipated operating conditions at the pollutant-specific emissions unit.


a. Monitor the overall process rate (tons/hour) for the Kiln 1, 2 & 3 Dust Bin and Transfers, as defined by total mass of material loaded out to trucks from the dust bins on a monthly basis. [401 KAR 52:020, Section 10]

b. Comply with the requirements specified below for the listed dust collections systems to

meet applicable particulate matter Compliance Assurance Monitoring requirements. [40 CFR 64]

Particulate Matter CAM Approach for LM04: Differential Pressure: Visible Emissions:

Indicator: Measurement of the resistance of flow across the fabric filter as the gas passes through the filter and filter cake.


Commented [A13]: Performance testing for EU 32-16 has been completed and compliance has been demonstrated.


Differential Pressure: Visible Emissions: Measurement Approach:



Indicator Range:

While the unit is operating, the indicator ranges are: 32-09: 1.5” to 7.5” 32-10: 1.0” to 7.0” 32-13: 1.5” to 9.0” 32-14: 1.5” to 9.0” 32-15: 1.0” to 7.0” 32-16: 1.5” to 10.5”

While operating, a daily QVO will be complete. Presence of visible emissions will trigger an immediate determination of opacity using EPA Reference Method 9

Excursion defined:

An excursion is defined as a manually recorded differential pressure reading outside the indicator range.





QA/QC Procedures:




Personnel will monitor the differential pressure across the fabric filter once per shift and at least once every twelve hours of operation, except when not in operation.

Daily


Differential Pressure: Visible Emissions: Data Collection Procedures:


Daily QVOs shall be maintained and shall include the time and date of the assessment, an indication of any visible emissions and the name of the person conducting the QVO.

c. For emission units 32-11 and 32-12, at least once per day prior to loading trucks (if trucks are loaded any time that day), the person(s) responsible for the loading operations shall inspect and document that the curtains are present, the loading sock has no holes or tears, and the dust collection system is operational. If the curtain is damaged, loading shall be delayed until the curtain is repaired or temporary measures to control emission are taken. On days when a truck loadout system is not operated, no inspection is required.

5. Specific Recordkeeping Requirements: a. Maintain records of visible emission observations required under 4. Specific Monitoring

Requirements b indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed and results of the EPA Reference Method 9 readings. [40 CFR Part 64, 401 KAR 52:020, Section 10]

b. Maintain records of inspections of loadout curtains, loading socks, and dust collection systems indicating for each the date and time, name of inspector, a description of any repairs needed and the date when such repairs were completed. [401 KAR 52:020, Section 10]

c. Maintain records of the differential pressure readings on the dust collection systems.


d. Maintain records of all routine and non-routine maintenance activities performed on the


e. Maintain records of the mass of material loaded out to trucks from the dust bins

(tons/month) for the Kiln 1, 2 & 3 Dust Bin and Transfers on a monthly basis. [401 KAR 52:020, Section 10].


6. Specific Reporting Requirements: See Section F - Monitoring, Recordkeeping, and Reporting Requirements


a. The dust collection systems shall be operated to maintain compliance with permitted emission limitations, consistent with good engineering practices. [401 KAR 50:055, Section 2]


[401 KAR 52:020, Section 10]


LIME: LM05 – Reject Lime Stockpiles

EU # Description Date

Constructed or Last Modified

Controls

32-01 Reject Lime Stockpile 2007 Wet Suppression

32-02 Reject Lime Stockpile (Reject Bunker) 2007 Wet Suppression

32-03 Reject Lime Stockpile (South of Hydrate Plant) 2007 Wet Suppression

32-04 Reject Lime Stockpile (South of Kiln #5) 2007 Wet Suppression

APPLICABLE REGULATIONS: 401 KAR 63:010, Fugitive emissions. 1. Operating Limitations:












Not applicable


4. Specific Monitoring Requirements: Inspect each stockpile and conduct visual observations at least once per week. If the stockpile is determined to have the potential to generate fugitive emissions (e.g. stockpiles are very dry, with no crust and wind speed is substantial enough to disturb the material) or visible emissions observed, take preventative actions to mitigate the potential for fugitive emissions (e.g. misting the stockpile), and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]


Maintain a log of stockpile inspections and visible observations as required under 4. Specific Monitoring Requirements, indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, corrective actions taken to mitigate any emissions observed, and results of the follow-up visual observation. [401 KAR 52:020, Section 10]

6. Specific Reporting Requirements: a. When a change in the location of one of the reject lime stockpiles is necessary, notify the

Division’s Central Office and Florence Regional Office in writing indicating the new location and date when the change will occur.

b. See Section F - Monitoring, Recordkeeping, and Reporting Requirements.


Wet suppression shall be applied when applicable, to ensure that reject lime material being stockpiled is sufficiently moist to control fugitive emissions. [401 KAR 50:055, Section 2]


LIME: LM06 – Reject Lime Processing


Controls

32-05 89-005 CM Screw Receiving Hopper 2007 89-004 Dust Collection System

32-07 Front End Loader Dump to High pH Pond 2007 Not applicable












3. Testing Requirements: Not applicable 4. Specific Monitoring Requirements:

Conduct visual observations weekly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]


5. Specific Recordkeeping Requirements: Maintain a log of visual observations as required under 4. Specific Monitoring Requirements, indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, corrective actions taken to mitigate any emissions observed, and the results of the follow-up visual observations. [401 KAR 52:020, Section 10]




LIME: LM06 – Reject Lime Processing (continued)

EU # Description Date Constructed or

Last Modified

32-06 89-004 Dust Collection System for CM Screw Receiving conveyor

2007

APPLICABLE REGULATIONS: 401 KAR 59:010, New process operations; applies to the CM Screw Receiving conveyor. 40 CFR 64, Compliance Assurance Monitoring (CAM) for particulate matter. 1. Operating Limitations: Not applicable 2. Emission Limitations:

a. Emissions of particulate matter shall not exceed the rate calculated by the following equations: [401 KAR 59:010, Section 3 (2)]

For process weight rates up to 30 ton/hr, E = 3.59P0.62 where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process


32-06 20

b. The opacity of emissions from Emission Unit 32 06 shall not exceed twenty percent (20%).

[401 KAR 59:010, Section 3 (1)]

Compliance Demonstration Method: The unit is considered to be in compliance with process weight rule limits and opacity limit when the Dust Collection system is operating and properly maintained.

3. Testing Requirements: Testing shall be conducted at such times as may be requested by the Cabinet in accordance

with 401 KAR 50:045, Section 4. 4. Specific Monitoring Requirements:

a. Monitor the estimated processing rate on a monthly basis. [401 KAR 52:020, Section 10] b. Comply with the requirements specified below to meet applicable particulate matter

Compliance Assurance Monitoring requirements [40 CFR 64]:


Particulate Matter CAM Approach for LM06, EU 32-06: Differential Pressure: Visible Emissions:

Indicator: Measurement of the resistance of flow across the fabric filter as the gas passes through the filter and filter cake.


Measurement Approach:



Indicator Range:

While the unit is operating, the indicator range is 1.5” to 9.0”.

While operating, a daily QVO will be completed. Presence of visible emissions will trigger an immediate determination of opacity using EPA Reference Method 9

Excursion defined:

An excursion is defined as a differential pressure reading outside the indicator range.





QA/QC Procedures:




Personnel will monitor the differential pressure across the fabric filter once per shift and at least once every twelve hours of operation, except when not in operation.

Daily


Differential Pressure: Visible Emissions: Data

Collection Procedures:


Daily QVOs shall be maintained and shall include the time and date of the assessment, an indication of any visible emissions and the name of the person conducting the QVO. EPA Reference Method 9 results will be documented in the format shown in Figure 9-1of Reference EPA Reference Method 9.


a. Maintain records of visible emission observations required under 4. Specific Monitoring Requirements b indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed and results of the EPA Reference Method 9 readings. [40 CFR Part 64, 401 KAR 52:020, Section 10]

b. Maintain records of the differential pressure readings on the dust collection systems.


c. Maintain records of all routine and non-routine maintenance activities performed on the


d. Records of material received and processed shall be maintained on a monthly basis. [401

KAR 52:020, Section 10]

6. Specific Reporting Requirements: See Section F - Monitoring, Recordkeeping, and Reporting Requirements


LIME: LM07 – Clinker Reclaim


Controls

12-01 89-800H Clinker Receiving Hopper to 89-800 Belt Conveyor


12-03 Front End Loader to Clinker Hopper 1997 84-018 Dust Collection System

* The 84-018 Dust Collection Systems are included in the Section B of the permit for LM01–Lime Dust Collection Systems. All applicable regulations pertaining to these dust collection systems are included in that Section B.














4. Specific Monitoring Requirements: Conduct visual observations weekly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]


Maintain a log of visual observations as required under 4. Specific Monitoring Requirements, indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, corrective actions taken to mitigate any emissions observed, and the results of the follow-up visual observation. [401 KAR 52:020, Section 10]




LIME: LM08 – Lime Loadout


Controls*

13-01 94-540 Railcar Loadout Spout (Lime) 1974 89-829 Dust Collection System

14-01 89-045 Truck Loadout for Lime Rejects 1995 89-858 Dust Collection System

14-02 94-002 Barge Loadout 1995 94-837 Dust Collection System

14-03 94-003 Truck Loadout 1995 94-833 Dust Collection System

* The 89-829, 89-858, 94-837, and 94-833 Dust Collection Systems are included in the Section B of the permit for LM01–Lime Dust Collection Systems. All applicable regulations pertaining to these dust collection systems are included there.














Conduct visual observations weekly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. [401 KAR 52:020, Section 10]


Maintain a log of visual observations as required under 4. Specific Monitoring Requirements, indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, corrective actions taken to mitigate any emissions observed, and the results of the follow-up visual observation. [401 KAR 52:020, Section 10]




HYDRATE: HY01 – Hydration Plant


Controls

Conveyor Transfers

21-02 90-050 Belt Conveyor Transfer to Hydrate Feed Bins #1 & #2

1980 Shrouded

Bin Vent and Dust Collection Systems:

20-20

90-138A Bin Vent Collector on 90-135 (Hydrator #1 Feed Bin)

1980

20-21 90-138B Bin Vent Collector on 90-133 (Hydrator #2 Feed Bin)

1980

21-18 90-128 Dust Collection System for Classifier Operations

1980

Hydrator:

21-12 Hydrator/Scrubber System 1980

APPLICABLE REGULATIONS: 401 KAR 63:010, Fugitive emissions; applies to EU 21-02 401 KAR 59:010, New process operations; applies to EU 20-20, 20-21, 21-18 and 21-12 1. Operating Limitations:








equipment to be deposited onto a paved street or roadway [401 KAR 63:010, Section 4].


2. Emission Limitations: a. No person shall cause or permit the discharge of visible fugitive dust emissions beyond the

lot line of the property on which the emissions originate. [401 KAR 63:010, Section 3(2)] Compliance Demonstration Method: Compliance shall be demonstrated with 1. Operating Limitations.

b. Emissions of particulate matter from the Bin Vent and Dust Collection Systems and the Hydrator shall not exceed the rate calculated by the following equations: [401 KAR 59:010, Section 3 (2)] For process weight rates up to 30 ton/hr, E = 3.59P0.62 For process weight rates in excess of 30 ton/hr, E = 17.31P0.16 where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process


20-20, 20-21 300

21-18, 21-12 30

Compliance Demonstration Method: 1. The bin vent filters and dust collection systems are considered to be in compliance with

process weight rule limits and the opacity limit when the filter systems are operating and properly maintained.

2. The Hydrator/Scrubber system is considered to be in compliance with process weight rule limits and the opacity limit when properly operated.

c. The opacity of emissions from the Bin Vent and Dust Collection Systems and the Hydrator

shall not exceed twenty percent (20%). [401 KAR 59:010, Section 3 (1)]

3. Testing Requirements: Testing shall be conducted at such times as may be requested by the cabinet in accordance with

401 KAR 50:045, Section 4. 4. Specific Monitoring Requirements:

a. Conduct visual observations weekly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference Method 9 reading. Perform a qualitative visual observation (QVO) of the stack of the dust collection system and bin vent collectors on a weekly basis. The permittee shall maintain a log of the observations. If visible emissions from the stack are observed, then opacity shall be determined by EPA Reference Method 9 as detailed in 40 CFR 60, Appendix A. If the opacity reading is greater than twenty (20) percent then initiate an inspection of the equipment and make repairs if necessary. [401 KAR 52:020, Section 10]



b. Monitor the material received and processed (tons/month) on a monthly basis. [401 KAR

52:020, Section 10] 5. Specific Recordkeeping Requirements:

a. Maintain a log of visual emission observations required under 4. Specific Monitoring Requirements a indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed, and the results of the EPA Reference Method 9 readings. [401 KAR 52:020, Section 10]

b. Maintain records of all routine and non-routine maintenance activities and inspections performed on the bin vents and dust collection systems. These records shall include, at a minimum, the date and time, the name(s) of the person or organization performing the maintenance or inspections, and a description of the maintenance completed or repairs needed and the date when such repairs were completed.. [401 KAR 52:020, Section 10]

c. Records of material received and processed (tons/month) shall be maintained on a monthly

basis. [401 KAR 52:020, Section 10] 6. Specific Reporting Requirements:


a. Each dust collection system shall be operated when controlled emission units are in operation to maintain compliance with permitted emission limitations, consistent with manufacturer’s specifications and good operating practices. [401 KAR 50:055, Section 2]

b. Maintain a log of routine and non-routine maintenance activities performed on the dust

collection systems. These records shall include, at a minimum, the date, the name(s) of the person or organization performing the maintenance, and a description of the maintenance completed. [401 KAR 52:020, Section 10]


HYDRATE: HY02 – Hydrate Bins to Loadout


Controls

Loadout Transfers:


21-27 90-124LS Reject Truck Loadout 1980 90-303 Dust Collection System


27-01 90-221LS Railcar Loadout 2004 90-221 Dust Collection System

Storage Bin Vent Filter System:

21-32 90-139A Bin Vent Collector on 90-222 (#3 Product Storage Bin)

1980

21-33 90-139B Bin Vent Collector on 90-223 (#2 Product Storage Bin)

1980

21-34 90-139C Bin Vent Collector on 90-224 (#1 Product Storage Bin)

1980


21-23 90-215 Dust Collection System for #3 Product Bin Truck Loadout

1980

21-31 90-170 Dust Collection System for #1 & #2 Product Bin Truck Loadout

1980

21-35 90-303 Dust Collection System for Hydrate Reject Loadout

1980

22-09 91-209 Dust Collection System for Hydrate Bagging Operation

1980

27-02 90-221 Dust Collection System for 90-221LS Railcar Loadout

1980

APPLICABLE REGULATIONS: 401 KAR 59:010, New process operations 1. Operating Limitations:

Not applicable


2. Emission Limitations: a. Emissions of particulate matter from the Bin Vent and Dust Collection Systems and the

Hydrator shall not exceed the rate calculated by the following equations: [401 KAR 59:010, Section 3 (2)] For process weight rates up to 30 ton/hr, E = 3.59P0.62 For process weight rates in excess of 30 ton/hr, E = 17.31P0.16 where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process


21-25, 21-28, 27-01, 21-23, 21-31, 21-35, 22-09, 27-02

100

21-27 85

21-32, 21-33, 21-34 30

b. The opacity of emissions from the Bin Vent Collectors and Dust Collection Systems and

shall not exceed twenty percent (20%). [401 KAR 59:010, Section 3 (1)]

Compliance Demonstration Method: This emission unit is considered to be in compliance with process weight rule limits and opacity limit when the dust collection system associated with the unit is operating and properly maintained.



a. Conduct visual observations weekly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference Method 9 reading. Perform a qualitative visual observation (QVO) of the dust collection system and bin vent collectors on a weekly basis. The permittee shall maintain a log of the observations. If visible emissions from the stack are observed, then opacity shall be determined by EPA Reference Method 9 as detailed in 40 CFR 60, Appendix A. If the opacity reading is greater than twenty (20) percent then initiate an inspection of the equipment and make repairs if necessary. [401 KAR 52:020, Section 10]


52:020, Section 10]



c. For emission units 21-25, 21-27, 21-28 and 27-01, at least once per day prior to loading

trucks or rail (if any are loaded any time that day), the person(s) responsible for the loading operations shall inspect and document that the curtains are present, the loading sock has no holes or tears, and the dust collection system is operational. If the curtain is damaged, loading shall be delayed until the curtain is repaired or temporary measures to control emission are taken. On days when a loadout system is not operated, no inspection is required.

5. Specific Recordkeeping Requirements: a. Maintain a log of visual emission observations required under 4. Specific Monitoring

Requirements a indicating or each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed, and the results of the EPA Reference Method 9 readings. [401 KAR 52:020, Section 10]

b. Maintain records of all routine and non-routine maintenance activities and inspections

performed on the bin vents and dust collection systems. These records shall include, at a minimum, the date and time, the name(s) of the person or organization performing the maintenance or inspections, and a description of the maintenance completed or repairs needed and the date when such repairs were completed.. [401 KAR 52:020, Section 10]

c. Maintain records of the total amount of material loaded out by truck or rail (tons/month)

on a monthly basis. [401 KAR 52:020, Section 10] 6. Specific Reporting Requirements:


7. Specific Control Equipment Operating Conditions: a. Each dust collection system shall be operated when controlled emission units are in

operation to maintain compliance with permitted emission limitations, consistent with manufacturer’s specifications and good operating practices. [401 KAR 50:055, Section 2]




HYDRATE: HY03 – Lime Pulverizer System


21-05 90-137 Dust Collection System for Mill Feed Bin 1980

21-08 90-142 Dust Collection System for Mill 1980

APPLICABLE REGULATIONS: 401 KAR 59:010, New process operations 1. Operating Limitations: Not applicable 2. Emission Limitations:

a. Emissions of particulate matter from the listed emission units shall not exceed the rate calculated by the following equations: [401 KAR 59:010, Section 3 (2)] For process weight rates up to 30 ton/hr, E = 3.59P0.62 where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process


21-05, 21-08 30

Compliance Demonstration Method: The dust collection systems are considered to be in compliance with process weight rule limits and opacity limit when the filter systems are operating and properly maintained.

b. The opacity of emissions from the listed emission units shall not exceed twenty percent (20%). [401 KAR 59:010, Section 3 (1)]



a. Conduct visual observations weekly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference Method 9 reading. Perform a qualitative visual observation (QVO) of the stack of the dust collection system on a weekly basis. The permittee shall maintain a log of the observations. If visible emissions from the stack are observed, then opacity shall be determined by EPA Reference Method 9 as detailed in 40 CFR 60, Appendix A. If the opacity reading is greater


than twenty percent then initiate an inspection of the equipment and make repairs if necessary. [401 KAR 52:020, Section 10]

b. Monitor the lime material processed through the lime pulverizer system (tons/month) on a

monthly basis. [401 KAR 52:020, Section 10]


Requirements a indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed, and results of the EPA Reference Method 9 readings.

b. Maintain records of all routine and non-routine maintenance activities and inspections

performed on the bin vents and dust collection systems. These records shall include, at a minimum, the date and time, the name(s) of the person or organization performing the maintenance or inspections, and a description of the maintenance completed or repairs needed and the date when such repairs were completed.. [401 KAR 52:020, Section 10]

c. Maintain records of the lime material processed through the lime pulverizer system

(tons/month) on a monthly basis. [401 KAR 52:020, Section 10] 6. Specific Reporting Requirements:




SOUTH HYDRATE: SH01 – South Hydrate Plant

EU # Description Date Constructed Controls

Quick Lime Handling and Storage

35-01 Transfer [From BC 89-815 to Bucket Elevator (35-02)]

2016 DC-06108 Dust Collector

35-02 Bucket Elevator BE-06103 2016

35-03 Screen SN-06104 2016

35-04 Transfer [From Screen (35-03) to Conveyor (35-05)]

2016

36-01 Fines Conveyor (SC-06106) [From Screen (35-04) to Lime Dust Collection Systems]

2016 Enclosed

36-02 Overs Bin (BN 06105) 2016 Enclosed

35-05 Belt Conveyor BC-06113 [To Bucket Elevator(35-06)]

2016 DC-06116 Cartridge Filter

35-06 Bucket Elevator BE-06118 (Lower Section) 2016

35-07 Bucket Elevator BE-06118 (Upper Section) 2016

35-08 Quick Lime Bin #1 BN-06120 Integrated Passive Bin Vent Filter (DC-06121)

2016 Inherent Vent Filter

35-09 Quick Lime Bin #2 BN-06125 Integrated Passive Bin Vent Filter (DC-06126)

2016 Inherent Vent Filter

35-10 Transfer BN-06120 [From Lime Bin #1 to Belt Conveyor (35-12)]


35-11 Transfer BN-06125 [From Lime Bin #2 to Belt Conveyor (35-12)]

2016

35-12 Belt Conveyor BC-22101[From Bins to Crusher]

2016

35-13 Crusher CR-22102 2016

35-14 Bucket Elevator BE-21101 (Lower Section) 2016

35-15 Conveyor and Transfer Points (SC-21102) [From Bucket Elevator to Surge Bin]

2016

35-16 Crushed Quicklime Surge Bin(BN-21103) 2016

35-17 Rejects Bin BN-25104 [From Conveyor SC-25102]

2016


EU # Description Date Constructed Controls

Quick Lime Handling and Storage

35-18 Bucket Elevator BE-25107[From Conveyor SC-25102 to Conveyor SC-25110 or SC-

25109]


Hydrator and Drying

36-03 Conveyor (SC-21110) (Quicklime)[From Quicklime Bin to Conveyor (SC-21111)]

2016 Enclosed

36-04 Conveyor (SC-21111) (Quicklime) [From Conveyor (SC-21110) to Hydrator]

2016 Enclosed

35-19 Hydrator System HY-23101 with Integrated Process Filter (DC-23103)

2016 Inherent Process Filter

36-05 Conveyor (SC-23107) (Wet Hydrate) [From Hydrator to Rejects Container (BN-23110)]

2016 Enclosed

36-06 Rejects Container (Wet Hydrate) [From Conveyor (SC-23107)]

2016 Enclosed

35-20 Mill Dryer (ML-23116) with Integrated Process Filter (DC-23119)

2016 Inherent Process Filter

36-07 Conveyor (SC-25102) [To Rejects Bin (35-17) or Bucket Elevator (35-18)]

2016 Enclosed

Hydrate Storage and Loadout

36-08 Conveyor (SC-25109) [To Hydrate Bin (35-22)]

2016 Enclosed

36-09 Conveyor (SC-25110) [To Hydrate Bin (35-23)]

2016 Enclosed

35-22 Hydrate Bin #1 (BN-25111) with Integrated Bin Vent Filter (DC-25112)

2016 Inherent Bin Vent Filter

35-23 Hydrate Bin #2 (BN-25123) with Integrated Bin Vent Filter (DC-25124)

2016 Inherent Bin Vent Filter

35-24 Truck Loadout from Hydrate Bin #1 with Spout Filter

2016 DC-25120 Spout Filter

35-25 Truck Loadout from Hydrate Bin #2 with Spout Filter

2016 DC-25132 Spout Filter

APPLICABLE REGULATIONS: 401 KAR 59:010, New process operations


1. Operating Limitations: To preclude the applicability of 401 KAR 51:017, the controls listed shall be operated at all

times the associated equipment is in operation. [Permit V-14-002 R3] 2. Emission Limitations: a. Emissions of particulate matter from the affected facilities shall not exceed the rate

calculated by the following equations: [401 KAR 59:010, Section 3 (2)] For process weight rates up to 30 ton/hr, E = 3.59P0.62 For process weight rates in excess of 30 ton/hr, E = 17.31P0.16 where E is the rate of emission in lb/hr and P is the process weight rate in ton/hr

EU # Design Process


35-01 to 35-03 42

35-04 to 35-09 35

35-10 to 35-16, 35-19 9

35-17 to 35-18, 35-20 to 35-23

11

35-24 to 35-25 100

b. The opacity of emissions from the affected facilities shall not exceed twenty percent (20%).

[401 KAR 59:010, Section 3 (1)]

Compliance Demonstration Method: The emission points listed above are considered to be in compliance with process weight rule limits and the opacity limit when the control devices are operating and properly maintained.

3. Testing Requirements: a. Testing shall be conducted at such times as may be requested by the cabinet in

accordance with 401 KAR 50:045, Section 4. b. Conduct a performance test in accordance with EPA Reference Method 5 for particulate

matter within 180 days of initial operation for the following emission units to verify PM emission factors. Testing shall be conducted in accordance with 401 KAR 50:045, Performance Tests, and shall be conducted under conditions representative of maximum emissions potential under anticipated operating conditions. [401 KAR 50:055, General Compliance Requirements, 401 KAR 59:005, Section 2 (2), and 401 KAR 50:045, Section 1]


EU # Stack/Control Device to Test

35-01 to 35-04 DC-06108 Dust Collection System

35-05 to 35-0707 DC-21105 Dust Collection System

35-10 Integrated Process Filter DC-23103



a. Conduct visual observations weekly monthly during daylight hours. If visible emissions are observed, take corrective action and conduct a follow-up visual observation. If visible emissions are observed after the corrective action, conduct an EPA Reference Method 9 reading. Perform a qualitative visible observation (QVO) of the stack or vent for each affected facility on a weekly basis. The permittee shall maintain a log of the observations. If visible emissions from the stack are observed, then opacity shall be determined by EPA Reference Method 9 as detailed in 40 CFR 60, Appendix A. If the opacity reading is greater than twenty (20) percent, take corrective action and conduct a follow up EPA Reference Method 9 determination. If visible emissions are still in excess of the opacity limit after corrective action, the process shall be shut down and shall not operate again for production purposes until repairs have been made that result in opacity determined to be in compliance by EPA Reference Method 9. If the opacity limit is not exceeded, the process may continue to operate. [401 KAR 52:020, Section 10].


52:020, Section 10]. c. Install, calibrate, maintain and operate according to manufacturer’s specification a

monitoring device to determine the differential pressure across the following filter systems. This monitoring device shall be read and the reading records at least once daily during operation of the unit.

EU # Filter System

35-01:04 DC-06108 Dust Collection System

35-05:07 DC-21105 Dust Collection System



d. For emission units 35-24 and 35-25, at least once per day prior to loading the trucks (if

any trucks are loaded any time that day), the person(s) responsible for the loading operations shall inspect and document that the curtains are present, the loading sock has no holes or tears, and the dust collection system is operational. If the curtain is damaged, loading shall be delayed until the curtain is repaired or temporary measures



to control emission are taken. On days when the truck loadout system is not operated, no inspection is required


Requirements a indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any visible emissions observed, corrective actions taken to mitigate any visible emissions observed, and the results of EPA Reference Method 9 readings. [401 KAR 52:020, Section 10]

b. Maintain records of the differential pressure readings required in 4. Specific Monitoring

Requirements c Records shall, at a minimum, include the date and time of the reading, and the reading value. [401 KAR 52:020, Section 10]

c. Maintain log of all inspections of bin vents and dust collection systems indicating for

each the date and time, name of inspector, a description of any repairs needed and the date when such repairs were completed. [401 KAR 52:020, Section 10]

d. Records of material received and processed (tons/month) shall be maintained on a

monthly basis. [401 KAR 52:020, Section 10] 6. Specific Reporting Requirements:

See Section F - Monitoring, Recordkeeping, and Reporting Requirements. 7. Specific Control Equipment Operating Conditions: a. Each dust collection system shall be operated consistent with manufacturer’s

specifications and good operating practices when emission units are in operation to maintain compliance with permitted emission limitations. [401 KAR 50:055, Section 2]




SOUTH HYDRATE: SH02 – Hot Air Heater

EU # Description Date Constructed

Hot Air Heater for Hydrator System

35-21 Natural Gas-Fired Hot Air Heater (9.55 MMBtu/hr) (HU-23128) (For Hydrator System)

2016

APPLICABLE REGULATIONS: 401 KAR 59:015, New indirect heat exchangers 401 KAR 63:002, Section 2(4)(iiii) 40 C.F.R. 63.7480 to 63.7575, Tables 1 to 13 (Subpart DDDDD), National Emission Standards for Hazardous Air Pollutants for Major Sources: Industrial, Commercial, and Institutional Boilers and Process Heaters 1. Operating Limitations: a. The permittee must meet each work practice standard in Table 3 to 40 CFR 63, Subpart

DDDDD that applies to the affected facility except as provided under 40 CFR 63.7522. [40 CFR 63.7500(a)(1)]

b. At all times, the permittee must operate and maintain the Hot Air Heater (EU 35-21),

including associated air pollution control equipment and monitoring equipment, in a manner consistent with safety and good air pollution control practices for minimizing emissions. Determination of whether such operation and maintenance procedures are being used will be based on information available to the Division that may include, but is not limited to, monitoring results, review of operation and maintenance procedures, review of operation and maintenance records, and inspection of the source. [40 CFR 63.7500(a)(3)]

c. The permittee must demonstrate initial compliance with the applicable work practice

standards in Table 3 to 40 CFR 63, Subpart DDDDD, applicable to the Hot Air Heater (EU 35-21) within the applicable annual, biennial, or 5-year schedule as specified in 40 CFR 63.7515(d) following the initial compliance date specified in 40 CFR 63.7495(a). Thereafter, complete the applicable annual, biennial, or 5-year tune-up as specified in 40 CFR 63.7515(d). [40 CFR 63.7510 (g)]

d. The permittee must conduct a biennial performance tune-up for the Hot Air Heater (EU

35-21) according to 40 CFR 63.7540(a)(11). Each biennial tune-up specified in 40 CFR 63.7540(a)(11) must be no more than 25 months after the previous tune-up. For a new or reconstructed affected source, (as defined in 40 CFR 63.7490) the first biennial tune-up must be no later than 25 months after the initial startup of the new or reconstructed affected source. [40 CFR 63.7515(d)]

e. The permittee must conduct a tune-up of Hot Air Heater (EU 35-21) biennially to

demonstrate continuous compliance as specified: [40 CFR 63.7540(a)(10)]


1) As applicable, inspect the burner, and clean or replace any components of the burner as necessary (the burner inspection may be performed any time prior to the tune-up or delay the burner inspection until the next scheduled unit shutdown). Units that produce electricity for sale may delay the burner inspection until the first outage, not to exceed 36 months from the previous inspection. At units where entry into a piece of process equipment or into a storage vessel is required to complete the tune-up inspections, inspections are required only during planned entries into the storage vessel or process equipment;

2) Inspect the flame pattern, as applicable, and adjust the burner as necessary to optimize the flame pattern. The adjustment should be consistent with the manufacturer's specifications, if available;

3) Inspect the system controlling the air-to-fuel ratio, as applicable, and ensure that it is correctly calibrated and functioning properly (the permittee may delay the inspection until the next scheduled unit shutdown);

4) Optimize total emissions of CO. This optimization should be consistent with the manufacturer's specifications, if available,

5) Measure the concentrations in the effluent stream of CO in parts per million, by volume, and oxygen in volume percent, before and after the adjustments are made (measurements may be either on a dry or wet basis, as long as it is the same basis before and after the adjustments are made). Measurements may be taken using a portable CO analyzer; and

6) Maintain on-site and submit, if requested by the Division, a report containing the information in paragraphs (a)(10)(vi)(A) through (C) of this section,

i. The concentrations of CO in the effluent stream in parts per million by volume, and oxygen in volume percent, measured at high fire or typical operating load, before and after the tune-up of the boiler or process heater;

ii. A description of any corrective actions taken as a part of the tune-up; and iii. The type and amount of fuel used over the 12 months prior to the tune-up, but

only if the unit was physically and legally capable of using more than one type of fuel during that period. Units sharing a fuel meter may estimate the fuel used by each unit.

f. If the unit is not operating on the required date for a tune-up, the tune-up must be conducted

within 30 calendar days of startup. [40 CFR 63.7540(a)(13)]

2. Emission Limitations: a. Particulate matter (PM) emissions shall not exceed 0.56 lb/MMBtu actual heat input, based

on three hour average. [401 KAR 59:015, Section 5] b. Sulfur dioxide (SO2) emissions shall not exceed 3.0 lb/MMBtu actual heat input, based on

a twenty four hour average. [401 KAR 59:015, Section 5] c. Visible emissions from the shall not exceed twenty (20) percent opacity, based on a six-

minute average, except as follows: [401 KAR 59:015, Section 4 (2)]


1) A maximum of forty (40) percent opacity shall be allowed for a maximum of six (6) consecutive minutes in any sixty (60) consecutive minutes during fire box cleaning or soot blowing; and [401 KAR 59:015, Section 4(2)]

2) For emissions from an affected facility caused by building a new fire, emissions during the period required to bring the boiler up to operating conditions shall be allowed, if the method used is recommended by the manufacturer and the time does not exceed the manufacturer's recommendations.

Compliance Demonstration Method: Affected facilities are assumed to be in compliance with the PM, SO2, and visible emission

standards while burning natural gas.


401 KAR 50:045, Section 4. 4. Specific Monitoring Requirements: Monitor the gas usage rate for the Hot Air Heater (MMscf/month) on a monthly basis. [401

KAR 52:020, Section 10] 5. Specific Recordkeeping Requirements: a. Maintain records of gas usage rate (MMscf/month) [401 KAR 52:020, Section 10]

b. Maintain a copy of each notification and report that submitted to comply with 40 CFR 63, Subpart DDDDD, including all documentation supporting any Initial Notification or Notification of Compliance Status or semiannual compliance report submitted, according to the requirements in 40 CFR 63.10(b)(2)(xiv). [40 CFR 63.77555(a)(1)]

c. Records of tune-ups and compliance reports, must be maintained in accordance with the

following: [40 CFR 63.7560] 1) Records must be in a form suitable and readily available for expeditious review,

according to 40 CFR 63.10(b)(1). 2) As specified in 40 CFR 63.10(b)(1), keep each record for 5 years following the date of

each occurrence, measurement, maintenance, corrective action, report, or record. 3) Keep each record on site, or they must be accessible from on site (for example, through

a computer network), for at least 2 years after the date of each occurrence, measurement, maintenance, corrective action, report, or record, according to 40 CFR 63.10(b)(1). Keep the records off site for the remaining 3 years.


a. See Section F - Monitoring, Recordkeeping, and Reporting Requirements. b. As specified in 40 CFR 63.9(b)(4) and (5), the permittee must submit an Initial Notification not later than 15 days after the actual date of startup of the Hot Air Heater (EU 35-21). [40 CFR 63.7545(c)]


c. The permittee must submit a Notification of Compliance Status according to 40 CFR 63.9 h)(2)(ii). For the initial compliance demonstration, submit the Notification of Compliance Status before the close of business on the 60th day following the completion of all performance test and/or other initial compliance demonstrations according to 40 CFR 63.10(d)(2). The Notification of Compliance Status report must contain all the information: [40 CFR 63.7545(e)]

1) A description of the affected unit(s) including identification of which subcategories the unit is in, the design heat input capacity of the unit, a description of the add-on controls used on the unit to comply with this subpart, description of the fuel(s) burned, including whether the fuel(s) were a secondary material determined by the permittee or the EPA through a petition process to be a non-waste under 40 CFR 241.3 of this chapter, whether the fuel(s) were a secondary material processed from discarded non-hazardous secondary materials within the meaning of 40 CFR 241.3 of this chapter, and justification for the selection of fuel(s) burned during the compliance demonstration.

2) In addition to the information required in 40 CFR 63.9(h)(2), notification of compliance status must include the following certification(s) of compliance, as applicable, and signed by a responsible official: “This facility completed the required initial tune-up for all of the boilers and process heaters covered by 40 CFR part 63 subpart DDDDD at this site according to the procedures in 40 CFR 63.7540(a)(10)(i) through (vi).”

d. The permittee must submit to the Division all of the notifications in 40 CFR 63.7(b) and (c), 63.8(e), (f)(4) and (6), and 63.9(b) through (h) that apply to the Hot Air Heater (EU 35-21) by the dates specified. [40 CFR 63.7545(a)]

e. If the permittee switches fuels or makes a physical change to the unit and the fuel switch

or physical change resulted in the applicability of a different subcategory, the permittee must provide notice of the date upon which permittee switched fuels or made the physical change within 30 days of the switch/change. The notification must identify: [40 CFR 63.7545 (h)] 1) The name of the owner or operator of the affected source, as defined in 40 CFR

63.7490, the location of the source, the boiler(s) and process heater(s) that have switched fuels, were physically changed, and the date of the notice.

2) The currently applicable subcategory under this subpart. 3) The date upon which the fuel switch or physical change occurred. f. The permittee must submit each report in Table 9 to 40 CFR 63, Subpart DDDDD that

applies to the Hot Air Heater (EU 35-21). [40 CFR 63.7550(a)] g. The permittee must submit a signed statement in the Notification of Compliance Status

report that indicates that the permittee conducted a tune-up of the Hot Air Heater (EU 35- 21). [40 CFR 63.7530 (e)]

h. Unless the Division has approved a different schedule for submission of reports under

40CFR 63.10(a), the permittee must submit each report for the Hot Air Heater (EU 35-21), according to 40 CFR 63.7550(h), by the date in Table 9 to this subpart and according to


the requirements in 40 CFR 63.7550 (b)(1) through (4). For units that are subject only to a requirement to conduct subsequent annual, biennial, or 5-year tune-up according to 40 CFR 63.7540(a)(10), and not subject to emission limits or Table 4 operating limits, the permittee may submit only an annual as specified in 40 CFR 63.7550 (b)(1) through (4) of this section, instead of a semi-annual compliance report. [40 CFR 63.7550 (b)]

1) The first semi-annual compliance report must cover the period beginning on the compliance date that is specified for each boiler or process heater in 40 CFR 63.7495 and ending on June 30 or December 31, whichever date is the first date that occurs at least 180 days after the compliance date that is specified for the source in 40 CFR 63.7495. If submitting an annual, biennial, or 5-year compliance report, the first compliance report must cover the period beginning on the compliance date that is specified for each boiler or process heater in 40 CFR 63.7495 and ending on December 31 within 1, 2, or 5 years, as applicable, after the compliance date that is specified for the source in 40 CFR 63.7495.

2) The first annual compliance report must be postmarked or submitted no later than January 31.

3) Each subsequent annual compliance reports must cover the applicable 1-year periods from January 1 to December 31.

4) Each subsequent annual compliance reports must be postmarked or submitted no later than January 31.

i. The compliance report must contain the following information depending on how the

facility chooses to comply with the applicable requirements of 40 CFR 63, Subpart DDDDD: [40 CFR 63.7550(c)(1)]

1) Company and Facility name and address. 2) Process unit information, emissions limitations, and operating parameter limitations. 3) Date of report and beginning and ending dates of the reporting period. 4) The total operating time during the reporting period.

5) Include the date of the most recent tune-up for each unit subject to only the requirement to conduct an annual tune-up according to 40 CFR 63.7540(a)(10). Include the date of the most recent burner inspection if it was not done annually and was delayed until the next scheduled or unscheduled unit shutdown.

6) Statement by a responsible official with that official's name, title, and signature, certifying the truth, accuracy, and completeness of the content of the report.


ROADS: RD01 – Haul Roads


Controls

23-01 Haul Road and Yard Area (Paved) 1995 Wet Suppression

25-01 Haul Road and Yard Area (Coal) 2003 Wet Suppression














4. Specific Monitoring Requirements: Inspect each haul road and conduct visual observations at least once per week. If a haul road is determined to have the potential to generate fugitive emissions (e.g. road surface contains loose material, and wind speed is substantial enough to disturb the material, visible emissions observed) preventative actions shall be taken to mitigate the potential for fugitive emissions (e.g. watering or cleaning to road). [401 KAR 52:020, Section 10]


a. Maintain a log of haul road and yard area inspections and visual observations as required under 4. Specific Monitoring Requirements, indicating for each observation the date and time, name of observer, standing position, weather conditions, whether any emissions were visible, the suspected or known cause of any fugitive emissions observed, and corrective actions taken to mitigate any emissions observed. [401 KAR 52:020, Section 10]

b. Maintain a log of routine and non-routine maintenance activities performed on the road

maintenance and cleaning equipment. These records shall include, at a minimum, the date, the name(s) of the person or organization performing the maintenance, and a description of the maintenance completed. [401 KAR 52:020, Section 10]



Road maintenance and cleaning (including sweeping, watering and application of dust suppressants) shall be completed as required to ensure that haul roads are sufficiently moist or clean to control fugitive emissions. [401 KAR 50:055, Section 2]


ENGINES: EN01 – Stationary Engines


34-06 Kiln 1 Pony Motor Engine; New Holland, Model F4HFE413D*A008, 119 bhp

20162018


2015


2015


2015


2015

APPLICABLE REGULATIONS: 401 KAR 60:005, Section 2(2)(dddd) 40 C.F.R. 60.4200 to 60.4219, Tables 1 to 8 (Subpart IIII), Standards of Performance for Stationary Compression Ignition Internal Combustion Engines 401 KAR 63:002, Section 2(4)(eeee) 40 C.F.R. 63.6580 to 63.6675, Tables 1a to 8, and Appendix A (Subpart ZZZZ), National Emission Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines 1. Operating Limitations:

a. The facility must meet the requirements of 40 CFR 63, Subpart ZZZZ, by meeting the requirements of 40 CFR part 60 subpart IIII. No further requirements apply for such engines under this part. [40 CFR 63.6590(c)]

b.a.Beginning October 1, 2010, the owner and operator of stationary CI ICE subject to 40 CFR 60, Subpart IIII, with a displacement of less than 30 liters per cylinder that use diesel fuel must use diesel fuel that meets the requirements of 40 CFR 80.510(b) for non-road diesel fuel, except that any existing diesel fuel purchased (or otherwise obtained) prior to October 1, 2010, may be used until depleted. [40 CFR 60.4207(b)]

b. Except as permitted under 40 CFR 60.4211(g), the permittee must do all of the following to demonstrate compliance [40 CFR 60.4211(a)]: 1) Operate and maintain the stationary CI internal combustion engine and control device

according to the manufacturer's emission-related written instructions; 2) Change only those emission-related settings that are permitted by the manufacturer;

and 3) Meet the requirements of 40 CFR parts 89, 94 and/or 1068, as they apply.

Commented [A18]: Describes exemption criteria from Subpart ZZZZ requirements. This condition does not impose any additional requirements and for simplification it is recommended that this condition be removed.


c. If the engine and control device is not installed, configured, operated, and maintained according to the manufacturer's emission-related written instructions, or emission-related settings are changed in a way that is not permitted by the manufacturer, the permittee must keep a maintenance plan and records of conducted maintenance and must, to the extent practicable, maintain and operate the engine in a manner consistent with good air pollution control practice for minimizing emissions. In addition, conduct an initial performance test, according to 40 CFR 60.4212, to demonstrate compliance with the applicable emission standards within 1 year of startup, or within 1 year after an engine and control device is no longer installed, configured, operated, and maintained in accordance with the manufacturer's emission-related written instructions, or within 1 year after the emission-related settings are changed in a way that is not permitted by the manufacturer. [40 CFR 60.4211(g)(2)]

d. If the stationary CI internal combustion engine equipped with a diesel particulate filter to comply with the emission standards in §60.4204, the diesel particulate filter must be installed with a backpressure monitor that notifies the owner or operator when the high backpressure limit of the engine is approached. [40 CFR 60.4209(b)]

2. Emission Limitations: a. Owners and operators must comply with the emission standards for new CI engines in 40

CFR 60.4201. The engine must be certified to meet the certification emission standards for new nonroad CI engines in 40 CFR 89.112, 40 CFR 89.113, 40 CFR 1039.101, 40 CFR 1039.102, 40 CFR 1039.104, 40 CFR 1039.105, 40 CFR 1039.107, and 40 CFR 1039.115, as applicable, for all pollutants, for the same model year and maximum engine power. [40 CFR 60.4204(b)]

Compliance Demonstration Method: The permittee must comply by purchasing an engine certified to the emission standards in 40 CFR60.4204(b), as applicable, for the same model year and maximum (or in the case of fire pumps, NFPA nameplate) engine power. The engine must be installed and configured according to the manufacturer's emission-related specifications, except as permitted in 40 CFR 60.4211(g). [40 CFR 60.4211(c)]

b. The permittee must operate and maintain stationary CI ICE that achieve the emission

standards as required in 40 CFR 60.4204 over the entire life of the engine. [40 CFR 60.4206]


Not applicable


5. Specific Recordkeeping Requirements: If the stationary CI internal combustion engine is equipped with a diesel particulate filter, the owner or operator must keep records of any corrective action taken after the backpressure monitor has notified the owner or operator that the high backpressure limit of the engine is approached. [40 CFR 60.4214(c)]

6. Specific Reporting Requirements: See Section F - Monitoring, Recordkeeping, and Reporting Requirements for further requirements.


ENGINES: EN02 – Stationary Emergency-Use CI Engines (NSPS Applicable)


34-0611 Mine Escape Shaft Emergency Generator; Kohler, Model 125RE0ZJB, 166 bhp

2006

APPLICABLE REGULATIONS: 401 KAR 60:005, Section 2(2)(dddd) 40 C.F.R. 60.4200 to 60.4219, Tables 1 to 8 (Subpart IIII), Standards of Performance for Stationary Compression Ignition Internal Combustion Engines 401 KAR 63:002, Section 2(4)(eeee) 40 C.F.R. 63.6580 to 63.6675, Tables 1a to 8, and Appendix A (Subpart ZZZZ), National Emission Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines Note: D.C. Circuit Court [Delaware v. EPA, 785 F. 3d 1 (D.C. Cir. 2015)] has vacated the provisions in 40 CFR 60, Subpart IIII that contain the 100-hour exemption for operation of emergency engines for purposes of emergency demand response under 40 CFR 60.4211(f)(2)(ii)-(iii). The D.C. Circuit Court issued the mandate for the vacatur on May 4, 2016. 1. Operating Limitations:

a. Beginning October 1, 2010, owners and operators of stationary CI ICE subject to 40 CFR 60, Subpart IIII, with a displacement of less than 30 liters per cylinder that use diesel fuel must use diesel fuel that meets the requirements of 40 CFR 80.510(b) for non-road diesel fuel, except that any existing diesel fuel purchased (or otherwise obtained) prior to October 1, 2010, may be used until depleted. [40 CFR 60.4207(b)]

b. The owner or operator and must operate and maintain the stationary CI internal combustion

engine and control device according to the manufacturer's emission-related written instructions. [40 CFR 60.4211(a)(1)]

c. The emergency stationary ICE must be operated according to the requirements in

paragraphs (f)(1) through (3) of this section. In order for the engine to be considered an emergency stationary ICE under 40 CFR 60, Subpart IIII, any operation other than emergency operation, maintenance and testing, emergency demand response, and operation in nonemergency situations for 50 hours per year, as described in paragraphs (f)(1) through (3) of this section, is prohibited. If the engine is not operated according to the requirements in paragraphs (f)(1) through (3) of this section, the engine will not be considered an emergency engine under 40 CFR 60, Subpart IIII and must meet all requirements for non-emergency engines. [40 CFR 60.4211(f)] 1) There is no time limit on the use of emergency stationary ICE in emergency situations. 2) The permittee may operate the emergency stationary ICE for any combination of the

purposes specified in paragraphs (f)(2)(i) through (iii) of this section for a maximum

Commented [A19]: When KDAQ added the new pony motor engines to the permit as part of R2, the emission unit numbers used were inconsistent with what was in the application. Since KDAQ used IDs 34-06 and 34-07 for the Kiln #1 and #2 Pony Motor engines, the EU numbers for the Mine Escape Shaft Generator and BMS Generator should be revised to 34-11 and 34-12, respectively.


of 100 hours per calendar year. Any operation for non-emergency situations as allowed by paragraph (f)(3) of this section counts as part of the 100 hours per calendar year allowed by this paragraph (f)(2). i. Emergency stationary ICE may be operated for maintenance checks and readiness

testing, provided that the tests are recommended by federal, state or local government, the manufacturer, the vendor, the regional transmission organization or equivalent balancing authority and transmission operator, or the insurance company associated with the engine. The owner or operator may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not required if the owner or operator maintains records indicating that federal, state, or local standards require maintenance and testing of emergency ICE beyond 100 hours per calendar year.

3) Emergency stationary ICE may be operated for up to 50 hours per calendar year in non-emergency situations. The 50 hours of operation in non-emergency situations are counted as part of the 100 hours per calendar year for maintenance and testing and emergency demand response provided in paragraph (f)(2) of this section. Except as provided in paragraph (f)(3)(i) of this section, the 50 hours per calendar year for nonemergency situations cannot be used for peak shaving or non-emergency demand response, or to generate income for a facility to an electric grid or otherwise supply power as part of a financial arrangement with another entity. i. The 50 hours per year for nonemergency situations can be used to supply power as

part of a financial arrangement with another entity if all of the following conditions are met: A. The engine is dispatched by the local balancing authority or local transmission

and distribution system operator; B. The dispatch is intended to mitigate local transmission and/or distribution

limitations so as to avert potential voltage collapse or line overloads that could lead to the interruption of power supply in a local area or region.

C. The dispatch follows reliability, emergency operation or similar protocols that follow specific NERC, regional, state, public utility commission or local standards or guidelines.

D. The power is provided only to the facility itself or to support the local transmission and distribution system.

E. The owner or operator identifies and records the entity that dispatches the engine and the specific NERC, regional, state, public utility commission or local standards or guidelines that are being followed for dispatching the engine. The local balancing authority or local transmission and distribution system operator may keep these records on behalf of the engine owner or operator.


Nitrogen oxide emissions shall not exceed 6.9 g/HP-hr as measured by a performance test conducted in accordance with 40 CFR 60.4212. [40 CFR 60.4205(a), Table 1]

3. Testing Requirements: Conduct an initial performance test according to 40 CFR 60.4212(a)-(e) to demonstrate compliance with the NOX emission standards. [40 CFR 60.4211(b)(5)]


4. Specific Monitoring Requirements: a. Install a non-resettable hour meter prior to startup of the engine. [40 CFR 60.4209(a)]. b. Monitor the amount of fuel used for the engine on a monthly basis. [401 KAR 52:020,

Section 10]

5. Specific Recordkeeping Requirements: Maintain records of the amount of fuel used for the engine on a monthly basis. [401 KAR 52:020, Section 10]

6. Specific Reporting Requirements: a. If the emergency stationary CI ICE operates or is contractually obligated to be available

for more than 15 hours per calendar year for the purposes specified in 40 CFR 60.4211(f)(2)(ii) and (iii) or that operates for the purposes specified in 40 CFR 60.4211(f)(3)(i), the permittee must submit an annual report according to the requirements in paragraphs (d)(1) through (3) of this section. [40 CFR 60.4214(d)] 1) The report must contain the following information:

i. Company name and address where the engine is located. ii. Date of the report and beginning and ending dates of the reporting period. iii. Engine site rating and model year. iv. Latitude and longitude of the engine in decimal degrees reported to the fifth decimal

place. v. Hours operated for the purposes specified in 40 CFR 60.4211(f)(2)(ii) and (iii),

including the date, start time, and end time for engine operation for the purposes specified in 40 CFR 60.4211(f)(2)(ii) and (iii).

vi. Number of hours the engine is contractually obligated to be available for the purposes specified in 40 CFR 60.4211(f)(2)(ii) and (iii).

vii. Hours spent for operation for the purposes specified in 40 CFR 60.4211(f)(3)(i), including the date, start time, and end time for engine operation for the purposes specified in 40 CFR 60.4211(f)(3)(i). The report must also identify the entity that dispatched the engine and the situation that necessitated the dispatch of the engine.

2) The first annual report must cover the calendar year 2015 and must be submitted no later than March 31, 2016. Subsequent annual reports for each calendar year must be submitted no later than March 31 of the following calendar year.

3) The annual report must be submitted electronically using the 40 CFR 60, Subpart IIII specific reporting form in the Compliance and Emissions Data Reporting Interface (CEDRI) that is accessed through EPA’s Central Data Exchange (CDX) (www.epa.gov/cdx). However, if the reporting form specific to 40 CFR 60, Subpart IIII is not available in CEDRI at the time that the report is due, the written report must be submitted to the Administrator at the appropriate address listed in 40 CFR 60.4.

b. See Section F - Monitoring, Recordkeeping, and Reporting Requirements.


ENGINE: EN03 –Stationary Emergency-Use SI Engines (NSPS Applicable)


34-0712 Kiln BMS Emergency Generator; Kohler Model 20RESC, 27.1 bhp 2017

APPLICABLE REGULATIONS: 401 KAR 60:005, Section 2(2)(dddd) 40 C.F.R. 60.4200 to 60.4219, Tables 1 to 8 (Subpart IIII), Standards of Performance for Stationary Compression Ignition Internal Combustion Engines 401 KAR 60:005, Section 2(2)(eeee) 40 C.F.R. 60.4230 to 60.4248, Tables 1 to 4 (Subpart JJJJ), Standards of Performance for Stationary Spark Ignition Internal Combustion Engines 401 KAR 63:002, Section 2(4)(eeee) 40 C.F.R. 63.6580 to 63.6675, Tables 1a to 8, and Appendix A (Subpart ZZZZ), National Emission Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines Note: D.C. Circuit Court [Delaware v. EPA, 785 F. 3d 1 (D.C. Cir. 2015)] has vacated the provisions in 40 CFR 40 CFR 60, Subpart JJJJ that contain the 100-hour exemption for operation of emergency engines for purposes of emergency demand response under 40 CFR 60.4243(d)(2)(ii)-(iii)]. The D.C. Circuit Court issued the mandate for the vacatur on May 4, 2016. 1. Operating Limitations:

a. For engines built on or after July 1, 2008, the permittee must install a non-resettable hour meter prior to startup of the engine. [40 CFR 6360.4237(c)]

b. The permittee must operate the emergency stationary ICE according to the requirements in 40 CFR 60.4243(d)(1) through (3). In order for the engine to be considered an emergency stationary ICE under this subpart, any operation other than emergency operation, maintenance and testing, emergency demand response, and operation in non-emergency situations for 50 hours per year, as described in 40 CFR 60.4243(d)(1) through (3), is prohibited. If you do not operate the engine according to the requirements in 40 CFR 60.4243(d)(1) through (3), the engine will not be considered an emergency engine under this subpart and must meet all requirements for non-emergency engines. [40 CFR 6360.4243(d)] 1) There is no time limit on the use of emergency stationary ICE in emergency situations.

2) The permittee may operate your emergency stationary ICE for any combination of the purposes specified in 40 CFR 6360.4243(d)(2)(i) through (iii) for a maximum of 100 hours per calendar year. Any operation for non-emergency situations as allowed by in 40 CFR 6360.4243 (d)(3) counts as part of the 100 hours per calendar year allowed by this in 40 CFR 6360.4243(d)(2).

i) Emergency stationary ICE may be operated for maintenance checks and readiness

Commented [A20]: When KDAQ added the new pony motor engines to the permit as part of R2, the emission unit numbers used were inconsistent with what was in the application. Since KDAQ used IDs 34-06 and 34-07 for the Kiln #1 and #2 Pony Motor engines, the EU numbers for the Mine Escape Shaft Generator and BMS Generator should be revised to 34-11 and 34-12, respectively.


testing, provided that the tests are recommended by federal, state or local government, the manufacturer, the vendor, the regional transmission organization or equivalent balancing authority and transmission operator, or the insurance company associated with the engine. The owner or operator may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not required if the owner or operator maintains records indicating that federal, state, or local standards require maintenance and testing of emergency ICE beyond 100 hours per calendar year.

3) Emergency stationary ICE may be operated for up to 50 hours per calendar year in non-emergency situations. The 50 hours of operation in non-emergency situations are counted as part of the 100 hours per calendar year for maintenance and testing and emergency demand response provided in 40 CFR 6360.4243(d)(2). Except as provided in 40 CFR 6360.4243(d)(3)(i), the 50 hours per year for non-emergency situations cannot be used for peak shaving or non-emergency demand response, or to generate income for a facility to an electric grid or otherwise supply power as part of a financial arrangement with another entity.

i) The 50 hours per year for non-emergency situations can be used to supply power as part of a financial arrangement with another entity if all of the following conditions are met:

A) The engine is dispatched by the local balancing authority or local transmission and distribution system operator;

B) The dispatch is intended to mitigate local transmission and/or distribution limitations so as to avert potential voltage collapse or line overloads that could lead to the interruption of power supply in a local area or region.

C) The dispatch follows reliability, emergency operation or similar protocols that follow specific NERC, regional, state, public utility commission or local standards or guidelines.

D) The power is provided only to the facility itself or to support the local transmission and distribution system.

E) The owner or operator identifies and records the entity that dispatches the engine and the specific NERC, regional, state, public utility commission or local standards or guidelines that are being followed for dispatching the engine. The local balancing authority or local transmission and distribution system operator may keep these records on behalf of the engine owner or operator.

c. The permittee may operate the engines using propane for a maximum of 100 hours per year

as an alternative fuel solely during emergency operations, but must keep records of such use. If propane is used for more than 100 hours per year in an engine that is not certified to the emission standards when using propane, the owners and operators are required to conduct a performance test to demonstrate compliance with the emission standards of 40 CFR 60.4233. [40 CFR 60.4243 (e)]


a. The permittee shall comply with the applicable emission standards in Table 1 of 40 CFR 60, Subpart JJJJ. [40 CFR 60.4233(d), Table 1]


Emission Standards NOx +HC CO g/HP-hr 10 387

b. The permittee must operate and maintain stationary SI ICE that achieve the emission

standards as required in 40 CFR 60.4233 over the entire life of the engine. [40 CFR 60.4234] Compliance Demonstration Method: 1. The engines purchased must be certified to the emission standards in Table 1 of 40 CFR

60, Subpart JJJJ for the same engine class, maximum engine power, the same model year and demonstrating compliance according to one of the methods specified in 40 CFR 60.4243 (a). [40 CFR 60.4243(b)(1)]

2. The permittee must operate and maintain the certified stationary SI internal combustion engine and control device according to the manufacturer's emission-related written instructions, the permittee must keep records of conducted maintenance to demonstrate compliance, but no performance testing is required if you are an owner or operator. The permittee must also meet the requirements as specified in 40 CFR part 1068, subparts A through D, as they apply. If the permittee adjusts engine settings according to and consistent with the manufacturer's instructions, the stationary SI internal combustion engine will not be considered out of compliance. [40 CFR 60.4243 (a)(1)]

3. Testing Requirements: Testing shall be conducted at such times as may be required by the Cabinet in accordance with 401 KAR 50:045

4. Specific Monitoring Requirements: The permittee shall monitor hours of operation for each unit on a monthly basis. [40 CFR 6360.4245(b)]

5. Specific Recordkeeping Requirements: a. The permittee must keep records of the information in 40 CFR 60.4245(a)(1) through (4) .

[40 CFR 60.4245 (a)] 1) All notifications submitted to comply with 40 CFR, Subpart JJJJ and all documentation

supporting any notification. 2) Maintenance conducted on the engine. 3) If the stationary SI internal combustion engine is a certified engine, documentation

from the manufacturer that the engine is certified to meet the emission standards and information as required in 40 CFR parts 90, 1048, 1054, and 1060, as applicable.

4) If the stationary SI internal combustion engine is not a certified engine or is a certified engine operating in a non-certified manner and subject to 40 CFR 60.4243(a)(2), documentation that the engine meets the emission standards.

b. The permittee must keep records of the hours of operation of the engine that is recorded

through the non-resettable hour meter. The permittee must document how many hours are


spent for emergency operation, including what classified the operation as emergency and how many hours are spent for non-emergency operation. [40 CFR 60.4245 (b)]

c. The permittee shall maintain records of the hours of operation each engine uses propane as

an alternative fuel during emergency situations. [40 CFR 60.4243 (e)]

6. Specific Reporting Requirements: See Section F - Monitoring, Recordkeeping, and Reporting Requirements.

Permit Number: V-14-002 R6 Page: 113 of 124 SECTION C - INSIGNIFICANT ACTIVITIES

The following listed activities have been determined to be insignificant activities for this source pursuant to 401 KAR 52:020, Section 6. Although these activities are designated as insignificant the permittee must comply with the applicable regulation. Process and emission control equipment at each insignificant activity subject to an opacity standard shall be inspected monthly and a qualitative visible emissions evaluation made. Results of the inspection, evaluation, and any corrective action shall be recorded in a log.

Description Generally Applicable Regulation

Fuel Oil Storage Tanks: 3 tanks, 25 gallons each, 2 tanks, 40 gallons each, 1 tank, 139 gallons

None