## Iowa Department of Natural Resources Title V Operating Permit

Name of Permitted Facility: Lafarge North America Inc. Facility Location: 30 1 East Front Street Buffalo, IA 52728 Air Quality Operating Permit Number: 04-TV-007-M001 Expiration Date: March 28, 2009

EIQ Number: 92-3093 Facility File Number: 82-04-005

________________________________________________________________________

Responsible Official

Name: Alain Pfaff Title: Plant Manager Mailing Address: P.O. Box 690 Buffalo, IA 52728 Phone #: (563) 328-6201

Permit Contact Person for the Facility

Name: Scott Nielson Title: Environmental Manager Mailing Address: P.O. Box 690 Buffalo, IA 52728 Phone #: (563) 328-6206

________________________________________________________________________

This permit is issued in accordance with 567 Iowa Administrative Code Chapter 22, and is issued subject to the terms and conditi ons contained in this permit.

For the Director of the Department of Natural Resources

________________________________________________________________________

Douglas A. Campbell, Supervisor of Air Operating Permits Section Date

## Table of Contents

I. Facility Descri ption and Equipment List

....................................................................... 4

II. Plant - Wide Conditions

................................................................................................ 10

III. Emission Point Specific Conditions

.............................................................................. 14

IV. General Condition s

........................................................................................................ 65 G1. Duty to Com p ly

G2. Per m it Expiration G3. Certification Requirem e nt f o r Title V Rela te d Docum e nts
G4. Annual Com p liance Certification

G5. Se m i -Annual Monitoring Report

G6. Annual Fee G7. Inspection of Pre m ises, Records, Equipm ent, Methods and Discharges G8. Duty to Provide Inform ation G9. General Maintenance and Repair Duties G10. Recordkeeping Requirem ents for Com p liance Monitoring

G11. Evidence used in es tablishing that a violatio n has or is occurring.

G12. Prevention of Accidental Release: Ri sk Managem e nt Plan Notification and Compliance Certification

G13. Hazardous Release

G14. Excess Em issions and Excess Em issions Reporting Requirem ents
G15. Per m it Deviation R e porting Requirem e nts G16. Notification Requirem e nts for Sources That Becom e Sub j ect to NSPS and NESHAP Regulations G17. Requirem e nts for Making Changes to Em i ssion Sources That Do Not Require T itle

V Perm it Modification G18. Duty to Modify a Title V Perm it G19. Duty to Obtain Construction P e rm its

G20. Asbestos

G21. Open Burning G22. Acid Rain (Title IV) Em issions Allowances G23. Stratospheric Ozone and Clim at e Protection (Title VI) R e quirem e nts
G24. Per m it Reopenings

G25. Per m it Shield

G26. Severability G27. Property Rights

G28. Transferability

G29. Disclaim er G30. Notification and Reporting Requirem ents for Stack Tests or Monitor Certification G31. Prevention of Air Pollution Emergency Episodes

G32. Contacts List

V. Appen d i x A...Administrati ve Consent Order No. 98-AQ-08

.................................... 78

Title V Perm it 03 / 29 /04 2VI. Appendix B...Operation & Maintenance Plans

............................................................ 105

VII. Appendix C...Applicable Limits a nd Requirements From 40 CFR 63 § LLL

........... 135

VIII. Appendix D...IDNR Air Quality Policy 3b08 (Opacity)

.............................................. 149



### Abbreviations

acfm

........................... actual cubic feet per m i nute
CFR

........................... Code of Federal Regulation dscf......................dry standard cubic feet

dscm .....................dry standard cubic m e ters

o F

............................... degrees Fahrenheit EIQ

............................ em issions inventory questionnaire gr./dscf

....................... grains per dr y standard cubic foot gr./100 cf

................... grains per one hundred cubic feet hp./hr.....................horsepower hours

IAC

............................ Iowa Adm i nistrative Code

IDNR

......................... Iowa Departm e nt of Natural Resources KWH....................kilowatts per hour

MVAC

....................... motor vehicle air conditioner N/A.............................not applicable ng./dscm .................nanogram per dry standard cubic m e ter
NSPS

......................... new source perform a nce standard

ppm v

.......................... parts per m illion by volu m e lb./hr

.......................... pounds per hour

lb./MMBtu

................. pounds per m illion British therm a l units

MMcf./hr... ..............m illion cubic feet per ho ur scfm

........................... standard cubic feet per minute TEQ.....................toxicity equivalents

TPY

........................... tons per year TPH......................tons per hour

USEPA

...................... United States Environm ental Protection Agency

VMT/hr.................vehicle m iles traveled per hour

Pollutants

PM

............................. particulate m a tter

PM 10

.......................... particulate m a tter ten micr ons or less in diam eter
SO 2

............................ sulfur dioxide

NO

x ............................ nitrogen oxides

VOC

.......................... volatile organic com pound

CO

............................. carbon m o noxide

HAP

........................... hazardous air pollu tant
D/F.......................dioxins and f u rans

3 Title V Perm it 1 0 / 2 6 / 0 44 Title V Permit 10/26/04 

## I. Facility Description and Equipment List

Facility Name: Lafarge North America, Inc.

Permit Number: 04-TV-007-M001 Facility Description: Portland Cement Plant

________________________________________________________________________ Equipment List

_______________________________________________________________________

A. Fugitives Subject to Fu gitive Dust Rule Only

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

0040-0-F 0040-3-F Raw Materials Screening

0070-0-F 0070-1-F Raw Materials Loading in Quarry

0081-0-F 0081-1-F Quarry Drilling

0110-1-F Raw Materials Storage Pile 0110-0-F 0110-2-F Storage Pile Load In/Out

0120-1-F Raw Materials Storage Pile 0120-0-F 0120-2-F Storage Pile Load In/Out

0130-1-F Raw Materials Storage Pile 0130-0-F 0130-2-F Storage Pile Load In/Out

0200-1-F Front End Loader Filling Clay Hopper

0200-2-F Front End Loader Filling Stone Hopper

0200-3-F Raw Material Tran sfer to Apron Feeder

0200-4-F Dump Hopper to Apron Feeder

0200-5-F Apron Feeder Transfer to Primary Crusher

0200-6-F 0225 Crusher Transfer to 0221

0200-7-F 0221 Belt Transfer to 0208 0200-0-F

0200-8-F 0225 Primary Crusher Fugitives

0203-0-F 0203-1-F Raw Material Tr ansfer-Conveyor to Conveyor5 Title V Permit 03 / 29/04 A. Fugitives Subject to Fugitive Dust Rule Only (cont.)

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

0300-1-F Raw Material Transfer-Conveyor to Conveyor

0300-2-F Raw Material Transfer-Conveyor to Conveyor

0300-3-F Raw Material Transfer-Conveyor to Pile 0300-0-F

0300-4-F Raw Material Transfer-Pile to Conveyor

0387-0-F 0387-1-F Raw Material Tr ansfer-Conveyor Over Road

0684-0-F 0684-1-F Conveyor Transfer to Coal Silo

B. Fugitives Subject to 40 CFR 63 Subpart LLL

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

0400-0-F 0400-1-F Raw Material Transf er – Weigh Feeder to Conveyor

0487-0-F 0487-1-F 0487 Slide Gate Truck Loading

0488-0-F 0488-1-F 0488 Manual Flop Gate Truck Loading

0576-0-F 0576-1-F 0576 Manual Flop Gate-Truck Loading

0718-0-F 0718-1-F Clinker Bin Load Out-Truck Loading

0766-0-F 0766-1-F 0766 Feeder Transfer to 0722 Belt Conveyor

0800-1-F Finish Mill Building Fugitives – Interior DC 0800-0-F 0889-1-F Belt Conveyor to Belt Conveyor Transfer – Interior DC

0906-0-F 0906-1-F Belt Conveyor to Belt Conveyor Transfer – Interior DC

0926-0-F 0926-1-F Belt Conveyor to Belt Conveyor Transfer – Interior DC

1300-1-F Rail Loading Fugitives 1300-0-F 1300-2-F Truck Loading Fugitives

2601-0-F 2601-1-F Barge Loading System (Fugitives)Title V Permit 03 / 29/04 6 C. Haulroads Subject to Administra tive Consent Order No. 98-AQ-08

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

0155-0-F 0155-1-F Quarry Haulroad-Rock Hauling

0160-0-F 0160-1-F Quarry Haulroad-Clay Hauling

0165-0-F 0165-1-F Haulroad-Clay from Storage Piles to Crusher

0691-0-F 0691-1-F Haulroad-Rail Unloading Raw Materials

0692-0-F 0692-1-F Haulroad-Rail Unloading Clinker

0695-0-F 0695-1-F Haulroad-Rail Unloading Fuel

0765-1-F Unpaved Haulroad to 0765 Feeder
0765-0-F 0765-2-F Paved Haulroad to 0765 Feeder

1301-0-F 1301-1-F Haulroad-Truck Loadout of Cement

D. Conveying System Transfer Points\ Raw and Finish Mills\ Storage Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

0404-0 0404-1 Raw Material Transfer- Conveyor to Homogenization Silos

0420-0 0420-1 Raw Material Transfer- Airslides to Vertical Conveyor

0498-0 0498-1 Raw Material Transf er- Conveyors to Preblend Bin

0504-0 0504-1 Raw Material Transfer- Ai rslides/Separator/Bin to Kiln

0709-0 0709-1 Drag Conveying Clinker

0743-0 0743-1 Drag Conveying Clinker

0811-0 0811-1 Finish Mill Holding Bin

0817-1 Finish Mill (Particulate Emissions) 0817-0 0817-2 Finish Mill (VOC Emissions)

0822-0 0822-1 Finish Mill Air Separator

0950-0 0950-1 Barge Loading SiloTitle V Permit 03 / 29/04 7 D. Conveying System Transfer Points\ Raw and Finish Mills\ Storage Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL (cont.)

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

1007-0 1007-1 A.E. Silos # 15-30

1017-0 1017-1 Conebottom Silos # 31-40

1041-0 1041-1 Rail Car Loading System- Silo # 41

1044-0 North Truck Loading Spout

1440-03 Airslide Conveyor 1044-0

1442-05 Airslide Conveyor

1045-0 1045-1 South Bulk Truck Loadout System

1047-0 1047-1 Rail Car Loading System- Silos # 47 & 48

1053-0 1053-1 West Overtrack Silos

2601-0 2601-1 Barge Loading Spout System

E. Miscellaneous Sources

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

0020-0 0020-1 Emergency Generator

0030-0 0030-1 Diesel Water Pump

0081-0 0081-1 Quarry Drill

0203-0 0203-1 Raw Material Transfer-Conveyor to Conveyor

0218-0 0218-1 Primary Crusher a nd Conveyor Belt Transfer

0327-0-F 0327-1-F Raw Material Transfer - Vibrating Feeder to Conveyor

0466-1 Preheater/Precalciner/Kiln/Raw Mill System 0466-0 0466-2 Alkali Bypass

0499-0 0499-1-F 20,000 gallon Fuel Oil Tank

0535-0 0535-1 CKD Handling Silo

0611-0 0611-1 Clinker Cooler and Drag ConveyorTitle V Permit 03 / 29/04 8 E. Miscellaneous Sources (cont.)

Emission

Point

Number Associated

Emission Unit

Number Associated Emission Unit Description

0667-1 Coal Mill and Bins 0667-0 0667-1 Coal Mill and Bins

0684-0 0684-1 Coal Silo

0690-0-F 0690-3-F Coal Hopper/We igh Feeder-Load In/Out

0723-0-F 0723-1-F Clinker Reclaim Vibrating Feeders

Insignificant Equipment List

Insignificant Emission

Unit Number Insignificant Emission Unit Description

I-1 2,000 Gallon Waste Motor Oil Storage Tank

I-2 5,524 Gallon #2 Fuel Oil Storage Tank

I-3 10,000 Gallon Grinding Aid Storage Tank (maximum vapor pr essure 0.00003psia)

I-4 10,000 Gallon Grinding Aid Storage Tank (maximum vapor pr essure 0.00003psia)

I-5 Maintenance Welding

I-6 Maintenance Chute-Preheater Tower

I-7 Maintenance Chute-Clinker Cooler

I-8 Maintenance Chute-Coal Mill

I-9 Maintenance Chute-Raw Mill

I-10 Hot Water Heater (0.095 MMBtu/hr)

I-11 Hot Water Heater ( 30 psi boiler 1.2 MMBtu/hr)

I-12 Parts Washer-44 Gallon Cap.

I-13 Parts Washer-44 Gallon Cap.

0040-1-F Raw Materials Storage Pile

0040-2-F Raw Materials Storage Pile Load In/Out

0040-4-F Load Out of Screened Material

0060-1-F Overburden Removal

0082-1-F Quarry Blasting

0204-1-F Road Stone/Mason Stone Stockpile

0204-2-F Road Stone/Mason Stone Stockpile-Load In/Out

0207-1-F Raw Material Transfer-Flop Gate

0538-1-F CKD Load Out

0538-2-F Haulroad-CKD to Landfill

0538-3-F CKD Landfill Load Out

0576-1-F 0576 Manual Slide Gate Load Out

0655-1-F Barge Load In/Out (Coal)

0655-2-F Haulroad - Barge to Coal StockpileTitle V Permit 03 / 29/04 9 Insignificant Equipment List (cont.)

Insignificant Emission

Unit Number Insignificant Emission Unit Description

0677-1-F 0677 Manual Flop Gate-Truck Loading

0690-1-F Coal Transfer-Conveyor to Conveyor

0690-2-F Coal/Raw Material/Clinker Piles Wind Erosion

0690-4-F Coal Stockpile Load In/Out

0696-1-F Raw Materials Stockpile – Wind Erosion

0696-2-F Raw Material Stockpile-Load In/Out

0697-1-F Rail Unloading-Fuel, Raw Materials

0697-2-F Rail Unloading-Clinker

0760-1-F Stockpiles (North of Silo)-Wind Erosion

0760-2-F Clinker Stockpile-Load In/Out

0760-3-F Raw Material Stockpile-Load In/Out

0761-1-F Unloading Gypsum Into Gypsum Hopper

0761-2-F Unloading Clinker Into Gypsum Hopper

0770-1-F Storage Hall St ockpile-Wind Erosion

0770-2-F Stockpile-Load In/Out Clinker

0770-3-F Stockpile-Load In/Out Raw Materials

## II. Plant-Wide Conditions

Facility Nam e : Lafarge North Am erica In c. Perm it Number: 04-TV-007-M001

Perm it conditions are established in accord w ith 567 Iowa Adm i nist rative Code rule 22.108

______________________________________________________________________________

Permit Duration

The term of this pe rm it is: Five (5 ) y ears Comm encing on: March 29, 2004 Ending on: March 28, 2009

Am endm ent s , m odi fications and reop enings of th e perm it shall be ob tained in acco rda n ce with 56 7

Iowa Adm i nistrative Code rules 22.110 - 22.114. Perm its may be suspended, term inated, or revoked as specified in 567 Iowa Adm i nistrative Code Rules 22.115.

____________________________________________________________________________

Emission Limits Unless specified otherwise in the Source Spe cific Conditions, the fo llowing limitations and supporting regulations apply to a ll emission points at this plant:

Opacity (v is ible em issio n s): 40% opacity Authority for Requirem e nt: 567 IAC 23.3(2)"d"

Sulfur Dioxide (SO 2 ): 500 parts per m illion by volum e Authority for Requirem e nt: 567 IAC 23.3(3)"e"

Particulate Matter (s tate enforceable only) 1 : No person shall cause or allow the em ission of part iculate m a tter from a ny source in excess of the

em ission standards specified in this chapter, exce pt as provided in 567 – Chapter 24. For sources constructed, modified or recons tructed after July 21, 1999, the em i ssion of particulate m a tter from any process shall not exceed an em ission standard of 0.1 grain per dry standard cubic foot of exhaust gas, except as provided in 567 – 21.2(455B), 23.1(455B), 23.4(455B) and 567 – Chapter

24. For sources constructed, modifi ed or reconstructed prior to July 21, 1999, the em ission of particulate m a tter from any pro cess shall not exceed the am ount determ ined from Table I, or

am ount specified in a perm it if based on an em ission standard of 0.1 grain per standard cubic foot of exhaust gas or established from standa rds provided in 23.1(455B) and 23.4(455B). Authority for Requirem e nt: 567 IAC 23.3(2)"a" (as revised 7/21/1999)

1 Th is is t h e cu rren t lang u a g e in th e Iowa Ad min i strativ e Code (IAC). Th is version o f th e rule is awaitin g EPA approval t o be com e part of Iowa' s Stat e Im ple m entation Pla n (SIP). Whe n EPA approves this rule, it will re place the

o l d e r v e rsi o n an d will b e con s id ered fed e rally en fo rceab l e.

10 Title V Perm it 1 0 / 2 6 / 0 411 Title V Permit 03 / 29/04 Particulate Matter (federally enforceable) 2 : The emission of particulate matter from any proce ss shall not exceed the amount determined from Table I, except as provided in 567 — 21.2( 455B), 23.1(455B), 23.4(455B) and 567 — Chapter 24.

If the director determines that a process complying with the emissi on rates specified in Table I is causing or will cause air pollution in a specific area of the state, an emission standard of 0.1 grain per standard cubic foot of exhaust gas may be imposed.

Authority for Requirement: 567 IAC 23.3(2)"a" (prior to 7/21/1999)

Fugitive Dust: Attainment and Unclassified Areas - No person shall allow, cause or permit any materials to be handled, transporte d or stored; or a building, its appur tenances or a construction haul road to be used, constructed, altered repaired or demolished, with the exception of farming operations or dust generated by ordinary travel on unpaved public roads, without taking reasonable precautions to prevent particulate matter in quantitie s sufficient to create a nuisance, as defined in Iowa Code section 657.1, from becoming airborne. All persons, with the above exceptions, shall take reasonable precautions to prevent the discha rge of visible emissions of fugitive dusts beyond the lot line of the property on which the emissions originate. The highway authority shall be responsible for taking corrective action in those cases where said authority has received complaints of or has actual knowledge of dust conditions which require abatement pursuant to this subrule. Reasonable precautions may include, but not limited to, the following procedures.

1. Use, where practical, of water or chemicals for control of dusts in the demolition of existing buildings or structur es, construction operations, th e grading of roads or the clearing of land.

2. Application of suitable materi als, such as but not limited to asphalt, oil, water or chemicals on unpaved roads, material stockpile s, race tracks and other surfaces which can give rise to airborne dusts.

3. Installation and use of containment or contro l equipment, to enclose or otherwise limit the emissions resulting from the handling and tran sfer of dusty materials, such as but not limited to grain, fertilizers or limestone.

4. Covering at all times when in motion, open-bodi ed vehicles transporting materials likely to give rise to airborne dusts.

5. Prompt removal of earth or other material fr om paved streets or to which earth or other material has been transported by trucking or earth-moving equipment, erosion by water or

other means. Authority for Requirement: 567 IAC 23.3(2)"c"

__________________________________________________________________________ Compliance Plan The owner/operator shall comply with the applicabl e requirements listed below. The compliance status is based on information provided by the applicant.

Unless otherwise noted in Section III of this permit, Lafarge North America Inc. is in compliance with all applicable requirements and shall continue to comply with all such requirements. For those applicable requirements which become effectiv e during the permit term, Lafarge North America Inc. shall comply with such re quirements in a timely manner. Authority for Requirement: 567 IAC 22.108(15)

2 This is the current language in the Iowa SIP, and is enforceable by EPA.Title V Permit 03 / 29/04 12 Operational Limits & Requirements The owner/operator of this facil ity shall comply with the opera tional limits and requirements listed

below.

Terms and Conditions: The Permittee shall comp ly with all applicable requirements of Iowa Department of Natural Resources Admi nistrative Consent Order No. 98-AQ-08 . The Permittee shall also comply with all applicable re quirements of 40 CFR 63 Subpart LLL- National Emission Standards for Hazardous Air Pollu tants for Source Categories; Po rtland Cement Manufacturing Industry, and the applicable requirements of 40 CFR 63 Subpart A General Provisions as listed in Table 1 of 40 CFR 63 Subpart LLL. Per 40 CF R 63.1356 any affected source subject to the provisions of 40 CFR 63 Subpart LLL will be exem pt from any otherwise applicable new source performance standard contained in 40 CFR 60 S ubpart F or Subpart OOO, and the requirements of 40 CFR 63 Subpart Y do not apply to conveying syst em transfer points used to convey coal from

the mill to the kiln that are asso ciated with coal preparation.

Applicable Limits and Requirements From Iowa Department of Natural Resources Administrative Consent Order No. 98-AQ-08

Haul Road Fugitive Dust Plan

(a) Control of dust on frequently traveled pave d and unpaved roads with in the facility and quarry shall be performed in accordance with Plan A, Plan C, or Plan D, as specified in Exhibit "B" of Appendix A, Iowa Departme nt of Natural Resources Administrative Consent Order No. 98-AQ-08. For purposes of Plans A and D contained in Exhibit "B", an operating day is a 24-hour period beginning at 6 am. Lafarge may change the definition of operating day for the purposes of the consent order by submitting advance notice of the change to DNR in writing. Sweeping or watering need not occur when a rain gauge located at the site indicates that at least 0.2 inch per day of precipitation (water equivalent) has occurred. Lafarge shall conduct its fugitive dust maintenance program according to the specifications in E xhibit "B" which is recognized as providing a 95 percent control efficiency. Lafarge sh all maintain a daily log of the following: (1) the date and time (2) the specific watering plan used (3) the volume of water or other dust suppressant applied (if applicable to the plan being utilized), and the areas of application, and (4) the distance traveled (if applicable to the plan utilized).

Or (5a) the amount and t ype of precipitation, if the daily pr ecipitation is greater than 0.2 inches. (The calculations listed on page 8 of Exhibit "B", Appendix A indicate that additional watering beyond 0.2 inches of precipitation will not be needed to achieve 95 percent control). (5b) if the ambient temperature during the day is less than 35 o F, or conditions due to

weather in combination w ith the application of wate r or dust suppressant would create dangerous conditions, then the f ugitive dust plan will be postponed for that operating day and the temp erature recorded in a log. (5c) records to demonstrate that the source will not be in operation during the operating day, such that fugitive dust cont rols will not be required (such asTitle V Permit 03 / 29/04 13 described on pages 8-9 of Exhibit "B", Appendix A).

The records shall be retained for a period of five (5) years following the date of such applications and measurements and shall be made available to the Department of Natural Resources upon request.

(b) For purposes of the annual average emission rate for PM-10, Lafarge shall follow the "Monthly Limits" listed in Exhibit "C ", Appendix A. The applicable parameters specified in Exhibit "C" shall be entered in a monthly log to demonstrate compliance with the monthly limits list. Monthly logs shall be retained for a period of five (5) years following the date of such entries and shall be made available to the Department of Natural Resources upon request.

(c) Lafarge shall continue to comply with a ll paragraphs of Iowa DOT Agreement No.

94-16-69. A copy of this agreement is provide d in Exhibit "E" of Appendix A.

(d) Lafarge shall submit to the Washington DNR Field Office written quarterly reports detailing progress toward the completion of the requirements of Consent Order No. 98-AQ-08, including compliance with all air qua lity permits issued as a result of the Consent Order. The quarterly reports sha ll be due no later than 30 days following the close of each quarter.

Authority for Requirement: Iowa Department of Natural Resources Administrative Consent Order No. 98-AQ-08

## III. Emission Point-Specific Conditions

Facility Nam e : Lafarge North Am erica, In c. Perm it Number: 04-TV-007-M001

______________________________________________________________________________



### Emission Point ID Number: See Table: Fugitives Subject to Fugitive Dust Rule Only

Associated Equipm ent

Associated Em ission Unit ID Num b ers: See Tab l e: Fugitives Subject to Fugitive Du st Rule Only

______________________________________________________________________________


### Applicable Requirements

Table: Fugitives Subject to Fugitive Dust Rule Only

Emission

Point

Number Ass o ciated

Emission Unit

Number Emissio n Unit Descriptio n Raw Materi al Ra ted C a p a cit y

0 040 -0 -F 0 040 -3 -F Raw Mater i als Scr e en ing Raw Mater i als (1) 76.0 TP H

0 070 -0

- F 0 070 -1

- F Raw Materials Lo ad ing in Qua rry Raw Materials (1) 2

, 00 0 TP H

0 081 -0 -F 0 081 -1 -F Qu arry Drilling Li m e sto n e 2

, 5 0 0 TPH

0 110 -1 -F Raw Materials Sto r ag e Pile Raw Materials (1) 0

. 5 8 a c r e 0 110 -0 -F

0 110 -2 -F Sto r ag e Pile Lo ad In /Ou t Raw Materials (1) 2 1 0 T P H

0 120 -1 -F Raw Materials Sto r ag e Pile Raw Materials (1) 0

. 4 1 a c r e 0 120 -0 -F

0 120 -2 -F Sto r ag e Pile Lo ad In /Ou t Raw Materials (1) 2 1 0 T P H

0 130 -1 -F Raw Materials Sto r ag e Pile Raw Materials (1) 0

. 5 8 a c r e

0 130 -0 -F 0 130 -2 -F Sto r ag e Pile Lo ad In /Ou t Raw Materials (1) 2 1 0 T P H

14 Title V Perm it 1 0 / 2 6 / 0 4Table: Fugitives Subject to Fugi tive Dust Rule Only (Cont.)

Emission

Point

Number Ass o ciated

Emission Unit

Number Emissio n Unit Descriptio n Raw Materi al Ra ted C a p a cit y

0 200 -1 -F Fron t End Lo ad er Fillin g Clay

H opp er C l ay 2 1 0 T P H

0 200 -2 -F Fron t End Lo ad er Fillin g Ston e H opp er Lim e st o n e 1

, 40 0 TP H

0 200 -3 -F Raw Material Transfe r to Apron

Feede r Raw Materials (1) 21 0 TPH

0200-4-F Dum p Hoppe r to Apron Feeder Raw Materials (1) 1, 40 0 TP H

0 200 -5 -F Apron Fee d er Transfe r to

Pr im ar y Cr u s her Raw Materials (1) 1, 40 0 TP H

02 0 0

- 6

- F 02 2 5 C r us her Tran sfe r t o 0 2 21 R a w M a t e ri al s (1) 1, 40 0 TP H

0 200 -7 -F 0 221 Belt Tr ansf er to 02 08 Raw Mater i als (1) 1, 40 0 TP H 0 200 -0 -F

0 200 -8 -F 0 225 Prim ary Cru s h e r Fu g itiv es Raw Materials (1) 1, 40 0 TP H

0 203 -0

- F 0 203 -1

- F Raw M a terial Tran sfe r-C on v e y o r

to Conv eyo r Raw Materials (1) 1

, 40 0 TP H

0 300 -1

- F Raw M a terial Tran sfe r-C on v e y o r

to Conv eyo r Raw Materials (1) 1, 40 0 TP H

0 300 -0

- F 0 300 -2

- F Raw M a terial Tran sfe r-C on v e y o r

to Conv eyo r Raw Materials (1) 1, 40 0 TP H

0 300 -3

- F Raw M a terial Tran sfe r-C on v e y o r

to Pile Raw Materials (1) 1, 40 0 TP H

0 300 -4

- F Raw M a terial Tran sfe r-Pile t o Co nv eyor Raw Materials (1) 30 0 TPH

0 387 -0

- F 0 387 -1

- F Raw M a terial Tran sfe r-C on v e y o r Ove r R o ad Raw Materials (1) 1, 40 0 TP H

0 684 -0 -F 0 684 -1 -F Co nv eyor Tr ansf er to C o al Silo Co al 2 0 0 TPH

(1 ) Raw m a terials refers to any one o r a m i xture o f the kiln-s tock m a terials used to produce cem ent, which are prim arily lim estone, cla y, or alternative raw m a terials such as hydrocarbon contam inated soils. Coal and other prim ary fuel sour ces are not included in this category.

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.)

The emissio n s from thes e emission p o ints sh a ll n o t exceed th e levels specified below.

Pollutan t: F ugitiv e Dust

Em ission Lim it: No person shall allow, cause or perm it any m a terials to be handled, transpo r ted or stored; or a building, its appurtenances or a c onstruction haul road to be used, constructed, altered, repaired or demolished, without taking r easonab l e precau tions to prevent a nuisance. All persons sha l l take reaso n able pre c a u tions to p r ev ent th e discharge of v i sible em issions of f

ugitive dusts beyond the lot line of the property on which the em issions originate.

Authority for Requirem e nt: 567 IAC 23.3(2)"c"

1 5 Title V Perm it 03 / 29 /04Title V Permit 03 / 29/04 16 Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements listed below in Table: Fugitives Subject to F ugitive Dust Rule Only-Operational Limits & Requirements.

Table: Fugitives Subject to Fugitive Dust Rule Only-Ope rational Limits & Requirements

Emission

Point

Number Associated

Emission Unit

Number Process Throughput

Limit Reporting & Recordkeeping (1) Authority for Requirements

0070-0-F 0070-1-F 365,000 tons of raw material crushed per month The quantity of raw

materials crushed shall be recorded monthly.

0081-0-F 0081-1-F 365,000 tons of raw material crushed per month The quantity of raw

materials crushed shall be recorded monthly.

0110-1-F 0110-0-F 0110-2-F 55,480 tons of clay crushed per month The quantity of clay crushed shall be recorded monthly.

0120-1-F 0120-0-F 0120-2-F

0130-1-F 0130-0-F 0130-2-F 55,480 tons of clay crushed per month The quantity of clay crushed shall be recorded monthly.

0200-1-F

0200-2-F

0200-3-F

0200-4-F

0200-5-F

0200-6-F

0200-7-F 0200-0-F

0200-8-F 365,000 tons of raw materials crushed per month

and transferred to the kiln, of which 128,480 tons may

be alternative raw materials and clay. The quantity of raw material and clay crushed shall be recorded monthly

0203-0-F 0203-1-F 365,000 tons of raw material crushed per month The quantity of raw material

crushed shall be recorded monthly.

0300-1-F

0300-2-F

0300-3-F 0300-0-F

0300-4-F 365,000 tons of raw material crushed per month The quantity of raw

materials crushed shall be recorded monthly. Section IV(2) Iowa Department of

Natural Resources

Administrative

Consent Order No. 98-AQ-08Title V Permit 03 / 29/04 17 Table: Fugitives Subject to Fugi tive Dust Rule Only-Operationa l Limits & Requirements (Cont.)

Emission

Point

Number Associated

Emission Unit

Number Process Throughput

Limit Reporting & Recordkeeping (1) Authority for Requirements

0387-F 0387-1-F 365,000 tons of raw material crushed per month The quantity of raw

materials crushed shall be recorded monthly. Section IV(2) Iowa Department of

Natural Resources

Administrative

Consent Order No. 98-AQ-08

(1) The records shall be kept on site for a minimu m of five years, and shall be available for inspection by the Department.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03 / 29/04 18 

### Emission Point ID Number: See Tabl e: Fugitives Subject to 40 CFR 63 Subpart

LLL

Associated Equipment

Associated Emission Unit ID Numbers: See Table: Fugitives Subject to 40 CFR 63 Subpart LLL

______________________________________________________________________________


### Applicable Requirements

Table: Fugitives Subject to 40 CFR 63 Subpart LLL

Emission

Point

Number Associated

Emission Unit

Number Emission Unit Description Raw Material Rated Capacity

0400-0-F 0400-1-F Raw Material Transfer-Weigh Feeders to Conveyor Raw Materials (1) 300 TPH

0487-0-F 0487-1-F 0487 Slide Ga te-Truck Loading Raw Materials (1) 10 TPH

0488-0-F 0488-1-F 0488 Manual Flop Gate-Truck Loading Raw Materials (1) 300 TPH

0576-0-F 0576-1-F 0576 Manual Slide Gate Load Out Clinker 30 TPH

0718-0-F 0718-1-F Clinker Bin Load Out-Truck Loading Clinker 180 TPH

0766-0-F 0766-1-F 0766 Feeder Transfer to 0722 Belt Conveyor Gypsum 180 TPH

0800-1-F Finish Mill Building Fugitives Clinker 180 TPH

0800-0-F 0889-1-F 0886 Belt Conveyor Transfer to 0905 Belt Conveyor Cement 200 TPH

0906-0-F 0906-1-F 0905 Belt Conveyor Transfer to 0908 Hopper Cement 200 TPH

0926-0-F 0926-1-F 0914 Belt Conveyor Transfer to 0916 Hopper Cement 200 TPH

1300-1-F Rail Loading System (Fugitives) Cement 600 TPH
1300-0-F

1300-2-F Truck Loading System (Fugitives) Cement 300 TPH

2601-0-F 2601-1-F Barge Loading System (Fugitives) Cement 100 TPH

(1) Raw materials refers to any one or a mixture of the kiln-stock materials used to produce cement, which are primarily limestone, cla y, or alternative raw materials such as hydrocarbon contaminated soils. Coal and other primary fuel sour ces are not included in this category.Title V Permit 03 / 29/04 19 Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from these emission points sh all not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 10% Authority for Requirement: 567 IAC 23.1(4)"bl"

40 CFR 63.1348

Pollutant: Fugitive Dust Emission Limit: No person shall allow, cause or permit any materials to be handled, transported or stored; or a building, its appur tenances or a construction haul road to be used, constructed, altered, repaired or demolished, without taking reas onable precautions to prevent a nuisance. All persons shall take reasonable precautions to preven t the discharge of visible emissions of fugitive dusts beyond the lot line of the property on which the emissions originate.

Authority for Requirement: 567 IAC 23.3(2)"c"

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Process throughput: See Table: Fugitives Subject to Subpart LLL-Operational Limits & Requirements

Reporting & Recordkeeping:

A. Recordkeeping for NESHAP 40 CFR 63 Subpart LLL at the facility shall be done per

40 CFR 63.1355.

Authority for Requirement: 567 IAC 23.1(4)"bl"

40 CFR 63.1355

B. See Table: Fugitives Subject to 40 CFR 63 Subpart LLL-Operational Limits & Requirements.Title V Permit 03 / 29/04 20 Table: Fugitives Subject to 40 CFR 63 Subpa rt LLL-Operational Limits & Requirements

Emission

Point

Number Associated

Emission Unit

Number Process Throughput

Limit Reporting & Recordkeeping (1) Authority for Requirements

0400-0-F 0400-1-F 365,000 tons of raw material crushed per month The quantity of raw

materials crushed shall be recorded monthly.

0800-0-F 0800-1-F 17,082 tons of gypsum usage per month The quantity of gypsum

used shall be recorded monthly.

1300-1-F
1300-0-F
1300-2-F

2601-0-F 2601-1-F 262,800 tons of cement production per month The quantity of cement produced shall be recorded monthly. Section IV(2) Iowa Department of

Natural Resources

Administrative

Consent Order No. 98-AQ-08

(1) The records shall be kept on site for a minimum of five (5) years, and shall be available for inspection by the Department.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

With the exception of emission po ints 0400-0-F and 1300-0-F, which ar e totally enclosed and thus exempt from periodic opacity monitoring, the facility shall check the opacity monthly as described in (a)(4)(i-iv) of Plant-Wide Conditions

- Applicable Limits and Requirements From 40 CFR 63 Subpart LLL

- Monitoring Requirements

. Authority for Requirement

- 567 IAC 23.1(4)"bl" 40 CFR 63.1350(a)(4)

Agency Approved Operation & Maintenance Plan Required? Yes No Relevant requirements of O & M plan for this equipment: Opacity- see Appendix B.

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 23.1(4)"bl" 40 CFR 63.1350(a)"Title V Permit 03 / 29/04 21 

### Emission Point ID Numbers: See Table: Haulroads Subject to Administrative Consent Order No. 98-AQ-08

Associated Equipment

Associated Emission Unit ID Numbers: See Table: Haulroads Subject to Administrative Consent Order No. 98-AQ-08

______________________________________________________________________________


### Applicable Requirements

Table: Haulroads Subject to Admini strative Consent Order No. 98-AQ-08

Emission

Point

Number Associated

Emission Unit

Number Emission Unit Description Raw Material Rated Capacity

0155-0-F 0155-1-F Quarry Haulroad-Rock Hauling Unpaved Road 16.47 VMT/hr

0160-0-F 0160-1-F Quarry Haulroad-Clay Hauling Unpaved Road 2.47 VMT/hr

0165-0-F 0165-1-F Haulroad-Clay from Storage

Piles to Crusher Unpaved Road 3.31 VMT/hr

0691-0-F 0691-1-F Haulroad-Rail Unloading Raw

Materials Paved Road 14.77 VMT/hr

0692-0-F 0692-1-F Haulroad-Rail UnloadingClinker Paved Road 2.27 VMT/hr

0695-0-F 0695-1-F Haulroad-Rail Unloading Fuel Paved Road 4.55 VMT/hr

0765-1-F Unpaved Haulroad to 0765

Feeder Unpaved Road 0.63 VMT/hr
0765-0-F

0765-2-F Paved Haulroad to 0765 Feeder Paved Road 0.63 VMT/hr

1301-0-F 1301-1-F Haulroad-Truck Loadout of

Cement Paved Road 0.93 VMT/hr

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from these emission points sh all not exceed the levels specified below.

Pollutant: Fugitive Dust Emission Limit: No person shall allow, cause or permit any materials to be handled, transported or stored; or a building, its appurtenances or a c onstruction haul road to be used, constructed, altered, repaired or demolished, without taking r easonable precautions to prevent a nuisance. All persons shall take reasonable precautions to prev ent the discharge of visible emissions of fugitive dusts beyond the lot line of the property on which the emissions originate.

Authority for Requirement: 567 IAC 23.3(2)"c"Title V Permit 03 / 29/04 22 Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Process throughput: See Table: Haul roads Subject to Administrative Consent Order No. 98-AQ-08 Operational Limits & Requirements

Work practice standards: See Haul Road Fugitive Dust Plan under Plant-Wide

Conditions.

Reporting & Record keeping:

A. Records as specified under Haul Road Fugitive Dust Plan under Plant-Wide Conditions shall be kept on site for a minimu m of five years. The records shall be available for inspection upon request by repres entatives of the Department of Natural

Resources.

B. See Table: Haulroads Subject to Admi nistrative Consent Order No. 98-AQ-08- Operational Limits & Requirements

Table: Haulroads Subject to Ad ministrative Consent Order No. 98-AQ-08-Operational Limits & Requirements

Emission

Point

Number Associated

Emission Unit

Number Process Throughput

Limit Reporting & Recordkeeping (1) Authority for Requirements

0155-0-F 0155-1-F 365,000 tons of raw material crushed per month The quantity of raw materials

crushed shall be recorded monthly.

0160-0-F 0160-1-F 55,480 tons of clay crushed per month The quantity of clay crushed shall be recorded monthly.

0165-0-F 0165-1-F 55,480 tons of clay crushed per month The quantity of clay crushed shall be recorded monthly.

0691-0-F 0691-1-F 55,480 tons of clay crushed per month The quantity of clay crushed shall be recorded monthly.

0692-0-F 0692-1-F 262,800 tons of cement production per month The quantity of cement produced shall be recorded monthly

0695-0-F 0695-1-F 32,761 tons of fuel used per month The quantity of fuel usage shall be recorded monthly.

0765-1-F

0765-0-F

0765-2-F 262,800 tons of cement production per month The quantity of cement produced shall be recorded monthly

1301-0-F 1301-1-F 262,800 tons of cement production per month The quantity of cement produced shall be recorded monthly Section IV(2) Iowa Department of Natural

Resources

Administrative

Consent Order No. 98- AQ-08

(1) The records shall be kept on site for a minimum of five (5) years, and shall be available for inspection by the Department.Title V Permit 03 / 29/04 23 Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03 / 29/04 24 

### Emission Point ID Numbers: See Table: Conveying System Transfer Points\

Raw and Finish Mills\ Storage Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL

Associated Equipment

Associated Emission Unit ID Numbers: See Table: Conveying System Transfer Points\ Raw and Finish Mills\ Storage Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL

__________________________________________________________________________



### Applicable Requirements

Table: Conveying System Transfer Points\ Raw and Finish Mills\ Stor age Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL

Emission

Point

Number Associated

Emission Unit

Number Emission Unit Description Control Equipment

Number Control Equipment Description Raw

Material Rated Capacity

0404-0 0404-1 Raw Material TransferConveyor to Homo. Silos 0404-C Baghouse Raw

Materials (1) 1,400 TPH

0420-0 0420-1 Raw Material TransferAirslides to Vert. Conveyor 0420-C Baghouse Raw

Materials (1) 300 TPH

0498-0 0498-1 Raw Material TransferConveyors to Preblend Bin 0498-C Baghouse Raw

Materials (1) 300 TPH

0504-0 0504-1 Raw Material TransferAirslides/Separator/Bin to Kiln 0504-C Baghouse Raw

Materials (1) 300 TPH

0709-0 0709-1 Drag Conveying Clinker 0709-C Baghouse Clinker 220 TPH

0743-0 0743-1 Drag Conveying Clinker 0743-C Baghouse Clinker 220 TPH

0811-0 0811-1 Finish Mill Holding Bin 0811-C Baghouse Cement 180 Tons

0817-1 Finish Mill (Particulate Emissions) 0817-C Baghouse Clinker, Gypsum 180 TPH

0817-0

0817-2 Finish Mill (VOC Emissions) Grinding

Aid 26 gal./hr

0822-0 0822-1 Finish Mill Air Separator 0822-C Baghouse Cement 180 TPH

0950-0 0950-1 Barge Loading Silo 0950-C Baghouse Cement 100 TPH

1007-0 1007-1 A.E. Silos # 15-30 1007-C Baghouse Cement 200 TPH

1017-0 1017-1 Conebottom Silos # 31-40 1017-C Baghouse Cement 200 TPH

1041-0 1041-1 Rail Car Loading SystemSilo # 41 1041-C Baghouse Cement 300 TPH

1044-0 North Truck Loading Spout 150 TPH

1440-03 Airslide Conveyor 150 TPH 1044-0

1442-05 Airslide Conveyor 1044-C Baghouse Cement

150 TPHTitle V Permit 03 / 29/04 25 Table: Conveying System Transfer Points\ Raw and Finish Mills\ Stor age Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL (cont.)

Emission

Point

Number Associated

Emission Unit

Number Emission Unit Description Control Equipment

Number Control Equipment Description Raw

Material Rated Capacity

1045-0 1045-1 South Bulk Truck Loadout System 1045-C Baghouse Cement 150 TPH

1047-0 1047-1 Rail Car Loading SystemSilos # 47 & 48 1047-C Baghouse Cement 300 TPH

1053-0 1053-1 West Overtrack Silos 1053-C Baghouse Cement 200 TPH

2601-0 2601-1 Barge Loading System Spout 2601-C Baghouse Cement 250 TPH

(1) Raw materials refers to any one or a mixture of the kiln-stock materials used to produce cement, which are primarily limestone, cla y, or alternative raw materials such as hydrocarbon contaminated soils. Coal and other primary fuel sour ces are not included in this category.

Emission Limits (lb/hr, gr/dsc f, lb/MMBtu, % opacity, etc.) The emissions from these emission points shall not exceed the levels specified in Table: Conveying System Transfer Points\ Raw and Finish Mills\ Storage Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL -Emission Limits

Table: Conveying System Transfer Points\ Raw and Finish Mills\ Stor age Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL-Emission Limits.

Emission

Point

Number Associated

Emission Unit

Number Opacity

Limit PM 10 Limit (lb/hr) PM Limit (gr/scf) Construction
Permit #

0404-0 0404-1 10 % (1) 3.33 0.1 78-A-229-S3

0420-0 0420-1 10 % (1) 0.56 0.1 78-A-228-S4

0498-0 0498-1 10 % (1) 1.16 0.1 78-A-226-S4

0504-0 0504-1 10 % (1) 2.08 0.1 78-A-230-S4

0709-0 0709-1 10 % (1) 0.64 0.1 80-A-012-S2

0743-0 0743-1 10 % (1) 3.02 0.1 78-A-235-S3

0811-0 0811-1 10 % (1) 0.62 0.1 80-A-013-S3

0817-1 0817-0 0817-2 10 % (1) 6.17 0.1 78-A-237-S4

0822-0 0822-1 10% (1) 2.66 0.1 78-A-238-S4

0950-0 0950-1 10 % (1) 2.05 0.1 85-A-050-S2

1007-0 1007-1 10 % (1) 0.60 0.1 76-A-003-S2

1017-0 1017-1 10 % (1) 0.60 0.1 76-A-004-S3

1041-0 1041-1 10 % (1) 0.34 0.1 88-A-076-S2

1044-0

1440-03 1044-0

1442-05 10 % (1) 0.52 0.1 86-A-015-S3

1045-0 1045-1 10 % (1) 0.52 0.1 86-A-014-S2

1047-0 1047-1 10 % (1) 0.38 0.1 83-A-041-S2

1053-0 1053-1 10 % (1) 1.44 0.1 78-A-242-S5

2601-0 2601-1 10 % (1) 0.38 0.1 85-A-052-S426 Title V Permit 10/26/04 Pollutant: Opacity

Emission Limit: 10 % (1)
Authority for Requirement: Iowa DNR Constructi on Permits specified in Table: Authority for Requirement: Iowa DNR Construction Permits speci fied in Table: Conveying System Transfer Points\ Raw and Finish Mills\ Storage Bins\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL -Emission Limits 567 IAC 23.1(4)"bl"

40 CFR 63.1348

(1) If opacity greater than that obser ved in the initial performance test is viewed other than startup, shutdown, or malfunction, a stack test may be required to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter Emission Limit: 0.1 gr/scf Authority for Requirement: Iowa DNR Construction Permits specified in Table: Conveying System Transfer Points\ Raw and Finish Mills\ Storage Bi ns\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL -Emission Limits 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limit: As specified in Table: Non-Fugi tive Sources Subject to 40 CFR 63 Subpart LLL-

Emission Limits Authority for Requirement: Iowa DNR Construction Permits specified in Table: Conveying System Transfer Points\ Raw and Finish Mills\ Storage Bi ns\ Bulk Loading and Unloading Units Subject to 40 CFR 63 Subpart LLL -Emission Limits

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Reporting & Record keeping: All records as required by th is permit shall be kept on-site for a minimum of five (5) years and shall be available for inspection by the DNR. Records sh all be legible and maintained in an orderly

manner. The records sh all show the following: Recordkeeping for NESHAP 40 CFR 63 Subpart LLL at the facility shall be done per 40 CFR

63.1355

Authority for Requirement: Iowa DNR Construction Permits specified in Table: Non-Fugitive Sources Subject to 40 CFR 63 Subpart LLL-Emission Limits 567 IAC 23.1(4)"bl"

40 CFR 63.135527 Title V Permit 10/26/04 Emission Point Characteristics These emission points shall conform to the condit ions specified in Tabl e: Non-Fugitive Sources Subject to 40 CFR 63 Subpart LLL-Em ission Point Characteristics

Table: Non-Fugitive Sources Subject to 40 CFR 63 Subpart LLL-Emission Point

Characteristics

Stack Characteristics

Emission

Point

Number Emission

Unit

Number Construction

Permit # Height (ft.) Diameter (inches) Exhaust

Flowrate (scfm) Exhaust Temp. ( o F) Discharge Style

0404-0 0404-1 78-A-229-S3 133 25 X 46 19,500 70 Vertical, Unobstructed

0420-0 0420-1 78-A-228-S4 97 12 x 18 2,700 200 Vertical, Unobstructed

0498-0 0498-1 78-A-226-S4 35.3 15 x 26 6,800 70 Horizontal

0504-0 0504-1 78-A-230-S4 322 21 x 29 10,500 150 Vertical, Unobstructed

0709-0 0709-1 80-A-012-S2 101 11.5 x 20 3,800 70 Horizontal

0743-0 0743-1 78-A-235-S3 208 26 X 38 17,600 70 Horizontal

0811-0 0811-1 80-A-013-S3 116.5 56 2,900 200 Vertical, Unobstructed

0817-1 0817-0 0817-2 78-A-237-S4 116.5 21 X 52 28,900 200 Vertical, Unobstructed

0822-0 0822-1 78-A-238-S4 116.5 36 X 29 12,400 200 Vertical, Unobstructed

0950-0 0950-1 85-A-050-S2 96 12 X 18 9,600 200 Horizontal

1007-0 1007-1 76-A-003-S2 105 10.5 x 12 3,000 150 Horizontal

1017-0 1017-1 76-A-004-S3 105 17 x 20 2,800 200 Horizontal

1041-0 1041-1 88-A-076-S2 30 8 2,000 70 Horizontal

1044-0

1440-03 1044-0

1442-05 86-A-015-S3 49.3 12 x 18 3,000 70 Horizontal

1045-0 1045-1 86-A-014-S2 54.3 12 x 18 3,000 70 Horizontal

1047-0 1047-1 83-A-041-S2 20 8 2,200 70 Horizontal

1053-0 1053-1 78-A-242-S5 140 21 7,300 150 Horizontal

2601-0 2601-0 85-A-052-S4 42 12.75 X 11 2,000 70 Horizontal Authority for Requirement: Conveying System Tran sfer Points\ Raw and Finish Mills\ Storage Bins\ Bulk Loading and Unloading Units S ubject to 40 CFR 63 Subpart LLL –Emission Point

Characteristics.

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.28 Title V Permit 10/26/04 Periodic Monitoring Requirements The owner/operator of this equipment shall comp ly with the periodic monitoring requirements

The facility shall check the opacity as described in (a)(4)(i-vii) and (e) of Appendix C

- Applicable Limits and Requirements Fr om 40 CFR 63 Subpart LLL

- Monitoring Requirements

.

Authority for Requirement: Iowa DNR Construction Permits specified in Table: Non-Fugitive Sources Subject to 40 CFR 63 Subpart LLL-Emission Limits 567 IAC 23.1(4)"bl" 40 CFR 63.1350(a)(4) 40 CFR 63.1350(e)

Stack Testing: For Emission Point 2601-0 only

Pollutant – Opacity Stack Test to be Completed by (date) – S ee Condition(s) under Compliance Plan, above. Test Method – 40 CFR 60 Appendix A, Method 9 Authority for Requirement - Iowa DNR Construction Permit 85-A-052-S4

Pollutant – PM 10 Stack Test to be Completed by (date) – S ee Condition(s) under Compliance Plan, above. Test Method – 40 CFR 51, Appendix M, 201A with 202 Authority for Requirement - Iowa DNR Construction Permit 85-A-052-S4

The owner of this equipment or the owner’s author ized agent shall provide written notice to the Director, not less than 30 days before a require d stack test or performance evaluation of a

continuous emission monitor. Results of the test shall be submitted in writing to the Director in the form of a comprehensive report within 6 weeks of the completion of the testing. 567 IAC 25.1(7)

Agency Approved Operation & Maintenance Plan Required? Yes No Relevant requirements of O & M plan for this equipment: Particulate Matter and Opacity - see Appendix B.

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 23.1(4)"bl" 40 CFR 63.1350(a)

### Emission Point ID Number: 0020-0

Associated Equipm ent

Associated Em ission Unit ID Num b ers: 0020-1

______________________________________________________________________________


### Applicable Requirements

Em ission Unit vented through this E m ission Point: 0020-1

Em ission Unit Description: Em ergency Generator

Raw Material/Fue l: #2 Fuel Oil Rated Capacity: 250 K W H

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.)

The emissio n s from this emission point s hall n o t exceed the levels sp ecified below.

Pollutan t: O p acity

Em ission Lim its: 40 % Authority for Requirem e nt: Iowa DNR Construction Perm it 99-A-136 567 IAC 23.3(2)"d"

Pollutan t: P a rticula t e M a tte r (PM)

Em ission Lim it(s): 0.6 lb./MMBtu Authority for Requirem e nt: 567 IAC 23.3(2)"b"

Pollutan t: P M 10 Em ission Lim its: 0.74 lb./hr Authority for Requirem e nt: Iowa D N R Construction Perm it 99-A-136

Pollutan t: S u lf ur Dioxid e (SO 2 )

Em ission Lim it(s): 2.5 lb./MMBtu Authority for Requirem e nt: Iowa DNR Construction Perm it 99-A-136 567 IAC 23.3(3)"b"

Operational Limits & Requireme n ts The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Hours of operation: This em ission unit sha ll operate no m o re than 500 hours per year.

Process throughput: The fuel us ed shall not have a sulfur content greater than 0.5%.

2 9 Title V Perm it 03 /29 / 04Title V Permit 03/29/04 30 Reporting & Record keeping: All records as required below shall be satisfactory for demonstrating compliance with all applicable operating limits. Records shall be maintained on site for five (5) years and be available fo r inspection upon request by representatives of the Department of Natural Re sources. These records shall show the following:

A. the date, type of fuel used, sulfur content of the fuel, time of startup, time of shutdown, and the total hours the emission unit operated that day.

B. during the first twelve (12) months of ope ration, determine the total hours of operation for each month of operation.

C. after the first twelve (12) months of operation, the annual hours of operation shall be recorded on a rolling 12-month basis for each month of operation.

Authority for Requirement: Iowa DNR Construction Permit 99-A-136

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 14 Stack Diameter (inches): 6 Stack Exhaust Flow Rate (scfm): 200
Stack Temperature ( o F): 500 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 99-A-136

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 31 

### Emission Point ID Number: 0030-0

Associated Equipment

Associated Emission Unit ID Numbers: 0030-1

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0030-1 Emission Unit Description: Diesel Water Pump

Raw Material/Fuel: #2 Fuel Oil Rated Capacity: 182 hp/hr

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity

Emission Limits: 40 % (1)
Authority for Requirement: Iowa DNR Construction Permit 99-A-137 567 IAC 23.3(2)"d"

(1) If an opacity > 20% is observed other than startup, shutdown or malfunction, a stack test may be required to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter (PM) Emission Limit(s): 0.1 gr./dscf Authority for Requirement: 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.43 lb./hr Authority for Requirement: Iowa DNR Construction Permit 99-A-137

Pollutant: Sulfur Dioxide (SO 2 ) Emission Limit(s): 2.5 lb./MMBtu Authority for Requirement: Iowa DNR Construction Permit 99-A-137 567 IAC 23.3(3)"b"

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Hours of operation: This emission unit sha ll operate no more than 500 hours per year.

Process throughput: The fuel us ed shall not have a sulfur content greater than 0.5%.Title V Permit 03/29/04 32 Reporting & Record keeping: All records as required below shall be satisfactory for demonstrating compliance with all applicable operating limits. Records shall be maintained on site for five (5) years and be available fo r inspection upon request by representatives of the Department of Natural Re sources. These records shall show the following:

A. the date, type of fuel used, sulfur content of the fuel, time of startup, time of shutdown, and the total hours the emission unit operated that day.

B. during the first twelve (12) months of ope ration, determine the total hours of operation for each month of operation.

C. after the first twelve (12) months of operation, the annual hours of operation shall be recorded on a rolling 12-month basis for each month of operation.

Authority for Requirement: Iowa DNR Construction Permit 99-A-137

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 12.75 Stack Diameter (inches): 6 Stack Exhaust Flow Rate (scfm): 800
Stack Temperature ( o F): 500 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 99-A-137

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 33 

### Emission Point ID Number: 0081-0

Associated Equipment

Associated Emission Unit ID Numbers: 0081-1 Emissions Control Equipment ID Number: 0081-C Emissions Control Equipment Description: Bag Filter

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0081-1 Emission Unit Description: Quarry Drill

Raw Material/Fuel: N/A Rated Capacity: N/A

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity

Emission Limits: 40 % (1)
Authority for Requirement: Iowa DNR Construction Permit 87-A-080-S2 567 IAC 23.3(2)"d"

(1) If visible emissions are observed other than start up, shutdown or malfunction, a stack test may be required to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter (PM) Emission Limit(s): 0.1 gr./scf Authority for Requirement: Iowa DNR Construction Permit 87-A-080-S2 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.13 lb./hr Authority for Requirement: Iowa DNR Construction Permit 87-A-080-S2

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 8 Stack Diameter (feet): 0.67 Stack Exhaust Flow Rate (scfm): 2,700
Stack Temperature ( o F): 70 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 87-A-080-S2Title V Permit 03/29/04 34 The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 35 

### Emission Point ID Number: 0203-0

Associated Equipment

Associated Emission Unit ID Numbers: 0203-1 Emissions Control Equipment ID Number: 0203-C Emissions Control Equipment Description: Baghouse

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0203-1 Emission Unit Description: Raw Material Tran sfer in Transfer House-Conveyor to Conveyor

Raw Material/Fuel: Raw Materials (1)
Rated Capacity: 1,400 TPH

(1) Raw materials refers to any one or a mixture of the kiln-stock materials used to produce cement, which are primarily limestone, cla y, or alternative raw materials such as hydrocarbon contaminated soils. Coal and other primary fuel sour ces are not included in this category.

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 40% (1)
Authority for Requirement: Iowa DNR Construction Permit 78-A-221-S6 567 IAC 23.3(2)"d"

(1) Per DNR Air Quality Policy 3-b-08, Opacity Limits , an exceedence of the indicator opacity of (10%) will require the owner/operator to prom ptly investigate the emission unit and make corrections to operations or equipment associated with the exceedence. The permit holder shall also file an "indicator opacity exceedence report" with the DNR field office and keep records as required in the policy. If exceedences continue after the corrections, the DNR may require additional proof to demonstrate compliance (e.g., stack testing).

Pollutant: Particulate Matter Emission Limits: 0.1 gr./dscf Authority for Requirement: Iowa DNR Construction Permit 78-A-221-S6 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.72 lb./hr Authority for Requirement: Iowa DNR Construction Permit 78-A-221-S6Title V Permit 03/29/04 36 Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Process throughput: This process is limited to tr ansferring 365,000 tons of raw materials per month.

Reporting & Record keeping: The quantity of ra w material transferred to the crusher shall be recorded monthly, records shall be kept on site for a minimum of five years, and shall be available for inspection by the Department.

Authority for Requirement: Section IV(2) Iowa Department of Natural Resources Administrative Consent Order No. 98-AQ-08

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 5.6 Stack Diameter (inches): 7.8 Stack Exhaust Flow Rate (scfm): 4,200
Stack Temperature ( o F): Ambient Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 78-A-221-S6

The temperature and flowrate are intended to be re presentative and characteri stic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process a nd ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Facility operation and maintenance plans must be suff icient to yield reliable data from the relevant time period that are representative of the source ’s compliance with the applicable requirements.

Facility operation and maintenance plans are to be d eveloped by the facility with in six(6) months of the issuance date of this permit and the data pertaini ng to the plan maintained on site for at least 5Title V Permit 03/29/04 37 years. The plan and associated recordkeeping provides documentation of this facility’s implementation of its obligation to operate ac cording to good air pollution control practice.

Good air pollution control practice is achieved by adoption of quality c ontrol standards in the operation and maintenance procedures for air pollu tion control that are comparable to industry quality control standards for the production proce sses associated with this emission point.

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 38 

### Emission Point ID Number: 0218-0

Associated Equipment

Associated Emission Unit ID Numbers: 0218-1 Emissions Control Equipment ID Number: 0218-C Emissions Control Equipment Description: Baghouse

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0218-1 Emission Unit Description: Crushing and Conveying of Raw Materials

Raw Material/Fuel: Raw Materials (1)
Rated Capacity: 1,400 TPH

(1) Raw materials refers to any one or a mixture of the kiln-stock materials used to produce cement, which are primarily limestone, cla y, or alternative raw materials such as hydrocarbon contaminated soils. Coal and other primary fuel sour ces are not included in this category.

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the level s specified below.

Pollutant: Opacity Emission Limit(s): 40% (1)
Authority for Requirement: Iowa DNR Construction Permit 78-A-218-S6 567 IAC 23.3(2)"d"

(1) Per DNR Air Quality Policy 3-b-08, Opacity Limits , an exceedence of the indicator opacity of (10%) will require the owner/operator to prom ptly investigate the emission unit and make corrections to operations or equipment associated with the exceedence. The permit holder shall also file an "indicator opacity exceedence report" with the DNR field office and keep records as required in the policy. If exceedences continue after the corrections, the DNR may require additional proof to demonstrate compliance (e.g., stack testing).

Pollutant: Particulate Matter Emission Limits: 0.1 gr./dscf Authority for Requirement: Iowa DNR Construction Permit 78-A-218-S6 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 5.59 lb./hr Authority for Requirement: Iowa DNR Construction Permit 78-A-218-S6Title V Permit 03/29/04 39 Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Process throughput: The following supplemental materials may be u tilized in the crushers as listed below:

Material Maximum Tons Per Hour

1. Coal Combustion Residue 55 2. Foundry By-Products 1300 3. Hydrocarbon Containing Soils 210 4. Refinery By-Products 105

5. Oils and Greases 0

Total Feed 1300

Reporting & Record keeping: All re cords, as required by this perm it, shall be kept on site for a minimum of five (5) years and be available for in spection by the DNR. Records shall be legible and maintained in an orderly manner. Th e records shall show the following: Materials utilized by the crushers. This record shall s how the individual ma terial, the amount of that material (in tons), the percentage of the total for that material, and the total of all materials (in tons/hr).

Authority for Requirement: Iowa DNR Construction Permit 78-A-218-S6

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 4 Stack Opening (inches): 12 x 30 Stack Exhaust Flow Rate (scfm): 32,600
Stack Temperature ( o F): Ambient Discharge Style: Horizontal Authority for Requirement: Iowa DNR Construction Permit 78-A-218-S6

The temperature and flowrate are intended to be re presentative and characteri stic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process a nd ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.Title V Permit 03/29/04 40 Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Facility operation and maintenance plans must be suff icient to yield reliable data from the relevant time period that are representative of the source ’s compliance with the applicable requirements.

Facility operation and maintenance plans are to be d eveloped by the facility with in six(6) months of the issuance date of this permit and the data pertaini ng to the plan maintained on site for at least 5 years. The plan and associated recordkeeping provides documentation of this facility’s implementation of its obligation to operate ac cording to good air pollution control practice.

Good air pollution control practice is achieved by adoption of quality c ontrol standards in the operation and maintenance procedures for air pollu tion control that are comparable to industry quality control standards for the production proce sses associated with this emission point.

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 41 

### Emission Point ID Number: 0327-0-F

Associated Equipment

Associated Emission Unit ID Numbers: 0327-1-F

______________________________________________________________________________ 

### Applicable Requirements

Emission Unit vented through this Emission Point: 0327-1 Emission Unit Description: Raw Material Transfer-Vibrating Feeder to Conveyor

Raw Material/Fuel: Raw Materials (1)
Rated Capacity: 250 TPH

(1) Raw materials refers to any one or a mixture of the kiln-stock materials used to produce cement, which are primarily limestone, cla y, or alternative raw materials such as hydrocarbon contaminated soils. Coal and other primary fuel sour ces are not included in this category.

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 10% (1)
Authority for Requirement: Iowa DNR Construction Permit 78-A-223-S4 567 IAC 23.3(2)"d"

(1) If opacity greater than that observed in the initial performance test is viewed other than startup, shutdown, or malfunction, a stack test may be re quired to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter Emission Limits: 0.1 gr/dscf Authority for Requirement: Iowa DNR Construction Permit 78-A-223-S4 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.34 lb/hr Authority for Requirement: Iowa DNR Construction Permit 78-A-223-S4

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): Vents into preblend storage dome Stack Diameter (inches): Vents into preblend storage dome Stack Exhaust Flow Rate (acfm): Vents into preblend storage dome Stack Temperature ( o F): Vents into preblend storage dome Authority for Requirement: Iowa DNR Construction Permit 78-A-223-S4Title V Permit 03/29/04 42 The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 43 

### Emission Point ID Number: 0466-0

Associated Equipment

Associated Emission Unit ID Numbers: 0466-1, 0466-2 Emissions Control Equipment ID Number: 0466-C, 0594-C Emissions Control Equipment Description: Baghouses

Continuous Emissions Monitors ID Numbers: 0466-1-M, 0466-2-M

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0466-1 Emission Unit Description: Preheater/Precalciner/Kiln/Raw Mill System

Raw Material/Fuel: Raw Materials (1) and Coal Rated Capacity: 145.3 tons clinker/hr.

Emission Unit vented through this Emission Point: 0466-2 Emission Unit Description: Alkali Bypass

Raw Material/Fuel: N/A Rated Capacity: N/A

(1) Raw materials refers to any one or a mixture of the kiln-stock materials used to produce cement, which are primarily limestone, cla y, or alternative raw materials such as hydrocarbon contaminated soils. Coal and other primary fuel sour ces are not included in this category.

BACT Emission Limits (lb./hr, gr ./dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 10% Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

Pollutant: Particulate Matter Emission Limit(s): 0.51 6 lb./ton of clinker (2)
Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

Pollutant: PM 10 Emission Limit(s): 0.516 lb./ton of clinker (2)
Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

Pollutant: Sulfur Dioxide (SO 2 ) Emission Limit(s): 4,850 tons/yr (2,3,4)
Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1Title V Permit 03/29/04 44 Pollutant: Nitrogen Oxides (NOx) Emission Limit(s): 2,546 tons/yr (2,3,4) , 4.0 lb./ton of clinker (3,5)
Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

Pollutant: Carbon Monoxide (CO) Emission Limit(s): 4.5 lb./ton of clinker (2)
Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

(2) After completion of construction.

(3) Compliance with the applicable emission standards of this permit are based on the CEM data from the owner/operator. Hourly emissions shall be the averag e of four 15-minute averages analyzed and recorded by the CEM.

(4) Limit is a 12-month rolling total. Applies at al l times including periods of startup, shutdown, or

malfunction.

(5) Limit is a monthly rolling average. Lim it does not apply during startup, shutdown, or malfunction. Compliance with this emission standard shall be calculated by the owner/operator by:

• Totaling the pounds of NO

x recorded by the CEMS during norma l operation over the last twelve months of operation.

• Totaling the tons of clinker produced over the last twelve months operation.

• Dividing the pounds of NO

x by the tons of clinker produced.

Other Emission Limits

Pollutant: Particulate Matter Emission Limit(s): 0.3 lb./ton of feed Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1 567 IAC 23.1(4)"bl" 40 CFR 63.1343(b)(1)

Pollutant: PM 10 Emission Limit(s): 75 lb./hr Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

Pollutant: Sulfur Dioxide (SO 2 ) Emission Limit(s): 2,900 lb./hr (5) 66,500 lbs/day (6,7)
Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

Pollutant: Nitrogen Oxides (NOx) (8)

Emission Limit(s): 465.65 lb./hr Authority for Requirement: U.S. EPA PSD Permit 82-04-005

Pollutant: Dioxins and Furans (D/F) Emission Limit(s): 0.4 ng./dscm (1.7E-10 gr./dscf ) (TEQ) (9)
Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1 567 IAC 23.1(4)"bl" 40 CFR 63.1343(b)(3)Title V Permit 03/29/04 45 (6) Compliance with the applicable emission standards of this permit are based on the CEM data from the owner/operator. Hourly emissions shall be the averag e of four 15-minute averages analyzed and recorded by the CEM.

(7) Limit is a 24-hour rolling total. Applies at all times including periods of startup, shutdown, or

malfunction.

(8) Limit only when clinker production is at or below 108 TPH.

(9) Limit is corrected to 7% oxygen and when the average of the performance test run average temperatures at the inlet to the pa rticulate matter c ontrol device is 204 o C (400 o F) or less. If the average of the performance test run average temp eratures at the inlet to the particulate matter control device is greater than 204 o C (400 o F) then the D/F standard is 0.2 ng/dscm (8.7 E-11 gr./dscf)(TEQ) corrected to 7% oxygen.

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Operating Limits:

A. The kiln is limited to firing on used oil as defined by 40 CFR 279, fuel oil, natural gas, coal, and coke.

B. The following supplemental materials may be u tilized by the roller m ill and kiln as listed

below:

MAXIMUM TONS PER HOUR

Material Roller Mill Kiln

1. Coal Combustion Residue 30 30 2. Foundry By-Products 30 30 3. Hydrocarbon Containing Soils 46 46 4. Refinery By-Products 30 30 5. Oils and Greases 0 2_

Total Feed 300 300

C. Simultaneous feeding of the alternative ma terials listed in B, above, is allowed,

but the combined total of the materials shall not exceed twenty (20) percent of the total material being fed into the kiln at any given time. Refer to 40 CFR 63.1349(e) for performance testing requirements.

D. In accordance with 40 CFR 60 Subpart F (Standards of Performance for Portland Cement Plants), the facility (plant number 82-04-005) shall record its daily production

rates and kiln feed rates.

E. The kiln shall be operated such that the temperature of the gas at the inlet to the kiln particulate matter control device (PMCD) a nd alkali bypass PMCD, if applicable, meets the requirements of 40 CFR 63.1344 (Subpart LLL-National Emission Standards for

Hazardous Air Pollutants from the Por tland Cement Manufacturing Industry)Title V Permit 03/29/04 46 F. In accordance with 40 CFR 63.1349(c), PM performance tests shall be repeated every five years.

G. In accordance with 40 CFR 63.1349(d), D/F performance tests shall be repeated every 30 months.

Reporting & Record keeping: All records, as required below, shall be satisfactory for demonstrating compliance with a ll applicable operating limits. Records shall be maintained on site for five (5) years and be available fo r inspection upon request by representatives of the Department of Natural Re sources. These records shall show the following:

A. The sulfur content (in lb./MMBtu) of all individual fuels and the total sulfur (in lb./MMBtu) of any combinati on of fuels that are fired in the kiln. The fuel analysis sent with the fuel shipment can be an adequate demonstration for this record.

B. The Pb content of each batch of used oil fired in the kiln. The fuel analysis sent with the fuel shipment can be an adequate demonstration fo r this record.

C. The daily kiln production rates and kiln feed rates.

D. Copies of the semiannual excess emissions reports per 40 CFR 60.65.

E. Materials utilized by the roller mill and kil n. This record shall show the individual material, the amount of that ma terial (in tons/hr), the percen tage of the total for that material, the total of all materials (in tons/hr), and whether the roller mill or kiln or both were utilizing the material.

F. Determine the total SO 2 emissions for each operating day. An operating day is defined as a 24-hour period between 12:00 midnight and the following midnight during which any clinker is produced at any time in the ki ln. It is not necessary for clinker to be produced continuously by the kiln for the entire 24-hour period.

G. Upon issuance of Iowa DNR Construction Pe rmit 99-A-579-P1 and prior to the kiln modification, Lafarge shall calculate the monthly rolling average for the pounds of

NO

x /ton of clinker emission limit for the pr evious full 12 months. Lafarge shall

continue to determine the 12-month ro lling average each month thereafter.

H. After the kiln modification, Lafarge shall rest art the calculation fo r the monthly rolling average for the pounds of NO

x /ton of clinker. The calculation shall start the first full

month after the modification to the kiln a nd Lafarge shall continue to determine the monthly rolling average for each month thereafter.

I. Upon issuance of DNR Construction Pe rmit 99-A-579-P1 calculate the total NO

x emissions for the twelve (12) months pr evious to the issuance of the permit.

J. After the issuance of Iowa DNR Construc tion Permit 99-A-579-P1, determine the annual

NO

x emissions on a rolled 12-month total for each month of operation.Title V Permit 03/29/04 47 K. For the first twelve months after the kiln modification, calculate the cumulative SO

x emissions for each month of operation.

L. After the first twelve months after the k iln modification, calcul ate the cumulative SO

x emissions on a rolling 12-month to tal for each month of operation.

M. Monitoring for NESHAP Subpart LLL at the facility shall be done per 40 CFR 63.1350.

N. Recordkeeping requirements for NESHAP Subp art LLL at the facility shall be done per

40 CFR 63.1355.

Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 340 Stack Diameter (inches): 108 Stack Exhaust Flow Rate (scfm): 215,000
Stack Temperature ( o F): 300 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 99-A-579-P1

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Stack Testing:

Pollutant – Particulate Matter (PM) (NESHAP) Stack Test to be Comple ted by (date) – June 4, 2007 Test Method - 40 CFR 60, Appendix A, Method 5 Authority for Requirement - 40 CFR 63.1349(c) 567 IAC 23.1(4)"bl"

Pollutant - CO Stack Test to be Completed by (date) – W ithin 60 to 180 days after completion of

modifications Test Method - 40 CFR 60, Appendix A, Method 10 (2)
Authority for Requirement - Iowa DNR Construction Permit 99-A-579-P1Title V Permit 03/29/04 48 Pollutant - Dioxins/Furans (D/F) Stack Tests to be Completed by (date) – December 4, 2005 and June 4 2008 (3)
Test Method - 40 CFR 60, Appendix A, Method 23 (4)
Authority for Requirement - Iowa DNR Construction Permit 99-A-579-P1 40 CFR 63.1349(b)(3) 567 IAC 23.1(4)"bl"

(1) Or approved alternate

(2) The CO compliance tests shall be conducte d under the same operating and combustion

conditions as the NOx CEMS certification test s. Compliance with the NOx BACT emission limit shall take preference if difficulti es are encountered in achieving simultaneous compliance with these BACT emission limits . If such difficulties are encountered, the owner may subsequently request a revision of the CO BACT limit.

(3) And every 30 months thereafter.

(4) Test shall be done in order to meet compliance as outlined in 40 CFR 63.1349.

Continuous Emissions Monitoring:

In accordance with the New Source Performance Standards (NSPS) Subpart F (Standards of Performance for Portland Cement Plants), the facility (plant number 82-04-005) shall install, calibrate, maintain, and operate a continuous em ission monitoring system (CEMS) for measuring the opacity of the emissions discha rged to the atmosphere and reco rd the output of the system. The system shall be designed to meet the 40 CFR 60, Appendix B, Performance Specification 1 (PS1).

Compliance with the sulfur dioxide emission limits of this permit shall be continuously demonstrated by the owner/operato r through the use of a CEMS. Th erefore, the facility (plant number 82-04-005) shall install, calibrate, maintain, and operate a CEMS for measuring sulfur dioxide emissions discharged to the atmosphere a nd record the output of the system. The system shall be designed to meet the 40 CFR 60, Appendix B, Performance Specification 2 (PS2) and Performance Specification 6 (PS6) requirements. The specifications of 40 CFR 60 Appendix F (Quality Assurance/Quality Cont rol) shall apply. Appendix F re quirements shall be supplemented with a quarterly notice to the De partment with the dates of the quarterly cylinder gas audits and annual relative accuracy test audit.

Compliance with the nitrogen oxide emission lim its of this permit shall be continuously demonstrated by the owner/operato r through the use of a CEMS. Th erefore, the facility (plant number 82-04-005) shall install, calibrate, maintain, and operate a CEMS for measuring nitrogen oxides emissions discharged to the atmosphere a nd record the output of the system. The system shall be designed to meet the 40 CFR 60, Appendix B, Performance Specification 2 (PS2) and Performance Specification 6 (PS6) requirements. The specifications of 40 CFR 60 Appendix F (Quality Assurance/Quality Cont rol) shall apply. Appendix F re quirements shall be supplementedTitle V Permit 03/29/04 49 with a quarterly notice to the De partment with the dates of the quarterly cylinder gas audits and annual relative accuracy test audit.

The CEMS required by this permit shall be operat ed and data recorded during all periods of operation of the kiln except for CEM breakdowns a nd repairs. Data is r ecorded during calibration checks, and zero and span adjustments.

The 1-hour average sulfur dioxide and nitrogen dioxide emissi on rates measured by the CEMS required by this permit shall be used to calculate compliance with the emission standards of this permit. At least 2 data points must be used to calculate each 1-hour average.

The owner or operator shall obtain emission data for at least 90% of the hours in a day for a monitor day. In addition, the owner or operator shall obtain emission data in at least 22 out of 30 successive kiln operating days. For each hour of missing sulf ur dioxide or nitrogen dioxide emission data, the owner or operator shall substitute data by averaging the hourly SO 2 or NO

x emission rate recorded for the kiln operating hour immediately before a nd the kiln operating hou r immediately after the missing data point for each hour of missing data. Fo r each day of missing sulfur dioxide or nitrogen dioxide emission data, the owner or operator shall s ubstitute the highest value from the previous 30 days of SO 2 or NO

x emission data for each day of missing data.

Failure to obtain 90% of the hours per day will require Lafarge to obtain actual emission data by alternative testing or monitoring.

Authority for Requirement - Iowa DNR Construction Permit 99-A-579-P1

The owner of this equipment or the owner’s author ized agent shall provide written notice to the Director, not less than 30 days before a require d stack test or performance evaluation of a

continuous emission monitor. Results of the test shall be submitted in writing to the Director in the form of a comprehensive report within 6 weeks of the completion of the testing. 567 IAC 25.1(7)

Agency Approved Operation & Maintenance Plan Required? Yes No Relevant requirements of O & M plan for th is equipment: Particulate Matter and Opacity see Appendix B.

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b" 567 IAC 23.1(4)"bl" 40 CFR 63 1350(a)Title V Permit 03/29/04 50 

### Emission Point ID Number: 0499-0

Associated Equipment

Associated Emission Unit ID Numbers: 0499-1-F

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0499-1-F Emission Unit Description: Fuel Oil Tank Raw Material/Fuel: 20,000 gal Fuel Oil Tank Rated Capacity: 2,400 gal/hr

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 40% (1)
Authority for Requirement: Iowa DNR Construction Permit 98-A-1055-S1 567 IAC 23.3(2)"d"

(1) If visible emissions exceed the indicator opac ity (25%) other than startup, shutdown or malfunction, a stack test may be re quired to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter Emission Limits: 0.1 gr./scf Authority for Requirement: Iowa DNR Construction Permit 98-A-1055-S1 567 IAC 23.3(2)"a"

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Process throughput: The storag e tank is limited to stori ng distillate fuel oil.

Reporting & Record keeping: All records, as required below, shall be satisfactory for demonstrating compliance with all applicable operat ing limits. Records of the fuel type must be maintained onsite for at least five (5) years, and the records showing the tank dimensions and capacity must be maintained onsite for the lifetim e of the tank. These records are to be made available to DNR upon request. The owner or operator of the equipment shall maintain the following records:

A. the type of fuel stored in the tank.Title V Permit 03/29/04 51 B. records showing the dimensions of the storage vessel and the capacity.

Authority for Requirement: Iowa DNR Construction Permit 98-A-1055-S1 567 IAC 23.1(2)"ddd" 40 CFR 60.116b(b)

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Source: Storage Tank

Tank Shell Diameter: 11 ft Tank Shell Height: 28 ft Tank Volume (Gallons): 20,000 Exhaust Flow Rate: Fugitive Authority for Requirement: Iowa DNR Construction Permit 98-A-1055-S1

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 52 

### Emission Point ID Number: 0535-0 Associated Equipment

Associated Emission Unit ID Numbers: 0535-1 Emissions Control Equipment ID Number: 0535-C Emissions Control Equipment Description: Baghouse

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0535-1 Emission Unit Description: CKD Handling Silo

Raw Material/Fuel: CKD Rated Capacity: 405 TPH

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the level s specified below.

Pollutant: Opacity Emission Limit(s): 40% (1)
Authority for Requirement: Iowa DNR Construction Permit 97-A-789-S2 567 IAC 23.3(2)"d"

(1) If opacity greater than that observed in the initial performance test is viewed other than startup, shutdown, or malfunction, a stack test may be re quired to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter Emission Limits: 0.1 gr./scf Authority for Requirement: Iowa DNR Construction Permit 97-A-789-S2 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.55 lb./hr Authority for Requirement: Iowa DNR Construction Permit 97-A-789-S2

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 102 Stack Diameter (inches): 16 x 7 Stack Exhaust Flow Rate (scfm): 2,900Title V Permit 03/29/04 53 Stack Temperature ( o F): 140 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 97-A-789-S2

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Facility operation and maintenance plans must be suff icient to yield reliable data from the relevant time period that are representative of the source ’s compliance with the applicable requirements.

Facility operation and maintenance plans are to be devel oped by the facility with in six(6) months of the issuance date of this permit and the data pertaining to the plan ma intained on site for at least 5 years. The plan and associated recordkeeping pr ovides documentation of this facility’s implementation of its obligation to operate ac cording to good air pollution control practice.

Good air pollution control practice is achieved by adoption of quality control standards in the operation and maintenance procedures for air po llution control that are comparable to industry quality control standards for the production proce sses associated with this emission point.

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 54 

### Emission Point ID Number: 0611-0

Associated Equipment

Associated Emission Unit ID Number: 0611-1 Emissions Control Equipment ID Number: 0611-C Emissions Control Equipment Description: Baghouse

Continuous Emissions Monito rs ID Number: 0611-1-M

______________________________________________________________________________



### Applicable Requirements

Emission Unit vented through this Emission Point: 0611-1 Emission Unit Description: Cli nker Cooler and Drag Conveyor

Raw Material/Fuel: Clinker Rated Capacity: 145.3 TPH

BACT Emission Limits (lb./hr, gr ./dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 5% (1)
Authority for Requirement: Iowa DNR Construction Permit 01-A-878-P

(1) The averaging period for this standard is one (1) hour.

Pollutant: Particulate Matter Emission Limit(s): 0.015 gr./dscf Authority for Requirement: Iowa DNR Construction Permit 01-A-878-P1

Pollutant: PM 10 Emission Limit(s): 0.015 gr./dscf Authority for Requirement: Iowa DNR Construction Permit 01-A-878-P1

Other Emission Limits (lb./hr, gr ./dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the level s specified below.

Pollutant: Opacity Emission Limit(s): 10% Authority for Requirement: Iowa DNR Construction Permit 01-A-878-P 567 IAC 23.1(4)"bl"

40 CFR 63.1345Title V Permit 03/29/04 55 Pollutant: Particulate Matter Emission Limit(s): 0.1 lb./ton feed Authority for Requirement: Iowa DNR Construction Permit 01-A-878-P 567 IAC 23.1(4)"bl"

40 CFR 63.1345

Pollutant: PM 10 Emission Limit(s): 17.92 lb./hr Authority for Requirement: Iowa DNR Construction Permit 01-A-878-P

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Control equipment parameters: The facility is required to conduct a PM 10 compliance test within thirty (30) days if it exceeds the one (1) hour, 5% BACT opacity limit.

Reporting & Record keeping: All records as requi red by this permit shall be kept on-site for a minimum of five (5) years and shall be available for inspecti on by the DNR. Records shall be legible and maintained in an orderly manne r. The records sha ll show the following:

A. Copies of the excess emissions reports required per NSPS 40 CFR 60 Subpart F and NESHAP 40 CFR 63 Subpart LLL

B. Monitoring for NESHAP 40 CFR 63 Subpart LLL at the facility (plant number 17-01-005) shall be done per 40 CFR §63.1350

C. Recordkeeping for NESHAP 40 CFR Subpart LLL at the facility (plant number 17-01-005) shall be done per 40 CFR 63.1355

D. A log of one (1) hour opacity averages, da tes & times of exceedences, and dates of PM 10 compliance tests.

Authority for Requirement: Iowa DNR Construction Permit 01-A-878-P

Emission Point Characteristics The emission point shall conform to the specifications listed below. Stack Height (feet): 113 Stack Diameter (inches): 126 Stack Exhaust Flow Rate (scfm): 133,000 Stack Temperature ( o F): 340 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 01-A-878-PTitle V Permit 03/29/04 56 The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Stack Testing:

Pollutant – Particulate Matter (PM) (NESHAP) Stack Test to be Comple ted by (date) – June 4, 2007 Test Method - 40 CFR 60, Appendix A, Method 5 Authority for Requirement - 40 CFR 63.1349(c) 567 IAC 23.1(4)"bl"

Continuous Emissions Monitoring:

Pollutant - Opacity Operational Specifications – 40 CFR 63 Subpart A and 40 CFR 60, Appendix B PS-1 Date of Initial System Calibration and Quality Assurance – August 14, 1997 Ongoing System Calibration/Quality Assu rance - 40 CFR 63 Subpart A and 40 CFR 60, Appendix B PS-1 Reporting & Record keeping - 40 CFR 63 Subpart A and 40 CFR 60, Appendix B PS-1 Authority for Requirement – Iowa DNR Construction Permit 01-A-878-P 567 IAC 23.1(3)"bl" 40 CFR 63.1350(d)

The owner of this equipment or the owner’s authorized agent shall provide written notice to the Director, not less than 30 days before a required stack test or performance evaluation of a continuous emission monitor. Results of the test s hall be submitted in writing to the Director in the form of a comprehensive report within 6 weeks of the completion of the testing. 567 IAC 25.1(7)

Agency Approved Operation & Maintenance Plan Required? Yes No Relevant requirements of O & M plan for th is equipment: Particulate Matter and Opacity see Appendix B.

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b" 567 IAC 23.1(4)"bl" 40 CFR 63 1350(a)Title V Permit 03/29/04 57 

### Emission Point ID Number: 0667-0

Associated Equipment

Associated Emission Unit ID Numbers: 0667-1, 0667-2 Emissions Control Equipment ID Number: 0667-C Emissions Control Equipment Description: Baghouse

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0667-1 Emission Unit Description: Coal Mill and Bins

Raw Material/Fuel: Coal Rated Capacity: 20 TPH

Emission Unit vented through this Emission Point: 0667-2 Emission Unit Description: Coal Mill Air Heater

Raw Material/Fuel: Natural Gas Rated Capacity: 0.01 MMcf/hr

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the level s specified below.

Pollutant: Opacity Emission Limit(s): 20% (1)
Authority for Requirement: Iowa DNR Construction Permit 78-A-232-S3 567 IAC 23.1(2)"v" 40 CFR 60.252(c)

(1) If opacity greater than th at observed in the initial performance test is viewed other than startup, shutdown, or malfunction, a stack test may be required to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter Emission Limits: 0.1 gr./scf Authority for Requirement: Iowa DNR Construction Permit 78-A-232-S3 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 5.76 lb./hr Authority for Requirement: Iowa DNR Construction Permit 78-A-232-S3

Pollutant: Sulfur Dioxide (SO 2 ) Emission Limit(s): 500 ppmv Authority for Requirement: 567 IAC 23.3(3)"e"Title V Permit 03/29/04 58 Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 113 Stack Opening (inches): 11 x 14 Stack Exhaust Flow Rate (scfm): 29,000 Stack Temperature ( o F): 140 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 78-A-232-S3

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

The facility shall check the opacity weekly duri ng a period when the emission unit on this emission point is at or near full capacity and record the reading. Maintain a written record of the observation and any action resulting from the observation for a minimum of five years. Opacity shall be

observed to ensure that no visible emissions occur during the material handling operation of the

unit. If visible emissions are observed corrective action will be taken as soon as possible, but no later than eight hours from the observation of visibl e emissions. If corrective action does not return the observation to no visible emissions, then a Me thod 9 observation will be required. If an opacity (>20 %) is observed, this would be a violation and corrective action will be taken as soon as possible, but no later than eigh t hours from the observation of visible emissions. If weather conditions prevent the observer from conducting an opacity observation, the observer shall note

such conditions on the data observation sheet. At least three attempts shall be made to retake opacity readings at approximately 2-hour intervals throughout the da y. If all observation attempts for a week have been unsuccessful due to weather, an observation shall be made the next operating day where weather permits.

Authority for Requirement: 567 IAC 22.108(14)

Agency Approved Operation & Maintenance Plan Required? Yes No Relevant requirements of O & M plan for this equipment: Particulate Matter- see Appendix B.

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 59 

### Emission Point ID Number: 0684-0 Associated Equipment

Associated Emission Unit ID Numbers: 0684-1 Emissions Control Equipment ID Number: 0684-C Emissions Control Equipment Description: Baghouse

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0684-1 Emission Unit Description: Coal Silo

Raw Material/Fuel: Coal Rated Capacity: 200 TPH

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 20% (1)
Authority for Requirement: Iowa DNR Construction Permit 78-A-248-S6 567 IAC 23.1(2)"v" 40 CFR 60.252(c)

(1) If opacity greater than th at observed in the initial performance test is viewed other than startup, shutdown, or malfunction, a stack test may be required to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter Emission Limits: 0.1 gr./scf Authority for Requirement: Iowa DNR Construction Permit 78-A-248-S6 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.67 lb/hr Authority for Requirement: Iowa DNR Construction Permit 78-A-248-S6

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): 142 Stack Opening (inches): 12 x 21 Stack Exhaust Flow Rate (scfm): 4,000 Stack Temperature ( o F): 70 Vertical, Unobstructed Di scharge Required: Yes No Authority for Requirement: Iowa DNR Construction Permit 78-A-248-S6Title V Permit 03/29/04 60 The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

The facility shall check the opacity weekly duri ng a period when the emission unit on this emission point is at or near full capacity and record the reading. Maintain a written record of the observation and any action resulting from the observation for a minimum of five years. Opacity shall be

observed to ensure that no visible emissions occur during the material handling operation of the

unit. If visible emissions are observed corrective action will be taken as soon as possible, but no later than eight hours from the observation of visibl e emissions. If corrective action does not return the observation to no visible emissions, then a Me thod 9 observation will be required. If an opacity (>20 %) is observed, this would be a violation and corrective action will be taken as soon as possible, but no later than eigh t hours from the observation of visible emissions. If weather conditions prevent the observer from conducting an opacity observation, the observer shall note

such conditions on the data observation sheet. At least three attempts shall be made to retake opacity readings at approximately 2-hour intervals throughout the da y. If all observation attempts for a week have been unsuccessful due to weather, an observation shall be made the next operating day where weather permits.

Authority for Requirement: 567 IAC 22.108(14)

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Facility operation and maintenance plans must be suff icient to yield reliable data from the relevant time period that are representative of the source ’s compliance with the applicable requirements.

Facility operation and maintenance plans are to be devel oped by the facility with in six(6) months of the issuance date of this permit and the data pertaining to the plan ma intained on site for at least 5 years. The plan and associated recordkeeping pr ovides documentation of this facility’s implementation of its obligation to operate ac cording to good air pollution control practice.

Good air pollution control practice is achieved by adoption of quality control standards in the operation and maintenance procedures for air po llution control that are comparable to industry quality control standards for the production proce sses associated with this emission point.

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 61 

### Emission Point ID Number: 0690-0-F

Associated Equipment

Associated Emission Unit ID Numbers: 0690-3-F

______________________________________________________________________________


### Applicable Requirements

Emission Unit vented through this Emission Point: 0690-3-F Emission Unit Description: Hopper/Weigh Feeder

Raw Material/Fuel: Coal Rated Capacity: 200 tons/hr

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from these emission points sh all not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 40% (1)
Authority for Requirement: Iowa DNR Construction Permit 96-A-645-S3 567 IAC 23.3(2)"d"

(1) Per DNR Air Quality Policy 3-b-08, Opacity Limits , an exceedence of the indicator opacity of (10%) will require the owner/operator to prom ptly investigate the emission unit and make corrections to operations or equipment associated with the exceedence. The permit holder shall also file an "indicator opacity exceedence report" with the DNR field office and keep records as required in the policy. If exceedences continue after the corrections, the DNR may require additional proof to demonstrate compliance (e.g., stack testing).

Pollutant: Particulate Matter Emission Limits: 0.1 gr./dscf Authority for Requirement: Iowa DNR Construction Permit 96-A-645-S3 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.95 lb./hr and 0.52 tons/yr Authority for Requirement: Iowa DNR Construction Permit 96-A-645-S3

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Process throughput: The transfer of coal associated with this process shall not exceed the rate of 200 tons/hr or 600 tons/day.Title V Permit 03/29/04 62 Reporting & Record keeping: All records, as required below, shall be satisfactory for demonstrating compliance with a ll applicable operating limits. Records shall be maintained on site for five (5) years and be available fo r inspection upon request by representatives of the Department of Natural Resources. The records sh all show the following: A log shall be kept showing the date, the amount of coal (in tons/day) transfer associated with source 0690-4-F on that date, the total hours (in hrs/day) of opera tion for source 0690-3-F on that date, and the average rate (in tons/hr) of coal transfer fo r source 0690-3-F for that day.

Authority for Requirement: Iowa DNR Construction Permit 96-A-645-S3

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

Agency Approved Operation & Maintenance Plan Required? Yes No

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 63 

### Emission Point ID Number: 0723-0-F

Associated Equipment

Associated Emission Unit ID Numbers: 0723-1-F Emissions Control Equipment ID Nu mbers: 0723-C to 0727-C and 1732-C Emissions Control Equipment Description: Baghouses

______________________________________________________________________________ 

### Applicable Requirements

Emission Unit vented through this Emission Point: 0723-1-F Emission Unit Description: Cli nker Reclaim Vibrating Feeders

Raw Material/Fuel: Clinker Rated Capacity: 180 TPH

Emission Limits (lb./hr, gr./ dscf, lb./MMBtu, % opacity, etc.) The emissions from this emission point s hall not exceed the levels specified below.

Pollutant: Opacity Emission Limit(s): 10% (1)
Authority for Requirement: Iowa DNR Construction Permit 78-A-236-S4 567 IAC 23.1(4)"bl"

40 CFR 63.1348

(1) If opacity greater than that observed in the initial performance test is viewed other than startup, shutdown, or malfunction, a stack test may be re quired to demonstrate compliance with the particulate standard.

Pollutant: Particulate Matter Emission Limits: 0.1 gr/dscf Authority for Requirement: Iowa DNR Construction Permit 78-A-236-S4 567 IAC 23.3(2)"a"

Pollutant: PM 10 Emission Limits: 0.43 lb/hr Authority for Requirement: Iowa DNR Construction Permit 78-A-236-S4

Operational Limits & Requirements The owner/operator of this equipment shall comp ly with the operational limits and requirements

listed below.

Reporting & Record keeping:Title V Permit 03/29/04 64 All records as required by th is permit shall be kept on-site for a minimum of five (5) years and shall be available for inspection by the DNR. Records sh all be legible and maintained in an orderly

manner. The records sh all show the following:

Recordkeeping for NESHAP 40 CFR 63 Subpart LLL at the facility shall be done per 40 CFR

63.1355.

Authority for Requirement: Iowa DNR Construction Permit 78-A-236-S4 567 IAC 23.1(4)"bl"

40 CFR 63.1355

Emission Point Characteristics The emission point shall conform to the specifications listed below.

Stack Height (feet): Vents inside. Stack Diameter (inches): Vents inside. Stack Exhaust Flow Rate (acfm): Vents inside. Stack Temperature ( o F): Vents inside. Authority for Requirement: Iowa DNR Construction Permit 78-A-236-S4

The temperature and flow rate are intended to be representative and characte ristic of the design of the permitted emission point. The Department rec ognizes that the temperature and flow rate may vary with changes in the process and ambient conditions. If it is dete rmined that any of the emission point design characteristics are different than the values stated above, the owner/operator must notify the Department and obtain a permit amendment, if required.

Periodic Monitoring Requirements The owner/operator of this equipment shall comply with the periodic monitoring requirements listed

below.

The facility shall check the opacity as described in (a)(4)(i-vii) of Plant-Wide Conditions

Applicable Limits and Requiremen ts From 40 CFR 63 Subpart LLL

- Monitoring Requirements

.

Stack Testing: Pollutant – Opacity Stack Test to be Comp leted by (date) – May 31, 2004 Test Method – 40 CFR 60 Appendix A, Method 9 Authority for Requirement - Iowa DNR Construction Permit 85-A-052-S4

Agency Approved Operation & Maintenance Plan Required? Yes No Relevant requirements of O & M plan for th is equipment: Particulate Matter and Opacity - see Appendix B.

Facility Maintained Operation & Maintenance Plan Required? Yes No

Authority for Requirement: 567 IAC 22.108(3)"b"Title V Permit 03/29/04 65 

## IV. General Conditions

This permit is issued under th e authority of the Iowa Code subsection 455B.133(8) and in

accordance with 567 Iowa Admini strative Code chapter 22. G1. Duty to Comply 1. The permittee must comply with all conditions of the Title V permit. Any permit noncompliance constitutes a violation of the Act and is grounds for enforcement action; for a permit termination, revocation and reissuance, or modification; or for denial of a permit renewal application. 567 IAC 22.108(9)"a" 2. Any compliance schedule shall be supplemental to, and shall not sanction noncompliance with, the applicable requirements on which it is based. 567 IAC 22.105 (2)"h"(3) 3. Where an applicable requirement of the Act is more stringent than an applicable requirement of regulations promulgated under Titl e IV of the Act, both provisi ons shall be enforceable by the administrator and are incorporated into this permit. 567 IAC 22.108 (1)"b" 4. Unless specified as either "state enforceable only " or "local program enforceable only", all terms and conditions in the permit, including provision s to limit a source's potential to emit, are enforceable by the administrator and citizens under the Act. 567 IAC 22.108 (14) 5. It shall not be a defense for a permittee, in an enforcement ac tion, that it would have been necessary to halt or reduce the permitted activity in order to maintain compliance with the conditions of the permit. 567 IAC 22.108 (9)"b" G2. Permit Expiration 1. Except as provided in 567 IAC 22.104, the expirati on of this permit terminates the permittee's right to operate unless a timely and complete ap plication has been submitted for renewal. Any testing required for renewal shall be comp leted before the application is submitted. 567 IAC 22.116(2) 2. To be considered timely, the ow ner, operator, or designated repr esentative (where applicable) of each source required to obtain a Title V permit sha ll present or mail the Air Quality Bureau, Iowa Department of Natural Resources, Air Qualit y Bureau, 7900 Hickman Rd, Suite #1, Urbandale, Iowa 50322, two copies (three if your facility is located in Linn or Polk county) of a complete permit application, at least 6 months but not more than 18 months prior to the date of permit expiration. An additional copy must also be sent to EPA Region VII, Attention: Chief of Air Permits, 901 N. 5th St., Kansas City, KS 66101. The application must include all emission points, emission units, air pollution contro l equipment, and monitoring de vices at the facility. All emissions generating activities, in cluding fugitive emissions, must be included. The definition of a complete application is as indicated in 567 IAC 22.105(2). 567 IAC 22.105 G3. Certification Requirement fo r Title V Related Documents Any application, report, compliance certification or other document submitted pursuant to this permit shall contain certification by a responsible o fficial of truth, accuracy, and completeness. All certifications shall state that, based on informati on and belief formed after reasonable inquiry, the

statements and information in the docu ment are true, accurate, and complete. 567 IAC 22.107 (4)

G4. Annual Compliance Certification By March 31 of each year, the permittee shall su bmit compliance certifications for the previous calendar year. The certifications shall include de scriptions of means to monitor the compliance

status of all emissions sources including emissions limitations, sta ndards, and work practices in accordance with applicable requirements. The ce rtification for a source shall include the identification of each term or condition of the perm it that is the basis of the certification; theTitle V Permit 03/29/04 66 compliance status; whether compliance was conti nuous or intermittent; the method(s) used for determining the compliance status of the source, currently and over the re porting period consistent with all applicable department rules. For sources determined not to be in compliance at the time of compliance certification, a compliance schedule sh all be submitted which provides for periodic progress reports, dates for achievi ng activities, milestones, and an explanation of why any dates were missed and preventive or corrective measures. The compliance certification shall be submitted to the administrator, director, a nd the appropriate DNR Field office. 567 IAC 22.108 (15)"e" G5. Semi-Annual Monitoring Report By March 31 and September 30 of each year, the permittee shall submit a report of any monitoring required under this permit for the 6 month periods of July 1 to December 31 and January 1 to June 30, respectively. All instances of deviations from permit requireme nts must be clearly identified in these reports, and the report must be signed by a responsible official, consistent with 567 IAC 22.107(4). The semi-annual monitoring report shall be s ubmitted to the director and the appropriate

DNR Field office. 567 IAC 22.108 (5)

G6. Annual Fee 1. The permittee is required under subrule 567 IAC 22.106 to pay an annual fee based on the total tons of actual emissions of each regulated air pollutant. Beginning July 1, 1996, Title V operating permit fees will be paid on July 1 of each year. Th e fee shall be based on emissions for the previous calendar year.

2. The fee amount shall be calcula ted based on the first 4,000 tons of each regulated air pollutant emitted each year. The fee to be charged per ton of pollutant will be available from the department by June 1 of each year. The Responsible Official w ill be advised of any change in the annual fee per ton of pollutant. 3. The following forms shall be submitted annually by March 31 documenting actual emissions for the previous calendar year. a. Form 1.0 "Facility Identification"; b. Form 4.0 "Emissions unit-actual operations and emissions" for each emission unit; c. Form 5.0 "Title V annual emissions summary/fee"; and d. Part 3 "Application certification." 4. The fee shall be submitted annually by July 1. The fee shall be submitted with the following

forms: a. Form 1.0 "Facility Identification"; b. Form 5.0 "Title V annual emissions summary/fee"; c. Part 3 "Application certification." 5. If there are any changes to the emission calcul ation form, the department shall make revised forms available to the public by January 1. If revised forms are not available by January 1, forms from the previous year may be used and th e year of emissions documented changed. The department shall calculate the total statewide Title V emissions for the prior calendar year and make this information available to the publi c no later than Apr il 30 of each year.

6. Phase I acid rain affected units under section 404 of the Act sha ll not be required to pay a fee for emissions which occur during th e years 1993 through 1999 inclusive. 7. The fee for a portable emissions unit or stationary source which operates both in Iowa and out of state shall be calculated only for emissions from the source while operating in Iowa. 8. Failure to pay the appropriate Ti tle V fee represents cause for revocation of the Title V permit as indicated in 567 IAC 22.115(1)"d". G7. Inspection of Premises, Records, Equipment, Methods and DischargesTitle V Permit 03/29/04 67 Upon presentation of proper credentials and any ot her documents as may be required by law, the permittee shall allow the director or the di rector's authorized representative to: 1. Enter upon the permittee's premises where a Title V source is located or emissions-related activity is conducted, or where records must be kept under the conditions of the permit; 2. Have access to and copy, at reasonable times, a ny records that must be kept under the conditions of the permit; 3. Inspect, at reasonable times, any facilities, equipment (including mon itoring and air pollution control equipment), practices, or operations regulated or required under the permit; and 4. Sample or monitor, at reasonable times, substa nces or parameters for the purpose of ensuring compliance with the permit or ot her applicable requirements. 567 IAC 22.108 (15)"b" G8. Duty to Provide Information The permittee shall furnish to the director, within a reasonable time, any information that the director may request in writing to determine whether cause exists for modifying, revoking and reissuing, or terminating the perm it or to determine compliance w ith the permit. Upon request, the permittee also shall furnish to the di rector copies of records required to be kept by the permit, or for information claimed to be confidential, the perm ittee shall furnish such records directly to the administrator of EPA along with a claim of confidentiality. 567 IAC 22.108 (9)"e" G9. General Maintenance and Repair Duties The owner or operator of any air emissi on source or control equipment shall: 1. Maintain and operate the equipment or control e quipment at all times in a manner consistent with good practice for minimizing emissions. 2. Remedy any cause of excess emissi ons in an expeditious manner. 3. Minimize the amount and duration of any exce ss emission to the maximum extent possible during periods of such emissions. These measures ma y include but not be limited to the use of clean fuels, production cutbacks, or the use of alternate proce ss units or, in the case of utilities, purchase of electrical power until repairs are completed. 4. Schedule, at a minimum, routine maintenance of equipment or control equipment during periods of process shutdowns to the maximum extent possible. 567 IAC 24.2(1) G10. Recordkeeping Requirements for Compliance Monitoring 1. In addition to any source spec ific recordkeeping requirements contained in this permit, the permittee shall maintain the following compliance monitoring records, where applicable: a. The date, place and time of sampling or measurements b. The date the analyses were performed. c. The company or entity that performed the analyses. d. The analytical techniques or methods used. e. The results of such analyses; and f. The operating conditions as existing at the time of sampling or measurement. g. The records of quality assurance for continuous compliance monitoring systems (including but not limited to quality control activitie s, audits and calibration drifts.) 2. The permittee shall retain reco rds of all requ ired compliance monitoring data and support information for a period of at least 5 years fr om the date of compliance monitoring sample, measurement report or application. Support inform ation includes all calibration and maintenance records and all original strip ch art recordings for continuous comp liance monitoring, and copies of all reports require d by the permit. 3. For any source which in its application identi fied reasonably anticipated alternative operating scenarios, the permittee shall:Title V Permit 03/29/04 68 a. Comply with all terms and c onditions of this permit specific to each alternative scenario. b. Maintain a log at the permitted facility of the scenario under which it is operating. c. Consider the permit shield, if provided in this permit, to extend to all terms and conditions under each operating scenario. 567 IAC 22.108(4), 567 IAC 22.108(12) G11. Evidence used in establishing that a violation has or is occurring. Notwithstanding any other provisions of these rules, any credible evidence may be used for the purpose of establishing whether a person has violated or is in violation of any provisions herein. 1. Information from the use of the following methods is presumptively credible evidence of whether

a violation has occurred at a source: a. A monitoring method approved for the source and incorporated in an operating permit pursuant to 567 Chapter 22; b. Compliance test methods speci fied in 567 Chapter 25; or c. Testing or monitoring methods approved for th e source in a constructio n permit issued pursuant to 567 Chapter 22. 2. The following testing, monitoring or informati on gathering methods are presumptively credible testing, monitoring, or inform ation gathering methods: a. Any monitoring or testing methods provided in these rules; or b. Other testing, monitoring, or information gathering methods that produce information comparable to that produced by any met hod in subrule 21.5(1) or this subrule. 567 IAC 21.5(1)- 567 IAC 21.5(2)

G12. Prevention of Accidental Release: Risk Manage ment Plan Notification and Compliance

Certification If the permittee is required to develop and register a risk mana gement plan pursuant to section 112(r) of the Act, the permittee shall notify the depa rtment of this requirement. The plan shall be filed with all appropriate authorities by the deadline specified by EPA. A certification that this risk management plan is being properly implemented shall be included in the annual compliance certification of this permit. 567 IAC 22.108(6)

G13. Hazardous Release The permittee must report any situation involving the actual, imminent, or probable release of a hazardous substance into the atmosphere which, because of the quantity, strength and toxicity of the substance, creates an immediate or potential da nger to the public health, safety or to the environment. A verbal report shall be made to the department at (515) 281-8694 and to the local police department or the office of the sheriff of th e affected county as soon as possible but not later than six hours after the discovery or onset of the condition. This verbal report must be followed up with a written report as indicated in 567 IAC 131.2(2). 567 IAC Chapter 131-State Only

G14. Excess Emissions and Excess Emissions Reporting Requirements 1. Excess Emissions. Excess emission during a period of startup, shutdown, or cleaning of control equipment is not a violation of the emission stan dard if the startup, shutdown or cleaning is accomplished expeditiously and in a manner c onsistent with good practice for minimizing emissions. Cleaning of control equipment which does not require the shutdown of the process equipment shall be limited to one six-minute pe riod per one-hour period. An incident of excess emission (other than an incident during startup, shutdown or cleaning of c ontrol equipment) is a violation. If the owner or operato r of a source maintains that the incident of excess emission was due to a malfunction, the owner or operator must s how that the conditions wh ich caused the incident of excess emission were not preventable by r easonable maintenance and control measures. Determination of any subsequent enforcement action will be made following review of this report. If excess emissions are occurring, either the control equipment causing the excess emission shall beTitle V Permit 03/29/04 69 repaired in an expeditious manner or the process generating the emissions shall be shutdown within a reasonable period of time. An expeditious manner is the time nece ssary to determine the cause of

the excess emissions and to correct it within a reasonable period of time. A reasonable period of time is eight hours plus the period of time required to shut down the process without damaging the process equipment or control equipment. In the cas e of an electric utility, a reasonable period of time is eight hours plus the period of time until comp arable generating capacity is available to meet

consumer demand with the affected unit out of servic e, unless, the director shall, upon investigation, reasonably determine that continued operation cons titutes an unjustifiable environmental hazard and issue an order that such operation is not in the public interest and require a process shutdown to commence immediately. 2. Excess Emissions Reporting a. Oral Reporting of Excess Emissions. An incident of excess emission (other than an incident of excess emission during a period of startup, shutdown, or cleani ng) shall be reported to the appropriate field office of the department within ei ght hours of, or at the st art of the first working day following the onset of the incident. The report ing exemption for an incident of excess emission during startup, shutdown or cleani ng does not relieve the owner or operator of a source with continuous monitoring equipment of the obligati on of submitting reports required in 567-subrule 25.1(6). An oral report of excess emission is not required for a source with operational continuous monitoring equipment (as specified in 567-subrul e 25.1(1) ) if the incident of excess emission

continues for less than 30 minutes and does not exceed the applicable visible emission standard by more than 10 percent opacity. The oral report may be made in person or by telephone and shall include as a minimum the following: i. The identity of the equipment or source operati on from which the excess emission originated and

the associated stack or emission point. ii. The estimated quantity of the excess emission. iii. The time and expected duration of the excess emission.

iv. The cause of the excess emission. v. The steps being taken to remedy the excess emission. vi. The steps being taken to limit the excess emission in the interim period. b. Written Reporting of Excess Emissions. A written re port of an incident of excess emission shall be submitted as a follow-up to all required oral reports to the department within seven days of the onset of the upset condition, and shal l include as a minimum the following: i. The identity of the equipment or source operation point from which the excess emission originated and the associat ed stack or emission point. ii. The estimated quantity of the excess emission.

iii. The time and duration of the excess emission.

iv. The cause of the excess emission. v. The steps that were taken to remedy and to pr event the recurrence of the incident of excess

emission. vi. The steps that were taken to limit the excess emission.

vii. If the owner claims that the excess emissi on was due to malfunction, documentation to support

this claim. 567 IAC 24.1(1)-567 IAC 24.1(4) 3. Emergency Defense for Excess Emissions. For th e purposes of this permit, an “emergency” means any situation arising from sudden and reas onably unforeseeable even ts beyond the control of the source, including acts of God, which requires immediate corrective ac tion to restore normal operation, and that causes the source to exceed a technology-based emission limitation under the permit due to unavoidable increases in emissions attributable to the emergency. An emergency shallTitle V Permit 03/29/04 70 not include non-compliance, to the extent caus ed by improperly designed equipment, lack of preventive maintenance, careless or improper operation or operator error. An emergency constitutes an affirmative defense to an action brought for non-compliance with technology based limitations if it can be demonstrated through properly signed c ontemporaneous operating logs or other relevant

evidence that: a. An emergency occurred and that the permittee can identify the cause(s) of the emergency; b. The facility at the time was being properly operated; c. During the period of the emergency, the permitt ee took all reasonable steps to minimize levels of

emissions that exceeded the emissions standard s or other requirements of the permit; and d. The permittee submitted notice of the emergency to the director by certified mail within two working days of the time when the emissions limita tions were exceeded due to the emergency. This notice must contain a description of the emergenc y, any steps taken to mitigate emissions, and

corrective actions taken. 567 IAC 22.108(16) G15. Permit Deviation Reporting Requirements A deviation is any failure to meet a term, cond ition or applicable requirement in the permit. Reporting requirements for deviations that result in a hazardous re lease or excess emissions have been indicated above (see G13 and G14). Unless mo re frequent deviation re porting is specified in the permit, any other deviation shall be documen ted in the semi-annual m onitoring report and the annual compliance certification (see G4 and G5). 567 IAC 22.108(5)"b" G16. Notification Requirements for Sources That Become Subject to NSPS and NESHAP Regulations During the term of this permit, the permittee must notify the department of any source that becomes subject to a standard or othe r requirement under 567-subrule 23.1(2) (standards of performance of new stationary sources) or sect ion 111 of the Act; or 567-subrule 23.1(3) (emissions standards for hazardous air pollutants), 567-subrule 23.1(4) (emissi on standards for hazardous air pollutants for source categories) or section 112 of the Act. This notification shall be su bmitted in writing to the department pursuant to the notification requi rements in 40 CFR Section 60.7, 40 CFR Section 61.07, and/or 40 CFR Section 63.9. 567 IAC 23.1(2), 567 IAC 23.1(3), 567 IAC 23.1(4) G17. Requirements for Making Changes to Emis sion Sources That Do Not Require Title V

Permit Modification 1. Off Permit Changes to a Source. Pursuant to section 502(b)(10) of the CAAA, the permittee may make changes to this installation/f acility without revising this permit if: a. The changes are not major modifications under any provision of any program required by section 110 of the Act, modifications under section 111 of the act, modifications u nder section 112 of the act, or major modifications as defined in 567 IAC Chapter 22. b. The changes do not exceed the emissions allowa ble under the permit (wheth er expressed therein as a rate of emissions or in terms of total emissions); c. The changes are not modifications under any provi sions of Title I of the Act and the changes do not exceed the emissions allowable under the perm it (whether expressed therein as a rate of emissions or as total emissions); d. The changes are not subject to any requirement under Title IV of the Act. e. The changes comply with all applicable requirements. f. For such a change, the permitted source provides to the department and the administrator by certified mail, at least 30 days in advance of the proposed change, a written notification, including the following, which must be attached to th e permit by the source, the department and the

administrator:Title V Permit 03/29/04 71 i. A brief description of the change within the permitted facility, ii. The date on which the change will occur, iii. Any change in emission as a result of that change, iv. The pollutants emitted subject to the emissions trade v. If the emissions trading provisions of the st ate implementation plan are invoked, then Title V permit requirements with which the source shall comply; a description of how the emissions increases and decreases will comp ly with the terms and conditions of the Title V permit. vi. A description of the trading of emissions increases and decrea ses for the purpose of complying with a federally enforceable emissions cap as sp ecified in and in compliance with the Title V permit; and vii. Any permit term or condition no longe r applicable as a result of the change. 567 IAC 22.110(1) 2. Such changes do not include ch anges that would violate applicable requirements or contravene federally enforceable permit terms and conditions that are monitoring (including test methods), record keeping, reporting, or comp liance certifica tion requirements. 567 IAC 22.110(2) 3. Notwithstanding any other part of this rule, the director may, upon review of a notice, require a stationary source to apply for a Title V permit if the change does not meet the requirements of subrule 22.110(1). 567 IAC 22.110(3) 4. The permit shield provided in subrule 22.108(18) shall not apply to any change made pursuant to this rule. Compliance with the permit requirement s that the source will meet using the emissions trade shall be determined according to requirements of the state implementation plan authorizing the

emissions trade. 567 IAC 22.110(4) 5. No permit revision shall be required, under an y approved economic incentives, marketable permits, emissions trading and other similar progra ms or processes, for changes that are provided for in this permit. 567 IAC 22.108(11) G18. Duty to Modify a Title V Permit

1. Administrative Amendment. a. An administrative permit amendment is a perm it revision that is requ ired to do any of the following: i. Correct typographical errors ii. Identify a change in the name, address, or telephone number of any person identified in the permit, or provides a similar minor ad ministrative change at the source; iii. Require more frequent monitoring or reporting by the permittee; or iv. Allow for a change in ownership or operational control of a source where the director determines that no other change in the permit is necessar y, provided that a writte n agreement containing a specific date for transfer of pe rmit responsibility, coverage and lia bility between the current and new permittee has been submitted to the director. b. The permittee may implement the changes addr essed in the request for an administrative amendment immediately upon submittal of the re quest. The request shall be submitted to the

director. c. Administrative amendments to portions of permits containing provisions pursuant to Title IV of the Act shall be governed by regulations promulgated by the administrator under Title

IV of the Act.

2. Minor Permit Modification. a. Minor permit modification procedures may be used only for those permit modifications that do any of the following:Title V Permit 03/29/04 72 i. Do not violate any applicable requirements ii. Do not involve significan t changes to existing monitori ng, reporting or recordkeeping requirements in the Title V permit. iii. Do not require or change a case by case determination of an emission limitation or other standard, or increment analysis. iv. Do not seek to establish or change a permit term or condition for which there is no corresponding underlying applicable requirement and that the source has assumed in order to avoid an applicable requirement to which the source would otherwise be subject. Such terms and conditions include any federally enforceable em issions caps which the source would assume to

avoid classification as a modification under a ny provision under Title I of the Act; and an alternative emissions limit approved pursuant to re gulations promulgated under section 112(i)(5) of the Act.; v. Are not modifications under any pr ovision of Title I of the Act; and vi. Are not required to be pro cessed as significant modification. b. An application for minor permit revision shall be on the minor Title V modification application form and shall include at least the following: i. A description of the change, the emissions re sulting from the change, and any new applicable requirements that will apply if the change occurs. ii. The permittee's sugge sted draft permit iii. Certification by a responsible official, pursuant to 567 IAC 22.107(4), that the proposed

modification meets the criteria for use of a minor permit modification procedures and a request that such procedures be used; and iv. Completed forms to enable the department to no tify the administrator and the affected states as required by 567 IAC 22.107(7). c. The permittee may make the change proposed in its minor permit modification application immediately after it files the application. After the permittee makes this change and until the director takes any of the actions specified in 567 IAC 22.112(4) "a" to "c", the permittee must comply with both the applicable requirements governing the change and the proposed permit terms and conditions. During this time, the permittee need not comply with the existing permit terms and conditions it seeks to modify. However, if the permittee fails to comply with its proposed permit terms and conditions during this time period, exis ting permit term terms and conditions it seeks to modify may subject the faci lity to enforcement action.

3. Significant Permit Modification. Significant Title V modification procedures shall be used for applications requesting Title V permit modifica tions that do not qualify as minor Title V

modifications or as administrative amendments. Th ese include but are not limited to all significant changes in monitoring permit terms, every relaxati on of reporting or recordkeeping permit terms, and any change in the method of measuring compliance with existing requirements. Significant Title V modifications shall meet all requireme nts of 567 IAC Chapter 22, including those for applications, public participation, review by affected states, and review by the administrator, and those requirements that apply to Title V issuance and renewal. 567 IAC 22.111-567 IAC 22.113 The permittee shall submit an application for a si gnificant permit modification not later than three months after commencing operation of the change d source unless the existing Title V permit would prohibit such construction or change in operatio n, in which event the op eration of the changed source may not commence until the de partment revises the permit. 567 IAC 22.105(1)"a"(4) G19. Duty to Obtain Construction PermitsTitle V Permit 03/29/04 73 Unless exempted under 567 IAC 22.1(2), the permittee must not construct, install, reconstruct, or alter any equipment, control equipment or anaer obic lagoon without first obtaining a construction permit, conditional permit, or permit pursuant to 567 IAC 22.8, or permits required pursuant to 567 IAC 22.4 and 567 IAC 22.5. Such permits shall be obtai ned prior to the initi ation of construction,

installation or alterati on of any portion of th e stationary source. 567 IAC 22.1(1)

G20. Asbestos The permittee shall comply with 567 IAC 23.1(3) "a", and 567 IAC 23.2(3)"g" when conducting any renovation or demolition activities at the facility. 567 IAC 23.1(3)"a", and 567 IAC 23.2 G21. Open Burning The permittee is prohibited from conducting open burning, except as may be allowed by 567 IAC

23.2. 567 IAC 23.2 except 23.2(3)"h"; 567 IAC 23.2(3)"h" - State Only G22. Acid Rain (Title IV) Emissions Allowances The permittee shall not exceed any allowances that it holds under Title IV of the Act or the regulations promulgated there under . Annual emissions of sulfur dioxide in excess of the number of allowances to emit sulfur dioxide held by the owners and operators of th e unit or the designated representative of the owners and operators is pr ohibited. Exceedences of applicable emission rates are prohibited. “Held” in this context refers to both those allowances a ssigned to the owners and operators by USEPA, and those a llowances supplementally acquire d by the owners and operators. The use of any allowance prior to the year for which it was allocate d is prohibited. Contravention of any other provision of the permit is prohibited. 567 IAC 22.108(7) G23. Stratospheric Ozone and Climate Protection (Title VI) Requirements 1. The permittee shall comply with the standards for labeling of products using ozone-depleting substances pursuant to 40 CFR Part 82, Subpart E:

a. All containers in which a cl ass I or class II substance is st ored or transported, all products containing a class I substance, a nd all products directly manufactured with a class I substance must bear the required warning statement if it is bei ng introduced into interstate commerce pursuant to §

82.106.

b. The placement of the required warning statement must comply with the requirements pursuant to § 82.108. c. The form of the label bearing the required warn ing statement must comply with the requirements pursuant to § 82.110. d. No person may modify, remove, or interfere w ith the required warning statement except as described in § 82.112. 2. The permittee shall comply with the standards fo r recycling and emissions reduction pursuant to 40 CFR Part 82, Subpart F, except as provided for MVACs in Subpart B: a. Persons opening appliances for maintenance, serv ice, repair, or disposal must comply with the required practices pursuant to § 82.156. b. Equipment used during the maintena nce, service, repair, or dispos al of appliances must comply with the standards for recycling and recovery equipment pursuant to § 82.158. c. Persons performing maintenance, service, repair, or disposal of appliances must be certified by an approved technician certification program pursuant to § 82.161. d. Persons disposing of small appliances, MVACs, and MVAC-like appliances must comply with reporting and recordkeeping requirements pursuant to § 82.166. ("MVAC-like appliance" as defined at § 82.152) e. Persons owning commercial or industrial proce ss refrigeration equipment must comply with the leak repair requireme nts pursuant to § 82.156.Title V Permit 03/29/04 74 f. Owners/operators of appliances normally containing 50 or more pounds of refrigerant must keep records of refrigerant purch ased and added to such a ppliances pursuant to § 82.166. 3. If the permittee manufactures, transforms, imports, or exports a class I or class II substance, the permittee is subject to all the requirements as specified in 40 CFR part 82, Subpart A, Production and Consumption Controls. 4. If the permittee performs a service on motor (fl eet) vehicles when this service involves ozonedepleting substance refrigerant (or regulated s ubstitute substance) in the motor vehicle air conditioner (MVAC), the permittee is subject to all the applicable requirements as specified in 40 CFR part 82, Subpart B, Servicing of Motor Vehicl e Air Conditioners. The term "motor vehicle" as used in Subpart B does not include a vehicle in which final assemb ly of the vehicle has not been completed. The term "MVAC" as used in Subp art B does not include the air-tight sealed refrigeration system used as refrigerated cargo, or system used on passe nger buses using HCFC-22 refrigerant, 5. The permittee shall be allowed to switch from any ozone-depleti ng substance to any alternative that is listed in the Significant New Alternativ es Program (SNAP) promulgated pursuant to 40 CFR part 82, Subpart G, Significant Ne w Alternatives Policy Program. 40 CFR part 82 G24. Permit Reopenings 1. This permit may be modified, revoked, reopened, and reissued, or terminated for cause. The filing of a request by the permittee for a permit modificati on, revocation and reissuance, or termination, or of a notification of planned changes or anticipate d noncompliance does not stay any permit condition. 567 IAC 22.108(9)"c" 2. Additional applicable requirements under the Act become applicable to a major part 70 source with a remaining permit term of 3 or more years. Revisions shall be made as expeditiously as practicable, but not later than 18 months after the promulgation of such standards and regulations. a. Reopening and revision on this ground is not required if the permit has a remaining term of less than three years; b. Reopening and revision on this ground is not required if the effective date of the requirement is later than the date on which the permit is due to expi re, unless the original pe rmit or any of its terms and conditions have been extended pu rsuant to 40 CFR 70.4(b)(10)(i) or (ii) as amended to June 25,

1993. c. Reopening and revision on this ground is not required if the additiona l applicable requirements are implemented in a general permit that is applicab le to the source and the source receives approval for coverage under that general permit. 567 IAC 22.108(17)"a", 567 IAC 22.108(17)"b" 3. A permit shall be reopened and revise d under any of the following circumstances: a. The department receives notice that the admini strator has granted a petition for disapproval of a permit pursuant to 40 CFR 70.8(d) as amended to June 25, 1993, provided that the reopening may be stayed pending judicial revi ew of that determination; b. The department or the administrator determines that the Title V permit contains a material

mistake or that inaccurate statements were made in establishing the emissions standards or other terms or conditions of the Title V permit; c. Additional applicable requirements under the Act become applicable to a Title V source, provided that the reopening on this ground is not requi red if the permit has a remaining term of less than three years, the effective date of the requirement is later than the date on which the permit is due to expire, or the additional ap plicable requirements are implemented in a general permit that is applicable to the source and the source receives approval for coverage under that general permit. Such a reopening shall be complete not later than 18 months after promulga tion of the applicable requirement.Title V Permit 03/29/04 75 d. Additional requirements, including excess emissions requirements, become applicable to a Title IV affected source under the acid rain progr am. Upon approval by the administrator, excess emissions offset plans shall be deemed to be incorporated into the permit. e. The department or the administrator determines that the permit must be revised or revoked to ensure compliance by the source with the applicable requirements. 567 IAC 22.114(1) 4. Proceedings to reopen and reissue a Title V perm it shall follow the proc edures applicable to initial permit issuance and shall effect only thos e parts of the permit for which cause to reopen

exists. 567 IAC 22.114(2)

G25. Permit Shield 1. The director may expressly include in a Title V permit a provision stati ng that compliance with the conditions of the permit shall be deemed complia nce with any applicable requirements as of the date of permit issu ance, provided that: a. Such applicable requirements are included and are specifically identified in the permit; or b. The director, in acting on the permit application or revision, determines in writing that other requirements specifically identified are not applicable to the s ource, and the permit includes the determination or a concise summary thereof. 2. A Title V permit that does not expressly state that a permit shield exists shall be presumed not to provide such a shield. 3. A permit shield shall not al ter or affect the following: a. The provisions of Section 303 of the Act (emerg ency orders), including the authority of the administrator under that section; b. The liability of an owner or operator of a sour ce for any violation of applicable requirements prior to or at the time of permit issuance; c. The applicable requirements of the acid rain program, consistent with Section 408(a) of the Act; d. The ability of the department or the administrato r to obtain information from the facility pursuant

to Section 114 of the Act. 567 IAC 22.108 (18) G26. Severability The provisions of this permit are severable and if any provision or applica tion of any provision is found to be invalid by this department or a court of law, the application of such provision to other circumstances, and the remainder of this pe rmit, shall not be affected by such finding. 567 IAC 22.108 (8) G27. Property Rights The permit does not convey any property rights of any sort, or any exclusive privilege. 567 IAC 22.108 (9)"d" G28. Transferability This permit is not transferable from one source to anot her. If title to the facil ity or any part of it is transferred, an administrative amen dment to the permit must be sought to determine transferability of the permit. 567 IAC 22.111 (1)"d"

G29. Disclaimer No review has been undertaken on the engineering aspects of the equipment or control equipment other than the potential of that equipm ent for reducing air contaminant emissions. 567 IAC 22.3(3)"c" G30. Notification and Reporting Requirements for Stack Tests or Monitor Certification The permittee shall notify the department's stack test contact in writing not less than 30 days before a required test or performance evaluation of a continuous emission monitor is performed to determine compliance with an applicable requirement. For the department to consider test results a valid demonstration of compliance with applicable rules or a permit conditi on, such notice shall beTitle V Permit 03/29/04 76 given. Such notice shall include the time, the pl ace, the name of the person who will conduct the test and other information as required by the de partment. Unless specifically waived by the department's stack test contact, a pretest meeting shall be held not later than 15 days prior to conducting the compliance demonstration. The departme nt may accept a testing protocol in lieu of a pretest meeting. A representative of the department shall be permitted to witness the tests. Results

of the tests shall be submitted in writing to the department's stack test contact in the form of a comprehensive report within six weeks of the co mpletion of the testing. Compliance tests conducted pursuant to this permit shall be conducted with the source operating in a normal manner at its maximum continuous output as rated by the equipm ent manufacturer, or the rate specified by the owner as the maximum production rate at which th e source shall be operated. In cases where compliance is to be demonstrated at less than the maximum continuous output as rated by the equipment manufacturer, and it is the owner's inte nt to limit the capacity to that rating, the owner may submit evidence to the department that the sour ce has been physically altered so that capacity cannot be exceeded, or the department may re quire additional testing, continuous monitoring, reports of operating levels, or any other inform ation deemed necessary by the department to determine whether such source is in compliance.

Stack test notifications , reports and corresponden ce shall be sent to:

Stack Test Review Coordinator Iowa DNR, Air Quality Bureau 7900 Hickman Road, Suite #1 Urbandale, IA 50322 (515) 242-6001 Within Polk and Linn Counties, stack test notific ations, reports and correspondence shall also be directed to the supervisor of the respective county air pollution program. 567 IAC 25.1(7)"a", 567 IAC 25.1(9) G31. Prevention of Air Pollution Emergency Episodes The permittee shall comply with the provisions of 567 IAC Chap ter 26 in the prevention of excessive build-up of air contaminants during air pollution episodes, thereby preventing the occurrence of an emergency due to the effects of these contaminants on the health of persons. 567 IAC 26.1(1)

G32. Contacts List The current address and phone number for reports a nd notifications to the EPA administrator is:

Chief of Air Permits EPA Region 7 Air Permits and Compliance Branch

901 N. 5 th Street Kansas City, KS 66101 (913) 551-7020 The current address and phone number for reports and notifications to the department or the

Director is: Chief, Air Quality Bureau Iowa Department of Natural Resources 7900 Hickman Road, Suite #1 Urbandale, IA 50322 (515) 242-5100Title V Permit 03/29/04 77 Reports or notifications to the DNR Field Offices or local progr ams shall be directed to the supervisor at the appropriate fi eld office or local program. Curre nt addresses and phone numbers

are:

Field Office 1

909 West Main – Suite 4

Manchester, IA 52057 (563) 927-2640 Field Office 2

P.O. Box 1443 2300-15th St., SW Mason City, IA 50401 (641) 424-4073

Field Office 3

1900 N. Grand Ave. Spencer, IA 51301

(712) 262-4177 Field Office 4 1401 Sunnyside Lane

Atlantic, IA 50022

(712) 243-1934

Field Office 5

401 SW 7 th Street, Suite I

Des Moines, IA 50309 (515) 725-0268 Field Office 6

1023 West Madison Street Washington, IA 52353-1623 (319) 653-2135

Polk County Planning & Development Air Quality Division

5885 NE 14th St. Des Moines, IA 50313 (515) 286-3351 Linn County Public Health Dept.

Air Pollution Control Division 501 13th St., NW Cedar Rapids, IA 52405 (319) 892-6000Title V Permit 03/29/04 78 

## Appendix A: Administrative Consent Order # 98-AQ-08Title V Perm it 03 /29 / 04 79Title V Perm it 03 /29 / 04 80Title V Perm it 03 /29 / 04 81Title V Perm it 03 /29 / 04 82Title V Perm it 03 /29 / 04 83Title V Perm it 03 /29 / 04 84Title V Perm it 03 /29 / 04 85Title V Perm it 03 /29 / 04 86Title V Perm it 03 /29 / 04 87Title V Perm it 03 /29 / 04 88Title V Perm it 03 /29 / 04 89Title V Perm it 03 /29 / 04 90Title V Perm it 03 /29 / 04 91Title V Perm it 03 /29 / 04 92Title V Perm it 03 /29 / 04 93Title V Perm it 03 /29 / 04 94Title V Perm it 03 /29 / 04 95Title V Perm it 03 /29 / 04 96Title V Perm it 03 /29 / 04 97Title V Perm it 03 /29 / 04 98Title V Perm it 03 /29 / 04 99Title V Perm it 03 /29 / 04 10 0Title V Perm it 03 /29 / 04 10 1Title V Perm it 03 /29 / 04 10 2Title V Perm it 03 /29 / 04 10 3Title V Perm it 03 /29 / 04 10 4Title V Permit 03/29/04 105 

## Appendix B: Operation & Maintenance Plans

# Lafarge North AmericaDavenport Plant Operations & Maintenance

Plan

Davenport Plant

301 E

. Fr ont St.

PO Box 690 Buffalo, IA 52728

1 06 Title V Perm it 03 /29 / 04Title V Permit 03/29/04 107 TABLE OF CONTENTS

1.0 Introduction

1.1 Process Description

1.2 System Definition

2. 0 RAW MATERIAL PREPARATION SYSTEM

3.0 PYROPROCESSING (KILN) SYSTEM, COAL/COKE HANDLING SYSTEM

4.0 PYROPROCESSING (CLINKER COOLER) SYSTEM

5.0 CEMENT PRODUCTION SYSTEM

6.0 CEMENT SHIPPING SYSTEM

7.0 COMBUSTION SYSTEM INSPECTIONTitle V Permit 03/29/04 108 

### 1.0 Introduction

Lafarge North America owns and operates a cement manufacturing plant on its property in Scott County, approximately one-mile northeast of Buffalo, IA. The Lafarge-Buffalo property encompasses approximately 740 acres, situated at approximately 41 degrees, 28 minutes north latitude and 90 degrees, 41 minutes west longitude along Highway 22. The operation includes an open pit mine quarry north of the highway and a cement manufacturing plant south of the highway that includes a long, dry cement kiln, a preheater / precalciner tower and a finish mill. The loca tion of the facility is shown on Figure 1-1.

The plant street address is: Cement Group / Davenport Iowa

301 E. Front Street Buffalo, IA 52728

The facilities are subject to regulation under 40 CFR 63 Subpart LLL, National Emission Standards for

Hazardous Air Pollutants from the Portland Cement Manufacturing Industry (PC MACT Standards) and must be in compliance with the standards by June 14, 2002. In order to be in compliance, Lafarge has developed the compliance plans required to satisfy th e PC MACT standards including these Operations and Maintenance Plans for each system at the plant.



### 1.1 Process Description

Lafarge obtains the primary raw material (limestone ) for Portland cement manufacturing from an open pit mine adjacent to the cement plant. The limestone is crushed using a Humboldt Wedag impact type crusher with a capacity of 1300 tons per hour of minus 60” quarry run to 95% minus 3 1⁄2” product.

The crushed limestone is carried across highway 22 via a belt conveyor to the top of a storage dome on the plant side. The conveyor discharges to a motor operated 2-way gate which directs the material either to the stacker belt conveyor for building a storage pile in th e dome with a 15,000-ton capacity, or to another belt conveyor (360). 360-belt conveyor discharges the material to another motorized 2-way gate that directs the material either to the “high” lime s ilo with a capacity of 500 tons or to th e “low rock” silo with a capacity of 2,000 tons.

The “low rock” mixture is reclaimed from the dome storage using a slope-raking system consisting of adjustable harrows. The harrows rake the face of th e pile in a radial, back and forth motion causing a uniform layer of material from the entire pile face to flow to a scraper conveyor. The conveyor forces the material to the center column and discharg es to a surge bin with a 100-ton capacity.

“Low rock” and “high rock” are discharged from their respective bins and fed proportionally to the raw mill rotary air lock, which discharges directly to an Allis Chalmers roller mill with a SLF 6150 classifier. The rated capacity of the raw mill is 230 stph with a feed size of minus 4 inches to a fineness of 85% minus 200 mesh, while simultaneously drying the raw mix from a moisture content of 8.6% to 1⁄2%.

The raw mix from the roller mill is pneumatically conveye d via an airlift to the top of a homogenizing silo with a capacity of 10,000 tons. Another vertical ai rlift conveys material from the homogenizing silo (kiln feed) to the top of a preheater tower to a level storage bin. From the bin material is fed to an air duct between stages 1 and 2 of a 4-stage preheater/precalciner.Title V Permit 03/29/04 109 The preheated material is fed to a coal-fired precalcine r where the material and fuel are premixed before being introduced to a combustion air stream. The precalci ned material then enters a long dry rotary kiln that is coal fired through a combination burner pipe with oil nozzles used for warm up and start up.

Clinker is discharged from the kiln into an air quenchi ng moveable grate clinker cooler in which ambient air is blown up through the bottom of the cooler and up throug h the clinker bed. The hot air exiting the cooler is recycled to several different areas in the process.

Up to 50% of the kiln exhaust gases entering the preheater can be sent to an alkali bypass system in order to

decrease the amount of alkalis and sulfur in the clin ker product and to minimize buildup and plugging. The hot kiln gases are quenched through intermixing of ambi ent air. The gases leaving the quench chamber are then passed through a water spray gas conditioning towe r for further cooling before entering a dust collector.

Coal is reclaimed from its large outdoor storage pile through underground hoppers w ith vibrating feeders and fed to a 1250-ton storage silo. From the silo, coal is fed to a bowl mill where it is crushed and then conveyed to 2 – 5 ton tanks. 70% of the coal is used to fuel the precalciner and the remaining 30% is consumed in the kiln burner pipe.

Clinker discharges from the clinker cooler to a series of drag conveyors and elevators that eventually lead to one drag conveyor that can discharge the clinker into one of 2 – 37,500 ton silos. From the silos, clinker is conveyed to one of two finish mill storage bins and a thir d bin is used to store gypsum and can be filled with

a front-end loader.

Proportioned amounts of clinker and gypsum are fed to a 15-foot diameter, 51-foot long Allis Chalmers two compartment ball mill with a capacity of 180 tph. The cement product discharged from the mill passes through either a static separator, an air separator, or bot h. The fine material that makes its way through the separation process is passed through one of two cement coolers and then conveyed to storage silos in the shipping department.



### 1.2 System Definition

Based on the process description described above, Lafarge has divided opera tions at the cement plant into the following five systems:

1. Raw Material Preparation

2. Kiln, Coal/Coke Handling

3. Clinker Cooler

4. Cement Production

5. Cement ShippingTitle V Permit 03/29/04 110 

### PC MACT Operations an d Maintenance Plan

Raw Material Preparation System

1.0 Source Description

The Raw Material Preparation System is used to grind and combine raw materials prior to feeding them into the pyroprocessing systems. Its three main system components are:

• A raw material preparation system that reclaims individual raw materials and delivers them to the raw mill. The system includes the preblend dome , the limestone silos, and the reclaim conveyors

used to deliver material to the raw mill.

• A raw grinding system that prepares raw materials for combination. The system includes

the in-line raw mill.

• A homogenization silo (preheater/kiln feed) sy stem that combines and stores raw material mixture prepared for feed to the pyroprocessing system.



### 2.0 System Emission Points and Air Pollution Control Equipment

During Raw Material Preparation System operations, particulate matter are emitted at several emission points. The system includes five different baghouses to control particulate matter emissions during raw material preparation system operations. The fo llowing table summarizes system emission points and applicable air pollution control devices (APCDs), as we ll as the visual inspection interval (see Section 6.0):

Emission

Point # Description Air Pollution Control

Device Equipment

# VE Inspection

Interval

0404 Dust Collector – Homogenization

Silo Dust Collector Baghouse 31040400 Monthly

0420 Dust Collector – Raw Mill Airslides Dust Collector Baghouse 31042000 Monthly

0466 Dust Collector – In-line Raw Mill

and Kiln Dust Collector Baghouse 31046600 NA-COM

0498 Dust Collector – Raw Mill Feed Dust Collector Baghouse 31049800 Monthly

The dust collector baghouse for the in-line roller mill also services the kiln and preheat tower portions of the pyroprocessing system.



### 3.0 Applicable Emission Limit

The emission limits applicable to the Raw Ma terial Preparation System are the following:

• For the raw mill (40 CFR 63.1343): This will be covered in the O&M pl an for the Pyroprocessing – Kiln System

• For other equipment in the raw material preparation system (40 CFR 63.1348): Visible emissions must not exceed 10 percent opacity.Title V Permit 03/29/04 111 

### 4.0 Operator Procedures for Minimizing Visible Emissions From the Raw Material Preparation System During Normal Raw Material Preparation

Raw Material Preparation System operations are performed in accordance with the Lafarge Standard Operating Procedure (SOP) documents for Raw Material Preparation, Raw Material Grinding, and Homo Silo (Preheater/Kiln Feed). App licable SOPs include the following:

• Raw Mill—Normal Operation

• Homogenizing Silo—Normal Operation

These procedures are part of the plant’s electronic ope rating procedures system, which is maintained and kept current on the plant’s network drive (F:/shared/ environmental/O&M). The SOPs discuss how the plant shall be operated, and are used for job-specific traini ng. The tasks necessary to ensure proper operation of the Raw Material Preparation System with minimum emissions are also included within the SOPs.



### 5.0 Preventive Maintenance

Preventative maintenance work orders are maintain ed on MAXIMO, the Plant’s Windows-based electronic maintenance management system. Sample work orders are included in the appendices. All items on work orders are checked, but not recorded unless values are out of normal operating range. Maintenance Department technicians perform preventative maintenance (PM) tasks on the Raw Material Preparation System equipment, including:

Equipment # Equipment Description

– Function

21020200 Exhaust Fan – Dust Collector 203

21020300 Dust Collector – 207 Flop Gate, Head of 208 Belt, Tail of 387 Belt

21021600 Screw Conveyor – Dust Collector 218

21021700 Exhaust Fan – Dust Collector 218

21021800 Dust Collector – 225 Crusher, Head of 221 Belt, Tail of 208 Belt

31032700 Dust Collector – Dome, Reclaimer Tunnel, Tail of 320 Belt

31040300 Exhaust Fan – Dust Collector 404

31040400 Dust Collector – Homogenization Silo

31040500 Screw Conveyor – Dust Collector 405

31041900 Exhaust Fan – Dust Collector 420

31042000 Dust Collector – Roller Mill Airslides

31044000 Dust Collector – 475 Motor Cooling, ER 3A, ER 3B

31044100 Exhaust Fan – Dust Collector 440

31044200-31045800 Screw Conveyors 442-448, 452-458 – Dust Collector 466

31046600 Dust Collector – Kiln, In-line Raw Mill

31046700 Exhaust Fan – Dust Collector 466

31049800 Dust Collector – Raw Mill Feed

31049900 Exhaust Fan – Dust Collector 498

The Raw Material Preparation System PM schedule is maintained on MAXIMO. The PM schedules and the PM task lists for equipment in the Raw Material Pr eparation System are based upon past experience with similar equipment and the manufactur er’s documentation/recommendations.

Maintenance Technicians utilize ch ecklists from the MAXIMO database to conduct PM activities. The checklists include detailed steps and instructions for performance of these activities. Once work completionTitle V Permit 03/29/04 112 has been verified, checklist data is entered into MAXIMO. This and other relevant information are periodically archived within the database, establishing a verifiable record of ongoing PM activity completion and providing a method by which to review historical equipment performance.



### 6.0 Monitoring Requirements

6.1 Opacity Monitoring Requirements

The in-line roller mill baghouse opacity monitoring requi rements will be included in the O&M plan for

the Pyroprocessing – Kiln System.

6.2 Periodic Method 22 Visible Emi ssions Monitoring Requirements

As referenced in the table in Section 2.0, other part s of the Raw Material Preparation System, including the conveyors, limestone silo, homogenization silo will be tested for visible emissions once each month using USEPA Method 22 – Visual Determination of Fug itive Emissions from Material Sources and Smoke

Emissions from Flares. The Method 22 tests will be conducted by trained observers while the Raw Material Preparation System is in operation. The Maintenance Manager (or a designated representative) will schedule the Method 22 testing. Copies of the Method 22 procedures, Field Data Worksheets, and equipment needed to conduct the tests (stopwatch , etc.) will be maintained in the Environmental Department.

As noted in the Method 22 procedures, observers will take care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 22 test, the observer should determin e the presence or absence of visible emissions at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 22 tests will be one minute. Upon completion of the test, the observer will record the results on the Method 22 Field Data Worksheet, and submit the worksheet to the Maintena nce Manager, who will forward the results to the Environmental Manager (or a designated representative). The Environmental Manager (or a designated representative) will maintain the Method 22 records for a period of five years.

If visible emissions are noted during a monthly Method 22 test, the observer will immediately notify the Environmental Manager (or a designated representative) so that a six-minute Method 9 test can be started

within one hour of the initial observation.

Note: If monthly Method 22 tests indicate no visible emissions for six consecutive monthly tests, the testfrequency may be reduced to once every six months. If no visible emissions are detected on the next sixmonth test, the test frequency may be reduced to once per year. Any time visible emissions are detected by these Method 22 tests, monthly testing must be resumed [40 CFR 63.1350(a)(4)(ii) & (iii)].

6.3 Periodic Method 9 Opacity Tests

Whenever visible emissions are observed during a Method 22 test of the Raw Material Preparation System, an opacity test using the procedures described in USEPA Method 9 – Visual Determination of the Opacity of Emissions from Stationary Sources must be performed to determine if the 10 percent opacity limit is being met. If visible emissions are observed duri ng the one-minute Method 22 test, a six-minute Method 9

test must be conducted within one hour of the initial observation.Title V Permit 03/29/04 113 The Environmental Manager (or a designated representativ e) will ensure that trained and certified Method 9 observers are available each day the Method 22 t esting is conducted on the Raw Material Preparation System. Copies of the Method 9 procedures, Field Data Worksheets, and equipment needed to conduct the tests will be maintained in the Environmental Department.

As noted in the Method 9 procedures, observers will ta ke care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 9 test, the observer should determine the opacity of visible emissions plume at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 9 test will be six minutes. Upon completion of the test, the observer will record the results on the Method 9 Field Data Worksheet, and submit the worksheet to the Environm ental Department. The Environmental Manager (or a designated representative) will maintain the Me thod 9 records for a period of five years.

The observer will notify the Environm ental Manager (or a designated repr esentative) and initiate corrective action immediately if the Method 9 test indicates opacity exceeding 10 percent.



### 7.0 Periodic Review and Update of this Operations and Maintenance Plan

The Environmental Manager (or a designated representative) will review this Raw Material Preparation System Operations and Maintenance Plan once per year for adequacy and currency. Documentation of the annual review or update will be reta ined in Environmental Department files for five years.



### 8.0 Operations and Maintena nce Plan Revision History

Revision Date Purpose 1.0 March 2002 Initial plan generation

### PC MACT Operati ons an d Maintenance Plan

Pyroprocessing—Kiln System

1.0 Sour ce Description

The Kiln S y st em is used to manufacture cement c linker. Its five main s y stem co m ponents are:

• A solid fuel grinding and firing s y stem t h at pro cesses/ crushes coal and petroleum coke in preparation for fueling t h e kiln. .

• A preheater f eed and recir c ulation s y stem that routes raw material s to the preheater/precalcine r

tower.

• A preheater/p recalciner sy ste m that prepares ra w mate ri als to be fed to the kiln. The sy stem i n cludes the preheater/ p recalciner to wer.

• A kiln and i n

- line raw m ill dust collection sy stem th at rem oves dust from air leavi ng the ki ln be fore

it reaches the at m o sphere, i n cluding the kiln/raw m ill baghouse, the alkali by pass baghouse, and the

raw m ill/alkal i by pass stack.

• A rotary kiln sy stem that is used to m a nufact ure clinker from preheated and/or pre calcined raw

materi als. The sy stem incl udes the rotary kiln.



### 2.0 System Emi ssion Poi n ts and Air Pollution Control Equipment

During Kiln Sy stem operations, particul ate m a tt er ar e em itted at several em ission poi nts. The sy stem includes eight different baghouses to control particulate m a tter e m i s sions during kiln s y stem o p erations. The following table su mmarize s sy stem e m is sion points and a pplicable air pollution c ontrol devices (APCD s ), a s well as the visual inspection interval (see Section 6.0):

Emission

Point # Descripti o n A i r P o llution Co ntr o l

Device Equipment # VE Ins p ecti o n Inter val

0 466 Dust Colle ctor – Kiln and In- L in e Roll er Mi ll D u st co llector b a gho use 3 104 660 0 N A

- C O M

0 504 Dust C o l l ect or – 52 0 Ki l n Fee d

Lev e l Bin

, Ai rlift, Airslid es, 52 7 Sepa rator D u st co llector b a gho use 4 105 040 0 Mo n t h l y

05 3 5 Dust C o l l ect or – Wast e Dust B i n Dust col l ect o r bag h o u s e 41 0 5 3 5 00 M ont hl y

0 574 Dust C o l l ect or – T o p of C K D

Tank D u st co llector b a gho use 4 105 740 0 Mo n t h l y

0 594 D u st C o llecto r – A l k a li Byp a ss D u st co llector b a gho use 4 105 940 0 N A

- C O M

0 667 Du st C o llecto r

– C o al Mill

C y cl one D u st co llector b a gho use 4 306 670 0 Mo n t h l y

0 684 D u st C o llecto r

– C o al Silo D u st co llector b a gho use 4 306 840 0 Mo n t h l y



### 3.0 Applicable Emission Li mit

The em ission lim it s applicable to the Kiln S y stem are the following:

• For the kil n /i n-line raw m i ll sy stem (40 CFR 63.13 43 ):

1 14 Title V Perm it 03 /29 / 04Title V Permit 03/29/04 115 1. Particulate matter emissions must not exceed 0.15 kg/Mg of feed (dry basis);

2. Visible emissions must not exceed 20 percent opacity; and

3. Dioxin/furan emissions must be less than 0.40 ng/d scm (TEQ), corrected to 7% oxygen, with a baghouse inlet temperature less than 204 ° C; or

4. Dioxin/furan emissions must be less than 0.20 ng/d scm (TEQ, corrected to 7% oxygen, with a baghouse inlet temperature greater than or equal to 204 ° C.

• For other equipment in the kiln system (40 CFR 63. 1348): Visible emissions must not exceed 10 percent opacity.



### 4.0 Operator Procedures for Minimizing Visi ble Emissions From the Kiln System During Normal Kiln System Operations

Kiln System operations are performed in accordance w ith the Lafarge Standard Operating Procedure (SOP) documents for Solid Fuel Grinding and Firing, Preheater Feed and Recirculation, Preheater/Precalciner, Kiln and In-Line Raw Mill Dust Collection, and Rotary Kiln. Applicable SOPs include the following:

• Solid Fuel Grinding—Normal Operation

• Solid Fuel Handling/Loading-Normal Operation

• Preheater Tower—Normal Operation

• Rotary Kiln—Normal Operation

These procedures are part of the plant’s electronic ope rating procedures system, which is maintained and kept current on the plant’s network drive (F:/shared/ environmental/O&M). The SOPs discuss how the plant shall be operated, and are used for job-specific traini ng. The tasks necessary to ensure proper operation of the Kiln System with minimum emissions are also included within the SOPs.



### 5.0 Preventive Maintenance

Preventative maintenance work orders are maintain ed on MAXIMO, the Plant’s Windows-based electronic maintenance management system. Sample work orders are included in the appendices. All items on work orders are checked, but not recorded unless values are out of normal operating range. Maintenance Department technicians perform preventative mainte nance (PM) tasks on Kiln System and Coal/Coke Handling System equipment, including:

Equipment # Equipment Description – Function

31044200-31045800 Screw Conveyors 442-448, 452-458 – Dust Collector 466

31046600 Dust Collector – Kiln/In-Line Roller Mill

DAVYT4761 Thermocouple – Kiln/In-Line Roller Mill Dust Collector Inlet

31046700 Exhaust Fan – Dust Collector 466

31046400 Kiln Exhaust Stack

31046410 Gas Sampling – Kiln Exhaust Stack

31046420 O 2 Analyzer – Kiln Exhaust Stack

31046430 CO Analyzer – Kiln Exhaust Stack

31046440 NO X & SO 2 Analyzers – Kiln Exhaust Stack

31046460 Flowmeter – Kiln Exhaust Stack

31046621 Opacity Analyzer – Kiln Exhaust Stack

31046622 CEMS – Kiln Exhaust Stack

41050200 Screw Conveyor – Dust Collector 504

41050300 Exhaust Fan – Dust Collector 504Title V Permit 03/29/04 116 41050400 Dust Collector – 520 Kiln Feed Level Bin, Airlift, Airslides, 527 Separator

41053500 Dust Collector – Waste Dust Bin

41053600 Exhaust Fan – Dust Collector 535

41057400 Dust Collector – Top of CKD Tank
41058100-41058900,

41059200 Screw Conveyors 581-589, 592 – Dust Collector 594

41059400 Dust Collector – Alkali Bypass

41059401 Thermocouple – Alkali Bypass Dust Collector Inlet

41059500 Exhaust Fan – Dust Collector 594

41063600 Exhaust Fan – Dust Collector 637

41063700 Dust Collector – 610 Fan, Electric Room 2E

43066200 Screw Conveyor – Dust Collector 667

43066600 Exhaust Fan – Dust Collector 667

43066700 Dust Collector – Coal Mill Cyclone

43068300 Exhaust Fan – Dust Collector 684

43068400 Dust Collector – Coal Silo

The Kiln System and Coal/Coke Handling System PM schedules are maintained on MAXIMO. The PM schedules and the PM task lists for equipment in th ese systems are based upon past experience with similar equipment and the manufacturer’ s documentation/recommendations.

Maintenance Technicians utilize ch ecklists from the MAXIMO database to conduct PM activities. The checklists include detailed steps and instructions for performance of these activities. Once work completion has been verified, checklist data is entered into MAXIMO. This and other relevant information are periodically archived within the database, establishing a verifiable record of ongoing PM activity completion and providing a method by which to review historical equipment performance.



### 6.0 Monitoring Requirements

6.1 Opacity Monitoring Requirements

The kiln/in-line raw mill and alkali bypass baghouse emissions exit from a single stack (kiln exhaust stack) and are monitored for opacity using a continuous opacity monitor (COM) in accordance with 40 CFR 63.1350(c). The COM is installed, maintained, calibra ted, and operated as required by 40 CFR 63, Subpart A and 40 CFR 60 Appendix B PS-1. Opacity is maintained such that the 6-minute average opacity does not exceed 20 percent. (Note: The plant’s PSD permit re quires it to meet a 10 percent opacity on the kiln exhaust stack.)

6.2 Periodic Method 22 Visible Em issions Monitoring Requirements

As referenced in the table in Section 2.0, other parts of the Kiln System, including the CKD silo, kiln feed air lift, and coal mill/solid fuel grinding dust collector baghouses, will be tested for visible emissions once each month using USEPA Method 22 – Visual Determination of Fugitive Emissions from Material Sources and

Smoke Emissions from Flares. The Method 22 tests will be conducted by trained observers while the Kiln System is in operation. The Maintenance Manager (o r a designated representative) will schedule the Method 22 testing. Copies of the Method 22 procedures, Field Data Worksheets, and equipment needed to conduct the tests (stopwatch, etc.) will be maintained in the Environmental Department.Title V Permit 03/29/04 117 As noted in the Method 22 procedures, observers will take care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind. During the Method 22 test, the observer should determin e the presence or absence of visible emissions at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 22 tests will be one minute. Upon completion of the test, the observer will record the results on the Method 22 Field Data Worksheet, and submit the worksheet to the Maintena nce Manager, who will forward the results to the Environmental Manager (or a designated representative). The Environmental Manager (or a designated representative) will maintain the Method 22 records for a period of five years.

If visible emissions are noted during a monthly Method 22 test, the observer will immediately notify the Environmental Manager (or a designated representative) so that a six-minute Method 9 test can be started

within one hour of the initial observation.

Note: If monthly Method 22 tests indicate no visible emissions for six consecutive monthly tests, the testfrequency may be reduced to once every six months. If no visible emissions are detected on the next sixmonth test, the test frequency may be reduced to once per year. Any time visible emissions are detected by these Method 22 tests, monthly testing must be resumed [40 CFR 63.1350(a)(4)(ii) & (iii)].

6.3 Periodic Method 9 Opacity Tests

Whenever visible emissions are observed during a Method 22 test of the Kiln System, an opacity test using the procedures described in USEPA Method 9 – Visual Determination of the Opacity of Emissions from Stationary Sources must be performed to determine if the 10 percent opacity limit is being met. If visible emissions are observed during the one-minute Method 22 test, a six-minute Method 9 test must be conducted

within one hour of the initial observation.

The Environmental Manager (or a designated representativ e) will ensure that trained and certified Method 9 observers are available each day the Method 22 tes ting is conducted on the Kiln System. Copies of the Method 9 procedures, Field Data Worksheets, and equipm ent needed to conduct the tests will be maintained in the Environmental Department.

As noted in the Method 9 procedures, observers will ta ke care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 9 test, the observer should determine the opacity of visible emissions plume at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 9 test will be six minutes. Upon completion of the test, the observer will record the results on the Method 9 Field Data Worksheet, and submit the worksheet to the Environmental Department. The Environmental Manager (or a designated representative) will maintain the Me thod 9 records for a period of five years.

The observer will notify the Environm ental Manager (or a designated repr esentative) and initiate corrective action immediately if the Method 9 test indicates opacity exceeding 10 percent.



### 7.0 Periodic Review and Update of this Operations and Maintenance Plan

The Environmental Manager (or a designated representativ e) will review this Kiln System Operations and Maintenance Plan once per year for ad equacy and currency. Documentation of the annual review or update will be retained in Environmental Department files for five years.Title V Permit 03/29/04 118 

### 8.0 Operations and Maintena nce Plan Revision History

Revision Date Purpose 1.0 March 2002 Initial plan generation

### PC MACT Operati ons an d Maintenance Plan Coal/Coke Preparation System

1.0 Sour ce Description

The Coal/Coke Preparation System is used to gri nd and combine fuel m a teri als p r io r to f i ring the m into the pyroprocessing system s. Its two m a in system com ponents are:

• A silo for storing coarse coal and coke m a terial.

• A grinding system that prepares fuel m a terial s for com bustion. The system includes the coal

m ill.



### 2.0 System Emi ssion Poi n ts and Air Pollution Control Equipment

During Coal/Coke Preparation S y stem operations, particul ate m a tt er is em itted at several emission poi nts. The sy stem i n cludes two different baghouses to cont r o l particulate matter em issi ons duri ng coal/coke preparation sy stem operati ons. The following table summari zes sy ste m e m is sion points and a pplicable air pollution control devices (APCDs), a s well as the visual inspection interval (see Section 6.0):

Emission

Point # Description Air Po llutio n Contro l

Device Equipm ent

# VE Ins p ecti o n Inter val

0 667 Du st C o llecto r

– C o al Mill Du st C o llecto r Bag hou se 4 306 670 0 Week ly

06 8 4 Dust C o l l ect or – C o al / C oke Si l o Ve nt Dust C o l l ect or B a gh o u se 43 0 6 8 4 00 Weekl y



### 3.0 Applicable Emission Li mit

The em ission lim it s applicable to the Coa l/Coke Preparation Sy stem are the following:

• Em ission Points 0667 & 0684 have opacity lim its of 20%.



### 4.0 Operator Pr ocedures for Minimizin g Vi sible Emissions Fr om the Raw Material Preparation System During Normal Raw Material Preparation

Coal/Coke Preparation S y stem operations are perfor m ed in accordance with the Lafarge Standard Operating Procedure (SOP) docum ents for Solid Fuel Safety and Operations. Applicable SOPs include the following:

• Coal Mill-S afety and Operations

These procedures are part of the plant’s SOP da tabase located in the control room . The SOPs discuss how the plant shall be ope rated, and are us ed for job-sp ecific train i n g. The tasks necessary to ensure proper operation of the Fuel Preparation System wi th m i ni m u m em issions are also

included within the SOPs.



### 5.0 Preventive Maintenance

Preventative m a intenance work orders are m a intained on MAXIMO, the Plant’s W i ndows-based

electronic maintenance m a nage m e nt system . Sa mple work orders are include d in the appendices.

1 1 9 Title V Perm it 10 /26 / 04120 Title V Permit 10/26/04 All items on work orders are checked, but not recorded unless values are out of normal operating range. Maintenance Department technicians perform preventative maintenance (PM) tasks on the Coal/Coke Preparation System equipment, including:

Equipment # Equipment Description

– Function

43066600 666 DC Exhaust Fan-Dust Collector 667

43066200 662 Screw conveyor-Dust Collector 667

43068201 68201-Rotary Air Locks-Dust Collector 667

43066300 663- Rotary Air Locks-Dust Collector 667

43066400 664- Rotary Air Locks-Dust Collector 667

43066500 665- Rotary Air Locks-Dust Collector 667

43068700 687-Belt Conveyor

43068300 683 Exhaust Fan-Dust Collector 684

43066700 667 Dust Collector

43068400 684 Dust Collector

The Coal/Coke Preparation System PM schedule is maintained on MAXIMO. The PM schedules and the PM task lists for equipment in the Coal/CokePreparat ion System are based upon past experience with similar equipment and the manufacturer’ s documentation/recommendations.

Maintenance Technicians utilize ch ecklists from the MAXIMO database to conduct PM activities. The checklists include detailed steps and instructions for performance of these activities. Once work completion has been verified, checklist data is entered into MAXIMO. This and other relevant information are periodically archived within the database, establishing a verifiable record of ongoing PM activity completion and providing a method by which to review historical equipment performance.



### 6.0 Monitoring Requirements

6.1 Periodic Method 22 Visible Em issions Monitoring Requirements

As referenced in the table in Section 2.0, the co al mill and coal/coke si lo will be tested for visible emissions once each week using US EPA Method 22 – Visual Determination of Fugitive Emissions from Material Sources and Smoke Emissions from Flares. Trained

observers will conduct the Method 22 tests whil e the Coal/Coke Prepar ation System is in operation. The Maintenance Manager (or a designated representative) will schedule the Method 22 testing. Copies of the Method 22 procedures, Field Data Worksheets, and equipment needed to conduct the tests (st opwatch, etc.) will be maintained in the Environmental Department.

As noted in the Method 22 procedures, observers will take care to perform the test from the proper location relative to the sour ce and the sun, as well as to avoid degraded visibility of emissions caused by improper background contra st, ambient lighting, and observer position relative to lighting and wind.

During the Method 22 test, the observer should de termine the presence or absence of visible emissions at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 22 tests will be one minute. Upon completion of the test , the observer will121 Title V Permit 10/26/04 record the results on the Method 22 Field Data Worksheet, and submit the worksheet to the Maintenance Manager, who will forward the re sults to the Environmental Manager (or a designated representative). The Environmen tal Manager (or a desi gnated representative) will maintain the Method 22 records for a period of five years.

If visible emissions are noted during a monthly Method 22 test, the observer will immediately notify the Environmental Manager (o r a designated representative) so that a

six-minute Method 9 test can be started within one hour of the initial observation.



### 7.0 Periodic Review and Update of this Operations and Maintenance Plan

The Environmental Manager (or a designated representative) will review this Coal/Coke Preparation System Operations a nd Maintenance Plan once per year for adequacy and currency.

Documentation of the annual review or update will be retained in Environmental Department files for five years.



### 8.0 Operations and Maintena nce Plan Revision History

RevisionDate Purpose 1.0September 2004 Initial plan generation122 Title V Permit 10/26/04 

### PC MACT Operations an d Maintenance Plan

Pyroprocessing—Clinker Cooler System

1.0 Source Description

The Clinker Cooler System is used to cool cli nker produced by the kiln and prepare the clinker for storage and processing. Its three main system components are:

• A clinker cooler system that receives clinker fro m the kiln and blows air across it, including the clinker cooler, the clinker cooler fans, and the clinker chutes.

• A clinker handling and storage system that moves c linker from the clinker cooler to the clinker silos in preparation for further processing or handling. The system includes drag chains, a bucket elevator, and the clinker silos.

• A clinker cooler dust collection system that remov es dust from air leaving the clinker cooler before it reaches the atmosphere, including cooling fans, the clinker cooler baghouse, and the clinker cooler

stack.



### 2.0 System Emission Points and Air Pollution Control Equipment

During Clinker Cooler System operations, particulate matter are emitted at three emission points. The system includes one main baghouse and two dust collector baghouses to control particulate matter emissions at the clinker cooler, the clinker silo, and the cli nker elevator. The following table summarizes system emission points and applicable air pollution control devices (APCDs), as well as the visual inspection interval (See Section 6.0):

Emission

Point # Description Air Pollution Control

Device Equipment # VE Inspection

Interval

0611 Dust Collector – Clinker

Cooler Ductwork Dust collector baghouse 41061100 N/A—COM

0709 Dust Collector – Clinker/ Gypsum 712 Drag Conveyor Dust collector baghouse 41070900 Monthly

0743 Dust Collector – Clinker/ Gypsum Storage Silos Dust collector baghouse 41074300 Monthly



### 3.0 Applicable Emission Limit

The emission limit applicable to the Clinker Cooler System is particulate emissions must not exceed 0.050 kg/Mg of feed (dry basis), and visible emissions mu st not exceed 10 percent opacity (40 CFR 63.1345 and 63.1348).123 Title V Permit 10/26/04 

### 4.0 Operator Procedures for Minimizing Visibl e Emissions From the Clinker Cooler System During Normal Clinker Cooler System Operations

Clinker Cooler System operations are performed in accordance with the Lafarge Standard Operating Procedure (SOP) documents for Clinker Cooler, Clinke r Handling and Storage, and Clinker Cooler Dust Collection. Applicable SOPs include the following:

• Clinker Cooler—Normal Operation

• Clinker Handling—Normal Operation

These procedures are part of the plant’s electronic ope rating procedures system, which is maintained and kept current on the plant’s network drive (F:/shared/ environmental/O&M). The SOPs discuss how the plant shall be operated, and are used for job-specific traini ng. The tasks necessary to ensure proper operation of the Clinker Cooler System with minimum emissions are also included within the SOPs.



### 5.0 Preventive Maintenance

Preventative maintenance work orders are maintain ed on MAXIMO, the Plant’s Windows-based electronic maintenance management system. Sample work orders are included in the appendices. All items on work orders are checked, but not recorded unless valu es are out of normal operating range. Maintenance Department technicians perform preventative maintenance (PM) tasks on the Clinker Handling System equipment, including:

Equipment # Equipment Description - Function

41061000 Exhaust Fan – Dust Collector 611

41061100 Dust Collector – Clinker Cooler Ductwork

41061121 Opacity Analyzer – Clinker Cooler Exhaust Stack

410611A1, B1, C1, D1 Thermocouples – Dust Collector 611

41077400, 41077601, 41077602,

41077700-41078000 Screw Conveyors – Dust Collector 611

41070800 Exhaust Fan – Dust Collector 709

41070900 Dust Collector – Clinker/Gypsum 712 Drag Conveyor

41072300-41072700,

41073200 Dust Collectors – Clinker Tunnel

41074200 Exhaust Fan – Dust Collector 743

41074300 Dust Collector – Clinker/Gypsum Storage Silos

The Clinker Handling System PM schedule is maintain ed on MAXIMO. The PM schedules and the PM task lists for equipment in these systems are based upon past experience with similar equipment and the

manufacturer’s documentation/recommendations.

Maintenance Technicians utilize ch ecklists from the MAXIMO database to conduct PM activities. The checklists include detailed steps and instructions for performance of these activities. Once work completion has been verified, checklist data is entered into MAXIMO. This and other relevant information are periodically archived within the database, establishing a verifiable record of ongoing PM activity completion and providing a method by which to review historical equipment performance.124 Title V Permit 10/26/04 

### 6.0 Monitoring Requirements

6.1 Opacity Monitoring Requirements

The Clinker Cooler baghouse emissions are monitore d for opacity using a continuous opacity monitor (COM) in accordance with 40 CFR 63.1350(d). The COM is installed, maintained , calibrated, and operated as required by 40 CFR 63, Subpart A and 40 CFR 60 Appendix B PS-1. Opacity is maintained such that the 6-minute average opacity does not exceed 10 percent.

6.2 Periodic Method 22 Visible Em issions Monitoring Requirements

As referenced in the table in Section 2.0, other pa rts of the Clinker Cooler System, including the clinker elevator and clinker silo dust collector baghouses, will be tested for visible emissions once each month using USEPA Method 22 – Visual Determination of Fug itive Emissions from Material Sources and Smoke

Emissions from Flares. The Method 22 tests will be c onducted by trained observers while the Clinker Cooler System is in operation. The Maintenance Manager (o r a designated representative) will schedule the Method 22 testing. Copies of the Method 22 procedures, Field Data Worksheets, and equipment needed to conduct the tests (stopwatch, etc.) will be maintained in the Environmental Department.

As noted in the Method 22 procedures, observers will take care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 22 test, the observer should determin e the presence or absence of visible emissions at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 22 tests will be one minute. Upon completion of the test, the observer will record the results on the Method 22 Field Data Worksheet, and submit the worksheet to the Maintena nce Manager, who will forward the results to the Environmental Manager (or a designated representative). The Environmental Manager (or a designated representative) will maintain the Method 22 records for a period of five years.

If visible emissions are noted during a monthly Method 22 test, the observer will immediately notify the Environmental Manager (or a designated representative) so that a six-minute Method 9 test can be started

within one hour of the initial observation.

Note: If monthly Method 22 tests indicate no visible emissions for six consecutive monthly tests, the testfrequency may be reduced to once every six months. If no visible emissions are detected on the next sixmonth test, the test frequency may be reduced to once per year. Any time visible emissions are detected by these Method 22 tests, monthly testing must be resumed [40 CFR 63.1350(a)(4)(ii) & (iii)].

6.3 Periodic Method 9 Opacity Tests

Whenever visible emissions are observed during a Method 22 test of the Clinker Cooler System, an opacity test using the procedures described in USEPA Method 9 – Visual Determination of the Opacity of Emissions from Stationary Sources must be perform ed to determine if the 10 percent opacity limit is beingmet. If visible emissions are observed during the one-minute Method 22 test, a six-minute Method 9 test must be

conducted within one hour of the initial observation.

The Environmental Manager (or a designated representativ e) will ensure that trained and certified Method 9 observers are available each day the Method 22 testing is conducted on the Clinker Cooler System. Copies of the Method 9 procedures, Field Data Worksheets, a nd equipment needed to conduct the tests will be maintained in the Environmental Department.125 Title V Permit 10/26/04 As noted in the Method 9 procedures, observers will ta ke care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 9 test, the observer should determine the opacity of visible emissions plume at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 9 test will be six minutes. Upon completion of the test, the observer will record the results on the Method 9 Field Data Worksheet, and submit the worksheet to the Environmen tal Department. The Environmental Manager (or a designated representative) will maintain the Me thod 9 records for a period of five years.

The observer will notify the Environm ental Manager (or a designated repr esentative) and initiate corrective action immediately if the Method 9 test indicates opacity exceeding 10 percent.



### 7.0 Periodic Review and Update of this Operations and Maintenance Plan

The Environmental Manager will review this Clinker C ooler System Operations and Maintenance Plan once per year for adequacy and currency. Documentation of the annual review or up date will be retained in Environmental Department files for five years.



### 8.0 Operations and Maintena nce Plan Revision History

Revision Date Purpose 1.0 March 2002 Initial plan generation126 Title V Permit 10/26/04 

### PC MACT Operations an d Maintenance Plan

Cement Production System

1.0 Source Description

The Cement Production System is used to process clinker and gypsum into finished cement products ready for sale and shipping. Its three main system components are:

• A finish grinding system that processes/crushes clinker, including the gypsum and clinker weigh feeders, the finish mill conveyor, the finish mill, the grinding aid distribution system, the finish mill elevator, the separator, and the cement cooler.

• A cement transport system that routes finished ceme nt to the appropriate storage locations, including the conveyor belts to the overtrack silos and AE silos.

• A gypsum/clinker handling and storage system that is used to supply gypsum and clinker for finish milling of cement. The system includes the gypsum truck unloading, the gypsum reclaim loading hopper, th e gypsum storage silos, and the gypsum/clinker reclaim conveyors.



### 2.0 System Emission Points and Air Pollution Control Equipment

During Cement Production System operations, particulat e matter are emitted at several emission points. The system includes ten different baghouses to control pa rticulate matter emissions during cement finish mill operations, cement transfer and storage operations , and gypsum handling and storage operations. The following table summarizes system emission points and a pplicable air pollution control devices (APCDs), as well as the visual inspection interval (see Section 6.0):

Emission

Point # Description Air Pollution Control

Device Equipment

# VE Inspection

Interval

0709 Dust Collector – Clinker/Gypsum 712 Drag Conveyor Dust Collector Baghouse 41070900 Monthly

0743 Dust Collector – Clinker/ Gypsum Storage Silos Dust Collector Baghouse 41074300 Monthly

0811 Dust Collector – Surge Bins, Pumps Dust Collector Baghouse 52081100 Monthly

0817 Dust Collector – Finish Mill Dust Collector Baghouse 52081700 Daily

0822 Dust Collector – Finish Mill Air Separator Dust Collector Baghouse 52082200 Daily

0826 Dust Collector – Finish Mill Feed

Belt 862 Dust Collector Baghouse 52082600 Monthly

0956 Dust Collector – East & West River

Silos Dust Collector Baghouse 65095600 Monthly

1007 Dust Collector – AE Silos Dust Collector Baghouse 65100700 Monthly

1016 Dust Collector – Cone Bottom Silos Dust Collector Baghouse 65101600 Monthly

1053 Dust Collector – Overtrack Silos Dust Collector Baghouse 65105300 Monthly127 Title V Permit 10/26/04 

### 3.0 Applicable Emission Limit

The emission limit applicable to the Cement Producti on System is visible emissions that must not exceed 10 percent opacity (40 CFR 63.1347 and 63.1348).



### 4.0 Operator Procedures for Minimizing Visi ble Emissions From the Cement Production System During Normal Cement Production System Operations

Cement Production System operations are performed in accordance with the Lafarge Standard Operating Procedure (SOP) documents for Finish Grinding, Ceme nt Transport, and Gypsum Handling & Storage. Applicable SOPs include the following:

• 52-MID-01 PD Finish Mill—Normal Operation

These procedures are part of the plant’s electronic ope rating procedures system, which is maintained and kept current on the plant’s network drive (F:/shared/ environmental/O&M). The SOPs discuss how the plant shall be operated, and are used for job-specific training.



### 5.0 Preventive Maintenance

Preventative maintenance work orders are maintain ed on MAXIMO, the Plant’s Windows-based electronic maintenance management system. Sample work orders are included in the appendices. All items on work orders are checked, but not recorded unless valu es are out of normal operating range. Maintenance Department technicians perform preventative maintenance (PM) tasks on the Cement Production System equipment, including:

Equipment # Equipment Description - Function

41076500 Gypsum Reclaim Loading Hopper

41070800 Exhaust Fan – Dust Collector 709

41070900 Dust Collector – Clinker/Gypsum 712 Drag Conveyor

41074200 Exhaust Fan – Dust Collector 743

41074300 Dust Collector – Clinker/Gypsum Storage Silos

52081100 Dust Collector – Surge Bins, Pumps

52081200 Exhaust Fan – Dust Collector 811

52081700 Dust Collector – Finish Mill

52081701 Thermocouple– Dust Collector 817 Inlet

52081800 Exhaust Fan – Dust Collector 817

52082500 Screw Conveyor – Dust Collector 817

52082000 Screw Conveyor – Dust Collector 822

52082100 Exhaust Fan – Dust Collector 822

52082200 Dust Collector – Finish Mill Air Separator

52082600 Dust Collector – Finish Mill Feed Belt 862

52082700 Exhaust Fan – Dust Collector 826

52088900 Dust Collector – Feed End of 905 Belt

52089000 Exhaust Fan – Dust Collector 889

65090600 Dust Collector – Discharge of 905 Belt

65090700 Exhaust Fan – Dust Collector 906

65092600 Dust Collector – Discharge of 914 Belt

65092700 Exhaust Fan – Dust Collector 926128 Title V Permit 10/26/04 65095600 Dust Collector – East & West River Silos

65095700 Exhaust Fan – Dust Collector 956

65100600 Exhaust Fan – Dust Collector 1007

65100700 Dust Collector – AE Silos

65101600 Dust Collector – Cone Bottom Silos

65105200 Exhaust Fan – Dust Collector 1053

65105300 Dust Collector – Overtrack Silos

The Cement Production System PM schedule is main tained on MAXIMO. The PM schedules and the PM task lists for equipment in these systems are based upon past experience with similar equipment and the

manufacturer’s documentation/recommendations.

Maintenance Technicians utilize ch ecklists from the MAXIMO database to conduct PM activities. The checklists include detailed steps and instructions for performance of these activities. Once work completion has been verified, checklist data is entered into MAXIMO. This and other relevant information are periodically archived within the database, establishing a verifiable record of ongoing PM activity completion and providing a method by which to review historical equipment performance.



### 6.0 Monitoring Requirements

6.1 Periodic Method 22 Visible Em issions Monitoring Requirements

The finish mill portion of the Cement Production System must be tested for visible emissions once each day using the procedures described in USEPA Method 22 – Visual Determination of Fugitive Emissions from Material Sources and Smoke Emissions from Flares. Other parts of the Cement Production System, including the cement transport system, will be test ed for visible emissions using Method 22 once each month. (See the table in Section 2.0 for a summary of the testing frequency required for each emission point). The Method 22 tests will be conducted by trai ned observers while the Cement Production System is in operation. The Maintenance Manager (or a designate d representative) will schedule the Method 22 testing. Copies of the Method 22 procedures, Field Data Worksheets, and equipment needed to conduct the tests (stopwatch, etc.) will be maintained in the Environmental Department.

As noted in the Method 22 procedures, observers will take care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 22 test, the observer should determin e the presence or absence of visible emissions at points above or beyond the baghouse exhaust vents and stacks and the stilling shed covering, as applicable. The duration of the daily Method 22 tests will be six minutes; the monthly Method 22 tests will last one minute. Upon completion of the daily test, the observe r will record the results on the Method 22 Field Data Worksheet, and submit the worksheet to the Producti on Manager, who will forward the results to the Environmental Manager (or a designated representative ). Upon completion of the monthly tests, the

observer will record the result on the Method 22 Field Data Worksheet, and submit the worksheet to the Maintenance Manager who will forward the results to the Environmental Manager (or a designated representative). The Environmental Manager (or a designated representative) will maintain the Method 22 records for a period of five years.

If visible emissions are noted during a daily Method 22 test, maintenance will be notified and corrective actions taken within one hour by submitting a maintena nce work order request to the MAXIMO maintenance129 Title V Permit 10/26/04 control system. A follow-up six-minute Method 22 test of the stack will be conducted within 24 hours of the initial observation. If visible emissions are noted during the follow-up test, the observer will immediately notify the Environmental Manager (or a designated representative) so that a 30-minute Method 9 test can be

started within 24 hours of the second Method 22 obser vation. The observer will again initiate proper corrective actions within one hour by submitting a maintenance work order request to the MAXIMO maintenance control system.

If visible emissions are noted during a monthly Method 22 test, the observer will immediately notify the Environmental Manager (or a designated representative) so that a six-minute Method 9 test can be started

within one hour of the initial observation.

Note: If monthly Method 22 tests indicate no visible emissions for six consecutive monthly tests, the testfrequency may be reduced to once every six months. If no visible emissions are detected on the next sixmonth test, the test frequency may be reduced to once per year. Any time visible emissions are detected by these Method 22 tests, monthly testing must be resumed [40 CFR 63.1350(a)(4)(ii) & (iii)]. This provision to reduce testing frequencies does not apply to daily Method 22 tests required for the finish mill.

6.2 Periodic Method 9 Opacity Tests

Whenever visible emissions are observed during a monthly or follow-up daily Method 22 test of the Cement Production System, an opacity test using the pr ocedures described in USEPA Method 9 – Visual Determination of the Opacity of Emissions from Stationa ry Sources must be performed to determine if the 10 percent opacity limit is being met. If visible emissions are observed during a follow-up daily 6-minute Method 22 test, a 30-minute Method 9 test must be c onducted within 24 hours of the follow-up observation; if visible emissions are observed during a monthly (or less frequent) one-minute Method 22 test, a six-minute

Method 9 test must be conducted within one hour of the initial observation.

The Environmental Manager (or a designated representativ e) will ensure that trained and certified Method 9 observers are available each day the Cement Producti on System is in operation. Copies of the Method 9 procedures, Field Data Worksheets, and equipment need ed to conduct the tests will be maintained in the Environmental Department.

As noted in the Method 9 procedures, observers will ta ke care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 9 test, the observer should determine the opacity of visible emissions plume at points above or beyond the baghouse exhaust vents and stacks and the stilling shed covering, as applicable. The duration of the Method 9 test will be either thirty mi nutes (after a follow-up daily Method 22 test of the finish mill) or six minutes (following a monthly Method 22 test of other parts of the system). Upon completion of the test, the observer will record the re sults on the Method 9 Field Data Worksheet, and submit the worksheet to the Environmental Department . The Environmental Manager (or a designated representative) will maintain the Method 9 records for a period of five years.

The observer will notify the Environm ental Manager (or a designated repr esentative) and initiate corrective action immediately if the Method 9 test indicates opacity exceeding 10 percent.130 Title V Permit 10/26/04 

### 7.0 Periodic Review and Update of this Operations and Maintenance Plan

The Environmental Manager (or a designated represen tative) will review this Cement ProductionSystem Operations and Maintenance Plan once per year for ad equacy and currency. Documentation of the annual review or update will be retained in Environmen tal Department files for five years.



### 8.0 Operations and Maintena nce Plan Revision History

Revision Date Purpose 1.0 March 2002 Initial plan generation131 Title V Permit 10/26/04 

### PC MACT Operations an d Maintenance Plan

Cement Shipping System

1.0 Source Description

The Cement Shipping System is used to store fi nished cement products ready for sale and load the products for shipping. Its main system component is:

• A cement storage and bulk loading system that stores finished cement products and loads them for shipping, including the cement truck loadout chutes, railcar loadout chutes, and the barge loading silo and chute. (What about pneumatic pumps for barge systems, cement drag conveyors and elevators to go between the silos and the loadout systems?)



### 2.0 System Emission Points and Air Pollution Control Equipment

During Cement Shipping System operations, particulate matter are emitted at four emission points. The system includes four different dust collector baghouses to control particulate matter emissions at the truck and rail loadout chutes. The following table summariz es system emission points and applicable air pollution control devices (APCDs), as well as the visu al inspection interval (see Section 6.0):

Emission

Point # Description Air Pollution Control

Device Equipment # VE Inspection

Interval

1041 Dust Collector – East Rail

Scale Dust Collector Baghouse 65104100 Monthly

1044 Dust Collector – North

Truck Scale Dust Collector Baghouse 65104400 Monthly

1045 Dust Collector – South

Truck Scale Dust Collector Baghouse 65104500 Monthly

1047 Dust Collector – West

Rail Scale Dust Collector Baghouse 65104700 Monthly



### 3.0 Applicable Emission Limit

The emission limit applicable to the Cement Shipping System is visible emissions must not exceed 10 percent opacity (40 CFR 63.1348).



### 4.0 Operator Procedures for Minimizing Visi ble Emissions From the Cement Shipping System During Normal Cement Shipping Operations

Cement Shipping System operations are performed in accordance with the Lafarge Standard Operating Procedure (SOP) documents for (Cement Storage and Bulk Loading System). Applicable SOPs include the following:

• Truck Loading—Normal Operation

• Rail Loading—Normal Operation

• Barge Loading—Normal Operation132 Title V Permit 10/26/04 These procedures are part of the plant’s electronic ope rating procedures system, which is maintained and kept current on the plant’s network drive (F:/shared/environmental/O&M). The SOPs discuss how the plant shall be operated, and are used for job-specific traini ng. The tasks necessary to ensure proper operation of the Cement Shipping System with minimum em issions are also included within the SOPs.



### 5.0 Preventive Maintenance

Preventative maintenance work orders are maintain ed on MAXIMO, the Plant’s Windows-based electronic maintenance management system. Sample work orders are included in the appendices. All items on work orders are checked, but not recorded unless values are out of normal operating range. Maintenance Department technicians perform preventative mainte nance (PM) tasks on the Cement Shipping System equipment, including:

Equipment # Equipment Description - Function

65104100 Dust Collector – East Rail Scale

65104400 Dust Collector – North Truck Scale

65104500 Dust Collector – South Truck Scale

65104700 Dust Collector – West Rail Scale

The Cement Shipping System PM schedule is maintain ed on MAXIMO. The PM schedules and the PM task lists for equipment in these systems are based upon past experience with similar equipment and the

manufacturer’s documentation/recommendations.

Maintenance Technicians utilize ch ecklists from the MAXIMO database to conduct PM activities. The checklists include detailed steps and instructions for performance of these activities. Once work completion has been verified, checklist data is entered into MAXIMO. This and other relevant information are periodically archived within the database, establishing a verifiable record of ongoing PM activity completion and providing a method by which to review historical equipment performance.



### 6.0 Monitoring Requirements

6.1 Periodic Method 22 Visible Em issions Monitoring Requirements

As referenced in the table in Section 2.0, the Cement Shipping System must be tested for visible emissions once each month using the procedures described in U SEPA Method 22 – Visual Determination of Fugitive

Emissions from Material Sources and Smoke Emissions from Flares. The Method 22 tests will be conducted by trained observers while the Cement Shipping Syst em is in operation. The Maintenance Manager (or a designated representative) will schedule the Method 22 t esting. Copies of the Method 22 procedures, Field Data Worksheets, and equipment needed to conduct the tests (stopwatch, etc.) will be maintained in the Environmental Department.

As noted in the Method 22 procedures, observers will take care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 22 test, the observer should determin e the presence or absence of visible emissions at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 22 tests will be one minute. Upon completion of the test, the observer will record the results on the Method 22 Field Data Worksheet, and submit the worksheet to the Maintenance Manager, who will forward the results to the133 Title V Permit 10/26/04 Environmental Manager (or a designated representative). The Environmental Manager (or a designated representative) will maintain the Method 22 records for a period of five years.

If visible emissions are noted during a monthly Method 22 test, the observer will immediately notify the Environmental Manager (or a designated representative) so that a six-minute Method 9 test can be started

within one hour of the initial observation.

Note: If monthly Method 22 tests indicate no visible emissions for six consecutive monthly tests, the testfrequency may be reduced to once every six months. If no visible emissions are detected on the next sixmonth test, the test frequency may be reduced to once per year. Any time visible emissions are detected by these Method 22 tests, monthly testing must be resumed [40 CFR 63.1350(a)(4)(ii) & (iii)].

6.2 Periodic Method 9 Opacity Tests

Whenever visible emissions are observed during a Method 22 test of the Cement Shipping System, an opacity test using the procedures described in USEPA Method 9 – Visual Determination of the Opacity of Emissions from Stationary Sources must be performed to determine if the 10 percent opacity limit is being met. If visible emissions are observed during the one-minute Method 22 test, a six-minute Method 9 test

must be conducted within one hour.

The Environmental Manager (or a designated representativ e) will ensure that trained and certified Method 9 observers are available each day the Method 22 testin g is conducted on the Cement Shipping System. Copies of the Method 9 procedures, Field Data Worksheets, and equipment needed to conduct the tests will be maintained in the Environmental Department.

As noted in the Method 9 procedures, observers will ta ke care to perform the test from the proper location relative to the source and the sun, as well as to avoi d degraded visibility of emissions caused by improper background contrast, ambient lighting, and obser ver position relative to lighting and wind.

During the Method 9 test, the observer should determine the opacity of visible emissions plume at points above or beyond the baghouse exhaust vents and stacks. The duration of the Method 9 test will be six minutes. Upon completion of the test, the observer will record the results on the Method 9 Field Data Worksheet, and submit the worksheet to the Environmen tal Department. The Environmental Manager (or a designated representative) will maintain the Me thod 9 records for a period of five years.

The observer will notify the Environm ental Manager (or a designated repr esentative) and initiate corrective action immediately if the Method 9 test indicates opacity exceeding 10 percent.



### 7.0 Periodic Review and Update of this Operations and Maintenance Plan

The Environmental Manager (or a designated representa tive) will review this Cement Shipping System Operations and Maintenance Plan once per year for ad equacy and currency. Documentation of the annual review or update will be retained in Environmen tal Department files for five years.



### 8.0 Operations and Maintena nce Plan Revision History

Revision Date Purpose 1.0 March 2002 Initial plan generation134 Title V Permit 10/26/04 

### 7.0 Combustion Source Inspections

The main combustion source (burner pipe) in our operation is inspected on an annual basis during winter turnaround by the Production Manager (or designated representative) as well as representatives from the Maintenance Department.

The Production Manager (or designated representative) performs a thorough visual inspection for refractory damage and for damage or wear and tear on the tip of the burner pipe. Additional measures include inspecting for gaping holes and for even wear of metal around the tip. Devices called standoffs center the burner pipe. These standoffs are inspected to ensure the burner pipe is centered. A component known as the swirl channel is inspected for the wear pattern. In addition, a 6-inch metal washer is inspected closely for signs of wear and tear. Refractory located behind this metal washer is also inspected for signs of

wear.

The Maintenance Department also performs a visual in spection of the burner pipe and its components. The main focus of their inspection includ es the burner tip, castable and the area in side the pipe where the coal is injected. If the tip of the nozzle is found to be burned, then the pipe is pulled out of service and replaced by a spare burner pipe that is kept on our plant site. The pi pe taken out of service is sent for repair work on the castable and components. New parts are installed and the burner pipe is re-built for future use. Spare parts are kept on stock just for re-building of the burner pi pe. Maintenance will also inspect the flame itself for signs of distortion. In addition, they will perform UT (Ultrasonic Testing) to check the thickness on the wear area where coal is injected.135 Title V Permit 10/26/04 

## Appendix C: Applicable Limi ts and Requirements From 40 CFR 63 § LLL136 Title V Permit 10/26/04 Applicable Limits and Requi rements From 40 CFR 63 Subpa rt LLL-National Emission

Standards for Hazardous Air Pollutants From the Portland Cement Manufacturing Industry,

Compliance date The compliance date for Lafarge North America Inc. is June 14, 2002. 40 CFR 63.1351(a)

Applicability and designat ion of affected facility (a) The affected sources subj ect to this subpart are: (1) Each kiln and in-line kiln/raw mill. (2) Each clinker cooler. (3) Each raw mill. (4) Each finish mill. (5) Each raw material dryer. (6) Each raw material, clinker, orfinished product storage bin. (7) Each conveying system transfer point. (8) Each bagging system. (9) Each bulk loading or unloading system.

(b) The first affected source in the sequence of materials handling operations subject to this subpart is the raw material stor age, which is just prior to the raw mill. The primary and secondary crushers and any other equipment of the on-site nonmetallic mineral processing plant which precedes th e raw material storage are not subject to this subpart. Furthermore, the first conveyor tran sfer point subject to this subpart is the transfer point associated with th e conveyor transferring material fro m the raw material storage to the raw mill, emission unit 0400-1-F.

40 CFR 63.1340

Emission Standards and Operating Limits

Standards for kilns and in-line kiln/raw mills. (a) The permittee shall not cause to be discharged in to the atmosphere from any kiln or in-line kiln/raw mill (including any associated alkali bypass) any gases which: (1) Contain particulate matter in excess of 0.15 kg per metric ton ( 0.30 lb. per ton) of feed (dry basis) to the kiln. (2) Exhibit greater than 20 percen t opacity (reduced to 10% by Iowa DNR Construction Permit 99-A-579-P1). (3) Contain D/F (tetra-, penta-, hexa-, hepta-, a nd octa-chlorinated dibenzo dioxins and furans)

in excess of: (i) 0.20 ng per dscm (8.7E-11 gr per dscf) (TEQ ) corrected to seven percent oxygen:

or (ii) 0.40 ng per dscm (1.7E-10 gr per dscf) ( TEQ) corrected to seven percent oxygen, when the average of the performance test run average temperatures at the inlet to particulate matter control device is 204 o C (400 o F) or less. 40 CFR 63.1343(b)137 Title V Permit 10/26/04 Operating limits for kilns and in-line kiln/raw mills (a) The permittee must operate the in-line kiln/raw mill such that: (1) When the raw mill of the in- line kiln/raw mill is operating, the applicable temperature limit for the main in-line kiln/raw mill exhaust, specified in paragraph (b) of this section and established during the performance test when the raw mill was operating is not

exceeded. (2) When the raw mill of the in-line kiln/raw mill is not operating, the applicable temperature limit for the main in-line kiln/raw mill exhaust, specified in paragraph (b) of this section and established during the performance test, with or without the raw mill operating, operating is

not exceeded. (3) The applicable temperature for the alka li bypass, specified in para graph (b) of this section and established during the performance test when the raw mill was operating is not

exceeded.

(b) The temperature limit for affected sources m eeting the limits of paragraphs (a)(1) through (a)(3)of this section is de termined in accordance with paragraph (b)(3)(iv) of Performance testing requirements.

40 CFR 63.1344

Standards for clinker coolers (a) The permittee shall not cause to be discharged in to the atmosphere from any clinker cooler any gases which: (1) contain particulate matter in excess of 0.050 kg per Mg (0.10 lb per ton) of feed (dry basis)

to the kiln. (2) exhibit opacity greater th an ten (10) percent.

40 CFR 63.1345

Standards for new and reconstructed raw material dryers The permittee shall not cause to be disc harged into the atmosphere from any new or

reconstructed raw material dryer any gases which exhibit opacity greater than ten (10) pe rcent.
40 CFR 63.1346

Standards for raw and finish mills The permittee shall not cause to be disc harged into the atmosphere from the mill sweep or air separator air pollution control devices of any raw or finish mill any gases which exhibit opacity gr eater than ten (10) percent.

40 CFR 63.1347

Standards for affected sources other than kilns; in-line kiln/raw mills; cl inker coolers; new and reconstructed raw material dryers; and raw and finish mills The permittee shall not cause to be discharg ed into the atmosphere from any new or existing raw material, clinker, or finished product storage bin; conveying system transfer point; bagging system; or any existing raw materi al dryer any gases whic h exhibit opacity in excess of ten percent.

40 CFR 63.1348

Monitoring and Compliance Provisions138 Title V Permit 10/26/04 Performance testing requirements (a) The owner or operator shall de monstrate initial compliance with the above listed emission limits using the test methods and procedur es in paragraph (b ) of this section and 40 CFR 63.7. Performance tests shall be documented in complete test reports that contain the information required by paragraphs (a)(1) through (a)(10) of this section, as well as other relevant information. The plan to be followed during testin g shall be made available to the Administrator prior to testing, if requested. (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 pro cedures and any modifications to standard procedures; (4) Test results; (5) Quality assurance procedures and results; (6) Records of operating conditions during the test , preparation of standa rds, 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 parameters for compliance monitoring; and (10)Any other information required by the test method.

(b) Performance tests to demonstrate compliance with this subpart sh all be conducted as specified in paragraphs (1 ) to (4) of this section. (1) The permittee shall demonstrate initial complia nce for in-line kiln/r aw mill particulate matter emissions by conducting separate perf ormance tests as specified in paragraphs (b)(1)(i) to (b)(1)(iii) of this section while the raw mill of the in-line kiln/raw mill is under normal operating conditions and while the raw mill of the in-line kiln/raw mill is not operating. The permittee shall demonstrate initial compliance for clinker cooler particulate matter emissions by conducting a performan ce test as specified in paragraphs (b)(1)(i) to (b)(1)(iii) of this section. The opacity exhibite d during the period of the Method 5 of Appendix A CFR Part 60 performance te sts required by paragra ph (b)(1)((i) of this section shall be determined as required in pa ragraphs (b)(1)(i) through (iv) of this section. (i) EPA Method 5 of Appendix A CFR Part 60 sh all be used to determine Particulate Matter (PM) emissions. Each performance te st shall consist of three separate runs

under the conditions that exist when the aff ected source is operating at the highest load or capacity level reasona bly expected to occur. E ach run shall be conducted for at least one hour, and the minimum sample volume shall be 0.85 dscm (30 dscf). The average of the three runs shall be used to determine compliance. (ii) Suitable methods shall be used to determ ine the in-line kiln/r aw mill feed rate, except for fuels, for each run. (iii)The emission rate, E, of PM sh all be computed for each run using:

E=(C
s Q sd )/P

Where: E = emission rate of particulate matter, kg/Mg of kiln feed.

C
s = concentration of PM, kg/dscm. Q sd = volumetric flow rate of effluent gas, dscm/hr.139 Title V Permit 10/26/04 P = total kiln feed (dry basis), Mg/hr.

(iv)The opacity exhibited dur ing the Method 5 test required by(b) (1)(i) above shall be determined through the use of a c ontinuous opacity monitor (COM). The maximum six-minute average opacity during the three Method 5 test runs shall be determined during each Method 5 test run and used to demonstrate initial compliance with the applicable opacity limits of the kiln/raw mill. (2) The owner or operator of any aff ected sources subject to limitations on opacity under this subpart that is not subject to (b)(1) of this section shall demo nstrate initial compliance with the affected sour ce opacity limit by conducting a test in accordance Method 9 of Appendix A CFR Pa rt 60. The performance test shall be conducted under

the conditions that exist when the affect ed source is operating at the highest load or capacity level reasonably expected to occur. The maximum six-minute average opacity exhibited during the te st period shall be used to determin e whether the affected source is in compliance with the standard. The duration of the Method 9 performance test shall be 3-hours (30 6-minute averages), excep t that the duration of the of the Method 9 performance test may be reduced to 1-hour if (a) there are no indivi dual readings greater than 10 percent opacity, and (b) there ar e no more than three read ings of 10 percent for the first 1-hour period. (3) The owner or operator of an a ffected source subject to limitations on D/F emissions shall demonstrate initial compliance w ith the D/F emission limit by conducting a performance test using Method 23 of Appendi x A CFR Part 60. The owner or operator of an in-line kiln/raw mill shall demonstrate initial compliance by conducting separate performance tests while the raw mill of the in-line kiln/raw mill is under normal operating conditions and while the raw mill of the in-line kiln/raw mill is not operating. (i) Each performance test shall c onsist of three separate runs; each run shall be

conducted under the conditions th at exist when the affected source is operating at the highest load or cap acity level reasonably expected to occur. The duration of

each run shall be at least three hours a nd the sample volume for each run shall be at least 2.5 dscm (90 dscf). The concen tration shall be determined for each run and the arithmetic average of the concentr ations measured for the three runs shall be calculated and used to determine compliance. (ii) The temperature at the inlet to the ki ln/raw mill Particulate Matter Control Device (PMCD), and the temperature at the inlet to the alkali bypass PMCD must be continuously recorded during the period of the Me thod 23 test, and the temperature records must be include d in the performance test report. (iii) One-minute average temperatures must be calculated for each minute of each run

of the test. (iv) The run average temperature must be calcu lated for each run, and the average of the run average temperatures must be determined and included in the performance test report and will determine the applicable temperature limit in accordance with paragraph (b) of Operating limits for kilns and in-line kiln/raw

mills

.

(c) Except as provided in paragraph (e) of this section, performance tests required under paragraph (b)(1) shall be repeated every five year s, except that the initial performance test of opacity for the in-line kiln/raw mill and clinker cooler is not required.140 Title V Permit 10/26/04 (d) Performance tests D/F required under paragraph (b)(3 ) of this section sha ll be repeated every

30 months.

(e) The owner or operator is required to repeat the performance tests for in-line kiln/raw mills as specified in paragraphs (b)(1) and (b)(3) of th is section within 90 days of initiating any significant change in the feed or fuel from that used in the previous performance test.

(f) The table below provides a summary of the perf ormance test requirements of this section.

40 CFR 63.1349

Summary of Performance Test Requirements

__________________________________________________________________________ Affected source and pollutant Performance test

__________________________________________________________________________ New and existing kiln and in-line kiln/raw mill PM EPA Method 5 (1)
New and existing kiln and in-line kiln/raw mill Opacity COM New and existing kiln and in-line kiln/raw mill D/F EPA Method 23 (2)
New and existing clinker cooler PM EPA Method 5 (1)
New and existing clinker cooler Opacity COM New and existing raw and finish mill Opacity EPA Method 9 (1)
New and existing raw material dr yer and materials EPA Method 9 (1)
handling processes(raw material storage, clinker storage, finished product storage, conveyor transfer points, baging, and bulk loading and unloading systems) Opacity

___________________________________________________________________________ (1) Required initially and every five (5) years thereafter.

(2) Required initially and every 30 months thereafter.

Monitoring requirements (a) The owner or operator of this f acility shall prepare for each a ffected source subject to the provisions of this subpart, a written operations and maintenance plan. The plan shall be submitted to the Administrator for review and approval as part of the application for a part 70 permit and shall include the following information: (1) Procedures for proper operation and mainte nance of the affected source and air pollution control devices in order to meet the emission limits and operating limits listed

above under Emission Standards and Operating Limits ; (2) Corrective actions to be taken when requi red by paragraph (e) of this section; (3) Procedures to be used during an inspection of the components of the combustion system

of each kiln and each in-line kiln/raw mill located at the facility at least once per year;

and (4) Procedures to be used to pe riodically monitor affected sources subject to opacity

standards under Standards for new and reconstructed raw material dryers , and141 Title V Permit 10/26/04 Standards for affected sources other than kiln;, in-line kiln/raw mills ; clinker coolers;

new and reconstructed raw materi al dryers; and raw and finish mills . Such procedures must include the provisions of (a)(4)( i) through (a)(4)(iv) of this section. (i) The owner or operator must conduct a monthly 1-minute visible emissions test of

each affected source in accord ance with Method 22 of Appendix A of 40 CFR

60. The test must be conducted whil e the affected source is in operation. (ii) If no visible emissions are observed in six consecutive monthly tests for any affected source, the owner or operator may decrease the frequency of testing from monthly to semi-annually for that a ffected source. If visible emissions are observed during any semi-annual test, the owner or operator must resume testing

of that affected source on a monthl y basis and maintain that schedule until no

visible emissions are observed in six consecutive monthly tests. (iii) If no visible emissions are observed during the semi-annua l test for any affected source, the owner or operator may decrease the frequency of testing from semi- annually to annually for that affected source. If visible emissions are observed during any annual test, the owner or operato r must resume testing of that affected source on a monthly basis and maintain that schedule until no visible emissions are observed in six consecutive monthly tests. (iv) If visible emissions are observed during any Method 22 te st, the owner or operator must conduct a 6-minute test of opacity in accordance with Method 9 of Appendix A of 40 CFR 60. The Method 9 te st must begin within one hour of any observation of visible emissions. (v) The requirement to conduct a Me thod 22 visible emissions monitoring under this subsection shall not apply to any totally enclosed conveying system transfer point regardless of the locati on of the transfer point. "Totally enclosed conveying system transfer point" shall mean a conveying system transfer point that is enclosed on all sides, top, and bottom. The enclosur es for these transfer points shall be operated and maintained as total encl osures on a continuing basis in accordance with the facility operations and maintenance plan. (vi) If any partially enclosed or unenclo sed conveying system transfer point is located in a building, the owner or opera tor of the portland cement pl ant shall have the option

to conduct a Method 22 visible emissi ons monitoring test according to the requirements of (i) to (iv), above, for each conveying system transfer point within the building or for the building itself, according to (vii) below. (vii) If visible emissions from a building are monitored, the requirements of (i) through (iv) above apply to the monitoring of the building, and you must also do the following: Test visible emissions from each side, roof and vent of the building for at least one minute. The test must be conducted under normal operating conditions.

(b) Failure to comply with any provision of the operations and ma intenance plan developed in accordance with paragraph (a) of this secti on shall be a violation of the standard.

(c) The owner or operator of the kiln or in-lin e kiln/raw mill shall monitor opacity where

emissions are vented from these aff ected sources and the alkali bypass. (1) The owner or operator shall in stall, calibrate, and conti nuously operate a continuous opacity monitor (COM) to continuously m onitor the opacity of the emissions discharged to the atmosphere. The COM shall be inst alled, maintained, calibrated, and operated as142 Title V Permit 10/26/04 required by 40 CFR 63 Subpart A General Provisions , and according to Performance Specifications 1 (PS-1) of 40 CFR 60, Appendix B. (2) To remain in compliance, the opacity must be maintained such that the 6-minute average opacity for any-minute block period does not exceed 20 percent (reduced to 10 percent by Iowa DNR Construction Permit 78-A-579P). If the average opacity for any 6-minute block period exceeds 20 percent (redu ced to 10 percent by Iowa DNR Construction Permit 78-A579P), this shall constitute a violation of the standard.

(d) The owner or operator of a clinker cooler shall monitor opacity at each point where

emissions are vented from the clinker cooler in accordance with paragraphs (d)(1) and (d)(2) of this paragraph. (1) The owner or operator shall in stall, calibrate, and conti nuously operate a continuous opacity monitor (COM) to continuously m onitor the opacity of the emissions discharged to the atmosphere. The COM shall be inst alled, maintained, calibrated, and operated as required by 40 CFR 63 Subpart A General Provisions , and according to Performance Specifications 1 (PS-1) of 40 CFR 60, Appendix B. (2) To remain in compliance, the opacity must be maintained such that the 6-minute average opacity for any-minute block period does not exc eed 10 percent. If the average opacity for any 6-minute block period exceeds 10 percent, this shall constitute a violation of the

standard.

(e) The owner or operator of a raw mill or finish mill shall monitor opacity by conducting daily visual emissions observations of the mill sweep a nd separator PMCDs of these affected sources, in accordance with the procedures of Met hod 22 of 40 CFR 60, Appendix A . The Method 22

test shall be conducted while the affected source is operating at th e highest load or capacity level reasonably expected to occur within the da y. The duration of the Method 22 test shall be

six minutes. If visible emissions are observed during the Method 22 visibl e emissions test, the
owner or operator must: (1) Initiate, within one-hour, the corrective act ions specified in the site specific operations and maintenance plan developed in accordance with paragraphs (a)(1) and (a)(2) of this section; and (2) Within 22 hours of the end of the Method 22 test in which visible emissions were observed, conduct a visual opacity test of each stack from whic h visible emissions were observed in accordance with Method 9 of 40 CFR 60, Appendix A.

The duration of the Method 9 te st shall be thirty minutes.

(f) The owner or operator of an affected source subject to a limitation on D/F emissions shall monitor D/F emissions in accordance with paragraphs (f)(1) through (f)(6) of this section. (1) The owner or operator shall in stall, calibrate, maintain, and continuously operate a

continuous monitor to record th e temperature of the exhaust gases from the kiln, in-line kiln/raw mill and alkali bypass, if applicable, at the inlet to, or upstream of, the kiln, inline kiln/raw mill and/or alkali bypass PM control devices. (i) The recorder response range must include zero and 1.5 times either of the average temperatures established accordi ng to the requirements in (b)(3)(iv) of Performance testing requirements

. (ii) The reference method must be a National Institute of Standards and Technology calibrated reference thermocouple- potentiometer system or alternate reference,143 Title V Permit 10/26/04 subject to approval by the Administrator. (2) The owner or operator shall monitor and con tinuously record the temperature of the exhaust gases from the kiln, in-line kiln/raw mill and alkali bypass, if applicable, at the inlet to the kiln, in-line kiln/raw mill and/or alkali bypass PMCD. (3) The three-hour rolling average temperature shall be calculated as the average of 180 successive one-minute average temperatures. (4) Periods of time when one-minute averages are not available shall be ignored when calculating three-hour rolling averages. When one-minute averages become available, the first one-minute average is added to the previous 179 values to calculate the three-hour rolling average. (5) When the operating status of the raw mill of the in-line kiln/raw mill is changed from off to on, or from on to off the calculation of the three-hour rolling average temperature must begin anew without cons idering previous readings. (6) The calibration of all thermocouples and other temperature sensors sh all be verified at least once every three months.

(g) The owner or operator of any kiln or in-line kiln/raw mill subject to a D/F emission limit under this subpart shall conduct an inspection of the components of each kiln or in-line kiln/raw mill at least once per year.

(h) The owner or operator of an affected sour ce subject to a limitation on opacity under Standards for new and reconstructed raw material dryers , and Standards for affected sources other than kiln;, in-lin e kiln/raw mills; clinker coolers; new and reconstructed raw material dryers; and raw and finish mills shall monitor opacity in acco rdance with the operation and maintenance plan developed in accordance with paragraph (a) of this section.

(i) The owner or operator of an affected source su bject to a particulate matter standard under Standards for kilns and in-line kiln/raw mills shall install, calibrate, maintain and operate a particulate matter continuous emission mon itoring system (PM CEMS) to measure the particulate matter discharged to the atmosphere . The compliance deadline for installing the PM CEMS and all requirements relating to performa nce of the PM CEMS and implementation of the PM CEMS is deferred pending further rulemaking.

(j) An owner or operator may submit an applica tion to the Administrator for approval of alternate monitoring requirements to demonstr ate compliance with the emission standards of this subpart, except for emission standards for TH C, subject to the provi sions of paragraphs (j)(1) to (j)(6) of this section. (1) The Administrator will not approve averaging periods other than those specified in this section, unless the owner or operator docum ents, using data or information, that the longer averaging period will ensure that emi ssions do not exceed levels achieved during the performance test over a ny increment of time equivalent to the time required to conduct three runs of the performance test. (2) If the application to use an alternate monitoring requireme nt is approved, the owner or operator must continue to use the orig inal monitoring requirement until approval is received to use another monitoring requirement. (3) The owner or operator shall submit the a pplication for approva l of alternate monitoring requirements no later than the notification of performance test. The144 Title V Permit 10/26/04 application must contain the information specified in paragraphs (j)(3)(i) through (j)(3)(iii) of this section: (i) Data or information justifying the requ est, such as the technical or economic infeasibility, or the impracti cality of using the required approach; (ii) A description of the proposed alternativ e monitoring requirement, including the operating parameter to be monitored, the monitoring approach and technique, the averaging period for the limit, and how the limit is to be calculateed; and (iii) Data or information documenting that the alternative monitoring requirement would provide equivalent or better assurance of comp liance with the relevant

emission standard. (4) The Administrator will notify the owner or ope rator of the approval or denial of the application within 90 calendar da ys after receipt of the orig inal request, or within 60 calendar days of the receipt of any supplem entary information, whichever is later. The Administrator will not approve an altern ative monitoring application unless it would provide equivalent or better assurance of compliance with the relevant emission standard. Before disapproving any alternat e monitoring application, the Administrator will provide: (i) Notice of the information and findings upon which the intended disapproval is based; and (ii) Notice of opportunity for the owner or ope rator to present a dditional supporting

information before final action is take n on the application. This notice will specify how much additional time is allowed for the owner or operator to provide additional supporting information. (5) The owner or operator is responsible fo r submitting any supporting information in a timely manner to enable the Administrator to consider the application prior to the performance test. Neither submittal of an a pplication, nor the Administrator's failure to prove or disprove the applica tion relieves the owner or opera tor of the responsibility to comply with any provision of this subpart. (6) The Administrator may decide at any time, on a case-by-case basis that additional or alternative operating limits, or alternative approaches to establishing operating limits, are necessary to demonstrate compliance w ith the emission standards of this subpart.

40 CFR 63.1350

Reporting, and Recordkeeping

Reporting requirements (a) The reporting provisions of subpart A of this part that apply and those that do not apply to owners or operators of af fected sources subject to this subpar t are listed in Table 1 of this subpart. If any State requires a report that contains all of the information required in a report that contains all of the information required in a repor t listed in this se ction, the owner or operator may send the Administrator a copy of th e report sent to the State to satisfy the requirements of this section for that report.

(b) The owner or operator of an affected source sh all comply with the reporting requirements specified in Sec. 63.10 of the general provision s of this part 63, subpart A as follows: (1) As required by Sec. 63.10(d )(2), the owner or operator shall report the results of performance tests as part of the notification of compliance status.145 Title V Permit 10/26/04 (2) As required by Sec. 63.10(d )(3), the owner or operator of an aff ected source shall report the opacity results from tests required by Sec. 63.1349. (3) As required by Sec. 63.10(d )(4), the owner or ope rator of an affect ed source who is required to submit progress reports as a condition of receiv ing an extension of compliance under Sec. 63.6(i) shall subm it such reports by the dates specified in the written extension of compliance. (4) As required by Sec. 63.10(d)(5), if actions taken by an owner or operator during a startup, shutdown, or malfunction of an affected source (including actions taken to correct a malfunction) are consistent with the procedur es specified in the source's startup, shutdown, and malfunction pl an specified in Sec. 63.6(e)(3), the owner or operator shall state such inform ation in a semiannual report. Reports shall only be required if a startup, shutdown, or ma lfunction occurred during the reporting period. The startup, shutdown, and malfunction report may be submitted simultaneously with the excess emissions and continuous monitoring system performance reports;

and (5) Any time an action taken by an owner or operator during a startup, shutdown, or malfunction (including acti ons taken to correct a malfuncti on) is not consistent with the procedures in the startup, sh utdown, and malfunction plan, the owner or operator shall make an immediate report of the actions taken for that event within 2 working days, by telephone call or facsimile (FAX) transmission. The immediate report shall be followed by a letter, certified by the owner or operator or other responsible official, explaining the circumstan ces of the event, the reasons for not following the startup, shutdown, and malfunction plan, and whether any excess emissions and/or parameter monitoring exceedances are believed to have occurred. (6) As required by Sec. 63.10(e)(2), th e owner or operator sh all submit a written report of the results of th e performance evaluation for the continuous monitoring system required by Sec. 63.8(e). The owner or operator shall submit the report simultaneously with the resu lts of the performance test. (7) As required by Sec. 63.10(e)(2), the owner or operator of an affected source using a continuous opacity monitoring syst em to determine opacity compliance during any performance test required under Sec. 63.7 and described in Sec. 63.6(d)(6) shall report the results of the continuous opaci ty monitoring system performance

evaluation conduc ted under Sec. 63.8(e).

(8) As required by Sec. 63.10(e )(3), the owner or ope rator of an affected source equipped

with a continuous emission monitor shall submit an excess emissions and continuous monitoring system performance report for any event when the continuous monitoring system data indicate the source is not in compliance with the applicable emission limitation or operating parameter limit. (9) The owner or operator shall submit a su mmary report semiannually which contains the information specified in Sec. 63.10( e)(3)(vi). In addition, the summary report

shall include: (i) All exceedences of maximum control device inlet gas temperature limits specified in Sec. 63.1344(a) and (b); (ii) All failures to calib rate thermocouples and other temperature sensors as required under S ec. 63.1350(f)(7) of this subpart; and (iii) All failures to maintain the ac tivated carbon injection ra te, and the activated carbon injection carrier ga s flow rate or pressure146 Title V Permit 10/26/04 drop, as applicable, as required under Sec. 63.1344(c). (iv) The results of any combustion sy stem component inspections conducted within the reporting period as required under Sec. 63.1350(i). (v)All failures to comply with any provision of the operation and maintenance plan develope d in accordance with Sec. 63.1350(a). (10) If the total continuous monitoring system downtime for any CEM or any continuous monito ring system (CMS) for the reporting period is ten percent or greater of the total operating time for the reporting period, the owner or operato r shall submit an excess emissions and continuous monitoring system perfor mance report along with the summary report.

40 CFR 63.1354

Recordkeeping requirements (a) The permittee shall maintain files of all in formation (including all reports and notifications) required by this section recorded in a form suitable and readily available for inspection and review as required by Sec. 63.10(b)(1). The files shall be retained fo r at least five years following the date of each occurrence, m easurement, maintenance, corrective action, report, or record. At a minimum, the most recent two year s of data shall be retained on site. The remaining three years of data may be retained off site. The files may be maintained on microfilm, on a computer, on floppy disks, on magnetic tape, or on

microfiche.

(b) The owner or operator shall maintain records for each affected source as required by Sec. 63.10(b)(2) and (b)(3) of this part; and (1) All documentation supporting initial notifications and no tifications of compliance status under Sec. 63.9; (2) All r ecords of applicability determination, including supporting analyses; and (3) If the owner or operator has been granted a waiver under Sec. 63.8(f)(6), any information demons trating whether a source is meeting the requirements

for a waiver of recordkeeping or reporting requirements.

(c) In addition to the recordkeeping requi rements in paragraph (b) of this section, the owner or operator of an affect ed source equipped with a continuous monitoring system shall maintain all records required by Sec. 63.10(c).

40 CFR 63.1355

Temporary, conditioned exemption from pa rticulate matter and opacity standards (a) Subject to the limitations of paragraphs (b) through (f) of this section, an owner or operator conducting PM CEMS correlation tests (that is , correlation with manual stack methods) is exempt from: (1) Any particulate matter and opacity standards of part 60 or part 63 of this chapter that are applicable to cement kilns and in-line kiln/raw mills. (2) Any permit or other emissions or operating parameter or other limitation on workplace practices that are applicab le to cement kilns and in-line kiln raw mills to ensure compliance with any particulat e matter and opacity standard s of this part or part 60 of this chapter.147 Title V Permit 10/26/04 (b) The permittee must develop a PM CEMS correlation test plan. The plan must be submitted

to the Administrator fo r approval at least 90 days before the correlation test is scheduled to

be conducted. The plan must include: (1) The number of test conditions and the number of runs for each test condition; (2) The target particulate matter emission level for each test condition; (3) How the operation of the affected source will be modified to attain the desired particulate matter emission rate; and (4) The anticipated normal par ticulate matter emission level.

(c) The Administrator will review and approve or disapprove the correlation test plan in accordance with Sec. 63.7(c)(3)(i) and (iii). If the Administra tor fails to approve or disapprove the correl ation test plan within the time period specified in Sec. 63.7(c)(3)(iii), the plan shall be considered approved, unless the Administrator has requested additional

information.

(d) The stack sampling team must be on-si te and prepared to perform correlation testing no later than 24 hours after operations are modified to attain the desi red particulate matter emissions concentrations, unless the correlation test plan docum ents that a longer period is appropriate.

(e) The particulate matter a nd opacity standards and associ ated operating limits and conditions will not be waived for more than 96 hours, in the aggregate, for a correlation test, including all runs and conditions.

(f) The owner or operator must return the a ffected source to operating conditions indicative of compliance with the applicable particulate matter and opac ity standards as soon as possible after correlation testing is completed.

40 CFR 63.1357

Delegation of authority (a) In delegating implementation and enforcemen t authority to a State under subpart E of this part, the authorities contained in para graph (b) of this section sh all be retained by the

Administrator a nd not transferred to a State.

(b) Authority which will not be delegated to States: (1) Approval of alternativ e non-opacity emission standards under Sec. 63.6(g). (2) Approval of alternative opacity standards under Sec. 63.6(h)(9). (3) Approval of major ch anges to test methods under S ecs. 63.7(e)(2)(ii) and 63.7(f). A major change to a test method is a modification to a federa lly enforceable test method that uses unproven technology or procedures or is an entirely new method (sometimes necessary when the required test method is unsuitable). (4) Approval of major changes to monito ring under Sec. 63.8(f). A major change to monitoring is a modification to fede rally enforceable monitoring that uses unproven technology or procedures, is an enti rely new method (sometimes necessary when the148 Title V Permit 10/26/04 required monitoring is unsuitable), or is a chan ge in the averaging period. (5) Waiver of recordkeeping under Sec. 63.10(f).

40 CFR 63.1358

Authority for Requirement: 40 CF R 63 Subpart LLL and Subpart A 567 IAC 23.1(4)"bl"149 Title V Permit 10/26/04 

## Appendix D: IDNR Air Quality Policy 3-b-08 (Opacity)