SPECIAL CONDITIONS

Permit Numbers 1360A and PSD

- TX

- 632M1

GENERAL REQUIREMENTS AND FEDERAL APPLICABILITY

1

. General Requirements

A. This facility shall be constructed and operated in accordance with and subject to the

Texas Clean Air Act (TCAA) as amended, the Texas Health And Safety Code, Chapter 382, (Vernon 1992) and all applicable rules, regulations, and orders of the Texas Commission on Environmental Quality (TCEQ) in effect at the time of issuance. Said

construction an d operation is subject to any additional or amended rules, regulations, and orders of the TCEQ adopted pursuant to the TCAA. (3/01)

B. A copy of this permit, the August 7, 1995, renewal application, the March 10, 1998 amendment application, and all subse quent submittals pursuant to each application’s technical review shall be kept at the plant site and made available at the request of personnel from the TCEQ or any air pollution control agency with jurisdiction.

C. This permit covers only those sources o f emissions listed in the enclosed table entitled

“Emission Sources

- Maximum Allowable Emission Rates;” as those sources are limited to the emission limits and other conditions specified in that attached table. If one

emission rate limitation is more str ingent than another emission rate limitation, then the more stringent limitation shall govern and be the standard by which compliance will be demonstrated. The annual rates are based on a rolling 12

- month period.

D. Acceptance of a permit by a permit app lication constitutes an acknowledgment and agreement that the holder will comply with all rules, regulations, and orders of the Commission issued in conformity with the TCAA and the conditions precedent to the granting of the permit. If more than one stat e or federal rule or regulation or permit condition are applicable, then the most stringent limit or condition shall govern and be the standard by which compliance shall be demonstrated. Acceptance includes consent to the entrance of Commission employees and agents into the permitted premises at reasonable times to investigate conditions relating to the emission or concentration of air contaminants, including compliance with the permit. (3/01)

E. The facilities covered by the permit shall not be operated unless all air pollution emission capture and abatement equipment is maint ained in good working order and operating properly during normal facility operations. This facility shall not produce a nuisance that may cause or contribute to a condition of “air pollution” as defined in Title

30 Texas Administrative Code § 101.4 (30 TA C § 101.4). If the TCEQ Executive Director determines that such a condition or violation does occur, the holder of thisSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 2

permit shall implement additional abatement measures as necessary to control or prevent the condition or violation. This facility shal l provide notification of a major upset and maintenance to the TCEQ Regional Office as required in 30 TAC §§ 101.201 and

101.211. (9/05)

F. Upon request by the Executive Director of the TCEQ or local agency, the holder of this permit shall perform ambien t air monitoring or other testing as required to establish the actual pattern and quantities of air contaminants being emitted into the atmosphere.

G. Records required by this permit shall be recorded in a form suitable for inspection and

made available u pon request by the TCEQ and any local air pollution control programs. Scheduled and unscheduled maintenance performed shall comply with 30 TAC § 101.201 and 101.211, and these records shall be made available for inspection by the TCEQ and any local air p ollution program having jurisdiction. Records shall be

maintained on

- site, at minimum, for a rolling two

- year period. (9/05)

H

. The facilities covered by this permit shall be constructed and operated as specified in this permit application and the Part B a pplication required under Title 40 Code of Federal Regulations § 270.10 (40 CFR § 270.10). (3/01)

I. To the extent practicable, the permittee shall physically identify and mark in a conspicuous location all equipment that has the potential of emitting ai r contaminants as

follows:

(1) The facility identification numbers as submitted to the Emissions Inventory Section of the TCEQ.

(2) The emission point numbers (EPNs) as listed on the maximum allowable emission rates table (MAERT).

J. At the request of the Executive Director of the TCEQ or designated representative, the holder of this permit shall provide an analysis of any fuel listed in Special

Condition Nos. 8 and 9 or any available batch of waste

- derived fuel or clinker quench

waste water received from a generator or supplier. The holder of this permit shall allow the Executive Director of the TCEQ or designated representative to obtain samples of these materials for analysis upon request. ( 3/01)

K. This permit action authorizes th e construction of a dry process preheater precalciner kiln with associated raw material, solid fuel, and product handling systems, and associatedSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 3

abatement equipment. This action permits the construction of new sources and affects the operation of numerou s other permitted, exempted, and grandfathered sources as listed

below. (1/01)

(1) New Construction:

E1

- 27 Secondary Crusher

E1

- 28 Conveyor Transfer

E1

- 29 Enclosed Storage Building

E1

- 30 Underground Belt Feeder

E1

- 31 Raw Material Bins Baghouse

E1

- 32 Sand Hopper

E1

- 32a Sand Hopper to Conveyor

E2

- 7 Blending Silo Baghouse

E2

- 7a Blending Silo Air Slide Baghouse

E2

- 7b Pre

- heater Tower Feed Baghouse

E2

- 11 Lime Delivery Road Emission

E2

- 11b Lime Tank Baghouse

E2

- 22 No. 5 Kil n Exhaust Stack

E3

- 52 Clinker Pan Conveyor to Belt Baghouse

E3

- 53 Clinker Transfer Baghouse

E3

- 54 No. 6 Finish Mill Bins Baghouse

E3

- 55 No. 6 Finish Mill Separator Baghouse

E3

- 56 No. 6 Finish Mill Baghouse

E4

- 12 Cement Silo Baghouse

E6

- 27 Solid Fuel Transfer

E6

- 28 Coal Bin

E6

- 29 Coal Weigh Feeder

E6

- 30 Coal Mill Exhaust Baghouse

E6

- 31 Coal Fines Baghouse

(2) Consolidation of all sources previously authorized under Permit Nos. 22329

and X16044:

E1

- 24 Primary Crusher

E1

- 25 Transfer Point No. 1

E1

- 26 Transfer Point No. 2

E1

- 27 Transfer Point No. 3

E3

- 6 Surge Bin to 700, 703 to Pan BaghouseSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 4

E3

- 10 Clinker Silos 15

- 18 Baghouse

E3

- 11 Belt Transfer 707 Tail Pulley Baghouse

E3

- 12 Belt Transfer Head Wheel 703, 704, 721 Baghouse

E3

- 15 Transfer Head Pull 702 Pan; 748 Drag Baghouse

E3

- 24 Belt Transfer 707, 708, 780 Baghouse

E3

- 26 Belt Transfer 742, 703, 740, 741 Baghouse

E3

- 29 No. 2 Cooler Tunnel Baghouse

E3

- 30 No. 1 Cooler Tunnel Baghouse

E3

- 33 Transfer 708, 712, 713 Baghouse

E3

- 34 Surge Bin Transfer 713, 715, 717, 718 Baghouse

E3

- 35 Drag Conveyor 706 Baghouse

E3

- 37 Transfer 700, 704, 701 Baghouse

E3

- 38 712 Tunnel, Clinker Building Baghouse

E3

- 41 East Door, Clinker Building Baghouse

E3

- 42 West Door, Clinker Building Bagh ouse

(3) Consolidation of sources previously authorized under Permit No. 6698:

E1

- 7 Gypsum Drop to Pile

E3

- 23 Lower Reclaim Belt Baghouse

E3

- 50 Rail Drop to Hopper

E3

- 51 Hopper Drop to Belt

(4) Permitting of sources previously authorized under standard exemption: (1/01)

E1

- 30A Overland Conveyor Transfer

E1

- 31A Limestone Transfer Baghouse

E2

- 10a CKD Drop to Pile

E2

- 10b CKD Bin Baghouse

E2

- 12 Iron Component Road Emissions

E2

- 13 Iron Component Drop to Pile

E2

- 14 Iron Component Loader Road Emissions

E2

- 15 Iron Component Loader to Hopper

E2

- 16 Iron Component System Baghouse

(5) Permitting of previously grandfathered sources:

E1

- 1 Raw Material Delivery, Road Emission

E1

- 2 Cement Truck, Road Emission

E1

- 8 Anhydrite Pile, Drop Fugitive

E1

- 11 Sand Pile Drop

E1

- 12 Quarry Operations (Drilling and Blasting)

E1

- 13 Quarry Loader Road Emissions

E1

- 16 Limestone Belt HopperSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 5

E1

- 20 Front End Loader Road

E1

- 21 Sand Truck Road Emissions

E1

- 22 CKD Truck Road

E4

- 1 Cement Silo Baghouse

E4

- 3 Cement Silo Baghouse

E4

- 5 Cement Silo Baghouse

E4

- 6 Finish Silo Group 1 Baghouse

E4

- 7 Finish Silo Group 1 Baghouse

E4

- 8 Finish Silo Group 1 Baghouse

E4

- 9 Rail Loading Baghouse

E4

- 10 Rail Loading Baghouse

E4

- 11 Cement Rail Loadout Baghouse

E4

- 13 Truck Loadout Baghouse

E4

- 16 Cement Truck Loadout Baghouse

E4

- 17 Cement Truck Loadout Baghouse

E4

- 18 Cement Truck Loadout Baghouse

E4

- 19 Packhouse Elevator Baghouse

E4

- 20 Bagging Machine Baghouse

E4

- 21 M asonary Rail Loading Baghouse

E4

- 22 Cement Truck Loadout Baghouse

E4

- 25 Masonry Baggings Baghouse

CKDL

- 1 CKD Bulldozer, Road Emission

CKDL

- 2 CKD Pile, Wind Blown Fugitive

2. Federal Applicability

A

. These fa cilities shall comply with all applicable requirements of the U.S. Environmental Protection Agency (EPA) regulations in 40 CFR Part 60, Subpart A on Standards of Performance for New Stationary Sources promulgated, and the following:

(1) Subpart F

- Portla nd Cement Plants; includes Kiln No. 5 (E2

- 22), Finish Mill

No. 6, raw material and clinker storage, roller mills, and clinker cooler.

(2) Subpart Kb

- Standards of Performance for Volatile Organic Liquid Storage Vessels; includes storage tanks in the haza rdous waste storage and unloading area.

(3) Subpart Y

- Coal Preparation Plants; includes the coal processing and conveying equipment (including breaker and/or crusher), coal storage systems, and coal transfer and loading systems

(4) Subpart OOO

- Nonmet allic Mineral Processing Plants; includes the overlandSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 6

conveyor system and handling of all raw materials from the quarry operations to entry of the kiln system.

B. (1) Facilities involved with the treatment, storage, or disposal of hazardous waste,

includ ing Kilns No. 1 through 4 and the hazardous waste storage and unloading area, shall comply with all applicable requirements of the EPA regulations

in 40 CFR Part 61, Subparts A, J, and FF on National Emission Standards

for Hazardous Air Pollutants (NESHAPS ) promulgated pursuant to authority granted under the Federal Clean Air Act, Section 112 as amended and contained.

These facility units shall also be operated in compliance with all applicable requirements relating to air quality in the Resource Conservation and Recovery

Act (RCRA) and the rules promulgated thereunder, and in 30 TAC Chapter 335, Subchapter F (relating to Permitting Standards for Owners and Operators of Hazardous Waste Storage, Processing, and Disposal Facilities) promulgated by the TCEQ pursuant to the Solid Waste Disposal Act, Chapter 361 of the Texas Health and Safety Code (Vernon 1992).

(2) These fa cilities, including Kiln Nos. 1 through 5, shall be operated in compliance with all applicable requirements of the EPA regulations in 40 CFR Part 63, Subparts A and LLL, the NESHAPS from the Portland Cement Manufacturing Industry. (9/05)

C. Prior to the initial start

- up of Kiln No. 5 (E2

- 22), the permittee will: (1/01)

(1) Retrofit the baghouses of the existing Clinker Coolers No. 1 and 4 (EPNs E2

- 101

and E2

- 107) with high efficiency singed nomex membrane lined bags, or equivalent, such that they will a chieve an outlet grain loading of particulate matter (PM) of no more than 0.005 grain per dry standard cubic feet (gr/dscf). The baghouses of the existing Clinker Coolers Nos. 2 and/or 3 shall be retrofitted as described in this condition, if operated as specified in Special Condition No. 2D. (1/01)

(2) Retrofit the baghouses that control PM from the sources which formerly emitted

from EPNs E3

- 21, E4

- 5, E4

- 6, E4

- 7, E4

- 8, E4

- 9, E4

- 10, E4

- 11, E4

- 12, E4

- 13,

E4

- 16, E4

- 17, E4

- 18, E4

- 19, E4

- 20, E4

- 21, E4

- 22, E 4

- 25 with PTFE membrane lined high efficiency bags, or equivalent, such that each will achieve an outlet grain loading of PM of no more than 0.005 gr/dscf.SPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 7

In addition, the permittee will modify Permit No. 6698 to authorize a modification to the baghouse that controls Finish Mill No. 5 (EPN E3

- 21) with PTFE membrane lined high efficiency bags, or equivalent, such that the baghouse will achieve an outlet grain loading of PM of no more than 0.005 gr/dscf.

D. Kiln Nos. 2 and 3 (EPNs E2

- 4 and E2

- 6) are not authorized to operate under any circumstances while Kiln No. 5 (EPN E2

- 22) is operating or in start

- up mode with the following exception. Any two of the four wet kilns may operate in conjunction with Kiln No. 5, provided the clinker cooler b aghouse associated with any wet kiln that operates with Kiln No. 5 has been upgraded with high efficiency bags as described in Special Condition No. 2C(1). The TCEQ Arlington Regional Office shall be contacted at least five days prior to operating Kiln No . 2 and/or Kiln No. 3 in conjunction with Kiln No. 5, to provide an opportunity to confirm that the applicable clinker cooler baghouse has been upgraded with high efficiency bags. After the Kiln Nos. 2 or 3 clinker cooler baghouse has been upgraded under this special condition, at least three of the four clinker cooler baghouses shall be operated with high efficiency bags at any time that all four wet kilns are in operation. (1/01)

E. The facilities proposed for construction in the March 10, 1998, permit application have been reviewed for maximum achievable control technology (MACT) in accordance

with 30 TAC Chapter 116, Subchapter C. The conditions of this permit and MACT requirements support the determination of compliance with the MACT requirements. If the EPA subsequently promulgates a MACT standard applicable to these facilities which is less stringent than the determination made during the review of this permit, the requirements of this permit shall apply.

F. The following EPNs have relied upon reduced emissions as a result of retrofitting fabric filter baghouses with (PTFE) membrane lined high efficiency bags: EPNs E1

- 31, E2

- 7,

E2

- 7B, E3

- 1, E3

- 2, E3

- 6, E3

- 11, E3

- 26, E3

- 33, E4

- 1 , E4

- 2, E4

- 3, and E6

- 30. (1/01)

G. Kiln Nos. 1 through 4 (EPNs E2

- 2, E2

- 4, E2

- 6 E2

- 8) shall comply with all applicable requirements of 30 TAC 117, Subchapter B, Division 4 (Cement Kilns). (9/05)

FUGITIVE DUST SOURCES

3. Paved and Unpaved RoadsSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 8

A. Th e roadways of this facility shall comply with 30 TAC § 111.147.

B. A street sweeper and other mobile equipment shall pick up debris from the plant roads and dump inside an enclosed structure. A front

- end loader shall pick up the dust and

debris from this structure and load it onto trucks for disposal. The contents of the truck shall be controlled as necessary to prevent emissions during transit.

C. Plant roads shall be controlled as represented in Tables 4.2 and 4.3 of the

March 10, 1998, permit applica tion. Current copies of these tables shall be kept with

this permit. All roads shall be paved and either water sprinkled or swept, and

quarry roads shall be sprinkled with water and treated with dust suppressant chemicals to

control the emission of dust.

4. Solid Fuel Handling

A. Solid fuel (including coal and petroleum coke) stockpiles shall be sprayed with water and/or chemicals as necessary to control fugitive dust emissions to the minimize fugitive

dust emissions.

B. Solid fuel crushing (EPNs 6 through 10) emission limits for Kiln Nos. 1 through

No. 4 are based on a maximum hourly coal throughput of 150 tons and a maximum
annual throughput of 280,000 tons of coal crushed

. (9/99)

C. Water spray systems, reduced fall, full enclosures, and/or other abatement devices, as represented in Tables No. 4.1 and No. 4.4 and Appendix E of the March 10, 1998, permit application shall be operated, as necessary, to minimize fugitive dust emissions at the coal crusher, rail dump hoppe r, coal bin, weigh feeder, surge bin, coal mill, and all subsequent material transfer and drop points. Current copies of these tables shall be kept with the permit.

5. Raw Material Handling

A. Compliance with these permitted emission limits is based on a maximum hourly throughput rate of 1,600 tons and a maximum annual throughput rate of 4,000,000 tons

of limestone and shale crushed. (9/99)SPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 9

B. Opacity of emissions from any transfer point on belt conveyors must not exceed

5 percent averaged over a six

- m inute period except for those periods described

in 30 TAC § 111.111(a)(1)(E).

C. Opacity of emissions from the Primary and Secondary Crushers (EPNs E1

- 24 and

E1

- 27) must not exceed 5 percent averaged over a six

- minute period except for those periods descr ibed in 30 TAC § 101.201 and 101.211.

D. Sprays of foamable wetting agents shall be installed at the grizzly feeder that precedes the crusher inlet at the outlet of the crusher, and at all conveyor drop points except the final conveyor drop point which em pties into the raw material storage and blending building. These sprays of wetting agents at the grizzly feeder and at the crusher outlet shall be operated at all times while the crusher is operating. The sprays of wetting agent

installed at material tra nsfer points shall be operated as necessary to achieve maximum

control of dust emissions. (9/99)

E. Fixed conveyors shall be covered and transfer/drop points shall be enclosed.

F. Water spray systems, reduced fall, full enclosures, and /or other abatement devices, as represented in Tables No. 4.1 and No. 4.4 and Appendix E of the March 10, 1998 permit application shall be operated, as necessary, to minimize fugitive dust emissions associated with handling limestone, shale, sand, and iron component raw materials. Current copies of these tables shall be kept with the permit.

G. Outside storage piles of raw materials, in cluding limestone, shale, sand, and iron components, shall be watered and/or treated with dust suppressant chemicals to achieve

maximum control of dust emissions. (9/99)

6. Clinker and Finished Product Handling (1/01)

A. The cement distribution system to the main truck and rail car loading process shall not exceed 300 tons per hour per load spout. (1/01)

B. Opacity of emissions from clinker handling facilities, finish mills, storage silos and

loadouts must not exceed 5 percent averaged over a six

- minut e period except for thoseSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 10

periods described in 30 TAC § 101.201 and 101.211.

C. The top of all conveyor belts shall be covered. All conveyor belt transfer points shall

be enclosed. To the extent necessary to achieve compliance with opacity limits, these transfer points will either be vented to a dust collector or equipped with a water

spray. The dust collectors or water sprays shall be operated as necessary to achieve compliance with the opacity limits.

D. Outgoing railroad cars and trucks used in tran sporting cement and clinkers shall be cleaned and maintained as necessary to minimize fugitive emissions. Dust emissions from cement loading into trucks or railcars shall be controlled with a self

- sealing shroud at the loading point and venting of the dis placed air to the fabric filter.

7. Miscellaneous Fugitive Requirements

A. Material collected by air pollution abatement equipment which is not returned to the process shall be disposed of on

- site in a manner that minimizes any emissions in transit and p revents any emissions after disposal. A water sprinkler system or water truck shall be used to control dust emissions from any baghouse dust disposed of in on

- site

landfills.

B. All hoods, ducts, and collection systems shall be effective in preventing fu gitive emissions. Compliance with this condition shall be determined by the EPA Reference Method 22 with no visible emissions persisting for more than one six

- minute period

in a half

- hour.

C. As determined by a trained observer, no visi ble emissions shall leave the plant site. If this condition is violated, further controls shall be installed and/or implemented as required to limit visible emissions.

D. The active portion of the CKD landfill (CKDL

- 2) shall not exceed a size of 1.0 acre (4,050 m 2 ) and be covered as necessary to minimize fugitive emissions. (9/99)

CEMENT KILN EMISSION STANDARDS AND FUEL SPECIFICATIONS

8. Kiln Nos. 1 through No. 4 (EPNs E2

- 2, E2

- 4, E2

- 6, and E2

- 8)

A. The maximum sulfur content of fuels fired in the Kilns (EPNs E2

- 2, E2

- 4, E2

- 6, and

E2

- 8) shall not exceed the following:SPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 11

(1) Pipeline

- quality natural gas

- 0.25 grain hydrogen sulfide and 5.0 grains total sulfur

per 100 dscf.

(2) Fuel oil

- 1.5 percent b y weight.

(3) Coal or coke

- 3.5 percent by weight.

(4) Waste

- derived fuel

- 1.0 percent by weight.

B. Emissions from the cement kiln exhaust stacks shall not exceed 30 percent opacity (except at times when the only fuel burned in a kiln is fuel oil in which case the opacity

limit is 20 percent opacity averaged over a six

- minute period) as determined by the EPA Reference Method 9 or by the continuous opacity monitoring systems (COMS) required

pursu ant to Special Condition No. 13A. Also, while firing pumpable hazardous waste, emissions from any stack shall not exceed 20 percent opacity on a six

- minute

average, except for uncombined water, other than for those periods described in

30 TAC § 111.111.

C. The clinker production rate of each of Kiln Nos. 1 through 4 shall not exceed 375,000 tons of clinker per year.

D. The average oxygen (O 2 ) content measured at the kiln exit of Kilns No. 1 through 4 shall

be maintained at/or above 0.75 percent by volume on a five

- minute average. Monitoring of the kiln exit average O 2 content will be in accordance with Special Condition No.

13A.

E. Pursuant to 30 TAC § 111.124(2), hydrogen chloride (HCl) emissions from each kiln stack greater than 4.0 lbs/hr shall be co ntrolled with a minimum removal efficiency of

95.0 percent. At no time shall the emissions exceed the MAERT limits for HCl.

9. Kiln No. 5 (EPN E2

- 22)

A. Fuels fired in the main burner and precalciner of Kiln No. 5 (EPN E2

- 22) shall be

limited as follows:

(1) Pipeline

- quality, sweet natural gas containing no more than 5.0 grains of sulfur

per 100 dscf.SPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 12

(2) Coal containing no more than 3.5 percent sulfur by weight. (1/02)

No hazardous waste, as defined by the RCRA and the rules implementing that Act, may be fired in the dry process kiln or precalciner.

B. Opacity of emissions from the Kiln No. 5 (EPN E2

- 22) must not exceed 10 percent as determined by the EPA Reference Meth od 9 or by COMS, averaged over a six

- minute period, except for those periods described in 30 TAC § 111.111 or as otherwise

allowed by law.

C. The clinker production rate of Kiln No. 5 (E2

- 22) shall not exceed 2,800,000 tons of

clinker per year. (9/05)

INITIAL DETERMINATION OF COMPLIANCE

10. Kiln Nos. 1 Through No. 4 (Epns E2

- 2, E2

- 4, E2

- 6, E2

- 8)

- Compliance Testing Required by this Permit Was Conducted for Kiln Nos. 1 Through No. 4 in May 1988, July 1990, and April 1991.

11. Kiln No. 5 (E2

- 22)

A. Sampling ports and platform(s) shall be incorporated into the design of the kiln stack according to the specifications set forth in the enclosed entitled “Chapter 2, Stack Sampling Facilities.” Alternate sampling facility designs may be submitted for

appr oval by the TCEQ Regional Director or the Director of the TCEQ Austin Compliance Support Division.

B. The holder of this permit shall, within 180 days of start

- up of Kiln No. 5, perform stack sampling and other testing, as required, to e stablish the actual pattern and quantities of oxides of nitrogen (NO

x ), carbon monoxide (CO), sulfur dioxide (SO 2 ), sulfuric acid

mist (H 2 SO 4 ), total hydrocarbons, front and back

- half PM and PM equal to or less than

10 microns in diameter within 10 percent of the maximum proposed production rate with the raw mill operating. Additionally, sampling within 10 percent of the maximum production rate shall be performed for SO 2 , and H 2 SO 4 with the raw mill down

. Sampling must be conducted in accordance with appr opriate procedures of the TCEQ Sampling Procedures Manual and in accordance with the EPA Reference Methods. The holder of this permit is responsible for providing sampling and testing facilities and conducting the sampling and testing operations at its ex pense. (01/02)SPECIAL CONDITIONS

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- 632M1 Page 13

(1) The TCEQ Arlington Regional Office shall be contacted as soon as testing is scheduled, but not less than 45 days prior to sampling to schedule a pretest meeting. The notice shall include:

(a) Date for pretest meeting. (b) Date sam pling will occur. (c) Name of firm conducting sampling. (d) Type of sampling equipment to be used. (e) Method or procedure to be used in sampling. The purpose of the pretest meeting is to review the necessary sa mpling and testing procedures, to provide the proper forms for recording pertinent data, and to review the format and procedures for submitting the test reports.

A written proposed description of any deviation from sampling procedures specified in permit conditions or the TCEQ or EPA sampling procedures shall be made available to the TCEQ prior to the pretest meeting. The TCEQ Arlington Regional Director or the Director of the TCEQ Austin Compliance Support Division shall approve or disapprove of any devi ation from specified sampling procedures.

Test waivers and alternate/equivalent procedure proposals for New Source Performance Standards (NSPS) testing which must have the EPA approval shall

be submitted to the TCEQ Austin Compliance Support Division.

(2 ) The deadlines for the sampling specified above may be extended. Requests for additional time to perform sampling shall be submitted to the TCEQ Arlington Regional Office. Additional time to comply with the applicable requirements of

40 CFR Part 60 requ ires the EPA approval, and requests shall be submitted to

the TCEQ Austin Compliance Support Division.

(3) Primary operating parameters that enable determination of production rate shall be monitored and recorded during the stack test. These parameters a re to be recorded, at a minimum, once every 15 minutes and shall be reported on an hourly average basis.

In addition, operating parameters for the abatement equipment shall be recorded during each testing scenario. Parameters include th e outlet temperature of the regenerative thermal oxidizer and corresponding stack exit temperature; the pH and density of the scrubber liquid; the recirculation, concentration, and absorbent flowSPECIAL CONDITIONS

Permit Numbers 1360A and PSD

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- 632M1 Page 14

rates to the scrubber; and pressure differential across the main and alkali bypass baghouses and their respective cleaning cycles.

(4) Copies of each sampling report shall be forwarded to the TCEQ within 90 days after sampling is completed unless an extension is granted by the TCEQ Regional Office. Sampling reports shall comply with the enclosed provisions of Chapter 14 of the TCEQ Sampling Procedures Manual . The reports shall be

distributed as follows:

On e copy to the TCEQ Arlington Regional Office. One copy to the TCEQ Austin Office of Permitting, Remediation, and Registration,

Air Permits Division. One copy to the TCEQ Austin Compliance Support Division.

12. Any Authorized Unit Covered by this Permit and Listed on the MAERT. (9/05)

A

. If sampling of stacks or process vents is required, the permit holder shall contact the TCEQ Compliance Support Division prior to sampling to obtain the proper data forms and procedures. The permit holder is also responsi ble for providing sampling facilities

and conducting the sampling operations or contracting with an independent sampling consultant. All sampling and testing procedures must be approved by the Executive Director of the TCEQ and coordinated with the region al representatives of the Commission. The TCEQ Arlington Regional Office shall be notified at least 45 days prior to the initial start

- up of new or modified facility units authorized by this permit and prior to any required monitoring or sampling in such a manner that a representative of the TCEQ may be present at the time of the initial start

- up, monitoring, or sampling.

B

. Upon request by the Executive Director of the TCEQ, the permittee shall conduct sufficient sampling or other tests to prove satisfactory equipment performance. All calibration, sampling, and testing procedures shall be approved by the Executive

Director o f the TCEQ and coordinated with the TCEQ Arlington Regional Office representatives.

C. It shall be the responsibility of the permit holder to demonstrate or otherwise justify the equivalency of emission control methods, sampling or other emission testing methods, and monitoring methods proposed as alternatives to methods indicated in the conditions of this permit. Alternative methods shall be applied for in writing and must be reviewed and approved by the TCEQ Executive Director prior to their use in fulfillingSPECIAL CONDITIONS

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- 632M1 Page 15

any requirements of the permit.

CONTINUOUS DETERMINATION OF COMPLIANCE

13. Kiln Nos. 1 through 4 (EPNs E2

- 2, E2

- 4, E2

- 6, E2

- 8):

A. The holder of this permit shall operate, calibrate, and maintain continuous emission monitoring systems (CEMS) to measure and record the concentrations of NO

x , SO 2 , O 2 , and opacity in the kiln stacks and kiln O 2 at the kiln exits of each cement kiln. The holder of this permit shall operate, calibrate, and maintain continuous flow rate sensors

to mea sure and record the exhaust flow rate in each kiln stack. (3/01)

(1) Each CEMS shall meet the design and performance specifications, pass the

field tests, and meet the installation requirements and the data analysis, and reporting requirements specified in the applicable Performance Specifications

in 40 CFR Part 60, Appendix B (or equivalent procedures specified by the TCEQ Compliance Support Division for kiln exit O 2 CEMS). Each flow rate sensor shall meet the design and performance specifications, pass the field tests, and meet the installation requirements and the data analysis and reporting requirements specified in 40 CFR Part 60, Appendix B, Performance Specification 6. (The SO 2 and opacity CEMS performance test results were approved by the TCEQ in August, 1986). Performance tests for the NO

x and O 2 CEMS, flow rate sensors, and if required by the TCEQ, kiln exit O 2 CEMS shall be conducted during the sampling completed in Special Condition No. 10. Written copies of the results shall be

submitted wi thin 60 days of completion of the tests to the TCEQ Arlington Regional Office and the TCEQ Compliance Support Division in Austin.

(2) Each CEMS shall be zeroed and spanned daily and corrective action taken

when the 24

- hour span drift exceeds two times the amount specified in

40 CFR Part 60, Appendix B for opacity, SO 2 , O 2 , and NO

x stack analyzers, or the amount specified by the TCEQ Austin Compliance Support Division for kiln exit

O 2 analyzers. Zero and span is not required on weekends and plant holidays if instrument technicians are not normally scheduled on those days, unless the monitor is required by a subpart of NSPS or NESHAPS, in which case zero and span shall be done daily wit hout exception.

(3) Each SO 2 and NO

x CEMS shall complete a minimum of one cycle of sampling, analyzing, and data recording for each successive 15

- minute period. One

- hour averages shall be computed from normally at least four, and a minimum of two,SPECIAL CONDITIONS

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data p oints equally spaced over each one

- hour period.

Data recorded during periods of CEMS breakdowns, repairs, calibration checks,

and zero and span adjustments shall not be included in the computed data

averages. A minimum of 23 hourly averages shall be generated per day.

Three

- hour rolling SO 2 averages shall be computed for each kiln. The three

- hour rolling average shall consider each clock hour and the two preceding clock hours.

A 30

- day rolling NO

x average sh all be computed for each kiln. A 30

- day rolling average is generated for each day as the average of all the day's hourly NO

x emission data and the preceding 29 days of hourly emission data (representing only hours of kiln operation). The gaseous monitori ng data shall be reduced to units of the permit allowable emission rate in pounds per hour (lbs/hr), calculated as a

three

- hour rolling average for SO 2 , and a 30

- day rolling average for NO

x at least once every week.

(4) The opacity monitor shall complete a minimum of one cycle of data recording for

each successive ten

- second period and one cycle of data recording for each

successive six

- minute period.

(5) The kiln exit and stack O 2 monitor shall complete a minimum of one cycle of data recording for each s uccessive 10

- second period and one cycle of date recording for

each successive 5

- minute period. The kiln exit O 2 monitoring data shall be

reduced to five

- minute average concentrations using normally at least 20 equally

- spaced data points from each five

- mi nute period. (3/01)

(6) Each SO 2 and opacity CEMS shall be operated in accordance with the quality

- assurance/quality control (QA/QC) plan approved by the TCEQ Regional Director. Each NO

x CEMS shall be quality

- assured at least quarterly using cylinder ga s audits (CGA). The CGA method to be used is contained

in 40 CFR Part 60, Appendix F, Procedure 1, Section 5.1.2. The kiln exit O 2 CEMS shall be operated in accordance with a QA/QC plan approved by the TCEQ Regional Director. The QA/QC plan for O 2 CEMS shall be submitted

within 60 days of completion of the tests completed in Special Condition No. 10 to the TCEQ Arlington Regional Office and Director of the TCEQ Compliance Support Division in Austin.

(7) All CGA exceedances of greater than ±15 percent ac curacy and any CEMS downtime shall be reported to the TCEQ Arlington Regional Director, and necessary corrective action shall be taken. The TCEQ Regional Director shallSPECIAL CONDITIONS

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be notified as soon as possible after discovery of any CEMS malfunction which

is expec ted to result in more than 24 hours of lost data. Supplemental stack concentration measurements may be required at the discretion of the TCEQ Regional Director.

(8) For NSPS sources subject to Appendix F, the TCEQ Arlington Regional Offic e shall be notified at least 30 days prior to each annual relative accuracy testing audit (RATA) in order to provide the TCEQ staff the opportunity to observe the testing.

After the required demonstrations of initial compliance for these facilities,

the C EMS and plans required in this condition shall be used to determine continuous compliance with the conditions of this permit and the rules and regulations of the TCEQ. Compliance with the emission limitations may also be determined by any TCEQ compliance sampling method.

(9) The CEMS for each kiln will not be inoperable in excess of 100 hours out of any

calendar month.

14. Kiln No. 5 (E2

- 22)

A. The holder of this permit shall install, calibrate, operate, and maintain a COMS for opacity and a CEMS to monitor the in

- stack concentrations of SO 2 , NO

x , total hydrocarbons (THC), and CO from the Kiln No. 5 Stack (EPN E2

- 22). The holder of this permit shall install, calibrate, and maintain a continuous flow rate sensor to

measure and record the exhau st flow rate in the dry kiln stack. (9/05)

(1) The CEMS, COMS, and flow rate sensor shall meet the design and performance specifications, pass the field tests, and meet the installation requirements and the

data analysis and reporting requirements specif ied in the applicable Performance Specifications (No. 2, No. 4 and No. 8A for the CEMS, No. 1 for the COMS, and

No. 6 for the flow rate sensor) of 40 CFR Part 60, Appendix B. (9/05)

(2) The CEMS, COMS, and flow rate sensor shall be zeroed and spanned dai ly and

corrective action taken when the 24

- hour span drift exceeds two times the amounts specified in 40 CFR Part 60, Appendix B, or as specified by the TCEQ if not specified in Appendix B.

Zero and span is not required on weekends and plant holidays if i nstrument technicians are not normally scheduled on those days, unless the monitor isSPECIAL CONDITIONS

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- 632M1 Page 18

required by a subpart of NSPS or NESHAPS, in which case zero and span shall be done daily without exception.

Each CEMS, COMS, and flow rate sensor shall be quality

- assured at least quarterly in accordance with 40 CFR Part 60, Appendix F. At a minimum, Data Assessment Reports and any downtime shall be reported to the appropriate TCEQ Regional Director on a quarterly basis. Necessary corrective action shal l be taken if the downtime exceeds 5 percent of the kiln operating hours in a quarter. Failure to complete any corrective action as directed by the TCEQ Arlington Regional Office may be deemed a violation of the permit. For non

- NSPS sources, an equivalen t method approved by the TCEQ may be used.

(3) Each CEMS and flow rate sensor shall complete a minimum of one cycle of sampling, analyzing, and data recording for each successive 15

- minute period.

One

- hour averages shall be computed from normally at leas t four, and a minimum of two, data points equally

- spaced over each one

- hour period. Data recorded during periods of CEMS breakdowns, repairs, calibration checks, and zero and span adjustments shall not be included in the computed data averages.

The CEMS data shall also be reduced to units of the permit allowable emission rate

in lbs/hr.

The COMS shall complete a minimum of one cycle of data recording for each

successive ten

- second period. Six

- minute averages shall be computed from normally at least 36 a nd a minimum of 18 data points equally spaced over each

six

- minute period. Data recorded during periods of COMS breakdowns, repairs, calibration checks, and zero, and span adjustments shall not be included in the computed data averages.

(4) The TCEQ Regional Director shall be notified as soon as possible after the discovery of any COMS or CEMS malfunction, which is expected to result in more

than 24

- hours of lost data. Supplemental stack concentration measurements may be required at the disc retion of the appropriate TCEQ Regional Director in case of

extended COMS or CEMS downtime.

(5) The TCEQ Arlington Regional Office shall be notified at least seven days prior to

the quarterly CGA required by Appendix F in order to provide the TCEQ staff t he opportunity to observe the testing.SPECIAL CONDITIONS

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(6) The SO 2 , NO

x , THC, and CO CEMS and the continuous flow rate sensor shall be

used as a continuous emission rate monitoring system for SO 2 , NO

x , THC, and CO to demonstrate continuous compliance with this permit. ( 9/05)

(7) The THC CEMS shall be installed and the requirements specified in paragraph (1) of this condition shall be completed within six months after issuance of the permit amendment to reduce operation of the regenerative thermal oxidizer. (9/05)SPECIAL CONDITIONS

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B. For purposes of demonstrating compliance with the Special Condition No. 1C the holder of this permit shall monitor the wet scrubber as follows:

(1) Uptime (in hour s) as a percentage of kiln operating hours.

(2) Scrubbing liquid pH, density, and flow rate recorded at least once per hour.

C. Within 90 days of start

- up of Kiln No. 5 (E2

- 22), the permittee will submit revised tables for all new and affected facilities which accurately represent the as

- built specifications of the equipment proposed.

D. (1) The holder of this permit must control THC emissions in the Kiln 5 gas stream to

the levels identified in the MAERT by operating the existing regenerative thermal oxidizer when Kiln 5 is in operation. THC compliance will be based on a 30

- day rolling average. (9/05)

(2) The holder of this pe rmit shall install, calibrate, operate, and maintain a continuous emissions monitoring system (CEMS) to measure and record the concentration of

THC in the Kiln 5 exhaust stack. The CEMS shall adhere to the conditions for CEMs listed for Kiln 5 under Speci al Condition 14 of this permit. (9/05)

(3) The THC CEMS requirements of this permit are applicable at all times Kiln 5 is in operation. (9/05)

REPORTING

15. Kiln Nos. 1

- No. 4 (EPNs E2

- 2, E2

- 4, E2

- 6, and E2

- 8)

A. The holder of this permit shall submit to the TCEQ Arlington Regional Office quarterly CEMS reports. Such reports are required for each kiln which is required to be monitored pursuant to Special Condition No. 13. All such reports shall be postmarked by t he 30th day following the end of each calendar quarter and shall include the following information for each monitor:

(1) The magnitude of excess emissions and the date and time of commencement and completion of each time period of excess emissions.

(2) F or each period of excess emissions, the nature and cause of any malfunctionSPECIAL CONDITIONS

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- 632M1 Page 21

(if known), the corrective action taken, or preventive measures adopted.

(3) The date and time identifying each period during which the CEMS was inoperative (e xcept for zero and span checks) and the nature of the system repairs or adjustments which occurred during the downtime. (4) When no excess emissions have occurred or the CEMS has not been inoperative, repaired, or adjusted, such information shall be stated in the report.

(5) The reporting of excess emissions required by this condition does not relieve the holder of this permit from the notification requirements for emission events or scheduled maintenance as required by 30 TAC §§ 101.201 and 101.211. (9/0 5)

(6) All NO

x CEMS data from the first quarter of monitoring following the NO

x CEMS performance test shall be submitted to the TCEQ Arlington Regional Office with the first quarterly report following the test.

B. For the purposes of reporting pursuant t o Special Condition No. 15A, noncomplying

emissions are defined as follows:

(1) Noncomplying emissions of SO 2 are each rolling three

- hour average period of operation during which the average hourly emissions of SO 2 , as measured and

recorded by the CEMS, e xceed the emission limitations of the MAERT.

(2) Noncomplying emissions of NO

x are each rolling 30

- day average period of operation during which the average hourly emissions of NO

x , as measured and recorded by the CEMS, exceed the emission limitations of the MAERT.

(3) Noncomplying emissions of opacity are each six

- minute period of operation during which the average opacity, as measured and recorded by the CEMS, exceeds the emission limitation of Special Condition No. 8B.

(4) Noncomplying kiln stack emissions of organic compounds, HCl, hydrogen fluoride, or metals are each period during which the laboratory and feed

rate calculations of Special Condition No. 22A(6) predict an exceedance of

the emission limitations of Special Condition No. 1C.

16. Kiln No. 5 (E2

- 22)

A. In addition to applicable NSPS reporting requirements, the holder of this permit shallSPECIAL CONDITIONS

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- 632M1 Page 22

submit one copy of quarterly CEMS and COMS reports to the TCEQ Arlington Regional Office in a format deemed acc eptable by the TCEQ Regional Office. All reports shall be postmarked by the 30th day following the end of each calendar quarter

and shall include the following information for each monitor:

(1) The date and duration of time from the c ommencement to the completion of an event which resulted in excess emissions of any pollutant. (2) The date and time of the commencement and completion of each specific time period of excess emissions within that event.

(3) The total time duration of excess emissions.

(4) The magnitude of the emissions, including the highest emission rate, and the average emission rate. All excess emissions shall be converted into the units of the permit. All conversion factors and equati ons shall be included.

(5) The nature and cause of any malfunction resulting in excess emissions and the corrective action taken and/or preventative measures adopted.

(6) The date and time identifying each period during which a CEMS or COMS was inope rative, except for zero span checks, and the nature of the system repairs and/or adjustments which occurred during the downtime.

(7) When no excess emissions have occurred or the CEMS or COMS have not been inoperative, repaired, or adjusted, such inform ation shall be stated in the report.

(8) The total tons of SO 2 , NO

x , THC, and CO emitted during the quarter and the total

h ours of kiln operation during the quarter shall be reported; and the total hours of raw mill operation during the quarter shall be maintained on

- site and in a form

suitable for inspection. (9/05)

(9) In addition to the other information required in thi s special condition, a summary of the excess emissions shall be reported as required by Subpart A of 40 CFR

Part 60.

( 10 ) The reporting of excess emissions required by this condition does not relieve the

holder of this permit from notification requirements of emission events as required by 30 TAC § 101.201 or notification of scheduled maintenance as required by 30 TAC § 101.211. (9/05)SPECIAL CONDITIONS

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- 632M1 Page 23

(11) Quarterly CGA reports and RATA pursuant to Appendix F of 40 CFR Part 60.

B. For the purposes of reporting pursuant to S pecial Condition No. 16A, excess emissions

are defined as follows: (3/01)

(1) Excess emissions of SO 2 are each rolling averaging period of operation specified

in the MAERT during which the hourly average emissions of SO 2 as measured and recorded by the CEMS, exceed the emission limitations of the MAERT.

(2) Excess emissions of NO

x are each period of operation during which the 30

- day rolling average of emission of NO

x as measured and recorded by the CEMS,

exceed the emiss ion limitations of the MAERT. (3/01)

(3) Excess emissions of CO are each one

- hour average period of operation during which the hourly average emissions of CO, as measured and recorded by the CEMS, exceed the emission limitations of the MAERT.

(4) Excess periods of opacity are each six

- minute period of operation during which

the average opacity, as measured and recorded by the COMS, exceed the emission limitations of Special Condition No. 9B.

(5) Excess emissions of THC are each daily period of operation during which the

30

- day rolling average emission of THC as measured and recorded by the CEMS,

exceed the emission limitations of the MAERT. (9/05)

RECORDKEEPING

17. A copy of the permit along with information and data sufficient to demonstrate complia nce with the permit shall be maintained in a file at the plant site and made available at the request of personnel from the TCEQ or any air pollution control program having jurisdiction. For facilities that normally operate unattended, this information sh all be maintained at the nearest staffed location within Texas specified by the permit holder in the Part B permit application. this information shall include, but is not limited to, production records and operating hours. Additional recordkeeping requir ements may be specified in special conditions of this permit. Information in the file shall be retained for at least two years on a rolling retention basis following the date that the information or data is obtained.SPECIAL CONDITIONS

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(03/01)

18. Kilns No. 1 through 4 (EPNs E2

- 2, E2

- 4, E2

- 6, and E2

- 8)

A. The CEMS Records Pursuant to Special Condition No. 13A

(1) Average hourly NO

x , SO 2 , and O 2 concentrations, and six

- minute average opacities which are monitored pursuant to Special Condition No. 1 3A; and

(2) The holder of this permit shall maintain a raw data file of all measurements (including continuous monitoring systems, monitoring device, and performance testing measurements), all continuous monitoring device calibration c hecks and adjustments, and maintenance performed on these systems or devices. The file

shall be kept in a permanent form suitable for inspection.

(3) The records required in this condition shall be maintained at the plant site on

a rolling two

- year reten tion basis following the date of such measurements, maintenance, reports, or records and shall be made available to the TCEQ or

any local air pollution agency having jurisdiction, upon request.

19. Kiln No. 5 (E2

- 22)

The following records shall be kept and made available upon request to the TCEQ or any air pollution control program having jurisdiction. Records shall be maintained on

- site on a rolling two

- year retention basis.

(1) Daily clinker production rates report ed in tons per hour and summed on an annual basis.

(2) Daily fuel consumption of coal and natural gas. Fuel consumption records shall be summed monthly.

(3) Fuel sulfur content for coal shall be obtained with each fuel contract and recorded as a
percent weight. Sulfur content may be verified by a vendor statement, on

- site analysis

or third

- party analysis. Fuel sulfur records for coal need only be updated if the supplier is changed.

(4) Fuel sulfur content for natural gas in grains per 100 dscf. A sin gle vendor statement verifying compliance with the natural gas sulfur limits of this permit shall suffice in complying with this requirement. Fuel sulfur records for natural gas need only be updated if the supplier is changed.SPECIAL CONDITIONS

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(5) Daily amounts of raw ma terial inputs to the kilns reported by type and in lbs/hr.

(6) Malfunctions of any air pollution abatement systems.

(7) Documentation of air pollution control equipment maintenance and repair.

(8) Continuous monitoring and recording of opacity shall be performed for EPN E2

- 22 as detailed in Special Condition No. 14A(3).

20. Raw Material Handling

A. Daily and annual throughput records for limestone, shale, anhydrite, iron components, and records of maintenance and malfunction of pollution abatement equipment shall be kept on

- site for a rolling two

- year period and made available at the request of TCEQ and

local air pollution control programs.

B. The permittee shall maintain documentation which demonstrates that the overland conveyor system is achieving compliance with all conditions of the permit. This documentation shall consist of a statement explai ning how each requirement in a condition is being met. It will also include a sample of each record sheet required to be maintained by any condition.

21. Clinker Handling System

A. Daily production records shall be recorded and made available for inspec tion by the TCEQ and any local air pollution control programs. Preventative maintenance, scheduled maintenance, and repair maintenance performed shall comply with the 30 TAC § 101.211, and these records shall be made available for inspection by the TCEQ a nd any local air pollution program having jurisdiction. Records shall include daily cement production and malfunctions in the process; daily raw material processing and handling; and malfunctions of any air pollution abatement device system(s). These re cords shall be summed monthly and shall be maintained on

- site for a rolling two

- year period. (9/05)

B. The permittee shall maintain documentation which demonstrates that the clinker handling system is achieving compliance with all conditions of this permi t. This documentation shall consist of a statement explaining how each requirement in a condition is being met. It will include a sample of each record sheet required to be maintained by any condition.SPECIAL CONDITIONS

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WASTE

- DERIVED FUEL AND CLINKER QUENCH WASTEWATER C ONDITIONS

22. Kiln Nos. 1 through 4 (EPNs E2

- 2, E2

- 4, E2

- 6, and E2

- 8)

A. The waste

- derived fuel shall contain no more than 1.5 percent by weight of the following compounds: creosote, creosols, cresylic acid, and coal tars.

B. The clinker quench wastewater, as received at the facility, shall not

containChlorofluorocarbon.

C. The holder of this permit shall comply with these requirements for all equipment items

which contact waste

- derived fuel or clinker quench wastewater, excep t relief valves and

sump pumps.

(1) These conditions shall not apply (1) where the volatile organic compound (VOC)

have an aggregate partial pressure or vapor pressure of less than 0.05 psia at 20 ° C, (2) to pipi ng and valves two inches nominal size and smaller, or (3) operating

pressure is at least 5 kilopascals (0.725 psi) below ambient pressure. Equipment

excluded from this condition shall be identified in a list to be made available upon
request.

(2) Const ruction of new and reworked piping, valves, pump systems, and compressor systems shall conform to applicable American National Standards Institute,

American Petroleum Institute, American Society of Mechanical Engineers, or equivalent codes.

(3) New and reworked underground process pipelines shall contain no buried valves such that fugitive emission monitoring is rendered impractical.

(4) To the extent that good engineering practice will permit, new and reworked valves and piping connections sh all be so located to be reasonably accessible for

leak

- checking during plant operation. Nonaccessible valves shall be identified in a list to be made available upon request.

(5) New and reworked piping connections shall be welded or flanged. Screwed

c onnections are permissible only on piping smaller than two

- inch diameter. No later than the next scheduled quarterly monitoring after initial installation or replacement, all new or reworked connections shall be gas

- tested or hydraulically

- tested at no le ss than normal operating pressure and adjustments made, as necessary, to obtain leak

- free performance. Flanges shallSPECIAL CONDITIONS

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- 632M1 Page 27

be inspected by visual, audible, and/or olfactory means at least weekly by operating personnel walk

- through.

Each open

- ended valve or lin e shall be equipped with a cap, blind flange, plug, or a

second valve.

(6) Accessible valves shall be monitored by leak

- checking for fugitive emissions at least quarterly using an approved gas analyzer with a directed maintenance program. Sealless/leak less valves (including, but not limited to, bellows and diaphragm valves) and relief valves equipped with a rupture disc or venting to a control device are not required to be monitored. For valves equipped with rupture discs, a pressure gauge shall be ins talled between the relief valve and rupture disc to monitor disc integrity. All leaking discs shall be replaced at the earliest opportunity, but no later than the next process shutdown.

A directed maintenance program shall consist of the repair and maint enance of components assisted simultaneously by the use of an approved gas analyzer such that a minimum concentration of leaking VOC is obtained for each component being maintained.

(7) All new and replacement pumps and compressors sha ll be equipped with a shaft sealing system that prevents or detects emissions of VOC from the seal. These seal systems need not be monitored and may include (but are not limited to) dual pump seals with barrier fluid at higher pressure than process pressu re, seals degassing to vent control systems kept in good working order, or seals equipped with an automatic seal failure detection and alarm system. Submerged pumps or sealless pumps (including, but not limited to, diaphragm, canned, or magnetic driven

pu mps) may be used to satisfy the requirements of this condition and need not

be monitored.

All other pump and compressor seals emitting VOC shall be monitored with an approved gas analyzer at least quarterly.

(8) Damaged or leaking valves, flanges, compressor seals, and pump seals found to

be emitting VOC in excess of 500 ppmv or found by visual inspection to be leaking (e.g., dripping liquids) shall be tagged and replaced or repaired. Every reasonable

effort shal l be made to repair a leaking component, as specified in this paragraph,

within 15 days after the leak is found. If the repair of a component would require a unit shutdown, the repair may be delayed until the next scheduled shutdown. AllSPECIAL CONDITIONS

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leaking componen ts which cannot be repaired until a scheduled shutdown shall be identified for such repair by tagging. The TCEQ Executive Director, at her discretion, may require early unit shutdown or other appropriate action based on the number and severity of tagged l eaks awaiting shutdown.

(9) The results of the required fugitive monitoring and maintenance program shall be made available to the TCEQ Executive Director or her designated representative upon request. Records shall indicate appropriate dates, test met hods, instrument readings, repair results, and corrective actions taken. Records of flange inspections are not required unless a leak is detected.

(10) Compliance with the requirements of this condition does not assure compliance with requirements of 30 TAC Chapter 115, an applicable NSPS, or an applicable NESHAPS and does not constitute approval of alternative standards for

these regulations.

( 11 ) Audio, olfactory, and/or visual checks for any piping, valves, pumps, agitator seals or other components in haza rdous waste service within the operating area shall be made at least weekly. (3/01)

A. Immediately, but no later than one hour upon detection of a leak, plant personnel shall take the following actions: (3/01)

(1) Isolate the leak.

(2) Use a leak collection or containment system to prevent the leak until repair or replacement can be made if immediate is not possible. Date and time of each inspection shall be noted in the operator’s log or equivalent. Records shall be

maintained at the plant site of all repairs and replacements made due to leaks. These records shall be made available to representatives of the TCEQ or any other local program with jurisdiction upon request.

(3) The facility must maintain a closed vapor vent back/vapo r balance system on all tanks

in Hazardous Waste Service. (3/01)

( 4 ) The holder of this permit shall clean up any spills of VOC or inorganic compounds as expeditiously as possible. All colleted liquids and spills shall be stored and disposed of in a vapor

- t ight container such that no detectable emissions to the atmosphere will result. Records of all spills (date of spill, time of spill, and corrective action taken)SPECIAL CONDITIONS

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shall be maintained on

- site for a two year rolling retention basis following the date of

reco rded information and made available to the TCEQ or any other local program with jurisdiction. (3/01)

( 5 ) Operation without visible liquid leaks or spills shall be maintained at the storage and unloading facility, regardless of vapor pressure. This does not apply to momentary dripping associated with the initial connection or disconnection of fittings. Any liquid spills that occur during unloading shall be reported pursuant to 30 TAC §§ 101.201 and 101.211, and shall be cleaned up immediately, to minimize ai r emissions. (9/05)

(6) The holder of this permit shall make and maintain records of the following on a

two

- year rolling retention basis:

a. Kiln Fuels:

(1) The received percent sulfur for the kiln fuels; and

(2) The percent sulfur of the fuels as burned.

b. Clinker Quench Wastewater: quantity of wastewater accepted. (3/01)

c. Waste

- Derived Fuel: quantity of waste

- derived fuel accepted. (3/01)

d. Monitoring and Maintenance Records Pursuant to Special Condition No. 22C.

(1) A list of all components affected by this condition;

(2) Checklists indicating that the daily inspections are being performed;

(3) Checklists indicating the hydrocarbon analyzer inspections are being performed;

(4) Summaries including date, time, equipment identification, and monitoring results for all leaking items;

(5) Summaries including date, time, equipment identification, and corrective actions for all isolations, replacements, and/or repairs performed, includ ing monitoring results immediately after repairs; andSPECIAL CONDITIONS

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(6) Records of the calibration of the portable monitoring instruments.

The records required in this condition shall be maintained at the plant site on a rolling two

- year retention basis following the date of such measurements, maintenance, reports, or records and shall be made available to the TCEQ or any local air pollution agency having jurisdiction, upon request.

(7) After the required demonstrations of initial compliance for these facilities,

the CEMS and QA/QC plans required in Special Condition No. 13A shall be used to determine continuous compliance with the conditions of this permit and the rules and regulations of the TCEQ. Compliance with the emission limitations may also be determined by an y TCEQ compliance sampling

method.

(8) Information and data concerning the date, type and quantity of wastes managed, waste analyses, facility inspections, operating hours, sampling, and monitoring data shall be maintained in the operating record at the p lant site in a form suitable for inspection and made available at the request of personnel from the TCEQ, or any local government having jurisdiction under the Texas

Clean Air Act. (3/01)