# June27, 2009 () Ms. RandyHamilton Texas CommissiononEnvironmental Quality OfficeofPennitting andRegistration, AirPennits Division (MCI63) 12100Park 35 Circle Austin, TX 78753 

# AIRPERMHSDIV/SION VIAFedEx TRK#797717837453 

# JUN 29

# 2009**~til1~,~;** 

# REGEU/ED**'!~** 

## RE: 

# PM, VOC, HCL, CL2, METALS (INCLUDING MECURy), AND DIOXINIFURAN PERFORMANCE TESTING CEMEX CEMENT OF TEXAS, L.P., BALCONES CEMENTPLANT PennitNo. 6048IPSD-TX-74Ml, TCEQACCOUNTNO. CS-0022-K DearMr. Hamilton+ Attached is the completed perfonnance testing for PM, VOCs, HCL, CL2, Metals and Dioxin/Furan (DF). The testing for the PM and DF is required by 

# 40 CFR Part 63 

# Table 1 

# to §63.1349.

- 

# Summary of Performance Test Requirements. This report has also been sent to 

# "TCEQAirSection Manager, Region 13" as required by SPECIAL CONDITION 13 E. The TCEQ, Region 13 Air Sectionwas notified oforiginal testing onMarch 26, 2009 and then faxed an amended notification onApril 7, 2009 due to majorrepairwork on the burnerpipe. We have also included the VOCs, HCL, CL2 and Metals (including Mercury) tests for more accurate ·emissions rates for ourEmission Inventory, in which previouslyused were AP-42 factors. The facility is testingunderthepromulgatedNational Emission Standard forHazardous AirPollutant (NESHAP) regulations forthe Portland CementIndustry. Clean Air Engineering conducted the testing and has provided the final report ofthe results for your review. If you have any concerns or questions, please contact me at 210-250-4009 concerning thesereports. Sincerely,
%y7Dabn;rr---

Environmental Manager CEMEXCementofTexas, Balcones Plant Attachments: OP-CROI
cc: Amarjit SinghGill, P.E, Director, Environmental-EnvironmentalAffairs Michael Gonzalez, PlantManager TCEQAir SectionManagerRegion 13 United States Operations 2580Wald Road, NewBraunfels, Texas. 78132. USA. Phone: (830) 625-7338 NewBraunfels, Fax: (210) 250-4044, (210) 250-4100 San Antonio

# CleanAir.

CleanAirEngineering 321 CenturyPlaza Suite 130 Houston, TX77073-6041 800-723-0362 www.c1eanair.comlll> 

### TexasRegisteredEngineeringFirmF-001749



# CEMEX CementofTexas, LP 2580 Wald Road New Braunfels, TX

REPORT ON COMPLIANCE TESTING 

# Performed for: CEMEX CEMENT OF TEXAS, LP LINE 2 MAIN KILN STACK, LINE 2 CLINKER COOLER BALCONES PLANT 

# ClientReferenceNo: DC04062009 CleanAirProjectNo: 10773 Revision 0, Final: June 26, 2009

To the bestofourknowledge, the datapresented inthis report are accurate, complete, errorfree, legible andrepresentative ofthe actual emissions during the testprogram.



# u Submittedby, 

# (\)1(\'&\

# \1l]£~~ai

.

# ~Nunez ProjectManager dnunez@cleanair.com (800) 723-0362

RPTv4 6 3.dot 10773 -CEMEX a.doc 06262ii09 072800 10773 

# Reviewedby,

# B~~1-- SouthernEngineering Group Leader bdelatte@cleanair.com (800) 723-0362

# :f) CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT Client Reference No: DC04062009 CleanAir Project No: 10773
REVISION HISTORY REPORT ON COMPLIANCE TESTING

DRAFTREPORTREVISIONHISTORY

Revision: Date Pages Comments DOa 06/25/09 All Draft version of original document.



### FINAL REPORTREVISIONHISTORY

Revision: Date Pages Comments 0 06/26/09 All Final version of original document.



### Revision 0, Final 

# ii

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
CONTENTS Client Reference No: DC04062009 CleanAir Project No: 10773


# iii 1 PROJECT OVERViEW 1-1 INTRODUCTION 1-1 Key Project Participants 1-1 Test Program Parameters 1-1 TEST PROGRAM SYNOPSIS 1-3 Test Schedule 1-3 Table 1-1: Schedule ofActivities 1-3 

### Results Summary 1-4 Table 1-2: Summary ofTest Results 1-4 Table 1-3: Summary ofTest Results 1-5 

### Discussion ofTest Program 1-6 

## 2 RESULTS 2-1 Table 2-1: Line 2 Main Kiln Stack
- Filterable PM 1o, 

### Raw Mill On 2-1 Table 2-2: Line 2 Main Kiln Stack
- Condensable PM, Raw Mill On 2-2 Table 2-3: Line 2 Main Kiln Stack
- Filterable PM > 10l.lm, Raw Mill On 2-3 Table 2-4: Line 2 Main Kiln Stack -Total HCI, Raw Mill On 2-4 Table 2-5: Line 2 Main Kiln Stack
- Total C12, 

### Raw Mill On 2-5 Table 2-6: Line 2 Main Kiln Stack
- Total NH3, Raw Mill On 2-6 Table 2-7: Line 2 Main Kiln Stack
- PCCDs/PCCDFs, Raw Mill On 2-7 Table 2-8: Line 2 Main Kiln Stack
- NOx, CO, S02, THC, Raw Mill On 2-8 Table 2-9: Line 2 Main Kiln Stack
- Filterable PM 1o, 

### Raw Mill Off 2-9 Table 2-10: Line 2 Main Kiln Stack
- Condensable PM, Raw Mill Off 2-10 Table 2-11: Line 2 Main Kiln Stack
- Filterable PM 

### > 10l.lm, Raw Mill Off 2-11 Table 2-12: Line 2 Main Kiln Stack
- Total HCI, Raw Mill Off 2-12 Table 2-13: Line 2 Main Kiln Stack
- Total C12, 

### Raw Mill Off 2-13 Table 2-14: Line 2 Main Kiln Stack
- Total NH3, Raw Mill Off .2-14 Table 2-15: Line 2 Main Kiln Stack
- PCCDs/PCCDFs, Raw Mill Off 2-15 Table 2-16: Line 2 Main Kiln Stack
- NOx, CO, S02, THC, Raw Mill Off 2-16 Table 2-17: Line 2 Clinker Cooler
- Filterable PM1Q 2-17 Table 2-18: Line 2 Clinker Cooler
- Condensable PM 2-18 Table 2-19: Line 2 Clinker Cooler
- Filterable PM > 10l.lm 2-19 

## 3 DESCRIPTION OF INSTALLATION 3-1 PROCESS DESCRIPTION 3-1 Figure 3-1: Process Schematic 3-1 

### DESCRIPTION OF SAMPLING LOCATIONS 3-2 Table 3-1: Sampling Points 3-2 Figure 3-2: Line 2 Main Kiln Stack Sampling Point Determination (EPA Method 1) 3-3 Figure 3-3: Line 2 Clinker Cooler Sampling Point Determination (EPA Method 1) 3-4 

## 4 METHODOLOGY 4-1 Table 4-1: Summary of Sampling Procedures 4-1 

## 5 APPENDiX 5-1 TEST METHOD SPECIFICATIONS A SAMPLE CALCULATIONS 8 Revision 0, Final

# (---) 

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
CONTENTS Client Reference No: DC04062009 CleanAir Project No: 10773
iv



# ) PARAMETERS 

## C QAlQC 

## DATA D FIELD 

## DATA E FIELD DATA PRINTOUTS 

## F LABORATORY 

## DATA G PLANT 

## DATA H PROTOCOL 1 

### RESUMES 

## J

Revision 0, Final

# () CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
PROJECT OVERVIEW Client Reference No: DC04062009 CleanAir Project No: 10773
1-1 

## INTRODUCTION CEMEX CementofTexas, LP contracted Clean AirEngineering (CleanAir) to perform emissions testing attheirfacility located inNew Braunfels, TX forthepurpose of demonstrating compliance with EPA Federal Operating PermitNo. 01126 and Special Conditions ofTCEQ Permits Numbers 6048 andPSD-TX-74Ml. Alltesting was conducted in accordance with the regulations set-forthby the United States Environmental ProtectionAgency (USEPA) andthe Texas Commission on Environmental Quality (TCEQ). KeyProjectParticipants Individuals responsible for coordinating and conductingthetestprogram were: S. Dabney II

- CEMEX CementofTexas, LP 

# B. Delatte

- CleanAir TestProgram Parameters Thetesting performed atthe Line 2 Main Kiln Stackand Line 2 Clinker Cooleron April 21 5t

## through 29th
, 

## 2009 includedthe following emissions measurements:
• particulate matterless than 10microns in diameter (filterable PMIO)

• condensable particulate matter (CPM)

• particulate matter greaterthan 10 microns in diameter

• total suspendedparticulate (TSP)

• hydrogen chloride (HCI)

• chlorine (CI2)

• ammonia (NH3)


## • polychlorinated dibenzo-p-dioxins andpolychlorinated dibenzofurans (PCDD/F)

• nitrogen oxide (NOx)

• sulfurdioxide (S02)

• carbon monoxide (CO)

• volatile organic compounds (VOC) as Total Hydrocarbons (THC)

• flue gas composition (e.g., 02, C02, H2 0)

• flue gas temperature

• flue gas flow rate
• mercury (Hg)

Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
PROJECT OVERVIEW Client Reference No: DC04062009 CleanAir Project No: 10773


# 1-2



# )



# ) • trace metals: antimony (Sb), arsenic (As), barium (Ba), beryllium (Be), cadmium (Cd), chromium (Cr), copper (Cu), lead (Pb), manganese 

# (Mn), molybdenum (Mo), nickel (Ni), phosphorus (P), selenium (Se), silver (Ag), thallium (TI), zinc (Zn)

Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
PROJECT OVERVIEW Client Reference No: DC04062009 CleanAir Project No: 10773


# 1-3 TEST PROGRAM SYNOPSIS 

# TestSchedule The on-site schedule followed during the testprogram is outlined in Table 1-1. Table 1-1: Schedule ofActivities

Run start End Number Location Method Analyte Date Time Time Cooler Stack USEPA M201A1202 Particulate 4126/09 15:23 18:07 Cooler Stack USEPA M201A1202 Particulate 4/26/09 18:42 20:26 Cooler Stack USEPA M201A1202 Particulate 4/26/09 20:55 22:35
1 Kiln Stack USEPA Method 23 PCDD/F 04/23/09 12:13 15:38 2 Kiln Stack USEPA Method 23 PCDD/F 04/23/09 16:22 19:37 3 Kiln Stack USEPA Method 23 PCDD/F 04/23/09 19:37 22:57 Kiln Stack USEPA Methods, 6C, SO" NOx, CO, VOCs 04/23/09 12:13 15:14 7E, 10, 25A Kiln Stack USEPA Methods, 6C, Se" NO", CO, VOCs 04/23109 17:01 18:01 7E, 10, 25A Kiln Stack USEPA Methods, 6C, SO" NOx, CO, VOCs 04123/09 18:29 19:29 7E,10,25A Kiln Stack USEPA Methods, 6C, SO" NOx, CO, VOCs 04/23/09 20:03 21:03 7E,10,25A Kiln Stack USEPA Method 29 Trace Metals 04/25/09 09:26 11:48 Kiln Stack USEPA Method 29 Trace Metals 04/25/09 13:08 15:42 

# ) Kiln Stack USEPA Method 29 Trace Metals 04/26/09 08:31 11:13 Kiln Stack USEPA Method 28 HCI 04/25/09 09:26 11:48 Kiln Stack USEPA Method 28 HCI 04/25/09 13:08 15:42 Kiln Stack USEPA Method 26 HCI 04/26/09 08:31 11:13 Kiln Stack USEPA M201A1202 Particulate 04/25/09 09:26 11:49 Kiln Stack USEPA M201A1202 Particulate 04/25/09 13:08 15:44 Kiln Stack USEPA M201A1202 Particulate 04/26/09 08:31 11:12 Kiln Stack USEPA Methods, 6C, SO" NOx, CO, VOCs 04/25/09 09:26 10:27 7E,10,25A Kiln Stack USEPA Methods, 6C, S02, NOx, CO, VOCs 04/25/09 13:08 14:21 7E, 10, 25A Kiln Stack USEPA Methods, Be, S02. NOx, CO, VOCs 04/25/09 18:45 19:46 7E,10,25A Kiln Stack USEPA Method 25A VOCs 04/26/09 08:31 09:31 Kiln Stack USEPA M201A1202 Particulate 04/27/09 18:10 20:29 Kiln Stack USEPA M201A1202 Particulate 04/27/09 21:30 23:48 Kiln,Stack USEPA M201A1202 Particulate 04/27/09 14:31 16:59 Kiln Stack USEPA Method 29 Trace Metals 04/27/09 10:43 14:29 Kiln Stack USEPA Method 29 Trace Metals 04/27/09 18:10 20:29 Kiln Stack USEPA Method 29 Trace Metals 04/27/09 21:30 11:48 Kiln Stack USEPA Method 26 HCI 04/27/09 10:43 14:29 Kiln Stack USEPA Method 26 HCI 04/27/09 18:10 20:29 Kiln Stack USEPA Method 26 HCI 04/27/09 21:30 23:48 Kiln Stack USEPA Methods, 6C, SO" NO", CO, VOCs 04/27/09 10:43 12:31 7E, 10, 25A Kiln Stack USEPA Methods, 6C, SO" NOx, CO, VOCs 04/27/09 18:10 19:10 7E, 10, 25A Kiln Stack USEPA Methods, 6C, SO" NO", CO, VOCs 04/27/09 21:31 22:31 7E, 10, 25A Kiln Stack USEPA Method 23 PCDD/F 04/28/09 10:10 13:24 Kiln Stack USEPA Method 23 PCDD/F 04/28/09 13:24 16:41 Kiln Stack USEPA Method 23 PCDD/F 04/28/09 16:41 19:55


# ) /' 

### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
PROJECT OVERVIEW TEST PROGRAM SYNOPSIS (CONTINUED) Client Reference No: DC04062009 CleanAir Project No: 10773


# 1-4
Results Summary Table 1-2 and 1-3 summarize the results ofthetestprogram. A more detailed presentation ofthetestconditions and results ofanalysis are shown in Tables 2-1 through 2..;19 on pages 2-1 through 2-19. Table 1-2: Summary ofTest Results Source Sampling Pending Permit Constituent Method Average Emission Permit Limit1 Limit2 Line 2 Main Kiln Stack RawMill On Iblhr TPY PM,o (lb/hrffPY) EPA 201A10TM-028 <6.777 <29.683 8.06/27.09

FPM

# '0 (/b/hrfTPY) EPA 201A <1.729 <7.572 n.s. 10.72/36.01 CPM(/b/hrfTPY) EPAOTM-02B 5.048 22.111 n,s. 11.85/49.77 PM>10 (Ib/hr) EPA201A 2.101 9.202 n.s, PM total (/b/hr) EPA 201A/OTM-02B <8.878 <38.885 9.6132.25 PM (fronthalf) EPA 201A <3.630 <16.774 n.a, 12.76I42.87 PM (backhalf) EPA OTM-02B 5.048 22.111 n.s, 11.B5/49.77 HCI (lblhrffPY) EPA26A <0.027 <0.120 0.52/2.25 CI2 (lb/hrffPY) EPA26A 0.295 1.292 n.a. NH3 (lb/hrffPY) EPA26A1CTM-027 <0.006 <0.028 n.s. 

# ) PCCDsIPCCDFs (ng/dscm @7%O2) EPA 23 0.000005 0.20 NOx (Ib/hrITPY) EPA7E 317.15 1389.12 326.67 I 1431.0 CO (Ib/hrffPY) EPA10 87.78 384.48 772.0/879.0 502 (Iblhr/TPY) EPA6C 0.17 0.73 106.0 I58.0 VOC (Iblhr/ TPY) EPA25A 3.08 13.49 13.07 /43.90 RawMill Off PM,o (lb/hrffPY) EPA 201A10TM-028 <8.854 <38.779 8.06/27.09

FPM (lb/hrfTPY) EPA201A <1.664 <7.289 n.a. 10.72/36.01 CPM (lb/hrfTPY) EPAOTM-028 7.190 31.490 n.a. 11.85/49.77 PM>10 (/b/hr) EPA 201A <2.226 <9.749 n.s. PM total (/b/hr) EPAOTM·028 <11.079 <48.527 9.6/32.25 PM (fronthalf) EPA20tA <3.890 <17.037 n.a. 12.76/42.87 PM (backhalf) EPAOTM-028 7.190 31.490 n.a. 11.85/49.77 HCI (lb/hrffPY) EPA26A <0.027 <0.120 0.52/2.25 CI2 (lblhrffPY) EPA26A 0.295 1.292 n.s. NH3 (lb/hrffPY) EPA26A1CTM·027 <0.006 <0.028 n.s. PCCDsIPCCDFs (ng/dscm @7%02) EPA 23 0.000003 0.20 NOx (Ib/hr/ TPY) EPA 7E 304.40 1333.25 326.67 I 1431.0 CO (Ib/hrffPY) EPA 10 102.28 448.00 772.0/879.0 802 (Ib/hr/TPY) EPA6C 0.32 1.39 106.0I58.0 VOC (Ib/hrITPY) EPA25A 3.31 14.50 13.07 I43.90 Line 2 ClinkerCooler PM,o (lblhrffPY) EPA 201A10TM·028 <2.356 <10.317 6.02/20.23 7.87/26.45

FPM (lblhrfTPY) EPA 201A <1.241 <5.434 n.•. CPM (lb/hrfTPY) EPA OTM-02B <1.115 <4.883 n.s. PM>10 (Ib/hr) EPA201A <1.351 <5.918 n.a. PM total(Ib/hr) EPA 201A/OTM-02B <3.707 <16.235 7.92/29.61 10.36/34.81

, Permit limits obtained from CEMEX EPA Federal Operating Permit No. 01126 and Special Conditions ofTCea Permits Numbers6048 and PSo-TX-74M1 2Air PermitAmendment Supplementsubmitted on November5, 2008. awaiting final determination by Air Permit Division, TCEQ Austin.



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
PROJECT OVERVIEW Client Reference No: DC04062009 CleanAir Project No: 10773


# 1-5 Table 1-3: Summary ofTest Results
Source Sampling Constituent Method Emission Average Line 2 Main Kiln Stack Run 1 Run 2 Run 3 

### RawMill On Hg (Ib/hr) EPA M29 <4.506E-04 <4.490E-04 <4.510E-04 <4.502E-04 Sb (Ib/hr) EPAM29 O:OOOE+OO O.OOOE+OO <5.011E-05 <i.670E-05 As (Ib/hr) EPAM29 <5.006E-05 <4.988E-05 <5.011E-05 <5.002E-05 Ba (Ib/hr) EPA M29 1.295E-02 1.343E-02 1.319E-02 i.319E-02 Be (Ib/hr) EPA M29 <1.252E-05 <1.247E-05 <1.253E-05 <i.25iE-05 Cd (Ib/hr) EPAM29 5.257E-06 1.821E-05 O.OOOE+OO 7.822E-06 Cr (Ib/hr) EPAM29 O.OOOE+OO 4.240E-05 O.OOOE+OO i.4i3E-05 Co (Ib/hr) EPA M29 <5.006E-05 <4.988E-05 <5.011E-05 <5.002E-05 Cu (Ib/hr) EPA M29 1.287E-04 1.207E-04 5.613E-05 i.018E-04 Pb (Ib/hr) EPA M29 O.OOOE+OO O.OOOE+OO O.OOOE+OO O.OOOE+OO Mn (Ib/hr) EPAM29 9.437E-04 8.281E-04 4.635E-04 7.451E-04 Mo (Ib/hr) EPA M29 O.OOOE+OO 3.741E-05 O.OOOE+OO 1.247E-05 

### Ni (Ib/hr) EPA M29 1.928E-04 1.796E-04 8.519E-05 i.525E-04 Pb (Ib/hr) EPA M29 2.967E-02 3.081E-02 2.745E-02 2.93iE-02 Se (Ib/hr) EPA M29 <5.006E-05 <4.988E-05 <5.011 E-05 <5.002E-05 

# ) Ag (Ib/hr) EPAM29 <5.006E-05 <4.988E-05 <5.011 E-05 <5.002E-05 

### TI (Ib/hr) EPAM29 <5.006E-05 <4.988E-05 <5.011E-05 <5.002E-05 Zn (Ib/hr) EPAM29 6.458E-03 2.519E-03 2.881E-04 3.089E-03 Line 2 Main Kiln Stack Run4 Run 5 Run 6 

### RawMill Off Hg (Ib/hr) EPAM29 1.641E-04 1.957E-04 6.663E-04 3.420E-04 Sb (Ib/hr) EPAM29 <5.160E-05 <5.163E-05 O.OOOE+OO <3.44iE-05 As (Ib/hr) EPAM29 <5.160E-05 <5.163E-05 <5.165E-05 <5.i63E-05 Ba (Ib/hr) EPA M29 1.260E-02 1.256E-02 1.341E-02 i.286E-02 Be (Ib/hr) EPA.M29 <1.290E-05 <1.291 E-05 <1.291E-05 <i.29iE-05 Cd (Ib/hr) EPA M29 O.OOOE+OO O.OOOE+OO 5.165E-07 i.722E-07 Cr (Ib/hr) EPAM29 O.OOOE+OO O.OOOE+OO O.OOOE+OO O.OOOE+OO Co (Ib/hr) EPA M29 <5.160E-05 <5.163E-05 <5.165E-05 <5.163E-05 Cu (Ib/hr) EPA M29 1.429E-04 1.136E-05 O.OOOE+OO 5.i43E-05 Pb (Ib/hr) EPAM29 O.OOOE+OO O.OOOE+OO O.OOOE+OO O.OOOE+OO Mn (Ib/hr) EPAM29 7.921 E-04 4.518E-04 1.291 E-05 4.i89E-04 Mo (Ib/hr) EPA M29 O.OOOE+OO O.OOOE+OO O.OOOE+OO O.OOOE+OO 

### Ni (Ib/hr) EPA M29 1.522E-04 5.938E-05 O.OOOE+OO 7.053E-05 Pb (Ib/hr) EPA M29 2.981E-02 2.854E-02 2.958E-02 2.931E-02 Se (Ib/hr) EPA M29 <5.160E-05 <5.163E-05 <5.165E-05 <5.i63E-05 Ag (Ib/hr) EPA M29 <5.160E-05 <5.163E-05 <5.165E-05 <5.i63E-05 

### TI (Ib/hr) EPA M29 <5.160E-05 <5.163E-05 <5.165E-05 <5.i63E-05 Zn (Ib/hr) EPA M29 2.400E-03 1.652E-03 O.OOOE+OO i.35iE-03



## Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
PROJECT OVERVIEW Client Reference No: DC04062009 CleanAir Project No: 10773
1-6



# ) Discussion 

# of TestProgram 

# ClinkerCooler Stack Thetestprogram began on April 22, 2009 atthe ClinkerCooler Stack. Oneparticulate run was completed and anotherwas started. Duringthis time the facility was having issues keeping the coolerbaghouse running properly, which necessitatedprocess and control changes during the firstrun. In additionto this there were concerns that since the facility recently came outofan outage anumber ofissues existed which could adversely impactthe test. These includedthe facts thatinventory was extremely low from the outage and contributingto possible excessively dusty conditions, chemistry was not optimal, and the lackofan established filter cake onthe bags. Based on these facts and an observeduncharacteristically dirty filter from the firstrun, itwas determinedthatthe unitwas notrunning in normal operating conditions and a representative stacktestcouldnotbe conducted atthis time. As such, itwas decidedto abortthe secondrun and resumetesting atthis location atthe end ofthe testprogram starting overwith three new testruns. Run 1 was collected and archived, butnot analyzed. Testingresumed on the afternoon ofApril 26, 2009. In the morning testing had been done atthe main Kiln Stackduring which time there were anumber ofissues withthe fuel transport system. These issues carried overinto the afternoon testing atthe cooler stack. During Run 3 (the first ofthe day) flows were observedto drop offsignificantly partway through the test. This was related to the fuel transport system causing a "push" and shutting down the unit. The delay extended long enough that itwas not reasonable to delay the test and the run was aborted. When testing resumedthe unit was still stabilizing, butno further upsets were observed. Three runs (Runs 4-6) were completed andrecovered. It

# was noted thatthe cyclone from Run 4 had a significant, visible, amount ofparticulate. Priortesting at this location, as well as all laterruns, showedno to very little visible particulate from this catch. It 

# is believedthatthis is due to the unitnothaving settled outpriorto the beginning ofthe run. This run is reported (See tables 2-17 through 2-19) butnot included inthe average since itis notbelievedto be representative ofnormal operation. It 

# should bepointed outthat only the PM 

# > 10**~m** 

# portion ofthis run (the cyclone rinse) was unusually high. The filterable PMIO and the condensableportions are in line with the other2runs. Main Kiln Stack Testingbegan atthe Kiln Stackon April 23, 2009 withtheRawMill On. Three Dioxin runs along with simultaneous CEMs runs forNOx, CO, S02, and THC were conducted. Flows and moisture from the Dioxinruns were used to calculatemass emissionrates for each ofthe gaseous pollutants. Afterthe first CEMs run, the NOx

Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT


## PROJECT OVERVIEW Client Reference No: DC04062009 CleanAir Project No: 10773
1-7 

# monitorpassedthe bias check, but failed the drift check. The monitorwas recalibrated and afourth run was required and completed. The following day testing was delayed while ports were installed that were large enough in diameterto accommodatethe PMIO probes. Duringthis time datafrom the previous day's testing was further analyzed and itwas discoveredthattheNOx emissions were overthepermitted limit. After athorough investigation, itwas discoveredthatthe control systemthatregulates ammoniainjection determines the amount ofammoniato injectbasedupon a calculated emissionrate which is determined from a flow calculatedusing a fixed moisture constant. Comparison ofthis constantmoisture percentage to that determinedby Clean Air's reference methodtests revealed a difference ofa couplepercentagepoints. While facility CEMs were reasonably close to the reference method CEMs (within 5%), this small discrepancy in moisture was enough to affectthe calculated flows enough thatthe facility was actually slightly overthe permitted limiteven though the systemwas reporting under. Priorto the beginning oftesting the following day, the facility adjustedtheirmoisture constantto be in line with what Clean Airwas measuring. Also the control system's ammonia setpointwas adjustedbased on reference method lb/hrmeasurements. ) Reported CEMs emissions are those from testing conducted afterthe changes to the ammoniainjection control systemwere made. Forcompleteness, the original CEMs runs are located in the appendix ofthis report. Testing conducted onApril 25, 2009 was comprised ofsimultaneous runs of particulate, metals, HCI, C12, ammonia, as well as all thepreviously mentioned CEMs. The THC monitordid notpass the Run 1 bias, so an additional THC run was planned. Two sets ofruns were completed and athird was started. Two minutes into Run 3, the wetmethod tests had to be halted due to a failure oftheparticulateprobe. While repairs began, CEMs Run 3 continued. Ultimately, itwas determinedthatthe final wet methods runs wereto be delayed until the following day, butthe CEMs run finished. An additional velocity traverse was conducted onthe stackin orderto provide flow datafor mass emission calculations for this run. On April 26, 2009 the final wetmethodruns were finished along with the THe run requiredbythe THC bias failure the previous day. During the particulate run, itwas suspectedthatfilterplugging was causing high vacuum and the PMIO head was switched out. Both filters were recovered, analyzed, and summed for emission calculations. The front halfrinse from bothheads were combined as were the cyclone rinses. 

# ) Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
PROJECT OVERVIEW 

## Client Reference No: DC04062009 CleanAir Project No: 10773
1-8



# ) When testing resumed on April 27, 2009, the raw mill was turned offandthe Kiln Stacktestprogram was repeated. CEMs, particulate, HCl, C12, ammonia, and metals were once again measured. Three runs ofeach (Runs 4-7) were conducted. Duringthis time there weretwo notable incidents. The first was anoticeable reddish brown color observedinthe first three impingers ofthe metals trains from Runs 4 and 5. The facility had observedthis phenomenonbefore in waterexiting the bottom ofthe stack afterheavyrains. 

# Itis believedto be rust. The second was aback flushing ofthe particulatetrain during apostrun leakcheckfor Run 4, which necessitated anotherrun beperformed. This run was conductedthe following day, along withthree dioxin runs.

End

### ofSection 

## 1 - Project Overview



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-1 Table 2-1: Line 2 Main Kiln Stack
- Filterable PM1o, 

## Raw Mill On Run No. 2 4 Average Date (2009) Apr 25 Apr25 Apr 26 StartTime (approx.) 09:26 13:08 08:31 Stop lime (approx.) 11:49 15:44 11 :12 Process Conditions

R

p Production rate (Ton Clinker/hour) 155 155 155 155 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 8.0 7.6 7.2 7.6 CO2 Carbon dioxide (dry volume %) 22.0 21.4 19.6 21.0 Ts Sample temperature ('F) 209 227 217 218 

### B

w Actual watervapor in gas (% by volume) 11.30 13.05 11.93 12.09 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 252,756 268,305 275,611 265,557 

### Q

s Volumetric flow rate, standard (scfm) 194,436 200,808 209,197 201,481 

### Q

std Volumetric flow rate, dry standard (dscfm) 172,457 174,609 184,244 177,103 Sampling Data

Vms1d Volume metered, standard (dscf) 44.8260 46.0110 44.6154 45.1508 %1 Isokinetic sampling (%) 100.7553 100.5030 91.1141 97.4574 Filterable Particulate Matter< 10 11m (FPM,o) Laboratory Data

mpPM10 Filterable particulate matter< 10 11m (FPM,o) collected (g <0.00333 <0.00333 <0.00333 Filterable Particulate Matter< 10 11m (FPM,o) Results

Csd Particulate Concentration (Ib/dscf) <1.638E-07 <1.596E-07 <1.646E-07 <1.627E-07 Elblhr Particulate Rate (Ib/hr) <1.6949 <1.6719 <1.8193 <1.7287 E

Tlyr Particulate Rate (Ton/yr) <7.4238 <7.3229 <7.9687 <7.5718 ERp Particulate Rate - Production-based (lblTon Clinker) <0.0109 <0.0108 <0.0117 <0.0111



### Revision 0, Final

# -.,j 

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


## 2-2 Table 2-2: Line 2 Main Kiln Stack
- Condensable PM, Raw Mill On
Run No. 2 4 Average Date (2009) Apr25 Apr25 Apr26 Start TIme (approx.) 09:26 13:08 08:31 Stop Time (approx.) 11:49 15:44 11:12 Process Conditions

Rp Production rate (Ton Clinker/hour) 155 155 155 155 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dryvolume %) 8.0 7.6 7.2 7.6 CO2 Carbon dioxide (dry volume %) 22.0 21.4 19.6 21.0 Ts Sample temperature (OF) 209 227 217 218 

### B

w Actual watervapor in gas (% byvolume) 11.30 13.05 11.93 12.09 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 252,756 268,305 275,611 265,557 

### Q

s Volumetric flow rate, standard (scfm) 194,436 200,808 209,197 201,481 

### Q

Sld Volumetric flow rate, dry standard (dscfm) 172,457 174,609 184,244 177,103 Sampling Data

Vmstd Volumemetered, standard (dscf) 44.8260 46.0110 44.6154 45.1508 %1 Isokinetic sampling (%) 100.7553 100.5030 91.1141 97.4574 Laboratory Data

miT Total Inorganic CPM Result (g) 0.01178 0.00312 0.00936 moo Total Organic CPM Result (g) 0.00355 0.00131 0.00000 mT Total Gravimetric Result (g) 0.01533 0.00443 0.00936 mCPM Total CPM (g) 0.01533 0.00443 0.00936 Condensable Particulate Results

Csd Particulate Concentration (Ib/dscf) 7.541E-07 2.125E-07 4.627E-07 4.764E-07 E1t.lhr Particulate Rate (Ib/hr) 7.8027 2.2266 5.1152 5.0482 

### E

T1yr Particulate Rate (Ton/yr) 34.1759 9.7527 22.4044 22.1110 ERp Particulate Rate - Production-based (lblTon Clinker) 0.0502 0.0143 0.0329 0.0325



## Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773
2-3 Table 2-3: Line 2 Main Kiln Stack
- Filterable PM 

## > 101Jm, Raw Mill On
Run No. 2 4 Average Date (2009) Apr25 Apr 25 Apr 26 Start Time (approx.) 09:26 13:08 08:31 Stop Time (approx.) 11:49 15:44 11:12 Process Conditions

Rp Production rate (Ton Clinker/hour) 155 155 155 155 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 8.0 7.6 7.2 7.6 CO2 Carbon dioxide (dry volume %) 22.0 21.4 19.6 21.0 Ts Sample temperature ('F) 209 227 217 218 

### B

w Actual watervapor in gas (% by volume) 11.30 13.05 11.93 12.09 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 252,756 268,305 275,611 265,557 

### Q

s Volumetric flow rate, standard (scfm) 194,436 200,808 209,197 201,481 

### Q

S1d Volumetric flow rate, dry standard (dscfm) 172,457 174,609 184,244 177,103 Sampling Data



### Vmstd Volume metered, standard (dscf) 44.8260 46.0110 44.6154 45.1508 %1 Isokinetic sampling (%) 100.7553 100.5030 91.1141 97.4574

"

# ) Filterable Particulate Matter> 10 11m (FPM,) Laboratory Data mFPM> Filterable particulate matter> 10 11m (FPM,) collected (g) 0.00355 0.00446 0.00413 Filterable Particulate Matter> 10 11m (FPM,) Results

Csd Particulate Concentration (Ib/dscf) 1.746E-07 2.137E-07 2.041 E-07 1.975E-07 E1blhr Particulate Rate (Ib/hr) 1.8069 2.2392 2.2564 2.1009 ET/yr Particulate Rate (Ton/yr) 7.9143 9.8079 9.8831 9.2017 ERP Particulate Rate - Production-based (lblTon Clinker) 0.0116 0.0144 0.0145 0.0135



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-4 Table 2-4: Line 2 Main Kiln Stack-Total Hel, Raw Mill On
Run No. 2 4 Average Date (2009) Apr 25 Ap(25 Apr 26 StartTime (approx.) 09:26 13:08 08:31 Stop Time (approx.) 11:48 15:42 11 :13 Process Conditions

Rp Production rate - (Ton Clinker/hour) 155 155 155 155 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen**(d~** volume %) 7.4 9.2 7.4 8.0 CO2 Carbon dioxide**(d~** volume %) 21.6 18.0 20.6 20.1 Ts Sample temperature 

### (OF) 210 229 218 219 Bw Actual watervapor in gas (% by volume) 14.94 11.95 14.13 13.67 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 259,571 268,373 237,535 255,160 

### Q

s Volumetric flow rate, standard (scfm) 199,234 200,373 179,872 193,160 

### Q

std Volumetric flow rate,**d~** standard (dscfm) 169,477 176,422 154,452 166,784 Sampling Data

Vms1d Volume metered, standard (dscf) 82.5757 85.4126 76.4884 81.4923 %1 Isokinetic sampling (%) 101.5680 100.9216 98.4127 100.3008**Laborato~** Data mn Total HCI collected (mg) <0.03926 <0.02997 0.23742 Hydrogen Chloride (HCI) Results

Csd HCI Concentration (Ib/dscf) <1.048E-09 <7.736E-10 6.844E-09 <2.889E-09 E1blhr HCI Rate (Ib/hr) <0.0107 <0.0082 0.0634 <0.0274 ETlyr HCI Rate (Ton/yr) <0.0467 <0.0359 0.2778 <0.1201 ERp HCI Rate - Production-based (lblTon Clinker) <0.0001 <0.0001 0.0004 <0.0002



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS 

## Client Reference No: DC04062009 CleanAir Project No: 10773
2-5



# ) Table 2-5: Line 2 Main Kiln Stack
- Total C1 2, 

## Raw Mill On
Run No. 

### 2 4 Average Date 

### (2009) Apr

### 25 Apr

### 25 Apr 

### 26 StartTime (approx.) 

### 09:26 13:08 08:31 Stop Time (approx.) 

### 11:48 15:42 11 :13 Process Conditions

Rp Production rate - (Ton Clinker/hour) 

### 155 155 155 155 Cap Capacity factor (hours/year) 

### 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 

### 7.4 9.2 7.4 8.0 CO2 Carbon dioxide (dry volume %) 

### 21.6 18.0 20.6 20.1 Ts Sample temperature CF) 

### 210 229 218 219 

## B

w Actual watervaporin gas (% by volume) 

### 14.94 11.95 14.13 13.67 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 

### 259,571 268,373 237,535 255,160 

### Q

s Volumetric flow rate, standard (scfm) 

### 199,234 200,373 179,872 193,160 

### Q

std Volumetric flow rate, dry standard (dscfm) 

### 169,477 176,422 154,452 166,784 Sampling Data

Vrrstd Volume metered, standard (dscf) 

### 82.5757 85.4126 76.4884 81.4923 %1 lsokinetic sampling (%) 

### 101.5680 100.9216 98.4127 100.3008 Laboratory Data

mn Total Cl2 collected (mg) 

### 0.89698 1.34673 1.02292 Chlorine (C1 2) Results

Csd Chlorine Concentration (Ib/dscf) 

### 2.395E-08 3.477E-08 2.949E-08 2.940E-08 E

1blhr Chlorine Rate (Ib/hr) 

### 0.2436 0.3680 0.2733 0.2950 E

Tlyr Chlorine Rate (Ton/yr) 

### 1.0668 1.6119 1.1970 1.2919 ERp Chlorine Rate - Production-based (lblTon Clinker) 

### 0.0016 0.0024 0.0018 0.0019



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT


## RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773
2-6 Table 2-6: Line 2 Main Kiln Stack
- Total NH3 • 

## Raw Mill On
Run No. 

### 2 4 Average Date 

### (2009) Apr 

### 25 Apr 

### 25 Apr

### 26 Start Time (approx.) 

### 09:26 13:08 08:31 Stop Time (approx.) 

### 11:48 15:42 11 :13 Process Conditions



### Rp Production rate - (Ton Clinker/hour) 

### 155 155 155 155 Cap Capacity factor (hours/year) 

### 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 

### 7.4 9.2 7.4 8.0 CO2 Carbon dioxide (dry volume %) 

### 21.6 18.0 20.6 20.1 Ts Sample temperature (OF) 

### 210 229 218 219 

### B

w Actual watervapor in gas (% by volume) 

### 14.94 11.95 14.13 13.67 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 

### 259,571 268,373 237,535 255,160 

### Q

s Volumetric flow rate, standard (scfm) 

### 199,234 200,373 179,872 193,160 

### Q

std Volumetric flow rate, dry standard (dscfm) 

### 169,477 176,422 154,452 166,784 Sampling Data

Vms1d Volume metered, standard (dscf) 

### 82.5757 85.4126 76.4884 81.4923 ) %1 Isokinetic sampling (%) 

### 101.5680 100.9216 98.4127 100.3008 I Laboratory Data mn Total NH3 collected (mg) 

### <0.02575 <0.01966 <0.02461 Ammonia (NH3) Results

Csd Ammonia Concentration (Ib/dscf) 

### <6.877E-10 <5.074E-10 <7.096E-10 <6.349E-10 E1blhr Ammonia Rate (Ib/hr) 

### <0.0070 <0.0054 <0.0066 <0.0063 E

Tlyr Ammonia Rate (Ton/yr) 

### <0.0306 <0.0235 <0.0288 <0.0277 ERp Ammonia Rate - Production-based (lblTon Clinker) 

### <0.0000 <0.0000 <0.0000 <0.0000



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT


# RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-7 Table 2-7: Line 2 Main Kiln Stack
- PCCDs/PCCDFs, Raw Mill On
Run No. 2 3 Average Date (2009) Apr23 Apr23 Apr 23 Start Time (approx.) 12:13 16:22 19:37 Stop Time (approx.) 15:38 19:37 22:57 Process Conditions

Rp Production rate - (Ton Clinker/hour) 155 155 155 155 Cap Capacityfactor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 7.7000 8.2000 7.5000 7.8000 CO2 Carbon dioxide (dry volume %) 21.7000 21.0000 21.7000 21.4667 Ts Sample temperature (OF) 218.0 218.4 213.0 216.5 B w Actual watervapor in gas (% by volume) 12.4954 13.2128 13.3277 13.0119 Gas Flow Rate

Os Volumetric flow rate, actual (acfm) 240,596 255,284 248,437 248,106 Os Volumetric flow rate, standard (scfm) 182,666 193,707 190,028 188,801 OSld Volumetricflow rate, dry standard (dscfm) 159,842 168,113 164,702 164,219 Sampling Data

V_ Volume metered, standard (dscl) 117.6858 131.7431 122.6914 124.0401 %1 Isokinetic sampling (%) 102.3192 99.8513 103.5234 101.8980 Laboratory Data from USEPA Method 23 Total PCDDs (ng) 0.0183 0.0365 0.0000 Total PCDFs (ng) 0.0000 0.0046 0.0000 mn Total PCDDs & PCDFs (ng) 0.0183 0.0411 0.0000 Total TEO PCDDs (ng) 0.0000 0.0000 0.0000 Total TEO PCDFs (ng) 0.0000 0.0000 0.0000 m"-TEQ Total TEO PCDDs & PCDFs (ng) 0.0000 0.0000 0.0000 Total PCDD/F TEO Results (using USEPAJINTL 1989 TEFs)

CSdTEQ TEO Concentration (ng/dscm) 5.491E-06 7.960E-06 O.OOOE+OO 4.484E-06 CSd7TEQ TEO Concentration @7% O2 (ng/dscm) 5.782E-06 8.712E-06 O.OOOE+OO 4.831E-06 ElblhrTEQ TEO Rate (Ib/hr) 3.288E-12 5.014E-12 O.OOOE+OO 2.767E-12 ERPTEO TEO Rate - Production-based (Ibffon Clinker) 2.116E-14 3.227E-14 O.OOOE+OO 1.781E-14



### Revision 0, Final

# .-,) 

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773
2-8

) 

### ./ 

## Table 2-8: Line 2 Main Kiln Stack
- NOx, CO, S02, THC, Raw Mill On
Run No. 2 3 4 Average Date (2009) Apr25 Apr 25 Apr25 Apr26 StartTime 9:27 13:09 18:46 8:31 End Time 10:27 14:21 19:46 9:31 Elapsed Time 1:00 1:12 1:00 1:00 Operating Conditions Production Rate - Line 2 Kiln Stack (Ton Clinker/hr) 155.396 155.397 155.409 155.399 155.400 Gas Parameters Actual Gas Flow Rate - Line 2 Kiln Stack (acfm) 256,405 258,506 257,078 268,332 260,080 Standard Gas Flow Rate - Line 2 Kiln Stack (scfm) 197,295 193,333 194,994 203,656 197,319 Dry Standard Gas Flow Rate - Line 2 Kiln Stack (dscfm) 166,762 164,765 165,737 173,558 167,706 H20 - Line 2 Kiln Stack (%) 15.476 14.777 15.010 14.779 15.010 Nitrogen Oxides (NOX)
- Line 2 Kiln Stack Concentration (ppmdv) 265.16 .259.24 276.80 267.D7 Mass Rate (Ib/hr) 316.78 306.01 328.66 317.15 Mass Rate (lblTon Clinker) 2.04 1.97 2.11 2.04 Carbon Monoxide (CO)
- Line 2 Kiln Stack Concentration (ppmdv) 124.87 119.96 119.38 121.40 Mass Rate (Ib/hr) 90.83 86.22 86.30 87.78 Mass Rate (lblTon Clinker) 0.58 0.55 0.56 0.56 Sulfur Dioxide (502)
- Line 2 Kiln Stack Concentration (ppmdv) 0.02 0.13 0.15 0.10 Mass Rate (Ib/hr) 0.03 0.22 0.25 0.17 Mass Rate (lblTon Clinker) 2.08E-04 1.40E-03 1.60E-03 1.07E-03 Total Hydrocarbons (THC)
- Line 2 Kiln Stack Concentration (ppmwv) 2.00 2.13 2.66 2.27 Mass Rate (Ib/hr) 2.66 2.86 3.72 3.08 Mass Rate (lblTon Clinker) 0.02 0.02 0.02 0.02



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS 

## Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-9



# ) Table 2-9: Line 2 Main Kiln Stack
- Filterable PM10, 

## Raw Mill Off
Run No. 6 7 8 Average Date (2009) Apr27 Apr27 Apr 28 StartTime (approx.) 18:10 21:30 14:31 Stop Time (approx.) 20:29 23:48 16:59 Process Conditions

Rp Production rate (Ton Clinker/hour) 158 156 158 158 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dryvolume %) 6.0 6.0 6.3 6.1 CO2 Carbon dioxide (dry volume %) 24.6 24.0 24.0 24.2 Ts Sample temperature (OF) 307 323 370 333 

### B

w . Actual watervapor in gas (% by volume) 12.55 12.63 10.37 11.85 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 282,046 285,510 300,070 289,209 

### Qs Volumetricflow rate, standard (scfm) 189,206 187,670 186,105 187,660 

### Q

Sld Volumetric flow rate, dry standard (dscfm) 165,459 163,965 166,804 165,410 Sampling Data

Vmstd Volume metered, standard (dscf) 44.9884 44.8238 44.6969 44.8364 %1 Isokinetic sampling (%) 105.1393 107.9058 102.5307 105.1919 Filterable Particulate Matter< 10 IJm (FPM,o) Laboratory Data

mFPM'O Filterable particulate matter < 10 IJm (FPM,o) collected (9 <0.00333 0.00357 <0.00333 Filterable Particulate Matter< 10 IJm (FPM,o) Results

Csd Particulate Concentration (Ib/dscf) <1.632E-07 1.756E-07 <1.643E-07 <1.677E-07 E1blhr Particulate Rate (Ib/hr) <1.6203 1.7277 <1.6441 <1.6640 ETlyr Particulate Rate (Ton/yr) <7.0969 7.5674 <7.2012 <7.2885 ERp Particulate Rate - Production-based (lblTon Clinker) <0.0102 0.0111 <0.0104 <0.0106



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-10 Table 2-10: Line 2 Main Kiln Stack
- Condensable PM, Raw Mill Off Run No. 6 7 8 Average Date (2009) Apr27 Apr27 Apr28 StartTime (approx.) 18:10 21:30 14:31 Stop Time (approx.) 20:29 23:48 16:59 Process Conditions

Rp Production rate (Ton Clinker/hour) 158 156 158 158 Cap Capacityfactor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 6.0 6.0 6.3 6.1 CO2 Carbon dioxide (dry volume %) 24.6 24.0 24.0 24.2 Ts Sample temperature (OF) 307 323 370 333 

### B

w Actual watervapor in gas (% by volume) 12.55 12.63 10.37 11.85 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 282,046 285,510 300,070 289,209 

### Q

s Volumetric flow rate, standard (scfm) 189,206 187,670 186,105 187,660 

### Q

Std Volumetric flow rate, dry standard (dscfm) 165,459 163,965 166,804 165,410 Sampling Data

Vmstd Volume metered, standard (dscf) 44.9884 44.8238 44.6969 44.8364 %1 Isokinetic sampling (%) 105.1393 107.9058 102.5307 105.1919 

# ) Laboratory Data miT Total Inorganic CPM Result (g) 0.01221 0.00577 0.02028 mno Total Organic CPM Result (g) 0.00000 0.00582 0.00000 mT Total Gravimetric Result (g) 0.01221 0.01160 0.02028 mCPM Total CPM (g) 0.01221 0.01160 0.02028 Condensable Particulate Results

CSd Particulate Concentration (Ib/dscf) 5.986E-07 5.705E-07 1.001 E-06 7.232E-Q7 E1blhr Particulate Rate (Ib/hr) 5.9423 5.6124 10.0140 7.1896 E

Tlyr Particulate Rate (Ton/yr) 26.0272 24.5821 43.8614 31.4902 ERp Particulate Rate - Production-based (IblTon Clinker) 0.0375 0.0359 0.0632 0.0456



### Revision 0, Final

# .,) 

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-11

) Table 2-11: Line 2 Main Kiln Stack
- Filterable PM 

## > 10J,Jm, Raw Mill Off
Run No. 6 7 8 Average Date (2009) Apr 27 Apr27 Apr 28 StartTime (approx.) 18:10 21:30 14:31 Stop Time (approx.) 20:29 23:48 16:59 Process Conditions

Rp Production rate (Ton Clinker/hour) 158 156 158 158 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dryvolume %) 6.0 6.0 6.3 6.1 CO2 Carbon dioxide (dryvolume %) 24.6 24.0 24.0 24.2 Ts Sample temperature (OF) 307 323 370 333 

### B

w Actual watervapor in gas (% by volume) 12.55 12.63 10.37 11.85 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 282,046 285,510 300,070 289,209 

### Q

s Volumetric flow rate, standard (scfm) 189,206 187,670 186,105 187,660 

### Q

SId Volumetric flow rate, dry standard (dscfm) 165,459 163,965 166,804 165,410 Sampling Data

Vms1d Volume metered, standard (dscf) 44.9884 44.8238 44.6969 44.8364 

### %1 Isokinetic sampling (%) 105.1393 107.9058 102.5307 105.1919 Filterable Particulate Matter> 10 fJm (FPM» Laboratory Data

mFPM> Filterable particulate matter> 10 fJm (FPM» collected (g) 0.00622 <0.00333 0.00413 Filterable Particulate Matter> 10 fJm (FPM» Results

Coo Particulate Concentration (Ib/dscf) 3.049E-07 <1.638E-07 2.037E-07 <2.241E-07 E1blhr Particulate Rate (Ib/hr) 3.0265 <1.6116 2.0391 <2.2257 ET1yr Particulate Rate (Ton/yr) 13.2561 <7.0586 8.9313 <9.7487 ERp Particulate Rate - Production-based (lblTon Clinker) 0.0191 <0.0103 0.0129 <0.0141



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-12 Table 2-12: Line 2 Main Kiln Stack
- Total 

## Hel, Raw Mill Off
Run No. 5 6 7 Average Date (2009) Apr27 Apr 27 Apr 27 StartTime (approx.) 10:43 18:10 21:30 Stop Time (approx.) 14:29 20:29 23:48 Process Conditions

Rp Production rate - (Ton Clinker/hour) 156 158 156 157 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 5.8 6.0 6.0 5.9 CO2 Carbon dioxide (dry volume %) 25.2 24.4 23.4 24.3 Ts Sample temperature 

### (OF) 304 309 326 313 

## B

w Actual watervapor in gas (% by volume) 15.16 12.98 13.10 13.75 Gas Flow Rate



### Q. Volumetricflow rate, actual (acfm) 227,266 286,246 274,323 262,612 

### Q

s Volumetricflow rate, standard (scfm) 153,028 191,519 179,696 174,748 

### Q

std Volumetricflow rate, dry standard (dscfm) 129,835 166,651 156,157 150,881 Sampling Data

" \ Vmstd Volume metered, standard (dscf) 66.9929 82.8480 77.5162 75.7857



### ) %1 Isokinetic sampling (%) 102.5389 98.7923 98.6465 99.9926 Laboratory Data

mn Total HCI collected (mg) <0.03403 <0.03718 <0.03217 Hydrogen Chloride (HCI) Results

Csd HCI Concentration (Ib/dscf) <1.120E-09 <9.895E-10 <9.150E-10 <1.008E-09 E1blhr HCI Rate (Ib/hr) <0.0087 <0.0099 <0.0086 <0.0091 ET/yr HCI Rate (Ton/yr) <0.0382 <0.0433 <0.0376 <0.0397 ERp HCI Rate - Production-based (lblTon Clinker) <0.0001 <0.0001 <0.0001 <0.0001



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS 

## Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-13



# J Table 2-13: Line 2 Main Kiln Stack
- Total C1 2, 

## Raw Mill Off
Run No. 

### 5 6 7 Average Date 

### (2009) Apr

### 27 Apr 

### 27 Apr

### 27 StartTime (approx.) 

### 10:43 18:10 21:30 Stop Time (approx.) 

### 14:29 20:29 23:48 Process Conditions

Rp Production rate - (Ton Clinker/hour) 

### 156 158 156 157 Cap Capacityfactor (hours/year) 

### 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 

### 5.8 6.0 6.0 5.9 CO2 Carbon dioxide (dry volume %) 

### 25.2 24.4 23.4 24.3 Ts Sample temperature 

### (OF) 

### 304 309 326 313 

### Bw Actual watervapor in gas (% by volume) 

### 15.16 12.98 13.10 13.75 Gas Flow Rate

Q. Volumetricflow rate, actual (acfm) 

### 227,266 286,246 274,323 262,612 Q. Volumetricflow rate, standard (scfm) 

### 153,028 191,519 179,696 174,748 Q.td Volumetricflow rate, dry standard (dscfm) 

### 129,835 166,651 156,157 150,881 Sampling Data

Vmstd Volume metered, standard (dscf) 

### 66.9929 82.8480 77.5162 75.7857 %1 lsokinetic sampling (%) 

### 102.5389 98.7923 98.6465 99.9926 Laboratory Data

mn Total CI2 collected (mg) 

### 1.30343 1.08956 0.89411 Chlorine (CI2) Results

Csd Chlorine Concentration (Ib/dscf) 

### 4.290E-08 2.900E-08 2.543E-08 3.244E-08 Elb/hr Chlorine Rate (Ib/hr) 

### 0.3342 0.2900 0.2383 0.2875 E

Tlyr Chlorine Rate (Ton/yr) 

### 1.4638 1.2700 1.0437 1.2592 ERp Chlorine Rate - Production-based (lblTon Clinker) 

### 0.0021 0.0018 0.0015 0.0018



### Revision 0, Final

# '") 

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS 

## Client Reference No: DC04062009 CleanAir Project No: 10773
2-14 Table 2-14: Line 2 Main Kiln Stack
- Total NHa, 

## Raw Mill Off
Run No. 

### 5 6 7 Average Date 

### (2009) Apr

### 27 Apr

### 27 Apr 

### 27 Start Time (approx.) 

### 10:43 18:10 21:30 Stop Time (approx.) 

### 14:29 20:29 23:48 Process Conditions

Rp Production rate - (Ton Clinker/hour) 

### 156 158 156 157 Cap Capacity factor (hours/year) 

### 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 

### 5.8 6.0 6.0 5.9 CO2 Carbon dioxide (dry volume %) 

### 25.2 24.4 23.4 24.3 Ts Sample temperature (OF) 

### 304 309 326 313 

### B

w Actual watervapor in gas (% by volume) 

### 15.16 12.98 13.10 13.75 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 

### 227,266 286,246 274,323 262,612 

### Q

s Volumetric flow rate, standard (scfm) 

### 153,028 191,519 179,696 174,748 

### Q

s1d Volumetric flow rate, dry standard (dscfm) 

### 129,835 166,651 156,157 150,881 Sampling Data

Vmstd Volume metered, standard (dscf) 

### 66.9929 82.8480 77.5162 75.7857 

# ) %1 Isokinetic sampling (%) 

### 102.5389 98.7923 98.6465 99.9926 Laboratory Data

mn Total NH3 collected (mg) 

### 24.42921 31.91887 27.93553 Ammonia (NH3) Results

Csd Ammonia Concentration (Ib/dscf) 

### 8.041E-07 8.495E-07 7.946E-07 8.161E-07 E1blhr Ammonia Rate (Ib/hr) 

### 6.2637 8.4944 7.4453 7.4012 E

T/yr Ammonia Rate (Ton/yr) 

### 27.4350 37.2056 32.6106 32.4171 ERp Ammonia Rate - Production-based (lblTon Clinker) 

### 0.0401 0.0536 0.0477 0.0471



# )
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### "-

### ) 

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT


# RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-15 Table 2-15: Line 2 Main Kiln Stack
- PCCDs/PCCDFs, Raw Mill Off
Run No. 4 5 6 Average Date (2009) Apr2B Apr2B Apr2B Start Time (approx.) 10:10 13:24 16:41 Stop Time (approx.) 13:24 16:41 19:55 Process Conditions

Rp Production rate - (Ton Clinker/hour) 155 155 155 155 Cap Capacityfactor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 5.9000 6.0000 4.8000 5.5667 CO2 Carbon dioxide (dry volume %) 25.1000 24.2000 25.2000 24.8333 Ts Sample temperature (OF) 364.2 369.9 364.2 366.1 

### B

w Actual watervapor in gas (% by volume) 11.7693 11.6776 11.3789 11.6086 Gas Flow Rate

Q, Volumetric flow rate, actual (acfm) 269,766 272,657 271,424 271,282 Qs Volumetricflow rate, standard (scfm) 168,010 169,493 169,037 168,847 QStd Volumetricflow rate, dry standard (dscfm) 148,237 149,700 149,802 149,246 Sampling Data

Vmstd Volume metered, standard (dscf) 113.3170 107.7772 114.0954 111.7299 %1 Isokinetic sampling (%) 97.4015 95.3814 97.0458 96.6096 Laboratory Data from USEPA Method 23 

# ) Total PCDDs (ng) 0.0236 0.0000 0.0190 Total PCDFs (ng) 0.0000 0.0000 0.0000 mn Total PCDDs & PCDFs (ng) 0.0236 0.0000 0.0190 Total TEQ PCDDs (ng) 0.0000 0.0000 0.0000 Total TEQ PCDFs (ng) 0.0000 0.0000 0.0000 mn_TEQ Total TEQ PCDDs & PCDFs (ng) 0.0000 0.0000 0.0000 Total PCDD/F TEQ Results (using USEPA/INTL 1989 TEFs)

CsdTEO TEQ Concentration (ng/dscm) 5.328E-06 O.OOOE+OO 5.880E-06 3.736E-06 Csd7TEO TEQ Concentration @7% O2 (ng/dscm) 4.938E-06 O.OOOE+OO 5.077E-06 3.338E·06 EII"hrTEO TEQ Rate (Ib/hr) 2.959E-12 O.OOOE+OO 3.300E-12 2.087E-12 ERpTEO TEQ Rate - Production-based (lblTon Clinker) 1.904E-14 O.OOOE+OO 2.124E-14 1.343E-14



# )
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# ", ) 

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT 

# RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-16 Table 2-16: Line 2 Main Kiln Slack
- NOx, CO, 502, THC, Raw Mill Off Run No. 5 6 7 Average Date (2009) Apr 27 Apr27 Apr 27 Start Time 10:43 18:10 21:31 End Time 12:31 19:10 22:31 Elapsed Time 1:47 1:00 1:00 Operating Conditions Production Rate - Line 2 Kiln Stack (Ton Clinker/hr) 156.295 158.425 156.144 156.954 Gas Parameters Actual Gas Flow Rate - Line 2 Kiln Stack (acfm) 262,579 256,976 267,597 262,384 Standard Gas Flow Rate - Line 2 Kiln Stack (scfm) 175,990 172,160 175,486 174,545 Dry Standard Gas Flow Rate - Line 2 Kiln Stack (dscfm) 153,578 148,697 151,327 151,201 H20 - Line 2 Kiln Stack (0/0) 12.735 12.735 12.735 12.735 Nitrogen Oxides (NOX)
- Line 2 Kiln Stack Concentration (ppmdv) 282.47 277.95 282.54 280.99 Mass Rate (Ib/hr) 310.79 296.09 306.31 304.40 Mass Rate (lblTon Clinker) 1.99 1.87 1.96 1.94 Carbon Monoxide (CO)
- Line 2 Kiln Stack Concentration (ppmdv) 151.84 158.69 154.84 155.12 Mass Rate (Ib/hr) 101.72 102.92 102.21 102.28 Mass Rate (lblTon Clinker) 0.65 0.65 0.65 0.65 

### -"

# ) Sulfur Dioxide (S02)
- Line 2 Kiln Stack Concentration (ppmdv) 0.18 0.24 0.21 0.21 Mass Rate (Ib/hr) 0.28 0.35 0.32 0.32 Mass Rate (lblTon Clinker) 1.81E-03 2.21E-03 2.06E-03 2.03E-03 Total Hydrocarbons (THC)
- Line 2 Kiln Stack Concentration (ppmwv) 2.57 2.81 2.97 2.78 Mass Rate (Ib/hr) 3.10 3.29 3.54 3.31 Mass Rate (lblTon Clinker) 0.02 0.02 0.02 0.02



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS 

## Client Reference No: DC04062009 CleanAir Project No: 10773
2-17 Table 2-17: Line 2 Clinker Cooler
- Filterable PM10 Run No. 

### 4" 5 6 Average Date 

### (2009) Apr 

### 26 Apr

### 26 Apr 

### 26 Start Time (approx.) 

### 15:23 18:42 20:55 Stop Time (approx.) 

### 18:07 20:26 22:35 Process Conditions

Rp Production rate (Ton Clinker/hour) 

### 155 155 155 155 Cap Capacity factor (hours/year) 

### 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 

### 20.1 19.8 19.7 19.8 CO2 Carbon dioxide (dry volume %) 

### 0.1 0.0 0.1 0.1 Ts Sample temperature (OF) 

### 184 177 172 175 

## B

w Actual watervapor in gas (% by volume) 

### 1.94 2.80 3.21 3.00 Gas Flow Rate

Q. Volumetric flow rate, actual (acfm) 

### 141,658 142,739 142,337 142,538 Qs Volumetric flow rate, standard (scfm) 

### 113,046 115,167 115,709 115,438 Q'td Volumetric flow rate, dry standard (dscfm) 

### 110,853 111,947 111,996 111,971 Sampling Data

Vmstd Volume metered, standard (dscf) 

### 65.6484 39.9142 39.6070 39.7606 %1 Isokinetic sampling (%) 

### 89.8718 105.7965 88.2960 97.0463 

# ) Filterable Particulate Matter

### < 10 IJm (FPM10) Laboratory Data mFPM10 Filterable particulate matter

### < 10 IJm (FPM1

### o) collected (g 

### <0.00333 <0.00333 <0.00333 Filterable Particulate Matter

### < 10 IJm (FPM10) Results

Csd Particulate Concentration (Ib/dscf) 

### <1.118E-07 <1.840E-07 <1.854E-07 <1.847E-07 E1blhr Particulate Rate (Ib/hr) 

### <0.7439 <1.2356 <1.2458 <1.2407 E

T/yr Particulate Rate (Ton/yr) 

### <3.2584 <5.4120 <5.4564 <5.4342 ERp Particulate Rate - Production-based (lblTon Clinker) 

### <0.0048 <0.0080 <0.0080 <0.0080 Average includes 2 runs. "indicates that the run is not included in the average.



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT


## RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


## 2-18 Table 2-18: Line 2 ClinkerCooler
- Condensable PM Run No. 

### 4- 5 6 Average Date 

### (2009) Apr

### 26 Apr

### 26 Apr 

### 26 StartTime (approx.) 

### 15:23 18:42 20:55 Stop Time (approx.) 

### 18:07 20:26 22:35 Process Conditions

Rp Production rate (Ton Clinker/hour) 

### 155 155 155 155 Cap Capacity factor (hours/year) 

### 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 

### 20.1 19.8 19.7 19.8 CO2 Carbon dioxide (dry volume %) 

### 0.1 0.0 0.1 0.1 Ts Sample temperature 

### (OF) 

### 184 177 172 175 

## B

w Actual watervapor in gas (% by volume) 

### 1.94 2.80 3.21 3.00 Gas Flow Rate



### Q. Volumetricflow rate, actual (acfm) 

### 141,658 142,739 142,337 142,538 

### Q

s Volumetricflow rate, standard (scfm) 

### 113,046 115,167 115,709 115,438 

### Q

std Volumetric flow rate, dry standard (dscfm) 

### 110,853 111,947 111,996 111,971 Sampling Data

Vmstd Volume metered, standard (dscf) 

### 65.6484 39.9142 39.6070 39.7606 %1 Isokinetic sampling (%) 

### 89.8718 105.7965 88.2960 97.0463 Laboratory Data

miT Total Inorganic CPM Result (g) 

### 0.00368 0.00057 0.00356 moo Total Organic CPM Result (g) 

### 0.00000 0.00000 0.00000 mT Total Gravimetric Result (g) 

### 0.00368 0.00057 0.00356 mCPM Total CPM (g) 

### 0.00368 <0.00242 0.00356 Condensable Particulate Results

Csd Particulate Concentration (Ib/dscf) 

### 1.236E-07 <1.337E-07 1.982E-07 <1.659E-07 Eiblhr Particulate Rate (Ib/hr) 

### 0.8221 <0.8980 1.3318 <1.1149 E

Tlyr Particulate Rate (Ton/yr) 

### 3.6008 <3.9331 5.8333 <4.8832 ERp Particulate Rate - Production-based (lblTon Clinker) 

### 0.0053 <0.0058 0.0086 <0.0072 Average includes 2 runs. - indicates that the run is not included in the average.



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
RESULTS Client Reference No: DC04062009 CleanAir Project No: 10773


# 2-19



# ) Table 

## 2-19: Line 

## 2 Clinker Cooler- Filterable PM > 

## 10J./m Run No. 4" 5 6 Average Date (2009) Apr 26 Apr 26 Apr 26 StartTime (approx.) 15:23 18:42 20:55 Stop Time (approx.) 18:07 20:26 22:35 Process Conditions

Rp Production rate (Ton Clinker/hour) 155 155 155 155 Cap Capacity factor (hours/year) 8,760 8,760 8,760 8,760 Gas Conditions

O2 Oxygen (dry volume %) 20.1 19.8 19.7 19.8 CO2 Carbon dioxide (dry volume %) 0.1 0.0 0.1 0.1 Ts Sample temperature (OF) 184 177 172 175 

### B

w Actual watervapor in gas (% by volume) 1.94 2.80 3.21 3.00 Gas Flow Rate



### Q. Volumetric flow rate, actual (acfm) 141,658 142,739 142,337 142,538 

### Q

s Volumetric flow rate, standard (scfm) 113,046 115,167 115,709 115,438 

### Q

std Volumetric flow rate, dry standard (dscfm) 110,853 111,947 111,996 111,971 Sampling Data

Vmstd Volume metered, standard (dscf) 65.6484 39.9142 39.6070 39.7606 %1 Isokinetic sampling (%) 89.8718 105.7965 88.2960 97.0463 Filterable Particulate Matter> 10 11m (FPM» Laboratory Data

mFPM> Filterable particulate matter> 10 IJm (FPM» collected (g) 0.12384 <0.00333 0.00392 Filterable Particulate Matter> 10 11m (FPM» Results

CSd Particulate Concentration (Ib/dscf) 4.160E-06 <1.840E-07 2.182E-07 <2.011E-07 E1blhr Particulate Rate (Ib/hr) 27.6657 <1.2356 1.4665 <1.3511 ETlyr Particulate Rate (Ton/yr) 121.1759 <5.4120 6.4232 <5.9176 ERp Particulate Rate - Production-based (lblTon Clinker) 0.1780 <0.0080 0.0094 <0.0087 Average includes 2 runs. "indicates that the run is not included in the average.



### End

### of Section 

## 2 - Results



## Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
DESCRIPTION OF INSTALLATION Client Reference No: DC04062009 CleanAir Project No: 10773
3-1

) --/1 

## PROCESS DESCRIPTION The Balcones Plant is a "straight-lineplant", which means thatit is designed so thatthe process moves in a straightpath from where raw materials are introduced to where the finished product is produced. Equipmentupgrades and operational adjustments have increasedtheplants capacity. Theplantnowproduces over 1.1 milliontons ofcement annually, and is one ofthe mostefficient CEMEXplants inthe country. Thetestingreported inthis documentwas performed atthe Line 2 Main Kiln Stackand theLine 2 ClinkerCooler. A schematic oftheprocess indicating sampling locations is shown inFigure 3-1.

<;jlIl

....**gJ~J:l~j** 

## Figure 3-1: Process Schematic

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# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
DESCRIPTION OF INSTALLATION Client Reference No: DC04062009 CleanAir Project No: 10773


# 3-2 DESCRIPTION OF SAMPLING LOCATIONS Samplingpoint locations were determined according to EPA Method 1. Table 3-1 outlines the samplingpointconfigurations. Figure 3-:2through 3-3 illustrate the samplingpoints and orientation ofsamplingports for each ofthe sources tested in theprogram.
Table 3-1: Sampling Points Source Run Points per Minutes per Total Constituent Method No. Ports Port Point Minutes Line 2 Kiln Stack TSP, PM10•CPM EPA

### 201A1202 1_81 4 3 10 120 NOx. CO. S02. THC3 EPA M25A 1_81 CEMs 1 60 60 Hg. Trace Metals EPAM29 1_81 4 3 10 120 HCI/CI2 /NH4 EPM M26A 1_8' 4 3 10 120 PCDDs/PCDFs EPAM23 1_8' 4 3 152 180 Line 2 Clinker Cooler \ TSP. PM10•CPM EPA

### 201A1202 4-6 4 3 10 120 I /
1 Three test runs were performed with Raw Mill On and three with the Raw Mill Off 2 Readings were taken every five minutes 3 CEMs samples were taken from a single point located within the centrally located 10 percent area ofthe stack cross-section. Reading were collected at one-second intervals and presented as one-minute averages using a computer based data aquisition system



### Revision 0, Final Figure
3-2 3-2 3-2 3-2

3-3 052309 '42726

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
DESCRIPTION OF INSTALLATION Client Reference No: DC04062009 CleanAir Project No: 10773


# 3-3 DESCRIPTION OF SAMPLING LOCATIONS (CONTINUED)
124 in. --------l

.. lIoolf 

# t

North 

## Gas Flow Out of Page

Sampling Point 

## 1 2 3 Port to Point Distance (in.) 

### 42.7 24.1 11.4



## Duct diameters upstream from flow disturbance (A): Duct diameters downstream from flow disturbance (8): 13.3 Limit: 0.5 10.6 Limit: 2.0 

## Figure 3-2: Line 2 Main Kiln Stack Sampling Point Determination (EPA Method 1)

Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT
DESCRIPTION OF INSTALLATION Client Reference No: DC04062009 CleanAir Project No: 10773
3-4



# ') DESCRIPTION OF SAMPLING LOCATIONS (CONTINUED)**r~-~~~·** i02ln.

## -~---,--to.1 

## Porn

Port3
Sampling Point 

## 1 2 3 Port to Point Distance (in.) 30.2 

## 14.9 4.5 

## Duct diameters upstream from flow disturbance (A): Duct diameters downstream from flow disturbance (8): 3.4 Limit: 0.5 8.0 Limit: 2.0
Figure 3-3: Line 2 Clinker Cooler Sampling Point Determination (EPA Method 1)

End

### of Section 

### 3 - Description 

### ofInstallation



### Revision 0, Final

# CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT 

# METHODOLOGY Client Reference No: DC04062009 CleanAir Project No: 10773


## 4-1 

# Clean AirEngineering followed procedures as detailed in USEPA Methods 1,2, 3A, 4, 6C, 7E, 10 23, 25A, 26A, 29, 201A, 202 and CTM-027. The following table summarizes the methods and theirrespective sources. Table 4-1: Summary of Sampling Procedures Title 40 CFR Part 60 Appendix A Method 1 "Sample and VelocityTraverses for Stationary Sources" Method 2 "Determination of Stack Gas Velocity and Volumetric Flow Rate (Type S Pitot Tube)" Method 3A "Determination ofOxygen and Carbon Dioxide Concentrations in Emissions from Stationary Sources (Instrumental Analyzer Procedure)" Method 4 "Determination of Moisture Content in Stack Gases" Method 6C "Determination of Sulfur Dioxide Emissions from Stationary Sources (Instrumental Analyzer Procedure)" Method 7E "Determination of Nitrogen Oxides Emissions from Stationary Sources (Instrumental Analyzer Procedure)" Method 10 "Determination of Carbon Monoxide Emissions from Stationary Sources" Method 23 "Determination of Polychlorinated bibenzo-p-Dioxins and Polychlorinated Dibenzofurans from Municipal Waste Conductors" Method 25A "Determination ofTotal Gaseous Organic Concentration Using a Flame Ionization Analyzer" Method 26A "Determination of Hydrogen Halide and Halogen Emissions from Stationary Sources Isokinetic Method" ) Method 29 "Determination of Metals Emissions from Stationary Sources" / 

### Title 40 CFR Part 51 Appendix M Method 201A "Determination of PM 10 

### Emissions (Constant Sampling Rate Procedure)" Method 202 "Dry Impinger Method forthe Determination of Condensible Particulate Emissions from Stationary Sources" Conditional Test Methods (CTM) CTM-027 "Procedure for Collection and Analysis ofAmmonia in Stationary Sources"


# These methods appearin detail in Title 40 ofthe Code ofFederal Regulations (CFR) and onthe World Wide Web athttp://www.cleanair.com. Diagrams ofthe sampling apparatus andmajor specifications ofthe sampling, recovery and analytical procedures are summarized for each method in Appendix A. 

# CleanAirfollowed specific quality assurance and quality control (QA/Qc) procedures as outlined inthe individual methods and in USEPA "Quality Assurance Handbookfor AirPollutionMeasurement Systems: Volume III Stationary Source-Specific Methods", EPA/600/R-94/038C. Additional QA/QC methods as prescribed in CleanAir's internal Quality Manual were also followed. Results ofall QA/QC activities performedby CleanAirare summarized in Appendix D.

End

### ofSection 

### 4 - Methodology 

# )
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# (-'I CleanAir.

CEMEX CEMENT OF TEXAS, LP BALCONES PLANT


# APPENDIX Client Reference No: DC04062009 CleanAir Project No: 10773
5-1 TEST METHOD SPECIFICATIONS 

## A SAMPLE 

## CALCULATIONS B PARAMETERS 

## C QAlQC 

## DATA D FIELD 

## DATA E FIELD DATA PRINTOUTS 

## F LABORATORY 

## DATA G PLANT 

## DATA H PROTOCOL 1 RESUMES 

## J

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