COMMONWEALTH of VIRGINIA 

DEPARTMENT OF ENVIRONMENTAL QUALITY 

STATIONARY SOURCE PERMIT TO OPERATE 

This pel'mit implements the requil'ements for Best Available Retrofit Technology (BART) 

for PM, S02 and NO. in the Vallcy of Virginia Intrastatc Ail' Ouality Control Region. 

In compliance with the Federal Clean Air Act and the Commonwealth of Virginia 

Regulations for the Control and Abatement of Air Pollution, 

is authorized to operate 

located at 

O-N Minerals (Chemstone) Company 

Post Office Box 71 

Strasburg, Virginia 22657 

Registration No,: 80252 

a rotary kiln and 

a calcimatic kiln 

1696 Oranda Road 

Strasburg, Shenandoah County 

in accordance with the Conditions of this permit. 

Approved on 

Permit consists of 16 pages, 

Permit Conditions I to 48, 

Source Testing Report Format 

(X.~~ 1-6 / 2001 

~.,/,,~ 
PURPOSE 

O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 2 

This permit (i) is for the purpose of implementing the "best available retrofit technology" 

(BART) requirements of Article 52 (9 V AC 5-40-7550 et seq.) of 9 V AC 5 Chapter 40 of the 

Regulations of the Board and (ii) establishes control technology and other requirements for the 

control of visibility-impairing pollutants from the O-N Minerals (Chemstone) CompanyStrasburg Facility in the Valley of Virginia Intrastate Air Quality Control Region. These BART 

requirements shall be the legal and regulatory basis for control of visibility-impairing pollutants 

from this facility. 

INTRODUCTION 

This permit approval is based on the permit application dated February 21,2007, including 

supplemental information dated April 27, 2007, May 31, 2007, July 12, 2007, August 30, 2007, 

September 27,2007, November 12, 2007, December 5, 2007, December 14, 2007, January 7, 

2008, March 17, 2008, July 15, 2008, May 8, 2009, June 4, 2009, and August 27,2009. Any 

changes in the permit application specifications or any existing facilities which alter the impact 

of the facility on air quality may require a permit. Failure to obtain such a permit prior to 

construction may result in enforcement action. 

Words or telms used in this permit shall have meanings as provided in 9 VAC 5-10-10 and 9 

VAC 5-40-7570 C of the State Air Pollution Control Board Regulations for the Control and 

Abatement of Air Pollution. The regulatory reference or authority for each condition is listed in 

parentheses 0 after each condition. 

Annual requirements to fulfill legal obligations to maintain current stationary source emissions 

data will necessitate a prompt response by the permittee to requests by the DEQ or the Board for 

information to include, as appropriate: process and production data; changes in control 

equipment; and operating schedules. Such requests for information from the DEQ will be either 

in writing or by personal contact. 

The availability of information submitted to the DEQ or the Board will be governed by 

applicable provisions of the Freedom of Information Act, §§ 2.2-3700 through 2.2-3714 of the 

Code of Virginia, § 10.1-1314 (addressing information provided to the Board) of the Code of 

Virginia, and 9 V AC 5-170-60 of the State Air Pollution Control Board Regulations. 

Information provided to federal officials is subject to appropriate federal law and regulations 

governing confidentiality of such information. 
PROCESS REOUIREMENTS 

O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 3 

I. Equipment List - Equipment subject to this permit at this facility consists of the following: 

Equipment permitted prior to the date of this permit 

Reference No. Equipment DescriJltion Rated Capacity 

US Rotary kiln 25 tons lime/hr' 

Ul2 Calcimatic kiln 8 tons lime/hI' .. SpeCIficatIOns mciuded m the permIt under thIS CondItIOn are for informational purposes 

only and do not form enforceable terms or conditions of the permit. 

(9 VAC 5-80-850 and 9 VAC 5-40-7550) 

2. Emission Controls: Rotary Kiln-Nitrogen oxides (NOx) emissions from the rotary kiln 

(U5) shall be controlled by good combustion practices and by use of an indirect firing 

system. The indirect firing system shall be provided with adequate access for inspection and 

shall be in operation when the rotary kiln is operating. 

(9 V AC 5-80-850 and 9 VAC 5-40-7580) 

3. Emission Controls: Rotary Kiln - Particulate matter having an aerodynamic diameter less 

than or equal to ten micrometers (PM-lO) emissions from the rotary kiln (U5) shall be 

controlled by a muiticycione and fabric filters. The multicyclone and fabric filters shall each 

be provided with adequate access for inspection and shall each be in operation when the 

rotary kiln is operating. 

(9 V AC 5-80-850 and 9 VAC 5-40-7580) 

4. Emission Controls: Rotary Kiln- No later than September lO, 2010, sulfur dioxide (S02) 

emissions from the rotary kiln (U5) shall be controlled to achieve the S02 limits in Condition 

23. Unless the Director, Valley Regional Office, approves inherent process scrubbing as an 

alternative control technology by September 10,2011, a wet scrubber shall be installed by 

August 1, 2012. The wet scrubber or other technology employed to meet the S02 limits shall 

be provided with adequate access for inspection and shall be in operation when the rotary 

kiln is operating. 

(9 V AC 5-80-850, 9 V AC 5-40-7580, 9 V AC 5-40-7590 and 9 V AC 5-40-7650) 

5. Emission Controls: Calcimatic Kiln - NOx emissions from the calcimatic kiln (U12) shall 

be controlled by good combustion practices. 

(9 VAC 5-80-850 and 9 VAC 5-40-7580) 

6. Emission Controls: Calcimatic Kiln - PM-1 0 emissions from the calcimatic kiln (Ul2) 

shall be controlled by a muiticycione and Ventnri scrubber. The multi cyclone and Ventnri 

scrubber shall each be provided with adequate access for inspection and shall each be in 

operation when the calcimatic kiln is operating. 

(9 VAC 5-80-850 and 9 VAC 5-40-7580) 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 4 

7. Emission Controls: Calcimatic Kiln - Sulfur dioxide (S02) emissions from the calcimatic 

kiln (Ul2) shall be controlled by Venturi scrubber. The Venturi scrubber shall be provided 

with adequate access for inspection and shall be in operation when the calcimatic kiln is 

operating. 

(9 V AC 5-80-850 and 9 VAC 5-40-7580) 

8. Monitoring Devices: Fabric Filter - Each fabric filter serving the rotary kiln (U5) shall be 

equipped with devices to continuously measure the differential pressure across the filter. 

Each monitoring device shall be installed, maintained, calibrated or verified, and operated in 

accordance with approved procedures which shall include, as a minimum, the manufacturer's 

written requirements or recommendations. Each monitoring device shall be provided with 

adequate access for inspection and shall be in operation when the rotary kiln is operating. 

(9 V AC 5-80-850 and 9 VAC 5-40-7670) 

9. Monitoring Devices: Wet Scrubber - If a wet scrubber is used to meet the S02limits in 

Condition 23, it shall be equipped with devices to continuously measure and record liquid 

flow rate and the differential pressure across the scrubber. Each monitoring device shall be 

installed, maintained, calibrated and operated in accordance with approved procedures which 

shall include, as a minimum, the manufacturer's written requirements or recommendations. 

Each monitoring device shall be provided with adequate access for inspection and shall be in 

operation when the scrubber is operating. 

(9 VAC 5-80-850 and 9 VAC 5-40-7670) 

10. Monitoring Devices: Venturi Scrubber - The Venturi scrubber serving the calcimatic kiln 

(UI2) shall be equipped with devices to continuously measure the scrubber liquid flow rate, 

the exit gas temperature, and the differential pressure across the scrubber. Each monitoring 

device shall be installed, maintained, calibrated or verified, and operated in accordance with 

approved procedures which shall include, as a minimum, the manufacturer's written 

requirements or recommendations. Each monitoring device shall be provided with adequate 

access for inspection and shall be in operation when the calcimatic kiln is operating. 

(9 VAC 5-80-850 and 9 V AC 5-40-7670) 

II. BART Monitoring Plan- The permittee shall prepare and implement, for each kiln (U5 

and UI2), a written BART monitoring plan. The permittee shall submit the plan to the 

Director, Valley Regional Office, for review and approval within 180 days of permit 

issuance. Any subsequent changes to the plan must be submitted to the Director, Valley 

Regional Office, for review and approval. Pending approval by the Director, Valley 

Regional Office, of an initial or amended plan, the permittee shall comply with the 

provisions of the submitted plan. Each plan shall contain the following information: 

a. Process and control device parameters to be monitored to determine compliance with 

NOx emission limits and good combustion practices, along with established operating 

limits or ranges, as applicable, for each kiln (U5 and UI2). 

b. A monitoring schedule for each kiln (U5 and UI2). 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 5 

c. Procedures for the proper operation and maintenance of each kiln (U5 and U12) and each 

air pollution control device used to meet the applicable emission limitations in Conditions 

22,23 and 24. 

d. Procedures for the proper installation, operation, and maintenance of monitoring devices 

or systems used to determine compliance or good combustion practices, including: 

1. Calibration and celtification of accuracy of each monitoring device; 

11. Perfotmance and equipment specifications for the sample interface, parametric 

signal analyzer, and the data collection and reduction systems; 

111. Ongoing operation and maintenance procedures; and 

IV. Ongoing data quality assurance procedures. 

e. Procedures for monitoring process parameters indicative of good combustion practices 

and control device parameters indicative of proper control device operation. 

f. Corrective actions to be taken when process or operating parameters or add-on control 

device parameters deviate from the values identified in Condition 11 e. 

g. A maintenance schedule for each kiln (U5 and U12) and control device that is consistent 

with the manufacturer's insttuctions and recommendations for routine and long-term 

maintenance. 

(9 VAC 5-80-850 and 9 V AC 5-40-7670) 

12. Monitoring Devices/Observations - Process parameters indicative of good combustion 

practices for the rotary kiln (U5) and the calcimatic kiln (UI2) shall be monitored in 

accordance with the BART monitoring plan required by Condition 11. 

(9 VAC 5-80-850 and 9 VAC 5-40-7670) 

13. Monitoring Device Observation: Fabric Filter - To ensure good performance, the fabric 

filter monitoring device used to continuously measure differential pressure shall be observed 

by the permittee with a frequency of not less than once per operating day. The permittee 

shall keep a log of the measurements of the fabric filter monitoring device. 

(9 VAC 5-80-850 and 9 VAC 5-40-7670) 

14. Monitoring Device Observation: Wet Scrubber - If a wet sctubber is used to meet the S02 

limits in Condition 23, the monitoring devices used to continuously measure liquid flow rate 

and pressure drop for the wet sctubber shall be observed by the permittee with a frequency of 

not less than once per operating day. The permittee shall continuously record measurements 

from the wet sctubber monitoring devices. 

(9 V AC 5-80-850 and 9 VAC 5-40-7670) 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 6 

15. Monitoring Device Observation: Venturi Scrubber - To ensure good performance, the 

magnahelic gauge used to continuously measure pressure drop across the Venturi sClUbber, 

the flow meter used to monitor sClUbber liquid flow rate, and the thermocouple used to 

measure exit gas temperature shall each be observed by the permittee with a frequency of not 

less than once per operating day. The permittee shall keep a log of the measurements from 

the magnahelic gauge, the flow meter, and the thermocouple. 

(9 V AC 5-80-850 and 9 VAC 5-40-7670) 

16. Monitoring: Rotary and Calcimatic Kilns - The combustion apparatus on the rotary and 

calcimatic kilns (U5 and U12) shall each be inspected at least annually or at the earliest 

shutdown following one year from the previous inspection. During the inspection, each 

apparatus shall be adjusted as necessary or tuned to ensure optimization such that NOx 

emissions are minimized. 

(9 VAC 5-80-850 and 9 V AC 5-40-7670) 

OPERATING LIMITS 

17. Fuel: Rotary Kiln - The approved fuels for the rotary kiln (U5) are coal, distillate oil, and 

natural gas. A change in the fuel may require a permit to modify and operate. 

(9 VAC 5-80-850) 

18. Fuel: Calcimatic Kiln - The approved fuels for the calcimatic kiln (UI2) are distillate oil, 

natural gas, and recycled oil. A change in the fuel may require a permit to modify and 

operate. 

(9 V AC 5-80-850) 

19. Fuel: Rotary Kiln - The coal and distillate oil shall meet the specifications below: 

COAL: 

Maximum sulfur content per shipment: 1.0% 

as determined by ASTM D3177, D4239, or a DEQ-approved equivalent method 

DISTILLATE OIL which meets the ASTM D396 specification for numbers 1 or 2 fuel oil: 

Maximum sulfur content per shipment: 0.5% 

(9 VAC 5-80-850 and 9 V AC 5-40-7580) 

20. Fuel: Calcimatic Kiln - The distillate oil and recycled oil shall meet the specifications 

below: 

DISTILLATE OIL which meets the ASTM D396 specification for numbers 1 or 2 fuel oil: 

Maximum sulfur content per shipment: 0.5% 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 7 

RECYCLED FUEL OIL which meets the following specifications: 

Maximum sulfur content per shipment: 0.5% 

(9 V AC 5-80-850 and 9 VAC 5-40-7580) 

21. Fuel Certification - The permittee shall obtain a celtification from the fuel supplier with 

each shipment of coal, distillate oil and recycled oil. Each fuel supplier certification shall 

include the following: 

a. The name of the fuel supplier; 

b. The date on which the coal, distillate oil or recycled oil was received; 

c. The quantity of coal, distillate oil or recycled oil delivered in the shipment; 

d. A statement that the distillate oil complies with the American Society for Testing and 

Materials specifications (ASTM D396) for numbers 1 or 2 fuel oil; 

e. The sulfur content of the coal, distillate oil, or recycled oil; 

f. The methods used to determine the sulfur content of the coal. 

Details of the content of certifications shall be arranged with the Director, Valley Regional 

Office. Fuel sampling and analysis, independent of that used for certification, as may be 

periodically required or conducted by DEQ, may be used to determine compliance with the 

fuel specifications stipulated in Conditions 19 and 20. Exceedance of these specifications 

may be considered credible evidence of the exceedance of emission limits. 

(9 V AC 5-80-850 and 9 V AC 5-40-7580) 

EMISSION LIMITS 

22. Process Emission Limits: Rotary Kiln - Emissions from the operation of the rotary kiln 

(US) shall not exceed the limits specified below. The PM and PMlO limits shall be effective 

180 days after the permit effective date. 

Particulate Matter (PM) 

PMlO 

Nitrogen Oxides 

(as N02) 

tsf = tons stone feed 

0.12 lbs/tsf 6.0lbs/hr 

0.12 lbs/tsf 6.0lbs/hr 

1.74lbs/tsf 87.01bslhr 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 8 

Hourly emission limits represent averages for a three-hour sampling period. 

Compliance with these emission limits may be determined as stated in Conditions 2, 3, II, 

19,21,27,30, and 31. Compliance with the Ib/tsflimits shall be based on the most recent 

DEQ-approved stack test. Compliance with the Ib/hr limits shall be calculated monthly (as a 

monthly average) based on the Ib/tsffactor determined in the most recent DEQ-approved 

stack test, the monthly limestone feed input, and kiln operating hours for the month. (9 V AC 

5-80-850 and 9 V AC 5-40-7580) 

23. Process Emission Limits: Rotary Kiln - No later than September 10,2010, emissions from 

the operation of the rotary kiln (U5) shall not exceed the limits specified below: 

Sulfur Dioxide 0.29 lbs/tsf 14.7lbs/hr 

tsf = tons stone feed 

Hourly emission limits represent averages for a 24-hour sampling period. 

The lbs/tsflimit shall apply at all times except during startup. The lbslhr limit shall apply at 

all times, including startup. Statiup is defined as the period commencing when fuel begins to 

flow to the burner and ending when any product is discharged to the cooler discharge weigh 

belt. For compliance purposes, emissions shall be calculated based on CEMS data and daily 

limestone feed input and using a DEQ-approved methodology. 

(9 VAC 5-80-850 and 9 VAC 5-40-7580) 

24. Process Emission Limits: Calcimatic Kiln - Emissions from the operation of the calcimatic 

kiln (UI2) shall not exceed the limits specified below: 

Patiiculate Matter (PM) 

PM-I0 

Nitrogen Oxides 

(as N02) 

Sulfur Dioxide 

tsf = tons stone feed 

0.60 Ibs/tsf 9.6lbs/hr 

0.60 lbs/tsf 9.6lbs/hr 

0.61lbs/tsf 9.8lbslhr 

0.16 Ibs/tsf 2.6lbs/hr 

Hourly emission limits represent averages for a three-hour sampling period. 

Compliance with these emission limits may be determined as stated in Conditions 5, 6, 7, II, 

20,21,29,30 and 31. Compliance with the lb/tsf limits shall be based on the most recent 

DEQ-approved stack test. Compliance with the lbllu'limits shall be calculated monthly (as a 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 9 

monthly average) based on the lb/tsffactor determined in the most recent DEQ-approved 

stack test, the monthly limestone feed input, and kiln operating hours for the month. 

(9 V AC 5-80-850 and 9 VAC 5-40-7580) 

25. Emission Testing - The rotary and calcimatic kilns (U5 and U12) shall each be constructed 

so as to allow for emissions testing upon reasonable notice at any time, using appropriate 

methods. This includes constructing the facility/equipment such that volumetric flow rates 

and pollutant emission rates can be accurately determined by applicable test methods and 

providing a stack or duct that is free from cyclonic flow. Sampling POlts shall be provided 

when requested at the appropriate locations and safe sampling platforms and access shall be 

provided. 

(9 VAC 5-80-880, 9 V AC 5-80-850 and 9 V AC 5-40-7660) 

RECORDS 

26. On Site Records - The permittee shall maintain records of emission data and operating 

parameters as necessary to demonstrate compliance with this permit. The content and format 

of such records shall be al1'anged with the Director, Valley Regional Office. These records 

shall include, but are not limited to: 

a. Annual consumption of each fuel used in each kiln, calculated monthly as the sum of 

each consecutive 12-month period. 

b. Records necessary to monitor the monthly and annual limestone feed input to each kiln in 

accordance with a DEQ-approved protocol. Annual limestone feed input shall be 

calculated monthly as the sum of each consecutive 12-month period. 

c. Monthly hours of operation for each kiln. 

d. All fuel supplier celtifications. 

e. Monthly emissions calculations for PM and NO, from the rotary kiln (U5) to verify 

compliance with the Ibs/hr emissions limitations in Condition 22. 

f. Beginning on September 10,2010, Continuous Emissions Monitoring System (CEMS) 

data from the rotary kiln (U5) to verify compliance with the Ibslhr emissions limitation in 

Condition 23. 

g. Beginning on September 10,2010, daily emissions calculations for S02 from the rotary 

kiln (U5) based on CEMS and production data to verify compliance with the Ib/tsf 

emissions limitation in Condition 23. 

h. Monthly emissions calculations for PM, S02 and NO, from the calcimatic kiln (UI2) to 

verify compliance with the lbslhr emissions limitations in Condition 24. 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 10 

i. Control device monitoring records for the fabric filter serving the rotary kiln (U5) as 

required in Conditions 8 and 13. 

j. Beginning on August I, 2012, control device monitoring records for the wet sctubber 

serving the rotary kiln (U5) as required in Conditions 9 and 14. 

k. Control device monitoring records for the Venturi sctubber serving the calcimatic kiln 

(UI2) as required in Conditions 10 and 15. 

1. Copy of the BART Monitoring Plan required by Condition 11, including any 

amendments made to the original plan. 

m. Records of monitoring conducted in accordance with the BART Monitoring Plan, as 

required by Condition 12. 

n. Records of rotary and calcimatic kilns (U5 and U12) combustion optimization/tuning 

conducted according to Condition 16. 

o. Scheduled and unscheduled maintenance, and operator training. 

p. Results of all stack tests, performance evaluations, and CEMS Quality Control Program 

documentation. 

These records shall be available for inspection by the DEQ and shall be current for the most 

recent five years. 

(9 VAC 5-80-900 and 9 VAC 5-40-7680) 

INITIAL COMPLIANCE DETERMINATION 

27. Stack Test: Rotary Kilu- Initial performance tests shall be conducted for NOx and PM 

from the rotary kiln (U5) using EPA Reference Methods 7 or 7E and 5 (40 CFR 60 Appendix 

A), respectively, to determine compliance with the emission limits contained in Condition 

22. The tests shall be performed and demonstrate compliance within 180 days after the 

effective date of the permit. Upon approval by the Director, Valley Regional Office, stack 

testing performed 12 months or less prior to the effective date of the permit may serve to 

satisfy this condition. Tests shall be conducted and repOlted and data reduced as set forth in 

9 V AC 5-40-30 and the test methods and procedures contained in each applicable section or 

subpart listed in 9 V AC 5-50-410. The details ofthe tests are to be arranged with the 

Director, Valley Regional Office. The pelmittee shall submit a test protocol at least 30 days 

prior to testing. A copy of the test results shall be submitted to the Director, Valley Regional 

Office, within 60 days after test completion and shall confOlm to the test repOlt format 

enclosed with this permit. 

(9 VAC 5-80-850 and 9 VAC 5-40-7660) 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 11 

28. Stack Test: Rotary Kiln - mitial perfmmance tests shall be conducted for S02 from the 

rotary kiln (U5) using EPA Reference Method 6 or 6C (40 CFR 60 Appendix A) to 

determine compliance with the emission limits contained in Condition 23. The tests shall be 

performed and demonstrate compliance within 60 days after the compliance date in 

Condition 23. Tests shall be conducted and reported and data reduced as set forth in 9 V AC 

5-40-30 and the test methods and procedures contained in each applicable section or subpati 

listed in 9 VAC 5-50-410. The details of the tests are to be arranged with the Director, 

Valley Regional Office. The permittee shall submit a test protocol at least 30 days prior to 

testing. A copy of the test results shall be submitted to the Director, Valley Regional Office, 

within 60 days after test completion and shall conform to the test report format enclosed with 

this permit. 

(9 V AC 5-80-850 and 9 VAC 5-40-7660) 

29. Stack Test: Calcimatic Kiln- mitial performance tests shall be conducted for NO" S02 and 

PM from the calcimatic kiln (UI2) using EPA Reference Methods 7 or 7E, 6 or 6C, and 5 (40 

CFR 60 Appendix A), respectively, to determine compliance with the emission limits 

contained in Condition 24. The tests shall be performed and demonstrate compliance within 

the latter of 180 days after the effective date of the pelmit or 90 days following resumption of 

the unit's normal operation. Tests shall be conducted and reported and data reduced as set 

fmih in 9 V AC 5-40-30 and the test methods and procedures contained in each applicable 

section or subpati listed in 9 V AC 5-50-410. The details of the tests are to be arranged with 

the Director, Valley Regional Office. The permittee shall submit a test protocol at least 30 

days prior to testing. A copy ofthe test results shall be submitted to the Director, Valley 

Regional Office, within 60 days after test completion and shall confmm to the test report 

format enclosed with this permit. 

(9 V AC 5-80-850 and 9 V AC 5-40-7660) 

CONTINUING COMPLIANCE DETERMINATION 

30. Stack Tests: PM - At least once every five years, or upon request by the DEQ, the permittee 

shall conduct additional performance tests for PM from the rotary and calcimatic kilns (U5 

and UI2) to demonstrate compliance with the emission limits contained in this permit. The 

details of the tests shall be arranged with the Director, Valley Regional Office. 

(9 VAC 50-80-850 and 9 V AC 5-40-7660) 

31. Annual Stack Test: NOx - An annual stack test shall be conducted on the rotary kiln (U5) 

and on the calcimatic kiln (UI2) for NO" using EPA Reference Method 7 or 7E (40 CFR 60 

Appendix A). Each annual stack test shall be conducted no later than 13 months after the 

previous stack test. The first test ofthe calcimatic kiln (UI2) shall be conducted within 90 

days after the unit resumes normal operation. If the calcimatic kiln (UI2) has ceased 

operation at the time the subsequent annual test is due (13 months after the previous test), 

testing shall be conducted within 60 days after the unit again resumes normal operation. 

Tests shall be conducted and reported and data reduced as set forth in 9 V AC 5-40-30 and the 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 12 

test methods and procedures contained in each applicable section or subpart listed in 9 V AC 

5-50-410. The details of the tests are to be arranged with the Director, Valley Regional 

Office. The permittee shall submit a test protocol at least 30 days prior to testing. Test 

results shall be submitted to the Director, Valley Regional Office, within 45 days after test 

completion and shall confotm to the test report format enclosed with this pelmit. 

(9 V AC 5-80-850 and 9 V AC 5-40-7660) 

32. Reduced Stack Testing - If three consecutive annual stack tests conducted in accordance 

with Condition 31 for either kiln (U5 or U12) demonstrate compliance with the NOx 

emission limits in Conditions 22 (for U5) or 24 (for UI2), the stack testing frequency 

required by Condition 31 shall be reduced to once every five years for the kiln. The 

permittee shall conduct another stack test for each kiln (U5 or U12) within 60 months of the 

date of the third consecutive stack test that shows compliance with the emission limits. 

Thereafter, the permittee must perform stack tests every fifth year but no later than 60 

months following the previous stack test. If the calcimatic kiln (UI2) has ceased operation at 

the time the subsequent fifth-year test is due (60 months after the previous test), testing shall 

be conducted within 60 days after the unit again resumes notmal operation. If a stack test for 

either kiln (U5 or U12) shows noncompliance with the NOx emission limits, the permittee 

shall conduct annual stack tests for the kiln until stack tests over three consecutive years 

show compliance with the emission limits. 

(9 V AC 5-80-850 and 9 VAC 5-40-7660) 

33. CEMS - No later than September 10, 2010, a Continuous Emission Monitoring Systems 

(CEMS) shall be installed to measure and record the emissions of S02 in pounds per hour 

from the rotary kiln (U5). CEMS for S02 shall be installed, evaluated, and operated 

according to the requirements of 9 VAC 5-40-41. For compliance with the emission limits 

contained in Condition 23, S02 data shall be reduced to 24-hour block averages. 

(9 VAC 5-80-850, 9 VAC 5-40-40 F and 9 VAC 5-40-7670) 

34. CEMS Performance Evaluations - Performance evaluations of the S02 continuous 

monitoring systems shall be conducted in accordance with 9 V AC 5-40-41 B.I and shall take 

place during the performance tests required by Condition 28 or within 30 days thereafter. 

One copy ofthe performance evaluation repoti shall be submitted to the Director, Valley 

Region, within 45 days of the evaluation. The continuous monitoring systems shall be 

installed and operational prior to conducting initial performance tests. Verification of 

operational status shall, as a minimum, include completion of the manufacturer's written 

requirements or recommendations for installation, operation and calibration of the device. A 

30-day notification, prior to the demonstration of the continuous monitoring system's 

performance, and subsequent notifications shall be submitted to the Director, Valley 

Regional Office. 

(9 V AC 5-80-850, 9 V AC 5-40-40 F and 9 VAC 5-40-7670) 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 13 

35. CEMS Quality Control Program - A CEMS quality control program which is equivalent to 

the requirements of 40 CFR 60.13 and 40 CFR 60, Appendix F shall be implemented for the 

CEMS. 

(9 V AC 5-80-850, 9 V AC 5-40-40 F and 9 V AC 5-40-7670) 

36. Reports - The permittee shall submit reports to the Director, Valley Regional Office, within 

90 days after the end of each semi-annual period ending June 30 and December 31. Each 

report shall contain, at minimum, the dates included in the semi-annual period and the 

following, reported separately for each unit (rotary kiln (US) and calcimatic kiln (UI2)): 

Monthly emissions calculations (or summary of CEMS measurements, as applicable) for PM, 

S02 and NOx to verify compliance with the lbs/hr and lbs/tsf emissions limitations in 

Conditions 22, 23, and 24. 

(9 V AC 5-80-850 and 9 VAC 5-40-7680) 

BART GENERAL CONDITIONS 

37. Relationship to Other Requirements - Except to the extent that conditions in this permit 

may be more stringent, this permit does not supersede or replace any other valid pelmit, 

regulatory or statutory requirement. FUlthermore, this approval to operate shall not relieve 

O-N Minerals (Chemstone) Company of the responsibility to comply with all other local, 

state and federal regulations, including permit regulations. 

(9 VAC 5-80-800 D, 9 V AC 5-80-820 F and 9 V AC 5-40-7580) 

38. Federal Enforceability - Once the permit is approved by the U.S. Environmental Protection 

Agency into the Commonwealth of Virginia State Implementation Plan, the permit is 

enforceable by EPA and citizens under the federal Clean Air Act. 

(9 V AC 5-80-800 C.2, 9 V AC 5-80-820 F and 9 V AC 5-40-7580) 

39. Permit Modification - The Board may revise (modify, rewrite, change or amend) or repeal 

this permit with the consent of O-N Minerals (Chemstone) Company, for good cause shown 

by O-N Minerals (Chemstone) Company, or on its own motion provided approval ofthe 

revision or repeal is accomplished in accordance with Regulations of the Board and the 

Administrative Process Act (§ 2.2-4000 et seq.). Such revision or repeal shall not be 

effective until the revision or repeal is approved by the U.S. Environmental Protection 

Agency following the requirements of 40 CFR Palt 51 (Requirements for Preparation, 

Adoption and Submittal ofImplementations Plans). 

(9 VAC 5-80-960, 9 VAC 5-80-1000 and 9 VAC 5-40-7710) 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 14 

40. Failure to Comply - Failure by O-N Minerals (Chemstone) Company to comply with any of 

the conditions of this pelmit shall constitute a violation ofa Pelmit of the Board. Failure to 

comply may result in a Notice of Violation and civil penalty. Nothing herein shall waive the 

initiation of appropriate enforcement actions or the issuance of orders as appropriate by the 

Board as a result of such violations. Nothing herein shall affect appropriate enforcement 

actions by any other federal, state, or local regulatory authority. 

(9 VAC 5-80-820 F, 9 VAC 5-80-910, 9 VAC 5-80-1010 and 9 VAC 5-40-7640) 

41. BART Determination Criteria: Operation and Maintenance - O-N Minerals 

(Chemstone) Company shall maintain the control equipment required by this permit and 

establish procedures to ensure such equipment is properly operated and maintained. 

(9 VAC 5-80-800 and 9 V AC 5-40-7590) 

SOP GENERAL CONDITIONS 

42. Right of Entry - The permittee shall allow authorized local, state, and federal 

representatives, upon the presentation of credentials: 

a. To enter upon the permittee's premises on which the facility is located or in which any 

records are required to be kept under the terms and conditions of this permit; 

b. To have access to and copy at reasonable times any records required to be kept under the 

telms and conditions of this permit or the State Air Pollution Control Board Regulations; 

c. To inspect at reasonable times any facility, equipment, or process subject to the terms and 

conditions of this permit or the State Air Pollution Control Board Regulations; and 

d. To sample or test at reasonable times. 

For purposes of this condition, the time for inspection shall be deemed reasonable during 

regular business hours or whenever the facility is in operation. Nothing contained herein 

shall make an inspection time umeasonable during an emergency. 

(9 V AC 5-170-130 and 9 V AC 5-80-850) 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 15 

43. Notification for Facility or Control Equipment Malfunction - The pelmittee shall fumish 

notification to the Director, Valley Regional Office, of malfunctions of the affected facility 

or related air pollution control equipment that may cause excess emissions for more than one 

hour, by facsimile transmission, telephone, or telegraph. Such notification shall be made as 

soon as practicable but no later than four daytime business hours after the malfunction is 

discovered. The permittee shall provide a written statement giving all pertinent facts, 

including the estimated duration of the breakdown, within two weeks of discovery of the 

malfunction. When the condition causing the failure or malfunction has been corrected and 

the equipment is again in operation, the pelmittee shall notify the Director, Valley Regional 

Office, in writing. 

(9 VAC 5-20-180 C, 9 V AC 5-80-850 and 9 V AC 5-40-7700) 

44. Violation of Ambient Air Quality Standard - The permittee shall, upon request of the 

DEQ, reduce the level of operation or shut down a facility, as necessary to avoid violating 

any primary ambient air quality standard and shall not retnm to normal operation until such 

time as the ambient air quality standard will not be violated. 

(9 VAC 5-20-180 I and 9 VAC 5-80-850) 

45. Maintenance/Operating Procedures - At all times, including periods of start-up, shutdown, 

and malfunction, the permittee shall, to the extent practicable, maintain and operate the 

affected source, including associated air pollution control equipment, in a manner consistent 

with good air pollution control practices for minimizing emissions. 

(9 VAC 5-50-20 E and 9 V AC 5-80-850) 

46. Permit SuspensionlRevocation - This pelmit may be revoked if the permittee: 

a. Knowingly makes material misstatements in the permit application or any amendments to 

it; 

b. Fails to comply with the terms or conditions of this permit; 

c. Fails to comply with any emission standards applicable to a permitted emissions unit; 

d. Causes emissions from this facility which result in violations of, or interferes with the 

attainment and maintenance of, any ambient air quality standard; 

e. Fails to operate this facility in conformance with any applicable control strategy, 

including any emission standards or emission limitations, in the State Implementation 

Plan in effect at the time that an application for this permit is submitted; or 

f. Fails to comply with the applicable provisions of Articles 6, 8 and 9 of9 VAC 5 Chapter 

80. 

(9 V AC 5-80-10 1 0) 
O-N Minerals (Chemstone) Company 

Registration Number: 80252 

Page 16 

47. Change of Ownership - In the case ofa transfer of ownership of a stationary source, the new 

owner shall abide by any current permit issued to the previous owner. The new owner shall 

notify the Director, Valley Regional Office, of the change of ownership within 30 days of the 

transfer. 

(9 VAC 5-80-940) 

48. Permit Copy - The pennittee shall keep a copy of this permit on the premises of the facility 

to which it applies. 

(9 VAC 5-80-860 D) 
SOURCE TESTING REPORT FORMAT 

Report Cover 

1. Plant name and location 

2. Units tested at source (indicate Ref. No. used by source in permit or registration) 

3. Test Dates. 

4. Tester; name, address and repolt date 

Certification 

l. Signed by team leader/certified observer (include celtification date) 

2. Signed by responsible company official 

3. *Signed by reviewer 

Copy of approved test protocol 

Summary 

1. Reason for testing 

2. Test dates 

3. Identification of unit tested & the maximum rated capacity 

4. *For each emission unit, a table showing: 

a. Operating rate 

b. Test Methods 

c. Pollutants tested 

d. Test results for each lUn and the lUn average 

e. Pollutant standard or limit 

5. Summarized process and control equipment data for each lUn and the average, as required by the 

test protocol 

6. A statement that test was conducted in accordance with the test protocol or identification & 

discussion of deviations, including the likely impact on results 

7. Any other important information 

Source Operation 

1. Description of process and control devices 

2. Process and control equipment flow diagram 

3. Sampling port location and dimensioned cross section Attached protocol includes: sketch of 

stack (elevation view) showing sampling port locations, upstream and downstream flow 

disturbances and their distances from ports; and a sketch of stack (plan view) showing sampling 

ports, ducts entering the stack and stack diameter or dimensions 

Test Results 

1. Detailed test results for each lUn 

2. *Sample calculations 

3. *Description of collected samples, to include audits when applicable 

Appendix 

1. *Raw production data 

2. *Raw field data 

3. *Laboratory reports 

4. *Chain of custody records for lab samples 

5. *Calibration procedures and results 

6. Project participants and titles 

7. Observers' names (industry and agency) 

8. Related cOlTespondence 

9. Standard procedures 

* Not applicable to visible emission evaluations