217/782-2113

CLEAN AIR ACT PERMIT PROGRAM (CAAPP) PERMIT

and

TITLE I PERMIT1

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 95090119 I.D. No.: 127855AAA

Applicant’s Designation: Date Received: September 8, 1995

Operation of: Portland Cement Manufacturing

Date Issued: November 14, 2002 Expiration Date2: November 14, 2007

Source Location: County Line Roads 1000N and 300E, Joppa, Massac County

Responsible Official: Ron Ryan

This permit is hereby granted to the above-designated Permittee to OPERATE 

Portland Cement Manufacturing plant, pursuant to the above referenced permit 

application. This permit is subject to the conditions contained herein.

If you have any questions concerning this permit, please contact Mangu Patel 

at 217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MJP:jar

cc: Illinois EPA, FOS, Region 2

USEPA

1

This permit may contain terms and conditions which address the applicability, and 

compliance if determined applicable, of Title I of the Clean Air Act and regulations 

promulgated thereunder, including 40 CFR 52.21 - federal Prevention of Significant 

Deterioration (PSD) and 35 IAC Part 203 - Major Stationary Sources Construction and 

Modification. Any such terms and conditions are identified within the permit.

2

Except as provided in condition 8.7 of this permit.
2

TABLE OF CONTENTS

PAGE

1.0 SOURCE IDENTIFICATION 4

1.1 Source

1.2 Owner/Parent Company

1.3 Operator

1.4 General Source Description

2.0 LIST OF ABBREVIATIONS/ACRONYMS USED IN THIS PERMIT 5

3.0 INSIGNIFICANT ACTIVITIES 7

3.1 Identification of Insignificant Activities

3.2 Compliance with Applicable Requirements

3.3 Addition of Insignificant Activities

4.0 SIGNIFICANT EMISSION UNITS AT THIS SOURCE 9

5.0 OVERALL SOURCE CONDITIONS 13

5.1 Source Description

5.2 Applicable Regulations

5.3 Non-Applicability of Regulations of Concern

5.4 Source-Wide Operational and Production Limits and Work 

Practices

5.5 Source-Wide Emission Limitations

5.6 General Recordkeeping Requirements

5.7 General Reporting Requirements

5.8 General Operational Flexibility/Anticipated Operating 

Scenarios

5.9 General Compliance Procedures

6.0 NOT APPLICABLE TO THIS PERMIT 18

7.0 UNIT SPECIFIC CONDITIONS 19

7.1 Unit 01 Cement Plant

7.2 Unit 02 Fugitive Emissions

8.0 GENERAL PERMIT CONDITIONS 36

8.1 Permit Shield

8.2 Applicability of Title IV Requirements

8.3 Emissions Trading Programs

8.4 Operational Flexibility/Anticipated Operating Scenarios

8.5 Testing Procedures

8.6 Reporting Requirements

8.7 Obligation to Comply with Title I Requirements
3

PAGE

9.0 STANDARD PERMIT CONDITIONS 41

9.1 Effect of Permit

9.2 General Obligations of Permittee

9.3 Obligation to Allow Illinois EPA Surveillance

9.4 Obligation to Comply with Other Requirements

9.5 Liability

9.6 Recordkeeping

9.7 Annual Emissions Report

9.8 Requirements for Compliance Certification

9.9 Certification

9.10 Defense to Enforcement Actions

9.11 Permanent Shutdown

9.12 Reopening And Reissuing Permit For Cause

9.13 Severability Clause

9.14 Permit Expiration and Renewal

10.0 ATTACHMENTS

10.1 Attachment 1 – Applicable New Source Performance 

standards (NSPS)

1-1

10.2 Attachment 2 - Applicable National Emission Standards 

for Hazardous Air Pollutants (NESHAP)

2-1

10.3 Attachment 3 - Applicable Regulations from 35 Illinois 

Administrative Code, Subtitle B: Air 

Pollution, Chapter I: Pollution Control 

Board

3-1

10.4 Attachment 4 - State Construction and Operating Permits 4-1

10.5 Attachment 5 - Example Certification by a Responsible 

Official

5-1

10.6 Attachment 6 - Guidance on Revising This Permit 6-1

10.7 Attachment 7 – Form 199-CAAPP, Application For 

Construction Permit (For CAAPP Sources 

Only)

7-1

10.8 Attachment 8 - Guidance on Renewing This Permit 8-1
4

1.0 SOURCE IDENTIFICATION

1.1 Source

LaFarge Midwest, Inc.

2500 Portland Road

Grand Chain, Illinois 62941

618/543-7541

I.D. No.: 127855AAA

Standard Industrial Classification: 3241, Cement Manufacturing

1.2 Owner/Parent Company

LaFarge Midwest, Inc. – U.S. Cement Region

400 Town Center, Suite 2000, P.O. Box 887

Southfield, Michigan 48075

1.3 Operator

LaFarge Midwest, Inc.

2500 Portland Road

Grand Chain, Illinois 62941

Ron Ryan

618/543-7541

1.4 General Source Description

Lafarge’s Joppa facility manufactures Portland Cement. Raw 

materials include sources of calcium, iron, silica, and alumina. 

The raw materials are ground into a fine mix and are introduced 

into a rotary kiln and exposed to temperatures near 3000°F. In 

the kiln, the four primary ingredients melt together and undergo 

chemical and mineralogical changes to produce an interim product 

called clinker. This clinker is a hard, black, glassy compound 

which does not resemble the raw materials. Gypsum is added to 

the clinker and the materials are ground to a fine powder which 

is the final product - Portland Cement.

Depending on the proportions of the original raw materials, the 

duration and intensity of the kiln processing, and the parameters 

set during grinding, different cements are produced with 

distinctly different capabilities and uses.

The manufacturing process consists of the following activities:

Raw material receiving; Raw material storage; Raw material 

reclaim; Raw material grinding; Raw material storage and kiln 

feed; Pyroprocessing (kilns); Clinker storage; Clinker reclaim; 

Clinker grinding; Cement storage and Cement loadout.
5

2.0 LIST OF ABBREVIATIONS/ACRONYMS USED IN THIS PERMIT

Act Illinois Environmental Protection Act [415 ILCS 5/1 et seq.]

AP-42 Compilation of Air Pollutant Emission Factors, Volume 1, 

Stationary Point and Other Sources (and Supplements A 

through F), USEPA, Office of Air Quality Planning and 

Standards, Research Triangle Park, NC 27711

ACMA Alternative Compliance Market Account

ATUs Allotment Trading Units

BAT Best Available Technology

Btu British thermal unit

°C Degrees Celsius

CAA Clean Air Act [42 U.S.C. Section 7401 et seq.]

CAAPP Clean Air Act Permit Program

CAM Compliance Assurance Monitoring

CFR Code of Federal Regulations

CO Carbon Monoxide

Cm Centimeter

ERMS Emission Reduction Market System

°F Degrees Fahrenheit

Ft2 Feet square

ft3 Cubic foot

gal Gallon

Gm Gram

HAP Hazardous Air Pollutant

Hp Horse power

hr Hour

IAC Illinois Administrative Code

I.D. No. Identification Number of Source, assigned by Illinois EPA

Illinois EPA Illinois Environmental Protection Agency

In Inch

°K degrees Kelvin

Kg kilo gram

KW Kilowatts

kpa Kilopascals

lb Pound

MACT Maximum Available Control Technology

mmcf Million cubic feet

MG Mega Gram

M Meter

mmBtu Million British thermal units

mmHg Millimeters of mercury

mo Month

MW Mega Watts

NOx Nitrogen Oxides

NSPS New Source Performance Standards

OM Organic Material

PM Particulate Matter

PM10 Particulate matter with an aerodynamic diameter less than or 

equal to a nominal 10 microns as measured by applicable test 

or monitoring methods
6

ppm parts per million

PSD Prevention of Significant Deterioration

psia Pounds per square inch absolute

RMP Risk Management Plan

scf Standard cubic foot

SO2 Sulfur Dioxide

T Ton

T1 Title I - identifies Title I conditions that have been 

carried over from an existing permit

T1N Title I New – identifies Title I conditions that are being 

established in this permit

T1R Title I Revised – identifies Title I conditions that have 

been carried over from an existing permit and subsequently 

revised in this permit

USEPA United States Environmental Protection Agency

VOL Volatile Organic Liquid

VOM Volatile Organic Material

wt. Weight

yr Year
7

3.0 INSIGNIFICANT ACTIVITIES

3.1 Identification of Insignificant Activities

The following activities at the source constitute insignificant 

activities as specified in 35 IAC 201.210:

3.1.1 Activities determined by the Illinois EPA to be 

insignificant activities, pursuant to 35 IAC 201.210(a)(1) 

and 201.211, as follows:

None

3.1.2 Activities that are insignificant activities based upon 

maximum emissions, pursuant to 35 IAC 201.210(a)(2) or 

(a)(3), as follows:

1 Grinding Aid Tank, 12,000 Gallons (JT-6)

1 Flambinder Tank, 12,000 Gallons (JT-9)

1 Water Tower Additive Tank (JT-11)

1 Chlorine Tank (JT-12)

1 Chemtron Tank-Liquid CO2 (JT-13)

3.1.3 Activities that are insignificant activities based upon 

their type or character, pursuant to 35 IAC 201.210(a)(4) 

through (18), as follows:

Number of 

Activities Activity Description

35 IAC 

Regulatory 

Citation

 1 #1 Kiln Emergency Drive Diesel 

Generator (J-42)

201.210(a)(16)

 1 Natural Gas Space Heater

(J-89)

201.210(a)(4A)

15 Kerosene Space Heaters (J-90) 201.210(a)(4B)

 1 Kerosene Tank, 550 Gallons 

(JT-3)

201.210(a)(11)

 1 Diesel Tank #2, 1,650 Gallons 

(JT-4)

201.210(a)(11)

 1 Gasoline Tank, 850 Gallons 

(JT-5)

201.210(a)(11)

 1 Used oil Tank, 2,000 Gallons 

(JT-7)

201.210(a)(11)

 1 Diesel Tank #3, 2,500 Gallons 

(JT-8)

201.210(a)(11)

 1 Portable Diesel Tank, 240 

Gallons (JT-10)

201.210(a)(11)

3.1.4 The Permittee has activities that are considered 

insignificant activities pursuant to 35 IAC 201.210(b).
8

3.2 Compliance with Applicable Requirements

Insignificant activities are subject to applicable requirements 

notwithstanding status as insignificant activities. In 

particular, in addition to regulations of general applicability, 

such as 35 IAC 212.301 and 212.123 (Condition 5.2.2), the 

Permittee shall comply with the following requirements, as 

applicable:

3.2.1 For each cold cleaning degreaser, the Permittee shall 

comply with the applicable equipment and operating 

requirements of 35 IAC 215.182, 218.182, or 219.182.

3.2.2 For each particulate matter process emission unit, the 

Permittee shall comply with the applicable particulate 

matter emission limit of 35 IAC 212.321 or 212.322. For 

example, the particulate matter emissions from a process 

emission unit shall not exceed 0.55 pounds per hour if the 

emission unit’s process weight rate is 100 pounds per hour 

or less, pursuant to 35 IAC 266.110.

3.2.3 For each organic material emission unit that uses organic 

material, e.g., a mixer or printing line, the Permittee 

shall comply with the applicable VOM emission limit of 35 

IAC 215.301, 218.301, or 219.301, which requires that 

organic material emissions not exceed 8.0 pounds per hour 

or do not qualify as photochemically reactive material as 

defined in 35 IAC 211.4690.

3.3 Addition of Insignificant Activities

3.3.1 The Permittee is not required to notify the Illinois EPA 

of additional insignificant activities present at the 

source of a type that is identified in Condition 3.1, 

until the renewal application for this permit is 

submitted, pursuant to 35 IAC 201.212(a).

3.3.2 The Permittee must notify the Illinois EPA of any proposed 

addition of a new insignificant activity of a type 

addressed by 35 IAC 201.210(a) and 201.211 other than 

those identified in Condition 3.1, pursuant to Section 

39.5(12)(b) of the Act.

3.3.3 The Permittee is not required to notify the Illinois EPA 

of additional insignificant activities present at the 

source of a type identified in 35 IAC 201.210(b).
9

4.0 SIGNIFICANT EMISSION UNITS AT THIS SOURCE*

Emission 

Unit

Plant 

Designation 

of Emission 

Unit Emission Unit Name

Control Equipment 

Name**

J-1a Raw Material Unloading from 

Barge

N/A

J-1b Clinker Unloading from Barge Barge Unloading 

Hopper DC

J-2 Raw Material Transfer from #9 

Belt to #10 Belt

N/A

J-3 Raw Material Transfer from 

#10 Belt to #11 Belt and From 

#11 Belt to #12 or #13 Belts

N/A

J-5 Raw Material Transfer from 

#12a Belt to Outside Storage

N/A

J-7 Reclaim of Outside Materials 

at Receiving Hopper South of 

Administrative Building

N/A

J-9 Rock/Sand Transfer from #13 

Belt Tripper to South 

Rock/Sand Storage

N/A

J-11 Rock/Sand Transfer from #14 

Belt Tripper to North 

Rock/Sand Storage

N/A

J-12 Raw Material Transfer from 

#14 Belt and/or #18 Belt to 

#19 Belt and from #19 Belt to 

Storage Hall

N/A

J-16 FCC Tank FCC Tank DC

J-17 #1 Raw Mill (Grinding and 

Combustion Emissions)

#1 Raw Mill - North 

DCs #1 and #2, 

South DCs #1 and 

#2, and Auxiliary 

DC

J-21 #2 Raw Mill (Grinding and 

Combustion Emissions)

#2 Raw Mill -

Utility DC #2 and 

Air Separator DC #1

J-23 #2 Raw Mill - FK Pump Hopper #2 Raw Mill - FK 

Pump Hopper DC #6

J-25 Blending Silo #1 Blending Silo #1 DC

J-26 Blending Silo #2 Blending Silo #2 DC

J-27 Blending Silo #3 Blending Silo #3 DC

J-28 Blending Silo #4 Blending Silo #4 DC

J-39 #1 Kiln Schenck Feed Tank Schenck Feed Tank 

DC

J-41 #1 Kiln #1 Kiln ESP

J-43 #1 Clinker Cooler #1 Clinker Cooler 

DC

01

J-44 #1 Kiln Clinker Elevator and 

Transfers from the Elevator 

to #26 and #30 Belts

#1 Clinker Elevator 

Utility DC
10

Emission 

Unit

Plant 

Designation 

of Emission 

Unit Emission Unit Name

Control Equipment 

Name**

J-45 #2 Kiln Feed Tank #2 Kiln Feed Tank 

DC

J-46 #2 Kiln Flowmeter #2 Kiln Flowmeter 

DC

J-47 #2 Kiln #2 Kiln Baghouse

J-49a Waste Dust Tank Waste Dust Tank DC

J-49b Waste Dust Load-Out Spout Load-Out Spout DC

J-50 #2 Clinker Cooler #2 Clinker Cooler 

Gravel Bed Filter 

and #2 Clinker 

Cooler Vent DC

J-51 #2 Kiln Clinker Elevator and 

Transfers from the Elevator 

to #27 and #31 Belts

#2 Clinker Elevator 

Utility DC

J-52 Transfer to Outside Clinker 

Reclaim Hopper Then to #1 

Belt

N/A

J-53 Outside Clinker Crusher 

(Emissions from Crusher, 

Screen, and Transfers to and 

from Crusher and Screen)

Outside Clinker 

Crusher DC

J-54 Transfer from #2 Belt to 

Clinker Storage Hall

N/A

J-55 Transfer from #31 Belt to #32 

Belt

Transfer from #31 

Belt to #32 Belt DC

J-56 #32 Belt Discharge #32 Belt Discharge 

and DC

J-57/58 Clinker Feed from #26 and #27 

to #28 Belt in Storage Hall

Clinker Feed from 

#26 and #27 to #28 

Belt DC

J-59 Clinker Feed to Storage Hall 

(From #28 Belt and/or #32 

Belt)

N/A

J-60 Feed from Bucket Elevator to 

#7 Belt

N/A

J-61 Feed from #7 Belt N/A

J-62 Clinker Transfer - Storage to 

#5 Belt

Transfer to #5 Belt 

DC

J-64/65 Clinker Transfer - #5 Belt to 

#6 Belt; #6 Belt to Bucket 

Elevator

Transfer from #6 

Belt to Bucket 

Elevator DC

J-67 Clinker Bins Discharge to 

Feed Belts and Transfer from 

Feed Belts to #22 Belt

Clinker Bins 

Discharge to Feed 

Belts and Transfer 

from Feed Belts to 

#22 Belt DC #4

01 

(Cont.)

J-69 Clinker/Gypsum Transfer to 

#23 Belt

Clinker/Gypsum 

Transfer to #23 

Belt DC #5
11

Emission 

Unit

Plant 

Designation 

of Emission 

Unit Emission Unit Name

Control Equipment 

Name**

J-70 #1 Finish Mill #1 Finish Mill -

North Main DC #1 

and Auxiliary DC #3

J-71 #1 Finish Mill - FK Pump 

Hopper

#1 Finish Mill - RK 

Pump Hopper DC

J-74 Clinker/Gypsum Transfer #39 

Belt

Clinker/Gypsum 

Transfer to #39 

Belt DC

J-75 #39 Belt Discharge #39 Belt Discharge 

DC

J-76 #2 Finish Mill #2 Finish Mill -

Vent DC

J-77 #2 Finish Mill - FK Pump 

Hopper

#2 Finish Mill - FK 

Pump Hopper DC

J-78 Group #1 (West) Cement Silos Group #1 (West) 

Cement Silo Fill 

Vent DC

J-79 Group #2 (East) Cement Silos Group #2 (East) 

Cement Silo Fill 

Vent DC

J-80 Upstream Barge Cement Loading 

Spout

Upstream Barge 

Cement Load Out DC

J-81 Downstream Barge Cement 

Loading Spout

Downstream Barge 

Cement Load Out DC

J-82 Group #1 Cement Silos East 

Truck Load Out

Group #1 Cement 

Silos East Truck 

Load Out DC #1

J-83 Group #1 Cement Silos West 

Truck Load Out

Group #1 Cement 

Silos West 

Truck/Railroad Load 

Out DC #2

J-84 Group #1 Cement Silos West 

Truck/Railroad Load Out

Group #1 Cement 

Silos East 

Truck/Railroad Load 

Out DC #3

J-85 Group #1 Cement Silos East 

Truck/Railroad Load Out

Group #1 Cement 

Silos East 

Truck/Railroad Load 

Out DC #4

J-86 Group #2 Cement Silos Truck 

Load Out

Group #2 Cement 

Silos Truck Load 

Out DC #4

J-95 #2 Kiln Back-Up Feed System Schenck Feed Tank 

DC

J-96 #1 Clinker Cooler Ray-Jet 

Burner

#1 Kiln Indirect 

Firing System DC

J-97 #2 Clinker Cooler Ray-Jet 

Burner

#2 Kiln Indirect 

Firing System DC

01 

(Cont.)

J-106 Raw Material Stacker N/A
12

Emission 

Unit

Plant 

Designation 

of Emission 

Unit Emission Unit Name

Control Equipment 

Name**

J-107 Portable Clinker Stacker N/A

J-108 #2 Kiln Dust Return System #2 Kiln Dust Return 

System DC

J-111 Cement Surge Bin Cement Surge Bin DC

J-112 Cement Fringe Bin Cement Fringe Bin 

DC

01 

(Cont.)

J-113 #2 Finish Mill Air Separator Air Separator DC

J-100 Handling of Materials Stored 

Outside

---

J-101 Alternate Raw/Intermediate 

Material Unloading

---

J-102 Material Transfers Without 

100 Percent Capture 

Efficiencies

---

J-103 Storage Piles ---

J-104 Unpaved Haul Roads ---

02

J-105 Paved Haul Roads ---

* The above list of emission units may not include units 

constructed after the submittal of the original application. 

However, any such units are identified in the attached state 

construction and operating permits that are incorporated here in 

(see Attachment 4). These units are permitted to operate under 

this permit in accordance with the conditions of these attached 

permits. This list will be revised to include such units in 

subsequent reopening of this permit in accordance with the timely 

submittal of the necessary information.

** In this column DC is for Dust Collector
13

5.0 OVERALL SOURCE CONDITIONS

5.1 Source Description

5.1.1 This permit is issued based on the source requiring a 

CAAPP permit as a major source of NOx, PM, SO2 and HAP 

emissions.

5.2 Applicable Regulations

5.2.1 Specific emission units at this source are subject to 

particular regulations as set forth in Section 7 (UnitSpecific Conditions) of this permit.

5.2.2 In addition, emission units at this source are subject to 

the following regulations of general applicability:

a. No person shall cause or allow the emission of 

fugitive particulate matter from any process, 

including any material handling or storage activity, 

that is visible by an observer looking generally 

overhead at a point beyond the property line of the 

source unless the wind speed is greater than 40.2 

kilometers per hour (25 miles per hour), pursuant to 

35 IAC 212.301 and 212.314.

b. No person shall cause or allow the emission of smoke 

or other particulate matter, with an opacity greater 

than 30 percent, into the atmosphere from any 

emission unit other than those emission units subject 

to the requirements of 35 IAC 212.122, pursuant to 35 

IAC 212.123(a), except as allowed by 35 IAC 

212.123(b) and 212.124.

5.2.3 Ozone Depleting Substances

The Permittee shall comply with the standards for 

recycling and emissions reduction of ozone depleting 

substances pursuant to 40 CFR Part 82, Subpart F, except 

as provided for motor vehicle air conditioners in Subpart 

B of 40 CFR Part 82:

a. Persons opening appliances for maintenance, service, 

repair, or disposal must comply with the required 

practices pursuant to 40 CFR 82.156.

b. Equipment used during the maintenance, service, 

repair, or disposal of appliances must comply with 

the standards for recycling and recovery equipment 

pursuant to 40 CFR 82.158.

c. Persons performing maintenance, service, repair, or 

disposal of appliances must be certified by an 
14

approved technician certification program pursuant to 

40 CFR 82.161.

5.2.4 Risk Management Plan

Should this stationary source, as defined in 40 CFR 

Section 68.3, become subject to the Accidental Release 

Prevention regulations in 40 CFR Part 68, then the owner 

or operator shall submit [40 CFR 68.215(a)(2)(i) and 

(ii)]:

a. A compliance schedule for meeting the requirements of 

40 CFR Part 68 by the date provided in 40 CFR 

68.10(a); or

b. A certification statement that the source is in 

compliance with all requirements of 40 CFR Part 68, 

including the registration and submission of the Risk 

Management Plan (RMP), as part of the annual 

compliance certification required by 40 CFR Part 70 

or 71.

5.2.5 a. Should this stationary source become subject to a 

regulation under 40 CFR Parts 60, 61, or 63, or 35 

IAC after the date issued of this permit, then the 

owner or operator shall, in accordance with the 

applicable regulation(s), comply with the applicable 

requirements by the date(s) specified and shall 

certify compliance with the applicable requirements 

of such regulation(s) as part of the annual 

compliance certification, as required by 40 CFR Part 

70 or 71.

b. No later than upon the submittal for renewal of this 

permit, the owner or operator shall submit, as part 

of an application, the necessary information to 

address either the non-applicability of, or 

demonstrate compliance with all applicable 

requirements of any potentially applicable regulation 

which was promulgated after the date issued of this 

permit.

5.2.6 Episode Action Plan

a. The source is required to have an episode action plan 

pursuant to 35 IAC 244.142, the Permittee shall 

maintain at the source and have on file with the 

Illinois EPA a written episode action plan (plan) for 

reducing the levels of emissions during yellow 

alerts, red alerts, and emergencies, consistent with 

safe operating procedures. The plan shall contain 

the information specified in 35 IAC 244.144.
15

b. The Permittee shall immediately implement the 

appropriate steps described in this plan should an 

air pollution alert or emergency be declared.

c. If a change occurs at the source which requires a 

revision of the plan (e.g., operational change, 

change in the source contact person), a copy of the 

revised plan shall be submitted to the Illinois EPA 

for review within 30 days of the change. Such plans 

shall be further revised if disapproved by the 

Illinois EPA.

d. For sources required to have a plan pursuant to 35 

IAC 244.142, a copy of the original plan and any 

subsequent revisions shall be sent to Illinois EPA, 

Compliance Section.

5.2.7 CAM Plan

This stationary source has a pollutant-specific emissions 

unit that is subject to 40 CFR Part 64, Compliance 

Assurance Monitoring (CAM) for Major Stationary Sources. 

The source must submit a CAM plan for each affected 

pollutant-specific emissions unit upon application for 

renewal of the initial CAAPP permit, or upon a significant 

modification to the CAAPP permit for the construction or 

modification of a large pollutant-specific emissions unit 

which has the potential post-control device emissions of 

the applicable regulated air pollutant that equals or 

exceeds major source threshold levels.

5.3 Non-Applicability of Regulations of Concern

None

5.4 Source-Wide Operational and Production Limits and Work Practices

In addition to the source-wide requirements in the Standard 

Permit Conditions in Section 9, the Permittee shall fulfill the 

following source-wide operational and production limitations 

and/or work practice requirements:

None

5.5 Source-Wide Emission Limitations

5.5.1 Permitted Emissions for Fees

Emission limitations are not set for this source for the 

purpose of permit fees. The Permittee shall be required 

to pay the maximum fee of $100,000.00 per year, pursuant 

to Section 39.5(18)(a)(ii)(A) of the Act.
16

5.5.2 Emissions of Hazardous Air Pollutants

Source-wide emission limitations for HAPs as listed in 

Section 112(b) of the CAA are not set. This source is 

considered to be a major source of HAPs.

5.5.3 Other Source-Wide Emission Limitations

Other source-wide emission limitations are not set for 

this source pursuant to either the federal rules for 

Prevention of Significant Deterioration (PSD), 40 CFR 

52.21, Illinois EPA rules for Major Stationary Sources 

Construction and Modification, 35 IAC Part 203, or Section 

502(b)(10) of the CAA. However, there may be unit 

specific emission limitations set forth in Section 7 of 

this permit pursuant to these rules.

5.6 General Recordkeeping Requirements

5.6.1 Emission Records

The Permittee shall maintain records of the following 

items for the source to demonstrate compliance with 

Condition 5.5.1, pursuant to Section 39.5(7)(b) of the 

Act:

Total annual emissions on a calendar year basis for the 

emission units covered by Section 7 (Unit Specific 

Conditions) of this permit.

5.6.5 Records for Operating Scenarios

N/A

5.6.6 Retention and Availability of Records

a. All records and logs required by this permit shall be 

retained for at least five years from the date of 

entry (unless a longer retention period is specified 

by the particular recordkeeping provision herein), 

shall be kept at a location at the source that is 

readily accessible to the Illinois EPA or USEPA, and 

shall be made available for inspection and copying by 

the Illinois EPA or USEPA upon request.

b. The Permittee shall retrieve and print, on paper 

during normal source office hours, any records 

retained in an electronic format (e.g., computer) in 

response to an Illinois EPA or USEPA request for 

records during the course of a source inspection.
17

5.7 General Reporting Requirements

5.7.1 General Source-Wide Reporting Requirements

The Permittee shall promptly notify the Illinois EPA, 

Compliance Section, of deviations of the source with the 

permit requirements as follows, pursuant to Section 

39.5(7)(f)(ii) of the Act. Reports shall describe the 

probable cause of such deviations, and any corrective 

actions or preventive measures taken.

5.7.2 Annual Emissions Report

The annual emissions report required pursuant to Condition 

9.7 shall contain emissions information for the previous 

calendar year.

5.8 General Operational Flexibility/Anticipated Operating Scenarios

N/A

5.9 General Compliance Procedures

5.9.1 General Procedures for Calculating Emissions

Compliance with the source-wide emission limits specified 

in Condition 5.5 shall be based on the recordkeeping and 

reporting requirements of Conditions 5.6 and 5.7, and 

compliance procedures in Section 7 (Unit Specific 

Conditions) of this permit.
18

6.0 NOT APPLICABLE TO THIS PERMIT
19

7.0 UNIT SPECIFIC CONDITIONS

7.1 Unit 01: Cement Plant

7.1.1 Description

Raw Material Receiving:

Raw materials are received at the facility primarily by 

barge, but are also received by truck, pneumatic pipeline, 

and potentially by rail. Typical raw materials include 

(but are not limited to) limestone, sand, clay, gypsum, 

bottom ah, fly ash, iron oxide, mill scale, iron slag, 

shale, alumina, spent industrial catalysts, foundry sand, 

coal tailings, and fuels such as coal and/or petroleum 

coke. Raw materials unloaded also include purchased 

clinker.

Materials can be transferred from barges in several ways:

Clam-shell crane transfer to Lafarge conveyor system; Self 

unloading barge transfer to Lafarge conveyor system

(self-unloading barges have built-in conveyors to unload 

materials); Clam-shell crane transfer to river-side 

storage piles with subsequent transfer to appropriate 

storage areas using end-loader and/or trucks; Certain raw 

materials, such as flay-ash or other powdered materials, 

can also be pneumatically conveyed directly to storage 

tanks from trucks, or, in one case, via a permanent 

pipeline from an adjoining power plant.

Raw Material Storage:

Raw materials re stored in several areas: Outside storage 

piles; Covered storage piles; Concrete storage bins; 

Enclosed steel storage tanks. In general, the larger 

shipments are stored either in the outside or covered 

storage piles where the materials can be gradually 

reclaimed for use.

Raw Material Reclaim:

Materials are reclaimed from storage by several methods.

Materials can be transferred via end-loader and/or truck 

from covered storage piles or outside storage piles to one 

of several reclaim hoppers that feed various conveyors. 

Lafarge can also operate portable belts to transfer 

materials to many locations on the conveyor system. It 

should be noted that the reclaim hoppers and portable 

belts could also be used to transfer purchased materials 

directly to the conveyor system from trucks.
20

Materials from inside storage can feed directly to 

conveyors via vibratory feeders located under the covered 

storage hall.

Materials stored in bins and tanks are fed directly to the 

conveyor system.

Raw Material Grinding:

Materials are fed to the raw mill system by conveyors. 

The raw materials used by Lafarge are typically coarse and 

wet. The raw materials are fed into one of two 3,000 

horsepower Nordberg ball mills (referred to as #1 Raw Mill 

and #2 Raw Mill), where hot dry gas recovered from the 

kiln systems (and supplemented as by natural gas furnaces) 

is drawn through the grinding system as the raw materials 

are ground. The raw mills mix and grind the raw materials 

to a fine consistency.

The typical feed to the raw mill consists of approximately 

90 percent limestone with the balance made of sand, clay, 

mill scale, bottom ash, fly ash, and other materials. In 

general, all raw material is added here with the exception 

of gypsum and clinker. However, manufacturing 

specifications may require the addition of gypsum or 

clinker into the raw mills. To assist in the grinding 

process, a liquid grinding aid is sometimes injected into 

the raw mills.

The supply air to the raw mills can be heated to facilitate 

drying. Pre-heated supply air for the #2 Raw Mill can be

drawn from the #2 Clinker Cooler exhaust. For both raw 

mills, further heating of the supply air is performed as 

needed by direct-fire, natural gas furnaces.

The raw mills are air swept. Material in the raw mills is 

recycled through the mills via air conveyance, air 

separators, screw conveyors, and/or belt conveyors. As 

the materials are ground to the desired particle size, 

they are removed in the air separators. The resulting 

mixture, often referred to as kiln feed, is pneumatically 

conveyed to four storage silos located near the feed and 

of the kilns.

Kiln Feed Storage and Transfer to Kilns:

Kiln feed from the raw mill system is pneumatically 

conveyed to four large storage and blending silos located 

near the feed end of the kilns. Kiln feed is then

transferred to smaller surge tanks before transfer to the 

kilns. One feed tank, the #2 Kiln feed tank, currently 

can feed only the #2 Kiln. However, another surge tank, 

the “Schenck Feed Tank” that typically feeds to the #1 
21

Kiln, can actually feed to either kiln as part of a backup feed system to either kiln.

A hopper and conveyor system at the feed end of the kilns 

allows reclaim of outside materials (typically clinker) at 

the feed end of the kilns.

Coal and Coke Tank Filling Flow:

Coal and (petroleum) coke is transferred from covered 

storage via a system of vibratory feeders, conveyors, and 

a bucket elevator. As a last step before being 

transferred to the coal or coke tanks, the fuel is crushed 

in an enclosed coal and coke crusher.

Pyroprocessing (Kilns):

Kiln Feed Flow

Both kilns at the Joppa facility are long dry kilns. Each 

kiln is essentially a slightly inclined rotating cylinder. 

Raw kiln feed is introduced into the uphill end of each 

kiln while fuel and air is introduced into the downhill 

end. As the kiln rotates, the raw feed and combustion air 

flow counter-current.

In the #1 Kiln, kiln feed is introduced directly into the 

kiln via a bucket elevator. The #2 Kiln, on the other 

hand, is equipped with a 1-stage preheater, where the raw 

kiln feed is introduced into a series of cyclones. In the 

cyclones, the material flows counter-current with the kiln 

exhaust, thus recovering heat from the exhaust gases to 

preheat the raw feed.

Once in the kilns, the materials undergo complex chemical 

and physical changes. The ratio of raw kiln feed to kiln 

product (clinker) ranges between 1.5:1 and 1.6:1. This 

loss during pyroprocessing results from moisture being 

driven off as well as chemical reactions yielding gaseous 

products.

As the clinker leaves the kiln, it resembles road gravel 

in size and consistency, with most material typically on 

the order of one-half to one inch in diameter.

The clinker is fed directly from the kiln to the clinker 

cooler, where it is air-cooled. In the clinker cooler, 

the clinker travels across grates as air is blown upward 

through the product.

The clinker is transferred via belt conveyors from the 

clinker cooler to storage to await grinding.
22

Fuel Combustion:

The kiln fuel consists typically of coal or petroleum 

coke. In the future, Lafarge may also fire tire derived 

fuel in either kiln. The fuel, which has been transferred 

to steel tanks, is transferred by conveyors to coal mills 

where it is milled to a consistency that can be 

pneumatically transferred. The fuel is pneumatically 

transferred to storage tanks at the top of the kiln burner 

building. The transfer air is de-dusted by one of two 

baghouses (one for each kiln system). From these storage 

tanks, the pulverized coal is pneumatically injected into 

the kiln. Transfer air for fuel injection into the kiln 

is carefully controlled to optimize the combustion 

conditions. In addition to the transfer air, combustion 

air is injected at various locations in the burner to 

achieve optimum flame control.

Clinker Storage:

Clinker from the clinker coolers is transferred via 

conveyors either to covered storage piles, covered storage 

bins, or directly to the steel feed tanks associated with 

the finish mill feed systems. From the covered storage 

piles, clinker can be transferred as needed to outside 

storage piles for long-term storage.

Clinker Reclaim:

From outside storage piles, clinker can be trucked to 

outside crusher/reclaim systems. From covered storage 

piles, reclaimed clinker an be transferred via conveyors 

to the concrete bins that feed the #1 Finish Mill system 

or the steel tanks that feed the #2 Finish Mill system.

Clinker Grinding:

Clinker and gypsum are introduced into the ball mills at a 

typical ratio of approximately 95:5.

Finish mill operation is very similar to raw mill 

operation. The finish mills re air swept. Material in 

the finish mills is recycled through the mills via air 

conveyance, air separators, screw conveyors, and/or belt 

conveyors. As the materials are ground to the desired 

particle size, they re removed in the air separators. The 

resulting product, which is finished cement, is 

pneumatically conveyed to the storage silos.

To assist in the grinding process, water and a liquid 

grinding aid are injected into the finish mills 

themselves.
23

Cement Storage and Loadout:

Cement is conveyed pneumatically from the finish mill air 

separators to several storage silos. From each storage 

silo, the cement can be further transferred either to 

other storage silos, to trucks, or to barges. All 

conveyance of finished cement is pneumatic.

7.1.2 List of Emission Units and Pollution Control Equipment*

Plant 

Designation 

of Emission 

Unit

Emission Unit 

Name

Control 

Equipment 

Name**

Date of 

Construction***

J-1a Raw Material 

Unloading from 

Barge

N/A 1998

J-1b Clinker 

Unloading from 

Barge

Barge Unloading 

Hopper DC

1999

J-2 Raw Material 

Transfer from #9 

Belt to #10 Belt

N/A 1960

J-3 Raw Material 

Transfer from 

#10 Belt to #11 

Belt and From 

#11 Belt to #12 

or #13 Belts

N/A 1960

J-5 Raw Material 

Transfer from

#12a Belt to 

Outside Storage

N/A Post 1990

J-7 Reclaim of 

Outside 

Materials at 

Receiving Hopper 

South of 

Administrative 

Building

N/A 1960

J-9 Rock/Sand 

Transfer from 

#13 Belt Tripper 

to South 

Rock/Sand 

Storage

N/A 1960

J-11 Rock/Sand 

Transfer from 

#14 Belt Tripper 

to North 

Rock/Sand 

Storage

N/A 1960
24

Plant 

Designation 

of Emission 

Unit

Emission Unit 

Name

Control 

Equipment 

Name**

Date of 

Construction***

J-12 Raw Material 

Transfer from 

#14 Belt and/or 

#18 Belt to #19 

Belt and from 

#19 Belt to 

Storage Hall

N/A 1960

J-16 FCC Tank FCC Tank DC 1960

J-17 #1 Raw Mill 

(Grinding and 

Combustion 

Emissions)

#1 Raw Mill -

North DCs #1 

and #2, South 

DCs #1 and #2, 

and Auxiliary 

DC

1960, Upgraded 

Baghouses 1994

J-21 #2 Raw Mill 

(Grinding and 

Combustion 

Emissions)

#2 Raw Mill -

Utility DC #2 

and Air 

Separator DC #1

1976

J-23 #2 Raw Mill - FK 

Pump Hopper

#2 Raw Mill -

FK Pump Hopper 

DC #6

1976, added 

Baghouse 1980

J-25 Blending Silo #1 Blending Silo 

#1 DC

1960, Baghouse 

Replaced 1979

J-26 Blending Silo #2 Blending Silo 

#2 DC

1960, Baghouse 

Replaced 1979

J-27 Blending Silo #3 Blending Silo 

#3 DC

1960, Baghouse 

Replaced 1979

J-28 Blending Silo #4 Blending Silo 

#4 DC

1960, Baghouse 

Replaced 1979

J-39 #1 Kiln Schenck 

Feed Tank

Schenck Feed 

Tank DC

1980

J-41 #1 Kiln #1 Kiln ESP 1960, Replaced 

#1 & #1A ESPs 

with #2 ESP

J-43 #1 Clinker 

Cooler

#1 Clinker 

Cooler DC

1960

J-44 #1 Kiln Clinker 

Elevator and 

Transfers from 

the Elevator to 

#26 and #30 

Belts

#1 Clinker 

Elevator 

Utility DC

1960, New 

Control Added

J-45 #2 Kiln Feed 

Tank

#2 Kiln Feed 

Tank DC

1992

J-46 #2 Kiln 

Flowmeter

#2 Kiln 

Flowmeter DC

1992

J-47 #2 Kiln #2 Kiln 

Baghouse

1975
25

Plant 

Designation 

of Emission 

Unit

Emission Unit 

Name

Control 

Equipment 

Name**

Date of 

Construction***

J-49a Waste Dust Tank Waste Dust Tank 

DC

1997

J-49b Waste Dust LoadOut SpoutLoad-Out Spout 

DC

1975

J-50 #2 Clinker 

Cooler

#2 Clinker 

Cooler Gravel 

Bed Filter and 

#2 Clinker 

Cooler Vent DC

1975

J-51 #2 Kiln Clinker 

Elevator and 

Transfers from 

the Elevator to 

#27 and #31 

Belts

#2 Clinker 

Elevator 

Utility DC

1977

J-52 Transfer to 

Outside Clinker 

Reclaim Hopper 

Then to #1 Belt

N/A 1977

J-53 Outside Clinker 

Crusher 

(Emissions from 

Crusher, Screen, 

and Transfers to 

and from Crusher 

and Screen)

Outside Clinker 

Crusher DC

1977

J-54 Transfer from #2 

Belt to Clinker 

Storage Hall

N/A 1977

J-55 Transfer from 

#31 Belt to #32 

Belt

Transfer from 

#31 Belt to #32 

Belt DC

1975, Baghouse 

Added 1992

J-56 #32 Belt 

Discharge

#32 Belt 

Discharge and 

DC

1975, Baghouse 

Added 1992

J-57/58 Clinker Feed 

from #26 and #27 

to #28 Belt in 

Storage Hall

Clinker Feed 

from #26 and 

#27 to #28 Belt 

DC

1960, DC Added 

1998

J-59 Clinker Feed to 

Storage Hall 

(From #28 Belt 

and/or #32 Belt)

N/A 1975

J-60 Feed from Bucket 

Elevator to #7 

Belt

N/A 1975

J-61 Feed from #7 

Belt

N/A 1975
26

Plant 

Designation 

of Emission 

Unit

Emission Unit 

Name

Control 

Equipment 

Name**

Date of 

Construction***

J-62 Clinker Transfer 

- Storage to #5 

Belt

Transfer to #5 

Belt DC

1975, Ductwork 

Modified 1998

J-64/65 Clinker Transfer 

- #5 Belt to #6 

Belt; #6 Belt to 

Bucket Elevator

Transfer from 

#6 Belt to

Bucket Elevator 

DC

1977, Ductwork 

Modified 1998

J-67 Clinker Bins 

Discharge to 

Feed Belts and 

Transfer from 

Feed Belts to 

#22 Belt

Clinker Bins 

Discharge to 

Feed Belts and 

Transfer from 

Feed Belts to 

#22 Belt DC #4

1960

J-69 Clinker/Gypsum 

Transfer to #23 

Belt

Clinker/Gypsum 

Transfer to #23 

Belt DC #5

1960, Baghouse 

Added 1993

J-70 #1 Finish Mill #1 Finish Mill 

- North Main DC 

#1 and 

Auxiliary DC #3

1960, Baghouse 

Upgraded 1993

J-71 #1 Finish Mill -

FK Pump Hopper

#1 Finish Mill 

- RK Pump 

Hopper DC

1960, Baghouse 

Added 1993

J-74 Clinker/Gypsum 

Transfer #39 

Belt

Clinker/Gypsum 

Transfer to #39 

Belt DC

1975, Baghouse 

Added 1992

J-75 #39 Belt 

Discharge

#39 Belt 

Discharge DC

1975, Baghouse 

Added 1992

J-76 #2 Finish Mill #2 Finish Mill 

- Vent DC

1975, Baghouse 

Added 1992

J-77 #2 Finish Mill -

FK Pump Hopper

#2 Finish Mill 

- FK Pump 

Hopper DC

1975

J-78 Group #1 (West) 

Cement Silos

Group #1 (West) 

Cement Silo 

Fill Vent DC

1960

J-79 Group #2 (East) 

Cement Silos

Group #2 (East) 

Cement Silo 

Fill Vent DC

1960

J-80 Upstream Barge 

Cement Loading 

Spout

Upstream Barge 

Cement Load Out 

DC

1999

J-81 Downstream Barge 

Cement Loading 

Spout

Downstream 

Barge Cement 

Load Out DC

1999
27

Plant 

Designation 

of Emission 

Unit

Emission Unit 

Name

Control 

Equipment 

Name**

Date of 

Construction***

J-82 Group #1 Cement 

Silos East Truck 

Load Out

Group #1 Cement 

Silos East 

Truck Load Out 

DC #1

1960

J-83 Group #1 Cement 

Silos West Truck 

Load Out

Group #1 Cement 

Silos West 

Truck/Railroad 

Load Out DC #2

1960

J-84 Group #1 Cement 

Silos West 

Truck/Railroad 

Load Out

Group #1 Cement 

Silos East 

Truck/Railroad 

Load Out DC #3

1960

J-85 Group #1 Cement 

Silos East 

Truck/Railroad 

Load Out

Group #1 Cement 

Silos East 

Truck/Railroad 

Load Out DC #4

1960

J-86 Group #2 Cement 

Silos Truck Load 

Out

Group #2 Cement 

Silos Truck 

Load Out DC #4

1960

J-95 #2 Kiln Back-Up 

Feed System

Schenck Feed 

Tank DC

1988

J-96 #1 Clinker 

Cooler Ray-Jet 

Burner

#1 Kiln 

Indirect Firing 

System DC

1960

J-97 #2 Clinker 

Cooler Ray-Jet 

Burner

#2 Kiln 

Indirect Firing 

System DC

1975

J-106 Raw Material 

Stacker

N/A 1998

J-107 Portable Clinker 

Stacker

N/A 1999

J-108 #2 Kiln Dust 

Return System

#2 Kiln Dust 

Return System 

DC

1997

J-111 Cement Surge Bin Cement Surge 

Bin DC

1999

J-112 Cement Fringe 

Bin

Cement Fringe 

Bin DC

1999

J-113 #2 Finish Mill 

Air Separator

Air Separator 

DC

1999

* The above list of emission units may not include 

units constructed after the submittal of the original 

application. However, any such units are identified 

in the attached state construction and operating 

permits that are incorporated here in (see Attachment 

4). These units are permitted to operate under this 

permit in accordance with the conditions of these 
28

attached permits. This list will be revised to 

include such units in subsequent reopening of this 

permit in accordance with the timely submittal of the 

necessary information.

** In this column Dust Collector is abbreviated to DC

*** State Construction and Operating Permits (Attachment 4) 

provides dates of latest modification.

7.1.3 Applicability Provisions and Applicable Regulations

a. An “affected Cement Plant” for the purpose of these 

unit-specific conditions is an emission unit 

described in Conditions 7.1.1 and 7.1.2.

b. The affected Cement Plant is subject to the emission 

limits identified in Condition 5.2.2.

c. The affected Cement Plant is subject to 35 IAC Part 

212 Subpart L, Particulate Matter Emissions From 

Process Emission Sources. This regulation is 

attached hereto and incorporated herein by reference 

(see Attachment 3).

d. The affected Cement Plant is subject to 35 IAC Parts 

212.421 and 212.422, Subpart Q, Particulate Matter 

Emissions From Stone, Clay, Glass and Concrete 

Manufacturing. This regulation is attached hereto 

and incorporated herein by reference (see Attachment 

3).

e. The affected Cement Plant is subject to 35 IAC Part 

214 Subpart K, Sulfur Limitations from Process 

Emission Sources. This regulation is attached hereto 

and incorporated herein by reference (see Attachment 

3).

f. No person shall cause or allow the discharge of more 

than 3.6 kg/hr (8 lb/hr) of organic material into the 

atmosphere from an affected cement plant, except as 

provided in Sections 215.302, 215.303, 215.304 of 

this Part and the following exception: If no odor 

nuisance exists the limitation of this Subpart shall 

apply only to photochemically reactive material (see 

Attachment 3).

g. The affected Cement Plant is subject to 40 CFR 60 

Subparts A and y, Standards of Performance for New 

Pulverized Solid Fuel Firing System Under Coal 

Preparation Plants. The Illinois EPA is 

administering NSPS in Illinois on behalf of the USEPA 

under a delegation agreement. This regulation is 
29

attached hereto and incorporated herein by reference 

(see Attachment 1).

h. The affected Cement Plant is subject to the NESHAP 

for the Portland Cement Manufacturing Industry, 40 

CFR 63 Subparts A and LLL. The Illinois EPA is 

administering NESHAP in Illinois on behalf of the 

USEPA under a delegation agreement. This regulation 

is attached hereto and incorporated herein by 

reference (see Attachment 2).

7.1.4 Non-Applicability of Regulations of Concern

a. The affected Cement Plant is not subject to 35 IAC 

212.324, Process Emission Units In Certain Areas, 

because the source is not located in a non-attainment 

area for PM10, as identified in 35 IAC 212.324(a)(1).

b. The affected cement kiln is not subject to 35 IAC 

216.121 for emissions of carbon monoxide because the 

kiln is not by definition a fuel combustion emission 

unit.

c. The affected cement kiln is not subject to 35 IAC 

217.121 for emissions of nitrogen oxides because the 

kiln is not by definition a fuel combustion emission 

unit.

d. This permit is issued based on the affected Cement 

Plant not being subject to 40 CFR Part 60 Subparts A 

and F, Standards of Performance for Portland Cement 

Plants pursuant to 40 CFR 63.1356.

7.1.5 Operational and Production Limits and Work Practices

a. The affected facilities shall operate in compliance 

with the facility Startup, Shutdown and Malfunction 

Plan (40 CFR 63 Subpart LLL).

b. The Permittee shall follow good operating practices 

for the dust collection systems, including periodic 

inspection, routine maintenance and prompt repair of 

defects.

7.1.6 Emission Limitations

In addition to Condition 5.2.2 and the source wide 

emission limitations in Condition 5.5, the affected Cement 

Plant is subject to the following:

a. The affected Cement Plant is subject to emission 

limitations established in State Construction and 

Operating Permits, which have been attached hereto 

and incorporated herein by reference (see Attachment 
30

4). In the event that there are conflicting 

provisions in the incorporated State Construction and 

Operating Permits, the most recently issued permit 

conditions shall apply.

b. The limitations in the State Construction and 

Operating Permits were established pursuant to 40 CFR 

52.21, Prevention of Significant Deterioration (PSD) 

[T1].

c. Compliance with annual limits shall be determined on 

a monthly basis from the sum of the data for the 

current month plus the preceding 11 months (running 

12 month total) [T1].

7.1.7 Testing Requirements

a. The affected Cement Plant is subject to the 

applicable testing requirements in 40 CFR 60.675. 

This regulation is attached hereto and incorporated 

herein by reference (see Attachment 1).

b. The affected Cement Plant is subject to the 

applicable testing requirements in 35 IAC Part 212 

Subpart A. This regulation is attached hereto and 

incorporated herein by reference (see Attachment 3).

c. The affected Cement Plant is subject to the 

applicable testing requirements established in State 

Construction and Operating Permits, which have been 

attached hereto and incorporated herein by reference 

(see Attachment 4).

7.1.8 Monitoring Requirements

a. The affected Cement Plant is subject to the 

applicable monitoring requirements in 40 CFR 60 and 

40 CFR 63. These regulations are attached hereto and 

incorporated herein by reference (see Attachment 1).

7.1.9 Recordkeeping Requirements

In addition to the records required by Condition 5.6, the 

Permittee shall maintain records of the following items 

for the affected Cement Plant to demonstrate compliance 

with Conditions 5.5.1, 7.1.3, and 7.1.6, pursuant to 

Section 39.5(7)(b) of the Act:

a. The affected Cement Plant is subject to the 

applicable recordkeeping requirements in 35 IAC Part 

212, Subparts A. These regulations are attached 

hereto and incorporated herein by reference (see 

Attachment 3).
31

b. The affected Cement Plant is subject to the 

applicable recordkeeping requirements established in 

State Construction and Operating Permits, which have 

been attached hereto and incorporated herein by 

reference (see Attachment 4).

c. Records addressing use of good operating practices 

for the dust collection systems:

i. Records for periodic inspection of the dust 

collection systems with date, individual 

performing the inspection, and nature of 

inspection; and

ii. Records for prompt repair of defects, with 

identification and description of defect, 

effect on emissions, date identified, date 

repaired, and nature of repair.

d. The affected Cement Plant is subject to the 

applicable recordkeeping requirements in 40 CFR 60.65 

and 40 CFR 63 Subpart LLL. These regulations are 

attached hereto and incorporated herein by reference 

(see Attachment 1).

e. Monthly and aggregate annual NOx, PM, SO2, and VOM 

emissions from the affected Cement Plant shall be 

maintained, based on material throughput/production, 

fuel usage and the applicable emission factors, with 

supporting calculations.

7.1.10 Reporting Requirements

The Permittee shall promptly notify the Illinois EPA, 

Compliance Section, of deviations of the affected Cement 

Plant with the permit requirements as follows, pursuant to 

Section 39.5(7)(f)(ii) of the Act. Reports shall describe 

the probable cause of such deviations, and any corrective 

actions or preventive measures taken:

a. The affected Cement Plant is subject to the 

applicable reporting requirements in 35 IAC Part 212, 

Subparts A and Q. These regulations are attached 

hereto and incorporated herein by reference (see 

Attachment 3).

b. The affected Cement Plant is subject to the 

applicable reporting requirements established in

State Construction and Permits, which have been 

attached hereto and incorporated herein by reference 

(see Attachment 4).

c. The affected Cement Plant is subject to the 

applicable reporting requirements in 40 CFR 60 and 40 
32

CFR 63 Subpart LLL. These regulations are attached 

hereto and incorporated herein by reference (see 

Attachment 1).

d. Emissions of NOx, PM, SO2, and/or VOM in excess of 

limits in Condition 7.2.6 within 30 days of such an 

occurrence.

7.1.11 Operational Flexibility/Anticipated Operating Scenarios

None

7.1.12 Compliance Procedures

Compliance with the emission limits shall be based on the 

recordkeeping requirements in Condition 7.1.9 and the 

emission factors and formulas listed below:

To determine compliance with Conditions 5.5.1, 7.1.3 and 

7.1.6, emissions from the affected Cement Plant shall be 

calculated based on the emission rates from the State 

Construction and Operating Permits (See attachment 4) 

and/or applicable emission factors from AP-42, Volume I, 

Fifth Edition, Supplement D, January, 1995 and subsequent 

revisions.
33

7.2 Unit 02: Fugitive Emissions

7.2.1 Description

Fugitive emissions are defined as those emissions, which 

would not reasonably pass through a stack, vent or other 

functionally equivalent opening.

7.2.2 List of Emission Units

Plant Designation of 

Emission Unit Description of Emission Unit

J-100 Handling of Materials Stored 

Outside

J-101 Alternate Raw/Intermediate 

Material Unloading

J-102 Material Transfers Without 100 

Percent Capture Efficiencies

J-103 Storage Piles

J-104 Unpaved Haul Roads

J-105 Paved Haul Roads

7.2.3 Applicability Provisions and Applicable Regulations

a. The “affected fugitive emission sources” for the 

purpose of these unit-specific conditions, are 

emission sources described in Conditions 7.2.1 and 

7.2.2.

b. No person shall cause or allow the emission of 

fugitive particulate matter from any process, 

including any material handling or storage activity, 

that is visible by an observer looking generally 

toward the zenith at a point beyond the property line 

of the source.

7.2.4 Non-Applicability of Regulations of Concern

a. The affected fugitive emission sources of PM are not 

subject to the requirements of 35 IAC 212.321, 

Emissions of Particulate Matter from Process Emission 

Units, because due to the unique nature of this 

process, such rules cannot reasonably be applied.

7.2.5 Operational and Production Limits and Work Practices

None

7.2.6 Emission Limitations

In addition to Condition 5.2.2 and the source wide 

emission limitations in Condition 5.5, the affected 

fugitive emission sources are subject to the following:
34

a. The affected fugitive emission sources are subject to 

emission limitations established in State 

Construction and Operating Permits, which have been 

attached hereto and incorporated herein by reference 

(see Attachment 4). In the event that there are 

conflicting provisions in the incorporated State 

Construction and Operating Permits, the most recently 

issued permit conditions shall apply.

b. The limitations in the State Construction and 

Operating Permits were established pursuant to 40 CFR 

52.21, Prevention of Significant Deterioration (PSD) 

[T1].

c. Compliance with annual limits shall be determined on 

a monthly basis from the sum of the data for the 

current month plus the preceding 11 months (running 

12 month total) [T1].

7.2.7 Testing Requirements

None

7.2.8 Inspection Requirements

None

7.2.9 Recordkeeping Requirements

In addition to the records required by Condition 5.6, the 

Permittee shall maintain records of the following items 

for the affected fugitive emission sources to demonstrate 

compliance with Conditions 5.5.1, 7.2.3, and 7.2.6, 

pursuant to Section 39.5(7)(b) of the Act:

a. The affected fugitive emission sources are subject to 

the applicable recordkeeping requirements in 35 IAC 

Part 212, Subpart A. These regulations are attached 

hereto and incorporated herein by reference (see 

Attachment 3).

b. The affected fugitive emission sources are subject to 

the applicable recordkeeping requirements established 

in State Construction and Operating Permits, which 

have been attached hereto and incorporated herein by 

reference (see Attachment 4).

7.2.10 Reporting Requirements

The Permittee shall promptly notify the Illinois EPA, 

Compliance Section of deviations of the affected fugitive 

emission source with the permit requirements as follows, 

pursuant to Section 39.5(7)(f)(ii) of the Act. Reports 
35

shall describe the probable cause of such deviations, and 

any corrective actions or preventive measures taken.

7.2.11 Operational Flexibility/Anticipated Operating Scenarios

N/A

7.2.12 Compliance Procedures

Compliance with the limits in Conditions 5.5.1 shall be 

based on the recordkeeping requirements in Condition 7.2.9 

and the emission factors listed below:

a. To determine compliance with Conditions 5.5.1, 7.2.3 

and 7.2.6, PM emissions from the affected fugitive 

emission sources shall be calculated based on the 

applicable emission factors for Fugitive dust 

sources, Section 13.2, AP-42, Volume I, Fifth 

Edition, Supplement D, January, 1995.
36

8.0 GENERAL PERMIT CONDITIONS

8.1 Permit Shield

Pursuant to Section 39.5(7)(j) of the Act, the Permittee has 

requested and has been granted a permit shield. This permit 

shield provides that compliance with the conditions of this 

permit shall be deemed compliance with applicable requirements 

which were applicable as of the date the proposed permit for this 

source was issued, provided that either the applicable 

requirements are specifically identified within this permit, or 

the Illinois EPA, in acting on this permit application, has 

determined that other requirements specifically identified are 

not applicable to this source and this determination (or a 

concise summary thereof) is included in this permit.

This permit shield does not extend to applicable requirements 

which are promulgated after September 7, 2002 (the date of 

issuance of the draft permit) unless this permit has been 

modified to reflect such new requirements.

8.2 Applicability of Title IV Requirements (Acid Deposition Control)

This source is not an affected source under Title IV of the CAA 

and is not subject to requirements pursuant to Title IV of the 

CAA.

8.3 Emissions Trading Programs

No permit revision shall be required for increases in emissions 

allowed under any USEPA approved economic incentives, marketable 

permits, emissions trading, and other similar programs or 

processes for changes that are provided for elsewhere in this 

permit and that are authorized by the applicable requirement 

[Section 39.5(7)(o)(vii) of the Act].

As of the date of issuance of this permit, there are no such 

economic incentive, marketable permit or emission trading 

programs that have been approved by USEPA.

8.4 Operational Flexibility/Anticipated Operating Scenarios

8.4.1 Changes Specifically Addressed by Permit

Physical or operational changes specifically addressed by 

the Conditions of this permit that have been identified as 

not requiring Illinois EPA notification may be implemented 

without prior notice to the Illinois EPA.

8.4.2 Changes Requiring Prior Notification

The Permittee is authorized to make physical or operational 

changes that contravene express permit terms without 
37

applying for or obtaining an amendment to this permit, 

provided that [Section 39.5(12)(a)(i) of the Act]:

a. The changes do not violate applicable requirements;

b. The changes do not contravene federally enforceable 

permit terms or conditions that are monitoring 

(including test methods), recordkeeping, reporting, 

or compliance certification requirements;

c. The changes do not constitute a modification under 

Title I of the CAA;

d. Emissions will not exceed the emissions allowed under 

this permit following implementation of the physical 

or operational change; and

e. The Permittee provides written notice to the Illinois 

EPA, Division of Air Pollution Control, Permit 

Section, at least 7 days before commencement of the 

change. This notice shall:

i. Describe the physical or operational change;

ii. Identify the schedule for implementing the 

physical or operational change;

iii. Provide a statement of whether or not any New 

Source Performance Standard (NSPS) is 

applicable to the physical or operational 

change and the reason why the NSPS does or 

does not apply;

iv. Provide emission calculations which 

demonstrate that the physical or operational 

change will not result in a modification; and

v. Provide a certification that the physical or 

operational change will not result in 

emissions greater than authorized under the 

Conditions of this permit.

8.5 Testing Procedures

Tests conducted to measure composition of materials, efficiency 

of pollution control devices, emissions from process or control 

equipment, or other parameters shall be conducted using standard 

test methods. Documentation of the test date, conditions, 

methodologies, calculations, and test results shall be retained 

pursuant to the recordkeeping procedures of this permit. Reports 

of any tests conducted as required by this permit or as the 

result of a request by the Illinois EPA shall be submitted as 

specified in Condition 8.6.
38

8.6 Reporting Requirements

8.6.1 Monitoring Reports

If monitoring is required by any applicable requirements 

or conditions of this permit, a report summarizing the 

required monitoring results, as specified in the 

conditions of this permit, shall be submitted to the Air 

Compliance Section of the Illinois EPA every six months as 

follows [Section 39.5(7)(f) of the Act]:

Monitoring Period Report Due Date

January – June September 1

July – December March 1

All instances of deviations from permit requirements must 

be clearly identified in such reports. All such reports 

shall be certified in accordance with Condition 9.9.

8.6.2 Test Notifications

Unless otherwise specified elsewhere in this permit, a 

written test plan for any test required by this permit 

shall be submitted to the Illinois EPA for review at least 

60 days prior to the testing pursuant to Section 

39.5(7)(a) of the Act. The notification shall include at 

a minimum:

a. The name and identification of the affected unit(s);

b. The person(s) who will be performing sampling and 

analysis and their experience with similar tests;

c. The specific conditions under which testing will be 

performed, including a discussion of why these 

conditions will be representative of maximum 

emissions and the means by which the operating 

parameters for the source and any control equipment 

will be determined;

d. The specific determination of emissions and operation 

which are intended to be made, including sampling and 

monitoring locations;

e. The test method(s) which will be used, with the 

specific analysis method, if the method can be used 

with different analysis methods;

f. Any minor changes in standard methodology proposed to 

accommodate the specific circumstances of testing, 

with justification; and
39

g. Any proposed use of an alternative test method, with 

detailed justification.

8.6.3 Test Reports

Unless otherwise specified elsewhere in this permit, the 

results of any test required by this permit shall be 

submitted to the Illinois EPA within 60 days of completion 

of the testing. The test report shall include at a 

minimum [Section 39.5(7)(e)(i) of the Act]:

a. The name and identification of the affected unit(s);

b. The date and time of the sampling or measurements;

c. The date any analyses were performed;

d. The name of the company that performed the tests 

and/or analyses;

e. The test and analytical methodologies used;

f. The results of the tests including raw data, and/or 

analyses including sample calculations;

g. The operating conditions at the time of the sampling 

or measurements; and

h. The name of any relevant observers present including 

the testing company’s representatives, any Illinois 

EPA or USEPA representatives, and the representatives 

of the source.

8.6.4 Reporting Addresses

a. The following addresses should be utilized for the 

submittal of reports, notifications, and renewals:

i. Illinois EPA - Air Compliance Section

Illinois Environmental Protection Agency

Bureau of Air

Compliance Section (MC 40)

P.O. Box 19276

Springfield, Illinois 62794-9276

ii. Illinois EPA - Air Regional Field Office

Illinois Environmental Protection Agency

Division of Air Pollution Control

5415 North University

Peoria, Illinois 61614
40

iii. Illinois EPA - Air Permit Section

Illinois Environmental Protection Agency

Division of Air Pollution Control

Permit Section (MC 11)

P.O. Box 19506

Springfield, Illinois 62794-9506

iv. USEPA Region 5 - Air Branch

USEPA (AE - 17J)

Air & Radiation Division

77 West Jackson Boulevard

Chicago, Illinois 60604

b. Unless otherwise specified in the particular 

provision of this permit, reports shall be sent to 

the Illinois EPA - Air Compliance Section with a copy 

sent to the Illinois EPA - Air Regional Field Office.

8.7 Obligation to Comply with Title I Requirements

Any term, condition, or requirement identified in this permit by 

T1, T1R, or T1N is established or revised pursuant to 35 IAC Part 

203 or 40 CFR 52.21 (“Title I provisions”) and incorporated into 

this permit pursuant to both Section 39.5 and Title I provisions. 

Notwithstanding the expiration date on the first page of this 

permit, the Title I conditions remain in effect pursuant to Title 

I provisions until the Illinois EPA deletes or revises them in 

accordance with Title I procedures.
41

9.0 STANDARD PERMIT CONDITIONS

9.1 Effect of Permit

9.1.1 The issuance of this permit does not release the Permittee 

from compliance with State and Federal regulations which 

are part of the Illinois State Implementation Plan, as 

well as with other applicable statutes and regulations of 

the United States or the State of Illinois or applicable 

ordinances, except as specifically stated in this permit 

and as allowed by law and rule [Section 39.5(7)(j)(iv) of 

the Act].

9.1.2 In particular, this permit does not alter or affect the 

following:

a. The provisions of Section 303 (emergency powers) of 

the CAA, including USEPA's authority under that 

Section;

b. The liability of an owner or operator of a source for 

any violation of applicable requirements prior to or 

at the time of permit issuance;

c. The applicable requirements of the acid rain program 

consistent with Section 408(a) of the CAA; and

d. The ability of USEPA to obtain information from a 

source pursuant to Section 114 (inspections, 

monitoring, and entry) of the CAA.

9.1.3 Notwithstanding the conditions of this permit specifying 

compliance practices for applicable requirements, any 

person (including the Permittee) may also use other 

credible evidence to establish compliance or noncompliance 

with applicable requirements.

9.2 General Obligations of Permittee

9.2.1 Duty to Comply

The Permittee must comply with all terms and conditions of 

this permit. Any permit noncompliance constitutes a 

violation of the CAA and the Act, and is grounds for any 

or all of the following: enforcement action, permit 

termination, revocation and reissuance, modification, or 

denial of a permit renewal application [Section 

39.5(7)(o)(i) of the Act].

The Permittee shall meet applicable requirements that 

become effective during the permit term in a timely manner 

unless an alternate schedule for compliance with the 

applicable requirement is established.
42

9.2.2 Duty to Maintain Equipment

The Permittee shall maintain all equipment covered under 

this permit in such a manner that the performance or 

operation of such equipment shall not cause a violation of 

applicable requirements.

9.2.3 Duty to Cease Operation

No person shall cause, threaten or allow the continued 

operation of any emission unit during malfunction or 

breakdown of the emission unit or related air pollution 

control equipment if such operation would cause a 

violation of an applicable emission standard, regulatory 

requirement, ambient air quality standard or permit 

limitation unless such malfunction or breakdown is allowed 

by a permit condition [Section 39.5(6)(c) of the Act].

9.2.4 Disposal Operations

The source shall be operated in such a manner that the 

disposal of air contaminants collected by the equipment 

operations, or activities shall not cause a violation of 

the Act or regulations promulgated thereunder.

9.2.5 Duty to Pay Fees

The Permittee must pay fees to the Illinois EPA consistent 

with the fee schedule approved pursuant to Section 

39.5(18) of the Act, and submit any information relevant 

thereto [Section 39.5(7)(o)(vi) of the Act]. The check 

should be payable to "Treasurer, State of Illinois" and 

sent to: Fiscal Services Section, Illinois Environmental 

Protection Agency, P.O. Box 19276, Springfield, Illinois 

62794-9276.

9.3 Obligation to Allow Illinois EPA Surveillance

Upon presentation of proper credentials and other documents, the 

Permittee shall allow the Illinois EPA, or an authorized 

representative to perform the following [Section 39.5(7)(a) and 

(p)(ii) of the Act and 415 ILCS 5/4]:

a. Enter upon the Permittee's premises where an actual or 

potential emission unit is located; where any regulated 

equipment, operation, or activity is located or where 

records must be kept under the conditions of this permit;

b. Have access to and copy, at reasonable times, any records 

that must be kept under the conditions of this permit;

c. Inspect during hours of operation any sources, equipment 

(including monitoring and air pollution control 
43

equipment), practices, or operations regulated or required 

under this permit;

d. Sample or monitor any substances or parameters at any 

location:

i. At reasonable times, for the purposes of assuring 

permit compliance; or

ii. As otherwise authorized by the CAA, or the Act.

e. Obtain and remove samples of any discharge or emission of 

pollutants authorized by this permit; and

f. Enter and utilize any photographic, recording, testing, 

monitoring, or other equipment for the purposes of 

preserving, testing, monitoring, or recording any 

activity, discharge or emission at the source authorized 

by this permit.

9.4 Obligation to Comply with Other Requirements

The issuance of this permit does not release the Permittee from 

applicable State and Federal laws and regulations, and applicable 

local ordinances addressing subjects other than air pollution 

control.

9.5 Liability

9.5.1 Title

This permit shall not be considered as in any manner 

affecting the title of the premises upon which the 

permitted source is located.

9.5.2 Liability of Permittee

This permit does not release the Permittee from any 

liability for damage to person or property caused by or 

resulting from the construction, maintenance, or operation 

of the sources.

9.5.3 Structural Stability

This permit does not take into consideration or attest to 

the structural stability of any unit or part of the 

source.

9.5.4 Illinois EPA Liability

This permit in no manner implies or suggests that the 

Illinois EPA (or its officers, agents or employees) 

assumes any liability, directly or indirectly, for any 
44

loss due to damage, installation, maintenance, or 

operation of the source.

9.5.5 Property Rights

This permit does not convey any property rights of any 

sort, or any exclusive privilege [Section 39.5(7)(o)(iv) 

of the Act].

9.6 Recordkeeping

9.6.1 Control Equipment Maintenance Records

A maintenance record shall be kept on the premises for 

each item of air pollution control equipment. As a 

minimum, this record shall show the dates of performance 

and nature of preventative maintenance activities.

9.6.2 Records of Changes in Operation

A record shall be kept describing changes made at the 

source that result in emissions of a regulated air 

pollutant subject to an applicable requirement, but not 

otherwise regulated under this permit, and the emissions 

resulting from those changes [Section 39.5(12)(b)(iv) of 

the Act].

9.6.3 Retention of Records

a. Records of all monitoring data and support 

information shall be retained for a period of at 

least 5 years from the date of the monitoring sample, 

measurement, report, or application. Support 

information includes all calibration and maintenance 

records, original strip-chart recordings for 

continuous monitoring instrumentation, and copies of 

all reports required by this permit [Section 

39.5(7)(e)(ii) of the Act].

b. Other records required by this permit shall be 

retained for a period of at least 5 years from the 

date of entry unless a longer period is specified by 

a particular permit provision.

9.7 Annual Emissions Report

The Permittee shall submit an annual emissions report to the 

Illinois EPA, Compliance Section no later than May 1 of the 

following year, as required by 35 IAC Part 254.

9.8 Requirements for Compliance Certification

Pursuant to Section 39.5(7)(p)(v) of the Act, the Permittee shall 

submit annual compliance certifications. The compliance 
45

certifications shall be submitted no later than May 1 or more 

frequently as specified in the applicable requirements or by 

permit condition. The compliance certifications shall be 

submitted to the Air Compliance Section, Air Regional Field 

Office, and USEPA Region 5 – Air Branch. The addresses for the 

submittal of the compliance certifications are provided in 

Condition 8.6.4 of this permit.

a. The certification shall include the identification of each 

term or condition of this permit that is the basis of the 

certification; the compliance status; whether compliance 

was continuous or intermittent; the method(s) used for 

determining the compliance status of the source, both 

currently and over the reporting period consistent with 

the conditions of this permit.

b. All compliance certifications shall be submitted to USEPA 

Region 5 in Chicago as well as to the Illinois EPA.

c. All compliance reports required to be submitted shall 

include a certification in accordance with Condition 9.9.

9.9 Certification

Any document (including reports) required to be submitted by this 

permit shall contain a certification by a responsible official of 

the Permittee that meets the requirements of Section 39.5(5) of 

the Act [Section 39.5(7)(p)(i) of the Act]. An example 

Certification by a Responsible Official is included as an 

attachment to this permit.

9.10 Defense to Enforcement Actions

9.10.1 Need to Halt or Reduce Activity Not a Defense

It shall not be a defense for the Permittee in an 

enforcement action that it would have been necessary to 

halt or reduce the permitted activity in order to maintain 

compliance with the conditions of this permit [Section 

39.5(7)(o)(ii) of the Act].

9.10.2 Emergency Provision

a. An emergency shall be an affirmative defense to an 

action brought for noncompliance with the technologybased emission limitations under this permit if the 

following conditions are met through properly signed, 

contemporaneous operating logs, or other relevant 

evidence:

i. An emergency occurred as provided in Section 

39.5(7)(k) of the Act and the Permittee can 

identify the cause(s) of the emergency. 
46

Normally, an act of God such as lightning or 

flood is considered an emergency;

ii. The permitted source was at the time being 

properly operated;

iii. The Permittee submitted notice of the 

emergency to the Illinois EPA within two 

working days of the time when emission 

limitations were exceeded due to the 

emergency. This notice must contain a 

detailed description of the emergency, any 

steps taken to mitigate emissions, and

corrective actions taken; and

iv. During the period of the emergency the 

Permittee took all reasonable steps to 

minimize levels of emissions that exceeded the 

emission limitations, standards, or 

regulations in this permit.

b. This provision is in addition to any emergency or 

upset provision contained in any applicable 

requirement. This provision does not relieve a 

Permittee of any reporting obligations under existing 

federal or state laws or regulations.

9.11 Permanent Shutdown

This permit only covers emission units and control equipment 

while physically present at the indicated source location(s). 

Unless this permit specifically provides for equipment 

relocation, this permit is void for the operation or activity of 

any item of equipment on the date it is removed from the 

permitted location(s) or permanently shut down. This permit 

expires if all equipment is removed from the permitted 

location(s), notwithstanding the expiration date specified on 

this permit.

9.12 Reopening and Reissuing Permit for Cause

9.12.1 Permit Actions

This permit may be modified, reopened, and reissued, for 

cause pursuant to Section 39.5(15) of the Act. The filing 

of a request by the Permittee for a permit modification, 

revocation, and reissuance, or of a notification of 

planned changes or anticipated noncompliance does not stay 

any permit condition [Section 39.5(7)(o)(iii) of the 

Act].
47

9.12.2 Reopening and Revision

This permit must be reopened and revised if any of the 

following occur [Section 39.5(15)(a) of the Act]:

a. Additional requirements become applicable to the 

equipment covered by this permit and three or more 

years remain before expiration of this permit;

b. Additional requirements become applicable to an 

affected source for acid deposition under the acid 

rain program;

c. The Illinois EPA or USEPA determines that this permit 

contains a material mistake or inaccurate statement 

when establishing the emission standards or 

limitations, or other terms or conditions of this 

permit; and

d. The Illinois EPA or USEPA determines that this permit 

must be revised to ensure compliance with the 

applicable requirements of the Act.

9.12.3 Inaccurate Application

The Illinois EPA has issued this permit based upon the 

information submitted by the Permittee in the permit 

application. Any misinformation, false statement or 

misrepresentation in the application shall be grounds for 

revocation under Section 39.5(15)(b) of the Act.

9.12.4 Duty to Provide Information

The Permittee shall furnish to the Illinois EPA, within a 

reasonable time specified by the Illinois EPA any 

information that the Illinois EPA may request in writing 

to determine whether cause exists for modifying, revoking 

and reissuing, or terminating this permit, or to determine 

compliance with this permit. Upon request, the Permittee 

shall also furnish to the Illinois EPA copies of records 

required to be kept by this permit, or for information 

claimed to be confidential, the Permittee may furnish such 

records directly to USEPA along with a claim of 

confidentiality [Section 39.5(7)(o)(v) of the Act].

9.13 Severability Clause

The provisions of this permit are severable, and should any one 

or more be determined to be illegal or unenforceable, the 

validity of the other provisions shall not be affected. The 

rights and obligations of the Permittee shall be construed and 

enforced as if this permit did not contain the particular 

provisions held to be invalid and the applicable requirements 
48

underlying these provisions shall remain in force [Section 

39.5(7)(i) of the Act].

9.14 Permit Expiration and Renewal

The right to operate terminates on the expiration date unless the 

Permittee has submitted a timely and complete renewal 

application. For a renewal to be timely it must be submitted no 

later than 9 and no sooner than 12 months prior to expiration. 

The equipment may continue to operate during the renewal period 

until final action is taken by the Illinois EPA, in accordance 

with the original permit conditions [Section 39.5(5)(l), (n), 

and (o) of the Act].
1-1

10.0 ATTACHMENTS

The following permits and attachments contain applicable requirements 

to this source and are an integral part of this permit. The permit 

conditions contained in theses attachments should be thoroughly 

reviewed and complied with, including all emission limitations, 

monitoring, record keeping and reporting. Any requirements these 

permits and attachments that conflict with those requirements found in 

Sections 3 through 9 are superseded by those found in Sections 3 

through 9.

10.1 Attachment 1 - Applicable New Source Performance Standards (NSPS)

10.1.1 40 CFR 60 Subpart Y--Standards of Performance for Coal 

Preparation Plants
2-1

10.2 Attachment 2 - Applicable National Emission Standards for 

Hazardous Air Pollutants (NESHAP)

10.2.1 40 CFR 63 Subpart LLL--National Emission Standards for 

Hazardous Air Pollutants: Portland Cement Manufacturing 

Industry
3-1

10.3 Attachment 3- Applicable Regulations from 35 Illinois 

Administrative Code, Subtitle B: Air Pollution, 

Chapter I: Pollution Control Board

10.3.1 35 IAC Part 212, Emission Standards and Limitations for 

Visible and Particulate Matter Emissions from Stationary 

Sources

Subpart A: General

Section 212.100 Scope and Organization

a. This Part contains standards and limitations for 

visible and particulate matter emissions from 

stationary emission units.

b. Permits for sources subject to this Part may be 

required pursuant to 35 Ill. Adm. Code 201.

c. Notwithstanding the provisions of this Part, the air 

quality standards contained in 35 Ill. Adm. Code 243 

may not be violated.

d. This Part includes Subparts which are arranged as 

follows:

i. Subpart A: General Provisions;

ii. Subpart B: Visible Emissions;

iii. Subparts C-J: Incinerators and Fuel Combustion 

Emission Units;

iv. Subparts K-M: Fugitive and Process Emission 

Units;

v. Subparts N-T: Site specific and industry 

specific rules; and

vi. Subpart U: Additional control measures.

e. Rules have been grouped for the convenience of the 

public; the scope of each is determined by its 

language and history.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.107 Measurement Method for Visible Emissions

For both fugitive and nonfugitive particulate matter 

emissions, a determination as to the presence or absence 

of visible emissions from emission units shall be 

conducted in accordance with Method 22, 40 CFR part 60, 
3-2

Appendix A, incorporated by reference in Section 212.113 

of this Subpart, except that the length of the observing 

period shall be at the discretion of the observer, but not 

less than one minute. This Subpart shall not apply to 

Section 212.301 of this Part.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.108 Measurement Methods for PM-10 Emissions 

and Condensable PM-10 Emissions

a. Emissions of PM-10 shall be measured by any of the 

following methods at the option of the owner or 

operator of an emission unit.

i. Method 201, 40 CFR part 51, Appendix M, 

incorporated by reference in Section 212.113 

of this Subpart.

ii. Method 201A, 40 CFR part 51, Appendix M, 

incorporated by reference in Section 212.113 

of this Subpart.

iii. Method 5, 40 CFR part 60, Appendix A, 

incorporated by reference in Section 212.113 

of this Subpart, provided that all particulate 

matter measured by Method 5 shall be 

considered to be PM-10.

b. Emissions of condensable PM-10 shall be measured by 

Method 202, 40 CFR part 51, Appendix M, incorporated 

by reference in Section 212.113 of this Subpart.

c. The volumetric flow rate and gas velocity for stack 

test methods shall be determined in accordance with 

Methods 1, 1A, 2, 2A, 2C, 2D, 3, or 4, 40 CFR part 

60, Appendix A, incorporated by reference in Section 

212.113 of this Subpart.

d. Upon a written notification by the Illinois 

Environmental Protection Agency (Agency), the owner 

or operator of a PM-10 emission unit subject to this 

Section shall conduct the applicable testing for 

PM-10 emissions, condensable PM-10 emissions, 

opacity, or visible emissions at such person's own 

expense, to demonstrate compliance. Such test 

results shall be submitted to the Agency within 

thirty (30) days after conducting the test unless an 

alternative time for submittal is agreed to by the 

Agency.

e. A person planning to conduct testing for PM-10 or 

condensable PM-10 emissions to demonstrate compliance 
3-3

shall give written notice to the Agency of that 

intent. Such notification shall be given at least 

thirty (30) days prior to initiation of the test 

unless a shorter pre-notification is agreed to by the 

Agency. Such notification shall state the specific 

test methods from subsection (a) of this Section that 

will be used.

f. The owner or operator of an emission unit subject to 

this Section shall retain records of all tests which 

are performed. These records shall be retained for at 

least three (3) years after the date a test is 

performed.

g. This Section shall not affect the authority of the 

United States Environmental Protection Agency (USEPA) 

under Section 114 of the Clean Air Act (CAA) (42 

U.S.C. § 7414 (1990)).

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.109 Measurement Methods for Opacity

Except as otherwise provided in this Part, and except for 

the methods of data reduction when applied to Sections 

212.122 and 212.123 of this Part, measurements of opacity 

shall be conducted in accordance with Method 9, 40 CFR 

part 60, Appendix A, and the procedures in 40 CFR 

60.675(c) and (d), if applicable, incorporated by 

reference in Section 212.113 of this Subpart, except that 

for roadways and parking areas the number of readings 

required for each vehicle pass will be three taken at 

5-second intervals. The first reading shall be at the 

point of maximum opacity and second and third readings 

shall be made at the same point, the observer standing at 

right angles to the plume at least 15 feet away from the 

plume and observing 4 feet above the surface of the 

roadway or parking area. After four vehicles have passed, 

the 12 readings will be averaged.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.110 Measurement Methods For Particulate Matter

a. Measurement of particulate matter emissions from 

stationary emission units subject to this Part shall 

be conducted in accordance with 40 CFR part 60, 

Appendix A, Methods 5, 5A, 5D, or 5E, as incorporated 

by reference in Section 212.113 of this Subpart.

b. The volumetric flow rate and gas velocity shall be 

determined in accordance with 40 CFR part 60, 
3-4

Appendix A, Methods 1, 1A, 2, 2A, 2C, 2D, 3, and 4, 

incorporated by reference in Section 212.113 of this 

Subpart.

c. Upon a written notification by the Agency, the owner 

or operator of a particulate matter emission unit 

subject to this Part shall conduct the applicable 

testing for particulate matter emissions, opacity, or 

visible emissions at such person's own expense, to 

demonstrate compliance. Such test results shall be 

submitted to the Agency within thirty (30) days after 

conducting the test unless an alternative time for 

submittal is agreed to by the Agency.

d. A person planning to conduct testing for particulate 

matter emissions to demonstrate compliance shall give 

written notice to the Agency of that intent. Such 

notification shall be given at least thirty (30) days 

prior to the initiation of the test unless a shorter 

period is agreed to by the Agency. Such notification 

shall state the specific test methods from this 

Section that will be used.

e. The owner or operator of an emission unit subject to 

this Part shall retain records of all tests which are 

performed. These records shall be retained for at 

least three (3) years after the date a test is 

performed.

f. This Section shall not affect the authority of the 

USEPA under Section 114 of the CAA.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.111 Abbreviations and Units

a. The following abbreviations are used in this Part:

Btu British thermal units (60 1/4°F)

dscf dry standard cubic foot

Ft foot

ft2 square feet

Fpm feet per minute

Gal gallon

gr grains

gr/scf grains per standard cubic foot

gr/dscf grains per dry standard cubic foot

Hr hour

J Joule

Kg kilogram

kg/MW-hr kilograms per megawatt-hour

Km kilometer

L liter
3-5

Lbs pounds

Lbs/hr pounds per hour

Lbs/mmBtu pounds per million Btu

M meter

m

2 square meters

mph miles per hour

mg milligram

mg/scm milligrams per standard cubic meter

mg/dscm milligrams per dry standard cubic 

meter

mg/L milligrams per liter

Mg megagram, metric ton or tonne

mi mile

mmBtu million British thermal units

mmBtu/hr million British thermal units per 

hour

MW megawatt; one million watts

MW-hr megawatt-hour

μg nanogram; one billionth of a gram

μg/J nanograms per Joule

scf standard cubic foot

scfm standard cubic feet per minute

scm standard cubic meter

T short ton (2000 lbs)

yd2 square yards

b. The following conversion factors have been used in 

this Part:

English Metric

2.205 lb 1 kg

1 T 0.907 Mg

1 lb/T 0.500 kg/Mg

mmBtu/hr 0.293 MW

1 lb/mmBtu 1.548 kg/MW-hr or 430 ng/J

1 mi 1.61 km

1 gr 64.81 mg

1 gr/scf 2289 mg/scm

1 ft2 0.0929 m2

1 ft 0.3048 m

1 gal 3.785 L

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.112 Definitions

The definitions of 35 Ill. Adm. Code 201 and 211 apply to 

this Part.

(Source: Added and codified at 7 Ill. Reg. 13591)
3-6

Section 212.113 Incorporations by Reference

The following materials are incorporated by reference. 

These incorporations do not include any later amendments 

or editions.

a. 40 CFR part 60, Appendix A (1991):

i. Method 1: Sample and Velocity Traverses for 

Stationary Sources;

ii. Method 1A: Sample and Velocity Traverses for 

Stationary Source with Small Stacks or Ducts;

iii. Method 2: Determination of Stack Gas Velocity 

and Volumetric Flow Rate (Type S pitot tube);

iv. Method 2A: Direct Measurement of Gas Volume 

Through Pipes and Small Ducts;

v. Method 2C: Determination of Stack Gas Velocity 

and Volumetric Flow Rate in Small Stacks or 

Ducts (Standard Pitot Tube);

vi. Method 2D: Measurement of Gas Volumetric Flow 

Rates in Small Pipes and Ducts;

vii. Method 3: Gas Analysis for Carbon Dioxide, 

Oxygen, Excess Air, and Dry Molecular Weight;

viii. Method 4: Determination of Moisture Content in 

Stack Gases;

ix. Method 5: Determination of Particulate 

Emissions From Stationary Sources;

x. Method 5A: Determination of Particulate 

Emissions From the Asphalt Processing and 

Asphalt Roofing Industry;

xi. Method 5D: Determination of Particulate Matter 

Emissions From Positive Pressure Fabric 

Filters;

xii. Method 5E: Determination of Particulate 

Emissions From the Wool Fiberglass Insulation 

Manufacturing Industry;

xiii. Method 9: Visual Determination of the Opacity 

of Emissions from Stationary Sources;

ix. Method 22: Visual Determination of Fugitive 

Emissions from Material Sources and Smoke 

Emissions from Flares.
3-7

b. 40 CFR part 51 Appendix M (1994):

i. Method 201: Determination of PM-10 Emissions;

ii. Method 201A: Determination of PM-10 Emissions 

(Constant Sampling Rate Procedure);

iii. Method 202: Determination of Condensable 

Particulate Emissions from Stationary Sources.

c. 40 CFR 60.672(b), (c), (d) and (e) (1991).

d. 40 CFR 60.675(c) and (d) (1991).

e. ASAE Standard 248.2, Section 9, Basis for Stating 

Drying Capacity of Batch and Continuous-Flow Grain 

Dryers, American Society of Agricultural Engineers, 

2950 Niles Road, St. Joseph, MI 49085.

f. U.S. Sieve Series, ASTM-E11, American Society of 

Testing Materials, 1916 Race Street, Philadelphia, PA 

19103.

g. Standard Methods for the Examination of Water and 

Wastewater, Section 209C, "Total Filterable Residue 

Dried at 103 - 105° C," 15th Edition, 1980, American 

Public Health Association, 1015 Fifteenth Street, 

N.W., Washington, D.C. 20005.

h. "Guideline on the Identification and Use of Air 

Quality Data Affected by Exceptional Events," U.S. 

Environmental Protection Agency, Office of Air and 

Radiation, Office of Air Quality Planning and 

Standards Monitoring and Data Analysis Division, 

Research Triangle Park, N.C. 27711, EPA-450/4-86-007 

July 1986.

i. "Guideline on Air Quality Models (Revised)," U.S. 

Environmental Protection Agency, Office of Air 

Quality Planning and Standards, Research Triangle 

Park, N.C. 27711, EPA-450/2-78-027R July 1986.

j. 40 CFR 50, Appendix K (1992), "Interpretation of the 

National Ambient Air Quality Standard for Particulate 

Matter".

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)
3-8

SUBPART B: VISIBLE EMISSIONS

Section 212.121 Opacity Standards (Repealed)

(Source: Repealed at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.122 Visible Emissions Limitations for Certain 

Emission Units For Which Construction or Modification 

Commenced On or After April 14, 1972

a. No person shall cause or allow the emission of smoke 

or other particulate matter into the atmosphere from 

any fuel combustion emission unit for which 

construction or modification commenced on or after 

April 14, 1972, with actual heat input greater than 

73.2 MW (250 mmBtu/hr), having an opacity greater 

than 20 percent.

b. The emissions of smoke or other particulate matter 

from any such emission unit may have an opacity 

greater than 20 percent but not greater than 40 

percent for a period or periods aggregating 3 minutes 

in any 60 minute period, providing that such opaque 

emission permitted during any 60 minute period shall 

occur from only one such emission unit located within 

a 305 m (1000 ft) radius from the center point of any 

other such emission unit owned or operated by such 

person and provided further that such opaque 

emissions permitted from each such fuel combustion 

emission unit shall be limited to 3 times in any 24 

hour period.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.123 Visible Emissions Limitations for All 

Other Emission Units

a. No person shall cause or allow the emission of smoke 

or other particulate matter, with an opacity greater 

than 30 percent, into the atmosphere from any 

emission unit other than those emission units subject 

to Section 212.122 of this Subpart.

b. The emission of smoke or other particulate matter 

from any such emission unit may have an opacity 

greater than 30 percent but not greater than 60 

percent for a period or periods aggregating 8 minutes 

in any 60 minute period provided that such opaque 

emissions permitted during any 60 minute period shall 

occur from only one such emission unit located within 

a 305 m (1000 ft) radius from the center point of any 

other such emission unit owned or operated by such 
3-9

person, and provided further that such opaque 

emissions permitted from each such emission unit 

shall be limited to 3 times in any 24 hour period.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.124 Exceptions

a. Sections 212.122 and 212.123 of this Subpart shall 

apply during times of startup, malfunction and 

breakdown except as provided in the operating permit 

granted in accordance with 35 Ill. Adm. Code 201.

b. Sections 212.122 and 212.123 of this Subpart shall 

not apply to emissions of water or water vapor from 

an emission unit.

c. An emission unit which has obtained an adjusted 

opacity standard pursuant to Section 212.126 of this 

Subpart shall be subject to that standard rather than 

the limitations of Section 212.122 or 212.123 of this 

Subpart.

d. Compliance with the particulate regulations of this 

Part shall constitute a defense.

i. For all emission units which are not subject 

to Chapters 111 or 112 of the CAA and Sections 

212.201, 212.202, 212.203 or 212.204 of this 

Part but which are subject to Sections 212.122 

or 212.123 of this Subpart: the opacity 

limitations of Sections 212.122 and 212.123 of 

this Subpart shall not apply if it is shown 

that the emission unit was, at the time of 

such emission, in compliance with the 

applicable particulate emissions limitations 

of Subparts D through T of this Part.

ii. For all emission units which are not subject 

to Chapters 111 or 112 of the CAA but which 

are subject to Sections 212.201, 212.202, 

212.203 or 212.204 of this Part:

A. An exceedance of the limitations of 

Section 212.122 or 212.123 of this 

Subpart shall constitute a violation of 

the applicable particulate limitations of 

Subparts D through T of this Part. It 

shall be a defense to a violation of the 

applicable particulate limitations if, 

during a subsequent performance test 

conducted within a reasonable time not to 

exceed 60 days, under the same operating 
3-10

conditions for the unit and the control 

devices, and in accordance with Method 5, 

40 CFR part 60, incorporated by reference 

in Section 212.113 of this Part, the 

owner or operator shows that the emission 

unit is in compliance with the 

particulate emission limitations.

B. It shall be a defense to an exceedance of 

the opacity limit if, during a subsequent 

performance test conducted within a 

reasonable time not to exceed 60 days, 

under the same operating conditions of 

the emission unit and the control 

devices, and in accordance with Method 5, 

40 CFR part 60, Appendix A, incorporated

by reference in Section 212.113 of this 

Part, the owner or operator shows that 

the emission unit is in compliance with 

the allowable particulate emissions 

limitation while, simultaneously, having 

visible emissions equal to or greater 

than the opacity exceedance as originally 

observed.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.125 Determination of Violations

Violations of Sections 212.122 and 212.123 of this Subpart 

shall be determined:

a. By visual observations conducted in accordance with 

Section 212.109 of this Part; or 

b. By the use of a calibrated smoke evaluation device 

approved by the Agency as specified in Subpart J of 

35 Ill. Adm. Code 201; or

c. By the use of a smoke monitor located in the stack 

and approved by the Agency as specified in Subpart J 

or L of 35 Ill. Adm. Code 201.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 

1996)

Section 212.126 Adjusted Opacity Standards Procedures

a. Pursuant to Section 28.1 of the Environmental 

Protection Act (Act) [415 ILCS 5/28.1], and in 

accordance with 35 Ill. Adm. Code 106, Subpart E, 

provisions for adjusted standards for visible 

emissions for emission units subject to Sections 
3-11

212.201, 212.202, 212.203, or 212.204 of this Part 

shall be granted by the Board to the extent 

consistent with federal law based upon a 

demonstration by such owner or operator that the 

results of a performance test conducted pursuant to 

this Section, Section 212.110 of this Part, and 

Methods 5 and 9 of 40 CFR part 60, Appendix A, 

incorporated by reference in Section 212.113 of this 

Part, show that the emission unit meets the 

applicable particulate emission limitations at the 

same time that the visible emissions exceed the 

otherwise applicable standards of Sections 212.121 

through 212.125 of this Subpart. Such adjusted 

opacity limitations:

i. Shall be specified as a condition in operating 

permits issued pursuant to 35 Ill. Adm. Code 

201 and Section 39.5 of the Act;

ii. Shall substitute for that limitation otherwise 

applicable;

iii. Shall not allow an opacity greater than 60 

percent at any time; and

iv. Shall allow opacity for one six-minute 

averaging period in any 60 minute period to 

exceed the adjusted opacity standard.

b. For the purpose of establishing an adjusted opacity 

standard, any owner or operator of an emission unit 

which meets the requirements of subsection (a) of 

this Section, may request the Agency to determine the 

average opacity of the emissions from the emission 

unit during any performance tests conducted pursuant 

to Section 212.110 of this Part and Methods 5 and 9 

of 40 CFR part 60, Appendix A, incorporated by 

reference in Section 212.113 of this Part. The 

Agency shall refuse to accept the results of 

emissions tests if not conducted pursuant to this 

Section.

c. Any request for the determination of the average 

opacity of emissions shall be made in writing, shall 

include the time and place of the performance test 

and test specifications and procedures, and shall be 

submitted to the Agency at least thirty (30) days 

before the proposed test date.

d. The Agency will advise the owner or operator of an 

emission unit which has requested an opacity 

determination of any deficiencies in the proposed 

test specifications and procedures as expeditiously 

as practicable but no later than ten (10) days prior 
3-12

to the proposed test date so as to minimize any 

disruption of the proposed testing schedule.

e. The owner or operator shall allow Agency personnel to 

be present during the performance test.

f. The method for determining an adjusted opacity 

standard is as follows:

i. A minimum of 60 consecutive minutes of opacity 

readings obtained in accordance with Test 

Method 9, 40 CFR part 60, Appendix A, 

incorporated by reference in Section 212.113 

of this Part, shall be taken during each 

sampling run. Therefore, for each performance 

test (which normally consists of three 

sampling runs), a total of three sets of 

opacity readings totaling three hours or more 

shall be obtained. Concurrently, the 

particulate emissions data from three sampling 

runs obtained in accordance with Test 

Method 5, 40 CFR part 60, Appendix A, 

incorporated by reference in Section 212.113 

of this Part, shall also be obtained.

ii. After the results of the performance tests are 

received from the emission unit, the status of

compliance with the applicable particulate 

emissions limitation shall be determined by 

the Agency. In accordance with Test Method 5, 

40 CFR part 60, Appendix A, incorporated by 

reference in Section 212.113 of this Part, the 

average of the results of the three sampling 

runs must be less than the allowable 

particulate emission rate in order for the 

emission unit to be considered in compliance. 

If compliance is demonstrated, then only those 

test runs with results which are less than the 

allowable particulate emission rate shall be 

considered as acceptable test runs for the 

purpose of establishing an adjusted opacity 

standard.

iii. The opacity readings for each acceptable 

sampling run shall be divided into sets of 24 

consecutive readings. The six (6) minute 

average opacity for each set shall be 

determined by dividing the sum of the 24 

readings within each set by 24.

iv. The second highest six (6) minute average 

opacity obtained in subsection (f)(3) of this 

Section shall be selected as the adjusted 

opacity standard.
3-13

g. The owner or operator shall submit a written report 

of the results of the performance test to the Agency 

at least thirty (30) days prior to filing a petition 

for an adjusted standard with the Board.

h. If, upon review of such owner's or operator's written 

report of the results of the performance tests, the 

Agency determines that the emission unit is in 

compliance with all applicable emission limitations 

for which the performance tests were conducted, but 

fails to comply with the requirements of Section 

212.122 or 212.123 of this Subpart, the Agency shall 

notify the owner or operator as expeditiously as 

practicable, but no later than twenty (20) days after 

receiving the written report of any deficiencies in 

the results of the performance tests.

i. The owner or operator may petition the Board for an 

adjusted visible emission standard pursuant to 35 

Ill. Adm. Code 106.Subpart E. In addition to the 

requirements of 35 Ill. Adm. Code 106.Subpart E, the 

petition shall include the following information:

i. A description of the business or activity of 

the petitioner, including its location and 

relevant pollution control equipment;

ii. The quantity and type of materials discharged 

from the emission unit or control equipment 

for which the adjusted standard is requested;

iii. A copy of any correspondence between the 

petitioner and the Agency regarding the 

performance tests which form the basis of the 

adjusted standard request;

iv. A copy of the written report submitted to the 

Agency pursuant to subsection (g) of this 

Section;

v. A statement that the performance tests were 

conducted in accordance with this Section and 

the conditions and procedures accepted by the 

Agency pursuant to Section 212.110 of this 

Part;

vi. A statement regarding the specific limitation 

requested; and

vii. A statement as to whether the Agency has sent 

notice of deficiencies in the results of the 

performance test pursuant to subsection (h) of 

this Section and a copy of said notice.
3-14

j. In order to qualify for an adjusted standard the

owner or operator must justify as follows:

i. That the performance tests were conducted in 

accordance with Test Methods 5 and 9, 40 CFR 

part 60, Appendix A, incorporated by reference 

in Section 212.113 of this Part, and the 

conditions and procedures accepted by the 

Agency pursuant to Section 212.110 of this 

Part;

ii. That the emission unit and associated air 

pollution control equipment were operated and 

maintained in a manner so as to minimize the 

opacity of the emissions during the 

performance tests; and

iii. That the proposed adjusted opacity standard 

was determined in accordance with subsection 

(f) of this Section.

k. Nothing in this Section shall prevent any person from 

initiating or participating in a rulemaking, 

variance, or permit appeal proceeding before the 

Board.

(Source: Amended at 20 Ill. Reg.7605, effective May 22, 1996)

SUBPART L: PARTICULATE MATTER EMISSIONS FROM PROCESS 

EMISSION SOURCES

Section 212.321 Process Emission Units For Which 

Construction or Modification Commenced On or After 

April 14, 1972

a. Except as further provided in this Part, no person 

shall cause or allow the emission of particulate 

matter into the atmosphere in any one hour period 

from any new process emission unit which, either 

alone or in combination with the emission of 

particulate matter from all other similar process 

emission units for which construction or modification 

commenced on or after April 14, 1972, at a source or 

premises, exceeds the allowable emission rates 

specified in subsection (c) of this Section.

b. Interpolated and extrapolated values of the data in 

subsection (c) of this Section shall be determined by 

using the equation:

E = A (P)Β

Where:
3-15

P = Process weight rate; and

E = Allowable emission rate; and,

1. Up to process weight rates of 408 MG/hr (450 

T/hr):

Metric English

P Mg/hr T/hr

E kg/hr lbs/hr

A 1.214 2.54

B 0.534 0.534

2. For process weight rate greater than or equal 

to 408 Mg/hr (450 T/hr):

Metric English

P Mg/hr T/hr

E kg/hr lbs/hr

A 11.42 24.8

B 0.16 0.16

c. Limits for Process Emission Units For Which 

Construction of Modification Commenced On or After 

April 14,1972

Metric English

P E P E

Mg/hr kg/hr T/hr lbs/hr

0.05 0.25 0.05 0.55

0.1 0.29 0.10 0.77

0.2 0.42 0.20 1.10

0.3 0.64 0.30 1.35

0.4 0.74 0.40 1.58

0.5 0.84 0.50 1.75

0.7 1.00 0.75 2.40

0.9 1.15 1.00 2.60

1.8 1.66 2.00 3.70

2.7 2.1 3.00 4.60

3.6 2.4 4.00 5.35

4.5 2.7 5.00 6.00

9. 3.9 10.00 8.70

13. 4.8 15.00 10.80

18. 5.7 20.00 12.50

23. 6.5 25.00 14.00

27. 7.1 30.00 15.60

32. 7.7 35.00 17.00

36. 8.2 40.00 18.20

41. 8.8 45.00 19.20

45. 9.3 50.00 20.50

90. 13.4 100.00 29.50

140. 17.0 150.00 37.00

180. 19.4 200.00 43.00
3-16

Metric English

P E P E

Mg/hr kg/hr T/hr lbs/hr

230. 22. 250.00 48.50

270. 24. 300.00 53.00

320. 26. 350.00 58.00

360. 28. 400.00 62.00

408. 30.1 450.00 66.00

454. 30.4 500.00 67.00

Where:

P = Process weight rate in metric or T/hr, and

E = Allowable emission rate in kg/hr or lbs/hr.

(Source: Amended at 20 Ill. Reg. 7605, effective 

May 22, 2996)

Section 212.322 Process Emission Units For Which 

Construction or Modification Commenced Prior to 

April 14,1972.

a. Except as further provided in this Part, no 

person shall cause or allow the emission of 

particulate matter into the atmosphere in any 

one hour period from any process emission unit 

for which construction or modification 

commenced prior to April 14,1972, which, 

either alone or in combination with the 

emission of particulate matter from all other 

similar process emission units at a source or 

premises, exceeds the allowable emission rates 

specified in subsection (c) of this Section.

b. Interpolated and extrapolated values of the 

data in subsection (c) of this Section shall 

be determined by using the equation:

E = C + A (P)Β

Where:

P = Process weight rate; and,

E = Allowable emission rate; and,

1. For process weight rates up to 27.2 Mg/hr 

(30 T/hr):

Metric English

P Mg/hr T/hr

E kg/hr lbs/hr

A 1.985 4.10

B 0.67 0.67

C 0 0
3-17

2. For process weight rates in excess or 

27.2 Mg/hr (30 T/hr):

Metric English

P Mg/hr T/hr

E kg/hr lbs/hr

A 25.21 55.0

B 0.11 0.11

C -18.4 -40.0

c. Limits for Process Emission Units For Which 

Construction or Modification Commenced Prior to 

April 14, 1972

Metric English

P E P E

Mg/hr kg/hr T/hr lbs/hr

0.05 0.27 0.05 0.55

0.1 0.42 0.10 0.87

0.2 0.68 0.20 1.40

0.3 0.89 0.30 1.83

0.4 1.07 0.40 2.22

0.5 1.25 0.50 2.58

0.7 1.56 0.75 3.38

0.9 1.85 1.00 4.10

1.8 2.9 2.00 6.52

2.7 3.9 3.00 8.56

3.6 4.7 4.00 10.40

4.5 5.4 5.00 12.00

9. 8.7 10.00 19.20

13. 11.1 15.00 25.20

18. 13.8 20.00 30.50

23. 16.2 25.00 35.40

27.2 18.15 30.00 40.00

32.0 18.8 35.00 41.30

36.0 19.3 40.00 42.50

41.0 19.8 45.00 43.60

45.0 20.2 50.00 44.60

90.0 23.2 100.00 51.20

140.0 25.3 150.00 55.40

180.0 26.5 200.00 58.60

230.0 27.7 250.00 61.00

270.0 28.5 300.00 63.10

320.0 29.4 350.00 64.90

360.0 30.0 400.00 66.20

400.0 30.6 450.00 67.70

454.0 31.3 500.00 69.00

Where:

P = Process weight rate in Mg/hr or T/hr, and
3-18

E = Allowable emission rate in kg/hr or lbs/hr.

(Source: Amended at 20 Ill. Reg. 7605, effective May 22, 

1996)

Section 212.323 Stock Piles

Sections 212.321 and 212.322 of this Subpart shall not 

apply to emission units, such as stock piles of 

particulate matter, to which, because of the disperse 

nature of such emission units, such rules cannot 

reasonably be applied.

(Source: Amended at 20 Ill. Reg. 7605, effective May 22, 

1996)

SUBPART Q: STONE, CLAY, GLASS AND CONCRETE MANUFACTURING

Section 212.421 Portland Cement Processes For Which 

Construction of Modification Commenced On or After 

April 14, 1972

No person shall cause or allow the emission of smoke or 

other particulate matter from any Portland cement process 

for which construction or modification commenced on or 

after April 14, 1972, into the atmosphere having an 

opacity greater than 10 percent.

(Source: Amended at 20 Ill. Reg. 7605, effective May 22, 

1996)

Section 212.422 Portland Cement Manufacturing Processes

Section 212.321 of this Part shall not apply to the kilns 

and coolers of Portland cement manufacturing processes.

a. The kilns and clinker coolers of Portland cement 

manufacturing processes for which construction 

commenced prior to April 14, 1972, shall comply with 

the emission standards and limitations of Section 

212.322 of this Part.

b. The kilns and clinker coolers of Portland cement 

manufacturing processes for which construction or 

modification commenced on or after April 14, 1972, 

shall comply with the following emission standards 

and limitations:

i. No person shall cause or allow the emission of 

particulate matter into the atmosphere from 

any such kiln the exceed 0.3 lbs/T of feed to 

the kiln.
3-19

ii. No person shall cause or allow the emission of 

particulate matter into the atmosphere from 

any such clinker cooler to exceed 0.1 lbs/T of 

feed to the kiln.

(Source: Amended at 20 Ill. Reg. 7605, effective May 22, 

1996) 

10.3.2 35 IAC Part 215, Emission Standards and Limitations for 

Organic Material Emissions from Stationary Sources

SUBPART B: ORGANIC EMISSIONS FROM STORAGE AND LOADING 

OPERATIONS

Section 215.121 Storage Containers

No person shall cause or allow the storage of any volatile 

organic liquid with a vapor pressure of 17.24 kPa (2.5 

psia) or greater at 294.3 K (70 F) or any gaseous organic 

material in any stationary tank, reservoir or other 

container of more than 151 cubic meters (40,000 gal) 

capacity unless such tank, reservoir or other container: 

a. Is a pressure tank capable of withstanding the vapor 

pressure of such liquid or the pressure of the gas, 

so as to prevent vapor or gas loss to the atmosphere 

at all times; or,

b. Is designed and equipped with one of the following 

vapor loss control devices:

i. A floating roof which rests on the surface of 

the volatile organic liquid and is equipped 

with a closure seal or seals between the roof 

edge and the tank wall. Such floating roof 

shall not be permitted if the volatile organic 

liquid has a vapor pressure of 86.19 kPa (12.5 

psia) or greater at 294.3 K (70 F). No person 

shall cause or allow the emission of air 

contaminants into the atmosphere from any 

gauging or sampling devices attached to such 

tanks, except during sampling or maintenance 

operations.

ii. A vapor recovery system consisting of:

A. A vapor gathering system capable of 

collecting 85% or more of the 

uncontrolled volatile organic material 

that would be otherwise emitted to the 

atmosphere; and,

B. A vapor disposal system capable of 

processing such volatile organic material 
3-20

so as to prevent its emission to the 

atmosphere. No person shall cause or 

allow the emission of air contaminants 

into the atmosphere from any gauging or 

sampling devices attached to such tank, 

reservoir or other container except 

during sampling.

iii. Other equipment or means of equal efficiency 

approved by the Agency according to the 

provisions of 35 Ill. Adm. Code 201.

(Source: Amended at 12 Ill. Reg. 815, effective 

December 24, 1987) 

Section 215.122 Loading Operations

a. No person shall cause or allow the discharge of more 

than 3.6 kg/hr (8 lbs/hr) of organic material into 

the atmosphere during the loading of any organic 

material from the aggregate loading pipes of any 

loading facility having through-put of greater than 

151 cubic meters per day (40,000 gal/day) into any 

railroad tank car, tank truck or trailer unless such 

loading facility is equipped with submerged loading 

pipes, submerged fill, or a device that is equally 

effective in controlling emissions and is approved by 

the Agency according to the provisions of 35 Ill. 

Adm. Code 201.

b. No person shall cause or allow the loading of any 

organic material into any stationary tank having a 

storage capacity of greater than 946 1 (250 gal), 

unless such tank is equipped with a permanent 

submerged loading pipe, submerged fill, or an 

equivalent device approved by the Agency according to 

the provisions of 35 Ill. Adm. Code 201 or unless 

such tank is a pressure tank as described in Section 

215.121(a) or is fitted with a recovery system as 

described in Section 215.121(b)(2).

c. Exception: If no odor nuisance exists the limitations 

of this Section shall only apply to the loading of 

volatile organic liquid with a vapor pressure of 

17.24 kPa (2.5 psia) or greater at 294.3°K (70°F).

(Source: Amended at 14 Ill. Reg. 9173, effective May 23, 

1990)

Section 215.123 Petroleum Liquid Storage Tanks

a. The requirements of subsection (b) below shall not

apply to any stationary storage tank:
3-21

i. Equipped before January 1, 1979 with one of 

the vapor loss control devices specified in 

Section 215.121(b) of this Part, except 

Section 215.121(b)(1) of this Part;

ii. With a capacity of less than 151.42 cubic 

meters;

iii. With a capacity of less than 1,600 cubic 

meters (422,400 gallons) and used to store 

produced crude oil and condensate prior to 

custody transfer;

iv. With a capacity of less than 1,430 cubic 

meters (378,000 gallons) and used to store 

produced oil or condensate in crude oil 

gathering;

v. Subject to new source performance standards 

for storage vessels of petroleum liquid, 40 

CFR 60, incorporated by reference in Section 

215.105 of this Part. The provisions of 

Section 111 of the Clean Air Act relating to 

standards of performance for new stationary 

sources...are applicable in this State and are 

enforceable under [The Environmental 

Protection Act]. (Ill. Rev. Stat., Ch. 111 

1/2, par. 1009.1(b)).

vi. In which volatile petroleum liquid is not 

stored; or

vii. Which is a pressure tank as described in 

Section 215.121(a) of this Part.

b. Subject to subsection (a) above no owner or operator 

of a stationary storage tank shall cause or allow the 

storage of any volatile petroleum liquid in the tank 

unless:

i. The tank is equipped with one of the vapor 

loss control devices specified in Section 

215.121(b) of this Part;

ii. There are no visible holes, tears or other 

defects in the seal or any seal fabric or 

material of any floating roof;

iii. All openings of any floating roof deck, except 

stub drains, are equipped with covers, lids or 

seals such that:

A. The cover, lid or seal is in the closed 

position at all times except when 
3-22

petroleum liquid is transferred to or 

from the tank;

B. Automatic bleeder vents are closed at all 

times except when the roof is floated off 

or landed on the roof leg supports; and

C. Rim vents, if provided, are set to open 

when the roof is being floated off the 

roof leg supports or at the 

manufacturer's recommended setting;

iv. Routine inspections of floating roof seals are 

conducted through roof hatches once every six 

months;

v. A complete inspection of the cover and seal of 

any floating roof tank is made whenever the 

tank is emptied for reasons other than the 

transfer of petroleum liquid during the normal 

operation of the tank, or whenever repairs are 

made as a result of any semi-annual inspection 

or incidence of roof damage or defect; and

vi. A record of the results of each inspection 

conducted under subsection (b)(4) or (b)(5) 

above is maintained.

c. Owners and operators of petroleum liquid storage 

tanks were required to have compliance schedules as 

summarized in Appendix C of this Part.

(Source: Amended at 16 Ill. Reg. 13849, effective 

August 24, 1992)

Section 215.124 External Floating Roofs

a. In addition to meeting the requirements of Section 

215.123(b), no owner or operator of a stationary 

storage tank equipped with an external floating roof 

shall cause or allow the storage of any volatile 

petroleum liquid in the tank unless:

i. The tank has been fitted with a continuous 

secondary seal extending from the floating 

roof to the tank wall (rim mounted secondary 

seal) or any other device which controls 

volatile organic material emissions with an 

effectiveness equal to or greater than a 

rimmounted secondary seal;

ii. Each seal closure device meets the following 

requirements:
3-23

A. The seal is intact and uniformly in place 

around the circumference of the floating 

roof between the floating roof and tank 

wall; and

B. The accumulated area of gaps exceeding 

0.32 centimeter (1/8 inch) in width 

between the secondary seal and the tank 

wall shall not exceed 21.2 square 

centimeters per meter of tank diameter 

(1.0 square inches per foot of tank 

diameter).

iii. Emergency roof drains are provided with 

slotted membrane fabric covers or equivalent 

covers across at least 90 percent of the area 

of the opening;

iv. Openings are equipped with projections into 

the tank which remain below the liquid surface 

at all times;

v. Inspections are conducted prior to May 1 of 

each year to insure compliance with subsection 

(a);

vi. The secondary seal gap is measured prior to 

May 1 of each year;

vii. Records of the types of volatile petroleum 

liquid stored, the maximum true vapor pressure 

of the liquid as stored, the results of the 

inspections and the results of the secondary 

seal gap measurements are maintained and 

available to the Agency, upon verbal or 

written request, at any reasonable time for a 

minimum of two years after the date on which 

the record was made.

b. Subsection (a) does not apply to any stationary 

storage tank equipped with an external floating roof:

i. Exempted under Section 215.123(a)(2) through 

215.123(a)(6);

ii. Of welded construction equipped with a 

metallic-type shoe seal having a secondary 

seal from the top of the shoe seal to the tank 

wall (shoe-mounted secondary seal);

iii. Of welded construction equipped with a 

metallic-type shoe seal, a liquid-mounted foam 

seal, or a liquid-mounted liquid-filled-type 

seal, or other closure device of equivalent 
3-24

control efficiency approved by the Agency in 

which a petroleum liquid with a true vapor 

pressure less than 27.6 kPa (4.0 psia) at 

294.3 K (70 F) is stored; or

iv. Used to store crude oil.

(Source: Amended at 14 Ill. Reg. 9173, effective May 23, 

1990)

Section 215.125 Compliance Dates and Geographical Areas

a. Except as otherwise stated in subsection (b), every 

owner or operator of an emission source subject to 

Sections 215.123 or 215.124 shall comply with its 

standards and limitations by December 31, 1983.

b. If an emission source is not located in one of the 

counties listed below and is also not located in any 

county contiguous thereto, the owner or operator of 

the emission source shall comply with the 

requirements of Sections 215.123 and 215.124 no later 

than December 31, 1987: 

Cook Macoupin

DuPage Madison

Kane Monroe

Lake Saint Clair

(BOARD NOTE: These counties are proposed to be 

designated as nonattainment by the United States 

Environmental Protection Agency at 47 Fed. Reg. 

31588, July 21, 1982).

c. Notwithstanding subsection (b), if any county is 

designated as nonattainment by the United States 

Environmental Protection Agency (USEPA) at any time 

subsequent to the effective date of this Section, the 

owner or operator of an emission source located in 

that county or any county contiguous to that county 

who would otherwise be subject to the compliance date 

in subsection (b) shall comply with the requirements 

of Sections 215.123 and 215.124 within one year from 

the date of redesignation but in no case later than 

December 31, 1987.

(Source: Adopted at 7 Ill. Reg. 1244, effective 

January 21, 1983)

Section 215.126 Compliance Plan

a. The owner or operator of an emission source subject 

to Section 215.125(a) shall submit to the Agency a 

compliance plan as required by 35 Ill. Adm. Code 
3-25

201.241, including a project completion schedule 

where applicable, no later than April 21, 1983.

b. The owner or operator of an emission source subject 

to Section 215.125(b) shall submit to the Agency a

compliance plan, including a project completion 

schedule where applicable, no later than December 31, 

1986.

c. The owner or operator of an emission source subject 

to Section 215.125(c) shall submit a compliance plan, 

including a project completion schedule within 90 

days after the date of redesignation, but in no case 

later than December 31, 1986.

d. Unless the submitted compliance plan or schedule is 

disapproved by the Agency, the owner or operator of a 

facility or emission source subject to the rules 

specified in subsections (a), (b) or (c) may operate 

the emission source according to the plan and 

schedule as submitted.

e. The plan and schedule shall meet the requirements of 

35 Ill. Adm. Code 201.241 including specific interim 

dates as required in 35 Ill. Adm. Code 201.242.

(Source: Adopted at 7 Ill. Reg. 1244, effective 

January 21, 1983)

Section 215.127 Emissions Testing

a. Any tests of organic material emissions, including 

tests conducted to determine control equipment 

efficiency, shall be conducted in accordance with the 

methods and procedures specified in Section 215.102.

b. Upon a reasonable request by the Agency, the owner or 

operator of an organic material emission source 

required to comply with this Subpart shall conduct 

emissions testing, at such person's own expense, to 

demonstrate compliance.

c. A person planning to conduct an organic material 

emission test to demonstrate compliance with this 

Subpart shall notify the Agency of that intent not 

less than 30 days before the planned initiation of 

the tests so the Agency may observe the test.

(Source: Added at 14 Ill. Reg. 9173, effective May 23, 

1990)
3-26

Section 215.128 Measurement of Seal Gaps

a. Any measurements of secondary seal gaps shall be 

conducted in accordance with the methods and 

procedures specified in 40 CFR 60, Subpart Kb 

incorporated by reference in Section 215.105.

b. A person planning to conduct a measurement of seal 

gaps to demonstrate compliance with this Subpart 

shall notify the Agency of that intent not less than 

30 days before the planned performance of the tests 

so the Agency may observe the test.

(Source: Added at 14 Ill. Reg. 9173, effective May 23, 

1990)

SUBPART K: USE OF ORGANIC MATERIAL

Section 215.301 Use of Organic Material

No person shall cause or allow the discharge of more than 

3.6 kg/hr (8 lbs/hr) of organic material into the 

atmosphere from any emission source, except as provided in 

Sections 215.302, 215.303, 215.304 and the following 

exception: If no odor nuisance exists the limitation of 

this Subpart shall apply only to photochemically reactive 

material.

(Source: Amended at 3 Ill. Reg. 30, p. 124, effective 

July 28, 1979)

Section 215.302 Alternative Standard

Emissions of organic material in excess of those permitted 

by Section 215.301 are allowable if such emissions are 

controlled by one of the following methods:

a. Flame, thermal or catalytic incineration so as either 

to reduce such emissions to 10 ppm equivalent methane 

(molecular weight 16) or less, or to convert 85 

percent of the hydrocarbons to carbon dioxide and 

water; or,

b. A vapor recovery system which adsorbs and/or 

condenses at least 85 percent of the total 

uncontrolled organic material that would otherwise be 

emitted to the atmosphere; or,

c. Any other air pollution control equipment approved by 

the Agency capable of reducing by 85 percent or more 

the uncontrolled organic material that would be 

otherwise emitted to the atmosphere.
3-27

(Source: Amended at 3 Ill. Reg. 30, p. 124, effective 

July 28, 1979)

Section 215.303 Fuel Combustion Emission Sources

The provisions of Sections 215.301 and 215.302 shall not 

apply to fuel combustion emission sources.

(Source: Amended at 3 Ill. Reg. 30, p. 124, effective 

July 28, 1979)

Section 215.304 Operations with Compliance Program

The provisions of Section 215.301 and 215.302 shall not 

apply to any owner, operator, user or manufacturer of 

paint, varnish, lacquer, coatings or printing ink whose 

compliance program and project completion schedule, as 

required by 35 Ill. Adm. Code 201, provides for the 

reduction of organic material used in such process to 20 

percent or less of total volume by May 30, 1975.

(Source: Amended at 3 Ill. Reg. 30, p. 124, effective 

July 28, 1979)

Section 215.305 Viscose Exemption (Repealed)

(Source: Repealed at 9 Ill. Reg. 13960, effective 

August 28, 1985)
4-1

10.4 Attachment 4 - State Construction and Operating Permits

217/782-2113

JOINT CONSTRUCTION/OPERATING PERMIT --NSPS SOURCE

PERMITTEE

LaFarge Corporation

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 02030051 I.D. No.: 127855AAA

Applicant's Designation: CKD/Synthetic Blending System

Subject: CKD/Synthetic Blending System Date Received: March 18, 2002

Date Issued: May 23, 2002 Expiration Date: May 23, 2007

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT emission unit(s) and/or air pollution control equipment 

consisting of a new CKD/Synthetic Gypsum Blending System that 

consists of one pugmill controlled by filter DC, feed hopper with 

belt conveyor, CKD storage tank, and belt conveyor as described 

in the above-referenced application. This Permit is subject to 

standard conditions attached hereto and the following special 

conditions:

1.0 Unit Specific Condition

1.1 CKD/Synthetic Gypsum Blending System

1.1.1 Description

Construction and operation of a system to 

blend cement kiln dust (CKD), i.e., 

particulate matter captured by the cyclones, 

ESPs, and baghouses from the cement kiln’s 

exhaust with synthetic gypsum, that is 

interground with clinker product from the kiln 

to make finished cement. Particulate matter 

emissions from the CKD storage tank and pug 

mill are controlled with a new filter DC.

1.1.2 List of Emission Units and Pollution Control 

Equipment
4-2

Emission

Unit Description

Emission 

Control 

Equipment

01 Feed Hopper with 

Belt Conveyor

None

02 CKD storage tank DC

03 Pugmill DC

04 Belt conveyor None

1.1.3 Applicability Provisions and Applicable 

Regulations

a. The new CKD/Synthetic Gypsum Blending 

System is subject to the New Source 

Performance Standard (NSPS) for Portland 

Cement Plants, 40 CFR 60, Subpart A and 

F. The Illinois EPA is administrating 

NSPS in Illinois on behalf of the United 

States EPA under a delegation agreement.

b. Emissions of particulate matter from each 

emission point on the CKD/Synthetic 

Gypsum Blending System shall not exceed 

10 percent opacity, pursuant to 40 CFR 

60.62(c).

c. At all times, the Permittee shall 

maintain and operate the new 

CKD/Synthetic Gypsum Blending System, 

including associated air pollution 

control equipment, in a manner consistent 

with good air pollution control practice 

for minimizing emissions, pursuant to 40 

CFR 60.11 (d).

1.1.4 Non-Applicability of Regulations of Concern

The CKD/Synthetic Gypsum Blending System is 

not a modification subject to Section 112(g), 

Hazardous Air Pollutants (HAPs) because 

emissions from HAPs are less than 10 tons/year 

for a single HAP and less than 25 tons/year 

for all combined HAPs.

1.1.5 Operational and Work Practices 

a. Operation of the new CKD/Synthetic Gypsum 

Blending System shall not exceed the 

following limits:

Throughput of Blended CKD

(Ton/Mo) (Ton/Yr)

18,000 150,000
4-3

b. The Permittee shall follow good operating 

practices for the DC, including periodic 

inspection routine maintenance and prompt 

repair of defects.

c. The new CKD/Synthetic Gypsum Blending 

System shall not operate more than 2,000 

hours per year.

1.1.6 Emission Limitations

a. Particulate matter (PM) emissions of the 

new CKD/Synthetic Gypsum Blending System 

shall not exceed the following limits:

Emission Unit PM Emissions

(Lb/Hr) (Ton/Yr)

Gypsum 0.5 0.5

DC (Filter) 0.8 0.8

Product Belt 0.3 0.3

Total 1.6 1.6

Compliance with annual limits shall be 

based on the running total of 12 months 

of data.

1.1.7 Testing Requirements

a. Within 60 days after achieving maximum 

production rate but no later than 180 

days after initial startup, the opacity 

of the particulate matter from each 

emission point of the new CKD/Synthetic 

Gypsum Blending System shall be measured 

in accordance with USEPA Reference Method 

9 and the procedures of 40 CFR 60.11, 

pursuant to 40 CFR 60.8 and 60.64(b)(4).

b. In addition to the applicable 

notification requirements of 40 CFR 60.7, 

the Permittee shall notify the Illinois 

EPA in writing a minimum of thirty (30) 

days prior to the expected date of these 

tests and further notified, a minimum of 

five (5) working days prior to the test, 

of the exact date, time and place of 

these tests, to enable the Illinois EPA 

to witness these tests.

c. Copies of the final test report shall be 

submitted to the Illinois EPA within 14 

days after the test results are compiled 

and finalized. The final test report 

shall include:
4-4

i. A summary of results;

ii. General information;

iii. Detailed description of test 

conditions including process weight 

rates, control equipment operating 

parameters, and preparatory 

inspections and maintenance;

iv. Data and calculations, including 

copies of all raw data sheets and 

records, sample calculations, and 

emissions results; and

v. An explanation of any discrepancies 

among individual test runs or 

anomalous data.

1.1.8 Monitoring Requirements

None

1.1.9 Recordkeeping Requirements

a. Permittee shall keep operating records of 

the following items on a monthly basis:

i. Operating hours,

ii. Throughput of CKD and synthetic 

gypsum;

iii. The average CKD content in the 

CKD/Synthetic Gypsum blend;

b. The Permittee shall keep records 

addressing use of good operating 

practices for the CKD/Synthetic Gypsum 

system, including the DC:

i. Records for periodic inspection of 

the DC with date, individual 

performing the inspection, and 

nature of inspection; and

ii. Records for prompt repair of 

defects, with identification and 

description of defect, effect on 

emissions, date identified, date 

repaired, and nature of repair.
4-5

c. The Permittee shall keep the following 

records relating to emissions:

i. PM emissions (lbs/month, tons/year)

d. All records and logs required by this 

permit shall be retained at a readily 

accessible location at the source for at 

least five years from the date of entry 

and shall be made available for 

inspection and copying by the Illinois 

EPA upon request. Any records retained 

in electronic forma (e.g. computer) shall 

be capable of being retrieved and printed 

on paper during normal source office 

hours so as to be able to respond to an 

Illinois EPA request for records during 

the course of a source inspection.

1.1.10 Reporting Requirements

a. Two copies of the required reports and 

applicable notifications shall be sent to:

Illinois Environmental Protection Agency

Division of Air Pollution Control

Compliance Section (#40)

P.O. Box 19276

Springfield Illinois 62794-9276

and one copy shall be sent to the 

Illinois EPA’s regional office at the 

following address:

Illinois Environmental Protection Agency

Division of Air Pollution Control

2009 Mall Street

Collinsville, Illinois 62234

b. The Permittee shall promptly notify the 

Illinois EPA, Compliance Section of 

noncompliance with the permit 

requirements. Reports shall describe the 

probable cause of such deviations and any 

corrective actions or preventive measures 

taken.

1.1.11 Compliance Procedures

a. The Permittee shall demonstrate 

compliance with hourly emissions limits 

in Condition 1.1.6 by proper operation of 

equipment
4-6

b. The Permittee shall demonstrate 

compliance with annual emission limits in 

Condition 1.1.6 by multiplying the hours 

of operation by the applicable emission 

rate, i.e., the rates in Condition 1.1.6 

if the equipment is properly operated.

If you have any questions on this, please call Kaushal Desai at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:KKD:psj

cc: Region 3
4-7

217/782-2113

JOINT CONSTRUCTION AND OPERATING PERMIT

PERMITTEE

Lafarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 01040057 I.D. No.: 127855AAA

Applicant's Designation: BARGELOAD Date Received: April 20, 2001

Subject: Modification to Barge Loading System

Date Issued: July 18, 2001 Operating Permit Expiration

Date: July 18, 2006

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT and OPERATE emission source(s) and/or air pollution 

control equipment consisting of modification to existing barge 

loading system as described in the above-referenced application. 

This Permit is subject to standard conditions attached hereto and 

the following special condition(s):

1. Operation of the emission source(s) included in this 

permit shall not begin until all associated air pollution 

control equipment has been constructed and is operational.

2. This permit is issued based on the modification to 

existing barge loading system (lowering the DC JA-12510 

and JA-12520 into position over the hatches and control 

the dust generated during the loading to Carlsen barges by 

DC JA-12550 in lieu of the older portable DCs) without any 

increase in emissions to the atmosphere. The existing 

barge loading system is covered by separate operating 

permits, 76120076 and 98040049.

If you have any questions on this, please call Minesh Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:psj

cc: Region 3
4-8

217/782-2113

CONSTRUCTION PERMIT GRANT -- NESHAP SOURCE

PERMITTEE

Lafarge Corporation

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 01020048 I.D. No.: 127855AAA

Applicant's Designation: INSUFFLATI Date Received: February 20, 2001

Subject: Insufflation System

Date Issued: March 23, 2001

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT emission unit(s) and/or air pollution control equipment 

consisting of a new limestone insufflation system (including, 

truck unloading, feed hopper, feed belt, and educator) for kiln 2 

as described in the above-referenced application. This Permit is 

subject to standard conditions attached hereto and the following 

special conditions:

1.0 Insufflation System

1.1 Insufflation System

1.1.1 Description

The insufflation system introduces limestone 

to kiln 2 at a point upstream of the clinker 

discharge. The limestone will absorb heat 

from the clinker causing the limestone to 

undergo a calcination reaction, converting 

some of it to lime. The calcined limestone in 

the clinker will improve the quality of the 

finished cement product for use in winter 

weather.

1.1.2 List of Emission Units and Pollution Control 

Equipment

Emission

Unit Description

Emission Control

Equipment

01 Insufflation 

System

None
4-9

1.1.3 Applicability Provisions and Applicable 

Regulations

a. This permit is issued based on the source 

being a major source for purpose of 40 

CFR 63 so that the insufflation system 

for Portland cement manufacturing 

facility is subject to a National 

Emission Standard for Hazardous Air 

Pollutants (NESHAP) From the Portland 

Cement Manufacturing Industry, 40 CFR 63, 

Subpart A and LLL. The Illinois EPA is 

administering NESHAP in Illinois on 

behalf of the United States EPA under a 

delegation agreement.

i. Pursuant to 40 CFR 63.1348, the 

Permittee shall not cause to be 

discharged any gases from the 

insufflation system that exhibit 

opacity in excess of ten percent.

b. The Permittee shall use good air 

pollution control practices to minimize 

emissions of particulate matter from the 

insufflation system.

1.1.4 Non-Applicability of Regulations of Concern

a. Pursuant to 40 CFR 63.1356, the New 

Source Performance Standard (NSPS) for 

Portland Cement Plants, 40 CFR 60, 

Subpart F is not applicable to the 

affected system since the system is 

subject to the NESHAP.

b. This permit is issued based on the 

insufflation system not being associated 

with a modification of the source, 

subject to PSD (40 CFR 52.21) because it 

does not change fuel consumption by the 

kiln and does not significantly change 

the throughput of other system at the 

source. The increases in emission of 

particulate matter due to the increased 

throughput is estimated to be at most 1 

ton/year.

c. This permit is issued based on kiln 2 and 

its associated clinker cooler being 

subject to the NSPS for Portland Cement 

Plants, 40 CFR 60 Subpart F at this time, 

so that applicability of the NSPS is 

unaffected by the insufflation system. 
4-10

Note: for purpose of the NSPS, the 

limestone fed to the kiln by insufflation 

system shall not be considered “feed” to 

the kiln for determining compliance.

1.1.5 Operational and Production Limits and Work 

Practices

Feed rate of limestone by insufflation system 

shall not exceed 7 tons/hour and 35,000 

tons/year.

1.1.6 Emission Limitations

This permit is issued based on negligible 

emissions of particulate matter from the 

insufflation system shall. For this purpose, 

emissions shall not exceed 0.04 lb/hour and 

0.50 tons/year. Compliance with annual limit 

shall be determined from a running total of 12 

months of data.

1.1.7 Testing Requirements

Permittee shall demonstrate compliance with 

the emission limits in Condition 1.1.3(a) 

using the applicable test method and 

procedures described in 40 CFR 63.7, 

63.1349(b), and 63.1350.

1.1.8 Monitoring Requirements

The Permittee shall prepare a written 

operations and maintenance plan for the 

insufflation system pursuant to 40 CFR 

63.1350. The plan shall be submitted for 

review and approval as part of the application 

for part 70 permit and shall include the 

information required in 40 CFR 63.1350(a)(1) 

through (10).

1.1.9 Recordkeeping Requirements

a. Permittee shall maintain the following 

records for insufflation system:

i. Limestone throughput for the 

insufflation system (tons/month and 

tons/year)

ii. At all times the Permittee shall to 

the extent practicable, maintain 

and operate the insufflation 

system, including associated air 
4-11

pollution control equipment, in a 

manner consistent with good air 

pollution control practice for 

minimizing emissions.

iii. Records of determinations of 

visible emission, an observation of 

opacity in accordance with 40 CFR 

63.1349 and 63.1350 for 

insufflation system.

b. Permittee shall maintain all the records 

required by the 40 CFR 63.1355.

c. The Permittee shall maintain all 

information (including all reports and 

notifications) required by this permit 

readily available for inspection by 

Illinois EPA. The files shall be 

retained for at least five years 

following the date of each occurrence, 

measurement, maintenance, corrective 

action, report, or record. At a minimum, 

the most recent two years of data shall 

be retained on site.

1.1.10 Reporting Requirements

a. The Permittee shall fulfill all 

applicable notification and reporting 

requirements of the 40 CFR 63 Subpart 

LLL.

b. The Permittee shall promptly notify the 

Illinois EPA, Compliance Section of 

noncompliance of the insufflation system 

with permit requirements within 30 days 

of the violation. The report shall 

describe the probable cause of such 

deviation, and any corrective actions or 

preventative measures taken.

1.1.11 Compliance Procedures

The Permittee shall use the records required 

by the Condition 1.1.9 along with the emission 

factors from the AP-42, control efficiency (if 

applicable) to show compliance with the 

emission limits.

2.0 The Permittee may operate source with the insufflation 

system pursuant to this permit until the CAAPP permit for 

the source is issued, provided the testing required by 
4-12

Condition 1.1.7 is performed in a timely manner and 

demonstrates compliance with Condition 1.1.3(a)(i).

If you have any questions on this, please call Minesh Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:psj

cc: Region 3
4-13

CONSTRUCTION PERMIT GRANT -- OPERATING PERMIT DENIAL -- NESHAP SOURCE

PERMITTEE

Lafarge Corporation

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 00050016 I.D. No.: 127855AAA

Applicant's Designation: STORAGEOPT Date Received: May 5, 2000

Subject: Material Storage Optimization

Date Issued: September 6, 2000

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT emission unit(s) and/or air pollution control equipment 

consisting of modification to the river belt conveyor system; 

modification to the material handling system within the existing 

material storage hall; construction of three silos to store 

clinker in an enclosed manner; construction of two process tanks 

to handle hot and off-spec clinker; construction of conveyor 

systems to transfer the clinker to the new silos; construction of 

a new solid fuels outside storage area; and construction of 

conveyor systems for transfer of fuel to and from the new storage 

location as described in the above-referenced application. This 

Permit is subject to standard conditions attached hereto and the 

following special conditions:

1.0 Modification to existing Material Handling and Storage

1.1 Material Handling and Storage System

1.1.1 Description

Portland cement manufacturing plant includes 

facilities for receipt of raw materials and 

fuels by barge, rail and truck; facilities for 

loading bares and trucks; conveying systems to 

transfer raw materials and fuels to and from 

loading and unloading facilities; a covered 

storage hall for clinker and raw materials; 

two raw mill grinding systems; two dry process 

cement kilns; tow finish mill grinding 

systems; cement storage silos; and outdoor 

storage piles for raw materials and clinker.

To improve the facility’s ability to produce 

quality cement in an economical manner, 

facility intends to undertake several changes 

in the plant’s material storage and handling 

systems. These changes will provide benefits 

to the facility and to the environment. The 
4-14

time and labor required transferring materials 

from the river barge unloading facility to 

their storage locations would be reduced. The 

emissions of particulate matter from material 

transfer and storage operation will be 

reduced. Less material will be exposed to the 

environmental elements because of the 

increased capacity to store and handle 

material in sheltered locations.

Implementation of the material handling and 

storage projects will not increase the plant’s 

production capacity. The changes will include 

modification to the river belt conveyor 

system; modification to the material handling 

system within the existing material storage 

hall; construction of three silos to store 

clinker in an enclosed manner; construction of 

two process tanks to handle hot and off-spec 

clinker; construction of conveyor systems to 

transfer the clinker to the new silos; 

construction of a new solid fuels outside 

storage area; and construction of conveyor 

systems for transfer of fuel to and from the 

new storage location.

1.1.2 List of Emission Units and Pollution Control 

Equipment

Emission

Unit Description

Emission Control

Equipment

01 Clinker Silo 

Tanks and 

Conveyors

Eighteen new or 

relocated DCs (DCB002-

010, 012, 014-016, 018-

020, 022, and 023) and 

one existing DC (DCB024)

02 Fuel Storage and 

Conveyors

None

03 Storage Haul and 

Reclaim System

None

04 Raw Material 

Conveyor System

None

1.1.3 Applicability Provisions and Applicable 

Regulations

a. This material handling and storage system 

for Portland cement manufacturing 

facility is subject to a National 

Emission Standard for Hazardous Air 

Pollutants (NESHAP) From the Portland 

Cement Manufacturing Industry, 40 CFR 63, 

Subpart A and LLL. The Illinois EPA is 

administering NESHAP in Illinois on 
4-15

behalf of the United States EPA under a 

delegation agreement.

b. Pursuant to 40 CFR 63.1348, the owner or 

operator of each new or existing raw 

material, clinker, or finished product 

storage bin; conveying system transfer 

points; bagging system; and bulk loading 

and unloading system; and each existing 

raw material dryer, at a facility shall 

not cause to be discharged any gases from 

affected sources which exhibit opacity in 

excess of ten percent.

1.1.4 Non-Applicability of Regulations of Concern

a. Pursuant to 40 CFR 63.1356, the New 

Source Performance Standard (NSPS) for 

Portland Cement Plants, 40 CFR 60, 

Subpart F is not applicable since the 

facility is subject to the NESHAP 

regulation.

b. As a consequence of the limits in Condition 

1.1.6, this permit is issued based upon the 

modification of material handling and 

storage system not constituting a new major 

source or major modification subject to 

Prevention of Significant Deterioration 

(PSD), 40 CFR 52.21.

1.1.5 Operational and Production Limits and Work 

Practices

a. Fuel stock piles of coke shall not exceed 

10,000 tons for fuel stock piles.

1.1.6 Emission Limitations

a. Emissions and operation shall not exceed 

the following limits:

PM EMISSION

Process Area (Tons/Mo) (Tons/Yr)

Barged Raw Material 1.08 12.87

Raw Material Reclaim 

from Storage Hall 0.04 0.51

Haul Roads for Fuel 0.36 4.22

Fuel Reclaim 0.02 0.13

Fuel Receiving 0.13 1.50

Fuel Stockpiles 1.25 11.21

Clinker Handling 13.56 162.76

Outdoor Manufactured 

Clinker Stockpile 0.56 6.71
4-16

These limits are based on the raw 

material throughput, number of the 

emission points in storage area, control 

efficiency, and the emission factors 

using the AP-42. Compliance with the 

annual limits shall be determined from

the running total of 12 months of data.

As a result of the above limits, 

modification to material handling and 

storage system does not constitute a 

major modification for Prevention of 

Significant Deterioration (PSD), 40 CFR 

52.21 because, the net increase in PM 

emissions is 19.48 ton/yr after 

modification. Emissions of PM-10 are 

below their PSD significance threshold.

1.1.7 Testing Requirements

Permittee shall demonstrate initial compliance 

with the emission limits Condition 1.1.3(b) 

using the test method and procedures described 

in 40 CFR 63.1349(b). 

1.1.8 Monitoring Requirements

The Permittee shall prepare for each affected 

sources a written operations and maintenance 

plan pursuant to 40 CFR 63.1350. The plan 

shall be submitted for review and approval as 

part of the application for part 70 permit and 

shall include the information required in 40 

CFR 63.1350(a)(1) through (10).

1.1.9 Recordkeeping Requirements

a. Permittee shall maintain the following 

records for affected sources:

i. Each raw material throughput (tons)

ii. Emission factor calculation for 

each process using the AP-42 

equations.

iii. PM emissions from each source and 

aggregate for the material handling 

as limited in Condition 1.1.6 with 

supporting calculation.

b. Permittee shall maintain all the records 

required by the 40 CFR 63.1355.
4-17

1.1.10 Reporting Requirements

The Permittee shall fulfill all applicable 

notification and reporting requirements of the 

40 CFR 63 Subpart LLL.

1.1.11 Compliance Procedures

The Permittee shall use the records required 

by the Condition 1.1.9 along with the emission 

factors from the AP-42, control efficiency (if 

applicable) to show compliance with the 

emission limits.

2.0 In order to insure that material handling system will be 

operated in compliance with 40 CFR 63, Subpart LLL. Tests 

must be conducted to measure opacity levels of affected 

source. The tests must be performed by an approved 

testing service in accordance with USEPA test methods.

The OPERATING permit application is DENIED because the Illinois 

Environmental Protection Act, Section 9, and 35 Ill. Adm. Code 

201.160 might be violated.

Pursuant to Section 201.160, an operating permit may not be 

issued until the equipment has been constructed or modified in 

accordance with applicable conditions in this construction 

permit. The Illinois EPA suggests that you reapply for the 

operating permit after the construction is completed in 

accordance with the construction permit. This information must 

be submitted in duplicate and should reference the application 

and I.D. numbers assigned above.

If you have any questions on this, please call Minesh Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:psj

cc: Region 3
4-18

217/782-2113

OPERATING PERMIT

PERMITTEE

Lafarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 99110051 I.D. No.: 127855AAA

Applicant's Designation: SLAG DRYER Date Received: January 8, 

2001

Subject: Slag Dryer

Date Issued: January 31, 2001 Expiration Date: January 31, 2006

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission source(s) and/or air pollution control equipment 

consisting of rotary slag dryer, slag dryer baghouse, and stacker 

as described in the above referenced application. This Permit is 

subject to standard conditions attached hereto and the following 

special conditions:

1. Description

Lafarge Corporation manufactures Portland cement, the 

current permit request is for the addition of a slag 

grinding operation with rotary dryer and corresponding 

baghouse which will allow for on-site preparation and use 

of granulated blast furnace slag (a waste product 

generated at steel manufacturing facilities)as an additive 

to their products to enhance desirable characteristics.

2. List of Emission Units and Pollution Control Equipment

Emission

Unit

Emission Control

Equipment

% Control Efficiency

Rotary Dryer Slag Dryer Bag-house 99.0

3. Applicability Provisions and Applicable Regulations

a. "Affected grinding equipment@ for the purpose of 

these unit-specific conditions, is each piece of 

equipment as described in Conditions 1 and 2 and 

associated handling and storage operations unless 

otherwise stated in the following conditions as unit 

specific.

b. The affected grinding equipment is subject to 35 IAC 

212.321(a), which provides that no person shall cause 

or allow the emission of particulate matter into the 

atmosphere in any one hour period from any new 
4-19

process emission unit, either alone or in combination 

with the emission of particulate matter from all 

other similar process emission units for which 

construction or modification commenced on or after 

April 14, 1972, at a source or premises, exceeds the 

allowable emission rates specified in subsection (c) 

of 35 IAC 212.321, [35 IAC 212.321(a)].

i. The emissions of particulate matter into the 

atmosphere in any one hour period from each of 

the affected coating lines shall not exceed 

the allowable emission rates specified in the 

following equation

E = A(P)B

Where:

P = Process weight rate; and,

E = Allowable emission rate; and,

A. For process weight rates up to 408 MG/hr 

(450 T/hr):

Metric English

P Mg/hr T/hr

E kg/hr lbs/hr

A 1.214 2.54

B 0.534 0.534

B. For process weight rates in excess of 408 

MG/hr (450 T/hr):

Metric English

P Mg/hr T/hr

E kg/hr lbs/hr

A 11.42 24.8

B 0.16 0.16

Where:

P = Process weight rate in metric or 

English tons per hour, and

E = Allowable emission rate in 

kilograms or pounds per hour.

[35 IAC 212.321]

c. The affected grinding equipment is subject to 35 IAC 

214.122b(1) which provides that no person shall cause 

or allow the emission of sulfur dioxide into the 
4-20

atmosphere in any one hour period from any new fuel 

combustion source with actual heat input smaller 

than, or equal to, 73.2 MW (250 mmBtu/hr), burning 

liquid fuel exclusively to exceed 0.46 kg of sulfur 

dioxide per MW-hr of actual heat input when 

distillate fuel oil is burned (0.3 lbs/mmBtu).

d. The affected grinding equipment is subject to 35 IAC 

216.121 which provides that no person shall cause or 

allow the emission of carbon monoxide (CO) into the 

atmosphere from any fuel combustion emission source 

with actual heat input greater than 2.9 MW (10 

mmBtu/hr) to exceed 200 ppm, corrected to 50 percent 

excess air.

4. Non-Applicability of Regulations of Concern

None

5. Operational and Production Limits and Work Practices

a. The affected grinding equipment shall not exceed the 

following material throughput limits:

Affected 

Equipment

Maximum Firing 

Rate Material

Throughput

(Tons/hour)

Throughput

(Tons/Year)

Rotary Dryer 75 mmBtu/hr Slag 150 150,000

6. Emission Limitations

The affected grinding equipment is subject to the 

following:

a. Emissions from the affected grinding equipment shall 

not exceed the following limits:

Emissions Tons/Year

 PM 15.79

 PM10 8.95

 SO2 18

 NOx 12.75

 CO 25.5

 VOM 3.46

 Pb 1.32e-3

These limits are based on the usage limits in 

Condition 5 and emission factors as listed in 

Condition 12.

b. Compliance with annual limits shall be determined on 

a monthly basis from the sum of the data for the 

current month plus the preceding 11 months (running 

12 month total).
4-21

7. Testing Requirements

None

8. Monitoring Requirements

None

9. Recordkeeping Requirements

The Permittee shall maintain records of the following 

items for the affected grinding equipment to demonstrate 

compliance with Conditions 3, 5, and 6, pursuant to 

Section 39.5(7)(b) of the Act:

a. Material throughput (tons/hour and tons/year).

b. Emissions of: PM, PM10, SO2, NOx, CO, VOM, Pb.

10. Reporting Requirements

The Permittee shall promptly notify the Illinois EPA, 

Compliance Section of noncompliance of affected grinding 

equipment with the permit requirements, pursuant to 

Section 39.5(7)(f)(ii) of the Act. Reports shall describe 

the probable cause of such deviations, and any corrective 

actions or preventive measures taken:

11. Operational Flexibility/Anticipated Operating Scenarios

None

12. Compliance Procedures

Compliance with the emission limits shall be based on the 

recordkeeping requirements in Condition 9 and the emission 

factors listed below:

a. To determine compliance with Condition 6, emissions 

from the affected grinding equipment shall be 

calculated based on the following emission factors:

Emission Fuel Usage Emission Factors*

 PM 0.085 Lb/Ton Throughput Fuel Oil

 PM10 0.061 Lb/Ton Throughput Fuel Oil

 SO2 0.24 Lb/Ton Throughput Fuel Oil

 NOx 0.17 Lb/Ton Throughput Fuel Oil

 CO 0.34 Lb/Ton Throughput Natural Gas

 VOM 0.046 Lb/Ton Throughput Fuel Oil

 Pb 0.005 Lb/1,000gal Waste Oil
4-22

Slag Handling Emission Factors

Wet Slag Storage and 

Handling

 PM = 0.0012 Lb/Ton

 PM10 = 0.000403 Lb/Ton

Dried Slag Handling and 

Storage

Conveyors 1 and 2 PM = 0.0176 Lb/Ton

 PM10 = 0.0061 Lb/Ton

Emission Points

J-67 and 69

 PM = 0.00106 Lb/Ton

 PM10 = 0.0004 Lb/Ton

Slag Grinding 

Operations

J-70C PM = 0.008 Lb/Ton

 PM10 = 0.004 Lb/Ton

J-70A/B PM = 0.028 Lb/Ton

 PM10 = 0.014 Lb/Ton

Ground Slag Handling 

and Storage

J-71/78/79 PM = 0.0024 Lb/Ton

 PM10 = 0.0020 Lb/Ton

J-82-J-86 PM = 0.0144 Lb/Ton

 PM10 = 0.0120 Lb/Ton

* Worst case emission factors are used for fuel 

usage.

If you have any questions on this, please call Ricardo NG at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:RNG:jar

cc: Region 3
4-23

217/782-2113

JOINT CONSTRUCTION AND OPERATING PERMIT - “REVISED”

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 99070031 I.D. No.: 127855AAA

Applicant's Designation: PORT SCREEN Date Received: July 13, 1999

Subject: Portable Screen Plant

Date Issued: October 1, 1999 Operating Permit Expiration

Date: October 1, 2004

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT and OPERATE emission source(s) and/or air pollution 

control equipment consisting of the portable screen plant 

consisting of Grizzly hopper, vibrating screen, and conveyor 

belts as described in the above-referenced application. This 

Permit is subject to standard conditions attached hereto and the 

following special condition(s):

1. Operation of the emission source(s) included in this 

permit shall not begin until all associated air pollution 

control equipment has been constructed and is operational.

2.0 Unit Specific Condition

2.1 Portable Screen Plant

2.1.1 Description

Portable screen plant used to screen out 

oversize material for further size reduction, 

while passing properly sized materials into 

the manufacturing process. The portable 

screen plant will process a variety of 

materials, including crushed stone and similar 

raw materials, as well as weathered clinker 

which has been stored outdoor stockpiles. The 

portable screen plant consist of a grizzly 

hopper, a vibrating screen, and conveyor 

belts.

2.1.2 List of Emission Units and Pollution Control 

Equipment
4-24

Emission

Unit Description

Emission 

Control

Equipment

01 Portable Screen 

Plant

None

2.1.3 Applicability Provisions and Applicable 

Regulations

a. No person shall cause or allow the 

emission of particulate matter into the 

atmosphere in any one hour period from 

any existing process emission source 

which, either alone or in combination 

with the emission of particulate matter 

from all other similar new or existing 

process emission sources at a plant or 

premises, exceeds the allowable emission 

rates specified in the following equation 

[35 IAC 212.321]:

E = A(P)B

Where:

P = Process weight rate

E = Allowable emission rate

For process weight rates up to 408 Mg/hr 

(450 T/hr):

 Metric English

P Mg/hr T/hr

E kg/hr lbs/hr

A 1.214 2.54

B 0.534 0.534

2.1.4 Non-Applicability of Regulations of Concern

As a consequence of limits in Conditions 2.1.5 

and 2.1.6 this permit is issued based on the 

portable screen plant not constituting a new 

major source or major modification subject to 

Prevention of Significant Deterioration (PSD), 

40 CFR 52.21.

2.1.5 Production Limits and Work Practices

a. The stone and general raw material 

throughput for the portable screen plant 

shall not exceed the 700,000 tons in any 

12 months period.
4-25

b. The clinker throughput for the portable 

screen plant shall not exceed the 60,000 

tons in any 12 months period.

c. The maximum processing rate when 

processing the clinker shall not exceed 

65 tons per hour.

2.1.6 Emission Limitations

a. The Particulate Matter (PM) emissions 

from the portable screen plant shall not 

exceed the 23.58 lb/hr and 24.36 tons/yr. 

The hourly limit is based on the maximum 

processing rate when processing clinker 

(65 ton/hr) and the emission estimated 

using the standard emission factors (0.36 

lb PM/ton). The annual limit is based on 

the maximum material process and the 

appropriate emission factors. Compliance 

with annual limits shall be determined 

from the running total of 12 months of 

data.

b. The PM-10 emissions from the portable 

screen plant shall not exceed the 11.88 

lb/hr and 12.05 tons/yr. The hourly limit 

is based on the maximum processing rate 

when processing clinker (65 ton/hr) and 

the emission estimated using the standard 

emission factors (0.18 lb PM-10/ton). 

The annual limit is based on the maximum 

material process and the appropriate 

emission factors. Compliance with annual 

limits shall be determined from the 

running total of 12 months of data.

2.1.7 Operating Requirements

None

2.1.8 Inspection Requirements

None

2.1.9 Recordkeeping Requirements

a. The Permittee shall maintain monthly 

records of the following items:

i. Stone and general raw material 

throughput (tons).

ii. Clinker throughput (tons).
4-26

iii. Maximum processing rate when 

screening the clinker.

iv. PM and PM-10 emissions calculated 

using the above records and 

emission factors.

b. These records shall be maintained at a 

readily accessible location at the plant 

for at least three years and shall be 

available for inspection and copying by 

the Illinois EPA upon request.

2.1.10 Reporting Requirements

None

2.1.11 Operational Flexibility/Anticipated Operating 

Scenarios

None

2.1.12 Compliance Procedures

a. Compliance with the emission limits in 

Condition 2.1.6 shall be based on the 

following formulas, emission factors and 

records required in Condition 2.1.9:

PM Emission = [(Stone/General Raw 

Material (Tons) *0.0365 lb PM/lb) + 

(Clinker Throughput (Tons) *0.36 lb 

PM/lb)]/2000.

PM-10 Emission = [(Stone/General Raw 

Material (Tons) *0.0168 lb PM-10/lb) + 

(Clinker Throughput (Tons) *0.18 lb PM10/lb)]/2000.

If you have any questions on this, please call Minesh Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:jar

cc: Region 3
4-27

217/782-2113

JOINT CONSTRUCTION AND OPERATION PERMIT - “REVISED”

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 99050056 I.D. No.: 127855AAA

Applicant=s Designation: GOOBER REC. Date Received: May 18, 1999

Subject: Goober Reclaim System

Date Issued: August 9, 1999 Expiration Date: August 9, 2004

Location: Rural 1000N and 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT and OPERATE emission source(s) and /or air pollution 

control equipment consisting of goober reclaim system, as 

described in the above referenced application. This Permit is 

subject to standard conditions attached hereto and the following 

special condition(s):

1. Emissions and operation of equipment shall not exceed the 

following limits:

Throughput Particulate Matter Emissions

Item of Equipment (Ton/Hour) (Lb/Hour) (Ton/Year)

Goober Reclaim System 300 0.744 3.26

These limits are based on the maximum throughput, standard 

emission factor (0.00248 lb PM/ton), and operating hours. 

Compliance with annual limits shall be determined from a 

running total of 12 months of data.

2. In the event that the operation of this facility results 

in an odor nuisance or any other nuisance due to process 

operating conditions, raw materials usage or any other 

cause, the Permittee shall take all appropriate and 

necessary actions, including but not limited to, changes 

in process conditions, raw materials, or installation of 

emission controls, in order to eliminate the nuisance.

3. Operation of the emission source(s) included in this 

permit shall not begin until all associated air pollution 

control equipment has been constructed and is operational.

4. No person shall cause or allow any visible emissions of 

fugitive particulate matter from any process, including 

any material handling or storage activity beyond the 

property line of the emission source, pursuant to 35 Ill. 

Adm. Code 212.301.
4-28

If you have any questions concerning this letter, please contact 

Minesh V. Patel at 217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:jar

cc: Region 3
4-29

217/782-2113

“REVISED”

OPERATING PERMIT GRANT

NSPS SOURCE

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 98090010 I.D. No.: 127855AAA

Applicant's Designation: E. CRANE Date Received: September 20, 1999

Subject: E. Crane Barge Unloading

Date Issued: November 30, 1999 Operating Permit Expiration

Date: November 30, 2004

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission unit(s) and/or air pollution control equipment 

consisting of a new raw material barge unloading system that 

includes an Equilibrated Crane, raw material hopper/feeder that 

has baghouse control and foam dust suppressant control for 

unloading of clinker, and a conveyor belt where all are atop a 

floating captive barge as described in the above-referenced 

application. This Permit is subject to standard conditions 

attached hereto and the following special conditions:

1a. The new raw material barge unloading system is subject to 

the New Source Performance Standard (NSPS) for Portland 

Cement Plants, 40 CFR 60, Subparts A and F. The Illinois 

EPA is administering NSPS in Illinois on behalf of the 

United States EPA under a delegation agreement.

 b. Emissions of particulate matter from each emission point 

of the new raw material barge unloading system shall not 

exceed 10 percent opacity, pursuant to 40 CFR 60.62(c).

 c. At all times, the Permittee shall maintain and operate the 

new raw material barge unloading system, including 

associated air pollution control equipment, in a manner 

consistent with good air pollution control practice for 

minimizing emissions, pursuant to 40 CFR 60.11 (d).

2a. This permit is issued based on the new raw material barge 

unloading system replacing the existing raw material barge 

unloading system with no net increase of particulate 

matter (PM) emissions or particulate matter with an 

aerodynamic diameter of 10 microns or less (PM10) 

emissions. The existing system will remain for back-up 

purposes but shall not be operated concurrently with the 

new system.
4-30

 b. Total throughput of unloading raw material shall not 

exceed the following limits:

Throughput

Material (Tons/Mo) (Tons/Yr)

Clinker 500,000 500,000

Other Raw Material That Includes

But Not Limited to Limestone,

Coal/Coke, Sand, Gypsum, Alumina Ash 300,000 3,000,000

These limits are based on maximum monthly and annual 

operation. Compliance with annual limits shall be 

determined from a running total of 12 months of data.

 c. Emissions of PM from unloading raw material shall not 

exceed the following limits:

Emission 

Factor PM Emissions

Material (Lbs/Ton) (Lbs/Mo) (Tons/Yr)

Clinker 0.01760 1,920 0.96

Other Raw Material That 

Includes But Not Limited 

to Limestone, Coal/Coke, 

Sand, Gypsum, Alumina Ash 0.00252 1,512 7.56

These limits are based on the maximum monthly and annual 

throughputs of Condition 2(b), emission factors derived 

from the equation in Section 13.2.4 of the AP-42, and two 

points of emission on the raw material barge unloading 

system where during unloading of clinker there is a 

capture efficiency of 80 percent for the hopper 

ventilation system, a capture efficiency of 100 percent 

for the feeder discharge emissions and a control 

efficiency of 99 percent for the baghouse. Compliance 

with annual limits shall be determined from a running 

total of 12 months of data.

 d. Emissions of PM10 from unloading raw material shall not 

exceed the following limits:

Emission 

Factor PM Emissions

Material (Lbs/Ton) (Lbs/Mo) (Tons/Yr)

Clinker 0.00615 720 0.36

Other Raw Material That 

Includes But Not Limited 

to Limestone, Coal/Coke, 

Sand, Gypsum, Alumina Ash 0.000882 529 2.65
4-31

These limits are based on the maximum monthly and annual 

throughputs of Condition 2(b), emission factors derived 

from the equation in Section 13.2.4 of the AP-42, and two 

points of emission on the raw material barge unloading 

system where during unloading of clinker there is a 

capture efficiency of 80 percent for the hopper 

ventilation system, a capture efficiency of 100 percent 

for the feeder discharge emissions and a control 

efficiency of 99 percent for the baghouse. Compliance 

with annual limits shall be determined from a running 

total of 12 months of data.

3. The Permittee shall keep all records necessary to 

demonstrate compliance with the conditions as set forth in 

this permit. These records shall include, but are not 

limited to, records of individual raw material loadout 

from barges compiled on a monthly basis and inspections 

and maintenance on the equipment including air pollution 

control equipment. The Permittee shall keep these records 

for a period of three years and make them available for 

inspection and copying by the Illinois EPA upon request.

If you have any questions on this, please call Minesh V. Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:jar

cc: Region 3

USEPA
4-32

217/782-2113

“REVISED”

OPERATING PERMIT -- NSPS SOURCES

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 98080093 I.D. No.: 127855AAA

Applicant's Designation: #2 FM HES Date Received: January 20, 2000

Subject: #2 FM HE Separator

Date Issued: March 23, 2000 Operating Permit Expiration

Date: March 23, 2005

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission unit(s) and/or air pollution control equipment 

consisting of a new #2 finish mill air separator and baghouse; 

and convert the existing air separator to the service of a cement 

fringe bin for temporary cement storage with the existing 

baghouse as its control that will also control the #15 and #16 

clinker tanks that were previously controlled by other baghouses 

as described in the above-referenced application. This Permit is 

subject to standard conditions attached hereto and the following 

special conditions:

1a. The new #2 finish mill air separator with baghouse and 

cement fringe bin with baghouse are subject to the New 

Source Performance Standard (NSPS) for Portland Cement 

Plants, 40 CFR 60, Subpart A and F. The Illinois EPA is 

administering NSPS in Illinois on behalf of the United 

States EPA under a delegation agreement.

 b. Emissions of particulate matter from each emission point 

of the new #2 finish mill air separator with baghouse and 

cement fringe bin shall not exceed 10 percent opacity, 

pursuant to 40 CFR 60.62(c).

 c. At all times, the Permittee shall maintain and operate the 

new #2 finish mill air separator with baghouse and cement 

fringe bin with baghouse, including associated air 

pollution control equipment, in a manner consistent with 

good air pollution control practice for minimizing 

emissions, pursuant to 40 CFR 60.11 (d).

2a. Emissions of PM from the cement fringe bin and baghouse 

shall not exceed 0.48 pounds per hour and 2.10 tons per 

year. This limit is based on the maximum hourly cement 

production capacity of the #2 finish mill of 200 tons per 
4-33

hour, the USEPA/AIRS PM uncontrolled emission factor for 

cement load-out of 0.24 pounds per ton cement, overall 

control efficiency of 99 percent, and 8760 hours per year 

operation.

 b. Emissions of PM10 from the cement fringe bin and baghouse 

shall not exceed 0.40 pounds per hour and 1.75 tons per 

year. This limit is based on the maximum hourly cement 

production capacity of the #2 finish mill of 200 tons per 

hour, the USEPA/AIRS PM10 uncontrolled emission factor for 

cement load-out of 0.20 pounds per ton cement, overall 

control efficiency of 99 percent, and 8760 hours per year 

operation.

3. The Permittee shall keep all records necessary to 

demonstrate compliance with the conditions as set forth in 

this permit. These records shall include, but are not 

limited to, records of #2 finish mill production rates 

compiled on a monthly basis and inspections and 

maintenance on the equipment including air pollution 

control equipment. The Permittee shall keep these records 

for a period of three years and make them available for 

inspection and copying by the Illinois EPA upon request.

If you have any questions on this, please call Minesh Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:psj

cc: Region 3

USEPA
4-34

217/782-2113

January 11, 2001

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

I.D. No.: 1278555AAA

Dear Mr. Ryan:

Enclosed is a revised permit letter which reflects only a change 

of name. Please note that if you have changed or intend to 

change this operation it will be necessary to apply for revision 

of your air pollution permit(s).

If you have any questions or require any assistance concerning 

these matters, contact Karen Luparell at 217/782-2113.

Very truly yours,

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:KJL:98080093:jar

Enclosure

cc: Region 3

I.D. File

Permit File
4-35

217/782-2113

“REVISED”

OPERATING PERMIT -- NSPS SOURCE

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 98060060 I.D. No.: 127855AAA

Applicant's Designation: Date Received: May 18, 1999

Subject: Synthetic Gypsum Storage and Handling

Date Issued: August 9, 1999 Expiration Date: August 9, 2004

Location: County Line Road 1000N and 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission unit(s) and/or air pollution control equipment 

consisting of a new synthetic gypsum storage and handling system 

that includes a new reclaim hopper that is loaded by a front-end 

loader, a new conveyor belt that transfers synthetic gypsum from 

the new reclaim hopper to a new bucket elevator, a new bucket 

elevator that loads synthetic gypsum to an existing storage tank, 

a new feeder that loads synthetic gypsum from the existing 

storage tank onto a new cross belt, a new cross belt that 

transfers synthetic gypsum from the synthetic storage tank feeder 

to an existing conveyor belt that transfers the synthetic gypsum 

to the existing #2 finish mill as described in the 

above-referenced application. This Permit is subject to standard 

conditions attached hereto and the following special conditions:

1a. The new synthetic gypsum storage and handling system is 

subject to the New Source Performance Standard (NSPS) for 

Portland Cement Plants, 40 CFR 60, Subpart A and F. The 

Illinois EPA is administrating NSPS in Illinois on behalf 

of the United States EPA under a delegation agreement.

 b. Emissions of particulate matter from each emission point 

on the new synthetic gypsum storage and handling system 

shall not exceed 10 percent opacity, pursuant to 40 CFR 

60.62(c).

 c. At all times, the Permittee shall maintain and operate the 

new synthetic gypsum storage and handling system, 

including associated air pollution control equipment, in a 

manner consistent with good air pollution control practice 

for minimizing emissions, pursuant to 40 CFR 60.11 (d).

2a. This permit is issued based on the new synthetic gypsum 

storage and handling system working in conjunction with 

the current system with no net increase in overall 

emissions of particulate matter (PM) emissions and 
4-36

particulate matter with an aerodynamic diameter of 10 

microns or less (PM10) emissions.

 b. Combined emissions of PM from all emission points on the 

new synthetic gypsum storage and handling system shall not 

exceed 0.32 pound per hour and 0.10 ton per year. This 

limit is based on the maximum hourly synthetic gypsum 

transfer from the storage pile to the storage tank of 250 

tons per hour, the maximum hourly synthetic gypsum 

transfer from the storage tank to the #2 finish mill of 10 

tons per hour, the maximum annual transfer of synthetic 

gypsum through the whole system of 150,000 tons per year, 

a combined emission factor for PM emissions from synthetic 

gypsum transfer from the storage pile to the storage tank 

derived from AP-42 emission factors of 0.00128 pound per 

ton, a combined emission factor for PM emissions from 

synthetic gypsum transfer from the storage tank to the #2 

finish mill derived from AP-42 emission factors of 

0.0000622 pound per ton, and a 50 percent control 

efficiency on transfer points where enclosures exist.

 c. Combined emissions of PM10 from all emission points on the 

new synthetic gypsum storage and handling system shall not 

exceed 0.11 pound per hour and 0.04 ton per year. This 

limit is based on the maximum hourly synthetic gypsum 

transfer from the storage pile to the storage tank of 250 

tons per hour, the maximum hourly synthetic gypsum 

transfer from the storage tank to the #2 finish mill of 10 

tons per hour, the maximum annual transfer of synthetic 

gypsum through the whole system of 150,000 tons per year, 

a combined emission factor for PM10 emissions from 

synthetic gypsum transfer from the storage pile to the 

storage tank derived from AP-42 emission factors of 

0.000449 pound per ton, a combined emission factor for PM10

emissions from synthetic gypsum transfer from the storage 

tank to the #2 finish mill derived from AP-42 emission 

factors of 0.0000218 pound per ton, and a 50 percent 

control efficiency on transfer points where enclosures 

exist.

3. The Permittee shall keep all records necessary to 

demonstrate compliance with the conditions as set forth in 

this permit. These records shall include, but are not 

limited to, records of synthetic gypsum throughput 

compiled on a monthly basis. The Permittee shall keep 

these records for a period of three years and make them 

available for inspection and copying by the Illinois EPA 

upon request.
4-37

If you have any questions on this, please call Minesh V. Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:jar
4-38

217/782-2113

“REVISED”

OPERATING PERMIT -- NSPS SOURCE

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 98040049 I.D. No.: 127855AAA

Applicant's Designation: Date Received: February 22, 2000

Subject: Gravity Cement Loading System

Date Issued: April 25, 2000 Operating Permit Expiration

Date: April 25, 2005

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission unit(s) and/or air pollution control equipment 

consisting of a new bulk cement barge loading system that 

includes the two existing pneumatic conveyance lines, a new 100-

ton cement surge bin that is controlled during cement filling by 

a DC, two movable air slides that convey cement to two cascading 

retractable loading chutes where each air slide/loading chute is 

controlled by its own DC as described in the above-referenced 

application. This Permit is subject to standard conditions 

attached hereto and the following special conditions:

1a. The new bulk cement barge loading system is subject to the 

New Source Performance Standard (NSPS) for Portland Cement 

Plants, 40 CFR 60, Subpart A and F. The Illinois EPA is 

administrating NSPS in Illinois on behalf of the United 

States EPA under a delegation agreement.

 b. Emissions of particulate matter from each emission point 

of the new bulk cement barge loading system shall not 

exceed 10 percent opacity, pursuant to 40 CFR 60.62(c).

 c. At all times, the Permittee shall maintain and operate the 

new bulk cement barge loading system, including associated 

air pollution control equipment, in a manner consistent 

with good air pollution control practice for minimizing 

emissions, pursuant to 40 CFR 60.11 (d).

2a. This permit is issued based on the new bulk cement barge 

loading system replacing the existing bulk cement barge 

loading system with no net increase of particulate matter 

(PM) emissions or particulate matter with an aerodynamic 

diameter of 10 microns or less (PM10) emissions. The 

existing system will remain for back-up purposes but shall 

not be operated concurrently with the new system.
4-39

 b. Emissions of PM and PM10 from the new bulk cement barge 

loading system shall not exceed 2.4 pounds per hour and 

3.00 tons per year. This limit is based on 100 percent of 

PM emissions as PM10, the maximum hourly cement loading of 

600 tons per hour to the surge bin and 300 tons per hour 

to each air slide/loading chute, the maximum annual cement 

loading of 1,500,000 tons per year to the surge bin and 

750,000 tons per year to each air slide/loading chute, an 

AIRS/FIRE 5.0 uncontrolled emission factor of 0.2 pound 

per ton of cement load out, and an overall control 

efficiency of 99 percent.

3. The Permittee shall keep all records necessary to 

demonstrate compliance with the conditions as set forth in 

this permit. These records shall include, but are not 

limited to, records of cement loading into barges compiled 

on a monthly basis and inspections and maintenance on the 

equipment including air pollution control equipment. The 

Permittee shall keep these records for a period of three 

years and make them available for inspection and copying 

by the Illinois EPA upon request.

If you have any questions on this, please call Minesh Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:psj

cc: Region 3
4-40

“REVISED”

JOINT CONSTRUCTION AND OPERATING PERMIT - NSPS SOURCE

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 98010026 I.D. No.: 127855AAA

Applicant's Designation: Date Received: January 13, 1998

Subject: Portable Clinker Stacker

Date Issued: January 27, 1998 Expiration Date: January 27, 2003

Location: County Line Roads 1000N and 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT and OPERATE emission source(s) and/or air pollution 

control equipment consisting of a clinker stacker as described in 

the above-referenced application. This Permit is subject to 

standard conditions attached hereto and the following special 

condition(s):

1. Operation of the emission source(s) included in this 

permit shall not begin until all associated air pollution 

control equipment has been constructed and is operational.

2a. The transfer points of the clinker stacker are subject to 

the New Source Performance Standard (NSPS) for Portland 

Cement Plants, 40 CFR 60, Subpart A and F. The Illinois 

EPA is administrating NSPS in Illinois on behalf of the 

United States EPA under a delegation agreement.

 b. Emissions of particulate matter from the transfer points 

of the clinker stacker shall not exceed 10 percent 

opacity, pursuant to 40 CFR 60.62(c).

 c. At all times, the Permittee shall maintain and operate the 

clinker stacker, including associated air pollution 

control equipment, in a manner consistent with good air 

pollution control practice for minimizing emissions, 

pursuant to 40 CFR 60.11 (d).

3a. Emissions of particulate matter (PM) from the clinker 

stacker shall not exceed 26.4 lbs/hour and 19.8 tons per 

year. This limit is based on the maximum hourly rated 

capacity of the stacker of 750 tons/hour, an emission 

factor of 0.0176 lb/ton derived from Equation 1 of AP-42, 

5th ed., Section 13.2.4, 1500 hours of operation per year, 

and the information provided in the permit application.

 b. Emissions of particulate matter with an aerodynamic 

diameter of 10 microns or less (PM10) from the clinker 

stacker shall not exceed 9.2 lbs/hour and 6.9 tons per 
4-41

year. This limit is based on the maximum hourly rated 

capacity of the stacker of 750 tons/hour, an emission 

factor of 0.0061 lb/ton derived from Equation 1 of AP-42, 

5th ed., Section 13.2.4, 1500 hours of operation per year, 

and the information provided in the permit application.

4. The Permittee shall comply with one of the following:

a. Within 60 days after achieving maximum production 

rate but no later than 180 days after initial 

startup, the opacity of the particulate matter 

emissions from the transfer points of the clinker 

stacker shall be measured in accordance with USEPA 

Reference Method 9 and the procedures of 40 CFR 

60.11, pursuant to 40 CFR 60.8 and 60.64(4); or

b. Have documentation of past testing of the equipment 

as mentioned above.

5. The Permittee shall keep all records necessary to demonstrate 

compliance with the conditions as set forth in this permit. 

These records shall include, but are not limited to, records 

displaying hours of operation and the results of any opacity 

test(s). The Permittee shall keep these records for a period of 

three years and make them available for inspection and copying 

by the Illinois EPA upon request.

It should be noted that this equipment replaced the equipment of permit 

number 97080050 that is now in the service of raw material handling.

If you have any questions on this, please call Darin Clutts at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:DCC:psj

cc: Region 3

USEPA
4-42

217/782-2113

JOINT CONSTRUCTION AND OPERATING PERMIT - “REVISED”

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 97110047 I.D. No.: 127855AAA

Applicant's Designation: AR 996389 Date Received: November 17, 1997

Subject: Clinker Handling System DCs

Date Issued: December 12, 1997 Operating Permit Expiration

Date: December 12, 2002

Location: County Line Roads 1000N and 300E

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT and OPERATE emission source(s) and/or air pollution 

control equipment consisting of a new DC that serves three (3) 

pickup points on existing clinker belt BC-6 and one (1) point on 

clinker reclaim elevator JC-24901; and a DC that serves four (4) 

pickup points at the transfer points between belts BC-26 and BC27 and tripper conveyor BC-28 as described in the 

above-referenced application. This Permit is subject to standard 

conditions attached hereto and the following special 

condition(s):

1. Operation of the emission source(s) included in this 

permit shall not begin until all associated air pollution 

control equipment has been constructed and is operational.

2. This permit is issued based on the above project resulting 

in no net increase of emissions.

If you have any questions on this, please call Darin Clutts at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:DCC:psj

cc: Region 3
4-43

OPERATING PERMIT - NSPS SOURCE - “REVISED”

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 97080050 I.D. No.: 127855AAA

Applicant's Designation: Date Received: February 20, 1998

Subject: Raw Material Stacker

Date Issued: March 30, 1998 Expiration Date: January 28, 2003

Location: County Line Roads 1000N and 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission source(s) and/or air pollution control equipment 

consisting of a raw material stacker as described in the 

above-referenced application. This Permit is subject to standard 

conditions attached hereto and the following special 

condition(s):

1a. The transfer points of the raw material stacker are 

subject to the New Source Performance Standard (NSPS) for 

Portland Cement Plants, 40 CFR 60, Subpart A and F. The 

Illinois EPA is administrating NSPS in Illinois on behalf 

of the United States EPA under a delegation agreement.

 b. Emissions of particulate matter from the transfer points 

of the raw material stacker shall not exceed 10 percent 

opacity, pursuant to 40 CFR 60.62(c).

 c. At all times, the Permittee shall maintain and operate the 

raw material stacker, including associated air pollution 

control equipment, in a manner consistent with good air 

pollution control practice for minimizing emissions, 

pursuant to 40 CFR 60.11 (d).

2a. Emissions of particulate matter (PM) from the raw material 

stacker shall not exceed 1.5 lbs/hour and 6.6 tons per 

year. This limit is based on the maximum hourly rated 

capacity of the stacker of 400 tons/hour, an emission 

factor of 0.0037 lb/ton derived from Equation 1 of AP-42, 

5th ed., Section 13.2.4 using an average material moisture 

content of 5%, 8,760 hours of operation per year, and the 

information provided in the permit application.

 b. Emission of particulate matter with an aerodynamic 

diameter of 10 microns or less (PM10) from the raw material 

stacker shall not exceed 0.5 lbs/hour and 2.3 tons per 

year. This limit is based on the maximum hourly rated 

capacity of the stacker of 400 tons/hour, an emission 

factor of 0.0013 lb/ton derived from Equation 1 of AP-42, 
4-44

5th ed., Section 13.2.4 using an average material moisture 

content of 5%, 8,760 hours of operation per year, and the 

information provided in the permit application.

3. The Permittee shall comply with one of the following:

a. Within 60 days after achieving maximum production 

rate but no later than 180 days after initial 

startup, the opacity of the particulate matter 

emissions from the transfer points of the raw 

material stacker shall be measured in accordance with 

USEPA Reference Method 9 and the procedures of 40 CFR 

60.11, pursuant to 40 CFR 60.8 and 60.64(4); or

b. Have documentation of past testing of the equipment 

as mentioned above.

4. The Permittee shall keep all records necessary to 

demonstrate compliance with the conditions as set forth in 

this permit. These records shall include, but are not 

limited to, records displaying the results of any opacity 

test(s) and moisture content test(s). The Permittee shall 

keep these records for a period of three years and make 

them available for inspection and copying by the Illinois 

EPA upon request.

It should be noted that this permit has been revised to show a 

higher moisture content of the material transferred based on the 

submittal of new data, a decrease of the hourly PM and PM10

emission rates due to the higher moisture content, an increase of 

the annual PM and PM10 emission rates due to the increased 

allowable hours of operation and the removal of the hours of 

operation recordkeeping requirement since revised emission rates 

are based on the maximum rated capacity of 400 tph and continuous 

operation of 8,760 hrs/yr.

If you have any questions on this, please call Darin Clutts at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:DCC:jar

cc: Region 3

USEPA
4-45

217/782-2113

JOINT CONSTRUCTION AND OPERATION PERMIT - “REVISED”

PERMITTEE

LaFarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No: 96100061 I.D. No.: 127855AAA

Applicants Designation: 7353WDTLOS Date Received: October 18, 1996

Subject: Kiln #2 Dust Return System

Date Issued: December 17, 1996 Expiration Date: December 16, 2001

Location: Rural 1000N & 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT and OPERATE emission source(s) and /or air pollution 

control equipment consisting of loadout spout controlled by 

baghouse, as described in the above referenced application. This 

Permit is subject to standard conditions attached hereto and the 

following special condition(s):

1. Operation of the emission source(s) included in this 

permit shall not begin until all associated air pollution 

control equipment has been constructed and is operational.

2. No person shall cause or allow any visible emissions of 

fugitive particulate matter from any process, including 

any material handling or storage activity beyond the 

property line of the emission source, pursuant to 35 Ill. 

Adm. Code 212.301.

3. This permit is issued based on negligible emissions of 

particulate matter from the loadout spout with baghouse 

control. For this purpose, emissions shall not exceed 

nominal emission rates of 0.1 lb/hour and 0.44 ton/year.

If you have any questions concerning this letter, please contact 

Bruce Rodely at 217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:BDR:jar

cc: Region 3
4-46

JOINT CONSTRUCTION AND OPERATION PERMIT - “REVISED”

PERMITTEE

Lafarge Midwest, Inc.

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 96060037 I.D. No.: 127855AAA

Applicant=s Designation: 7353#2kDRS Date Received: May 18, 1999

Subject: Kiln #2 Dust Return System

Date Issued: August 9, 1999 Expiration Date: June 26, 2001

Location: Rural 1000N and 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT and OPERATE emission source(s) and /or air pollution 

control equipment consisting of dust storage tank, bucket 

elevator, and associated conveyors all controlled by baghouse, as 

described in the above referenced application. This Permit is 

subject to standard conditions attached hereto and the following 

special condition(s):

1. Emissions and operation of equipment shall not exceed the 

following limits:

Throughput Particulate Matter Emissions

Item of Equipment (Lb/Hour) (Lb/Hour) (Ton/Year)

Kiln #2 Dust Return 

System

100,000 0.5 2.25

These limits are based on the information provided in the 

permit application. Compliance with annual limits shall 

be determined from a running total of 12 months of data.

2. In the event that the operation of this facility results 

in an odor nuisance or any other nuisance due to process 

operating conditions, raw materials usage or any other 

cause, the Permittee shall take all appropriate and 

necessary actions, including but not limited to, changes 

in process conditions, raw materials, or installation of 

emission controls, in order to eliminate the nuisance.

3. Operation of the emission source(s) included in this 

permit shall not begin until all associated air pollution 

control equipment has been constructed and is operational.

4. No person shall cause or allow any visible emissions of 

fugitive particulate matter from any process, including 

any material handling or storage activity beyond the 

property line of the emission source, pursuant to 35 Ill. 

Adm. Code 212.301.
4-47

It should be noted that this permit has been revised to show 

maximum throughput in Condition 1.

If you have any questions concerning this letter, please contact 

Minesh V. Patel at 217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:jar

cc: Region 3
4-48

CONSTRUCTION PERMIT GRANT -- OPERATING PERMIT DENIAL -- NESHAP SOURCE

PERMITTEE

Lafarge Corporation

Attn: Ron Ryan

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 00050016 I.D. No.: 127855AAA

Applicant's Designation: STORAGEOPT Date Received: May 5, 2000

Subject: Material Storage Optimization

Date Issued: September 6, 2000

Location: 2500 Portland Road, Grand Chain

Permit is hereby granted to the above-designated Permittee to 

CONSTRUCT emission unit(s) and/or air pollution control equipment 

consisting of modification to the river belt conveyor system; 

modification to the material handling system within the existing 

material storage hall; construction of three silos to store 

clinker in an enclosed manner; construction of two process tanks 

to handle hot and off-spec clinker; construction of conveyor 

systems to transfer the clinker to the new silos; construction of 

a new solid fuels outside storage area; and construction of 

conveyor systems for transfer of fuel to and from the new storage 

location as described in the above-referenced application. This 

Permit is subject to standard conditions attached hereto and the 

following special conditions:

1.0 Modification to existing Material Handling and Storage

1.1 Material Handling and Storage System

1.1.1 Description

Portland cement manufacturing plant includes 

facilities for receipt of raw materials and 

fuels by barge, rail and truck; facilities for 

loading bares and trucks; conveying systems to 

transfer raw materials and fuels to and from 

loading and unloading facilities; a covered 

storage hall for clinker and raw materials; 

two raw mill grinding systems; two dry process 

cement kilns; tow finish mill grinding 

systems; cement storage silos; and outdoor 

storage piles for raw materials and clinker.

To improve the facility’s ability to produce 

quality cement in an economical manner, 

facility intends to undertake several changes 

in the plant’s material storage and handling 

systems. These changes will provide benefits 

to the facility and to the environment. The 
4-49

time and labor required transferring materials 

from the river barge unloading facility to 

their storage locations would be reduced. The 

emissions of particulate matter from material 

transfer and storage operation will be 

reduced. Less material will be exposed to the 

environmental elements because of the 

increased capacity to store and handle 

material in sheltered locations.

Implementation of the material handling and 

storage projects will not increase the plant’s 

production capacity. The changes will include 

modification to the river belt conveyor 

system; modification to the material handling 

system within the existing material storage 

hall; construction of three silos to store 

clinker in an enclosed manner; construction of 

two process tanks to handle hot and off-spec 

clinker; construction of conveyor systems to 

transfer the clinker to the new silos; 

construction of a new solid fuels outside 

storage area; and construction of conveyor 

systems for transfer of fuel to and from the 

new storage location.

1.1.2 List of Emission Units and Pollution Control 

Equipment

Emission

Unit Description

Emission Control

Equipment

01 Clinker silo 

tanks and 

conveyors

Eighteen new or 

relocated DCs (DCB002-

010, 012, 014-016, 018-

020, 022, and 023) and 

one existing DC (DCB024)

02 Fuel storage and 

conveyors

None

03 Storage haul and 

reclaim system

None

04 Raw material 

conveyor system

None

1.1.3 Applicability Provisions and Applicable 

Regulations

a. This material handling and storage system 

for Portland cement manufacturing 

facility is subject to a National 

Emission Standard for Hazardous Air 

Pollutants (NESHAP) From the Portland 

Cement Manufacturing Industry, 40 CFR 63, 

Subpart A and LLL. The Illinois EPA is 

administering NESHAP in Illinois on 
4-50

behalf of the United States EPA under a 

delegation agreement.

b. Pursuant to 40 CFR 63.1348, the owner or 

operator of each new or existing raw 

material, clinker, or finished product 

storage bin; conveying system transfer 

points; bagging system; and bulk loading 

and unloading system; and each existing 

raw material dryer, at a facility shall 

not cause to be discharged any gases from 

affected sources which exhibit opacity in 

excess of ten percent.

1.1.4 Non-Applicability of Regulations of Concern

a. Pursuant to 40 CFR 63.1356, the New 

Source Performance Standard (NSPS) for 

Portland Cement Plants, 40 CFR 60, 

Subpart F is not applicable since the 

facility is subject to the NESHAP 

regulation.

b. As a consequence of the limits in 

Condition 1.1.6, this permit is issued 

based upon the modification of material 

handling and storage system not 

constituting a new major source or major 

modification subject to Prevention of 

Significant Deterioration (PSD), 40 CFR 

52.21.

1.1.5 Operational and Production Limits and Work 

Practices

a. Fuel stock piles of coke shall not exceed 

10,000 tons for fuel stock piles.

1.1.6 Emission Limitations

a. Emissions and operation shall not exceed 

the following limits:

PM EMISSION

Process Area (Tons/Mo) (Tons/Yr)

Barged Raw Material 1.08 12.87

Raw Material Reclaim 

from Storage Hall

 0.04 0.51

Haul Roads for Fuel 0.36 4.22

Fuel Reclaim 0.02 0.13

Fuel Receiving 0.13 1.50

Fuel Stockpiles 1.25 11.21

Clinker Handling 13.56 162.76

Outdoor Manufactured 

Clinker Stockpile

 0.56 6.71
4-51

These limits are based on the raw 

material throughput, number of the 

emission points in storage area, control

efficiency, and the emission factors 

using the AP-42. Compliance with the 

annual limits shall be determined from 

the running total of 12 months of data.

As a result of the above limits, 

modification to material handling and 

storage system does not constitute a 

major modification for Prevention of 

Significant Deterioration (PSD), 40 CFR 

52.21 because, the net increase in PM 

emissions is 19.48 ton/yr after 

modification. Emissions of PM-10 are 

below their PSD significance threshold.

1.1.7 Testing Requirements

Permittee shall demonstrate initial compliance 

with the emission limits Condition 1.1.3(b) 

using the test method and procedures described 

in 40 CFR 63.1349(b). 

1.1.8 Monitoring Requirements

The Permittee shall prepare for each affected 

sources a written operations and maintenance 

plan pursuant to 40 CFR 63.1350. The plan 

shall be submitted for review and approval as 

part of the application for part 70 permit and 

shall include the information required in 40 

CFR 63.1350(a)(1) through (10).

1.1.9 Recordkeeping Requirements

a. Permittee shall maintain the following 

records for affected sources:

i. Each raw material throughput (tons)

ii. Emission factor calculation for 

each process using the AP-42 

equations.

iii. PM emissions from each source and 

aggregate for the material handling 

as limited in Condition 1.1.6 with 

supporting calculation.

b. Permittee shall maintain all the records 

required by the 40 CFR 63.1355.
4-52

1.1.10 Reporting Requirements

The Permittee shall fulfill all applicable 

notification and reporting requirements of the 

40 CFR 63 Subpart LLL.

1.1.11 Compliance Procedures

The Permittee shall use the records required 

by the Condition 1.1.9 along with the emission 

factors from the AP-42, control efficiency (if 

applicable) to show compliance with the 

emission limits.

2.0 In order to insure that material handling system will be 

operated in compliance with 40 CFR 63, Subpart LLL. Tests 

must be conducted to measure opacity levels of affected 

source. The tests must be performed by an approved 

testing service in accordance with USEPA test methods.

The OPERATING permit application is DENIED because the Illinois 

Environmental Protection Act, Section 9, and 35 Ill. Adm. Code 

201.160 might be violated.

Pursuant to Section 201.160, an operating permit may not be 

issued until the equipment has been constructed or modified in 

accordance with applicable conditions in this construction 

permit. The Illinois EPA suggests that you reapply for the 

operating permit after the construction is completed in 

accordance with the construction permit. This information must 

be submitted in duplicate and should reference the application 

and I.D. numbers assigned above.

If you have any questions on this, please call Minesh Patel at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:MVP:psj

cc: Region 3
4-53

217/782-2113

OPERATING PERMIT -- NSPS SOURCE

PERMITTEE

Lafarge Corporation - Joppa Plant

Attn: Hans Schrama, Environmental Manager

Route 1, Box 84A

Grand Chain, Illinois 62941

Application No.: 77070038 I.D. No.: 127855AAA

Applicant's Designation: #2 Clinker Cooler

Date Received: December 19, 1994

Operating Permit Expiration Date: May 30, 1999

Subject: Clinker Cooler #2

Date Issued: August 5, 1998

Location: County Roads 1000N & 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission source(s) and/or air pollution control equipment 

consisting of clinker cooler #2 controlled by gravel bed filter 

with water spray, and an air-to-air heat exchanger for baghouse 

as described in the above referenced application. This Permit is 

subject to standard conditions attached hereto and the following 

special conditions:

1. This clinker cooler is subject to a New Source Performance 

Standard (NSPS), 40 CFR 60, Subpart F. The Illinois EPA 

is administering NSPS in Illinois on behalf of the United 

States EPA under a delegation agreement.

2. The particulate matter (TSP) from the clinker cooler shall 

not exceed 0.10 lb per ton feed (dry basis) to the kiln 

and 10 percent opacity pursuant to the New Source 

Performance Standard.

3. At all times, the Permittee shall also, to the extent 

practicable, maintain and operate the Portland Cement 

Plant, including associated air pollution control

equipment, in a manner consistent with good air pollution 

control practice for minimizing emissions.

4. The Permittee shall fulfill applicable recordkeeping 

requirements of the NSPS, 40 CFR 60.63.

5. Operation in excess of the applicable emission standards 

during startup is allowed.

6. Operation in excess of the applicable emission standards 

is allowed during malfunction and breakdown.

7. Applicant shall keep a log of each malfunction, breakdown 

and startup resulting in excess emissions, and submit a 

copy of the log to the Agency's regional office on or 
4-54

before the 45th day of each calendar quarter, starting on 

the date of issuance of this permit. This log shall 

contain all pertinent data such as production rate, date, 

time, cause, duration, cooler baghouse pressure drop, and 

efforts made to minimize duration and excess emissions.

8. The Clinker cooler baghouse shall be thoroughly inspected 

on a two month basis and any bags exhibiting sub-standard 

characteristics during said inspection be replaced before 

that section of the baghouse is returned to service. 

Records of all inspection and maintenance work conducted 

on the cooler's control will be kept and made available 

for Agency review upon request.

9. The Permittee shall maintain and operate a continuous 

opacity monitoring system on the above-referenced 

equipment. On or before the 45th day of each calendar 

quarter, the Permittee shall submit to the Agency a report 

for the last preceding calendar quarter of any and all 

opacity measurements which exceed 10 percent, averaged 

over a six minute period. These "excess opacity" reports 

shall provide, for each such incident, the percent opacity 

measured as well as the date and span of such incident. 

These reports shall also specify for each incident whether 

it occurred during startup, shut-down, or malfunction. If 

a malfunction is indicated in the report, all corrective 

actions taken, if any, shall be reported. The reports 

shall also specify, for each calendar quarter, the date of 

those periods during which the continuous monitoring 

system was not in operation.

10. This permit is issued based upon installation of 

air-to-air heat exchanger for existing clinker cooler #2 

with no net increase in emissions above that previously 

allowed.

11a. Prior to operation of the #2 clinker cooler at a raw feed 

rate in excess of 150 tons per hour (including fuel), the 

Permittee must demonstrate to the satisfaction of the 

Illinois EPA that a higher raw feed rate (up to 175 tons 

per hour) will comply with the applicable provisions of 

the 35 Ill. Adm. Code for Portland Cement Plants.

 b. The #2 clinker cooler may be operated on a limited time 

basis at a raw feed rate of up to 175 tph (including fuel) 

for the purpose of emission testing pursuant to a special 

written testing plan submitted to the Illinois EPA at 

least 30 days before beginning operation at a higher feed 

rate.

It should be noted that this permit is issued to incorporate 

information submitted in company’s letter dated March 3, 1998.
4-55

If you have any questions on this, please call Shashi Shah at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:SRS:psj

cc: IEPA, FOS, Region 3

IEPA, Compliance Section

IEPA, Source Monitoring Unit
4-56

217/782-2113

OPERATING PERMIT -- NSPS SOURCE - REVISED

PERMITTEE

Lafarge Corporation

Attn: Hans Schrama, Environmental Manager

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 77070037 I.D. No.: 127855AAA

Applicant's Designation: 7353-1 Date Received: August 14, 

1995

Subject: No. 2 Rotary Kiln

Date Issued: August 5, 1998 Expiration Date: May 30, 1999

Location: Country Roads 1000N and 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission source(s) and/or air pollution control equipment 

consisting of Rotary Kiln #2 with particulate emissions 

controlled by 2 cyclones, modified gas conditioning water spray 

tower, and a baghouse, and equipment consisting of introduction 

of whole tires at mid kiln and/or shredded tires as supplemental 

fuel, and petroleum coke as supplemental fuel as described in the 

above referenced application and in letters submitted to the 

Illinois EPA February 22, May 14, and May 26, 1993 and November 

30, 1994. This Permit is subject to standard conditions attached 

hereto and the following special conditions:

1. This Portland Cement Plant Rotary Kiln #2 is subject to a 

New Source Performance Standard (NSPS), 40 CFR 60, Subpart 

F. The Illinois EPA is administering NSPS in Illinois on 

behalf of the United States EPA under a delegation 

agreement.

2. The particulate matter from the #2 kiln shall not exceed 

0.3 pound particulate per ton of dry feed and 20% opacity, 

pursuant to the New Source Performance Standard.

3. At all times, the Permittee shall also, to the extent 

practicable, maintain and operate the Portland Cement 

Plant, including associated air pollution control 

equipment, in a manner consistent with good air pollution 

control practice for minimizing emissions.

4a. The raw feed rate to the #2 kiln shall not exceed 175 tons 

per hour (not including fuel). The raw feed rate to the 

#2 kiln shall include fresh feed from the kiln feed system 

as well as any net transfer of cement kiln dust between 

the #1 kiln and #2 kiln systems.

 b. The raw feed rate (not including fuel) to the #2 kiln 

shall not exceed 150 tons per hour until such time as the 

Permittee demonstrates to the satisfaction of the Illinois 

EPA that a higher raw feed rate (up to 175 tons per hours) 
4-57

will comply with the applicable emission limits specified 

in Special Condition 1 and 2 of this permit and as covered 

in the Construction Permit 93100068.

5. Kiln #2 shall operate only when the baghouse is operating 

with all components functioning properly and when visible 

emissions are not greater than 20% opacity, except during 

allowed malfunction conditions.

6. The Permittee shall maintain and operate a continuous 

opacity monitoring system on #2 kiln stack. On or before 

the 45th day of each calendar quarter, the Permittee shall 

submit to the Illinois EPA a report for the preceding 

calendar quarter of any and all opacity measurements which 

exceed 20 percent, averaged over a six minute period. 

These "excess opacity" reports shall provide, for each 

such incident, the percent opacity measured as well as the 

date and span of such incident. These reports shall also 

specify for each incident whether it occurred during 

startup, breakdown, or malfunction. If a malfunction is 

indicated in the report, all corrective actions taken, if 

any, shall be reported. The reports shall also specify, 

for each calendar quarter, the date of those periods 

during which the continuous monitoring system was not in 

operation.

7a. The particulate matter and opacity limitations in 

accordance with special condition #2 shall apply under 

supplemental fuel use for TDF and petroleum coke.

 b. This Permit is issued for the construction, if necessary, 

and substitution of TDF and petroleum coke as fuel to the 

Kiln without a net significant increase in emissions.

8a. Within 180 days from the date of completion of tire feed 

system (either from front end or at mid-kiln) for #2 kiln, 

and/or the petroleum coke feed system the effluent stream of 

#2 cement kiln shall be measured for pollutants, and as 

indicated in proposal plan dated February 22, May 14, and May 

26, 1993 and November 30, 1994 submitted to the Illinois EPA.

 b. i. The emission testing or continuous emission 

monitoring shall be performed for three modes of 

operation, namely: I, baseline stack test while 

burning coal; II, petroleum coke substitution with a 

minimum of 40% coal by weight; and III, TDF 

substitution with the petroleum coke substitution, 

and a 15% coal by weight, as indicated in the 

application.

ii. The test shall be conducted during circumstances 

which are representative of maximum emissions, and 

equipment data and material usage during the test 

shall be recorded.
4-58

 c. USEPA test methods 40 CFR 60, Appendix A shall be used for 

the following testing by an approved testing service 

unless another method is approved by the Illinois EPA or 

it is monitored by continuous emission monitoring system.

i Particulate Matter (Method 5)

ii. Sulfur Dioxide (Method 6)

iii. Carbon Monoxide (Method 10)

iv. Opacity (Method 9)

 d. Prior to carrying out these tests, the Illinois EPA's 

regional office and the Illinois EPA's Source Emission 

Test Specialist shall be notified a minimum of thirty (30) 

days prior to the expected date of these tests and further 

notified a minimum of five (5) working days prior to the 

test, of the exact date, time and place of these tests to 

enable the Illinois EPA to witness these tests sent to the 

following addresses.

Illinois Environmental Protection Agency

Division of Air Pollution Control

2009 Mall Street

Collinsville, Illinois 62234

Illinois Environmental Protection Agency

Division of Air Pollution Control

Compliance Section (#40)

P.O. Box 19276

Springfield, Illinois 62794-9276

 e. Three (3) copies of the Final Report(s) for these tests 

shall be submitted to the Illinois EPA within 14 days 

after the test results are compiled and finalized, prior 

to or accompanying the operating permit application. 

Satisfactory completion of these tests and compliance with 

the limitations of this Permit shall be a prerequisite to 

the issuance of an operating permit for these supplemental 

fuels.

 f. A copy of the Summary of Results, General Information, and 

Conclusions, as contained in the Final Report, shall also 

be submitted to the Source Emission Test Specialist. 

 g. The Final Report shall include records of laboratory 

analyses for the coal, coke and TDF, and the maximum TDF 

and petroleum coke substitution rate for the test plan.

 h. Fourteen days after test results are compiled and 

finalized, the Final Report shall include as a minimum:
4-59

i. A summary of results.

ii. General information.

iii. Description of test method(s), including description 

of sampling points, sampling train, analysis 

equipment, and test schedule.

iv. Detailed description of test conditions, including:

A. Process information, i.e., mode(s) of 

operation, process rate, e.g. fuel, raw 

material consumption and clinker production;

B. Control equipment information, i.e., equipment 

condition and operating parameters during 

testing; and

C. A discussion of any preparatory actions taken, 

i.e., inspections, maintenance and repair.

v. Data and calculations, including copies of all raw 

data sheets and records of laboratory analyses, 

sample calculations, and data on equipment 

calibration.

vi. An explanation of any discrepancies among individual 

tests or anomalous data.

9a. The use of a TDF shall be limited to normal mode of 

operation for the cement kiln.

 b. The use of TDF shall not be allowed during start up, malfunction 

and breakdown of the cement kiln or control equipment.

 c. The quantity of TDF use for this test plan shall not exceed 25% 

for TDF. After the Permittee satisfactorily completes the 

required testing showing compliance at a maximum of 60 percent 

petroleum coke, the Permittee may fire up to 60 percent 

petroleum coke during routine operation.

 d. The Permittee shall keep records of the days and quantity 

of TDF and petroleum coke used and submit it to the Field 

Engineer at Marion Office on a monthly basis during the 

180 day period specified in Special Condition 8(a).

 e. The Permittee shall provide updated information on how 

shredded tires and/or whole tire and petroleum coke feed 

system handling to insure a consistent TDF/petroleum 

coke/coal mixture as the information becomes available.

 f. The Permittee may increase pet coke firing above 60 

percent, provided that testing at that higher level is 
4-60

performed with a 180 days after the Permittee commences 

firing petroleum coke above the 60% limit. After the 

Permittee satisfactorily completes the required testing 

showing compliance at the higher level, the Permittee may 

fire coke at that higher percentage during routine 

operation. Testing at the higher percent coke shall 

follow the requirements outlined under Condition 8 of this 

permit, except that the mode of operation tested shall 

consider a higher firing percentage of coke.

It should be noted that this permit is revised to incorporate 

operation of a new baghouse at the process weight rate as 

reflected in Special Condition 4 and to clarify requirements of 

the permit per company’s letter dated March 3, 1998.

If you have any questions on this, please call Shashi Shah at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:SRS:jar

cc: IEPA, FOS Region 3

IEPA, Compliance Section

IEPA, Source Monitoring Unit

USEPA
4-61

217/782-2113

OPERATING PERMIT -- NSPS SOURCE – REVISED

PERMITTEE

Lafarge Corporation - Joppa Plant

Attn: Hans Schrama, Env. Mgr.

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 72121106 I.D. No.: 127855AAA

Applicant's Designation: 7353 #KFFS Date Received: December 19, 1994

Operating Permit Expiration Date: May 30, 1999

Subject: Portland Cement Manufacture

Date Issued: August 5, 1998

Location: County Line Roads 1000N and 300E, Joppa Plant

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission source(s) and/or air pollution control equipment 

consisting of #1 finish mill, covered conveyor belts, #1 raw 

mill, blending silo, #1 kiln feed bucket elevator, #1 kiln feed 

storage tank, #1 kiln feed air slides, #1 kiln feed system belt 

feeder and DC, a #2 kiln feed system controlled by two baghouses, 

raw material transfer from #12A belt to #14 belt and to outside 

storage, reclaim of outside material at receiving hopper, #1 and 

#2 kiln feed backup system as described in the above referenced 

application. This Permit is subject to standard conditions 

attached hereto and the following special conditions:

1a. This #1 kiln weigh feed system is subject to a New Source 

Performance Standard (NSPS), 40 CFR 60, Subpart F. The 

Illinois EPA is administering NSPS in Illinois on behalf 

of the United States EPA under a delegation agreement.

 b. The particulate matter from the above equipment shall not exceed 

10% opacity, pursuant to the New Source Performance Standard.

c. At all times, the Permittee shall also, to the extent 

practicable, maintain and operate the Portland Cement 

Plant, including associated air pollution control 

equipment, in a manner consistent with good air pollution 

control practice for minimizing emissions.

 d. Daily production rates and kiln feed rates shall be recorded 

in accordance with the provisions of 40 CFR 60.63.
4-62

2. Emissions and operation of equipment shall not exceed the 

following limits:

 Operating Particulate Matter

 Hours Process Rate Emissions

Item of Equipment (Hrs/Yr) (T/Hr) (Lb/Hr) (T/Yr)

#2 Kiln Feed

Flowmeter with

JK22570 Baghouse 8,400 175 0.1 0.44

#2 Kiln Feed Tank

with JK22560

Baghouse 8,400 175 0.17 0.72

These limits are based on the maximum emission rate and 

hours of operation indicated in the permit application. 

The annual limit is the product of the hourly limit and 

the maximum hours of operation. Compliance with annual 

limits shall be determined from a running total of 12 

months of data.

3. No person shall cause or allow any visible emissions of 

fugitive particulate matter from any process, including 

any material handling or storage activity beyond the 

property line of the emission source, pursuant to 35 Ill. 

Adm. Code 212.301.

4. No person shall cause or allow the emission of smoke or 

other particulate matter from any Portland cement kiln 

feed system into the atmosphere having an opacity greater 

than 10 percent.

5. This permit is issued based upon addition of four new 

baghouses and upgrading one existing baghouse for #1 Raw 

Mill system and #1 Finish Mill system without any increase 

in emissions above those previously allowed.

6a. This permit is issued based upon improvements to two 

existing baghouses for #1 raw mill without any increase in 

emissions of particulate matter to the atmosphere.

 b. Emissions and operation of equipment shall not exceed the 

following limits:

 Operating Particulate Matter

 Hours Emissions

Item of Equipment (Hour/Year) (Lb/Hour) (Ton/Yr)

#1 Raw Mill Baghouse 8,400 1.46 6.1

(JR12520)

#1 Raw Mill Baghouse 8,400 1.75 7.4

(JR12510)
4-63

These limits are based on the information provided in the 

permit application. Compliance with annual limits shall 

be determined from a running total of 12 months of data.

It should be noted that this permit has been revised only to

include operation of the equipment described in company’s letter 

dated August 29, 1995 and

July 15, 1996.

If you have any questions on this, please call Shashi Shah at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:SRS:jar

cc: IEPA, FOS, Region 3

IEPA, Compliance Section

IEPA, Source Monitoring Unit
4-64

217/782-2113

OPERATING PERMIT

PERMITTEE

Lafarge Corporation

Attn: Hans Schrama, Env. Mgr.

Route 1, Box 84A

Grand Chain, Illinois 62941

Application No.: 75100050 I.D. No.: 127855AAA

Applicant's Designation: #1 KILN Date Received: August 4, 1995

Subject: Kiln #1

Date Issued: August 5, 1998 Expiration Date: May 30, 1999

Location: County Line Roads 1000N and 300E, Joppa

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission source(s) and/or air pollution control equipment 

consisting of Kiln #1, a spray curtain, 2 cyclones in parallel, a 

settling chamber, ESP, and equipment consisting of introduction 

of whole tires at mid kiln and/or shredded tires as supplemental 

fuel, and petroleum coke as supplemental fuel as described in the 

above-referenced application and in letters submitted to the 

Illinois EPA February 22, May 14, and May 26, 1993 and November 

30, 1994. This Permit is subject to standard conditions attached 

hereto and the following special condition(s):

1. The raw feed rate to the #1 kiln shall not exceed 145 tons 

per hour (including fuel). The raw feed rate to the #1 

kiln shall include fresh feed from the kiln feed system as 

well as fuel and any net transfer of cement kiln dust 

between the #1 kiln and #2 kiln systems.

2a. Kiln #1 shall only operate when electrostatic precipitator 

is operating and when visible emissions are not greater 

than 30% opacity, except during startup, malfunction and 

breakdown conditions.

 b. The opacity from the ESP shall not exceed 30 percent 

except for a period or periods aggregating eight-minutes 

in any 60 minute period and not more than 60 percent 

opacity at any time and is limited to three times in any 

24 hour period pursuant to 35 Ill. Adm. Code Section 

212.123. This limit applies at all times except during 

startup, breakdown, or malfunction.

3. Operation during startup, when exceeding allowable 

emissions, is granted for a period of 6 hours.

4. Operation during malfunction and breakdown, when exceeding 

allowable emissions, is granted for a period of 6 hours.

5. The Permittee shall maintain and operate a continuous 

opacity monitoring system on #1 Kiln stack. On or before 
4-65

the 45th day of each calendar quarter, the Permittee shall 

submit to the Agency a report for the preceding calendar 

quarter of any and all opacity measurements which exceed 

30 percent, averaged over a one minute period. These 

“excess opacity” reports shall provide, for each such 

incident, the percent opacity measured as well as the date 

and span of such incident. These reports shall also 

specify for each incident whether it occurred during 

startup, breakdown, or malfunction. If a malfunction is 

indicated in the report, all corrective actions taken, if 

any, shall be reported. The reports shall also specify, 

for each calendar quarter, the date of those periods 

during which the continuous monitoring system was not in 

operation.

6. Applicant shall keep a log of each malfunction, breakdown 

and startup resulting in excess emissions and submit a 

copy of the log to the Agency Regional Office quarterly. 

This log shall consist of all pertinent data such as 

production rate, date, time, cause, duration, and efforts 

made to minimize duration and excess emissions.

7a. The particulate matter and opacity limitations in 

accordance with applicable regulation shall apply under 

TDF and petroleum coke use as supplemental fuel.

 b. This Permit is issued for the construction, if necessary, 

and substitution of TDF and petroleum coke as fuel to the 

kiln without a net significant increase in emissions.

8a. Prior to operation of the #1 kiln at a raw feed rate in 

excess of 130 tons per hour (including fuel), the 

Permittee must demonstrate to the satisfaction of the 

Illinois EPA that a higher raw feed rate (up to 145 tons 

per hour) will comply with the applicable provisions of 

the 35 Ill. Adm. Code for Portland Cement Plants.

 b. The #1 kiln may be operated on a limited time basis at a 

raw feed rate of up to 145 tph (including fuel) for the 

purpose of emission testing pursuant to a special written 

testing plan submitted to the Illinois EPA at least 30 

days before beginning operation at a higher feed rate.

9a. Within 180 days from the date of completion of tire 

delivery system (either from front end or at mid-kiln) for 

#1 kiln, and/or the petroleum coke feed system, the 

effluent stream of #1 cement kiln shall be measured for 

pollutants, as indicated in proposed plan dated 

February 22, May 14, and May 26, 1993 and November 30, 

1994 submitted to the Illinois Environmental Protection 

Agency.

 b. i. The emission testing or continuous emission 

monitoring shall be performed for three modes of 
4-66

operation, namely: I, baseline stack test at the 

maximum raw feed rate while burning coal; II, optimum 

successful TDF substitution rate established from 

progressive feed rates; and, III, petroleum coke 

substitution with a minimum of 15% coal by weight, as 

indicated in the application.

ii. The tests shall be conducted during circumstances 

which are representative of maximum processed weight 

rate, equipment data and material usage during the 

test shall be recorded.

iii. Satisfactory completion of these tests so as to 

demonstrate compliance with applicable emission 

limits (i.e., the kiln shall be tested at maximum 

rated load in order that the kiln can be approved to 

operate up to maximum rated load) is a prerequisite 

to revising or renewing of an operating permit, 

pursuant to 35 Ill. Adm. Code 210.160(a), (b) and 

(c).

 c. USEPA test methods 40 CFR 60, Appendix A shall be used for 

the following testing by an approved testing service 

unless another method is approved by the Agency or it is 

monitored by continuous emission monitoring system.

i. Particulate Matter (Method 5)

ii. Sulfur Dioxide (Method 6)

iii. Carbon Monoxide (Method 10)

iv. Opacity (Method 9)

 d. All reports, notifications, etc., required by this permit 

shall be sent to:

Illinois Environmental Protection Agency

Division of Air Pollution Control - Regional Office

2009 Mall Street

Collinsville, Illinois 62234

Telephone 618/346-5120

and

Illinois Environmental Protection Agency

Division of Air Pollution Control

Compliance Section (#40)

P.O. Box 19276

Springfield, Illinois 62794-9276

Telephone 217/782-5811

 e. Three (3) copies of the Final Report(s) for these tests 

shall be submitted to the Agency within 14 days after the 
4-67

test results are compiled and finalized, prior to or 

accompanying the operating permit application. 

Satisfactory completion of these tests and compliance with 

the limitations of this Permit shall be a prerequisite to 

the issuance of an operating permit for these supplemental 

fuels.

 f. The Final Report shall include records of laboratory 

analyses for the coal, coke and TDF, and the maximum TDF 

substitution rate for the test plan.

 g. Fourteen days after test results are compiled and 

finalized, the Final Report shall include as a minimum:

i. A summary of results.

ii. General information.

iii. Description of test method(s), including description 

of sampling points, sampling train, analysis 

equipment, and test schedule.

iv. Detailed description of test conditions, including:

A. Process information, i.e., mode(s) of 

operation, process rate, e.g. fuel or raw 

material consumption and clinker production;

B. Control equipment information, i.e., equipment 

condition and operating parameters during 

testing; and

C. A discussion of any preparatory actions taken, 

i.e., inspections, maintenance and repair.

v. Data and calculations, including copies of all raw 

data sheets and records of laboratory analyses, 

sample calculations, and data on equipment 

calibration.

vi. An explanation of any discrepancies among individual 

tests or anomalous data.

10a. The use of a TDF shall be limited to normal mode of 

operation for the cement kiln. 

 b. The use of TDF shall not be allowed during start up, 

malfunction and breakdown of the cement kiln or control 

equipment.

 c. The quantity of TDF and/or petroleum coke use for this 

test plan shall not exceed 25% for TDF and 60% for 

petroleum coke on a weight basis.
4-68

 d. After the Permittee satisfactorily completes the required 

testing at a maximum of 60 percent petroleum coke, the 

Permittee may upon Illinois EPA approval fire up to 60 

percent petroleum coke during routine operation.

 e. The Permittee may increase pet coke firing above 60 

percent, provided that testing at that higher level is 

performed within a 180 days after the Permittee commences 

firing petroleum coke above the 60% limit. The Illinois 

EPA and field office shall be notified in writing prior to 

substituting petroleum coke above 60% limit. After the 

Permittee satisfactorily completes the required testing at 

the higher level, the Permittee may fire coke at that 

higher percentage during routine operation upon Illinois 

EPA approval. Testing at the higher percent coke shall 

follow the requirements outlined under Condition 9 of this 

permit, except that the mode of operation tested shall 

consider a higher firing percentage of coke.

 f. The Permittee shall keep records of the days and quantity 

of TDF and petroleum coke used and submit it to the Field 

Engineer at Marion Office on a monthly basis during the 

180 day period specified in special condition 9(a).

g. The Permittee shall provide and update the information on 

how the shredded tires and/or whole tire feed system 

handling to insure a consistent TDF/petroleum coke/coal 

mixture as the information becomes available.

It should be noted that this permit is issued to incorporate 

operation of ESP TIE-IN to #1 Kiln (#2 Kiln’s ESP is connected to 

#1 Kiln replacing #1 Kiln’s old ESP, #2 Kiln now has new 

baghouse) as indicated in the application and company’s letter 

dated March 3, 1998.

If you have any questions on this, please call Shashi Shah at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:SRS:jar

cc: Region 3

USEPA Region V
4-69

217/782-2113

OPERATING PERMIT -- NSPS SOURCE – REVISED

PERMITTEE

Lafarge Corporation - Joppa Plant

Attn: Hans Schrama, Env. Mgr.

2500 Portland Road

Grand Chain, Illinois 62941

Application No.: 72121106 I.D. No.: 127855AAA

Applicant's Designation: 7353 #KFFS Date Received: December 19, 1994

Operating Permit Expiration Date: May 30, 1999

Subject: Portland Cement Manufacture

Date Issued: August 5, 1998

Location: County Line Roads 1000N and 300E, Joppa Plant

Permit is hereby granted to the above-designated Permittee to 

OPERATE emission source(s) and/or air pollution control equipment 

consisting of #1 finish mill, covered conveyor belts, #1 raw 

mill, blending silo, #1 kiln feed bucket elevator, #1 kiln feed 

storage tank, #1 kiln feed air slides, #1 kiln feed system belt 

feeder and DC, a #2 kiln feed system controlled by two baghouses, 

raw material transfer from #12A belt to #14 belt and to outside 

storage, reclaim of outside material at receiving hopper, #1 and 

#2 kiln feed backup system as described in the above referenced 

application. This Permit is subject to standard conditions 

attached hereto and the following special conditions:

1a. This #1 kiln weigh feed system is subject to a New Source 

Performance Standard (NSPS), 40 CFR 60, Subpart F. The 

Illinois EPA is administering NSPS in Illinois on behalf 

of the United States EPA under a delegation agreement.

 b. The particulate matter from the above equipment shall not 

exceed 10% opacity, pursuant to the New Source Performance 

Standard.

 c. At all times, the Permittee shall also, to the extent 

practicable, maintain and operate the Portland Cement 

Plant, including associated air pollution control 

equipment, in a manner consistent with good air pollution 

control practice for minimizing emissions.

 d. Daily production rates and kiln feed rates shall be 

recorded in accordance with the provisions of 40 CFR 

60.63.
4-70

2. Emissions and operation of equipment shall not exceed the 

following limits:

 Operating Process Particulate Matter

 Hours Rate Emissions

Item of Equipment (Hrs/Yr) (T/Hr) (Lb/Hr) (T/Yr)

#2 Kiln Feed

Flowmeter with

JK22570 Baghouse 8,400 175 0.1 0.44

#2 Kiln Feed Tank

with JK22560 Baghouse 8,400 175 0.17 0.72

These limits are based on the maximum emission rate and 

hours of operation indicated in the permit application. 

The annual limit is the product of the hourly limit and 

the maximum hours of operation. Compliance with annual 

limits shall be determined from a running total of 12 

months of data.

3. No person shall cause or allow any visible emissions of 

fugitive particulate matter from any process, including 

any material handling or storage activity beyond the 

property line of the emission source, pursuant to 35 Ill. 

Adm. Code 212.301.

4. No person shall cause or allow the emission of smoke or 

other particulate matter from any Portland cement kiln 

feed system into the atmosphere having an opacity greater 

than 10 percent.

5. This permit is issued based upon addition of four new 

baghouses and upgrading one existing baghouse for #1 Raw 

Mill system and #1 Finish Mill system without any increase 

in emissions above those previously allowed.

6a. This permit is issued based upon improvements to two 

existing baghouses for #1 raw mill without any increase in 

emissions of particulate matter to the atmosphere.

 b. Emissions and operation of equipment shall not exceed the 

following limits:

 Operating Particulate Matter

 Hours Emissions

Item of Equipment (Hour/Year) (Lb/Hour) (Ton/Yr)

#1 Raw Mill Baghouse 8,400 1.46 6.1

(JR12520)

#1 Raw Mill Baghouse 8,400 1.75 7.4

(JR12510)
4-71

These limits are based on the information provided in the 

permit application. Compliance with annual limits shall 

be determined from a running total of 12 months of data.

It should be noted that this permit has been revised only to 

include operation of the equipment described in company’s letter 

dated August 29, 1995 and

July 15, 1996.

If you have any questions on this, please call Shashi Shah at 

217/782-2113.

Donald E. Sutton, P.E.

Manager, Permit Section

Division of Air Pollution Control

DES:SRS:jar

cc: IEPA, FOS, Region 3

IEPA, Compliance Section
5-1

10.5 Attachment 5 - Example Certification by a Responsible Official

I certify under penalty of law that this document and all 

attachments were prepared under my direction or supervision in 

accordance with a system designed to assure that qualified 

personnel properly gather and evaluate the information submitted. 

Based on my inquiry of the person or persons directly responsible 

for gathering the information, the information submitted is, to 

the best of my knowledge and belief, true, accurate, and 

complete. I am aware that there are significant penalties for 

submitting false information, including the possibility of fine 

and imprisonment for knowing violations.

Signature: ______________________________________________

Name: ______________________________________________

Official Title: ______________________________________________

Telephone No.: ______________________________________________

Date Signed: ______________________________________________
6-1

10.6 Attachment 6 - Guidance on Revising This Permit

The Permittee must submit an application to the Illinois EPA 

using the appropriate revision classification in accordance with 

Sections 39.5(13) and (14) of the Act and 35 IAC 270.302. 

Specifically, there are currently three classifications for 

revisions to a CAAPP permit. These are:

1. Administrative Permit Amendment;

2. Minor Permit Modification; and

3. Significant Permit Modification.

The Permittee must determine, request, and submit the necessary 

information to allow the Illinois EPA to use the appropriate 

procedure to revise the CAAPP permit. A brief explanation of 

each of these classifications follows.

1. Administrative Permit Amendment

• Corrects typographical errors;

• Identifies a change in the name, address, or phone 

number of any person identified in the permit, or 

provides a similar minor administrative change at the 

source;

• Requires more frequent monitoring or reporting by the 

Permittee;

• Allows for a change in ownership or operational 

control of the source where no other change in the 

permit is necessary, provided that a written 

agreement containing a specific date for transfer of 

permit responsibility, coverage, and liability 

between the current and new Permittees has been 

submitted to the Illinois EPA;

• Incorporates into the CAAPP permit a construction 

permit, provided the conditions of the construction 

permit meet the requirements for the issuance of 

CAAPP permits; or

• Incorporates into the CAAPP permit revised 

limitations or other requirements resulting from the 

application of an approved economic incentives rule, 

marketable permits rule, or generic emissions trading 

rule.

2. Minor Permit Modification

• Do not violate any applicable requirement;
6-2

• Do not involve significant changes to existing 

monitoring, reporting, or recordkeeping requirements 

in the permit;

• Do not require a case-by-case determination of an 

emission limitation or other standard, or a 

source-specific determination of ambient impacts, or 

a visibility or increment analysis;

• Do not seek to establish or change a permit term or 

condition for which there is no corresponding 

underlying requirement and which avoids an applicable 

requirement to which the source would otherwise be 

subject. Such terms and conditions include:

• A federally enforceable emissions cap assumed 

to avoid classification as a modification 

under any provision of Title I of the CAA; and

• An alternative emissions limit approved 

pursuant to regulations promulgated under 

Section 112(i)(5) of the CAA.

• Are not modifications under any provision of Title I 

of the CAA; and

• Are not required to be processed as a significant 

permit modification.

An application for a minor permit modification shall 

include the following:

• A description of the change, the emissions resulting 

from the change, and any new applicable requirements 

that will apply if the change occurs;

• The source’s suggested draft permit/conditions;

• Certification by a responsible official that the 

proposed modification meets the criteria for use of 

minor permit modification procedures and a request 

that such procedures be used; and

• Information as contained on form 271-CAAPP for the 

Illinois EPA to use to notify USEPA and affected 

States.

3. Significant Permit Modification

• Applications that do not qualify as either minor permit 

modifications or as administrative permit amendments;
6-3

• Applications requesting a significant change in 

existing monitoring permit terms or conditions;

• Applications requesting a relaxation of reporting or 

recordkeeping requirements; and

• Cases in which, in the judgment of the Illinois EPA, 

action on an application for modification would require 

decisions to be made on technically complex issues.

An application for a significant permit modification shall 

include the following:

• A detailed description of the proposed change(s), 

including all physical changes to equipment, changes 

in the method of operation, changes in emissions of

each pollutant, and any new applicable requirements 

which will apply as a result of the proposed change. 

Note that the Permittee need only submit revised 

forms for equipment and operations that will be 

modified.

The Illinois EPA requires the information on the following 

appropriate forms to be submitted in accordance with the proper 

classification:

• Form 273-CAAPP, REQUEST FOR ADMINISTRATIVE PERMIT 

AMENDMENT FOR CAAPP PERMIT; or

• Form 271-CAAPP, MINOR PERMIT MODIFICATION FOR CAAPP 

PERMIT; or

• Form 200-CAAPP, APPLICATION FOR CAAPP PERMIT (for 

significant modification).

Application forms can be obtained from the Illinois EPA website 

at http://www.epa.state.il.us/air/forms.

Note that the request to revise the permit must be certified for 

truth, accuracy, and completeness by a responsible official.

Note that failure to submit the required information may require 

the Illinois EPA to deny the application. The Illinois EPA 

reserves the right to require that additional information be 

submitted as needed to evaluate or take final action on 

applications pursuant to Section 39.5(5)(g) of the Act and 35 IAC 

270.305.
10.7 Attachment 7 Form 199-CAAPP, Application For Construction 

Permit (For CAAPP Sources Only)

Illinois Environmental Protection Agency

Division Of Air Pollution Control -- Permit Section

P.O. Box 19506

Springfield, Illinois 62794-9506

This Agency is authorized to require and you must disclose this information under 415 ILCS 5/39. Failure to do so could result in the application 

being denied and penalties under 415 ILCS 5 et seq. It is not necessary to use this form in providing this information. This form has been 

approved by the forms management center.

Printed on Recycled Paper

199-CAAPP

Page 1 of 2

7-1

For Illinois EPA use only

I.D. number:

Permit number:

Application For Construction Permit 

(For CAAPP Sources Only)

Date received:

This form is to be used by CAAPP sources to supply information necessary to obtain a construction permit. Please attach other 

necessary information and completed CAAPP forms regarding this construction/modification project.

Source Information

1. Source name:

2. Source street address:

3. City: 4. Zip code:

5. Is the source located within city limits? Yes No

6. Township name: 7. County: 8. I.D. number:

Owner Information

9. Name:

10. Address:

11. City: 12. State: 13. Zip code:

Operator Information (if different from owner)

14. Name

15. Address:

16. City: 17. State: 18. Zip code:

Applicant Information

19. Who is the applicant? 20. All correspondence to: (check one)

 Owner Operator Owner Operator Source

21. Attention name and/or title for written correspondence:

22. Technical contact person for application: 23. Contact person's telephone number:
Printed on Recycled Paper

199-CAAPP

Page 2 of 2

7-2

Summary Of Application Contents

24. Does the application address whether the proposed project would 

constitute a new major source or major modification under each of the 

following programs:

a) Non-attainment New Source Review – 35 IAC Part 203;

b) Prevention of Significant Deterioration (PSD) – 40 CFR 52.21;

c) Hazardous Air Pollutants: Regulations Governing Constructed 

or Reconstructed Major Sources – 40 CFR Part 63?

 Yes No

25. Does the application identify and address all applicable emissions 

standards, including those found in the following:

a) Board Emission Standards – 35 IAC Chapter I, Subtitle B;

b) Federal New Source Performance Standards – 40 CFR Part 

60;

c) Federal Standards for Hazardous Air Pollutants – 40 CFR Parts 

61 and 63?

 Yes No

26. Does the application include a process flow diagram(s) showing all 

emission units and control equipment, and their relationship, for which a 

permit is being sought?

 Yes No

27. Does the application include a complete process description for the 

emission units and control equipment for which a permit is being 

sought?

 Yes No

28. Does the application include the information as contained in completed 

CAAPP forms for all appropriate emission units and air pollution control 

equipment, listing all applicable requirements and proposed exemptions 

from otherwise applicable requirements, and identifying and describing 

any outstanding legal actions by either the USEPA or the Illinois EPA?

Note: The use of "APC" application forms is not appropriate for 

applications for CAAPP sources. CAAPP forms should be used 

to supply information.

 Yes No

29. If the application contains TRADE SECRET information, has such 

information been properly marked and claimed, and have two separate 

copies of the application suitable for public inspection and notice been 

submitted, in accordance with applicable rules and regulations?

 Yes No

Not Applicable, 

No TRADE 

SECRET 

information in 

this application

Note 1: Answering “No” to any of the above may result in the application being deemed incomplete.

Signature Block

This certification must be signed by a responsible official. Applications without a signed 

certification will be returned as incomplete.

30. I certify under penalty of law that, based on information and belief formed after reasonable 

inquiry, the statements and information contained in this application are true, accurate and 

complete.

Authorized Signature:

BY:

_________________________________________________ _________________________________________________

AUTHORIZED SIGNATURE TITLE OF SIGNATORY

_________________________________________________ __________ / ___________ / ___________

TYPED OR PRINTED NAME OF SIGNATORY DATE

Note 2: An operating permit for the construction/modification permitted in a construction permit must be 

obtained by applying for the appropriate revision to the source’s CAAPP permit, if necessary.
Page 2

Printed on Recycled Paper

199-CAAPP

Page 2 of 2

7-2

10.8 Attachment 8 - Guidance on Renewing This Permit

Timeliness - Pursuant to Section 39.5(5)(n) of the Act and 35 IAC 

270.301(d), a source must submit to the Illinois EPA a complete 

CAAPP application for the renewal of a CAAPP permit not later 

than 9 months before the date of permit expiration of the 

existing CAAPP permit in order for the submittal to be deemed 

timely. Note that the Illinois EPA typically sends out renewal 

notices approximately 18 months prior to the expiration of the 

CAAPP permit.

The CAAPP application must provide all of the following 

information in order for the renewal CAAPP application to be 

deemed complete by the Illinois EPA:

1. A completed renewal application form 200-CAAPP, 

APPLICATION FOR CAAPP PERMIT.

2. A completed compliance plan form 293-CAAPP, COMPLIANCE 

PLAN/SCHEDULE OF COMPLIANCE FOR CAAPP PERMIT.

3. A completed compliance certification form 296-CAAPP, 

COMPLIANCE CERTIFICATION, signed by the responsible 

official.

4. Any applicable requirements that became effective during 

the term of the permit and that were not included in the 

permit as a reopening or permit revision.

5. If this is the first time this permit is being renewed and 

this source has not yet addressed CAM, the application 

should contain the information on form 464-CAAPP, 

COMPLIANCE ASSURANCE MONITORING (CAM) PLAN.

6. Information addressing any outstanding transfer agreement 

pursuant to the ERMS.

7. a. If operations of an emission unit or group of 

emission units remain unchanged and are accurately 

depicted in previous submittals, the application may 

contain a letter signed by a responsible official 

that requests incorporation by reference of existing 

information previously submitted and on file with the 

Illinois EPA. This letter must also include a 

statement that information incorporated by reference 

is also being certified for truth and accuracy by the 

responsible official’s signing of the form 200-CAAPP, 

APPLICATION FOR CAAPP PERMIT and the form 296-CAAPP, 

COMPLIANCE CERTIFICATION. The boxes should be marked 

yes on form 200-CAAPP, APPLICATION FOR CAAPP PERMIT, 
Page 3

Printed on Recycled Paper

199-CAAPP

Page 2 of 2

7-2

as existing information is being incorporated by 

reference.

b. If portions of current operations are not as 

described in previous submittals, then in addition to 

the information above for operations that remain 

unchanged, the application must contain the necessary 

information on all changes, e.g., discussion of 

changes, new or revised CAAPP forms, and a revised 

fee form 292-CAAPP, FEE DETERMINATION FOR CAAPP 

PERMIT, if necessary.

8. Information about all off-permit changes that were not 

prohibited or addressed by the permit to occur without a 

permit revision and the information must be sufficient to 

identify all applicable requirements, including 

monitoring, recordkeeping, and reporting requirements, for 

such changes.

9. Information about all changes made under 40 CFR 

70.4(b)(12)(i) and (ii) that require a 7-day notification 

prior to the change without requiring a permit revision.

The Illinois EPA will review all applications for completeness 

and timeliness. If the renewal application is deemed both timely 

and complete, the source shall continue to operate in accordance 

with the terms and conditions of its CAAPP permit until final 

action is taken on the renewal application.

Notwithstanding the completeness determination, the Illinois EPA 

may request additional information necessary to evaluate or take 

final action on the CAAPP renewal application. If such 

additional information affects your allowable emission limits, a 

revised form 292-CAAPP, FEE DETERMINATION FOR CAAPP PERMIT must 

be submitted with the requested information. The failure to 

submit to the Illinois EPA the requested information within the 

time frame specified by the Illinois EPA, may force the Illinois 

EPA to deny your CAAPP renewal application pursuant to Section 

39.5 of the Act.

Application forms may be obtained from the Illinois EPA website 

at http://www.epa.state.il.us/air/forms.html.

If you have any questions regarding this matter, please contact a 

permit analyst at 217/782-2113.

Mail renewal applications to:

Illinois Environmental Protection Agency

Division of Air Pollution Control

Permit Section (MC 11)
Page 4

Printed on Recycled Paper

199-CAAPP

Page 2 of 2

7-2

P.O. Box 19506

Springfield, Illinois 62794-9506

MJP:psj