DAQE-AN0007012-02

May 17, 2002

Kevin Ovard

Environmental Manager

Holcim (US) Incorporated

6055 E. Croydon Road

Morgan, Utah 84050

Dear Mr. Ovard:

Re: Approval Order: Process Change for Aluminum and Hi-Grade Limestone Material Addition at 

the Devil’s Slide Cement Plant- CDS -A, ATT; NSPS, PSD, Title V MAJOR

Project Code: N0007-012

The attached document is the Approval Order (AO) for the above-referenced project. 

Future correspondence on this Approval Order should include the engineer's name as well as the DAQE 

number as shown on the upper right-hand corner of this letter. Please direct any technical questions you 

may have on this project to Mr. John D. Jenks. He may be reached at (801) 536-4459.

Sincerely,

Richard W. Sprott, Executive Secretary

Utah Air Quality Board

RWS:JDJ:jc

cc: Weber County Health Department

Mike Owens, EPA Region VIII

State of Utah

DEPARTMENT OF ENVIRONMENTAL QUALITY

DIVISION OF AIR QUALITY

Michael O. Leavitt

Governor

Dianne R. Nielson, Ph.D.

Executive Director

Richard W. Sprott

Director

150 North 1950 West

P.O. Box 144820

Salt Lake City, Utah 84114-4820

(801) 536-4099 Fax

(801) 536-4414 T.D.D.

Web: www.deq.state.ut.us
STATE OF UTAH

Department of Environmental Quality

Division of Air Quality

APPROVAL ORDER: PROCESS CHANGE FOR ALUMINUM 

AND HI-GRADE LIMESTONE MATERIAL ADDITION AT 

THE DEVIL’S SLIDE CEMENT PLANT

Prepared By: John D. Jenks, Engineer

Email: jjenks@deq.state.ut.us

(801) 536-4459

APPROVAL ORDER NUMBER

DAQE-AN0007012-02

Date: May 17, 2002

HOLCIM (US) INCORPORATED

Source Contact

Kevin Ovard

(801) 829-2122

Richard W. Sprott

Executive Secretary

Utah Air Quality Board
ABSTRACT

Holcim (US) Incorporated, has submitted a Notice of Intent to complete a process change at their 

Devil’s Slide Cement Plant. The process change involves the storage and use of high-grade limestone 

and aluminum containing materials. There will be a couple of physical changes, namely the 

installation of an open-top hopper, and a conveyor/feeder system. While the new equipment does have 

the potential to emit particulate matter in the PM10 and PM2.5 range, emissions will be reduced from 

the current process of open pile storage. The Devil’s Slide Plant is located in Morgan County, which is 

an attainment area of the National Ambient Air Quality Standards (NAAQS) for all pollutants. New 

Source Performance Standards (NSPS) A and F (Portland Cement Plants) apply to this source, but not 

to this modification. National Emission Standards for Hazardous Air Pollutants (NESHAP) and 

Maximum Available Control Technology (MACT) regulations do not apply to this source. Title V of 

the 1990 Clean Air Act applies to this source. The Title V permit will be administratively amended 

after the AO has been issued. The emissions, in tons per year, will not change as Holcim wishes to 

retain the flexibility of their current emission totals. In addition, the anticipated decrease in actual 

emissions is 616 pounds per year of PM10.

The project has been evaluated and found to be consistent with the requirements of the Utah 

Administrative Code Rule 307 (UAC R307). A public comment period was held in accordance with 

UAC R307-401-4 and no comments were received. This air quality Approval Order (AO) authorizes the 

project with the following conditions, and failure to comply with any of the conditions may constitute a 

violation of this order.

General Conditions:

1. This Approval Order (AO) applies to the following company:

Site Office

Holcim (US) Inc.

6055 E. Croydon Road

Morgan, Utah 84050

Phone Number (801) 829-6821

Fax Number (801) 829-2100

The equipment listed in this AO shall be operated at the following location:

PLANT LOCATION:

6055 E. Croydon Road, Morgan, Utah 84050Universal Transverse Mercator (UTM) 

Coordinate System: UTM Datum NAD27

4,545.8 kilometers Northing, 455.4 kilometers Easting, Zone 12

2. Definitions of terms, abbreviations, and references used in this AO conform to those used 

in the Utah Administrative Code Rule 307 (UAC R307), and Series 40 of the Code of 

Federal Regulations (40 CFR). These definitions take precedence, unless specifically 

defined otherwise herein. 
DAQE-AN0007012-02

Page 3

3. Holcim (US) Inc. shall conduct its operations of the Devil’s Slide Cement Plant in 

accordance with the terms and conditions of this AO, which was written pursuant to 

Holcim (US) Inc.’s Notice of Intent submitted to the Division of Air Quality (DAQ) on 

October 23, 2001.

4. This AO shall replace the AO dated May 2, 2001 (DAQE-303-01).

5. The approved installations and facilities shall consist of the following equipment or 

equivalent*:

A. Five-stage suspension preheater kiln and “AS” precalciner using indirect coal 

firing 

Control Method: Kiln Main Stack Baghouse 135,000 ACFM **

Control Method: Alkali By-Pass Baghouse 75,000 ACFM **

B. Clinker Cooler

Control Method: Cooler Baghouse 95,000 ACFM **

C. #1 Finish Mill

Control Method: #1 Separator Baghouse 48,000 ACFM **

Control Method: #1 Cement Mill Baghouse nuisance dust collector

D. #2 Finish Mill

Control Method: #2 Separator Baghouse 43,000 ACFM **

Control Method: #2 Cement Mill Baghouse 17,000 ACFM **

E. #3 Finish Mill

Control Method: #3 Separator Cyclone/Baghouse 4,706 ACFM **

Control Method: #3 Cement Mill Baghouse 25,588 ACFM **

F. Coal Mill

Control Method: Baghouse 28,000 ACFM **

G. 62 additional baghouses of varying capacity for dust control. These include but 

are not limited to baghouses installed in the following areas:

Material Handling

Raw Material Grinding and Storage

Feeding

Cement and Clinker Storage (4 new silos)

H. Various quarry drilling and blasting equipment

I. Haul trucks and front-end loaders

J. Various covered conveyors

K. Open Top Material Hopper and Concrete Ramp

L. Two Diesel Powered Emergency Generators 
DAQE-AN0007012-02

Page 4

* Equivalency shall be determined by the Executive Secretary.

** Flow rates are listed for informational purposes only

Limitations and Tests Procedures

6. Emissions to the atmosphere at all times from the indicated emission point shall not 

exceed the following rates and concentrations:

Source: Kiln Main Stack Exhaust

Pollutant lb/hr

PM10 ..................................................................14

SO2 ..................................................................110

CO...................................................................438

7. Stack testing to show compliance with the emission limitations stated in the above 

condition shall be performed as specified below:

A. Testing Test

Emissions Point Pollutant Status Frequency

Kiln Main Stack PM10 ......................* .......................@

SO2 ........................* ....................... #

NOx........................** ..................... ##

CO .........................* ....................... #

B. Testing Status (To be applied above)

* The initial testing has already been performed.

** Initial compliance testing shall be performed within 180 days of the issuance of this AO. 

The initial testing shall show the source to be emitting less than 460 lbs/hr of NOx. This 

limit is for initial compliance determination only. Following a successful initial test, this 

emission limitation no longer applies.

@ Test every five years. The Executive Secretary may require testing at any time.

# Test every two years. The Executive Secretary may require testing at any time.

## Further compliance for NOx emissions shall be demonstrated through use of a continuous 

emissions monitoring system as outlined in Conditions 21 and 22.

C. Notification

The Executive Secretary shall be notified at least 30 days prior to conducting any 

required emission testing. A source test protocol shall be submitted to DAQ 

when the testing notification is submitted to the Executive Secretary. 
DAQE-AN0007012-02

Page 5

The source test protocol shall be approved by the Executive Secretary prior to 

performing the test(s). The source test protocol shall outline the proposed test 

methodologies, and stack to be tested. A pretest conference shall be held, if 

directed by the Executive Secretary.

D. Sample Location

The emission point shall be designed to conform to the requirements of 40 CFR 

60, Appendix A, Method 1, or other methods as approved by the Executive 

Secretary. Access that meets the standards of the Occupational Safety and 

Health Administration (OSHA) or the Mine Safety and Health Administration 

(MSHA) shall be provided.

E. Volumetric Flow Rate

40 CFR 60, Appendix A, Method 2

F. PM10

For stacks in which no liquid drops are present, the following methods shall be 

used: 40 CFR 51, Appendix M, Methods 201 or 201a. The back half 

condensibles shall also be tested using the method specified by the Executive 

Secretary. All particulate captured shall be considered PM10.

For stacks in which liquid drops are present, methods to eliminate the liquid 

drops should be explored. If no reasonable method to eliminate the drops exists, 

then the following methods shall be used: 40 CFR 60, Appendix A, Method 5, 

5a, 5d, or 5e as appropriate. The back half condensibles shall also be tested using 

the method specified by the Executive Secretary. The portion of the front half of 

the catch considered PM10 shall be based on information in Appendix B of the 

fifth addition of the EPA document, AP-42, or other data acceptable to the 

Executive Secretary.

The back half condensibles shall not be used for compliance demonstration but 

shall be used for inventory purposes.

G. Sulfur Dioxide (SO2)

40 CFR 60, Appendix A, Method 6, 6A, 6B or 6C

H. Nitrogen Oxides (NOx)

40 CFR 60, Appendix A, Method 7, 7A, 7B, 7C, 7D or 7E

I. Carbon Monoxide (CO)

40 CFR 60, Appendix A, Method 10
DAQE-AN0007012-02

Page 6

J. Calculations

To determine mass emission rates (lb/hr, etc.) the pollutant concentration as 

determined by the appropriate methods above shall be multiplied by the 

volumetric flow rate and any necessary conversion factors determined by the 

Executive Secretary, to give the results in the specified units of the emission 

limitation.

K. Existing Source Operation

For an existing source/emission point, the production rate during all compliance 

testing shall be no less than 90% of the maximum production achieved in the 

previous three (3) years

8. Visible emissions from the following emission points shall not exceed the following 

values:

A. All kiln exhaust gases - 20% opacity

B. All other point sources - 10% opacity

Opacity observations of emissions from stationary sources shall be conducted according

to 40 CFR 60, Appendix A, Method 9.

9. The following production limits shall not be exceeded:

A. 691,250 tons of clinker produced per rolling 12-month period

B. 2310 tons of clinker produced per day

C. 7900 hours per rolling 12-month period for operation of the main kiln

To determine compliance with a rolling 12-month total the owner/operator shall calculate 

a new 12-month total by the twentieth day of each month using data from the previous 12 

months. Records of production shall be kept for all periods when the plant is in 

operation. Production shall be determined by maintenance of a supervisor log. The 

records of production shall be kept on a daily basis.

10. The emergency generator hours of operation for maintenance purposes shall not exceed 

60 hours per 12-month period. Compliance with the annual limitation shall be 

determined on a rolling 12-month total. Based on the twentieth day of each month a new 

12-month total shall be calculated using the previous 12 months of engine hours and shall 

be kept for all periods when the plant is in operation. Engine hours of operation shall be 

determined by examination of maintenance records, which shall be kept on site.

Roads and Fugitive Dust

11. The facility shall abide by all applicable requirements of UAC R307- 205 for Fugitive 

Emission and Fugitive Dust sources. The provisions of R307-205 shall not apply to any 

sources for which limitations for fugitive dust or fugitive emissions are assigned pursuant 

to R307-401 or R307-305 nor shall they apply to agricultural or horticultural activities.
DAQE-AN0007012-02

Page 7

12. All unpaved roads and other unpaved operational areas that are used by mobile 

equipment shall be water sprayed and/or chemically treated to control fugitive dust. The 

application of water or chemical treatment shall be used. Treatment shall be of sufficient 

frequency and quantity to maintain the surface material in a damp/moist condition unless 

it is below freezing. The opacity shall not exceed 20% during all times the areas are in 

use. If chemical treatment is to be used, the plan must be approved by the Executive 

Secretary. Records of water and/or chemical treatment shall be kept for all periods when 

the plant is in operation. The records shall include the following items:

A. Date

B. Number of treatments made, dilution ratio, and quantity

C. Precipitation received, if any, and approximate amount

D. Time of day treatments were made

E. Records of temperature if the temperature is below freezing.

13. The haul road limitations shall be:

A. Twenty-five (25) miles per hour for all haulers

B. Fifteen (15) miles per hour for all loaders

These limitations shall not be exceeded. The vehicle speed on the haul road shall be 

posted, at a minimum, on site at the beginning of the haul road so that it is clearly visible 

from the haul road.

14. Visible fugitive dust emissions from haul-road traffic and mobile equipment in 

operational areas shall not exceed 20% opacity. Visible emissions determinations for 

traffic sources shall use procedures similar to Method 9. The normal requirement for 

observations to be made at 15-second intervals over a six-minute period, however, shall 

not apply. Six points, distributed along the length of the haul road or in the operational 

area, shall be chosen by the Executive Secretary or the Executive Secretary’s 

representative. An opacity reading shall be made at each point when a vehicle passes the 

selected points. Opacity readings shall be made  vehicle length or greater behind the 

vehicle and at approximately  the height of the vehicle or greater. The accumulated six 

readings shall be averaged for the compliance value.

15. A dust suppression system shall be installed at the following points to control fugitive 

emissions:

A. Crusher dump pocket

B. Conveyor transfer points

The system shall operate whenever dry conditions warrant or as determined necessary by 

the Executive Secretary.

Fuels

16. The owner/operator shall use only the following fuels in the kiln:

A. Coal

B. Diaper Derived Fuel (DDF)

C. Tire Derived Fuel (TDF)
DAQE-AN0007012-02

Page 8

D. Natural Gas

E. Coke

F. Fuel Oil

G. Used Oil

If any other fuel is to be used, an AO shall be required in accordance with R307-401, 

UAC.

17. The sulfur content of any coal or mixture of coals burned shall not exceed 1.0 pound of 

sulfur per million BTU of heat input. The sulfur content of any fuel oil or diesel burned 

shall not exceed 0.85 pounds sulfur per million gross BTU heat input. If any type of fuel 

that is to be used that has a higher sulfur content, an AO shall be required in accordance 

with R307-401, UAC.

Methods for determining sulfur content of coal and fuel oil shall be those methods of the 

American Society for Testing and Materials, UAC R307-203-1 (4)

(a) For determining sulfur content in coal, ASTM Methods D3177-75 or D4239-85 are 

to be used.

(b) For determining sulfur content in oil, ASTM Methods D2880-71 or D4294-89 are to 

be used.

(c) For determining the gross calorific (or BTU) content of coal, ASTM Methods 

D2015-77 or D3286-85 are to be used.

18. The concentration/parameters of contaminants in any used oil fuel shall not exceed the 

following levels:

1) Arsenic.....................................5 ppm by weight

2) Cadmium..................................2 ppm by weight

3) Chromium..............................10 ppm by weight

4) Lead .....................................100 ppm by weight

5) Total halogens...................1,000 ppm by weight

6) Sulfur .......................................0.5 percent by weight

A. The flash point of all used oil to be burned shall not be less than 100 F.

B. The owner/operator shall provide test certification for each load of used oil fuel 

received. Certification shall be either by their own testing or test reports from the 

used oil fuel marketer. Records of used oil fuel consumption and the test reports 

shall be kept for all periods when the plant is in operation.

C. Used oil that does not exceed any of the listed contaminants content may be 

burned. The owner/operator shall record the quantities of oil burned on a daily 

basis.

D. Any used oil fuel that contains more than 1000 ppm by weight of total halogens 

shall be considered a hazardous waste and shall not be burned in the boiler. The 

oil shall be tested for halogen content by ASTM Method D-808-81, EPA Method 

8240 or Method 8260 before used oil fuel is transferred to the boiler tank and 

burned.
DAQE-AN0007012-02

Page 9

E. Sources utilizing used oil as a fuel shall comply with the State Division of Solid 

and Hazardous Waste in accordance with R315-15, UAC.

Federal Limitations and Requirements

19. In addition to the requirements of this AO, all applicable provisions of 40 CFR 60, New 

Source Performance Standards (NSPS) Subpart A, 40 CFR 60.1 to 60.18 and Subpart F, 

40 CFR 60.60 to 60.66 (Standards of Performance for Portland Cement Plants) apply to 

this installation. To be in compliance, this facility must operate in accordance with the 

most current version of 40 CFR 60 applicable to this source.

Monitoring - Continuous Emissions Monitoring

20. The annual emissions of NOx from the main kiln stack shall not exceed 1,817 tons per 

rolling 12-month period. Compliance with this limitation will be through installation and 

use of a continuous emissions monitoring system as outlined in Condition 22 below.

21. The owner/operator shall install, calibrate, maintain, and continuously operate a 

continuous emissions monitoring system on the kiln main stack. The owner/operator 

shall record the output of the system, for measuring the NOx emissions. The monitoring 

system shall comply with all applicable sections of R307-170, UAC; 40 CFR 51, 

Appendix P; and 40 CFR 60, Appendix B.

All continuous emissions monitoring devices as required in federal regulations and state 

rules shall be installed and operational prior to placing the affected source in operation.

Except for system breakdown, repairs, calibration checks, and zero and span adjustments 

required under paragraph (d) 40 CFR 60.13, the owner/operator of an affected source 

shall continuously operate all required continuous monitoring devices and shall meet

minimum frequency of operation requirements as outlined in 40 CFR 60.13 and Section 

UAC R307-170.

Records & Miscellaneous

22. At all times, including periods of startup, shutdown, and malfunction, owners and 

operators shall, to the extent practicable, maintain and operate any equipment approved 

under this Approval Order including associated air pollution control equipment in a 

manner consistent with good air pollution control practice for minimizing emissions. 

Determination of whether acceptable operating and maintenance procedures are being

used will be based on information available to the Executive Secretary which may 

include, but is not limited to, monitoring results, opacity observations, review of 

operating and maintenance procedures, and inspection of the source. All maintenance 

performed on equipment authorized by this AO shall be recorded, and the records shall 

be maintained for a period of two years.

23. The owner/operator shall comply with UAC, R307-150 Series. Inventories, Testing and 

Monitoring. To be in compliance, this facility must operate in accordance with the most 

current version of the UAC, R307-150 series.
DAQE-AN0007012-02

Page 10

24. The owner/operator shall comply with R307-107, UAC, General Requirements: 

Unavoidable Breakdown. To be in compliance, this facility must operate in accordance 

with the most current version of the UAC, R307-107.

All records referenced in this AO, or in applicable NSPS, which are required to be kept by the 

owner/operator, shall be made available to the Executive Secretary or Executive Secretary’s 

representative upon request, and the records shall include the five-year period prior to the date of the 

request. A summary of those records that are required as part of this Approval Order is included herein. 

This summary shall not be considered an additional requirement, but is included for informational 

purposes only. The condition that requires that these records be kept as part of the compliance with this 

AO is listed following the individual record. Examples of records to be kept at this source shall include 

the following as applicable:

Production rate Condition number 9

Hours of operation Condition number 9

Test results Condition number 7

Fugitive emission control Condition number 12 

CEMS1records Condition number 22

Maintenance records Condition number 23

Emission inventory Condition number 24

Upset, breakdown episodes Condition number 25

The list above may not be a complete list of all records that are required to be kept by Holcim 

(US) Inc.. For a complete list of required records check all AO conditions, and all applicable 

Federal regulations such as NSPS standards that apply to this source.

Any changes which may affect the terms or conditions of this Approval Order shall be reviewed in 

accordance with R307-401, UAC.

The Executive Secretary shall be notified in writing if the company is sold or changes its name.

This AO in no way releases the owner or operator from any liability for compliance with all other 

applicable federal, state, and local regulations including UAC R307.

A copy of the rules, regulations and/or attachments addressed in this AO may be obtained by contacting 

the Division of Air Quality. The Utah Administrative Code R307 rules used by DAQ, the Notice of 

Intent (NOI) guide, and other air quality documents and forms may also be obtained on the Internet at the 

following web site: http://www.eq.state.ut.us/eqair/aq_home.htm

Annual emissions for this source (the entire plant) are currently calculated at the following values:

Pollutant Tons/yr

A. PM10 ..............................................................54.8

B. SO2 ..............................................................433.7

C. NOx............................................................1856.0

D. CO.............................................................1728.1

E. VOC..............................................................32.8

 

 

1 CEMS = Continuous Emission Monitor System
DAQE-AN0007012-02

Page 11

The annual emission estimations above are for the purpose of determining the applicability of Prevention 

of Significant Deterioration, nonattainment area, maintenance area, and Title V source requirements of 

the UAC R307. They are not to be used for determining compliance.

Approved By:

Richard W. Sprott, Executive Secretary

Utah Air Quality Board