Document ID: EPA-HQ-OAR-2007-0877-0049
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2008-06-16T04:00Z

Technical Support Document for Portland Cement New Source Performance
Standards Review

May 2008

Table of Contents

  TOC \o "1-3" \h \z \u  

  HYPERLINK \l "_Toc199222274"  I.	New Kilns	  PAGEREF _Toc199222274 \h 
1  

  HYPERLINK \l "_Toc199222275"  II.	Solid Waste from Alkali Bypass
Control Device	  PAGEREF _Toc199222275 \h  1  

  HYPERLINK \l "_Toc199222276"  III.	Recent BACT Determinations	 
PAGEREF _Toc199222276 \h  1  

  HYPERLINK \l "_Toc199222277"  IV.	Conversion of Input-Based Emission
Format and Concentration-Based Format	  PAGEREF _Toc199222277 \h  5  

  HYPERLINK \l "_Toc199222278"  V.	Emission Testing Results	  PAGEREF
_Toc199222278 \h  6  

  HYPERLINK \l "_Toc199222279"  VI.	Monitoring Benefit Analysis	 
PAGEREF _Toc199222279 \h  13  

  HYPERLINK \l "_Toc199222282"  VII.	References	  PAGEREF _Toc199222282
\h  13  

 

New Kilns

Our review of permits and discussions with industry representatives and
State environmental agencies indicates that older, less energy efficient
wet and long dry kilns are being replaced with preheater/precalciner
kilns because preheater/precalciner kilns have superior energy
efficiency and increased clinker capacity. All new kilns are
preheater/precalciner kilns due to energy savings and greater throughput
capacities compared to other kiln types. As described in this report,
the average capacity of a preheater/precalciner kiln is more than twice
that of a preheater kiln which is the closest in capacity to the
preheater/precalciner kiln. Heat input for a preheater/ precalciner kiln
is 3.3 mmBtu/ton of clinker compared to 3.8 for a preheater kiln,
4.5 for a long dry kiln, and 6.0 for a long wet kiln.

We also reviewed a detailed listing of portland cement kilns which
indicates that since 2000, 20 kilns that were constructed or modernized
are all preheater/precalciner design.

Because all new kilns are expected to be of a preheater/precalciner
design, we chose that kiln type as our model kiln to use in the
evaluation of cost and environmental impacts associated with the
proposed amendments to the portland cement NSPS. In selecting a
representative size kiln, we examined data compiled by the Portland
Cement Association. The average kiln size of kilns built between 2000
and 2006 was 1.3 million short tons of clinker per year (See Table I-1).
A 1.2 million tpy kiln was selected as the model as smaller models
typically provide somewhat more conservative estimates of impacts. 
Representative design parameters associated with this kiln include flue
gas flow rates of between about 350,000 and 390,000 acfm with exhaust
gas temperatures to the control device in the area of 300 to 400 °F.
Cost, energy and environmental impacts were estimated for a 1.2 million
tpy kiln.

Table I-1.  Portland cement kilns operating in 2006 that began
construction in 2000 or later

Company 	Location	Year Construction Began	Kiln Type	Kiln Capacity
(Thousand Metric Tons)	Kiln Capacity (Thousand Short Tons)	Comments

Ash Grove Cement	Chanute, KS	2001	PH/PC	1490	1642

	Buzzi Unicem	Chattanooga, TN	2000	PH/PC	816	899

	Buzzi Unicem	Greencastle, IN	2000	PH/PC	1224	1349	Modification

California Portland Cement	Rillito, AZ	2002	PH/PC	969	1068

	Cemex	Louisville, KY	2000	PH/PC	1407	1551

	Cemex	Victorville, CA	2001	PH/PC	1668	1838

	Dragon Products	Thomaston, ME	2004	PH/PC	776	855

	GCC of America	Rapid City, SD	2005	PH/PC	602	663

	Giant Cement Holding, Inc.	Harleyville, SC	2005	PH/PC	848	935

	Holcim (US) Inc.	Florence, CO	2001	PH/PC	1542	1699

	Holcim (US) Inc.	Holly Hill, SC	2003	PH/PC	1687	1859

	Holcim (US) Inc.	Midlothian, TX	2000	PH/PC	1028	1133

	Lafarge North America	Caldera, AL	2002	PH/PC	1467	1617

	Lafarge North America	Sugar Creek, MO	2001	PH/PC	924	1018

	Lehigh Cement Company	Union Bridge, MD	2001	PH/PC	1996	2200

	Phoenix Cement Company	Clarkdale, AZ	2002	PH/PC	912	1005

	Rinker Materials	Miami, FL	2000	PH/PC	985	1086

	Suwannee America Cement	Branford, FL	2003	PH/PC	820	904

	Texas Industries, Inc.	Midlothian, TX	2001	PH/PC	1964	2164

	Titan America L.L.C.	Medley, FL	2004	PH/PC	1634	1801

Maximum	1996	2200

Minimum	602	663

Average

Count	1238	1364

20

	All data are from U.S. and Canadian Portland Cement Industry:  Plant
Information Summary dated December 31, 2006

	

Solid Waste from Alkali Bypass Control Device

The quantity of solid waste generated from the alkali bypass as a
percentage of the total cement kiln dust (CKD) generated was estimated.
Information supplied by two cement manufacturers was examined.
Information from one manufacturer showed that 5,885 tpy waste was
generated from an alkali bypass on a kiln with a clinker capacity of
891,370 tpy. At a rate of 1.65 tons of feed for every ton of clinker,
the total material processed by this kiln is 1.47 million tons (891,370
x1.65). The total amount of waste generated in the form of CKD is,
therefore, approximately 579,391 tpy (1.47million–891,370).The waste
from the alkali bypass, 5,885 tpy, represents approximately 1 percent of
the total CKD produced (5885/579,531).

A second kiln with a capacity of 1,028,570 tpy of clinker reported 6,300
tpy of waste from its alkali bypass. As above, it is estimated that a
kiln of this capacity would process approximately 1.7 million (1,028,570
x 1.65) tpy of feed material. The total waste generated would be
approximately 669,000 tpy. The waste from the alkali bypass, 6,300 tpy,
represents approximately 0.9 percent of the total CKD produced
(6,300/669000). 

Recent BACT Determinations

The following three BACT analysis documents were reviewed.

1)	Technical Evaluation Preliminary Determination Draft BACT
Determinations: CEMEX Cement Company, Brooksville, Hernando County. New
Portland Cement Line. DEP File No. 0530010-029-AC (PSD-FL-384). April 3,
2007.

2)	Technical Support Document and Statement of Basis for Construction of
Drake Cement, L.L.C. Portland Cement Plant. Air Quality Permit Number
1001770. April 12, 2006.

3)	Technical Evaluation, Preliminary Determinations Draft BACT
Determinations, Sumter Cement Company, Sumter County, Florida. New
Portland Cement Plant. DEP File No. 1190041-001-AC (PSD-FL-358).
December 21, 2005. 

The purpose of the review was to examine recent BACT determinations for
portland cement (PC) plants, to identify permit limits that have been
established based on well-designed and operated emission reduction
processes and add-on controls, as part of a review of the PC NSPS
review. These documents were also reviewed to determine whether they
presented conflicting information, particularly regarding emission
permit limits for BACT analyses conducted in the U.S. The information in
the documents was compared with information from specific permits, or
information about the status of the plants available on the Internet.

The most important information in the documents with respect to the PC
NSPS review seems to be in tables in documents #1 and #3. Both of these
documents have tabular summaries of air pollutant permit levels in
recent BACT analyses conducted throughout the U.S. (but with emphasis on
Florida, because both are State of Florida reports). The data in the
BACT analyses tables are summarized in Table III-1, with updated
information as available from specific permits. Table III-1 also shows
the identification numbers for the kilns in the permits (note that the
kiln identification number might be higher than the number of operating
kilns at a plant, if the plant has shut down kilns), and the date of
initial operation of the kiln, if available (note that these dates are
approximate). 

The NOx limits show many plants with a value of 1.95 lb/ton. This is
particularly true of recently permitted Florida kilns. However, it
should be noted that many of these kilns have not yet started operation
(e.g., with operation dates of 2008 or 2009). The lowest limit for NOx
in Table III-1 is 1.14 lb/ton for the Drake Cement plant in Drake, AZ.
Note that the value of 1.14 lb/ton was not part of a BACT determination
(the BACT determination value was 1.95 lb/ton), but was instead required
in order to limit impacts on a nearby Class I area. The next lowest
values are 1.21 lb/ton, for #1 and #2 kilns at the CEMEX plant in
Brooksville, FL. Note that both of these kilns are operational, as of
the date of this review. 

The PM10 permit limits for several plants are confusing, particularly in
light of the NSPS and NESHAP limits of 0.30 lb/ton of dry feed material.
Some plants seem to have limits well below this value (e.g. the Suwannee
American Kiln #1 limit appears to be 0.093 lb/ton dry feed material).
Others seem to be higher than this value (e.g. the Florida Rock Kiln #1
value of 0.47 lb/ton). It’s possible that kilns with higher PM10
limits include clinker cooler emissions (because both pieces of
equipment are vented to a common stack). It is also possible that the
kilns with lower limits have separate, higher limits for total PM
(versus PM10). 

Table III-2 contains a summary of NOx controls for the kilns listed in
Table III-1. In many cases, it was not clear whether a particular type
of control was being employed at a particular kiln. If information was
not available, these cells are blank in Table III-2.

As part of the investigation of the status of these new plants, some
potential additional new kilns were identified, that weren’t mentioned
in any of the three BACT analyses documents reviewed. These potential
additional new kilns include kilns at the following plants:

●	CEMEX Balcones plant, in New Braunfels, TX

●	TXI plant in Oro Grande, CA

●	GCC America plant in Pueblo, CO

●	Eagle Materials plant, in LaSalle, IL

Table III-1. Permit Limits* (from Florida BACT Determination Reports,
References 1 and 3, Except Where Otherwise Noted).

Project	Kiln

#	Type1	Permit

Date	Year

Operational2	City	ST	NOx

(lb/ton)	SO2

(lb/ton)	CO

(lb/ton)	VOC

(lb/ton)	PM10

(lb/ton)

Drake Cement, LLC	1	PH/C	4/12/06	2009	Drake	AZ	1.14/1.953	0.06	3.6	0.12
0.21

Suwannee American	2	PH/C	6/9/06	Postponed?	Branford	FL	1.954	0.204	2.94
0.124	0.3/0.174

Suwannee American	1	PH/C	3/15/05	2005	Branford	FL	2.9/2.45	0.205	3.345
0.125	0.0935

CEMEX (Application/Determination)	3	PH/C	Withdrawn6	Withdrawn6
Brooksville	FL	1.95/1.507	0.20/0.20	2.9/2.07	0.12/0.1157	0.23/0.157

CEMEX	2	PH	12/22/06	2006	Brooksville	FL	1.218	0.20	2.0	0.115	0.15

CEMEX 	1	PH	12/22/06	2006	Brooksville	FL	1.218	N/A8	N/A8	N/A8	N/A8

Rinker/FCS (Florida Crushed Stone)	2	PH/C	7/7/05	2008	Brooksville	FL
1.95	0.23	3.6	0.12	0.20

Sumter Cement	1	PH/C	2/6/06	2009	Center Hill	FL	1.95	0.20	2.9	0.115
0.153

Titan America, Pennsuco Plant	1	PH/C	4/5/05	2005	Medley	FL	2.17	0.50	2.0
0.14	0.10

Florida Rock	2	PH/C	7/05	2006?	Newberry	FL	1.95	0.28	3.6	0.12	0.28

Florida Rock	1	PH/C	1995	2002	Newberry	FL	2.8/2.459	0.28	3.6	0.12	0.47

American Cement	1	PH/C	2/13/06	2008	Sumterville	FL	1.95	0.20	2.9	0.12
0.15

Holcim, Ste. Genevieve Plant	1	PH/C	6/8/04	2009	Bloomsdale	MO	2.4	1.26
6.0	0.33	0.35

Ash Grove (Draft)	1	PH/C	?	Cancelled10	Moapa	NV	1.95	0.42	1.05	0.0625
0.095

Holcim Holly Hill, SC	1	LW	?	2003	Holly Hill	SC	4.33	3.26	6.8	0.27	0.67

TXI, Midlothian TX 	5	PH/C	2/04	2005	Midlothian	TX	2.811	1.33	1.56	0.06
0.12

*  All permit limit values are per ton of clinker, except where noted.

1  Kiln type:  PH/C = preheater/calciner (also called
“preheater/precalciner”); PH = preheater; LW = long wet. 

2  Year operational is for the kiln or latest modifications (e.g., if
new controls were installed); year operational is tentative,
particularly for kilns projected to be operational in 2008 and beyond.

3 Drake Cement BACT determine value was 1.95 lb/ton; value of 1.14
lb/ton was permit limit, to reduce impact on nearby Class I area.

4	Specific limits for Kiln #2 (Emissions Unit 013) are as follows, with
averaging times in parenthesis; values are in lb/ton of clinker, except
where noted:  NOx = 1.95 (30 days);  SO2 = 0.20 (24 hours); CO = 2.90
(30 days); VOC = 0.12 (30 days) ; PM10 = 0.30 lb/ton of dry preheater
feed material / 0.17 lb/ton clinker (average of 3 1-hour runs).
Available at:    HYPERLINK
"http://www.dep.state.fl.us/Air/permitting/construction/suwannee.htm" 
http://www.dep.state.fl.us/Air/permitting/construction/suwannee.htm .
(Specifically at:   HYPERLINK
"http://www.dep.state.fl.us/Air/permitting/construction/Suwannee/final_d
raft.zip" 
http://www.dep.state.fl.us/Air/permitting/construction/Suwannee/final_dr
aft.zip .) 

5	Specific limits for Kiln #1 (Emissions Unit 004) are as follows, with
averaging times in parenthesis; values are in lb/ton of clinker, except
for PM10, which is in lb/ton of dry preheater feed:  NOx = 2.9 (24
hours), 2.4 (30 days);  SO2 = 0.20 (3 hours); CO = 3.34 (3 hours); VOC =
0.12 (30 days) ;PM10 = 0.093 (3 hours). Available at:    HYPERLINK
"http://www.dep.state.fl.us/Air/permitting/construction/suwannee.htm" 
http://www.dep.state.fl.us/Air/permitting/construction/suwannee.htm .
(Specifically at:   HYPERLINK
"http://www.dep.state.fl.us/Air/permitting/construction/Suwannee/prodinc
rease.zip" 
http://www.dep.state.fl.us/Air/permitting/construction/Suwannee/prodincr
ease.zip .) 

6 CEMEX apparently withdrew their permit application for Kiln #3 on July
31, 2007. See Withdrawl of Permit application letter to Florida DEP
dated July 31, 2007, available at:    HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex.htm" 
http://www.dep.state.fl.us/air/permitting/construction/cemex.htm .
(Specifically at:   HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex/cemexwithd
rawal.pdf" 
http://www.dep.state.fl.us/air/permitting/construction/cemex/cemexwithdr
awal.pdf .)   

7  Permit application and BACT determination values are not equal; BACT
determination values are lower.

8  The NOx permit levels for Kiln #1 and #2 at the CEMEX plant in
Brooksville, FL were reduced to 1.21 lb/ton of dry preheater feed, in
conjunction with installation of SNCR systems on both kilns. See
“Indirect Firing/SNCR System Kiln #1 and #2,” at:    HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex.htm" 
http://www.dep.state.fl.us/air/permitting/construction/cemex.htm .
(Specifically at:    HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex/026FinalPe
rmit.pdf" 
http://www.dep.state.fl.us/air/permitting/construction/cemex/026FinalPer
mit.pdf .)  Note that the permit limits for pollutants other than NOx
are not known for Kiln #1.

9  NOx limit was “subsequently reduced to 2.45 pounds per ton of
clinker (30-day rolling average) at the request of Florida Rock. This
revision was made in December 2002 in conjunction with a production rate
increase.”

10	Ash Grove appears to have cancelled plans to construct the Moapa, NV
plant. See “Ash Grove Cancels Southern Nevada Project,” on Cement
Americas Newsline, dated September 13, 2007. Available at:    HYPERLINK
"http://64.233.169.104/search?q=cache:6jS_jm8KGqUJ:enews.penton.com/enew
s/cementamericas/cement_americas/current+Ash+Grove+cancels+Moapa+plant&h
l=en&ct=clnk&cd=1&gl=us" 
http://64.233.169.104/search?q=cache:6jS_jm8KGqUJ:enews.penton.com/enews
/cementamericas/cement_americas/current+Ash+Grove+cancels+Moapa+plant&hl
=en&ct=clnk&cd=1&gl=us .

11	BACT analysis #1 (the BACT determination for CEMEX Kiln #3 in
Brooksville, FL) quotes the Texas Commission on Environmental Quality
(TCEQ) SIP Revision report of May 23, 2007 as stating, “The NOx
emissions factor for dry pre-heater-precalciner (PH/PC) or precalciner
(PC) kilns, 1.7 lb/ton, is based on TXI’s dry PH/PC kiln actual
overall average pound per ton of clinker emissions rate since 2001.” 
Also, “One dry kiln in Ellis County (TXI Kiln 5) that uses new process
designs rather than end-of-pipe controls is achieving lower emissions
than this already (1.36 lb/ton).”

Table III-2. NOx Controls for Cement Kilns.

Project	Kiln

#	City	ST	SNCR1	SCC1	LNB1	Indirect

Firing	Tires

(% Heat Input)

Drake Cement, LLC	1	Drake	AZ	Yes

Suwannee American	2	Branford	FL	Yes	Yes	Yes	Yes

	Suwannee American	1	Branford	FL	Yes

CEMEX (Application/Determination)	3	Brooksville	FL	Yes	Yes	Yes	Yes

	CEMEX	2	Brooksville	FL	Yes

CEMEX 	1	Brooksville	FL	Yes

Yes (20)

Rinker/FCS (Florida Crushed Stone)	1	Brooksville	FL	Yes	Yes	Yes	Yes

	Sumter Cement	1	Center Hill	FL	Yes	Yes	Yes	Yes

	Titan America, Pennsuco Plant	1	Medley	FL	No

Florida Rock	2	Newberry	FL	Yes	Yes	Yes	Yes

	Florida Rock	1	Newberry	FL	Yes

American Cement	1	Sumterville	FL	Yes	Yes	Yes	Yes

	Holcim, Ste. Genevieve Plant	1	Bloomsdale	MO	Yes

Ash Grove (Draft)	1	Moapa	NV	Yes	Yes	Yes

Holcim Holly Hill, SC	1	Holly Hill	SC	No

TXI, Midlothian TX 	5	Midlothian	TX	No

SNCR = Selective Non-Catalytic Reduction; SCC = Staged Combustion in
Calciner; LNB = Low NOx burners.

Cells that are blank indicate that information is not presently
available.

Conversion of Input-Based Emission Format and Concentration-Based
Format

Input-based emission levels and concentration-based emission levels can
be converted to output-based levels by using conversion factors based on
industry averages (see Docket item II-B-67, Docket no. A-92-53).
Although actual conversion factors are kiln specific, the following
factors can be used to convert from one emission format to a different
format:

1.65 tons of feed are required to produce 1 ton of clinker.

54,000 dscf are required for every ton of feed material.

Tables IV-1-IV-3 shows conversions of input, output and concentration
formats.

Table IV-1. Convert lb PM/ton clinker to gr/dscf

	lb/ton clinker	gr/lb	ton raw feed/ton  clinker	dscf/ton raw feed
gr/dscf	lb/ton feed

0.01	7000	1.65	54000	0.0008	0.01

0.0863	7000	1.65	54000	0.0068	0.05

0.09	7000	1.65	54000	0.0071	0.05

0.1	7000	1.65	54000	0.0079	0.06

0.11	7000	1.65	54000	0.0086	0.07

0.12	7000	1.65	54000	0.0094	0.07

0.13	7000	1.65	54000	0.0102	0.08

0.14	7000	1.65	54000	0.0110	0.08

0.15	7000	1.65	54000	0.0118	0.09

0.16	7000	1.65	54000	0.0126	0.10

0.17	7000	1.65	54000	0.0134	0.10

0.18	7000	1.65	54000	0.0141	0.11

0.5	7000	1.65	54000	0.0393	0.30

	Table IV-2. Convert gr PM/dscf to lb/ton clinker 

	gr/dscf	gr/lb	ton raw feed/ton  clinker	dscf/ton raw feed	lb/ton
clinker	lb/ton feed

0.002	7000	1.65	54000	0.0255	0.0154

0.004	7000	1.65	54000	0.0509	0.0024

0.006	7000	1.65	54000	0.0764	0.0036

0.008	7000	1.65	54000	0.1018	0.0048

0.01	7000	1.65	54000	0.1273	0.0061

0.015	7000	1.65	54000	0.1909	0.0091

0.02	7000	1.65	54000	0.2546	0.0121

0.025	7000	1.65	54000	0.3182	0.0152

0.0236	7000	1.65	54000	0.3004	0.0143

0.03	7000	1.65	54000	0.3819	0.0182

0.04	7000	1.65	54000	0.5091	0.0242

0.05	7000	1.65	54000	0.6364	0.0303

0.1	7000	1.65	54000	1.2729	0.0606

0.15	7000	1.65	54000	1.9093	0.0909

0.2	7000	1.65	54000	2.5457	0.1212

0.3	7000	1.65	54000	3.8186	0.1818

0.4	7000	1.65	54000	5.0914	0.2424

	Table IV-3. Convert lb PM/ton feed to lb/ton clinker 

	lb/ton feed

ton raw feed/ton  clinker	lb/ton clinker

0.01

1.65	0.0100

0.05

1.65	0.0863

0.05

1.65	0.0900

0.06

1.65	0.1000

0.07

1.65	0.1100

0.07

1.65	0.1200

0.08

1.65	0.1300

0.08

1.65	0.1400

0.09

1.65	0.1500

0.10

1.65	0.1600

0.10

1.65	0.1700

0.11

1.65	0.1800

0.30

1.65	0.5000

Emission Testing Results

We obtained and analyzed the results of emission testing at cement
kilns, to support development of revisions to the cement kiln New Source
Performance Standards (NSPS). The goal of this was to obtain criteria
pollutant (i.e., carbon monoxide, or CO; nitrogen oxides, or NOx; sulfur
dioxide, or SO2; particulate, or PM; particulate matter under
10 micrometers, or PM10) emission test results for kilns that have been
installed or significantly modified since 1996. The emission testing
results are also compared to permit limits for the kilns. As will be
discussed later in this section, the effort to obtain further emission
testing and continuous emission monitoring (CEM) data is ongoing.

Emission test results can be reported in many formats, e.g. as a mass
emission rate (lb/hr or tpy), as a concentration (ppm or gr/dscf), or as
an emission factor (lb/ton of feed, or lb/ton of clinker produced). In
order to facilitate comparisons between plants, this section limits
emission test report results to those presented in lb/ton of clinker or
lb/ton of feed. In fact, the final analysis converts all values to
lb/ton of clinker, using the plant-specific conversions, except where
noted. (Typically, a value of value of 1.65 tons of feed per ton of
clinker can be used to convert between the emission factors. However,
the Florida Department of Environmental Protection (DEP) provided values
per ton of feed and per ton of clinker for all plants, based on
plant-specific conversions. Therefore, this section has those Florida
DEP values for all Florida plants.)

We obtained emission test results for criteria pollutants from several
states. The most extensive set of emission test results came from the
Florida DEP, which provided a spreadsheet containing 567 records of
emission test results for criteria and other pollutants (e.g. sulfuric
acid mist, and dioxins/furans). These 567 records represented the
average result of each emission test (i.e., each emission test typically
involves three runs; the average result from the three runs is what was
reported in the spreadsheet from the Florida DEP). We sorted this list
of records according to pollutant, and selected the pollutants of
interest (approximately 489 records), removed tests conducted prior to
1997 (leaving approximately 351 records), removed tests conducted at
inactive facilities (leaving approximately 304 records), removed tests
that were reported in units other than lb/ton of clinker or lb/ton of
feed (leaving 248 records), and removed only single tests. The resulting
dataset contained 217 records.

The results of an analysis of the dataset of 217 records are summarized
in Table V-1. The first column in Table V-1 contains the criteria
pollutant (e.g., CO, NOx, PM, etc.). The next columns contain the plant
name and location, state, and kiln number. Note that there has been an
important change in ownership of several kilns in Florida. In late 2007,
CEMEX purchased Rinker (which had previously purchased Florida Crushed
Stone). Table V-1 reflects the results of both these purchases, with the
old plant names in parenthesis. 

The next two columns of Table V-1 contain permit values: the first
column contains limits from the permit values spreadsheet submitted by
the Florida DEP, and the second column contains values that were given
as the permit limit in the test results spreadsheet submitted by the
Florida DEP. Note that, in some cases, values are different; typically,
this means the permit limit was changed over the years since testing.
The units for the permit value are given in the next column (i.e.,
lb/ton of clinker, or lb/ton of feed).

The three columns to the right of the “units” column are the
average, minimum, and maximum values from the emission records for that
pollutant, plant, and kiln. The column after that contains the number of
tests (e.g., 12 tests for CO at Cemex Brooksville, FL, Kiln #1). Again,
these values represent tests, not single runs.

The three columns to the right of the “number of tests” column
compare the test results to the allowable value given on the permits
spreadsheet (i.e., not the testing spreadsheet) sent by the Florida DEP.
For example, the permit allowable for CO for the Cemex Brooksville, FL,
Kiln #1 is 1.2 lb/ton of feed. The average, minimum, and maximum of the
11 tests were 0.721 lb/ton of feed, 0.360 lb/ton of feed, and 1.14
lb/ton of feed, respectively. Therefore, the average test value was 0.60
(i.e., 0.721/1.2) times the permit allowable. Similar fractions can be
calculated for the minimum and maximum test results, and the resulting
factions were 0.30 and 0.95.

In order to compare the results across different plants more easily than
in Table V-1, it’s possible to convert all the test results in units
of lb/ton of clinker produced (rather than lb/ton of clinker for some,
and lb/ton of feed for others). This step is performed in Table V-2,
using plant-specific conversion factors from the Florida DEP permit
limits spreadsheet. For example, the Cemex Brooksville, FL, Kiln #1
permit allowable value for CO converts from 1.2 lb/ton of feed to 2.0
lb/ton of clinker.

The following comments will address the results presented in Table V-2
for each individual pollutant. Note that all values in Table V-2 are in
lb/ton of clinker produced (from the Florida permit values spreadsheet).

CO – Permit values range from approximately 2.0 to 3.3 lb/ton. Average
test values ranged from approximately 50 to 70 percent of permitted
values.

NOx – The average test values for Cemex Brooksville Kiln 1 and 
Florida Rock Newberry are 2.05 lb/ton and 2.01 lb/ton, respectively.
Note that none of the plants in Table 2 has a permit allowable below 2.0
lb/ton (e.g., 1.95 lb/ton), although the two CEMEX Brooksville (North)
kilns are permitted at 2.0 lb/ton. That’s because several kilns
permitted at 1.95 lb/ton are near completion in Florida, but haven’t
begun operation. Also, we have NOx CEM data for the Suwannee American
Cement Company plant in Branford, FL, which is operating with NOx
emissions at or below 2.0 lb/ton.

PM – The NESHAP value for PM from new kilns is 0.30 lb/ton of feed
(i.e., approximately 0.50 lb/ton of clinker). Several of the plants are
permitted well below 0.50 lb/ton of clinker (e.g., two at 0.30 lb/ton of
clinker, and one at 0.25 lb/ton of clinker). All the kilns easily meet
their permit limits for PM, with the average value as a fraction of the
permit limit being approximately 0.2 (i.e., the plants are running at
approximately a factor of 5 below their PM permit limits).

SO2 – All of the plants have SO2 permit values of approximately 0.20
lb/ton, except for Florida Crushed Stone (in Brooksville), which has a
permit value of 0.66 lb/ton. All the plants with values of 0.20 lb/ton
easily meet their permit limits for SO2, with the average values as a
fraction of the permit value being below 0.10 (i.e. less than 10 percent
of the permit limit). These kilns have very low-sulfur feed materials.

Table V-1. Comparison of Permit Values with Emission Test Results for
Florida Kilns (lb/ton feed or lb/ton clinker)

Pollutant	Facility1	City	State	Kiln	Kiln Type	Permit Value (permit page)
Permit Value (test page)	Units	Test Avg	Test Min	Test Max	Number of
Tests	Fraction of Permit Value

	Test Avg	Test Min	Test Max

CO	Suwannee American Cement	Branford	FL	Kiln 1	C	3.34	3.60	lb/ton
clinker	1.71	1.52	2.04	3	0.51	0.46	0.61

CO	CEMEX Miami (Rinker)	Miami	FL	Kiln 1	C	2.81	3.01/2.81	lb/ton clinker
1.74	1.25	1.79	5	0.62	0.44	0.64

CO	Florida Rock Industries	Newberry	FL	Kiln 12	C	2.50	2.50	lb/ton
clinker	1.8	1.14	2.82	12	0.72	0.46	1.13

CO	CEMEX Brooksville-North	Brooksville	FL	Kiln 1	PH	1.2	1.2	lb/ton feed
0.721	0.360	1.14	11	0.60	0.30	0.95

CO	CEMEX Brooksville-North	Brooksville	FL	Kiln 2	PH	1.2	1.2	lb/ton feed
0.81	0.43	1.18	13	0.68	0.36	0.98

	NOx	Suwannee American Cement	Branford	FL	Kiln 1	C	2.9 5	2.9	lb/ton
clinker	2.34	2.07	2.52	3	0.81	0.71	0.87

NOx	Florida Rock Industries	Newberry	FL	Kiln 12	C	2.45	2.8/2.45	lb/ton
clinker	2.01	1.22	2.30	6	0.82	0.50	0.94

NOx	CEMEX Brooksville - South 

(Rinker/Florida Crushed Stone)	Brooksville	FL	Kiln 12	PH	2.9	2.9	lb/ton
feed	2.16	1.51	2.9	15	0.74	0.52	1.00

NOx	CEMEX Brooksville - North	Brooksville	FL	Kiln 1	PH	1.83 3	1.83 3
lb/ton feed	1.24	0.86	1.77	11	0.68	0.47	0.97

NOx	CEMEX Brooksville - North	Brooksville	FL	Kiln 2	PH	1.72 3	1.72 3 
lb/ton feed	1.40	0.76	2.21	13	0.81	0.44	1.28

	PM	CEMEX Miami (Rinker)	Miami	FL	Kiln 1	C	0.152	0.2/0.142	lb/ton feed
0.027	0.010	0.043	2	0.17	0.07	0.28

PM	Florida Rock Industries	Newberry	FL	Kiln 12	C	0.22	0.20/0.23	lb/ton
feed	0.035	0.009	0.060	11	0.16	0.04	0.27

PM	CEMEX Brooksville - South

(Rinker/Florida Crushed Stone)	Brooksville	FL	Kiln 12	PH	0.40	0.4	lb/ton
feed	0.145	0.018	0.319	19	0.36	0.04	0.80

PM	CEMEX Brooksville - North	Brooksville	FL	Kiln 1	PH	0.18	0.18	lb/ton
feed	0.054	0.009	0.093	12	0.30	0.05	0.51

PM	CEMEX Brooksville - North	Brooksville	FL	Kiln 2+	PH	0.18	0.18	lb/ton
feed	0.054	0.020	0.086	12	0.30	0.11	0.48

	SO2	Suwannee American Cement	Branford	FL	Kiln 1	C	0.20	0.2/0.27	lb/ton
clinker	0.017	0.013	0.020	4	0.08	0.07	0.10

SO2	Florida Rock Industries	Newberry	FL	Kiln 12	C	0.16	0.28/0.16	lb/ton
clinker	0.015	0.002	0.030	4	0.09	0.01	0.19

SO2	CEMEX Brooksville - North	Brooksville	FL	Kiln 1	PH	0.10	0.10	lb/ton
feed	0.009	0.001	0.023	11	0.09	0.01	0.23

SO2	CEMEX Brooksville - North	Brooksville	FL	Kiln 2	PH	0.10	0.10	lb/ton
feed	0.013	0.004	0.035	13	0.13	0.04	0.35

SO2	CEMEX Brooksville - South

(Rinker/Florida Crushed Stone)	Brooksville	FL	Kiln 12	PH	0.60	0.60
lb/ton feed	0.184	0.009	0.599	15	0.31	0.01	1.00

	VOC	Suwannee American Cement	Branford	FL	Kiln 1	C	0.12	0.12	lb/ton
clinker	0.043	0.040	0.049	3	0.36	0.33	0.41

VOC	CEMEX Miami (Rinker)	Miami	FL	Kiln 1	C	0.12	0.12	lb/ton clinker
0.097	0.080	0.120	9	0.81	0.67	1.00

VOC	Florida Rock Industries	Newberry	FL	Kiln 1	C	0.11	0.12/0.11	lb/ton
clinker	0.067	0.001	0.094	8	0.61	0.01	0.85

VOC	CEMEX Brooksville - North	Brooksville	FL	Kiln 2	PH	0.09	0.09	lb/ton
feed	0.052	0.018	0.086	2	0.58	0.20	0.96

See Footnotes on next page.

Facility names reflect the April 2007 purchase of Rinker/Florida Crushed
Stone by CEMEX. Former facility names are in parenthesis.

Includes kiln and clinker cooler emissions (through a common stack).

Although not reflected in the Florida DEP spreadsheets for permit limits
or test results, the NOx permit levels for Kiln #1 and #2 at the CEMEX
Brooksville - North plant were reduced to 1.21 lb/ton of dry preheater
feed (2.0 lb/ton of clinker), in conjunction with installation of SNCR
systems on both kilns. See “Indirect Firing/SNCR System Kiln #1 and
#2,” at:    HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex.htm" 
http://www.dep.state.fl.us/air/permitting/construction/cemex.htm .
(Specifically at:    HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex/026FinalPe
rmit.pdf" 
http://www.dep.state.fl.us/air/permitting/construction/cemex/026FinalPer
mit.pdf .)

The CEMEX Brooksville – North plant had NOx testing conducted in
September 2007. The result for Kiln #1 was 0.859 lb/ton of feed (or 1.43
lb/ton of clinker). The result for Kiln #2 was 0.759 lb/ton of feed (or
1.27 lb/ton of clinker). Both these values are reflected in the “Test
Min” column of Table 1 (i.e., they were the lowest values in the data
set for those kilns). 

Kiln #1 at Suwannee American Cement in Branford, FL, has a NOx permit
limit of 2.9 lb/ton of clinker on a 24-hr basis, and a limit of 2.4
lb/ton of clinker as a 30-day average.

Table V-2. Comparison of Permit Values with Emission Test Results for
Florida Kilns (all values in lb/ton clinker)

Pollutant	Facility1	City	State	Kiln	Kiln Type	Permit Value (permit page)
Permit Value (test page)	Units	Test Avg	Test Min	Test Max	Number of
Tests	Fraction of Permit Value

	Test Avg	Test Min	Test Max

CO	Suwannee American Cement	Branford	FL	Kiln 1	C	3.34	3.60	lb/ton
clinker	1.71	1.52	2.04	3	0.51	0.46	0.61

CO	CEMEX Miami (Rinker)	Miami	FL	Kiln 1	C	2.81	3.01/2.81	lb/ton clinker
1.74	1.25	1.79	5	0.62	0.44	0.64

CO	Florida Rock Industries	Newberry	FL	Kiln 12	C	2.50	2.50	lb/ton
clinker	1.80	1.14	2.82	12	0.72	0.46	1.13

CO	CEMEX Brooksville-North	Brooksville	FL	Kiln 1	PH	2.0	2.0	lb/ton
clinker	1.20	0.60	1.90	11	0.60	0.30	0.95

CO	CEMEX Brooksville-North	Brooksville	FL	Kiln 2	PH	2.0	2.0	lb/ton
clinker	1.35	0.72	1.97	13	0.68	0.36	0.98

	NOx	Suwannee American Cement	Branford	FL	Kiln 1	C	2.9 5	2.9 5	lb/ton
clinker	2.34	2.07	2.52	3	0.81	0.71	0.87

NOx	Florida Rock Industries	Newberry	FL	Kiln 12	C	2.45	2.8/2.45	lb/ton
clinker	2.01	1.22	2.30	6	0.82	0.50	0.94

NOx	CEMEX Brooksville - South 

(Rinker/Florida Crushed Stone)	Brooksville	FL	Kiln 12	PH	4.32	4.32
lb/ton clinker	3.22	2.25	4.32	15	0.74	0.52	1.00

NOx	CEMEX Brooksville - North	Brooksville	FL	Kiln 1	PH	3.05 3	3.05 3
lb/ton clinker	2.07	1.43	2.95	11	0.68	0.47	0.97

NOx	CEMEX Brooksville - North	Brooksville	FL	Kiln 2	PH	2.87 3	2.87 3 
lb/ton clinker	2.34	1.27	3.69	13	0.81	0.44	1.28

	PM	CEMEX Miami (Rinker)	Miami	FL	Kiln 1	C	0.25	0.33/0.23	lb/ton clinker
0.044	0.016	0.071	2	0.17	0.07	0.28

PM	Florida Rock Industries	Newberry	FL	Kiln 12	C	0.37	0.34/0.39	lb/ton
clinker	0.059	0.015	0.101	11	0.16	0.04	0.27

PM	CEMEX Brooksville - South

(Rinker/Florida Crushed Stone)	Brooksville	FL	Kiln 12	PH	0.60	0.60
lb/ton clinker	0.218	0.026	0.479	19	0.36	0.04	0.80

PM	CEMEX Brooksville - North	Brooksville	FL	Kiln 1	PH	0.30	0.30	lb/ton
clinker	0.090	0.015	0.154	12	0.30	0.05	0.51

PM	CEMEX Brooksville - North	Brooksville	FL	Kiln 2+	PH	0.30	0.30	lb/ton
clinker	0.091	0.033	0.143	12	0.30	0.11	0.48

	SO2	Suwannee American Cement	Branford	FL	Kiln 1	C	0.20	0.2/0.27	lb/ton
clinker	0.017	0.013	0.020	4	0.08	0.07	0.10

SO2	Florida Rock Industries	Newberry	FL	Kiln 12	C	0.16	0.28/0.16	lb/ton
clinker	0.015	0.002	0.030	4	0.09	0.01	0.19

SO2	CEMEX Brooksville - North	Brooksville	FL	Kiln 1	PH	0.17	0.17	lb/ton
clinker	0.016	0.001	0.040	11	0.09	0.01	0.23

SO2	CEMEX Brooksville - North	Brooksville	FL	Kiln 2	PH	0.17	0.17	lb/ton
clinker	0.022	0.007	0.060	13	0.13	0.04	0.35

SO2	CEMEX Brooksville - South

(Rinker/Florida Crushed Stone)	Brooksville	FL	Kiln 12	PH	0.9	0.9	lb/ton
clinker	0.275	0.013	0.899	15	0.31	0.01	1.00

	VOC	Suwannee American Cement	Branford	FL	Kiln 1	C	0.12	0.12	lb/ton
clinker	0.043	0.040	0.049	3	0.36	0.33	0.41

VOC	CEMEX Miami (Rinker)	Miami	FL	Kiln 1	C	0.12	0.12	lb/ton clinker
0.097	0.080	0.120	9	0.81	0.67	1.00

VOC	Florida Rock Industries	Newberry	FL	Kiln 1	C	0.11	0.12/0.11	lb/ton
clinker	0.067	0.001	0.094	8	0.61	0.01	0.85

VOC	CEMEX Brooksville - North	Brooksville	FL	Kiln 2	PH	0.15	0.15	lb/ton
clinker	0.087	0.030	0.143	2	0.58	0.20	0.96

See footnotes on next page

Facility names reflect the April 2007 purchase of Rinker/Florida Crushed
Stone by CEMEX. Former facility names are in parenthesis.

Includes kiln and clinker cooler emissions (through a common stack).

Although not reflected in the Florida DEP spreadsheets for permit limits
or test results, the NOx permit levels for Kiln #1 and #2 at the CEMEX
Brooksville - North plant were reduced to 1.21 lb/ton of dry preheater
feed (2.0 lb/ton of clinker), in conjunction with installation of SNCR
systems on both kilns. See “Indirect Firing/SNCR System Kiln #1 and
#2,” at:    HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex.htm" 
http://www.dep.state.fl.us/air/permitting/construction/cemex.htm .
(Specifically at:    HYPERLINK
"http://www.dep.state.fl.us/air/permitting/construction/cemex/026FinalPe
rmit.pdf" 
http://www.dep.state.fl.us/air/permitting/construction/cemex/026FinalPer
mit.pdf .)

The CEMEX Brooksville – North plant had NOx testing conducted in
September 2007. The result for Kiln #1 was 0.859 lb/ton of feed (or 1.43
lb/ton of clinker). The result for Kiln #2 was 0.759 lb/ton of feed (or
1.27 lb/ton of clinker). Both these values are reflected in the “Test
Min” column of Table 1 (i.e., they were the lowest values in the data
set for those kilns). 

Kiln #1 at Suwannee American Cement in Branford, FL, has a NOx permit
limit of 2.9 lb/ton of clinker on a 24-hr basis, and a limit of 2.4
lb/ton of clinker as a 30-day average.

Monitoring Benefit Analysis

The principal benefit of improved monitoring is associated with reducing
the uncertainty of compliance status, and as a result, reducing
emissions.  Improving the knowledge of emissions control device or
control measure performance and ongoing compliance status at facilities
has been shown to reduce emissions.  By implementing a monitoring
program that requires continuous surveillance of conditions that affect
and are necessary to maintain emissions control, owners and operators of
facilities will achieve a higher level of compliance, and lower
emissions, than they otherwise would be able to achieve.  Improved
monitoring may impact emissions in two ways: (1) facilities operating
outside the range of conditions that indicate compliance (i.e.,
excursions) as defined by the monitoring will act to return operations
to acceptable conditions, thus reducing emissions, and (2) periods of
excursions from acceptable conditions will be identified more quickly
with continuous monitoring than with less frequent approaches, thus
reducing the duration of such excursions. Total emission reductions were
estimated by EPA’s Measurement Policy Group, Sector Policies and
Programs Division of OAQPS (EPA 2008).

The emission reductions that would occur as a result of the required
monitoring was estimated by assuming baseline controlled emissions for
PM, PM2.5, NOx, and SO2 as shown in the table. PM2.5 emissions are
estimated to be 45 percent of total PM emissions. Excess emissions were
assumed to be 5 percent above baseline for 12 percent of normal
operating time. Total emissions reductions due to improved monitoring
are estimated to be 12.4 tons per year (tpy) PM, 5.6 tpy PM2.5, 108 tpy
NOx, and 9.36 tpy SO2.

Monitoring Benefits - Emission reductions due to improved monitoring
(tpy)

	Pollutant

Parameter	PM	PM2.5	NOx	SO2

Controlled Emissions (tpy) clinker cooler	51.6	23.22	0	0

Controlled Emissions (tpy) kiln	51.6	23.22	900	390

Hours of operation/yr	7920	7920	7920	7920

Normal emissions/min (tpm)	0.00022	0.00010	0.00189	0.00082

Amt. of excess emissions above normal (%)	5%	5%	5%	5%

Amt. of excess emissions above normal (tons)	1.09E-05	4.89E-06	9.47E-05
4.10E-05

Time in excess emissions mode w/ baseline monitoring(%)	12%	12%	12%	12%

Time in excess emissions mode w/ baseline monitoring(min)	57024	57024
57024	57024

Emission reduction due to improved monitoring (tpy)	0.62	0.28	5.40	2.34

No. of new kilns affected	20	20	20	4

Total nationwide emission reduction due to improved monitoring (tpy)
12.38	5.57	108.00	9.36

References

Portland Cement Association. 2007. U.S. and Canadian Portland Cement
Industry Plant Information Summary December 31, 2006.

U.S. Environmental Protection Agency (EPA), 2007. Alternative Control
Technologies Document Update - NOx Emissions from New Cement Kilns,
EPA-453/R-07-006, November 2007.

Memorandum, from Elizabeth Health, RTI, to Joe Wood, EPA/MICG, April 09,
1996. Summary of Impacts of Control Options on Model Kilns and Clinker
Coolers. Legacy Docket item II-B-67, Docket no. A-92-53 and Electronic
Docket Item EPA-HQ-OAR-2002-005-0036.

Technical Evaluation Preliminary Determination Draft BACT
Determinations:  CEMEX Cement Company, Brooksville, Hernando County. New
Portland Cement Line. DEP File No. 0530010-029-AC (PSD-FL-384). April 3,
2007.

Technical Support Document and Statement of Basis for Construction of
Drake Cement, L.L.C. Portland Cement Plant. Air Quality Permit Number
1001770. April 12, 2006.

Technical Evaluation, Preliminary Determinations Draft BACT
Determinations, Sumter Cement Company, Sumter County, Florida. New
Portland Cement Plant. DEP File No. 1190041-001-AC (PSD-FL-358).
December 21, 2005.

Memorandum, from Mark Bahner, RTI, to Keith Barnett, EPA, March 3, 2008,
Emission Testing Results.

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Analysis Tool Cement Kiln Case Study, May 2008

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 PCA 2007.

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