Regulatory Text: 
Texas Chapter 117 --- Control of Air Pollution from Nitrogen Compounds

SUBCHAPTER B:  COMBUSTION AT EXISTING MAJOR SOURCES

DIVISION 4:  CEMENT KILNS

Outline of Division 4:
§117.260.  Cement Kiln Definitions.
§117.261.  Applicability.
§117.265.  Emission Specifications.
§117.273.  Continuous Demonstration of Compliance.
§117.279.  Notification, Recordkeeping, and Reporting Requirements.
§117.283.  Source Cap.


§117.260.  Cement Kiln Definitions.
As adopted by TCEQ 3/5/2003 effective 3/27/2003 (7-24).
Approved by EPA 3/26/2004 (69 FR 15681) effective 4/26/2004 (TXd43).

     Unless specifically defined in the Texas Clean Air Act (TCAA) or in the rules of the commission, the terms used by the commission have the meanings commonly used in the field of air pollution control.  In addition to the terms which are defined by the TCAA, the following terms, when used in this division, shall have the following meanings, unless the context clearly indicates otherwise.  Additional definitions for terms used in this division are found in §§3.2, 101.1, and 117.10 of this title (relating to Definitions).

          (1)  Clinker - The product of a portland cement kiln from which finished cement is manufactured by milling and grinding.

          (2)  Indirect-firing system - A system which reduces the amount of primary air used in a cement kiln by:

               (A)  separating the powdered fuel from the air stream that carries the fuel from the drying/milling equipment;

               (B)  storing the fuel briefly; and

               (C)  using an independent, significantly smaller stream of hot primary air to blow the fuel to the burner.

          (3)  Long dry kiln - A kiln which employs no preheating of the dry feed.  The inlet feed to the kiln is dry.

          (4)  Long wet kiln - A kiln which employs no preheating of the dry feed.  The inlet feed to the kiln is a slurry.

          (5)  Low-NOx burner - Either of the following:

               (A)  for long wet kilns, combustion equipment designed to reduce flame turbulence, delay fuel/air mixing, and establish fuel-rich zones for initial combustion; or

               (B)  a type of cement kiln burner that results in decreasing nitrogen oxides (NOx) emissions and which has an indirect-firing system and a series of channels or orifices that:

                    (i)  allow for the adjustment of the volume, velocity, pressure, and direction of the air carrying the fuel (known as primary air) and the combustion air (known as secondary air) into the kiln; and

                    (ii)  impart high momentum and turbulence to the fuel stream to facilitate mixing of the fuel and secondary air.

          (6)  Low-NOx precalciner - A process in which a portion of the fuel is injected near the raw material feed end of a preheater or precalciner kiln, resulting in a reducing atmosphere in the preheater or precalciner.

          (7)  Mid-kiln firing - Secondary combustion in long dry or long wet kilns by injecting solid fuel at (or to) an intermediate point in the kiln using a specially-designed feed injection mechanism for the purpose of decreasing NOx emissions through:

               (A)  burning part of the fuel at a lower temperature; and

               (B)  reducing conditions at the solid fuel injection point that may destroy some of the NOx formed upstream in the kiln burning zone.

          (8)  Portland cement - A hydraulic cement produced by pulverizing clinker consisting essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an interground addition.

          (9)  Portland cement kiln - A system, including any solid, gaseous, or liquid fuel combustion equipment, used to calcine and fuse raw materials, including limestone and clay, to produce portland cement clinker.

          (10)  Precalciner kiln - A kiln where the feed to the kiln system is preheated in cyclone chambers and utilizes a second burner to calcine material in a separate vessel attached to the preheater before the final fusion in a kiln which forms clinker.

          (11)  Preheater kiln - A kiln where the feed to the kiln system is preheated in cyclone chambers before the final fusion in a kiln which forms clinker.

          (12)  Secondary combustion - A system that employs a second combustion point in addition to the primary flame.  This definition includes mid-kiln firing in long dry and long wet kilns, and also additional combustion at the raw material feed end of the kiln in preheater-precalciner kilns.

Adopted March 5, 2003, Effective March 27, 2003
*******************************end tx 117.260*****TXd43***7-24********e3s**


§117.261.  Applicability.
As adopted by TNRCC 4/19/2000 effective 5/11/2000 (7-17).
Approved by EPA 3/26/2004 (69 FR 15681) effective 4/26/2004 (TXd43).

     This division (relating to Cement Kilns) applies to each portland cement kiln in Bexar, Comal, Ellis, Hays, and McLennan Counties that was placed into service before December 31, 1999, except as specified in §117.265 and §117.283 of this title (relating to Emission Specifications; and Source Cap).

Adopted April 19, 2000, Effective May 11, 2000
*******************************end tx 117.261*****TXd43***7-17********e3s**


§117.265.  Emission Specifications.
As adopted by TCEQ 3/5/2003 effective 3/27/2003 (7-24).
Approved by EPA 3/26/2004 (69 FR 15681) effective 4/26/2004 (TXd43).

     (a)  In accordance with the compliance schedule in §117.524 of this title (relating to Compliance Schedule for Cement Kilns), the owner or operator of each portland cement kiln shall ensure that nitrogen oxides (NOx) emissions do not exceed the following rates on a 30-day rolling average.  For the purposes of this section, the 30-day rolling average is calculated as the total of all the hourly emissions data (in pounds) that fuel was combusted in a cement kiln in the preceding 30 consecutive days, divided by the total number of tons of clinker produced in that kiln during the same 30-day period:

               (1)  for each long wet kiln:

                    (A)  in Bexar, Comal, Hays, and McLennan Counties, 6.0 pounds per ton (lbs/ton) of clinker produced; and

                    (B)  in Ellis County, 4.0 lbs/ton of clinker produced;

               (2)  for each long dry kiln, 5.1 lbs/ton of clinker produced;

               (3)  for each preheater kiln, 3.8 lbs/ton of clinker produced; and

               (4)  for each preheater-precalciner or precalciner kiln, 2.8 lbs/ton of clinker produced.

     (b)  If there are multiple cement kilns at the same account, the owner or operator may choose to comply with the emission limits of subsection (a) of this section on the basis of a weighted average for the cement kilns at the account that are subject to the same limit.  Each owner or operator choosing this option shall submit written notification of this choice to the executive director, the appropriate regional office, and any local air pollution control program with jurisdiction before the appropriate compliance date in §117.524 of this title (relating to Compliance Schedule for Cement Kilns).

     (c)  Each long wet or long dry kiln for which the following controls are installed and operated during kiln operation is not required to meet the NOx emission limits of subsection (a) of this section, provided that each owner or operator choosing this option submits written notification of this choice to the executive director, the appropriate regional office, and any local air pollution control program with jurisdiction before the appropriate compliance date in §117.524 of this title:

          (1)  a low-NOx burner and either:

               (A)  mid-kiln firing; or

               (B)  some other form of secondary combustion achieving equivalent levels of NOx reductions; or alternatively;

          (2)  other additions or changes to the kiln system achieving at least a 30% reduction in NOx emissions, provided the additions or changes are approved by the executive director with concurrence from EPA.

     (d)  Each preheater or precalciner kiln for which either a low-NOx burner or a low-NOx precalciner is installed and operated during kiln operation is not required to meet the NOx emission limits of subsection (a) of this section.  Each owner or operator choosing this option shall submit written notification of this choice to the executive director, the appropriate regional office, and any local air pollution control program with jurisdiction before the appropriate compliance date in §117.524 of this title.

     (e)  An owner or operator may use §117.570 of this title (relating to Use of Emissions Credits for Compliance) to meet the NOx emission control requirements of this section, in whole or in part.

Adopted March 5, 2003, Effective March 27, 2003
*******************************end tx 117.265*****TXd43***7-24********e3s**


§117.273.  Continuous Demonstration of Compliance.
As adopted by TNRCC 4/19/2000 effective 5/11/2000 (7-17).
Approved by EPA 3/26/2004 (69 FR 15681) effective 4/26/2004 (TXd43).

     (a)  Nitrogen oxides (NOx) monitors.  In accordance with the compliance schedule in §117.524 of this title (relating to Compliance Schedule for Cement Kilns), the owner or operator shall install, calibrate, maintain, and operate a continuous emissions monitoring system (CEMS) or predictive emissions monitoring system (PEMS) to monitor kiln exhaust NOx.

     (b)  CEMS requirements.  The owner or operator of any CEMS used to meet the monitoring requirement of subsection (a) of this section must comply with the following.

          (1)  The CEMS shall meet the requirements of 40 Code of Federal Regulations (CFR), Part 60 as follows:

               (A)  Section 60.13;

               (B)  Appendix B, Performance Specification 2, for NOx; and

               (C)  audits shall be in accordance with Section 5.1 of Appendix F, quality assurance procedures, except that a cylinder gas audit or relative accuracy audit may be performed in lieu of the annual relative accuracy test audit (RATA) required in Section 5.1.1.

          (2)  One CEMS may be shared among kilns, provided:

• •      (A)  the exhaust stream of each kiln is analyzed separately; and

               (B)  the CEMS meets the certification requirements of paragraph (1) of this subsection for each exhaust stream.

          (3)  The CEMS shall be subject to the approval of the executive director.

     (c)  PEMS requirements.  The owner or operator of any PEMS used to meet the monitoring requirement of subsection (a) of this section must comply with the following.

          (1)  The PEMS must predict the NOx emissions in the units of the applicable emission limitations of this division.

          (2)  The PEMS shall meet the requirements of §117.213(f)(2) - (7) of this title (relating to Continuous Demonstration of Compliance).

Adopted April 19, 2000, Effective May 11, 2000
*******************************end tx 117.273*****TXd43***7-17********e3s**


§117.279.  Notification, Recordkeeping, and Reporting Requirements.
As adopted by TCEQ 3/5/2003 effective 3/27/2003 (7-24).
Approved by EPA 3/26/2004 (69 FR 15681) effective 4/26/2004 (TXd43).

     (a)  Notification. The owner or operator of each portland cement kiln shall submit verbal notification to the executive director of the date of any continuous emissions monitoring system (CEMS) or predictive emissions monitoring system (PEMS) performance evaluation conducted under §117.273 of this title (relating to Continuous Demonstration of Compliance) at least 15 days before such date followed by written notification within 15 days after testing is completed.

     (b)  Reporting of test results.  The owner or operator of each portland cement kiln shall furnish the executive director and any local air pollution control agency having jurisdiction a copy of any CEMS or PEMS relative accuracy test audit conducted under §117.273 of this title:

          (1)  within 60 days after completion of such testing or evaluation; and

          (2)  not later than the appropriate compliance date in §117.524 of this title (relating to Compliance Schedule for Cement Kilns).

     (c)  Recordkeeping.  The owner or operator of a portland cement kiln subject to the requirements of this division shall maintain written or electronic records of the data specified in this subsection.  Such records shall be kept for a period of at least five years and shall be made available upon request by authorized representatives of the executive director, EPA, or local air pollution control agencies having jurisdiction.  The records shall include:

          (1)  for each kiln, monitoring records of:

               (A)  daily and rolling 30-day average (and, for each kiln subject to the source cap in §117.283 of this title (relating to Source Cap), rolling 90-day average) nitrogen oxides (NOx) emissions (in pounds (lbs));

               (B)  daily and rolling 30-day average (and, for each kiln subject to the source cap in §117.283 of this title, rolling 90-day average) production of clinker (in tons); and

               (C)  average NOx emission rate (in lbs/ton of clinker produced) on the basis of a rolling 30-day average (and, for each kiln subject to the source cap in §117.283 of this title, a rolling 90-day average);

          (2)  records of the results of initial certification testing, evaluations, calibrations, checks, adjustments, and maintenance of CEMS and PEMS; and

          (3)  records of the results of any stack testing conducted.

Adopted March 5, 2003, Effective March 27, 2003
*******************************end tx 117.279*****TXd43***7-24********e3s**


§117.283.  Source Cap.
As adopted by TCEQ 3/5/2003 effective 3/27/2003 (7-24).
Approved by EPA 3/26/2004 (69 FR 15681) effective 4/26/2004 (TXd43).

     (a)  As an alternative to complying with the requirements of §117.265 of this title (relating to Emission Specifications) in Bexar, Comal, Ellis, Hays, and McLennan Counties, an owner or operator may reduce total nitrogen oxides (NOx) emissions (in pounds per day (ppd)) from all cement kilns at the account (including any cement kilns placed into service on or after December 31, 1999) to at least 30% less than the total NOx emissions (in ppd) from all cement kilns in the account's 1996 emissions inventory (EI), on a 90-day rolling average basis.  For the purposes of this section, the 90-day rolling average is calculated as the total of all the hourly emissions data for the preceding 90 days.  For the calendar year which includes the appropriate compliance date in §117.524 of this title (relating to Compliance Schedule for Cement Kilns), only hourly emissions data on or after that compliance date is included, such that the first 90-day period ends 90 days after the appropriate compliance date in §117.524 of this title.  A 90-day rolling average emission cap shall be calculated using the following equation.


NOx 90-day rolling average emission cap (ppd)

     =  0.7 {sum from i = 1 to N}R_i


Where:

     i     =   Each cement kiln at a single account
     N     =   The total number of cement kilns at the account
     R_i     =  The kiln’s ozone season daily NOx emission rate (in ppd) reported in the account's 1996 EI

     (b)  To qualify for the source cap option available under this section, the owner or operator must submit an initial control plan to the executive director, the appropriate regional office, and any local air pollution control program with jurisdiction which demonstrates that the overall reduction of NOx emissions from all cement kilns at the account will be at least 30% from the 1996 baseline EI on a 90-day rolling average basis.  The plan shall be submitted no later than December 31 of the year preceding the appropriate compliance date in §117.524 of this title.  Each control plan must be approved by the executive director before the owner or operator may use the source cap available under this section for compliance.  At a minimum, the control plan shall include the emission point number (EPN), facility identification number (FIN), and 1996 baseline EI NOx emissions (in ppd) from each cement kiln at the account; a description of the control measures which have been or will be implemented at each cement kiln; and an explanation of the recordkeeping procedure and calculations which will be used to demonstrate compliance.

     (c)  Beginning on March 31 of the year following the appropriate compliance date in §117.524 of this title, the owner or operator shall submit an annual report no later than March 31 of each year to the executive director, the appropriate regional office, and any local air pollution control program with jurisdiction which demonstrates that the overall reduction of NOx emissions from all cement kilns at the account is at least 30% from the 1996 baseline EI on a 90-day rolling average basis.  At a minimum, the report shall include the EPN, FIN, and each 90-day rolling average NOx emissions (in ppd) during the preceding calendar year for the cement kilns at the account.

     (d)  All representations in control plans and annual reports become enforceable conditions.  The owner or operator shall not vary from such representations if the variation will cause a change in the identity of the specific cement kilns subject to this section or the method of control of emissions unless the owner or operator submits a revised control plan to the executive director, the appropriate regional office, and any local air pollution control program with jurisdiction no later than 30 days after the change.  All control plans and reports shall demonstrate that the total NOx emissions (in ppd) from all cement kilns at the account (including any cement kilns placed into service on or after December 31, 1999) are being reduced to at least 30% less than the total NOx emissions (in ppd) from all cement kilns in the account's 1996 EI on a 90-day rolling average basis.

     (e)  The NOx emissions monitoring required by §117.273 of this title (relating to Continuous Demonstration of Compliance) for each cement kiln in the source cap shall be used to demonstrate continuous compliance with the source cap.

     (f)  An owner or operator may use §117.570 of this title (relating to Use of Emissions Credits for Compliance) to meet the NOx emission control requirements of this section, in whole or in part.

Adopted March 5, 2003, Effective March 27, 2003
*******************************end tx 117.283*****TXd43***7-24********e3s**
*******end tx chapter 117 subchapter b division 4*******TXd43*********e3s**