Section 336.1817. Emission limitations and restrictions for Portland cement kilns.

Rule 817. (1) As used in this rule:

(a)    "Clinker" means the product of a Portland cement kiln from which finished cement is manufactured by milling and grinding.

(b)   "Long dry kiln" means a Portland cement kiln that employs no preheating of the feed. The inlet feed to the kiln is dry.

(c)   "Long wet kiln" means a Portland cement kiln that employs no preheating of the feed. The inlet feed to the kiln is a slurry.

(d)   "Low oxides of nitrogen burners" means a type of cement kiln burner system designed to lower oxides of nitrogen formation by controlling flame turbulence, delaying fuel/air mixing and establishing fuel-rich zones for initial combusting, that for firing of solid fuel by a kiln's main burner includes an indirect firing system or comparable technique for the main burner to lower the amount of primary combustion air supplied

with the pulverized fuel. In an indirect firing system, 1 air stream is used to convey pulverized fuel from the grinding equipment and another air stream is used to supply primary combustion air to the kiln burner with the pulverized fuel, with intermediate storage of the fuel.

(e)    "Malfunction" means any sudden, infrequent, and not reasonably preventable failure of air pollution control equipment, process equipment, or a process to operate in a normal or usual manner. Failures that are caused in part by poor maintenance or careless operation are not malfunctions.

(f)   "Mid-kiln firing" means the secondary firing in a kiln system by injecting solid fuel at an intermediate point in the kiln system using a specially designed feed injection mechanism for the purpose of decreasing oxides of nitrogen emissions through both of the following:

(i)   Burning part of the fuel at a lower temperature.

(ii)     Reducing conditions at the fuel injection point that may destroy some of the oxides of nitrogen formed upstream in the kiln system.

(g)    "Ozone control period" means the period beginning May 31, 2004, and ending September 30, 2004, and May 1 through September 30 each subsequent year.

(h)    "Portland cement" means a hydraulic cement produced by pulverizing clinker consisting essentially of hydraulic calcium silicates, usually containing 1 or more of the forms of calcium sulfate as an interground addition.

(i)    "Portland cement kiln" means 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.

(j)   "Precalciner kiln" means a kiln where the feed to the kiln system is preheated in cyclone chambers and a second burner is used to calcine material in a separate vessel attached to the preheater before the final fusion in a kiln that forms clinker.

(k)   "Preheater kiln" means a Portland cement kiln where the feed to the kiln system is preheated in cyclone chambers before the final fusion in a kiln that forms clinker.

(l)    "Shutdown" means the cessation of operation of a Portland cement kiln for any purpose.

(m)    "Start-up" means the setting in operation of a Portland cement kiln for any purpose.

(2)   This rule applies to any Portland cement kiln located in the Michigan fine grid zone as defined in R 336.1803, with process rates equal to or greater than the following:

(a)   Long dry kilns of 12 tons per hour.

(b)   Long wet kilns of 10 tons per hour.

(c)   Preheater kilns of 16 tons per hour.

(d)  Precalciner and combined preheater and precalciner kilns of 22 tons per hour.

(3)   A unit subject to this rule and a new source performance standard or a national emission standard for hazardous air pollutants shall comply with the limitations and requirements of this rule or the limitations and requirements of the new source performance standard or the national emission standard for hazardous air pollutants, whichever is more stringent.

(4)   The requirements of this rule shall not apply to a unit that is participating in the oxides of nitrogen budget trading program under R 336.1802 through R 336.1816.  The

requirements of subrule (5) of this rule shall not apply during start-up, shutdown, and malfunction periods.

(5)   After May 31, 2004, an owner or operator of a Portland cement kiln subject to the provisions of this rule shall not operate the kiln until September 30, 2004, and any subsequent year from May 1 through September 30, unless the owner or operator complies with 1 of the following requirements during the applicable May through September time period each year:

(a)   Operation of the kiln with 1 of the following:

(i)   Low oxides of nitrogen burners.

(ii)   Mid-kiln firing.

(b)    A limit on the amount of oxides of nitrogen emitted when averaged over the ozone control period as follows:

(i)   For long wet kilns, 6 pounds of oxides of nitrogen per ton of clinker produced.

(ii)   For long dry kilns, 5.1 pounds of oxides of nitrogen per ton of clinker produced.

(iii)   For preheater kilns, 3.8 pounds of oxides of nitrogen per ton of clinker produced.

(iv)    For precalciner and combined preheater and precalciner kilns, 2.8 pounds of oxides of nitrogen per ton of clinker produced.

(c)   Installation and use of alternative control techniques that may include kiln system modifications, such as conversions to semi-drying processing, subject to department and United States environmental protection agency approval, that achieve a 30% emissions decrease from baseline ozone control period emissions. Baseline emissions shall be the average of the sum of ozone control period emissions for the 2 highest emitting years from 1995 through 2000.

(6)   The owner or operator of any Portland cement kiln proposing to install and use an alternative control technique under subrule (5)(c) of this rule shall submit the proposed alternative control technique and calculation of baseline emissions with supporting documentation to the department and the United States environmental protection agency for approval by May 31, 2003. The department shall include the approved plan with emission limitations in the source's operating permit.

(7)    Ozone control period emissions shall be determined using 1 of the following methods:

(a)   The average of the emission factors for the type of kiln from the "Compilation of Air Pollutant Emission Factors. Volume 1. Stationary Point and Area Sources," PB95 196028, and the "Alternative Control Techniques Document: NOx Emissions from Cement Manufacturing,"PB94 183522. These documents are adopted by reference in this rule. Copies may be inspected at the Lansing office of the air quality division of the department of environmental quality. Copies may be obtained from the Air Quality Division, Department of Environmental Quality, 525 West Allegan Street, P.O. Box 30260-7760, Lansing, Michigan 48909, or from the National Technical Information Service, U.S. Department of Commerce, Springfield, Virginia 22161, at a cost at the time of adoption of this rule of $278.00 and $41.00, respectively.

(b)  The site-specific emission factor developed from representative emissions testing, pursuant to 40 C.F.R. part 60, appendix A, methods 7, 7A, 7C, 7D, or 7E, based on a range of typical operating conditions. The owner or operator shall establish that these operating conditions are representative, subject to approval by the department, and shall

certify that the emissions testing is being conducted under representative conditions.   The provisions of 40 C.F.R.  Part 60 are adopted by reference in R 336.1801.

(c)    An alternate method for establishing the emission factors, when submitted with supporting data to substantiate the emission factors and approved by the department and the United States environmental protection agency as set forth in subrule (5)(c) of this rule.

(8)   Beginning May 31, 2004, and each ozone control period thereafter, any owner or operator of a Portland cement kiln subject to this rule shall do either of the following:

(a)    Complete an initial performance test and subsequent annual testing during the ozone control period of each year consistent with the requirements of 40 C.F.R. part 60, appendix A, methods 7, 7A , 7C, 7D, or 7E or an alternate method approved pursuant to subrule (5)(c) of this rule.

(b)    Monitor oxides of nitrogen emissions during the ozone control period of each year using a continuous emissions monitoring system in accordance with 40 C.F.R., part 60, subpart A, and 40 C.F.R., part 60, appendix B, and comply with the quality assurance procedures in appendix F, or 40 C.F.R., part 75, and associated appendices, as applicable, and in a manner acceptable to the department.

(9)   Beginning May 31, 2004, and each ozone control period thereafter, any owner or operator of a Portland cement kiln subject to this rule shall comply with both of the following recordkeeping and reporting requirements:

(a)   An owner or operator shall create and maintain records that include, but are not limited to, both of the following:

(i)   All routine and nonroutine maintenance, repair, or replacement performed on the device or devices.

(ii)    The date, time, and duration of any start-up, shutdown, or malfunction in the operation of akiln or the device or devices.

(b)   An owner or operator shall create and maintain records that include, but are not limited to, all of the following:

(i)   The emissions, in pounds of oxides of nitrogen per ton of clinker produced from each affected Portland cement kiln.

(ii)    The date, time, and duration of any start-up, shutdown, or malfunction in the operation of any of the cement kilns or the emissions monitoring equipment.

(iii)   The results of any performance testing.

(iv)     If a unit is equipped with a continuous emissions monitoring system, the following information:

(A)    Identification of time periods during which oxides of nitrogen standards are exceeded, the reason for the exceedance, and action taken to correct the exceedance and to prevent similar future exceedances.

(B)   Identification of the time periods for which operating conditions and pollutant data were not obtained, including reasons for not obtaining sufficient data and a description of corrective actions taken.

(v)   All records required to be produced or maintained shall be retained on site for a period of 5 years. The records shall be made available to the department or the United States environmental protection agency upon request.

(10)    Any owner or operator of a Portland cement kiln subject to this rule shall comply with both of the following reporting requirements:

(a)  By May 31, 2004, submit to the department all of the following information:

(i)   The identification number and type of each unit subject to this rule.

(ii)   The name and address of the plant where the unit is located.

(iii)    The name and telephone number of the person responsible for demonstrating compliance with this rule.

(iv)   Anticipated control measures.

(b)   Submit a report documenting for that unit the total oxides of nitrogen emissions and the average oxides of nitrogen emission rate for the ozone control period of each year to the department by October 31, beginning in 2004 and each year thereafter.

History: 2002 MR 22, Eff. Dec. 4, 2002.