KA 860 19 01 October 7, 2019 Via Email and Hardcopy Eric Cornwell
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KA 860_19_01 October 7, 2019 Via email and hardcopy Mailing: Post Office Box 5127 Gainesville, FL 32627-5127 Physical: 4014 NW 13th Street Gainesville, FL 32609-1923 www.kooglerassociates.com 352.377.5822 Eric Cornwell Manager, Stationary Source Permitting Program Air Protection Branch, Georgia EPD 4244 International Parkway Suite 120 Atlanta 30354 [email protected] Subject: Submittal for Air Permit Application US Cement, LLC Proposed new cement facility at Houston County, Georgia Dear Mr. Cornwell, US Cement, LLC (US Cement) is proposing to construct a new Portland cement facility in Houston County, Georgia. Attached to this letter is the air permit application report prepared by Koogler and Associates, Inc. (Koogler) on behalf of US Cement. In addition to an electronic copy of the report in pdf and its excel spreadsheet attachments, we are submitting two hardcopies of the same to the address below: Stationary Source Permitting Program 4244 International Parkway, Suite 120 Atlanta, Georgia 30354 On behalf of US Cement, I sincerely appreciate your attention to this project. Please contact me at (352) 377-5822 or [email protected] if you have any questions regarding this project. Regards, Max Lee, PhD., P.E. KOOGLER AND ASSOCIATES, INC. cc: Cary Cohrs, US Cement, LLC, [email protected] Byeong Kim, Georgia EPD, [email protected] James Boylan, Georgia EPD, [email protected] John Koogler, Koogler & Associates, Inc., [email protected] Upasna Rai, Koogler & Associates, Inc., [email protected] Enc: Application Report (pdf) Electronic file to Report - Attachment F: Facility Modeling Inventory (Excel) Electronic file to Report - Attachment G: Facility Emissions Summary (Excel) REPORT IN SUPPORT OF AN APPLICATION FOR A PSD CONSTRUCTION PERMIT REVIEW U. S. CEMENT COMPANY Cement Plant Perry, Houston County, Georgia October 7, 2019 Prepared by Koogler and Associates, Inc. 4014 NW 13th St Gainesville, FL 32609 www.kooglerassociates.com 860_19_01 TABLE OF CONTENTS 1. INTRODUCTION .............................................................................................................................................. 1 1.1 APPLICANT ....................................................................................................................................................... 2 1.2 AREA MAP SHOWING FACILITY LOCATION ...................................................................................................... 2 2. DESCRIPTION OF PROPOSED CONSTRUCTION ................................................................................... 4 2.1 PROPOSED EMISSIONS UNITS ........................................................................................................................... 4 2.1.1 Raw Material Quarrying, Crushing and Storage (emission unit K101) ................................................ 4 2.1.2 Raw Materials Conveying, Storage and Processing (K102) .................................................................. 5 2.1.3 Pyroprocessing System (K103) .............................................................................................................. 6 2.1.4 Clinker and Additives Storage and Handling (K104) .......................................................................... 10 2.1.5 Cement Finish Mill (K105) .................................................................................................................. 11 2.1.6 Cement Handling, Storage, Packing and Loadout (K106) .................................................................. 11 2.1.7 Coal and Petroleum Coke Grinding System (K107) ............................................................................ 12 2.1.8 Stationary Emergency Generators CI RICE (K108) ............................................................................ 12 2.2 FUGITIVE EMISSIONS ...................................................................................................................................... 12 2.3 PRECAUTIONS TO PREVENT EMISSIONS OF UNCONFINED PARTICULATE MATTER ......................................... 13 2.4 FACILITY PLOT PLAN ..................................................................................................................................... 14 2.5 PROCESS FLOW DIAGRAM .............................................................................................................................. 14 2.6 FUEL ANALYSIS OR SPECIFICATION ............................................................................................................... 17 2.7 DESCRIPTION OF CONTROL EQUIPMENT ......................................................................................................... 17 2.7.1 PM/PM10 .............................................................................................................................................. 17 2.7.2 NOx ...................................................................................................................................................... 17 2.7.3 Dioxin/furan ......................................................................................................................................... 17 2.7.4 Mercury ............................................................................................................................................... 17 2.7.5 SO2, CO, VOC/THC and HCl .............................................................................................................. 18 2.7.6 Pollution Control Equipment – Ad Valorem ........................................................................................ 18 2.8 DESCRIPTION OF STACK SAMPLING FACILITIES ............................................................................................. 18 3. RULE APPLICABILITY ANALYSIS ........................................................................................................... 18 3.1 APPLICABLE FEDERAL AND STATE REQUIREMENTS ....................................................................................... 19 3.2 RULE 391-3-1-.03 – PERMITS ......................................................................................................................... 20 3.2.1 Rule 391-3-1-.03(1) – Construction (SIP) Permit ................................................................................ 20 3.2.2 Rule 391-3-1-.03(8) – Permit Requirements ........................................................................................ 21 3.3 RULE 391-3-1-.02(7) – PREVENTION OF SIGNIFICANT DETERIORATION ......................................................... 21 3.3.1 Rule 391-3-1-.02(7)(b) – PSD Standards ............................................................................................ 21 3.3.2 Rule 391-3-1-.03(6) – Exemptions ....................................................................................................... 24 3.3.3 Rule 391-3-1-.02(7)(a)4.(viii) – Federal Land Manager ..................................................................... 25 3.3.4 Rule 391-3-1-.02(7)(b)7. – Best Available Control Technology .......................................................... 27 4. AMBIENT IMPACT ANALYSIS .................................................................................................................. 28 5. ADDITIONAL IMPACT ANALYSES .......................................................................................................... 29 6. BEST AVAILABLE CONTROL TECHNOLOGY ANALYSIS ................................................................. 30 6.1 INTRODUCTION .............................................................................................................................................. 30 6.2 PARTICULATE MATTER (PM10/PM2.5) ............................................................................................................ 32 6.2.1. Proposed BACT ................................................................................................................................... 33 6.2.2. Federal Regulations Limiting PM/PM10/PM2.5 Emission Rates and Recent BACT Determinations .... 34 i 6.2.3. Particulate Matter Sources .................................................................................................................. 38 6.2.4. Description of Particulate Matter Control Technologies .................................................................... 38 6.2.5. Particulate Matter BACT Selection ..................................................................................................... 41 6.2.6. Summary .............................................................................................................................................. 43 6.3 SULFUR DIOXIDE ........................................................................................................................................... 43 6.3.1. Proposed BACT ................................................................................................................................... 44 6.3.2. Federal Regulations Limiting SO2 Emission Rates and Recent BACT Determinations ....................... 45 6.3.3. Sulfur Behavior in Dry-process Pyroprocessing Systems .................................................................... 47 6.3.4. Description of SO2 Control Technologies ............................................................................................ 51 6.3.5. SO2 Control .........................................................................................................................................