Tenn. Comp. R. & Regs. 1200-03-27-.04 - STANDARDS FOR CEMENT KILNS

(1) The requirements of this rule apply only to kilns with process rates of at least the following:
(a) Long dry kilns ------------ 12 tons per hour (TPH);
(b) Long wet kilns ------------ 10 TPH;
(c) Preheater kilns ------------ 16 TPH; and
(d) Precalciner and preheater/precalciner kilns -------- 22 TPH.
(2) For the purpose of this rule, definitions apply as follow:
(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 kiln 14 feet or larger in diameter, 400 feet or greater in length, which employs no preheating of the feed. The inlet feed to the kiln is dry.
(c) "Long wet kiln" means a kiln 14 feet or larger in diameter, 400 feet or greater in length, which employs no preheating of the feed. The inlet feed to the kiln is a slurry.
(d) "Low-NOx burners" means combustion equipment designed to reduce flame turbulence, delay fuel/air mixing, and establish fuel-rich zones for initial combustion.
(e) "Mid-kiln system firing" means secondary firing in kiln systems by injecting fuel at an intermediate point in the kiln system using a specially designed fuel injection mechanism for the purpose of decreasing nitrogen oxide (NOx ) emissions through:
1. Burning part of the fuel at a lower temperature; and
2. Reducing conditions at the fuel injection point that may destroy some of the NOx formed upstream in the kiln burning zone.
(f) "Portland cement" means a hydraulic cement produced by ssentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an interground addition.
(g) "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.
(h) "Precalciner kiln" means a kiln system where the feed to the kiln is preheated in cyclone chambers and utilizes a second burner to calcine material in a separate vessel attached to the preheater prior to the final fusion in a kiln which forms clinker.
(i) "Preheater kiln" means a kiln system where the feed to the kiln is preheated in cyclone chambers prior to the final fusion in a kiln which forms clinker.
(3) After May 31, 2004, the owner or operator of any Portland cement kiln subject to this rule shall not operate the kiln during May 1 through September 30 unless the kiln has installed and operates during May 1 to September 30 with at least one of the following:
(a) Low-NOx burners;
(b) Mid-kiln system firing;
(c) Alternative control techniques approved by the Technical Secretary and the EPA as achieving at least the same emissions decreases as with low-NOx burners or mid-kiln system firing; or
(d) Reasonably available control technology approved by the Technical Secretary and the EPA.
(4) The owner or operator subject to the requirements of Paragraph (3) of this rule shall comply with the requirements as follow:
(a) By May 31, 2004, submit to the Technical Secretary the identification number and type of each kiln subject to this rule, the name and address of the facility where the kiln is located, and the name and telephone number of the person responsible for demonstrating compliance with Paragraph (3); and
(b) By October 31, 2004, submit to the Technical Secretary a report documenting for that kiln the total NOx emissions from May 31, 2004, through September 30, 2004, and beginning in 2005 submit by October 31 of each year to the Technical Secretary a report documenting NOx emissions from May 1 through September 30 of that year.
(5) By May 31, 2004, the owner or operator of a kiln subject to this rule shall submit to the Technical Secretary a demonstration of compliance with the requirements of Paragraph (3). If compliance is being achieved by use of prescribed equipment, for example low-NOx burners or mid-kiln system firing, the demonstration of compliance shall be written certification to the Technical Secretary that this equipment is installed and is in use. If compliance is being achieved by use of alternative control techniques approved by the Technical Secretary and the EPA, demonstration of compliance shall as specified by the Technical Secretary and the EPA. In the case of compliance proposed to be achieved by use of alternative control techniques, a plan for compliance demonstration shall be submitted to the Technical Secretary by May 1, 2003. Upon receipt the Technical Secretary shall immediately forward a copy of the plan to the EPA. By November 1, 2003, the Technical Secretary shall specify in writing to the owner or operator of the kiln how compliance shall be demonstrated, this specification consistent with methods and requirements specified by the EPA following its review of the submitted plan.
(6) By December 31 of each year, beginning in 2004, the owner or operator of a kiln subject to this rule shall submit to the Technical Secretary a written certification that compliance with the requirements of Paragraph (3) has been maintained during that year's five-month period May 1 through September 30, except for 2004 when compliance is to be maintained from May 31 through September 30. The methods of determining that this compliance has been maintained shall be as specified on the major source operating permit issued for the facility at which the kiln is operated.
(7) Beginning May 31, 2004, the owner or operator of a kiln subject to this rule shall maintain records for May 31 through September 30 of that year, and in subsequent years for May 1 through September 30, that include the data as follow:
(a) The date, time, and duration of any startup, shutdown, or malfunction in the operation of the cement kiln or its emissions monitoring equipment or of any scheduled maintenance activity that affects NOx emissions or emissions monitoring;
(b) The results of any compliance testing; and
(c) Other data required by permit to be maintained.
(8) The records listed in Paragraph (7) of this rule shall be retained on-site for a minimum of 2 years following the calendar year for which they are made and shall be made available to the Technical Secretary for his review upon request.
(9) The requirements of this rule shall not apply to periods of scheduled maintenance activities that affect NOx emissions.
(10) The requirements of this rule shall not apply to periods of malfunctions, startups, and shutdowns. These periods are subject to the requirements of Chapter 1200-03-20.

Notes

Tenn. Comp. R. & Regs. 1200-03-27-.04
Original rule filed July 9, 2001; effective September 22, 2001.

Authority: T.C.A. ยงยง 68-201-105 and 4-5-201 et. seq.

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