Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 1 of 5 PI-15 Instructions 10/2006 PROCESS INFORMATION: Portland Cement Manufacturing – INSTRUCTIONS Microsoft Word version of PI-15 Adobe PDF version of PI-15 The purpose of PI-15 (state form 52556) is to obtain detailed information about the Portland cement manufacturing process. Complete one form for each process (or group of identical processes). PI-15 is a required form for all air permit applications submitted to IDEM, OAQ. For the purposes of this form, the term “source” refers to the plant as a whole and NOT to the individual emissions units. If you do not provide the enough information to adequately describe the process, the application process may be stopped. If you have any questions, contact the Air Permit Reviewer of the Day (PROD) at (317) 233-0178 or 1-800-451-6027 extension 3-0178 (toll free call within Indiana). Part A: Elements of Portland Cement Manufacturing Part A identifies the processes related to Portland cement manufacturing and additional forms that may be needed. For each process listed, specify the form(s) attached. If a listed process is not applicable to the process, choose “N/A”. If there is another process applicable beyond the listed items, specify the process under the “other” option, and identify any additional forms used to describe the process. 1. Process: a. Quarry and/or Mine Activities: Use the PI-03 form to describe all storage and handling activities. b. Raw Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. c. Non-Metallic Mineral Processing (crushing and sizing of raw materials): Use the PI-18 form to describe the mineral processing activities. d. Ground Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. e. Pre-heater / Pre-calciner: To adequately describe the pre-heater or pre-calciner, complete the PI-02A to summarize the combustion units, Complete the PI-02B to describe each pre-heater or pre-calciner, complete the PI-02G to identify all the emission factors applicable to the process, and complete PI-02H to identify any federal rules that apply to the combustion unit. f. Fuel type for Pre-heater / Pre-calciner: Complete the PI-02F form is a fuel other than natural gas is used. g. Kiln: To adequately describe the kiln, complete the PI-02A to summarize the combustion units, Complete the PI02E to describe each kiln, complete the PI-02G to identify all the emission factors applicable to the process, and complete PI-02H to identify any federal rules that apply to the combustion unit. h. Fuel Type for Kiln: Complete the PI-02F form is a fuel other than natural gas is used. i. Clinker Material Storage and Handling: Use the PI-03 form to describe all storage and handling activities. j. Non-Metallic Mineral Processing (crushing and sizing of clinker): Use the PI-18 form to describe the mineral processing activities. 2. Form: PI-03: Storage and Handling of Bulk Material PI-02A: Combustion Unit Summary PI-02B: Combustion – Boilers, Process Heaters & Furnaces PI-02E: Combustion – Kilns PI-02F: Combustion – Fuel Use PI-02G: Combustion – Emission Factors PI-02H: Combustion – Federal Rule Applicability American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 2 of 5 PI-15 Instructions 10/2006 PI-18: Mineral Processing Part B: Portland Cement Manufacturing Summary Part B summarizes the Portland cement manufacturing process. 3. Maximum Amount of Raw Material Processed: Quantify the maximum amount of raw material processed in tons per hour (ton/hr) and tons per year (tpy). 4. Raw Material: Identify each raw material used and include the percentage by weight (%) used compared to the total amount of raw materials processed. If there is another raw material applicable beyond the listed items, specify the raw material under the “other” option. 5. Maximum Amount of Portland Cement Produced: Provide the maximum amount of Portland cement produced in tons per year (tpy). Part C: Federal Rule Applicability Part C identifies any federal rules that apply to the process. 6. Is a New Source Performance Standard (NSPS) applicable to this source? Specify whether a New Source Performance Standard (NSPS) is applicable to the process unit(s). If a New Source Performance Standard (NSPS) applies, list the rule citation and title in the space provided and submit a FED-01 form to identify the applicable portions of the rule. 7. Unit IDs: Provide the identification numbers for the process units that are subject to an NSPS. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. 8. Is a National Emission Standard for Hazardous Air Pollutants (NESHAP) applicable to this source? Specify whether a National Emission Standard for Hazardous Air Pollutants (NESHAP) is applicable to the process unit(s). If a National Emission Standard for Hazardous Air Pollutants (NESHAP) applies, list the rule citation and title in the space provided and submit a FED-01 form to identify the applicable portions of the rule. The United States Environmental Protection Agency (U.S. EPA) provides lists of NESHAP on the Rules and Implementation section of the Air Toxics Website. 9. Unit IDs: Provide the identification numbers for the process units that are subject to a NESHAP. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. 10. Non-Applicability Determination: Provide an explanation of non-applicability if the process unit would appear to be subject to a rule (based on the rule title of affected source category), but the rule will not apply to the process. For example, if the process unit is part of the source category subject to a rule, but the process unit in question is not subject to the rule, state the reason why the unit is not subject. Part D: Cement Kiln Dust Operations Part D identifies the components associated with the Cement Kiln Dust (CKD) operations. 11. Type of Equipment: Specify the type of equipment used for cement kiln dust operations. 12. Unit ID: For each equipment type listed, provide the identification number(s) for the process unit(s). Please list each emission unit on a separate row, unless they are identical. Identical units must be of the same type, capacity, and installation date. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 3 of 5 PI-15 Instructions 10/2006 13. Installation Date: For each emission unit listed, provide the date on which the unit was installed. If the exact date is not known, provide the month and year of the installation. If the unit has not yet been installed, provide the anticipated installation date. If the unit has been modified since the original installation, include the most recent modification date. 14. Maximum Throughput: Specify the maximum throughput in tons per hour (ton/hr). 15. Air Pollutant: For each process identified, list each air pollutant emitted to the atmosphere during normal operation. If there are multiple pollutants for an process, use a new row for each pollutant. 16. Emission Factor: Provide the relevant emission factor including the appropriate units (e.g., lb/units, lbs/ton, lbs/gal, lbs/cf, etc.). 17. Source of Emission Factor: Provide the source of the emission factors. Common sources include AP-42, stack test data, engineering analysis. The United States Environmental Protection Agency (U.S. EPA) has developed a Clearinghouse for Inventories & Emission Factors containing AP-42 and other emission factors. Appendix A of AP-42 lists several common conversion factors that may be needed to calculate potential to emit. 18. Add-On Control Technology: Identify all control technologies used for this process, if applicable. A Control Equipment (CE) application form will need to be completed for each control device used, and a summary of control equipment should be submitted using form CE-01. 19. Control Techniques: Identify all control techniques used for this process. 20. Process Limitations / Additional Information: Use the space provided to identify any acceptable process limitations or to provide additional information. An example of an acceptable process limitation would be taking a limit on raw material usage. Such a limit would require an additional record keeping and reporting requirements to be enforceable. For some limitations, performance testing may also be required. Any future change to the established limit will require a permit modification. Part E: Clinker Cooler Operations Part E identifies the components associated with the clinker cooler operations. 21. Type of Clinker Cooler: Specify the type of clinker cooler used. 22. Unit ID: For each clinker cooler type listed, provide the identification number(s) for the process unit(s). Please list each emission unit on a separate row, unless they are identical. Identical units must be of the same type, capacity, and installation date. The identification numbers listed on this form should correspond to the emissions unit identified on the Plant Layout and Process Flow diagrams. 23. Installation Date: For each emission unit listed, provide the date on which the unit was installed. If the exact date is not known, provide the month and year of the installation. If the unit has not yet been installed, provide the anticipated installation date. If the unit has been modified since the original installation, include the most recent modification date. 24. Maximum Throughput: Specify the maximum throughput in tons per hour (ton/hr). 25. Air Pollutant: For each process identified, list each air pollutant emitted to the atmosphere during normal operation. If there are multiple pollutants for an process, use a new row for each pollutant. American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 4 of 5 PI-15 Instructions 10/2006 26. Emission Factor: Provide the relevant emission factor including the appropriate units (e.g., lb/units, lbs/ton, lbs/gal, lbs/cf, etc.). 27. Source of Emission Factor: Provide the source of the emission factors. Common sources include AP-42, stack test data, engineering analysis. The United States Environmental Protection Agency (U.S. EPA) has developed a Clearinghouse for Inventories & Emission Factors containing AP-42 and other emission factors. Appendix A of AP-42 lists several common conversion factors that may be needed to calculate potential to emit. 28. Add-On Control Technology: Identify all control technologies used for this process, if applicable. A Control Equipment (CE) application form will need to be completed for each control device used, and a summary of control equipment should be submitted using form CE-01. 29. Control Techniques: Identify all control techniques used for this process. 30. Process Limitations / Additional Information: Use the space provided to identify any acceptable process limitations or to provide additional information. An example of an acceptable process limitation would be taking a limit on raw material usage. Such a limit would require an additional record keeping and reporting requirements to be enforceable. For some limitations, performance testing may also be required. Any future change to the established limit will require a permit modification. ***SUBMISSION OF CONFIDENTIAL RECORDS*** All information submitted to IDEM will be made available to the public unless it is submitted under a claim of confidentiality. Claim of confidentiality must be made at the time the information is submitted to IDEM, and must follow the requirements set out in 326 IAC 17.1-4-1. Failure to follow these requirements exactly will result in your confidential information becoming a public record, available for public inspection. To ensure that your information remains confidential, refer to the IDEM, OAQ information regarding submittal of confidential business information. For more information on confidentiality for certain types of business information, please review IDEM’s Nonrule Policy Document Air-031-NPD regarding Emission Data. Summary of Websites 1. Microsoft Word version of form PI-15: www.in.gov/icpr/webfile/formsdiv/52556.doc 2. Adobe PDF version of form PI-15: www.in.gov/icpr/webfile/formsdiv/52556.pdf 3. Air Permit Reviewer of the Day (PROD) online form: www.in.gov/idem/permits/air/prodform.html 4. Plant Layout Diagram: www.in.gov/idem/permits/air/apps/instructions/pldexample.pdf 5. Example Process Flow Diagram: www.in.gov/idem/permits/air/apps/instructions/pfdexample.pdf 6. PI-03 Form: Storage and Handling of Bulk Material: www.in.gov/idem/permits/air/apps/instructions/pi03instructions.html 7. PI-02A Form: Combustion Unit Summary: www.in.gov/idem/permits/air/apps/instructions/pi02Ainstructions.html 8. PI-02B: Combustion – Boilers, Process Heaters & Furnaces: www.in.gov/idem/permits/air/apps/instructions/pi02Binstructions.html 9. PI-02E Form: Combustion – Kilns: www.in.gov/idem/permits/air/apps/instructions/pi02Einstructions.html 10. PI-02F Form: Combustion – Fuel Use: www.in.gov/idem/permits/air/apps/instructions/pi02Finstructions.html 11. PI-02G Form: Combustion – Emission Factors: www.in.gov/idem/permits/air/apps/instructions/pi02Ginstructions.html 12. PI-02H Form: Combustion – Federal Rule Applicability: www.in.gov/idem/permits/air/apps/instructions/pi02Hinstructions.html American LegalNet, Inc. www.FormsWorkflow.com Indiana Department of Environmental Management Office of Air Quality Air Permit Application Page 5 of 5 PI-15 Instructions 10/2006 13. PI-18 Form: Mineral Processing: www.in.gov/idem/permits/air/apps/instructions/pi18instructions.html 14. U.S. EPA’s Clearinghouse for Inventories & Emission Factors: www.epa.gov/ttn/chief/efpac/index.html 15. Appendix A of AP-42: www.epa.gov/ttn/chief/ap42/appendix/appa.pdf 16. United States Environmental Protection Agency (US EPA): www.epa.gov/ 17. Rules and Implementation section of U.S. EPA’s Air Toxics Website: www.epa.gov/ttn/atw/eparules.html 18. Article 17.1, Rule 4, Section 1 of the Indiana Administrative Code (326 IAC 17.1-4-1): www.in.gov/legislative/iac/T03260/A00171.PDF 19. IDEM, OAQ’s information regarding submittal of confidential business information: www.in.gov/idem/permits/air/apps/cbi.html 20. IDEM’s Nonrule Policy Document regarding Emission Data (Air-031-NPD): www.in.gov/idem/rules/policies/index.html American LegalNet, Inc. www.FormsWorkflow.com OAQ PROCESS INFORMATION APPLICATION PI-15: Portland Cement Manufacturing State Form 52556 (R / 1-07) INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT IDEM – Office of Air Quality – Permits Branch 100 N. Senate Ave., MC 61-53 Indianapolis, IN 46204-2251 Telephone: (317) 233-0178, or Toll Free: 1-800-451-6027 x30178 (within Indiana) Facsimile Number: (317) 232-6749 www.idem.IN.gov/permits/air/index.html • The purpose of this form is to obtain detailed information about the Portland Cement Manufacturing Processes. Complete one form for each process unit (or group of identical process units). • NOTES: Detailed instructions for this form are available online at www.idem.IN.gov/permits/air/apps/instructions/pi15instructions.doc . • All information submitted to IDEM will be made available to the public unless it is submitted under a claim of confidentiality. Claims of confidentiality must be made at the time the information is submitted to IDEM, and must follow the requirements set out in 326 IAC 17.1-4-1. Failure to follow these requirements exactly will result in your information becoming a public record, available for anyone to inspect and photocopy. PART A: Portland Cement Manufacturing Processes Part A identifies the processes related to Portland Cement manufacturing and additional forms that may be needed. 1. Process 2. Use the form listed for the specified processes. Check all that apply. a. Quarry and/or Mine Activities This form is included for quarrying and mine processes: b. Raw Material Storage and Handling This form is included for raw materials unloading / storage: c. Non-Metallic Mineral Processing (crushing and sizing of raw materials) PI-03 N/A PI-03 N/A This form is included for the raw materials processing: PI-18 N/A d. Ground Material Storage and Handling This form is included for the raw mills storage / handling: PI-03 N/A e. Pre-heater / Pre-calciner This form is included for the pre-heater: PI-02 N/A Submit form if fuel other than Natural Gas used: PI-02F N/A PI-02A N/A PI-02E N/A PI-02G N/A PI-02H N/A PI-02F N/A f. Fuel used for pre-heater / pre-calciner (if other than natural gas) g. Kiln These forms are included for the kiln: h. Fuel Type for Kiln (if other than Natural Gas) Submit form if fuel other than Natural Gas used in the kiln: i. Clinker Material Storage and Handling This form is included for the clinker storage / handling: PI-03 N/A j. Non-Metallic Mineral Processing (crushing and sizing of clinker) This form is included for clinker processing: PI-18 N/A k. Other process(es) This form is included for (specify process): N/A Continued on Next Page Page 1 of 4 American LegalNet, Inc. www.FormsWorkflow.com Indiana Department Of Environmental Management Office Of Air Quality State Form 52556 (R / 1-07) Process Information – Portland Cement FORM PI-15 Page 2 of 4 PART B: Portland Cement Manufacturing Summary Part B identifies the Portland Cement Manufacturing details. tons per hour (tons/hr) 3. Maximum Amount of Raw Materials Processed: tons per year (tpy) Calcium Carbonate Aragonite 4. Raw Material (as a percentage of total): Chalk Other (specify): 5. Maximum Amount of Portland Cement Produced: tons per year (tpy) Part C – Federal Rule Applicability Part C identifies any federal rules that apply to the process. 6. Is a New Source Performance Standard (NSPS) applicable to this source? If yes, identify the affected emission units and attach a completed FED-01 for each rule that applies. Yes 40 CFR Part 60, Subpart F No 9. Unit ID(s) Non-Metallic Mineral Processing Plants 40 CFR Part 60, Subpart UUU 7. Unit ID(s) Portland Cement Plants 40 CFR Part 60, Subpart OOO No Calciners and Dryers in Mineral Industries 8. Is a National Emission Standard for Hazardous Air Pollutants (NESHAP) applicable to this source? If yes, identify the affected emission units and attach a Yes completed FED-01 for each rule that applies. 40 CFR Part 63, Subpart LLL Portland Cement 10. Non-Applicability Determination: Provide an explanation if the process unit appears subject to a rule (based on the rule title or the source category), but the rule will not apply. This space is intentionally left blank. Continued on Next Page American LegalNet, Inc. www.FormsWorkflow.com Indiana Department Of Environmental Management Office Of Air Quality State Form 52556 (R / 1-07) Process Information – Portland Cement FORM PI-15 Page 3 of 4 PART D: Kiln Dust Operations Part D provides information about the Cement Kiln Dust (CKD) Operations. 11. Type of Equipment 12. Unit ID 13. Installation Date 14. Maximum Throughput (tons/hr) The following section identifies all emission factors used to calculate air emissions from the cement kiln dust operations. 15. Air Pollutant: 16. Emission Factor value 17. Source of Emission Factor units (if not using AP-42, include calculations) Carbon Monoxide (CO) AP-42 Other N/A Lead (Pb) AP-42 Other N/A Nitrogen Oxides (NOX) AP-42 Other N/A Particulate Matter (PM) AP-42 Other N/A Particulate Matter less than 10μm (PM10) AP-42 Other N/A Particulate Matter less than 2.5μm (PM2.5) AP-42 Other N/A Sulfur Dioxide (SO2) AP-42 Other N/A Volatile Organic Compounds (VOC) AP-42 Other N/A Worst Case HAP (specify): AP-42 Other N/A Other (specify): AP-42 Other N/A 18. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless “none”). None Baghouse / Fabric Filter – Attach CE-02. Cyclone – Attach CE-03. Electrostatic Precipitator – Attach CE-04. Absorption / Wet Collector / Scrubber – Attach CE-05. NOX Reduction – Attach CE-09. Other (specify): – Attach CE-10. 19. Control Techniques: Identify all control techniques used for this process. 20. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary. Continued on Next Page American LegalNet, Inc. www.FormsWorkflow.com Indiana Department Of Environmental Management Office Of Air Quality State Form 52556 (R / 1-07) Process Information – Portland Cement FORM PI-15 Page 4 of 4 PART E: Clinker Cooler Operations Part E provides information about the clinker cooler. 21. Type of Clinker Cooler 22. Unit ID 23. Installation Date 24. Maximum Throughput (tons/hr) The following section identifies all emission factors used to calculate air emissions from the clinker cooler. 25. Air Pollutant: 26. Emission Factor value 27. Source of Emission Factor units (if not using AP-42, include calculations) Carbon Monoxide (CO) AP-42 Other N/A Lead (Pb) AP-42 Other N/A Nitrogen Oxides (NOX) AP-42 Other N/A Particulate Matter (PM) AP-42 Other N/A Particulate Matter less than 10μm (PM10) AP-42 Other N/A Particulate Matter less than 2.5μm (PM2.5) AP-42 Other N/A Sulfur Dioxide (SO2) AP-42 Other N/A Volatile Organic Compounds (VOC) AP-42 Other N/A Worst Case HAP (specify): AP-42 Other N/A Other (specify): AP-42 Other N/A 28. Add-On Control Technology: Identify all control technologies used for this unit, and attach completed CE-01 (unless “none”). None Baghouse / Fabric Filter – Attach CE-02. Cyclone – Attach CE-03. Electrostatic Precipitator – Attach CE-04. Absorption / Wet Collector / Scrubber – Attach CE-05. NOX Reduction – Attach CE-09. Other (specify): – Attach CE-10. 29. Control Techniques: Identify all control techniques used for this process. 30. Process Limitations / Additional Information: Identify any acceptable process limitations. Attach additional information if necessary. American LegalNet, Inc. www.FormsWorkflow.com