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Departmental Findings of Fact and Order
Part 70 Air Emission License
A-326-70-A-I

Dragon Products Company, Inc.
Knox CountyThomaston, Maine

II. EMISSION UNIT DESCRIPTION
A. General Process Description
Dragon operates a cement manufacturing facility in Thomaston. The facility, built in 1971, is a wet process cement kiln. Dragon has been licensed to modernize the facility by converting to the more efficient dry cement manufacturing process. The modernization project was authorized by air license A-326-71-U-A/R in accordance with DEP Chapter 115.

Due to technology improvements that are part of the modernization project, the project does not result in a significant net emission increase. DEP found that federal New Source Review (i.e. PSD and Non attainment NSR) permits were not required for this project. The PSD avoidance and minor modification provisions of air license A-326-71-U-A/R are incorporated into this Part 70 license. As part of the review for issuance of license A-326-71-U-A/R, DEP determined that the proposed new and modified emission units, including the new cement kiln, will meet Best Available Control Technology (BACT) requirements.

As part of Dragon's application for the modernization project , refined modeling was performed to show that emissions from Dragon's new plant configuration, in conjunction with other sources, would not cause or contribute to violations of Maine's Ambient Air Quality Standards (MAAQS) for sulfur dioxide (SO2), Particulate Matter (PM10), Nitrogen Dioxide (NO2) and Carbon Monoxide (CO).

The modernization project will convert the existing wet process cement kiln to a dry process (preheater/precalciner type), convert the existing (wet) raw mill to a pregrinding finish cement mill, and improve other ancillary operations within the

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Departmental Findings of Fact and Order
Part 70 Air Emission License
A-326-70-A-I

Dragon Products Company, Inc.
Knox CountyThomaston, Maine

facility. The planned annual production rate of the new facility is approximately 766,500 tons of clinker.

The new dry cement manufacturing process can be divided into three main sections: 1) kiln feed preparation, 2) clinker production, and 3) finish cement operations.

1) Kiln Feed Preparation
The basic ingredients of cement include oxides of calcium, silica, aluminum, and iron. Due to the requirement for large quantities of calcium oxide (CaO), portland cement plants are generally located near a source of the calcareous material (limestone, in the case of Dragon). The limestone for Dragon's manufacturing process is mined from quarries located at the site. Raw limestone is transported from the quarry to a crusher and then to roller mills which grind the material to the desired fineness. The ground material is collected and fed to a blending system to provide the kiln with raw feed.

2) Clinker Production
Clinker production involves high temperature processing in the rotary kiln, where necessary chemical reactions take place to produce a product referred to as "clinker". The kiln is a counter-current heating device, meaning material fed into the cool upper end is drawn slowly by gravity to the hot discharge end. The burners at the discharge end of the kiln produce a current of hot gases that heat the clinker, the calcined material and raw materials in succession as the hot gases pass upward toward the feed end.

In the new kiln, the clinker formation process occurs in a series of stages that correlate with the temperature of the raw materials and in a unit called a calciner or precalciner. These stages and precalciner are located in a structure called a preheater tower. In the preheater, uncombined water evaporates from raw materials. Material temperature increases to the point where calcination begins. As calcination occurs, carbon dioxide is liberated from the carbonate component. Sintering of the oxides occurs in the burning zone of the kiln.

The sintering (or clinkering) reactions chemically combine calcines material with silica, alumina, and iron to form tricalium silicate (Ca3SiO5), dicalcium silicate (Ca2SiO4), tricalcium aluminate (Ca3Al2O6), and tetracalcium alumino-ferrite (Ca4AlFeO7). Following the sintering reactions, clinker is quickly cooled by contact with ambient air. Some heat transferred to the cooler air is recouped back into the process.

3) Finish Cement Operations
The cooled clinker is stored prior to being sent to the finishing mills where it is combined with gypsum and other additives. The clinker and gypsum are ground to a fine, homogenous powder in a series of ball mills. The finished portland cement is then transferred to the cement storage silos prior to shipment off-site.

B. New Portland Cement Kiln System
The new kiln has a nominal design heat input of 440 MMBtu/hr firing the following fuels:
1. A coal/coke blend of fuel,
2. #2-#4 fuel oil blend,
3. Specification and Non-Specification waste oil, and
4. Whole tires and tire chips.

And may use the following raw materials:
1. Petroleum-contaminated soils,
2. Landfill leachate,
3. Petroleum-contaminated water,
4. Fly ash,
5. Kraft pulp mill green liquor dregs,
6. Lime mud, and lime wastes (PCC Grit)
7. Slaker grit, and
8. Foundry Sand.

Dragon may also utilize alternate fuels and raw materials which meet the requirements of Condition 14(C) of this license.

Particulate emissions in the exhaust from the kiln and alkali bypass are controlled by a fabric filter baghouse.

The previously licensed NOx RACT requirements for Dragon's existing wet process cement kiln shall not apply to the new kiln system. The new kiln system is subject to more stringent BACT requirements.

Streamlining
1. 40 CFR Part 63.1343 (MACT) and MEDEP Chapter 105 regulate particulate matter (PM) emission limits from the new cement kiln system. However, Best Available Control Technology (BACT) in license A-326-71-U-A/R and the MACT limit in 40 CFR Part 63.1343 are more stringent than Chapter 105 so that only the BACT and MACT limits identified in Condition 14(F) in the Order section of this license are applicable.

2. Chapter 101 is applicable for visible emissions. However, 40 CFR Part 63.1343 (MACT) is more stringent so that only the MACT limit identified in Condition 14(H) in the Order section of this license is applicable. During periods of kiln preheat and start up, condensation in the kiln exhaust causes false positive readings by the opacity monitor. For this reason, when the exhaust, as measured at the kiln ID fan, is less than 250 oF, monitored opacity readings greater than 20% as measured on a six (6) minute block average basis are not considered an excess emission.

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Departmental Findings of Fact and Order
Part 70 Air Emission License
A-326-70-A-I

Dragon Products Company, Inc.
Knox CountyThomaston, Maine

3. 40 CFR Part 63.1350(c) and Chapter 117 require the use of Continuous Opacity Monitors (COM). However, Chapter 117 is at least as stringent as 40 CFR Part 63.1350(c) so that only the Chapter 117 requirement is identified in the Order section of this license.

4. 40 CFR Part 63.8 and Chapter 117 detail the sampling frequency of the CEM and COM. However, Chapter 117 is at least as stringent as 40 CFR Part 63.8 so that only the Chapter 117 requirement is identified in the Order section of this license

Periodic Monitoring
Stack testing for dioxin/furans every 2.5 years.
One time initial stack test for VOC with the first dioxin/furan stack test.
Daily records of fuel use including: gallons of #2 fuel oil, gallons of #4 fuel oil, fuel sulfur content, gallons of specification and/or non-specification waste oil, tons of tires/tire chips, tons of coal, tons of petroleum coke, tons of fly ash or any other alternative fuel used.

Continuous Monitoring
Documentation that the COM, SO2, CO, and NOx CEMs are continuously accurate, reliable and operated in accordance with Chapter 117, 40 CFR Part 51 Appendix P, and 40 CFR Part 60 Appendices B and F.

C. Existing Portland Cement Kiln System
The existing kiln is rated with a nominal heat input of 306 MMBtu/hr and is authorized to use one or a combination of the following as fuel:

1. A coal/coke blend of fuel,
2. #2 fuel oil,
3. #4 fuel oil,
4. Specification and Non-Specification waste oil, and
5. Whole tires and tire chips.

In addition to the basic raw materials used in the manufacture of clinker (sources of calcium, iron, silica, and alumina), Dragon may also use one or a combination of the following raw materials in the production of clinker:

1. Petroleum-contaminated soils,
2. Landfill leachate,
3. Petroleum-contaminated water,
4. Fly ash,
5. Kraft pulp mill green liquor dregs,
6. Lime mud, and lime wastes (PCC Grit)
7. Slaker grit, and
8. Foundry Sand.

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Departmental Findings of Fact and Order
Part 70 Air Emission License
A-326-70-A-I

Dragon Products Company, Inc.
Knox CountyThomaston, Maine

Dragon may also utilize alternate fuels and raw materials which meet the requirements of Special Condition 14(C) of the license. Particulate emissions on the existing Kiln are controlled by a fabric filter baghouse referred to as the kiln baghouse

NOx RACT for the existing kiln was previously determined to be: improvements to the kiln's chain hanging pattern, revisions to the clinker cooler, firing a blend of coal and petroleum coke as the primary fuel source, and low NOx burners.

Streamlining
1. 40 CFR Part 63.1343 (MACT) and MEDEP Chapter 105 regulate particulate matter (PM) emission limits from the existing kiln system. However, Best Available Control Technology (BACT) and MACT are more stringent so that only the BACT and MACT limits identified in Condition 16(G) in the Order section of this license are applicable.

2. Chapter 101 is applicable for visible emissions. However, 40 CFR Part 63.1343 (MACT) is more stringent so that only the MACT limit identified in Condition 16(G) in the Order section of this license is applicable. During periods of kiln preheat and start up, condensation in the kiln exhaust causes false positive readings by the opacity monitor. For this reason, when the exhaust, as measured at the kiln ID fan, is less than 250 oF, monitored opacity readings greater than 20% as measured on a six (6) minute block average basis are not considered an excess emission.

3. 40 CFR Part 63.1350(c) and Chapter 117 require the use of Continuous Opacity Monitors (COM). However, Chapter 117 is at least as stringent at 40 CFR Part 63.1350(c) so that only the Chapter 117 requirement is identified in the Order section of this license.

4. CFR Part 63.8 and Chapter 117 detail the sampling frequency of the CEMs and COM. However, Chapter 117 is at least as stringent as 40 CFR Part 63.8 so that only the Chapter 117 requirement is identified in the Order section of this license.

Periodic Monitoring Stack testing for dioxin/furans every 2.5 years. Daily records of fuel use including: gallons of #2 fuel oil, gallons of #4 fuel oil, fuel sulfur content, gallons of specification and/or non-specification waste oil, tons of tires/tire chips, tons of coal, tons of petroleum coke, tons of fly ash or other alternative fuel.

Continuous Monitoring Documentation that the COM, SO2, and NOx CEMs are continuously accurate, reliable and operated in accordance with Chapter 117, 40 CFR Part 51 Appendix P, and 40 CFR Part 60 Appendices B and F.

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