2002-12-16_REVISION - M1977344 - Laserfiche WebLink

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Please provide plans for preventing spilled CKD on the ground level at the CKD loading area from being carried by storm water runoff to the Arkansas River. As part of the current plant upgrade, Holnam will be installing a pug mill for the handling of the CKD. The new pug mill will mix water with the CKD at the point of discharge using aheavy-duty twin paddle mixer. Nozzles located above the mixer paddles, spray the material with a regulated curtain of water for complete and uniform wetting. Conditioning of the CKD in this manner will prevent fugitive emissions during the loading, transport to the quarry for landfilling, and unloading. In addition, daily cleanup will be performed in the loading area. Item No. 14 Does Holnam's new plant include a new kiln and/or a new kilning process? If so, what physical and chemical difference, if any, will there be in the resulting CKD? Provide characterization of the expected CKD. Holnam's new facility will include a new kilning process. The existing facility consists of three wet kilns that produce 800,000 tons of cement annually. The new facility currently under construction will replace these three wet kilns with a single state-of-the-art dry process kiln. The new facility will utilize afive-stage preheater /precalciner tower to prepare material for the kiln and will increase the capacity of the plant. The tower includes heat-exchanging cyclones (i.e., preheaters) in which the dry feed is preheated and partially calcined by the kiln's hot exit gasses prior to entering the actual kiln. A secondary firing device (i.e., precalciner) in the lower stage of the preheater will further calcinate the material. Construction of this new plant and demolition of the existing wet kilns includes the addition of new equipment and the modification of existing equipment. However, due to the state-of-the-art technology being used, the kiln will produce more cement, use less energy per ton of cement and dramatically reduce emissions of some criteria pollutants. As previously discussed, data from the currently operating wet kilns is included as Attachment 5. The new dry kiln process is expected to be brought online in June 2001. Predicting the resultant CKD composition from the new plant is difficult. Even though there are other dry kiln systems operating at other locations, the CKD generated by each plant has somewhat of a unique chemical makeup due to variations in raw materials, kiln design and kiln operating parameters. Analytical data for CKD generated by the new process will be submitted to DMG as soon as it is available. Item No. 15 In light the tnajor changes occurring at Hobzam the Division may want to review the reclamation bond when Holnam submits its permit amendment application. No response necessary. Item No. 16 Any changes in the seed mix or otDrer aspects of the reclamation plan should be included with this revision for the Division's review. Holnam recently requested the Natural Resources Conservation Service (NRCS) to review and update their