NOx Emissions from Cement Mfg - US Environmental Protection ...

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25. Letter from Wax, J., Institute of Clean Air Companies, to Neuffer, W.J., U.S. Environmental Protection Agency. August 27, 1992. Response to ACT Document - Control of NOx Emissions from Process Heaters. 26. Siddiqi, A.A., and J.W. Tenini. Hydrocarbon Processing. 115-124. October 1981. 27. Haas, G.A. Selective Noncatalytic Reduction (SNCR): Experience with the Exxon Thermal DeNox Process. Presented at the NOx Control V Conference. Council of Industrial Boiler Owners. Long Beach, CA. February 10-11, 1992. 28. San Bernardino County Air Pollution Control District. Compliance Demonstration Test of Tire Derived Fuel (TDF) at Black Mountain Quarry Plant Kiln #2 of Southwestern Portland Cement Company, Victorville, CA. April 1991. 29. Sun, W.H. NOxOUT Process Demonstration on a Cement Kiln/Calciner - Ash Grove Cement - Seattle Plant - Seattle, Washington. October 28, 1993. 30. Kupper, D., and Brentrup, L. SNCR Technology for NOx Reduction in the Cement Industry. World Cement 23(3):4-9. March 1992. 31. Moilanen, G.L., and B. Van Kalsbeek. NOx Control Options for Glass Furnaces. Ceram. Eng. Sci. Proc. 12(3-4):632-649. 1991. 32. McInnes, R., and M.B. von Wormer. Cleaning Up NOx Emissions. Chem. Eng. 130-135. September 1990. 33. Kokkinos, A., J.E. Cichanowicz, R.E. Hall, and C.B. Sedman. Stationary Combustion NOx Control: A Summary of the 1991 Symposium. J. Air Waste Manage. Assoc. 1252. 1991. 34. Teixeira, D. Widening the Urea Temperature Window. In Proceedings of 1991 Joint Symposium on Stationary Combustion NOx Control. NTIS. 1991. 5-30
CHAPTER 6 COSTS OF NOx CONTROL TECHNIQUES This chapter presents the cost estimates for the NOx emission control techniques discussed in Chapter 5. Section 6.1 presents the cost methodology used to develop capital and annual operating costs for these techniques. Based upon the distribution of the type of kilns used in the cement industry and their typical capacities, model plants were developed to perform cost calculations. Section 6.2 presents costs of selected in- combustion and postcombustion control approaches. The cost effectiveness of different control approaches is discussed in Section 6.3. All costs presented in this chapter are in 1992 dollars. 6.1 COST CALCULATION METHODOLOGY 6.1.1 Model Plants 6-1
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EPA-453/R-94-004 ALTERNATIVE CONTRO
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ALTERNATIVE CONTROL TECHNOLOGY DOCU
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Chapter Page 4.1 MECHANISMS OF NO F
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TABLE OF CONTENTS (con.) Chapter Pa
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LIST OF TABLES Number Page 2-1 UNCO
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CHAPTER 1 INTRODUCTION Congress, in
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CHAPTER 2 SUMMARY This chapter pres
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2.2 NO EMISSION CONTROL TECHNOLOGIE
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TABLE 2-2. ACHIEVABLE NO REDUCTIONS
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TABLE 2-4. CAPITAL AND ANNUAL COSTS
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TABLE 2-5. COST EFFECTIVENESS OF NO
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eductions ranged from 470 tons/year
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CHAPTER 3 INDUSTRY DESCRIPTION 3.1
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Type II. Moderate-heat-of-hardening
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3 a TABLE 3-2. UNITED STATES CEMENT
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Figure 3-1. U.S. Portland cement pl
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Table 3-3. (con.) Rank Clinker 3 (1
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5 cement processes: wet process and
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Figure 3-3. New technology in dry-p
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substantial levels of silica and al
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are achieved by clinker coolers of
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126,000 to 963,000 tons/year with a
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such as crushing and grinding opera
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4.1.1 Thermal NO Formation x Therma
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temperatures are on the order of 16
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4-6
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expected to produce more fuel NO th
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introduce a large proportion of com
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will also mean a somewhat lower sec
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ILC systems: In these systems, the
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which indicates an average and the
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Page 66 and 67: Uncontrolled NO x emissions Plant c
Page 68 and 69: from 2 to 9 lb/ton of clinker, and
Page 70 and 71: Capacity Heat in NO x emissions Met
Page 72 and 73: TABLE 4-3. (con.) Capacity Heat in
Page 78 and 79: in estimating uncontrolled and cont
Page 80 and 81: 13. Letter from Sheridan, S.E., to
Page 82 and 83: 44. Chemecology Corporation Source.
Page 84 and 85: 73. Letter and attachments from Smi
Page 86 and 87: NO control approaches applicable to
Page 88 and 89: 5.1.2.2 Kiln Fuel Changing the prim
Page 90 and 91: oxygen content of the primary air m
Page 92 and 93: tend to recirculate hot combustion
Page 94 and 95: e about 15 to 38 percent depending
Page 96 and 97: combustion system shown in Figure 5
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Page 100 and 101: Figure 5-3. Schematic of hazardous
Page 102 and 103: 5-18
Page 104 and 105: higher than typical cement kiln flu
Page 106 and 107: window is in the middle of a kiln.
Page 108 and 109: Figure 5-4. Application of the sele
Page 110 and 111: in Section 5.1.2 is usually difficu
Page 112 and 113: 5.4 REFERENCES 1. Helmuth, R.A., F.
Page 116 and 117: TABLE 6-1. CEMENT KILN MODEL PLANTS
Page 118 and 119: 6-4
Page 120 and 121: 6-6
Page 122 and 123: The total capital cost is the sum o
Page 124 and 125: TABLE 6-3. ANNUALIZED COST ELEMENTS
Page 126 and 127: 6-12
Page 128 and 129: 6.1.3.7 Administrative Charges. The
Page 130 and 131: At this time only three installatio
Page 132 and 133: 6-18
Page 134 and 135: The annualized costs for low NOx bu
Page 136 and 137: No additional costs for utilities o
Page 138 and 139: 20 percent PEC cost for contingenci
Page 140 and 141: TABLE 6-7. ANNUALIZED COSTS FOR RET
Page 142 and 143: 6-28
Page 144 and 145: PEC for model plant 300,000 ' Heat
Page 146 and 147: TABLE 6-9. ANNUALIZED COSTS FOR MID
Page 148 and 149: 6-34
Page 150 and 151: TABLE 6-10. CAPITAL COSTS FOR A URE
Page 152 and 153: TABLE 6-11. ANNUAL OPERATING COSTS
Page 154 and 155: 6-40
Page 156 and 157: TABLE 6-12. CAPITAL COSTS FOR AN AM
Page 158 and 159: TABLE 6-13. ANNUAL OPERATING COSTS
Page 160 and 161: 6-46
Page 162 and 163: costs range from $9.9 million for t
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The estimated annualized costs for
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6.3 COST EFFECTIVENESS OF NOx CONTR
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emoved. Cost effectiveness were det
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TABLE 6-17. COST EFFECTIVENESS OF R
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6-58
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TABLE 6-18. COST EFFECTIVENESS OF M
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TABLE 6-19. COST EFFECTIVENESS OF U
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6.3.4 Selective Catalytic Reduction
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6-66
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TABLE 6-21. COST EFFECTIVENESS OF S
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6-70
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11. Letter and attachments from Nov
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Tables 7-1 7-2
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TABLE 7-2. REDUCTION IN NO x EMISSI
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model plants described in Section 6
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temperature and excess air may be u
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NOxemissions will form. The heater
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equirement for the flue gas reheati
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