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

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No additional costs for utilities or operating labor were deemed necessary for NOx control purposes in addition to those required for normal burner operation. The low NOx burner maintenance costs were included at 10 percent of the PEC. Indirect annual costs were determined as described in Section 6.1.3. The total annualized costs for the eight low NOx burner retrofits ranged from a low of $77,000/yr for the small long dry kiln to a high of $111,000/yr for the large long wet kiln. Conversion of a direct-fired kiln to an indirect-fired kiln involves adding particle separation equipment such as a cyclone or a baghouse and a compressor for additional power. To reduce explosion potential due to concentrated coal flow, explosion vents are used. The total cost of equipment needed to convert an existing dry process facility with three kilns, with a combined 90 tons/hr clinker capacity, was estimated to be about $1.3 million in 1988.11 The equipment list included three parallel trains, each with dust collector, grit separator, screw conveyer, blower, primary air fan, explosion vent, ductwork, and auxiliary equipment such as flowmeters. Adding 8 percent PEC cost for sales tax and freight, 45 percent PEC cost for direct installation, 33 percent PEC cost for indirect installation, and 6-22
6-23
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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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4-18
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Uncontrolled NO x emissions Plant c
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from 2 to 9 lb/ton of clinker, and
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Capacity Heat in NO x emissions Met
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TABLE 4-3. (con.) Capacity Heat in
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in estimating uncontrolled and cont
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13. Letter from Sheridan, S.E., to
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44. Chemecology Corporation Source.
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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
Page 98 and 99: 5-14
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 114 and 115: 25. Letter from Wax, J., Institute
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 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
Page 164 and 165: The estimated annualized costs for
Page 166 and 167: 6.3 COST EFFECTIVENESS OF NOx CONTR
Page 168 and 169: emoved. Cost effectiveness were det
Page 170 and 171: TABLE 6-17. COST EFFECTIVENESS OF R
Page 172 and 173: 6-58
Page 174 and 175: TABLE 6-18. COST EFFECTIVENESS OF M
Page 176 and 177: TABLE 6-19. COST EFFECTIVENESS OF U
Page 178 and 179: 6.3.4 Selective Catalytic Reduction
Page 180 and 181: 6-66
Page 182 and 183: TABLE 6-21. COST EFFECTIVENESS OF S
Page 184 and 185: 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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