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

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20 percent PEC cost for contingencies the total installed capital cost may be estimated to be about $2.7 million. This estimate agrees well with a contractor's estimate of $2.9 million for the same facility.12 Since the $1.3 million equipment cost estimate was for three parallel systems, the cost of one conversion system to process coal for a 30 ton/hr dry facility was considered to be $522,000 accounting for 5 percent annual inflation rate. The amount of coal processed is proportional to heat requirement. For a dry process approximately 4.5 MM Btu/ton of clinker energy is required. Therefore, the cost of firing system conversion to process coal to provide 135 MM Btu/hr equivalent energy is considered to be $522,000. Cost of firing system conversion for other heat capacities was estimated using 0.6 power rule: PEC for model plant 522,000 ' Heat requirement for model plant 135 The PEC for installing a low NOx burner in an existing direct-fired kiln is determined by adding the cost of firing system conversion to the low NOx burner cost. For each model plant described in Table 6-1 the PEC for firing system conversion as well as for multichannel burner was determined based on the heat duty needed by the kiln. For long wet, long dry, and preheater kilns all the required heat is assumed to be provided by the low NOx burner, whereas for precalciner kilns only 60 percent of the heat duty is assumed to be provided by the low NOx burner at the hot end of the kiln. The capital costs for retrofitting the eight model plants in an existing direct-fired kiln are given in Table 6-6. The capital costs ranged from $1.27 million for the small long dry kiln to $2.18 million for the 6-24 0.6 .
large long wet kiln. TABLE 6-6. CAPITAL COSTS FOR RETROFIT LOW NO x BURNERS IN AN EXISTING DIRECT-FIRED KILN Installation costs Total capital costs ($) Contingency costs ($) $ Freight and sales tax ($) Heat duty (MM Btu/ hr) Kiln capacity (tons clinker/hr) Direct Indirect PEC ($) Kiln type Model no. 30 180 794,000 64,000 357,000 262,000 159,000 1,640,000 1 Long wet 50 300 1,059,000 85,000 477,000 349,000 212,000 2,180,000 2 Long wet 6-25 25 113 618,000 49,000 278,000 204,000 124,000 1,270,000 3 Long dry 40 180 794,000 64,000 357,000 262,000 159,000 1,640,000 4 Long dry 40 152 725,000 58,000 326,000 239,000 145,000 1,490,000 5 Preheater 70 266 988,000 79,000 445,000 326,000 198,000 2,040,000 6 Preheater 100 330 837,000 67,000 377,000 276,000 167,000 1,720,000 7 Precalciner 150 495 1,053,000 84,000 474,000 347,000 211,000 2,170,000 8 Precalciner
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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
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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 136 and 137: No additional costs for utilities o
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
Page 186 and 187: 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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