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

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PEC for model plant 300,000 ' Heat requirement for model plant 240 The total capital costs for mid-kiln firing conversion of the four long dry and wet model kilns are given in Table 6-8. The total capital costs range <strong>from</strong> $391,000 for a small dry kiln to $707,000 for a large wet kiln. The annualized costs for the mid-kiln firing conversions are presented in Table 6-9. Operating labor was assumed to be 1 hour per 8-hour shift, and maintenance labor was assumed to be 10 percent of PEC. The annualized costs ranged <strong>from</strong> a low of $128,000 for the small dry 6-30 0.6
kiln to a high of $207,000 for the large wet kiln. TABLE 6-8. CAPITAL COSTS FOR MID-KILN FIRING CONVERSION Total capital costs ($) Contingency costs ($) Installation costs direct and indirect ($) Freight and sales tax ($) PEC ($) Heat duty (MM Btu/ hr) Kiln capacity (tons clinker/ hr) Kiln type Model no. 30 180 252,000 20,200 197,000 50,400 520,000 1 Long wet 50 300 343,000 27,400 268,000 68,600 707,000 2 Long wet 25 113 190,000 15,200 148,000 38,000 391,000 3 Long dry 40 180 252,000 20,200 197,000 50,400 520,000 4 Long dry 6-31
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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
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5.1.2.2 Kiln Fuel Changing the prim
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oxygen content of the primary air m
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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 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 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 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
Page 188 and 189: Tables 7-1 7-2
Page 190 and 191: TABLE 7-2. REDUCTION IN NO x EMISSI
Page 192 and 193: 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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