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

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TABLE 6-13. ANNUAL OPERATING COSTS FOR AN AMMONIA-BASED SNCR PROCESS Total annualized costs ($/yr) Capital recovery ($/yr) Taxes insurance admin. ($/yr) Fuel penalty costs ($/yr) Maintenance and overhead costs ($/yr) Operating material costs ($/yr) Operating labor costs ($/yr) <strong>NOx</strong> emissions (lb/hr) Kiln capacity (tons clinker/ hr) Model no. Kiln type 5 Preheater 40 240 30,400 200,000 48,700 9,100 53,600 176,100 518,000 6 Preheater 70 410 30,400 341,000 48,700 16,000 73,900 243,000 753,000 7 Precalciner 100 340 30,400 283,000 48,700 19,800 66,000 217,000 665,000 8 Precalciner 150 510 30,400 424,000 48,700 29,700 84,200 277,000 894,000 6-44
6.2.2.2 Selective Catalytic Reduction. Although no selective catalytic reduction (SCR) systems are currently being used on cement plants in the United States, this control technique has been applied successfully in other industries. Capital costs for this control approach would include cost of the SCR unit, ammonia storage tank, and an ammonia heating/ vaporization injection system along with equipment needed for preheating flue gases to an appropriate temperature. Operating costs would include the cost of ammonia reagent, dilution steam, catalyst replacement and disposal costs, and energy cost associated with reheating the kiln exhaust gases as well as the operating labor and maintenance costs. Since the SCR technology has not been proven in cement plants in the United States, approximate capital and operating costs as applicable to the model plants were not available <strong>from</strong> any of the SCR control system vendors in the United States. An equipment cost estimate of an SCR system was submitted by a Japanese supplier to a cement company in the United States in 1991.19 For a dry long kiln with 1,120 tons/day (47 tons/hr) clinker capacity, the estimated equipment cost was 1 billion/Yen. With a current exchange rate of 108 Yen/$ and assuming 5 percent inflation, the estimated cost in 1992 U.S. dollars was about 9.72 6-45
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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
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e about 15 to 38 percent depending
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combustion system shown in Figure 5
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5-14
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Figure 5-3. Schematic of hazardous
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5-18
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higher than typical cement kiln flu
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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 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 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
Page 194 and 195: temperature and excess air may be u
Page 196 and 197: NOxemissions will form. The heater
Page 198: equirement for the flue gas reheati
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