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

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11. Letter and attachments from Novak, L.S., RC Cement Co., Inc., Bethlehem, PA, to Crolius, R.W., American Portland Cement Alliance, Washington, DC, August 23, 1993. Cost of firing system conversion. 12. Letter from Papa, E.S., Willis & Paul Group, Danville, NJ, to Stampf, F., Hercules Cement Company, Stockertown, PA, April 6, 1988. Cost of firing system conversion. 13. Telecon. Hansen, E.R., Ash Grove Cement Co., Overland Park, KS, with Damle, A.S., Research Triangle Institute, October 16, 1992. Mid-kiln firing of tires and waste-derived fuels in long kilns. 14. Telecon. Benoit, M.R., Cadence Chemical Resources, Inc., Greene, RI, with Damle, A.S., RTI, November 3, 1992. Midkiln firing of tires and waste-derived fuels in long kilns. 15. Letter and attachments from Pickens, R.D., Nalco Fueltech, Santa Fe Springs, CA, to Damle, A.S., Research Triangle Institute, October 15, 1992. Nalco Fueltech's urea-based SNCR technology. 16. Letter and attachments from Wax, M.J., Institute of Clean Air Companies, Washington, DC, to Damle A.S., Research Triangle Institute. December 7, 1992. Costs for application of SNCR systems to cement kilns. 17. Letter from Seebach, M.V., Polysius Corporation, Atlanta, GA, to Willis, D., Blue Circle Cement, Inc., Marietta, GA, June 18, 1993. Costs for Ammonia-based SNCR system. 18. Kupper, D., and Brentrup, L. SNCR Technology for NOx Reduction in the Cement Industry. World Cement 23(3):4-9. March 1992. 19. Letter and attachments from Akita, A., Hitachi Zosen Corporation, Tokyo, Japan, to Kohl, R.F., Arizona Portland Cement Company, August 2, 1991. Costs for an SCR unit for Colton plant. 20. Letter and attachments form Bennett, J.H., California Portland Cement Company, Glendora, CA, to Neuffer, W.J., U.S. Environmental Protection Agency, March 16, 1993. Costs for an SCR unit for Colton plant. 21. Smith, J.C., and M.J. Wax. Selective Catalytic Reduction (SCR) Controls to Abate NOx Emissions. White Paper sent by Wax, M.J., Institute of Clean Air Companies. September 1992. 6-72
CHAPTER 7 ENVIRONMENTAL AND ENERGY IMPACTS OF NOx CONTROLS This chapter presents the environmental and energy impacts for the NOx emissions control techniques described in Chapter 5. The impacts of in-combustion control approach of low NOx burners as well as postcombustion control approaches of selective and nonselective catalytic reduction on environmental pollution, and energy consumption are discussed. None of the NOx reduction technologies considered produce any water pollution impacts. Section 7.1 presents the environmental impacts, and Section 7.2 presents the energy consumption impacts. 7.1 ENVIRONMENTAL IMPACTS OF NOx CONTROLS 7.1.1 NOx Emission Reductions
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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.
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Figure 5-4. Application of the sele
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in Section 5.1.2 is usually difficu
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5.4 REFERENCES 1. Helmuth, R.A., F.
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25. Letter from Wax, J., Institute
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TABLE 6-1. CEMENT KILN MODEL PLANTS
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6-4
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6-6
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The total capital cost is the sum o
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TABLE 6-3. ANNUALIZED COST ELEMENTS
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6-12
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6.1.3.7 Administrative Charges. The
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At this time only three installatio
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6-18
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The annualized costs for low NOx bu
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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 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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