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

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model plants described in Section 6.1.1 using low NOx burners, mid-kiln firing, selective noncatalytic reduction (SNCR), and selective catalytic reduction (SCR) techniques, respectively. The NOx emission reduction efficiencies used are 25 percent for low NOx burners, and for mid-kiln firing of tires, 50 percent for SNCR, and 80 percent for SCR technology. As seen from these tables, substantial reductions in NOx emissions are possible with postcombustion technologies of SCR and SNCR. With these technologies, annual NOx emissions reduction ranged from 470 tons/year to 1,630 tons/year for the eight model plants. The annual NOx emissions reductions with the low NOx burner technology and mid-kiln firing of tires ranged from 210 tons/year to 510 tons/year. As discussed in Section 6.2.1.1 combustion zone control of 7-6
TABLE 7-4. REDUCTION IN NO EMISSIONS WITH SCR PROCESS x Controlled Uncontrolled NO x emissions (tons/yr) Heat Duty (MM Btu/hr) NOx Reduction (%) NO x Removed (tons/yr) NO x emissions (tons/yr) Kiln capacity (tons clinker/hr) Kiln Type Model Plant No. 1 Long Wet 30 180 1,160 230 930 80 2 Long Wet 50 300 1,940 390 1,550 80 3 Long Dry 125 113 860 170 690 80 4 Long Dry 40 180 1,380 280 1,100 80 5 Preheater 40 152 940 190 750 80 6 Preheater 70 266 1,650 330 1,320 80 7 Precalciner 100 330 1,360 270 1,090 80 7-7 8 Precalciner 150 495 2,040 410 1,630 80
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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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No additional costs for utilities o
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20 percent PEC cost for contingenci
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TABLE 6-7. ANNUALIZED COSTS FOR RET
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Page 144 and 145: PEC for model plant 300,000 ' Heat
Page 146 and 147: TABLE 6-9. ANNUALIZED COSTS FOR MID
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Page 150 and 151: TABLE 6-10. CAPITAL COSTS FOR A URE
Page 152 and 153: TABLE 6-11. ANNUAL OPERATING COSTS
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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 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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