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

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TABLE OF CONTENTS Chapter Page LIST OF FIGURES . . . . . . . . . . . . . . . . . . . v LIST OF TABLES . . . . . . . . . . . . . . . . . . vii 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . 1-1 2 SUMMARY . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 UNCONTROLLED NO EMISSIONS . . . . . . . . . . 2-1 x 2.2 NO EMISSION CONTROL TECHNOLOGIES . . . . . . . 2-2 x 2.3 COSTS AND COST EFFECTIVENESS OF NO CONTROL x TECHNOLOGIES . . . . . . . . . . . . . . . . . 2-5 2.4 IMPACTS OF NO CONTROLS . . . . . . . . . . . . 2-7 x 3 INDUSTRY DESCRIPTION . . . . . . . . . . . . . . . 3-1 3.1 BACKGROUND . . . . . . . . . . . . . . . . . . 3-1 3.2 TYPES OF CEMENT PRODUCED . . . . . . . . . . . 3-2 3.3 INDUSTRY CHARACTERIZATION . . . . . . . . . . 3-3 3.3.1 Description of the Cement Industry . . . 3-3 3.3.2 Overview of Cement Manufacturing Process . . . . . . . . . . . . . . . . 3-4 3.3.3 Raw Materials and Kiln Feed Preparation . . . . . . . . . . . . . 3-11 3.3.4 Pyroprocessing . . . . . . . . . . . . 3-13 3.3.4.1 Wet Process Kilns . . . . . . 3-15 3.3.4.2 Dry Process Kilns . . . . . . 3-15 3.3.4.3 Suspension Preheaters . . . . 3-16 3.3.4.4 Precalciner Systems . . . . . 3-17 3.3.5 Finish Grinding . . . . . . . . . . . 3-18 3.3.6 Quality Control . . . . . . . . . . . 3-18 3.3.7 Emission Control Systems . . . . . . . 3-18 3.4 REFERENCES . . . . . . . . . . . . . . . . . 3-19 4 UNCONTROLLED NO EMISSIONS . . . . . . . . . . . . 4-1 x i
Chapter Page 4.1 MECHANISMS OF NO FORMATION IN CEMENT x . . . . . . . . . . . . . . . . 4.1.1 Thermal NO x . . . . . . . . . . 4.1.2 Fuel NO x . . . . . . . . . . . 4.1.3 Feed NO x . . . . . . . . . . . 4.2 FACTORS AFFECTING NOx MANUFACTURING 4-7 4.2.1 Formation in the Kiln Burning Zone . x 4.2.2 NO . . . x 4.2.2.1 Suspension Preheater (SP) 4.2.3 ii . 4-10 Precalcining Kiln Systems 4-11 Process 4-12 4.3 EMISSIONS FROM CEMENT x MANUFACTURING FACILITIES . . . . . . . . . . 4-13 4.4 REFERENCES . . . . . . . . . . . . . . . . . 4-25 5 NO CONTROL TECHNIQUES . . . . . . . . . . . . . . 5-1 5.1 COMBUSTION CONTROL APPROACHES FOR REDUCTION IN NO FORMATION . . . . . . . . . . . . . . . . . 5-2 x 5.1.1 and Excess Air 5-2 5.1.2 . . . . . . . . . 5.1.2.1 Feed Mix Composition . . . . . . 5.1.2.2 Kiln Fuel . . . . . . . . . . . 5.1.2.3 Increasing Thermal Efficiency 5-4 5.1.3 Burner, x and Flue Gas Recirculation . . . . . . 5-4 5.1.4 Secondary Combustion of Fuel . . . . . . 5-8 5.2 POSTCOMBUSTION CONTROL APPROACHES FOR NO EMISSIONS CONTROL . . . . . . . . . . . . . 5-13 5.2.1 Selective Catalytic Reduction (SRC) . 5-13
Page 1 and 2: EPA-453/R-94-004 ALTERNATIVE CONTRO
Page 3: ALTERNATIVE CONTROL TECHNOLOGY DOCU
Page 7 and 8: TABLE OF CONTENTS (con.) Chapter Pa
Page 9 and 10: LIST OF TABLES Number Page 2-1 UNCO
Page 11 and 12: CHAPTER 1 INTRODUCTION Congress, in
Page 13 and 14: CHAPTER 2 SUMMARY This chapter pres
Page 15 and 16: 2.2 NO EMISSION CONTROL TECHNOLOGIE
Page 17 and 18: TABLE 2-2. ACHIEVABLE NO REDUCTIONS
Page 19 and 20: TABLE 2-4. CAPITAL AND ANNUAL COSTS
Page 21 and 22: TABLE 2-5. COST EFFECTIVENESS OF NO
Page 23 and 24: eductions ranged from 470 tons/year
Page 25 and 26: CHAPTER 3 INDUSTRY DESCRIPTION 3.1
Page 27 and 28: Type II. Moderate-heat-of-hardening
Page 29 and 30: 3 a TABLE 3-2. UNITED STATES CEMENT
Page 31 and 32: Figure 3-1. U.S. Portland cement pl
Page 33 and 34: Table 3-3. (con.) Rank Clinker 3 (1
Page 35 and 36: 5 cement processes: wet process and
Page 37 and 38: Figure 3-3. New technology in dry-p
Page 39 and 40: substantial levels of silica and al
Page 41 and 42: are achieved by clinker coolers of
Page 43 and 44: 126,000 to 963,000 tons/year with a
Page 45: such as crushing and grinding opera
Page 48 and 49: 4.1.1 Thermal NO Formation x Therma
Page 50 and 51: temperatures are on the order of 16
Page 52 and 53: 4-6
Page 54 and 55:
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
Page 62 and 63:
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
Page 74 and 75:
Page 76 and 77:
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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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6-28
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PEC for model plant 300,000 ' Heat
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TABLE 6-9. ANNUALIZED COSTS FOR MID
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6-34
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TABLE 6-10. CAPITAL COSTS FOR A URE
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TABLE 6-11. ANNUAL OPERATING COSTS
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6-40
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TABLE 6-12. CAPITAL COSTS FOR AN AM
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TABLE 6-13. ANNUAL OPERATING COSTS
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6-46
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costs range from $9.9 million for t
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The estimated annualized costs for
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6.3 COST EFFECTIVENESS OF NOx CONTR
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emoved. Cost effectiveness were det
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TABLE 6-17. COST EFFECTIVENESS OF R
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6-58
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TABLE 6-18. COST EFFECTIVENESS OF M
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TABLE 6-19. COST EFFECTIVENESS OF U
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6.3.4 Selective Catalytic Reduction
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6-66
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TABLE 6-21. COST EFFECTIVENESS OF S
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6-70
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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
Page 196 and 197:
NOxemissions will form. The heater
Page 198:
equirement for the flue gas reheati
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