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

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from 2 to 9 lb/ton of clinker, and precalciner-kiln emissions ranged from 2 to 7 lb/ton of clinker. During preparation of this ACT document, NO emissions data x were collected from major cement companies in the United States. Out of 48 cement kilns providing NO emissions data, 22 were from x long wet kilns, 8 were from long dry kilns, 8 were from preheater kilns, and 10 were from precalciner type cement kilns. Table 4-3 presents these most recent data on NO emissions along with the x kiln types and fuels burned. As seen from Table 4-3, in general, wet kilns were found to produce the highest NO emissions ranging from 3.6 to 19.5 lb x NO /ton of clinker with an average of 9.7 lb NO /ton of clinker. x x Wet kilns also consume the most energy among different cement kiln types. The energy consumption of wet kilns was found to be in the range of 4.9 to 8.8 MM Btu/ton of clinker with an average of 6.0 MM Btu/ton. Wet kilns burning gas were found to produce greater NO emissions as compared to those burning coal. Also in x some cases, high secondary combustion air temperatures were present with high NO emission rates. Twelve of the wet kilns x reported burning WDFs in significant quantities. Five of these kilns used "mid-kiln" firing of the solid and liquid waste fuel and the other seven kilns injected liquid waste in the hot kiln burning zone. The kilns with mid-kiln firing reported much greater NO emissions ranging from 9 to 18.3 lb/ton of clinker, x whereas other waste fuel burning wet kilns reported much lower NO emissions ranging from 3.6 to 8.1 lb NO /ton of clinker. NO x x x emissions data from these kilns prior to introducing waste fuels, however, were not available to directly assess the effect of waste fuel burning on NO emissions. x The long dry kilns were found to consume significantly less energy than wet kilns (about 4.5 MM Btu/ton on average) and also were found to produce less NO emissions in the range of 6.1 to x 10.5 lb NO /ton of clinker with an average of 8.6 lb NO /ton of x x clinker. The long wet and dry kilns are similar in terms of structure and firing of fuels. The difference in the NO x 4-22
TABLE 4-3. SUMMARY OF RECENTLY COLLECTED NO EMISSIONS DATA x Capacity Heat in NO x emissions Method and Location Kiln # Kiln type (tons/hr) Fuel burned MM Btu/ton (lb/ton clinker) date of data Reference 1. Ash Grove Cement Co. Foreman, AR 1 Wet 36 42% - Coal 6.86 13.51 CEM 63 42% - LWDF Jul-92 16% - SWDF 2 Wet 36 As above 7.1 18.34 CEM 63 Jul-92 3 Wet 54 As above 7.05 15.65 CEM 63 Jul-92 Chanute, KS 1 & 2 Wet 30% - Coal 6.56 9 CEM 63 7.1% - Coke 7/10/92 61.6% WDF 7/18/92 1.3% - Gas Durkee, OR 1 Four-stage 68.2 100% - Coal 3.88 5.06 CEM 63 Preheater during tests during test Method 7 95% - Gas 3.72 9/15/85 currently currently Nephi, UT 1 Precalciner 80 100% - Coal 3.6 3.43 Nov-82 63 2. Blue Circle Inc. 4-23 4.51 Jul-88 63 1.31 Apr-92 63 Calera, AL 1 Dry 38 100% - Coal 3.8 9.58 CEM 68 Atlanta, GA 1 Dry 38.5 50% - Coal 3.95 10.47 CEM 68 50% - Coke Ravena, NY 1 Wet 106.3 40% - Coal 4.9 9.38 CEM 68 60% - Coke Tulsa, OK 1 Dry 38.5 100% - Coal 4 7.5 CEM 68 Harleyville, SC 1 Preheater 85 100% - Coal 3.5 5.87 CEM 68
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EPA-453/R-94-004 ALTERNATIVE CONTRO
Page 3 and 4:
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
Page 11 and 12:
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
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
Page 56 and 57: introduce a large proportion of com
Page 58 and 59: will also mean a somewhat lower sec
Page 60 and 61: ILC systems: In these systems, the
Page 62 and 63: which indicates an average and the
Page 64 and 65: 4-18
Page 66 and 67: Uncontrolled NO x emissions Plant c
Page 70 and 71: Capacity Heat in NO x emissions Met
Page 72 and 73: TABLE 4-3. (con.) Capacity Heat in
Page 78 and 79: in estimating uncontrolled and cont
Page 80 and 81: 13. Letter from Sheridan, S.E., to
Page 82 and 83: 44. Chemecology Corporation Source.
Page 84 and 85: 73. Letter and attachments from Smi
Page 86 and 87: NO control approaches applicable to
Page 88 and 89: 5.1.2.2 Kiln Fuel Changing the prim
Page 90 and 91: oxygen content of the primary air m
Page 92 and 93: 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
Page 98 and 99: 5-14
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
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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
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NOxemissions will form. The heater
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equirement for the flue gas reheati
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