What’s Up With Cement Plant Permitting?

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Whats Up With Cement Plant Permitting?

• Whats BACT?
• Presented by
• A. A. Linero, P.E. Adminstrator
• New Source Review Section
• June 27, 2001

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Overview

• Kiln Construction is Back
• Focus on Preheater/Calciner Process
• Formation and Control of Pollutants
• Whats Going on in Europe
• Some BACT and LAER Ranges
• Look at a Current Project
• What Next? Questions?

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Views are Authors !

• Not Opinions of Florida DEP
• We do Case-by-Case Reviews
• Literature Search, Not a Technical Paper
• As Seen by a Permitting Engineer
• There are Very Diverse Opinions
• Greatly Simplified

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Dry Process Preheater Calciner Kilns
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Limited to New Dry Process Preheater Calciner
Kilns

• Rinker Photo By FDEP

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From Top of Preheater
Devils Slide Photos by FDEP
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Leaning Tower of Polysius?
Florida Rock Photo by A. Linero
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Lots of Projects

• Production is up Nationwide. 80 Million TPY
• Florida Rock First New Kiln in a Dozen Years
• New Plants CO, FL, MS, NY, TX
• Modernizations and Expansions
• AL, AZ, CA, CO, FL, IN, MS, SC, TX, UT
• Most Require PSD Review and BACT (or LAER)
• Others Net Out Switch Wet to Dry Process

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Pollutant Formation - NOX

• Thermal NOX
• Temp. gt 1200 OC
• Kiln Burner 2000 OC
• Oxidizing Conditions
• Calciner 1000 OC
• Fuel NOX
• Kiln and Calciner

Devils Slide Photo by FDEP
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Pollutant Control - NOX

• Minimize T and Raw Materials Fluctuations
• Optimum Process and Raw Mix Control
• Intelligent Systems Linkman, PyroExpert
• Minimize Primary Air from Coal Mill
• Maximize Hot Air From Clinker Cooler
• All New Projects Do These Things

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Kiln Burner NOX

• Graphic Source F.L.Smidth/Fuller
• Multi-channel Burner
• Pyrojet, Swirlax, Duoflex, GyroTherm, Rotoflam
• Flame Shaping and Localized Reducing Conditions
• High Momentum Primary Air Envelope
• Compatible with Low NOX. All New Projects Do.

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SC Calciner

• Staged Combustion (SC)
• Lower Stage Reducing Zone
• Tires (15), TDF, DDF, Bottle Caps
• Tertiary Air and Fuel
• Upper Stage Top Air
• Florida Rock Installing
• Maybe 30 45 Reduction
• All New Projects Do This
• Graphic Source Polysius

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Diaper Derived Fuel?

Devils Slide Filmed by FDEP
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Tire Gasification and SC

• Whole Tires
• Maybe 40 Tires
• Jura Cement - Wildegg
• Possible at Suwannee, FL
• Graphic Source Polysius

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SNCR

• Ammonia or Urea Injection
• High T, Near Calciner
• 15 Kilns in Europe
• Taiwan
• Most Without SC
• Zero in U.S.
• Graphic Source Fueltec

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SNCR Problems?
Graphic Source EnviroCare

• Much Resistance in U.S.
• Slip and Possibility of Detached Plume
• Often Occurs Even w/o SNCR
• Ammonia Sulfates and Chlorides
• Compatibility Question With SC

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SNCR Opacity?
Siggenthal Photo by A. Linero

• No Steam Plume in Dry Preheater Calciner Process
• Baghouse Will Help Ameliorate Problem
• Author saw No Plume at Siggenthal
• Still Getting Plume?
• Manage and Solve Detached Plume Problem
• Well Described by EnviroCare and CTL, Inc.
• Incorporate Into SO2 Control
• Hydrated Lime MicroMist, Avoid Aluminum Dross

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SNCR SC Compatibility
Graphic Source Jura Zement

• For SNCR to Work, Need High T and O2
• In SC Calciner, T is High where O2 is Low
• Outside of Calciner, O2 is High and T is Low
• Is Lower End of Window 800 or 900 OC
• Jura Zement Has SC and SNCR and Gasification!
• No Effect on (Pre-SNCR) Excellent Plume Opacity
• No Ammonia Slip (Low Removal Objective?)

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Selective Catalytic Reduction

• Catalyst and Low T Ammonia Injection
• Demonstration Stage at Solnhofen
• Extremely Dusty Environment
• Or Need to Re-heat Stack Gas
• Maybe Exotic Compared to Other Options
• Better to See What SC, SNCR, Achieve First

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European Emission Limits
Polysius Graphic Modified by A. Linero
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SNCR at Leimen Plant - Germany
3.7 lb/ton
2.3 lb/ton
1.3 ?
Graphic Source Heidelberger
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What is BACT?
Photo Source RMC Lonestar

• 2.5 lb/ton at Kiln Built Circa 1980!
• Slug of 2.3 2.9 lb/ton BACTs, e.g. FRI 2.8 in
  1996
• 1 lb/ton in Slite, Sweden (80 Reduction)
• 1 lb/ton in Taiwan by SNCR
• 1 lb/ton in 1994 Ash Grove SNCR Test
• 1.2 lb/ton Annual Limit at Holnam Midlothian
• European IPPC BAT (200 500 mg/m3)
• Equals 0.9 to 2.3 lb/ton
• LAER? Must Be Near 1 lb/ton. Lower if SCR

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Pollutant Formation SO2

• Fuel Sulfur Kiln/Calciner
• Roasting of Pyrites in PH
• Graphic Source F.L.Smidth/Fuller

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Pollutant Control SO2

• Raw Material Selection (Avoid Pyrites!)
• Fine CaO in Calciner Scrubs Kiln 100
• Move CaO by ?P to Upper Preheater
• Can Reduce Pyritic Emissions 20-30
• Capitol Cement and Ash Grove Chanute
• Need More Fuel, Balance Heat
• Capital Investment Looks Low
• Graphic Source F.L.Smidth/Fuller

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Pollutant Control SO2
Pfeiffer Raw Mill

• CaCO3 and Moisture on Raw Mill Surface
• Some of the CaO from D-SOX
• Maybe Together 70 Percent of Residual SO2
• When Raw Mill Out Control Gas Temperature
• Spray Fine Ca(OH)2 Mist into Conditioning Tower
• Not Enough - More Conventional Scrubbers
• Achieve as much as 90 Percent Removal

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Effect of Raw Materials Process on SO2
Florida Rock Photo By FDEP

• PH/Calciner Kilns in TX 1000s of TPY of SO2
• High Pyrites in Raw Materials
• Wet Kilns in Florida 1000s of TPY of SO2
• Fuel Sulfur, No Calciner - less Self Scrubbing
• PH/Calciner Kilns in Florida ltlt 100 TPY
• No Pyrites in Raw Materials
• Florida Rock Kiln, Rinker Modernization
• From 1000 TPY to 20 TPY

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What is BACT?

• lt 0.23 (or Better) in Florida With No Controls
• 0.05 at Siggenthal by (Incidental) Coke Filter
• 1.3 lb/ton at TXI Midlothian to Avoid PSD
• lt 1 lb/ton at Slite, Sweden (90 Reduction)
• European IPPC BAT (200 400 mg/m3)
• Equals 0.9 to 1.8 lb/ton
• D-SOx Lime Mist With Moderate Pyrites
• 90 Scrubber Control With Very High Pyrites

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Pollutant Formation - CO VOC

• CO From Incomplete Combustion
• Very Little VOC From Kiln and Calciner
• Evolution in Preheater
• Organic Carbon from Raw Materials
• Carbon from Coal Ash
• VOC from Mill Scale, etc.

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Pollutant Control - CO VOC

• Hot Excess Air, Mixing
• Tertiary Air After Calcining
• E.G. Pyrotop after SC
• Raw Material Selection e.g. Millscale
• 70 VOC Reduction at Florida Rock
• Must Install Continuous Monitor
• Grind and Introduce Directly into Kiln

Graphic Source KHD
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Regenerative Thermal Oxidation

• Texas Cement Midlothian
• About 10 Modules
• Area of a Football Field
• Enter Market at Earliest Date
• Avoid PSD Delays up to 3 Years
• 17,500,000 for RTO
• 13,000,000 for SO2 Scrubber

Graphic Sources Durr/Reeco
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Active Coke Filter

• Siggenthal Switzerland
• In Conjunction with Dried Sludge Burning
• 15,000,000 Partly Funded by Zurich
• Environmentally Friendly Dried Sludge Burning
• Concern Was Thallium and Mercury (on Cows?)
• Also Cleans up, SO2, dioxin/furan, and Ammonia
• With SNCR Constitutes POLVITEC by Polysius

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What is BACT?

• VOC 0.1 lb/ton in Florida (Hard to Meet!)
• VOC 0.026 lb/ton at TXI (By RTO - LAER?)
• CO 2 3.6 lb/ton in Florida
• CO 6 8 lb/ton in SC
• CO 0.37 lb/ton at TXI (By RTO - LAER?)

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European Rule 2000/76/EG

• Pollutant Concentration Process Limit
• Dust 30 mg/m3 0.14 lb/ton
• NOX 500 mg/m3 2.3 lb/ton
• 800 mg/m3 3.7 lb/ton
• SO2 50 mg/m3 0.23 lb/ton
• Mercury 0,05 mg/m3 0.00023 lb/ton
• Fluorides 1 mg/m3 0.0046
• TOC 10 mg/m3 0.046 lb/ton
• CO _
• New Sources
• Existing Sources (Swedish non-EU standard is
  200 mg/m3 0.9 lb/ton)
• Non Raw Material-Specific Emission

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European Rule 2000/76/EG

• Pollutant Concentration Process Limit
• Chlorides 10 mg/m3 0.046 lb/ton
• Cd and Thallium 0.05 mg/m3 0.00023 lb/ton
• SbAsPbCr
• CoCuMnNiV 0.5 mg/m3 0.0023 lb/ton
• Dioxin and Furan 0.1 ng ITEQ/m3

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Ozone Non-Attainment Area

• Initial Limit is 3.6 lb/ton during first two
  years by Staged Combustion 12-Month Average
• Limit is stepped down from 3.6 to 2.8 lb/ton
  between years 2 and 3
• Company proposes LAER after 38 months of
  operation. Department sets LAER (2007 ??)

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Final Thoughts

• 4000 TPY of NOX equates to
• 50 Gas-fired Combined Cycle Plants to 12,500 MW
• At 3 million Btu/ton of Clinker
• 3.6 lb NOX /ton limit equates to
• 1.2 lb NOX/million Btu heat input
• Order of magnitude gt than new coal power plant
• Two orders gt greater than gas-fired power plant
• Some low hanging fruit to pick here.

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Thank you, Any Questions?