Cement plants, pollution control

Environmental Pollution Control. The cement iadustry has had an iatensive program of capital expenditure to iastaH dust collection equipment on kilns and coolers siace the 1970s (60). Modem equipment collects dust at 99.8% efficiency. Many smaller dust collectors are iastaHed ia aew plants (61). 

Cement plants in the United States are now carehiUy monitored for compliance with Environmental Protection Agency (EPA) standards for emissions of particulates, SO, NO, and hydrocarbons. AH plants incorporate particulate collection devices such as baghouses and electrostatic precipitators (see Air POLLUTION CONTROL methods). The particulates removed from stack emissions are called cement kiln dust (CKD). It has been shown that CKD is characterized by low concentrations of metals which leach from the CKD at levels far below regulatory limits (63,64). Environmental issues continue to be of concern as the use of waste fuel in cement kilns becomes more widespread. 

Cement plant with vertical shaft kiln technology (pending certification of proven technology on pollution control)... 

A portland cement plant ball mill emits particulate matter (PM) emissions that must be controlled to meet state air pollution regulations. Three PM control devices, each of which can control these emissions to the same level, are being evaluated (1) a high-energy wet scrubber (scrubber), (2) an electrostatic precipitator (ESP), and (3) a fabric filter (baghouse). Unlike the wet scrubber, the ESP and the baghouse each recover salable cement dust, and, accordingly, revenue can be attributed to those two options. Two scenarios are visualized, with after-tax hurdle rates of 6% and 18%, respectively. The economic specifications for the three devices are as follows ... 

Measurement. The need for cost-effective pollution prevention, efficiency improvements, and emissions meastmement has created a need for new types of integrated control and meastirement systems. One of the best methods to improve environmental performance initially is to maximize efficiency through optimization in their manufacturing and energy processes. Many cement kilns now use continuous NOx measurement at the kiln exit to feed back information to the process control to optimize combustion. Capital costs are usually small, especially if PEM/ optimization software systems can be included at the time of a control system u rade. The increased operator awareness of the plant is a benefit, and fuel savings, qualify control, and maintenance planning can quickly pay back initial costs. 

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