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Klaus-Martin MeierEdward Le
Ted T ReeseCadence Environmental Energy
Maximizing the Benefits of Staged Combustion
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Europe has 2nd most plants in World
EUROPEAN CEMENT KILNS ARE WORLD LEADERS
Europe is 3rd largest producer of cement in World
World Leader in Alternative Fuel Use
World Leader in Meeting Strict Environmental Compliance
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Kilns currently running at lower utilization rates
Production
Opportunity lies in improving efficienciesand reducing operating costs
No current incentives for increasing production
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Alternative Fuels
Europe operating at 28% fuel substitution rate
Opportunity exists in optimizing current alternative fuel programs
High percentage of kilns invested
in alternative fuel programs
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Environmental Requirements
Regulations will continue to tighten
Optimized performance will help to meet new
requirements
1990 2000 2020 Future0
5000
10000
15000
20000
EU-27 Total NOx Emissions
Tons
NO
x
NOx emission requirements will become more stringent
Is it realistic to expect less environmental compliance?
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Lower Fuel Costs
What Does Everyone Want?
1.2.3.
Operation Efficiencies
Lower Emissions
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Lower Fuel Costs
What Does Everyone Want?
1.2.3.
Improved Operation
Lower EmissionsHOW DO YOU
GET ALL
THREE?
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Transition from Staged Fuel Combustion to…
Staged Combustion Benefits
Staged Air Combustion
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Reduce Baseline NOx
Improve SNCR Efficiencies
Increase Alternative Fuel Use
Staged Air Combustion Benefits
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Staged Air Combustion
Staged Air Combustion (SAC) puts mixing energy and combustion air in a critical kiln area
Addresses:• gas stratification• temperature imbalance
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Staged Air CombustionSAC reduces kiln gas stratification
Effectively utilizes the excess oxygen for CO reduction
SAC OFF
Kiln Gas Stratification
SAC ON
NO Kiln Gas Stratification
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Staged Air Combustion
BENEFITS
• CO reduction
• NOx reduction
• Higher AF rates
• Heat transfer
• Reduces excess air in burning zone
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Mixing Air Injection
Whole tires or Alt. fuels at the
feed shelf.
Preheater or Precalciner Kiln
Staged Air Combustion
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National Cement - Ragland, Alabama USA
Kiln information Clinker production = 108 tph
Heat consumption = 3.1 MMBtu/tkk
Type of fuels = Coal, TDF, Saw Dust, Glycerin
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Staged Air Combustion
Baseline With SAC
O2 3.0 % 3.0% 3.0%
PH CO 1200 ppm 410 ppm 1150 ppm
Stack NOx 475 ppm 314 ppm 314 ppm
%Alt. Fuel Substitution 21% 21% 26%
Process Modification
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Staged Air Combustion
Multiple Benefits
Operational Flexibility
EmissionReduction
CadenceMixing Air
Improved Alternative Fuel Usage
Heat Consumption Improvement
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2500
2000
1500
1000
500
0
PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln
Uncontrolled NOx(m
g/N
m3)
Normal Ranges
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2500
2000
1500
1000
500
0
PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln
Controlled NOx(m
g/N
m3)
BAT (Best Available Technology) for NOx Abatement
Normal Ranges
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2500
2000
1500
1000
500
0
PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln
(mg/
Nm
3)
BAT (Best Available Technology) for NOx Abatement
CURRENT – 500 mg/Nm3
Meeting Environmental Compliance
BAT does not guarantee meeting NOx requirements
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1000
800
600
400
200
0
PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln
NO
x (m
g/N
m3)
BAT (Best Available Technology) for NOx Abatement
Meeting Environmental Compliance
Current NOx requirement is 500 mg/Nm3
SNCR AGENT REQUIRED
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1000
800
600
400
200
0
PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln
NO
x (m
g/N
m3)
BAT (Best Available Technology) for NOx Abatement
MORE SNCR AGENT REQUIRED
Meeting Environmental Compliance
NOx regulations expected to further decrease permit levels
AMMONIA SLIP
HIGHER REAGENT COST
DETACHED PLUME CONCERNS
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Alternative Fuel• 5-8% Increase
Staged Combustion Benefits
Preheater Cement Kiln
Improve SNCR Efficiencies20-25% Molar Efficiency Improvement
Reduce Baseline NOx• 725 650 mg/Nm3 (10%) • 850 715 mg/Nm3 (16%)
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Reduce Baseline NOx• 950 600 mg/Nm3 (37%)
• 800 550 mg/Nm3 (31%)
Staged Combustion Benefits
Lime / White Cement Kiln
Improve SNCR Efficiencies
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Ash Grove Cement
Capitol Aggregates
Buzzi Unicem
California Portland Cement
Essroc Cement
Holcim Cement
Lafarge Cement
Lehigh Cement
St. Lawrence Cement
Over 21 line installations
Proven Technology
Over 37 years experience
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Aalborg CementDenmark
Akmenes CementasLithuania
JSC KrasnosBelarus
Kirchdorfer CementAustria
Lafarge CementEngland*
HolcimSpain*
HolcimBelgium*
Expanding…
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Klaus-Martin MeierEdward Le
Ted T ReeseCadence Environmental Energy
Maximizing the Benefits of Staged Combustion
Thank You!Come visit our team at Cadence Booth…