n ox reduction kick-off meeting presentation
TRANSCRIPT
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ACL Ambujanagar
NOx Emission Reduction Possibilities
by
Primary Measures
Thermal Process Technology 1
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NOx
Impact on Environment
Statutory Limits for Cement Plants
Formation in Cement Plants
Ways to reduce formation
Methods to control the emissions
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NOx: Impact on Environment
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NOx Measurement & Reporting
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Country Limit[mg/Nm3]
Comments
EU 500 / 800 IED (2011) – daily average
Germany 500
200-500
TA Luft (2007) – daily average
17th BImSchV – daily average
Switzerland 800
500 / 450
LRV - daily average
Sectoral NOx Agreement - yearly avg.
USA --
~200 - 400
Limits based on „annual loads“
NESHAP for new/modified kilns –
30 d rolling average
India 1000 Proposed limit (spot measurements)
Thailand 805 Spot measurements
Mexico 940 / 1028-1718 New / existing installations
Brasil 800 / 650 / 495 Existing / new installations
NOx Regulatory Requirements
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Holcim Group Average
NOx: ACC – ACL Performance in 2010
Basis: PEP 2010
695
mg
/Nm
3, d
ry a
t 1
0%
O2
CPCB expectation in 2 years
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NOx Formation in Cement Kilns
RT
-76500
14 e 10 x 2 k N NO O N2
O NO O N 2RT
-6300
9 e 10 x 6.3 k The NOX formation in calciner depends on
- Nitrogen content in the fuel
- O2 level in the firing zone.
- Initial NO concentrations in the combustion gas
- Temperature in firing region
- Volatile content in the fuel
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NOx Reduction Measures
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Process Optimization: Primary air and Excess air
NOx Reduction - Primary Measures
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Process Optimization: Fuel to Calciner
NOx Reduction – Primary Measures
Fuel with high volatile content*
Lump fuel(small portion at kiln inlet)
Low nitrogen fuel
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Process Optimization: Typical Nitrogen content of the fuels
NOx Reduction – Primary Measures
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Process Optimization: Burning Zone temperature
NOx Reduction – Primary Measures
Improve process stability
(Kiln feed / fuel feed uniformity, expert optimizer)
Improve kiln feed burnability
(feed mix, fineness)
Avoid over-burning
(strict control of clinker free lime, target >0.8 %)
Optimize burner operation
(Axial / tangential Momentum, fuel fineness)
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Flue gas re-circulation
NOx Reduction – Primary Measures
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Low NOx Burner
Burner designed to reduce flame turbulence by delaying the mixing of
fuel and air and by establishing fuel rich zones for initial combustion
NOx Reduction - Primary Measures
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Low NOx Calciner (Staged combustion)
NOx Reduction – Primary Measures
High Temperature:
Meal split for controlled
hot spot
Reducing Conditions:
Air Split or Calciner
fuel below tertiary air
entry
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Month average NOx emissions for the plants having CEMS
NOx Reduction – Primary Measures
Low NOx
calciners
Mg
/Nm
3, d
ry a
t 1
0%
O2
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Limitations of PRIMARY Measures
Primary measures can be applied as long as there is no negative
process, quality or emission impact.
Process optimizations have priority over NOx optimization
Clinker Quality ( Burning under reduced conditions).
NOx Reduction – Primary Measures
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NOx Reduction – Secondary Measures
Selective Non-Catalytic Reaction (SNCR)
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NOx Reduction – Secondary Measures
Selective Catalytic Reaction (SCR)
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0
20
40
60
80
100
Kiln
ope
ratio
n
Burn
er o
ptimiz
atio
n
Fuel m
ix
LowNOx
PC
SNCR
SCR
% N
Ox r
eduction
Effectiveness of NOx reduction measures
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NOx variations in a day - Normal Operation (13.10.11 00:01 hrs to
14.10.11 00:00 hrs.)
NOx emission at AM 1
~ 200 mg/Nm3
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NOx variations in a month (October 6 – 31, 2011)
NOx emission at GAJ 1N
Ox, m
g/N
m3, dry
@ 1
0%
O2
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NOx variations within the kilns (GAJ 1, GAJ2 and AM)
NOx emissions at Ambujanagar
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Thank You
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Typical exhaust gas amounts