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ACL Ambujanagar
NOx Emission Reduction Possibilities
by
Primary Measures
Thermal Process Technology 1
2
NOx
Impact on Environment
Statutory Limits for Cement Plants
Formation in Cement Plants
Ways to reduce formation
Methods to control the emissions
3
NOx: Impact on Environment
4
NOx Measurement & Reporting
5
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
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
7
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
8
NOx Reduction Measures
9
Process Optimization: Primary air and Excess air
NOx Reduction - Primary Measures
10
Process Optimization: Fuel to Calciner
NOx Reduction – Primary Measures
Fuel with high volatile content*
Lump fuel(small portion at kiln inlet)
Low nitrogen fuel
11
Process Optimization: Typical Nitrogen content of the fuels
NOx Reduction – Primary Measures
12
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)
13
Flue gas re-circulation
NOx Reduction – Primary Measures
14
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
15
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
16
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
17
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
18
NOx Reduction – Secondary Measures
Selective Non-Catalytic Reaction (SNCR)
19
NOx Reduction – Secondary Measures
Selective Catalytic Reaction (SCR)
20
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
21
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
22
NOx variations in a month (October 6 – 31, 2011)
NOx emission at GAJ 1N
Ox, m
g/N
m3, dry
@ 1
0%
O2
23
NOx variations within the kilns (GAJ 1, GAJ2 and AM)
NOx emissions at Ambujanagar
Thank You
24
25
Typical exhaust gas amounts