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Technical and Economic Review of Cement and Lime Process

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Technical and Economic Review of Cement and Lime Process Environment Agency Information Centre TECHNICAL AND ECONOMIC REVIEW OF CEMENT AND LIME PROCESS Research undertaken for the Environment Agency Contract Ref: HMIP/CPR2/41/197 Title: Technical & Economic Study of Processes Within the Minerals Processing Sector National Information Centre The Environment Agency Rio House Waterside Drive Aztec West BRISTOL BS12 4UD Due for return The results of this work will be used in the formulation of Environment Agency policy but Views expressed in this report do not necessarily represent Environment Agency policy. TECHNICAL AND ECONOMIC REVIEW OF CEMENT AND LIME PROCESSES A Report to the Environment Agency August 1996 TECHNICAL AND ECONOMIC REVIEW OF CEMENT AND UME PROCESSES CONTENTS EXECUTIVE SUMMARY i 1. BAT ASSESSMENT FOR CEMENT AND LIME INDUSTRIES 1 1.1 Background............................................................................................................... 1 1.2 Report Scop© ........................................................................................................... 1 1.3 Report Objectives..................................................................................................... 1 1.4 Report Structure ....................................................................................................... 2 2. CEMENT PROCESSES .................................................................................................................... 3 2.1 The Sector.................................................................................................. .............. 3 2.1.1 Sector Description................ ....................................................................... 3 2.1.2 Process Description ...................................................................................... 3 2.2 Impacts on the Environment - Qualitative Discussion........................................... 13 2.3 Achievement of Current Standards ........................................................................ 14 2.3.1 Actual Releases............................................................................................. 15 2.4 Review of Available Techniques.............................................................................. 20 2.4.1 General Techniques .................................................................................... 20 2.4.2 Specific Techniques...................................................................................... 26 2.5 Economic Impacts o f Controlling Releases From Cement Processes..................... 35 2.5.1 Industry Structure............................................. .............................. ............ 35 2.5.2 Markets ......................................................................................................... 36 2.5.3 International Com petition............................................................................ 38 2.5.4 Financial Performance o f UK Cement C om panies..................................... 38 2.5.5 Competition from Substitutes ...................................................................... 40 2.5.6 Costs of Controlling Releases ...................................................................... 40 2.5.7 Industry Costs of C ontrol.............................................................................. 41 2.6 Summary of Economic Impacts of Controlling Releases......................................... 45 3. LIME PROCESSES........................................................................................................................ 47 3.1 The Sector................................................................................................................. 47 3.1.1 Sector Description........................................................................................ 47 3.1.2 Process Description ...................................................................................... 48 3.2 Impacts on the Environment .................................................................................. 53 3.3 Achievement of Current Standards ........................................................................ 53 3.3.1 Actual Releases............................................................................................ 54 3.4 Review of Available Techniques.............................................................................. 58 3.4.1 General Techniques .................................................................................... 59 3.4.2“ “Specific Techniques............................................. '. ................................... 61 TECHNICAL AND ECONOMIC REVIEW OF CEMENT AND UME PROCESSES 3.5 Economic Assessment of Lime Processes....................................................................................6 3.5.1 Market and Industry Structure......................................................................6 3.5.2 Ownership and Extent of Activities of Firms................................................. 6 3.5.3 Financial Performance of Firms In the Sector ............................................. ..6 3.5.4 Capital V intage............................................................................................ ..6 3.5.5 Intra Industry Com petition..............................................................................6 3.5.6 Competition from Substitutes ...................................................................... ..6 3.5.7 Cost of Techniques to Control Releases ..................................................... ..71 3.5.8 Economic Implications of Additional Pollution Control Costs .......................71 4. SUMMARY AND CONCLUSIONS................................................................................................. ... 7 4.1 Key Technical Issues ................................................................................................. ..7: 4.2 Key Commercial Issues............................................................................................ ..7- REFERENCES....................................................................................................................................... ...7 CONSULTEES ....................................................................................................................................... 7< TECHNICAL AND ECONOMIC REVIEW OF CEMENT AND UME PROCESSES Appendix A.l : Environmental Impacts of Cement and Lime Process................................. 83 Appendix A.2 : Assessment of Environmental Impacts of Cement and Ume Processes ... 87 Appendix A.3 : Summary of Near Reid Environmental Impacts for Cement and Lime Processes....................................................................................................... 93 Appendix A.4 : Summary of Far Field Environmental Impact for Cement and Lime Processes....................................................................................................... 95 Appendix A.5 : Summary of Global Environmental Impacts for Cement and Lime Processes....................................................................................................... 97 Appendix B.l : Summary of UK Cement Clinker Production ............................................. ..101 Appendix B.2 : Summary of Releases from Cement Processes......................................... 102 Appendix B.3: Options for Controlling Releases from Cement Processes - Raw Materials 103 Appendix B.4: Options for Controlling Releases from Cement Processes Fuels ............... 104 Appendix B.5: Summary of Applicability, Advantages, Disadvantages, and Net Benefit of Control Techniques for Each Pollutant ..................................................... ..106 Appendix B.6: Profiles o f Abatem ent Techniques for Cement Processes - Costs and Applicabilities ............................................................................................ ..122 Appendix C .l: Summary of Releases from Lime Processes............................................... ..137 Appendix C.2: Options for Controlling Releases from Lime Processes - Raw Materials . 138 Appendix C.3: Options for Controlling Releases from Lime Process - Fuel ....................... ..139 Appendix C.4: Summary o f Abatem ent Techniques for Lime Processes - Costs and Applicabilities ............................................................................................ ..141 Appendix C.5: Summary of Applicability, Advantages, Disadvantages, and Net Benefit of Control Techniques for each Pollutant ................................. ...................151 TECHNICAL AND ECONOMIC REVIEW OF CEMENT AND UME PROCESSES TECHNICAL AND ECONOMIC REVIEW OF CEMENT AND UME PROCESSES EXECUTIVE SUMMARY The aims of this study are to examine the technical options for controlling releases from cement and lime processes and their respective costs. The study also assesses the economic situation of the cem ent and lime industries and the ability o f these industries to bear the costs o f moving from typical release levels towards the achievable release level for a new process. The technical scope of the study is to to establish and assess: i) the pollutants emitted from the process; ii) the environmental impact of the pollutants released; iii) the abatem ent techniques available. The main pollutants from both cement and lime processes are releases to air of: particulates, NO*, S02 and COz. Other pollutants such as dioxins and heavy metals are also present but in small quantities. The emissions and environmental impacts were considered
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