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I .6 Lime and Cement Industry AP-42 Section Number: 1 I .6 Reference Number: 3 Title: Lime and Cement Industry - Source Category Report, Volume I1 EPA-60017-87-007 USEPA February 1987 - AP-V Section - Reference -~ I Report Sect. __ United States EPA-6OOI7-r Reference - (i' Environmental Protection i- Agency February 19f GEPA Research and Development LIME AND CEMENT INDUSTRY PARTICULATE EMISSIONS: SOURCE CATEGORYREPORT Volume 11. Cement Industry Prepared for .Office of Air Quality Planning and Standards Prepared by Air and Energy Engineering Research Labor at or y Research Triangle Park NC 2771 1 RESEARCH REPORTING SERIES Research reports of the Office of Research and Development, US. Environmental Protection Agency, have been grouped into nine series. These nine broad cate- gories were established to facilitate further development and application of en- vironmental technology. Elimination of traditional grouping was consciousiy planned to foster technology transfer and a maximum interface In relared iieids. The nine series are: 1. Environmental Health Effects Research 2. Environmental Protection Technology 3. Ecological Research 4. Environmental Monitoring 5. Socioeconomic Environmental Studies 6. Scientific and Technical Assessment Reports (STAR) 7. Interagency Energy-Environment Research and Development 8. "Special" Reports 9. Miscellaneous Reports This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT RESEARCH AND DEVELOPMENT series. Reports in this series result from the effort funded under the 17-agency Federal EnergyEnvironment Research and Development Prcigram. These studios rele!e to EPAs mission to protect the public health and welfare from adverse effects of pollutants associated with energy sys- tems. The goal of the Program is to assure the rapid development of domestic energy supplies in an environmentally-compatible manner by providing the nec- essary environmental data and control technology. Investigations include analy- ses of the transport of energy-related pollutants and their health and ecological effects; assessments of, and development of, control technologies for energy systems; and integrated assessments of a wide range of energy-related environ- mental issues. EPA REVIEW NOTICE This report has been reviewed by the participating Federal Agencies. and approved for publication. Approval does not signify that the contents necessarily reflect the views and policies of the Government. nor does mention of trade names or commercial products constitute endorsement or recommendation for use. This document is available to the public through the National Technical Informa- tion Service, Springfield, Virginia 22161. EPA- 600 17- 87-007 February 1987 LIME AND CEMENT INDUSTRY PARTICULATE EMISSIONS: SOURCE CATEGORY REPORT Volume 11. Cement Industry . John S. Kinsey Midwest Research Institute 425 Volker Boulevard Kansas City, Missouri 64110 Contract 68-02-3891 Work Assignment No. 9 EPA Project Officer: Dale L. Earmon Air and Energy Engineering Research Laboratory Research Triangle Park, North Carolina 27711 Prepared for U.S. Environmental Protection Agency Office of Research and Development Washington. DC 20460 ABSTRACT The objective of this study was to develop particulate emission factors based on cutoff size for inhalable particles for the cement industry. After a review of available information characterizing partic- ulate emissions from cement plants, the data were suuuuarized and rated in terms of reliability. Size specific emission factors were developed from these data for the major processes used in the manufacture of cement. A detailed process description was presented with emphasis on factors affecting the generation of emissions. A replacement for Sections 8.6 (Portland Cement Manufacturing) of EPA report AP-42, A Compilation.of Air Pollutant Emissions Factors. was prepared, containing the size specific emission factors developed during this program. ii I .. CONTENTS PacJ-e PacJ-e Abstract ................................ ii 1.0 Introduction ............: ........... 1-1 2.0 Industry Description ................... 2-1 2.1 Introduction and industry overview ....... 2-1 2.2 Raw material ................: .. 2-11 2.3 Process description ............... 2-11 2.4 Control technology ............... 2-24 3.0 General Data Review and Analysis Procedures........ 3-1 3.1 Literature search and screening......... 3-1 3.2 Emission data rpia1it.y ratinn system ....... 3-2 3.3 Particle size determination ........... 3-4 3.4 Particle size data analysis methodology ..... 3-12 -3.5 Emission factor quality rating system ...... 3-18 4.0 Particulate Emission Factor Development .......... 4-1 4.1 Review of specific data sets .......... 4-1 4.2 Results of data analysis ............ 4-37 4.3 Development of candidate emission factors.... 4-51 4.4 Emission factor quality rating .......... 4-65 5.0 Proposed AP-42 Section 8.6 ................ 5-1 Appendices A . Excerpts from reference documents used in the development of particulate emission factors............. A-1 B . Uncontrolled total particulate emission factor calcula- tions .......................... B-1 c . iota1 particulate emission factor calculations for controlled kilns .................... C-1 D . Total particulate emission factor calculations for controlled coolers, mills. and crushing/screening .... D-1 E . Computer printouts of spline analyses for partjcle size distributions...................... E- 1 iii FIGURES Number .... 2-1 Geographical distribution of portland cement plants in the United States .................... 2-4 2-2 Flow diagram for dry process ............ ... 2-14 2- 3 Flow diagram for wet process ............ ... 2-15 3-1 Example output of "JSKPRG" ............. ... 3-15 3-2 Example output of "JSKRAW" ............. ... 3-16 3-3 Example output of "JSKLOG" ............. ... 3-17 4-1 Size specific emission factors for cement kilns ... ... 4-63 4-2 Size specific emission factors for clinker coolers . ... 4-64 8.6-1 Basic flow diagram of portland cement manufacturing process ...................... ~ . 5-3 ~ 8.6-2 Size specific emission factors for.cement kilns ... ... 5-0 8.6-3 Size specific emission factors for clinker coolers . ... 5-9 iv I I TABLES Number & 2-1 1984 Portland Cement Shipments from Plants in the U.S. 2-2 2-2 1984 Cement Use by Customer Category . 2-3 2-3 Portland Cement Producers (USA). 2-5 2-4 1984 Clinker Production by Type of Fuel. 2-10 2-5 Raw Materials Used in Portland Cement (1984) . 2-12 2- 6 Typical Particle Size Distribution for Type I1 Portland Cement . 2-25 2-7 Potential Sources of Air Pollutants in Cement Plants . 2-26 2-8 Distribution of Kiln Dust Collection Systems in Wet and Dry Process Cement Plants. 2-28 3-1 Equations Used for Particle Size Conversions . 3-7 3-2 Guide to Particle Size Measurement . 3-10 3- 3 Comparison of Computer Programs. 3-13 4-1 Summarv of NSPS Data Collected bv EPA. 4-3 4-2 Summa6 of Particle Size Data f& Reference 20 - ESP Inlet. 4-8 4-3 Summary of Particle Size Data for Reference 21 - Uncontrolled Clinker Cooler (Brink Impactor - August Tests) . :4-10 4-4 Summary of Particle Size Data for Reference 21 - Uncontrolled Clinker Cooler (Andersen Impactor Data - August Tests). 4-11 4-5 Summary of Particle Size Data for Reference 21 - Uncontrolled Clinker Cooler (Andersen Impactor Data - November Tests). 4-12 4- 6 Summary of Particle Size Data for Reference 21 - Clinker Cooler Controlled by Gravel Bed Filter (August Test Series). 4-13 4-7 Summary of Particle Size Data for Reference 21 - Clinker Cooler Controlled by Gravel Bed Filter (November Test Series). 4-14 4-8 Summary of Particle Size Data for Reference 26 - Locations 3 and 9 (Brink Data) . .. 4-17 4- 9 Summary of Particle Size Data for Reference 26 - Location 9 (SASS Data) . 4-19 4- 10 Summary of Particle Size Data for Reference 27 - Dry Process Kiln Controlled by a Baghouse Collector. 4-21 4-11 Summary of Particle Size Data for Reference 42 - No. 5 Kiln Baghouse Inlet. 4-28 4-12 Summary of Particle Size Data for Reference 42 - No. 5 Kiln Baghouse Outlet . 4-29 V TABLES (Concluded) Number 4-13 Summary of Particle Size Data for Reference 46 - Kiln No. 2 Electrostatic Precipitator Inlet . 4-32 4-14 Summary of Particle Size Data for Reference 46 - Kiln No. 2 Electrostatic Precipitator Outlet. 4-33 4-15 Summary nf Uncontrolled Total Particulate Emission Factors for Cement Plants. 4-39 4-16 Summary of Controlled Total Particulate Emission Factors for Cement Plants. 4-40 4-17 Calculated Particle Size Distributions for Reference 20 - ESP Inlet.'. 4-42 4-18 Calculated Particle Size Distributions and Uncontrolled Emission Factors for Reference 21. 4-43 4-19 Calculated Particle Size Distributions and Controlled Emission Factors for Reference 21. 4-44 4-20 Calculated Particle Size Distributions and Emission Factors for Reference 26 . 4-45 4-21 Calculated Particle Size Distributions and Controlled Emission Factors for Reference 27. 4-46 4-22 Calculated Emission Factors for Reference 42 - No. 5 Kiln Baghouse Inlet. 4-47 4-23 Calculated Emission Factors for Reference 42 - No. 5 Kiln Baghouse Outlet . 4-46 4-24 Calculated Emission Factors for Reference 46 - Kiln No. 2 Electrostatic Precipitator Inlet . 4-49 4-25 Calculated Emission Factors for Reference 46 - Kiln No. 2 Electrostatic Precipitator Outlet. 4-50 4-26 Summary of Candidate Emission Factors for Total Particulate Matter . 4-53 4-27 Candidate Size-Specific Emission Factors for Uncontrolled Wet Process Cement Kilns . 4-56 4-28 Candidate Size-Specific Emission Factors for Uncontrolled Dry Process Cement Kilns . 4-57 4-29 Candidate Size-Specific Emission Factors for Wet Process Kilns Controlled by Electrostatic Precipitators. 4-58 4-30 Candidate Size-Specific Emission Factors for Dry Process Cement Kilns Controlled by Baghouse Collectors . 4-59 4-31 Candidate Size-Specific Emission Factors for Clinker Coolers Controlled by a Gravel Bed Filter. 4-60 4-32 Summary of Candidate Size-Specific Emission Factors for Cement Kilns . 4-61 4-33 Summary of Candidate Emission Factors for Clinker Coolers. 4-62 8.6-1 Uncontrolled Emission Factors for Cement Manufacturing . 5-5 8.6-2 Controlled Particulate Emission Factors for Cement Manufacturing. 5-6 8.6-3 Size Specific Particulate Emission Factors for cement Ki 1 ns .
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