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Emissions Cement
Plants are
contributing to
2 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
Development of NOX Limits for Cement Plants in Germany
1500 mg/Nm³
800 mg/Nm³
existing plants
500 mg/Nm³
350 mg/Nm³
500 mg/m³ NH3=30mg/Nm³ 200 mg/Nm³
new plants NH3=30mg/Nm³
3
3 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
Capability of NOx-Abatement Technologies in Cement Plants
1500
Emission without Abatement
MSC+SNCR
SCR
MSC
mg NOx/m3
800
500
200
4 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
NOx Sources in the Clinker Burning Process
Sintering zone
Calciner firing
• High temperatures
• High oxygen levels at the flame
• Low oxygen levels
N2 + O2 → 2 NO
• Substoichiometric at the
ignition zone (N2 + 2 O2 → 2 NO2)
• Flameless oxidation Formation of thermal NOx
• Uniform temperature unavoidable
No thermal NOX
Fuel NOX only
Partly reduction of (kiln) NOX
5 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
Measures to influence the NOX emission – Theory of Low NOx Burner
CO
NOx
Sintering zone
6 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
Measures to influence the NOX emission – Theory of Low NOx Burner
clinker
quality
Thermal
NOx
7 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
NOx Development in the Calciner
Air Excess
Lack of Air
N2
8 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
MSC Multi-Stage-Combustion - A Primary Measure for NOx-Abatement
9 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
Latest References for MSC-Calciner Systems of TKIS
Natural Gas
RDF
Coal (40%)
Coal (28 %)
Coal (21%)/
Petcoke
10 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
SNCR - Selective Non Catalytic Reduction –
Secondary Measure for NOx-Abatement
2 NO + 2 NH3 + 0,5 O2 2 N2 + 3 H2O
2 NO + CH4N2O 2 N2 + 2 H2O + CO
Typical Calciner Temperature
Combustion,
NH3-Slip
NO formation
Ammonia
Urea
11 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
SNCR - Selective Non Catalytic Reduction –
Secondary Measure for NOx-Abatement
12 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
SNCR - Selective Non Catalytic Reduction –
Secondary Measure for NOx-Abatement
Risk of secondary
Emissions at higher
Reduction levels
Increase of CO likely
13 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
SCR - Selective Catalytic Reduction –
Secondary Measure for NOx-Abatement
NOX
Raw NOX
~300°C
Gas
NH4OH
SCR TiO2
Storage V2O5
reactor
WO3
14 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
SCR - Selective Catalytic Reduction – SCR Configurations
Secondary Measure for NOx-Abatement
Lowest investment costs High Dust (HD)
Suitable flue gas temperature
No interference with main process
Easiest option for retrofits
- Frequent cleaning of catalyst
15 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
SCR References / Projects of Elex CemCat
Rezatto (2014)
Mergelstetten
(2010)
Joppa (2013)
Monselice (2006)
16 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
SCR versus SNCR - Performance of NOx Abatement
100
90
SCR
NO-Abatement [%] 80
Monselice
70
60
50
40
SNCR
30
20
10
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5
NH3/NO
17 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
CemCat a Joint Venture of Elex and TKIS (Polysius)
Combustion/Fuels
Industrial References
SNCR
ESP
New products
Patents Patents
18 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
Conclusion - NOx in Cement Clinker Production
Formation and Measures to minimize Emissions
• Primary NOx Emission can be reduced significantly with modern MSC Calciners down to
500 – 800 mg/Nm³
• SCNR is effective for NOx abatements of 50-60%, further reduction only with secondary
emissions, mainly NH3
• SCR abatement is nearly unlimited, secondary Ammonia emissions are not only avoided,
but Ammonia is effectively used for the NO reduction
19 | June 22st, 2016 | Formation and Abatement of NOx-Emissions | Reinhard Beilmann tkIS
NOx in Cement Clinker Production
Formation and Measures to minimize Emissions
Any questions?