1. AAPCA 2016 Spring Meeting
Panel: NOx Controls Updates
Columbia Marriott Columbia, South Carolina April 28-29, Timothy L. Matz
Corporate Director of Environmental Affairs
Lehigh Hanson, Inc.
2011 Environmental Conference

2. Lehigh Hanson Overview 2016

3. Company history Lehigh Cement Company Hanson, plc
Founded in 1897 by several prominent businessmen from Allentown, Pennsylvania.
In 1977, Lehigh was acquired by HeidelbergCement and is now a top supplier of cement and related materials in the U.S. and Canada
Hanson, plc
Hanson, mainly an aggregates company was acquired by the HeidelbergCement in August 2007.
Lehigh Cement and Hanson, PLC were integrated in 2008
Today, the Lehigh Cement Company and the Hanson business in North America are collectively known as Lehigh Hanson, Inc.
Lehigh Hanson Overview 2016

4. Our business lines Cementitious Gray cement White cement
Cement distribution terminals
Ground granulated blast furnace slag (GGBS)
Aggregates and asphalt
Crushed rock, sand & gravel
Hot-mix asphalt and construction operations
Recycling operations
Various other materials
Concrete
Ready mixed concrete
Concrete block, precast concrete pipe (Canada) and other products
Lehigh Hanson Overview 2016

5. Core Business: Cement Manufacturing

6. NOx Control Updates in the Cement Industry
Hierarchy of Controls:
Selective Catalytic Reduction (SCR)
Selective Non-catalytic Reduction (SNCR)
Low NOx Calciner (Minox system)
Low NOx Burner
Staged combustion (mid-kiln firing/tires)
Oxygen enrichment
Smart logic controls (kiln burning/process controls)

7. SNCR in the Cement Industry

8. SNCR Chemical Reaction
2 NH3 + NO2 + 1/2 O2  3/2 N2 + 3 H2O
CO(NH2)2 + 2 NO + 1/2O2  2 N2 + CO2 + 2 H2O
Key to success is Temperature

9. Additional SNCR Installation
Tank installation
Pump and Control skid installation
Piping tie ins to kiln
Commissioning System

10. SNCR Equipment Required – Reagent tank – Distribution system
– Control system
– CEMS for NOx & ammonia required to determine optimum ammonia injection rate to maximum NOx control & minimize ammonia slip
– If urea used, water treatment system & heat traced storage & piping required

11. SNCR SNCR Results in Reduction in NOx -Typically between 35% and 65%
Higher Control Efficiencies Generally Associated with Higher Molar Ratios
Ammonia Slip & Detached Plumes May Result from High Molar Ratios

12. SNCR Lessons Learned
1. SO2 emissions can impact detached plume formation when using SNCR
–One plant with high SO2 emissions produces a detached plume when operating SNCR
2. Long dry kilns and wet kilns with SNCR will require additional maintenance on the rotary coupling
–One plant replaces coupling at least one time per year
3. Know your ammonia emissions before establishing or accepting a ammonia limit with SNCR
–One facility has 24 hour average ammonia emissions from 20 to 150 ppm from their limestone
–Accepted a limit of 10 ppm over the 24 hour average ammonia emission at one facility.

13. SCR in the Cement Industry
Plants with SCR worldwide
Solnhofen, Germany, High-Dust, started 2001, shut down 2005
Cementeria di Monselice, Italy, High-Dust, operating since 2006
Cementeria di Sarche, Italy, Semi-Dust, operating since 2007
Schwenk Mergelstetten, Germany, High-Dust, operating since 2010
Rohtdorf Zement, Germany, Tail-End, operating since 2011
Mannersdorf, Austria, Semi-Dust, operating since 2012
Joppa, IL USA, Lafarge, Semi-Dust operating since 2013

15. EPA Air Pollution Control Cost Manual
Chapter 1 – Selective Noncatalytic Reduction (SNCR)
Chapter 2 – Selective Catalytic Reduction (SCR)
Portland Cement Association (PCA) submitted comments last September to EPA on their cost manual
Provided additional information on the application of SNCR and SCR as they relate to the cement sector.
Clarified differences and challenges experienced by cement industry when compared to utilities and large industrial boilers
Currently 2 cement plants have SCR: one in operation, one under construction.
Lafarge: Joppa, IL. Installed (long dry kiln w/hot ESP/no re-heat)
Holcim: Midlothian, TX under construction

16. SNCR reaction takes place between 850-1050°C (1550-1900)
SNCR vs. SCR Recap
Both utilize ammonia to reduce NOx but SCR has a catalysts with a life expectancy
Temperature
SNCR reaction takes place between °C ( )
SCR reaction takes place between °C ( )
Three types of SCR
High dust
Semi dust
Low dust (Tail-End)
Availability
SNCR -100%
SCR –90-96% (Europe)

17. PCA’s Comments on EPA’s cost manual: SNCR
Control Efficiencies are higher than earlier predictions
SNCR is in use on many kilns in US
PCA survey indicated 67% of those kilns responding (representing ~70% of US kilns) had or will have SNCR by 2017
SNCR capital costs are correct
SNCR has high availability
Conclusion:
SNCR provides reliable, continuous control of NOx that approaches the control efficiency achieved with SCR

18. PCA’s Comments on EPA’s cost manual: SCR
Cement kiln application of SCR is more complicated than that for boilers
Actual capital costs for SCR in cement are much higher times higher than shown by EPA (European data)($20-30M)
Costs reported by EPA were outdated estimates not actual costs.
US cement kilns more challenging than European kilns for SCR implementation due to:
Sulfur and other constituents of raw materials
Kiln type, size, age
Dust loading
Cost calculation methodology/examples are not appropriate for cement applications

19. US vs. European Kilns
Unlike Europe, raw materials are more variable across the US and in many areas contain sulfur/pyrites and other catalyst poisons
The presence of sulfur prohibits low temperature catalysts (ABS formation)
Availability of control is a concern
SCR has not been installed in long dry kilns

20. Kilns vs. Boilers Dust loading is substantially higher
Boilers g/Nm3
Preheater kilns g/Nm3
Precalciner kilns up to 180 g/Nm3
Dust cleaning is more aggressive
Boiler use sonic horns and soot blowers periodically to remove dust from catalyst
Cement kilns utilize heated, dry compressed air systems that operating nearly continuously
Additional or upgraded ID fans needed
Catalyst life remains unknown and therefore catalyst costs cannot be predicted

21. PCA’s Comments on EPA’s cost manual: SCR
Conclusions:
SCR has not been established as a feasible control technology in the US.
Actual capital costs for cement kiln SCRs are much higher than EPA’s examples
The variability of kiln types, ages, sizes and raw material constituents in the US makes SCR design and operation more challenging than boilers or kilns in Europe
EPA’s cost methodology is not appropriate for cement kilns
Higher than predicted SNCR control efficiencies and high availability make SNCR comparable to the lower end of SCR control efficiency

22. THANK YOU