US Cement Industry Environmental Update

IEEE West Coast John Kline

Kline Consulting johnpkline1@gmail.com

The War on Cement NESHAP / CISWI Recap What Else is Coming ?

CO2

EPA - Cement Manufacturing Enforcement Initiative (War)

• Beginning in 2008, EPA has pursued a coordinated, integrated compliance and enforcement strategy to address Clean Air Act New Source Review compliance issues at the nation's cement manufacturing facilities.

• 2008-2010 New Source Review/Prevention of Significant Deterioration (NSR/PSD)

• 2011-2013 Reducing Air Pollution from the Largest Sources

• The cement sector is the third largest industrial source of pollution emitting more than 500,000 tons per year of sulfur dioxide, nitrogen oxide, and carbon monoxide.

EPA - Key Results EPA Web Site

Year

Emissions Reductions /

Treated

Environmental Investments

Civil Penalties

Tons / Year Millions $ Millions $

2008 1,700 $4,900 $18

2009 94 $320 $5.4

2010 370 $1,400 $14

Results of Actions Consent Decrees

# Kilns # SNCR # DSI #WGS Other Fines($000)

4 3 K4 Down $800

2 2 $2,000

23 17 13 4 SCR $5,075

1 1 1 $1,400

1 1 1 $1,425

7 5 7 2 SCR Demo $1,700

1 1 $1,000

11 6 2 Upgrade 2k $2,500

1 1 1 Upgrade ? $700

51 37 25 4 $16,600

Cement Kiln Regulations

All Cement Plants / Kilns

(NESHAP)

Commercial and Industrial Solid Waste Incinerators

(CISWI)

Hazardous Waste

Combustors (HWC)

Cement Kilns that burn

Hazardous Waste

Cement Kilns that burn Non-

Hazardous Waste

23 12

93

128 Kilns

Technologies to be Applied

Pollutant

Compliance Monitoring

Particulate Matter

Baghouses PM CEMs

Mercury Dust Shuttling & PAC

Hg CEMs & Traps

HCl DSI & DSA ???

THC ??? CEM - FIDs Field testing (OHAPs)

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500

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89

Po

un

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of

Me

rcu

ry p

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Mill

ion

To

ns

of

Clin

ker

Pro

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nApproximate Cement Plant Emissions

NESHAP Emission Limits

CSI Estimate of World Average

NESHAP - In or Out ?

Can I meet NESHAP requirements by 2013 ?, or

Can I meet NESHAP requirements by 2014 ?

Do I have one or more regular streams of alternative fuels ?

Are the regular streams of alternative fuels covered by EPA & State comfort letters ?

Do I have a robust QA / QC and record keeping system ?

I am planning a future plant modification ?

Alternative Fuel Workshop

• You are not communicating enough

• The public has access to just about everything

• Frame your numbers in terms the public can understand

• Stay away from materials that sound scary

• Remove “waste” and “alternative” from your vocabulary

• Focus on the positives

• Be very careful with plant modifications

Keys to a Successful Fuels Program

• Communications

• Ethics

• Maintaining trust

– Employees

– Community

– Regulators

• Good QA / QC

• Record Keeping (Plant is accountable)

What Else is Coming ?

What Else is Coming ?

What Else is Coming ?

California – CO2 Allocations

CO2 Capture Technologies

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Kiln Exit Calciner Exit Tower Exit Raw Mill Exit

Kgs

of

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ou

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Tho

usa

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Relative Gas Quantities in the Cement Process

Ar

O2

N2

SO2

H2O

CO2 1000 oC

950 oC 350 oC

90 oC

Costs of CO2 Avoidance (IEA 2013)

Pulp & Paper

Cement Specific Projects

• Norcem (Heidelberg) pilot projects at their Brevik, Norway cement works. – Three post-combustion pilots:

• Aker Clean Carbon’s amine scrubbing,

• Alstom’s chilled ammonia process, and

• Alstom’s regenerative carbonate cycle

– It is expected that this project will commence later this year.

• Taiwan Cement Project – Carbonate looping (quoted at $26/t-CO2 capture)

Cement Specific Projects

• Skyonics – mineralization – Converting CO2 to Sodium Bicarbonate (baking

soda)

– Capital Aggregates, San Antonio, TX

– Ground Breaking 2013

• Mantra – Electrolysis – Converting CO2 to formic acid

– Lafarge, Richmond, BC

– Lab Scale (electrolysis)

Cement Specific Projects

• Bio-fuels and foods (algae) – Votorantim – St. Mary’s Plant, Canada – Cementos Avellaneda - Argentina – Lafarge – Val d’Azergues, France – ItalCementi – Gargenville Plant, France – Holcim – Alicante Plant, Spain – Argos – Columbia – Cimpor & Valderrivas also reported having projects

• Hydrocarbon Products (microbes) – Heidelberg – Cupertino Plant, US

• ECRA – Oxy-Combustion – Phase IV – detailed engineering studies

CO2 Project Summary

• Most work completed in algae studies

– Negative energy (carbon) balances

– Large surface areas (ponds) required for natural light

– Bio-reactors less surface area, but more energy

• Specialty chemical products

– Interesting, but markets can become saturated quickly

CO2 Projects Summary

• There needs to be additional economic incentive to drive CCS further – Carbon Taxes

– Carbon emissions limitations / mandates

• Many companies are experimenting today – Lafarge, Heidelberg, Capital Aggregates, etc.

• Beneficial use projects that sequester CO2 provide an additional incentive for CCS projects

Overall Summary & Conclusions

• Expect EPA to knock on your door, if they haven’t already

• Fairly quiet on the Washington Front, but make sure you know which permit category you are in

• If not going for CISWI, get a letter of comfort

• CO2 reductions still in early stages, no solutions in sight

• Develop your portfolio of positive facts concerning your plant and industry