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Show 800 NO. limit = 422 pph 600 .saa::.. 400 d' z 200 O~-"""'- 1 3 5 7 9 11 13 1 5 17 19 21 23 25 27 29 Days (June, 1993) Figure 8 - Average daily NOx emissions 100 tonlhr normal output. The capital cost includes equipment, engineering, installation (estimate), license fee, service contract, start-up, optimization and training. CONCLUSIONS A short-term testing of the NOxOUT Process on a cement kilnlcalciner has demonstrated that the process is highly effective and efficient. At NSR of 1.5, NOx reduction was as high as 80% and chemical utilizations were typically higher than 50%. High degree of mixing and a long residence time at appropriate temperature contributed to the excellent process performance. The current limit of 422 pounds per hour was maintained under various kilnlcalciner operating conditions with less than 40 gph of NOxOUT-A or NSR of less than 0.5. As for byproducts, S02 and CO were unchanged from baseline levels at NSR less than 0.7. At higher flowrates, these emissions also remained near baseline levels when preheater oxygen concentration was greater than 2.3%. However, both S02 and CO increased slightly with increasing chemical injection rate at lower oxygen. Ammonia measurement at the exit of the preheater was erratic but ranged about 6 ppm under baseline condition and 10 ppm during chemical injection at NSR of l. The NOxOUT Process was easily installed, tested, and removed, using existing ports and available resources without a plant outage. The plant operation was unaffected during the NOxOUT testing. A commercial system should also be easily adapted to plant operations and easily maintained. An economic analysis using June, 1993 as an example showed that the average operating cost would be $0.18 per ton of clinker to meet the current limit of 0.6r-----____________ -. 0.5 r- Qj 0.4- .:£ ~ (3 '0 0.3 c: o ~ 0.2 0.1 r 0 1 Average for the month = $0.18/ton of clinker ,..-- --- --------- --- - - .- U J 1 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 Days (June, 1993) Figure 9 - Reagent cost in $Iton of clinker 422 pph. With the capital cost of $0.08 per ton, the NOxOUT Process is a cost-effective and flexible system to meet the current NOx requirement as well as any future lower limits. REFERENCES 1. Hofmann, J .E., Johnson, R.A., Schumacher, P.D., Sload, A., Monso, R., "Post-Combustion NOx Control for Coal-Fired Utility Boilers," EPRIlEPA Joint Symposium on Stationary Combustion NOx Control, Miami Beach, FL, May, 1993. 2. Shore, D.E., Buening, H.J ., Prodan, D.A., Teetz, R.D. , Muzio, L.J. , Quartucy, G.C., Sun, W.H., Carmignani, P.G., Stallings, J.W., O'Sullivan, R.C., "Urea SNCR Demonstration at Long Island Lighting Company's Port Jefferson Unit 3," EPRIJEPA Joint Symposium on Stationary Combustion NOx Control, Miami Beach, FL, May, 1993. 3. Hofmann, J.E., Albanese, VM., and Stamatakis, P., "NOx Control for Waste Combustors," Air & Waste Management Association Annual Meeting, Denver, CO, June, 1993. 4. U.S. Patent 3,900,544, Lyon, R.K., August, 1975. 5. U.S. Patent 4,208,386, Arand, J.K., Muzio, L.J., and Sotter, J.G., June, 1980. 6. Sun, W.H., Stamatakis, P., Hofmann, J.E., "Reaction Kinetics of Selective Non-Catalytic NOx Reduction with Urea," 205th American Chemical Society Meeting, Division of Fuel Chemistry, Denver, CO, March, 1993. 7. Steuch, H.E. , Johansen, V, "S02 Emissions from Cement Kilns," Proceedings of Rock Products International Seminar, December, 1990. |