• 53rd Cement Industry Technical Conference Next Week in St. Louis
• Cement Mact Rule and Air Pollution Issues Covered in McIlvaine Global Knowledge Orchard
• Turbosonic Technologies Adds Installation to Previous FGD, SNCR  Contract
• EPA Will Reconsider Minor Issues in Cement MACT                                    
• FLSmidth to Upgrade Russian Cement Plant and Add 4000 Tonnes/day Capacity
• KHD to Supply Equipment for 3500 t/d Plant in Turkey
• Keeping Abreast of the Developments
• Cement Plants to Spend $2.6 billion/yr for Air Pollution Control Over the Next Three Years

53rd Cement Industry Technical Conference Next Week in St Louis

Next week is the big conference and exhibit on cement technology. In our Cement Insights #1 we listed a number of interesting papers which will be presented. Participants will also have a chance to see the best and brightest technology in the form of the newest and largest plants; both plants are located about 40 miles south of St Louis. You can tour the new Buzzi Unicem 7,000 tpd Selma plant, as well as Holcim’s 12,000 tpd Ste. Genevieve plant. Both plants came online in 2009 and feature the latest in large plant equipment from a vast array of different suppliers and are among the most energy efficient plants in the world today.

We have pictures and audio interviews with the exhibitors from last year which you can access at:

http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/

seq2.asp?ref=1796&pref=1874&dp=Exhibitor.

Some of the attendees in the McIlvaine networking system will be:

In the McIlvaine Global Orchard you will find lists of exhibitors at the various upcoming conferences. Here is the IEEE list and link to the registration materials:

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Cement MACT Rule and Air Pollution Issues Covered in McIlvaine Global Knowledge Orchard

McIlvaine has conducted webinars on the new Cement MACT and is publishing Cement Insights to help cement companies stay abreast of developments relative to pollution control. You can click on Free News and Interwebviews and then on any of the following titles under Cement in the applications query.

Data Search by Application

The following Titles Reflect the Requested Application Sequencing:

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Turbosonic Technologies Adds Installation to Previous FGD, SNCR Contract

Turbosonic Technologies has been awarded a U.S. $1.25 million contract for the installation of equipment already on order from TurboSonic. The equipment will abate sulfur dioxide (SO₂) and nitrogen oxide (NO_x) emissions from a US cement plant. Completion is scheduled for May 2012.

The agreement includes installation, startup and commissioning services for TurboSonic's Selective Non-Catalytic Reduction (SNCR) system for NO_x control and TurboSorb Spray Dry Absorption (SDA) technology for SO₂ control.

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EPA Will Reconsider Minor Issues in Cement MACT   

Both cement companies and environmental groups have filed petitions asking EPA to take another look at the regulations, which will limit the amount of toxic emissions that cement kilns are allowed to release into the air. In a notice signed by Administrator Lisa Jackson on May 11, 2011, the agency said it will look into some of the concerns that were raised after the package of two rules was finalized last September.

"Both the rules (NSPS and HAP) will remain in place while EPA reconsiders these minor issues, to ensure that public health protections resulting from these rules are not delayed," the agency said.

.

Specifically, EPA denied reconsideration on:

·         Relationship between Portand Cement NESHAP, Solid Waste Definition and the CISWI rule.

·         Standards during periods of startup and shutdown

·         Standards for Particulate Matter

·         Monovents (vents on top of control device instead of stack)

·         Emissions from crushers

EPA is granting reconsideration on

·         Standards for clinker storage piles

·         Affirmative defense to civil penalties for exceedances occurring during malfunctions

·         Continuously monitored parameters for alternative THC standard

·         HCl limit of zero during startup for sources that do not have a CEM

·         Allowing sources with caustic scrubbers to comply with HCL standard during performance tests

·         Alternative PM Limit

·         Monitoring for Mercury and PM during periods of startup and shutdown

http://www.eenews.net/assets/2011/05/12/document_gw_02.pdf

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FLSmidth to Upgrade Russian Cement Plant and Add 4000 Tonnes/day Capacity

FLSmidth has been awarded a contract worth approximately EUR 55m by the Russian company Novoroscement, to supply equipment and supervision for modernization of its Proletariy cement plant. The plant is located at Novorossijsk in southern Russia, near the Black Sea. The order entails an upgrade of the existing production line from a present capacity of 1,740 tonnes per day to a future capacity of 6,000 tonnes per day. The modernization of the production line will lead to a more environmentally friendly and energy efficient production process. 

The equipment to be supplied comprises an Atox 57.5 raw mill, a 5-stage preheater, modification of the existing kiln shell, new filters, FLSmidth's latest design Cross-bar cooler, clinker storage and a complete new control system.  

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KHD to Supply Equipment for 3500 Tonnes/day Plant in Turkey

Askale Cimento placed an order with KHD for engineering and equipment supply for its new 3,500 t/d clinker production line at VAN cement plant, located near the town Van, East Anatolian region of Turkey.

Under a contract with Terbay-Aybars Is Ortakligi as general contractor, KHD received the order for engineering, equipment supply and supervision of erection and commissioning including on-shore training.

The new kiln line with similar design as kiln line II at Askale´s Erzurum cement plant, awarded to KHD in 2006 and in operation since the end of 2007, will be erected near the existing line # I in Van with a capacity of 850 t/d clinker.

Core components with KHD design are:

• 5-stage Humboldt preheater with PYROCLON® R calciner equipped with
  PYROTOP® compact mixing chamber and tertiary air duct with dust settling chamber,
• PYROBOX calciner firing system for coal dust,
• PYRORAPID® two-tire rotary kiln with diameter 4.6 m x 54.0 m long.
• PYRO-JET® kiln burner for coal and fuel oil,
• PYROFLOOR® clinker cooler equipped with a hammer-type clinker crusher and controlled by PFC Control System.

The new cooler will be the third PYROFLOOR® system installed at cement plants of Askale Cimento in Turkey.

Commissioning of the plant is scheduled for summer 2012.

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Keeping Abreast of the Developments

Cement companies and suppliers should take advantage of the free Cement Insights and Global Knowledge Orchard website. Suppliers can also track the individual projects and the markets in any one of the following reports:

Scrubber/Adsorber/Biofilter World Markets 

http://www.mcilvainecompany.com//brochures/air.html#n008        

NO_x Control World Markets

http://www.mcilvainecompany.com/brochures/air.html#n035

World Fabric Filter and Element Market

http://www.mcilvainecompany.com/brochures/air.html#n021

Air Pollution Monitoring & Sampling World Markets http://www.mcilvainecompany.com/brochures/air.html#no31

Thermal/Catalytic World Air Pollution Markets   http://www.mcilvainecompany.com/brochures/air.html#n007

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Cement Plants to Spend $2.6 Billion/yr for Air Pollution Control over the Next Three Years

The new cement hazardous air pollution rules will boost the market for air pollution control in the U.S.  But the infrastructure growth in the developing world will have a great impact on the market. This is the conclusion reached by the McIlvaine Company www.mcilvainecompany.com  by aggregating the projections in five of its online market reports.

Average Annual Expenditures 2011-2014 ($ Millions)

The U.S. market will be smaller than the Chinese market in the period despite the boost from the new U.S. rules.

The U.S. will lead in purchases of scrubbers and thermal oxidizers but fabric filters will be the largest equipment category.

The cement plants around the world are increasingly utilizing fabric filters for cleaning the gas from the kilns. Formerly, electrostatic precipitators were used for this application. For many years fabric filters have been used for coal grinding and material transfer points.  FLSmidth, KHD and other large cement plant suppliers are frequently furnishing fabric filters as an integral part of new plants they are building whether it is a developed or a developing country.

SO₂ is of increasing concern in the U.S. and Europe.  Wet limestone scrubbers will be a popular choice in the U.S.  They will also remove the HCl to the levels required in the new cement MACT rule.  Relative to NO_x control, selective non-catalytic reduction will be the most popular choice. However, the equipment cost is low. The big cost is in the urea or ammonia injection.

There will be a significant market for activated carbon in the U.S.  EPA expects most U.S. plants to install activated carbon injection systems to remove mercury. This could result in boosting total activated carbon sales in the U.S. by 5 to 10 percent. 

Kerogen (organic chemical compounds) in the limestone calcined to make cement are vaporized and form toxic organic air pollutants. EPA expects many plants to install thermal oxidizers to destroy these emissions.  However, it is also likely that some plants will be able to make sufficient reductions using activated carbon injection. Nevertheless the U.S. market for thermal oxidizers for this application will average $100 million/yr.

For more information on:

Scrubber/Adsorber/Biofilter World Markets 

http://www.mcilvainecompany.com//brochures/air.html#n008        

NO_x Control World Markets

http://www.mcilvainecompany.com/brochures/air.html#n035

World Fabric Filter and Element Market

http://www.mcilvainecompany.com/brochures/air.html#n021

Air Pollution Monitoring & Sampling World Markets http://www.mcilvainecompany.com/brochures/air.html#no31

Thermal/Catalytic World Air Pollution Markets   http://www.mcilvainecompany.com/brochures/air.html#n007

Bob McIlvaine

President

847 784 0012 ext 112

rmcilvaine@mcilvainecompany.com