1. US Cement Industry
Environmental Update
IEEE West Coast
John Kline
Kline Consulting
johnpkline1@gmail.com

2. The War on Cement
NESHAP / CISWI Recap
What Else is Coming ?
CO2

3. 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.

4. EPA - Key Results
EPA Web Site
Year
2008
Emissions
Reductions /
Treated
Tons / Year
1,700
Environmental Civil Penalties
Investments
2009
94
$320
$5.4
2010
370
$1,400
$14
Millions $
$4,900
Millions $
$18

5. Results of Actions
Consent Decrees
# Kilns
# SNCR
# DSI
#WGS
Other
Fines($000)
4
3
K4 Down
$800
2
2
23
17
13
1
1
1
$1,400
1
1
1
$1,425
7
5
7
1
1
11
6
2
Upgrade 2k
$2,500
1
1
1
Upgrade ?
$700
51
37
25
$2,000
4
SCR
2 SCR Demo
$5,075
$1,700
$1,000
4
$16,600

6. Cement Kiln Regulations
Cement Kilns
that burn
Hazardous
Waste
Hazardous
Waste
Combustors
(HWC)
128 Kilns
12
All Cement
Plants / Kilns
(NESHAP)
93
Cement Kilns that
burn NonHazardous Waste
23
Commercial and Industrial
Solid Waste Incinerators
(CISWI)

8. Technologies to be Applied
Pollutant
Compliance
Monitoring
Particulate
Matter
Mercury
Baghouses
PM CEMs
Dust Shuttling &
PAC
DSI & DSA
???
Hg CEMs & Traps
HCl
THC
???
CEM - FIDs
Field testing (OHAPs)

9. Approximate Cement Plant Emissions
Pounds of Mercury per Million Tons of Clinker Production
500
450
400
350
300
250
200
150
CSI Estimate of World Average
100
NESHAP Emission Limits
50
0
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

12. 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 ?

13. 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

14. Keys to a Successful Fuels Program
• Communications
• Ethics
• Maintaining trust
– Employees
– Community
– Regulators
• Good QA / QC
• Record Keeping (Plant is accountable)

15. What Else is Coming ?

16. What Else is Coming ?

17. What Else is Coming ?

18. California – CO2 Allocations

20. CO2 Capture Technologies

21. Kgs of Gas per Hour
Thousands
Relative Gas Quantities in the Cement Process
450
90 oC
400
350
300
950 oC
250
350
Ar
oC
O2
N2
200
SO2
150
H2O
100
CO2
1000 oC
50
Kiln Exit
Calciner Exit
Tower Exit
Raw Mill Exit

22. Costs of CO2 Avoidance (IEA 2013)
Pulp & Paper

23. 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)

24. 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)

25. 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

26. 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

27. 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

28. 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