Presentation Transcript
Slide1 : LONE STAR’S UNIQUE APPROACH TO ENVIRONMENTAL CHALLENGES
LONE STAR’S GREENCASTLE PLANT : LONE STAR’S GREENCASTLE PLANT Semi-Dry Kiln Conversion
Project
750,000 STPY
TO
1,400,000 STPY
KILN FEED ANALYSIS GREENCASTLE, INDIANA PLANT : KILN FEED ANALYSIS GREENCASTLE, INDIANA PLANT
Large Potential for High SO2, THC and CO Emissions
CONFIRMED BY LABORATORY OFF-GAS ANALYSIS OF KILN FEED : CONFIRMED BY LABORATORY OFF-GAS ANALYSIS OF KILN FEED
TRADITIONAL WET-TO-DRY CONVERSION OPTION : TRADITIONAL WET-TO-DRY CONVERSION OPTION For a Fully - Dry Conversion Expect:
4.1 lb/ST CO
10.0 lb/ST SO2
GASEOUS EMISSIONS PROJECTIONS : GASEOUS EMISSIONS PROJECTIONS
*NOTE:
Gaseous emission estimates for dry and semi-dry lines based on 0.55% organic carbon in raw mix
* *NOTE:
Gaseous emission estimates for dry and semi-dry lines based on 0.24% pyritic sulfur in raw mix
PLANT EXPANSION OPTIONS: : PLANT EXPANSION OPTIONS: TRADITIONAL WET-TO-DRY CONVERSION
ENVIRONMENTALLY-FRIENDLY SEMI-DRY CONVERSION 5-STAGE PREHEATER
MODERN LOW NOx CALCINER
COMPLETELY NEW “DRY” RAW MEAL PREPARATION SYSTEM WITH BLENDING SILO
REQUIRES WET SCRUBBER AND R-T-O FOR SO2/CO/THC EMISSIONS DUE TO “SLOW” PREHEAT IN TRADITONAL CYCLONE PREHEATER BEFORE CALCINER ENTRY 1-STAGE PREHEATER
MODERN LOW NOx CALCINER
RE-USE EXISTING ESP AND SLURRY BASINS
FLASH DRY SLURRY IN A DRYER-CRUSHER
FEED DRIED SLURRY DIRECTLY TO CALCINER WITHOUT PREHEAT
WHAT IS A SEMI-DRY PROCESS? : WHAT IS A SEMI-DRY PROCESS?
ALTERNATIVE SEMI-DRY SYSTEM USING: LOW NOX CALCINER, DRYER-CRUSHER, AND ADDITIONAL DE-DUSTING CYLCONES : ALTERNATIVE SEMI-DRY SYSTEM USING: LOW NOX CALCINER, DRYER-CRUSHER, AND ADDITIONAL DE-DUSTING CYLCONES For a Semi-Dry Conversion Expect:
Much Lower
NOx, SO2, PM, THC, DIOXIN, HCL
REASONS FOR LOWER EMISSIONS : REASONS FOR LOWER EMISSIONS FLASH DRY AT TEMPERATURES BELOW VOLATILIZATION (190°C)
FLASH CALCINE AND BURN COMBUSTIBLES IN LOW NOX CALCINER WITH LONG RETENTION TIME (900°C)
FLASH VOLATILIZE PYRITE IN CALCINER WITHOUT PREHEAT AND SCRUB THE VOLATILIZED SO2 WITH FREE LIME.
ADDITIONAL PM REDUCTION WITH DE-DUSTING CYCLONES SEMI-DRY SYSTEM
GREENCASTLE PROJECTPrevious Wet Process : GREENCASTLE PROJECT Previous Wet Process Long Wet Kiln 17’ x 580’
6-Piers
35:1 Length-to-Diameter Ratio
1000 Hp Dual Drive with Max Speed 1.2 rpm
GREENCASTLE PROJECTNew Semi-Dry ProcessRe-Use Existing Precipitator and Slurry Basins : GREENCASTLE PROJECT New Semi-Dry Process Re-Use Existing Precipitator and Slurry Basins Semi-Dry Kiln 17’ x 255’
3-Piers
16:1 Length-to-Diameter Ratio
900 Hp Single Drive with Max Speed 3.8 rpm
COMPARISON OF ACTUAL NOX EMISSIONS BETWEEN PREVIOUS WET PROCESS andNEW SEMI-DRY PROCESS : COMPARISON OF ACTUAL NOX EMISSIONS BETWEEN PREVIOUS WET PROCESS and NEW SEMI-DRY PROCESS 2.35 lb/st 2.08 lb/st 9.25 lb/st
COMPARISON OF ACTUAL CO EMISSIONS BETWEEN PREVIOUS WET PROCESS andNEW SEMI-DRY PROCESS : COMPARISON OF ACTUAL CO EMISSIONS BETWEEN PREVIOUS WET PROCESS and NEW SEMI-DRY PROCESS 0.35 lb/st 5.98 lb/st
COMPARISON OF ACTUAL SOX EMISSIONS BETWEEN PREVIOUS WET PROCESS andNEW SEMI-DRY PROCESS : COMPARISON OF ACTUAL SOX EMISSIONS BETWEEN PREVIOUS WET PROCESS and NEW SEMI-DRY PROCESS 0.01 lb/st 0.24 lb/st 7.64 lb/st
COMPARISON OF ACTUAL THC EMISSIONS BETWEEN PREVIOUS WET PROCESS andNEW SEMI-DRY PROCESS : COMPARISON OF ACTUAL THC EMISSIONS BETWEEN PREVIOUS WET PROCESS and NEW SEMI-DRY PROCESS 5 ppm 10 ppm
COMPARISON OF ACTUAL DIOXIN EMISSIONS BETWEEN PREVIOUS WET PROCESS andNEW SEMI-DRY PROCESS : COMPARISON OF ACTUAL DIOXIN EMISSIONS BETWEEN PREVIOUS WET PROCESS and NEW SEMI-DRY PROCESS 0.05 g/dscm 0.0015 g/dscm
COMPARISON OF HCl EMISSIONS : COMPARISON OF HCl EMISSIONS Dramatic Improvement in HCl Emissions Due To Scrubbing Effect of Dryer-Crusher at Low Temperatures Compared to Wet Kiln Process Mass % of HCl Emitted from Stack as a Function of Total HCl Input 0.4252% 3.3494%
COMPARISON OF PM EMISSIONS : COMPARISON OF PM EMISSIONS Dramatic Improvement in PM Emissions Due To De-Dusting Cyclones prior to ESP Compared to Wet Kiln Process 35.1 lb/hr 20.7 lb/hr
LONE STAR’S UNIQUE APPROACH TOENVIRONMENTAL CHALLENGES : PROVES TO BE THE RIGHT ONE LONE STAR’S UNIQUE APPROACH TO ENVIRONMENTAL CHALLENGES
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