**ppmvd can be converted to mg/dscm through the following equation.**

**mg/dscm** = P × ppmvd × MW R × (273 + C) For standard conditions: MW = molecular weight PV = nRT for n = 1.0 V = RT/P R = 0.0821 (L ·atm)/(mol·K) P = 1.0 atm T = 20.0 C V = 24.04 L/mol

**Simplified expression for standard conditions: Theoretical Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill**  **NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM. NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.** 

**mg/dscm** = ppmvd × MW V (24.04 l/mol)

**Due to the fact that V can vary, a referenced conversion value will be used for calculation.** Referencing 40 CFR 60.45(f)(2)
**mg/dscm** = ppmvd × MW × 41,500.0 1,000,000.0

**Conversions and other data** THC as propane, MW = 44.0 g/mol Conversion = 453,592.4 mg/lb Conversion = 35.3 dscf/dscm



### 6/28/2012 1 of 4**Theoretical Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill**

**NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM. NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.** 

**Step 1: Determine the allowable mass emissions of THC based on 24 ppmvd @ 7% O2 standard.** Max Kiln gas flow rate = 54,000.0 dscf/ton feed Max hourly production = 151.5 ton clinker/hr Conversion = 1.6 ton of feed/ton of clinker Hourly max kiln gas flow rate = 13,090,909.1 dscf/hr Hourly max kiln gas flow rate = 370,742.3 dscm/hr THC Standard = 24.0 ppmvd @ 7% O2 Concentration = 43.82 mg/dscm Allowed mass emissions rate = 35.8 lb/hr

**Step 2: Determine the actual mass emissions of THC leaving the alkali by-pass.** Actual alkali by-pass flow rate = 37,074.2 dscm/hr Example assumes 10 % of max kiln gas. Normally determine by stack test. Determine THC concentration = 56.0 ppmvd Determined by stack test. Concentration = 102.26 mg/dscm Actual mass emissions rate = 8.4 lb/hr

**Step 3: Determine the actual mass emissions of THC upstream of the coal mill.** Actual coal mill flow rate = 55,611.3 dscm/hr Example assumed 15 % of max kiln gas. Normally determine by stack test. Determine THC concentration = 56.0 ppmvd Determined by stack test. Concentration = 102.26 mg/dscm Actual mass emissions rate = 12.5 lb/hr

**Step 4: Back Calculate allowable limit to be measured by CEMS using mass and flow data** Kiln stack flow rate = 278,056.7 dscm/hr Example assumes max kiln gas minus bypass and coal mill. Normally determine by CEMS. Allowable mass emission rate = 14.9 lb/hr Calculated as max allowable emission rate minus actual mass from by-pass and coal mill. Allowable concentration = 24.3 mg/dscm Allowable concentration as ppmvd = 13.3 ppmvd Allowable concentration as ppmvd at 7 % O2



### 6/28/2012 2 of 4**Theoretical Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill**

**NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM. NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.** 

**Step 5: Check data against total limit** Total concentration = **24.0** ppmvd assumes all values are based on 7% O2.

Calculates as: (Qab × Cab) + (Qcm × Ccm) + (Qks × Cks) (Qab + Qcm + Qks)

**Step 6: Simplify expression for quick calculation method of required CEMS value.**

(Qab × Cab) + (Qcm × Ccm) + (Qks × Cks) ≤ 24

(Qab + Qcm + Qks)

(Qab × Cab) + (Qcm × Ccm) + (Qks × Cks) ≤ (24 × (Qab + Qcm + Qks))

(Qks × Cks) ≤ (24 × (Qab + Qcm + Qks)) - (Qab × Cab) - (Qcm × Ccm)

Cks ≤ (24 × (Qab + Qcm + Qks)) - (Qab × Cab) - (Qcm × Ccm) Qks Cks ≤ **13.3** ppmvd Allowable concentration as ppmvd at 7 % O2



### 6/28/2012 3 of 4**kiln stack (ks) exhaust** 9,818,181.8 dscf/hr = Qks 278,056.7 dscm/hr = Qks 14.9 lb/hr = Calculated Mks 24.3 mg/dscm = Dks **13.3** ppmvd = Cks

**alkali by-pass (ab) exhaust** APCD CEMS **Theoretical Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM.**  **NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.**

**alkali by-pass (ab) exhaust** Qab = 1,309,090.9 dscf/hr Qab = 37,074.2 dscm/hr Cab = 56.0 ppmvd Dab = 102.3 mg/dscm Mab = 8.4 lb/hr **coal mill (cm) exhaust** 1,963,636.4 dscf/hr = Qcm 55,611.3 dscm/hr = Qcm 56.0 ppmvd = Ccm 102.3 mg/dscm = Dcm **kiln gasses** 12.5 lb/hr = Mcm



### 6/28/2012 4 of 4**ppmvd can be converted to mg/dscm through the following equation.**

**mg/dscm** = P × ppmvd × MW R × (273 + C) For standard conditions: MW = molecular weight PV = nRT for n = 1.0 V = RT/P R = 0.0821 (L ·atm)/(mol·K) P = 1.0 atm T = 20.0 C V = 24.04 L/mol

**Simplified expression for standard conditions: Actual Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill**  **NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM. NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.** 

**mg/dscm** = ppmvd × MW V (24.04 l/mol)

**Due to the fact that V can vary, a referenced conversion value will be used for calculation.** Referencing 40 CFR 60.45(f)(2)
**mg/dscm** = ppmvd × MW × 41,500.0 1,000,000.0

**Conversions and other data** THC as propane, MW = 44.0 g/mol Conversion = 453,592.4 mg/lb Conversion = 35.3 dscf/dscm



### 6/28/2012 1 of 4**Actual Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill**

**NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM. NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.** 

**Step 1: Determine the actual mass emissions of THC leaving the alkali by-pass.** Actual alkali by-pass flow rate = 38,232.8 dscm/hr Determine by stack test. Determine THC concentration = 56.0 ppmvd Determined by stack test. Concentration = 102.26 mg/dscm Actual mass emissions rate = 8.6 lb/hr

**Step 2: Determine the actual mass emissions of THC upstream of the coal mill.** Actual coal mill flow rate = 57,349.2 dscm/hr Determine by stack test. Determine THC concentration = 56.0 ppmvd Determined by stack test. Concentration = 102.26 mg/dscm Actual mass emissions rate = 12.9 lb/hr

**Step 3: Determine the actual total flow of kiln gas and calculate actual allowable mass emissions of THC based on 24 ppmvd @ 7% O2 standard.** Actual kiln stack flow rate (at CEMS) = 286,746.0 dscm/hr Determined by CEMs. Actual kiln stack flow rate (at CEMS) 286,746.0 dscm/hr Determined by CEMs. Total actual kiln gas flow rate = 382,328.0 dscm/hr Sum of alkali by-pass, coal mill, and kiln stack CEMS. THC Standard = 24.0 ppmvd @ 7% O2 Concentration = 43.82 mg/dscm Actual allowed mass emissions rate = 36.9 lb/hr

**Step 4: Back Calculate allowable limit to be measured by CEMS using mass and flow data** Actual kiln stack flow rate (at CEMS) = 286,746.0 dscm/hr Determined by CEMs. Allowable mass emission rate = 15.4 lb/hr Calculated as actual allowable emission rate minus actual mass from by-pass and coal mill. Allowable concentration = 24.3 mg/dscm Allowable concentration as ppmvd = 13.3 ppmvd Allowable concentration as ppmvd at 7 % O2



### 6/28/2012 2 of 4**Actual Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill**

**NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM. NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.** 

**Step 5: Check data against total limit** Total concentration = **24.0** ppmvd assumes all values are based on 7% O2.

Calculates as: (Qab × Cab) + (Qcm × Ccm) + (Qks × Cks) (Qab + Qcm + Qks)

**Step 6: Simplify expression for quick calculation method of required CEMS value.**

(Qab × Cab) + (Qcm × Ccm) + (Qks × Cks) ≤ 24

(Qab + Qcm + Qks)

(Qab × Cab) + (Qcm × Ccm) + (Qks × Cks) ≤ (24 × (Qab + Qcm + Qks))

(Qks × Cks) ≤ (24 × (Qab + Qcm + Qks)) - (Qab × Cab) - (Qcm × Ccm)

Cks ≤ (24 × (Qab + Qcm + Qks)) - (Qab × Cab) - (Qcm × Ccm) Qks Cks ≤ **13.3** ppmvd Allowable concentration as ppmvd at 7 % O2



### 6/28/2012 3 of 4**kiln stack (ks) exhaust** 10,125,000.0 dscf/hr = Qks 286,746.0 dscm/hr = Qks 15.4 lb/hr = Calculated Mks 24.3 mg/dscm = Dks **13.3** ppmvd = Cks

**alkali by-pass (ab) exhaust Actual Calculation Method for Kiln Gas Diversion to Alkali By-pass and Coal Mill**  **NOTE: THIS CALCULATION ONLY REQUIRED IF ALKALI BY-PASS OR COAL MILL EXCEED 24 PPM. NOTE: FOR THE PURPOSES OF THIS CALCULATION, APPLICABLE VALUES ARE ASSUMED TO BE AT OR CORRECTED TO 7 % O2.** 

CEMS APCD

**alkali by-pass (ab) exhaust** Qab = 1,350,000.0 dscf/hr Qab = 38,232.8 dscm/hr Cab = 56.0 ppmvd Dab = 102.3 mg/dscm Mab = 8.6 lb/hr **coal mill (cm) exhaust** 2,025,000.0 dscf/hr = Qcm 57,349.2 dscm/hr = Qcm 56.0 ppmvd = Ccm 102.3 mg/dscm = Dcm **kiln gasses** 12.9 lb/hr = Mcm



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