From: "Linero, Alvaro" <Alvaro.Linero@dep.state.fl.us>
08/23/2006 11:09 AM

To: Bill Neuffer/RTP/USEPA/US@EPA
Subject: SCR Solnhofen/Monselice/Brescia Update

Hello again Bill:

Here is what EPA's German counterpart (Umweltbundesamt) said about my informal trip report. As you know, he accompanied me. He thinks my little report is worth sending to his colleague who is
coordinating the European effort on their cement industry BAT update.

Included are the files he sent me with the message below about Slite and Skovde in Sweden. The

installation are now a number of years old.

But note how Skovde reduced NOx from 2.2 kg/tonne (4.4 lb/ton) in the early years to values on the

order of 0.7 lb/ton clinker today. Note the cost

‐ effectiveness values they cite. Note also the cost ‐ effectiveness values from the German submittal that I personally received from UBA experts and have

also attached.

Sebastian Plickert's e

‐ mail is: sebastian.plickert@uba.de

Thanks.

Al Linero.

_______________________________________ Dear Alvaro,

Thank you very much for the nice Photos and your very instructive report. The only thing I could add

would be some details of the German NOx regulations for cement plants, but I am not sure if that is

relevant for the purpose of your paper:

According to the German waste incineration ordinance, cement plants where more than 60% of the

rated thermal capacity originates from MSW or MSW

‐ like waste fractions (or more than 40% in case of

hazardous wastes) have a sliding scale of applicable emission limits between 320 and 200 mg/m3

, depending on the fraction of waste they burn. Please note that those plants that already use between

60% and 100% waste as fuel make use of a transition rule that allows them to emit up to 500 mg/m3

until the end of October 2007.

We are all curious about news from Monselice. I hope there will be something available in autumn, so
that we can incorporate it in the BREF review. Fortunately (for that occasion) the next meeting of the

Technical Workung Group in Seville was postponed to January 2007. If you don't mind, I would like to

forward your report to the BREF author in Seville, Ms Schorcht, who is working there as a 'detached

national expert' from Germany. Although the formal deadline for submissions to the BREF review is

over, any indication for new BAT data may be helpful and may give her reason to ask for details.

Please find attached the Swedish contributions to the BREF review (the text is also available as a 2.5 MB

Word file, so please tell me if you would prefer that).By the way, my colleague Ms Bernicke is back to office after her maternity leave, and she takes over the

competence for the cement and lime industries again. But, of course, we will co

‐ operate very closely,

and I will stay on the ball as 'second line' expert.

Sincerely yours,

Sebastian

Von: aalinero@comcast.net [mailto:aalinero@comcast.net]

Gesendet: Dienstag, 8. August 2006 03:16

An: Plickert, Sebastian; LFU

‐ Ebertsch@exchange

‐ root.bayern.de

Betreff: SCR Solnhofen/Monselice/Brescia Update

Dear Mr. Plickert and Mr. Ebertsch:

Attached is an informal trip report that I prepared about our visit to Solnhofen and my subsequent visits to Monselice and Brescia.

I hope you can let me know of any factual errors if you find any.

Mr. Plickert: Do you have the Swedish document in WORD or pdf? I can ask Per junker for it

if you don't have.

Sincerely,

Alvaro A. Linero01 st June 2006

Annex VI: Selective Catalytic Reduction (SCR)

Description

Selective catalytic reduction (SCR) reduces NO and NO 2 to N 2 with the help of NH 3 and a catalyst at a temperature range of about 300-400 °C. This technology is widely used for NO

x abatement in other industries (coal fired power stations, waste incinerators).

In the cement industry, basically two arrangements of the SCR reactor have to be considered: low dust configuration (between dedusting unit and stack) and high dust configuration (between preheater and dedusting unit). Low dust exhaust gas systems require re-heating of the exhaust gases after dedusting, which may cause additional energy costs and pressure losses. High dust systems do not require re-heating, because the waste gas temperature at the outlet of the preheater system is usually in the right temperature range for SCR operation. But the high dust levels (100 to 200 g/Nm 3 ) impose high demands on the durability and the operation of the catalyst. Until now, only high dust systems have been tested in the cement industry. For high dust systems, a lot of attention has to be paid on the design and the chemical composition of the catalyst. Catalysts designed for low dust operation in other industries might not be suitable for high dust operation in a cement plant. High dust operation of an SCR reactor requires a high mechanical durability of the catalyst, a wider pitch than usual for low dust operation and an integrated dedusting system, in order to avoid plugging and activity losses. The appropriate chemical composition of the catalyst has to be evaluated by trials with high dust off-gases of

cement kilns.

The first full-scale SCR demonstration plant was built in Germany with governmental financial support. This plant (Solnhofer Portland-Zementwerke) is in operation since 2001. Solnhofer Portland-Zementwerke decided to implement a high dust SCR system because of the following reasons [Sauter/Samant, 2003]:

x Lower consumption of NH 3 in comparison to SNCR, resulting in lower operational costs

x At the top of the four-stage preheater the waste gas has a temperature of 320–350 °C that is suitable for SCR and does not require re-heating (as in the case of configuration between fabric filter and stack), thus reducing energy costs and pressure loss.

The SCR reactor in Solnhofen allows the installation of 6 layers of catalytic elements, while only 3 of these layers have been in use. A layer consists of 6 modules, each with 72 catalytic elements. The catalytic elements have a size of 15x15x90 cm each, a comb-like structure and a special composition based on TiO 2 and V 2 O 5 . A pitch of 13 mm (10 mm in the middle layer) waschosen in order to avoid plugging. The integrated dedusting system uses preheated, highpressurized air to remove dust accumulations from the catalyst surface. The air nozzles are moved continuously over each catalyst layer, thus no service interruption is necessary to remove dust from the catalyst. By optimisation of the dedusting system, the consumption of high-pressurized air was reduced from initially 100 m 3 /t to 18 m 3 per ton of cement klinker, resulting in energy costs for the operation of the catalyst of about 0.098 € per ton of cement klinker [Sauter, 2006].



### 4201 st June 2006

Figure 1 Flow diagram of the SCR demonstration plant at Solnhofer Portland-Zementwerk

In order to ensure a maximum lifetime of the SCR reactor, it was designed to facilitate either upstream or downstream operation (see Figure 1 ). Accordingly, the integrated dedusting system is able to blow away dust accumulations either from the upper or the lower surface of each catalyst layer. As long-term experience in Solnhofen did not prove expected advantages for upstream operation, there is no need for switching the gas flow direction. Accordingly, future implementations of high dust SCR could be designed for downstream operation only, thus reducing investment costs.

The reduction agent, a water solution with 25% NH 3 , is added to the off-gas at the upper stages of the preheater in a molar ratio of 0.8 to 0.9 to the stoichiometric demand, according to the waste gas flow, the initial NO

x concentration and the target value.

The first set of catalysts was in operation for 40.000 h without excessive use or loss of activity. Later trials with plate-type catalysts showed higher mechanical use and unexpected losses of activity. In order to ensure full-time ELV compliance, the Solnhofen plant was equipped with an SNCR system for backup operation in 2006. At the moment only the SNCR- technique is operated at the kiln for comparison of operational costs with the SCR.

Operational data / Achieved environmental benefits

The NO

x abatement efficiency of the SCR plant in Solnhofen usually is in the range of 59% to 67%. Under unusual operating conditions with raw gas concentrations of 3000 mg/Nm 3 and higher, NO

x abatement efficiencies of more than 80% were observed. In regular operation, the

SCR reduces NO

x emissions from raw gas concentrations of 1000 to 1600 mg/Nm 3 to about 400 to 550 mg/Nm 3 . It has to be noted that the Solnhofen plant was designed to comply with a

NO

x emission limit value of 500 mg/Nm 3 and that it has been operated accordingly, but sometimes the emission limit value of 500 mg/m 3 was exceeded.

With a molar ratio of 0.8 to 0.9, the consumption of NH 3 is significantly lower than by application

of SNCR. It has to be noted that NH 3 from the raw material also serves as reduction agent in the reactor, thus the emission level of residual NH 3 is very low. At Solnhofen, the SCR usually led to

NH 3 emissions below 1 mg/Nm 3

.



### 4301 st June 2006

In one campaign the NH 3 dosage was increased according to a target NO

x level of 200 mg/Nm 3

. In this campaign an emission level of around 300 mg/Nm 3 was achieved. These results may indicate the potential of the technique, especially as they were also achieved with 3 catalytic layers only, and the emission level of residual NH 3 was still around 1 mg/Nm 3

.

Cross-media effects The only negative cross-media effect is a minor increase of electrical energy demand due to the internal dedusting system of the SCR reactor and additional pressure losses.

Applicability Up to now SCR has only been tested on preheater and semi-dry (Lepol) kiln systems, but it might be applicable to other kiln systems as well.

Economics The total investment costs of the SCR project in Solnhofen were about 3.5 million €, including extra expenditures for development reasons such as the capacity for 6 catalyst layers and the ability to operate either in upstream or in downstream mode. The investment cost of a new plant based on the Solnhofen experience are estimated to approximately 2.2 million for the SCR reactor, including ca. 250,000 € for the catalyst (to be calculated as replacement costs each 5–6 years). This amount does not include costs for ammonia storage and ductwork, as they vary significantly from site to site. In the costs for NO

x reduction by SCR or by SNCR are estimated by the German federal environmental agency (UBA) for a kiln capacity of 1,500 t/d and a NO

x reduction from 1,000 to 500 mg/Nm 3 based on practical experience from the Solnhofen plant. In the last two columns the cost estimations are extrapolated for a NO

x reduction to 200 mg/Nm 3

.

As a result of the UBA calculations, the operating costs for SNCR and SCR – including replacement costs for the catalyst – are roughly the same for a target NO

x level of 500 mg/Nm 3

, while the total specific costs for SCR are approximately 50% higher than for SNCR. At a target

NO

x level of 200 mg/Nm 3 , SCR seems to be more efficient regarding operating costs, but the total specific costs are still in the same level of magnitude than for SNCR. When comparing these figures, it has to be noted that long-term experience with a NO

x level of 200 mg/Nm 3 is neither available for SCR nor for SNCR yet. In the case of SNCR, higher emissions of NH 3 also

have to be taken into account.

Table 1: UBA cost comparison for NO

x abatement by SCR vers. SNCR at a 1.500 t/d cement plant

Basic assumptions Unit

Klinker production rate t/a 480,000

t/d 1,500

Operation time h/a 7,680

Waste gas flow Nm 3 /t 2,300

Initial NO
x level mg/Nm 3 1,000

kg/t 2.3

NH 3 price (25% solution) €/t 90.00

Catalyst price €/m 3 7,500

Useful life of catalyst H 40,000

Useful life of investments A 20

Hurdle/inflation rate % 3.0%



### 4401 st June 2006

NOx abatement system SNCR SCR SNCR SCR

NO
x target value mg/Nm 3 500 500 200 200

NH 3 equivalent Kg/t 0.44 0.44 0.71 0.71

Stoichiometric factor 1.7 0.8 2.5 1.0

NH 3 (25%) consumption Kg/t 3.02 1.42 7.11 2.84

Kg/d 4,550 2,150 10,650 4,250

No. of catalytic layers 3 4

Catalyst volume M 3 33.6 44.8

Operating costs

NH 3 consumption €/t 0.27 € 0.13 € 0.64 € 0.26 €

Electric energy consumption €/t 0.03 € 0.10 € 0.06 € 0.11 €

Catalyst replacement costs €/t 0.10 € 0.13 €

Total operating costs €/t 0.30 € 0.33 € 0.70 € 0.50 €

Investment costs

Ammonia system € 600,000 250,000 1,000,000 350,000

SCR reactor (except catalyst) € 1,950,000 2,350,000

Total investment € 600,000 2,200,000 1,000,000 2,700,000

Specific investment costs €/t 0.08 € 0.30 € 0.14 € 0.37 €

Total specific costs €/t 0.38 € 0.62 € 0.83 € 0.87 €

NO
x abatement costs €/t NO
x 330.00 € 540.00 € 450.00 € 470.00 €

A cost calculation of the German cement industry (VDZ) comprises a detailed approach concerning the costs of SCR technique [Scur, 2006]. Besides the investment costs this study considers also the whole operating costs including the costs for ammonia water, power consumption due to compressed air for the cleaning of the catalyst and the pressure drop due to the catalyst itself along with other cement plant typical economic assessment figures. Here it was shown that the costs for SNCR are always lower than those of SCR if European energy

and NH 3 prices are used as a basis. Theoretically, SCR could only become less costly than SNCR at very high reduction rates, if NH 3 prices would rise extremely and energy prices would decrease. This situation however seems not be applicable for the EU region, since ammonia and energy costs are not opposing each other, as they tend to rise and concurrently fall. It could

also be shown that efforts to reduce NO

x by primary measures (~ 800 mg/m3 as average now in Germany) brought about better economics for SNCR, which costs are largely influenced by the

costs for ammonia.

The SCR results have shown a cost level of 1.25 to 2.00 €/t, depending on plant size and NO

x removal efficiency required. The SCR is, in contrast to SNCR, dominated by the investment costs, which are 4 to 9 times higher than for a SNCR system. Furthermore the energy consumption is essentially due to pressure drop and cleaning air for the catalyst. The latest specific figures for the SCR system are reflecting the development of the technology. As an earlier VDZ study stated 3 €/t cli. as specific costs of the SCR, this value figure has now

declined to around 1.75 €/t.

Costs calculated by VDZ for a full scale installation (kiln capacity 1500 t cli./d, initial emissions of 1200 mg/m 3 and a final level of 200, 500 and 800 mg/m 3 ) is shown in table 2



### 4501 st June 2006

Table 2: VDZ cost calculation for NO

x abatement by SCR at a 1.500 t/d cement plant

Kiln systems Reduction Reported costs Technique applicability efficiency Investment

Mill. € Operating

€

SCR Possibly all 85-95 % 3.2 - 4.2 0,54 - 0,94

Driving force for implementation

Implementation of SCR may be suitable to archive higher NO

x abatement efficiency or to archive

simultaneous reduction of NO

x and other pollutants, e.g. ammonia and SO 2 from raw materials.

Example plant

Solnhofer Portland-Zementwerke, Frauenbergerweg 20, D-97801 Solnhofen

Reference literature

[Sauter/Samant, 2003] G. Sauter, G. Samant: Demonstrationsanlage zur Minderung der Stickoxidemissionen in der High-Dust-SCR-Anlage mit Wabenkatalysator zur Herstellung von Zementklinker – Final report No. 50441-2/92 on the investment project funded by the German Federal Ministry of Environment and Nuclear Safety. – Not yet published. [Sauter, 2006] G. Sauter, Solnhofer Portland Zementwerke: Personal information, 12 th April 2006

[Scur, 2006] P. Scur, H. Hoppe: Current state of NO

x abatement with the SNCR process. Cement International, 2/2006, Vol. 4, pp. 1-11



### 46Cementa AB, Sweden has been operating high efficiencies SNCR since 1997 on three cement kilns. In 2001 Per Junker, Sweden published a paper regarding the SNCR installations. Now an update is offered in a joint paper prepared by Per Junker and Anders Lyberg reflecting the long term experience since 1997.

SNCR Principle of Selective Non-Catalytic Reduction of Nitrogen- Oxides (NO, NOx)

SNCR systems are applied where favourable reduction conditions in the cement burning process are found, at a temperature window of 850 – 1100°C with sufficient retention time. An injection of ammonia water as the carrier of the reduction agent ammonia is the most applied technique.

A favourable good ammonia distribution is in the interest of agent utilisation and efficiency of NOx-reduction. It also reduces ammonia slip.

Kiln 8, Slite, original NH3-aq injection points. Normally 3-4 pair of nozzles are in use.Nozzle plan for the Skövde-plant (1900 tpd 4-stage PH kiln with satellite coolers)

Stable Process

The cement kilns operated with these high effi ciency SNCR system are the kiln of Skövde (1900 tpd) and the two kilns of the Slit e cement works (1200 and 5800 tpd capacity).Flow sheet of kiln 8 in Slite

The data collected illustrates the effectiv eness and stability of the s ystem. It includes NOxemissions, ammonia water consumption and ammonia slip from the SNCR operation.

Since 1997 about 63.500 t of ammonia water was consumed to abate approx. 45.000 t of

NOx.

One of the most signific ant figures to establish that the process is operating stable, is to show the average annual NOx-emission versus the ammonia consumption. Latter also though dependent from the NO x developed from the combustion process. However it remained at both plants in the initial corridor of 800 – 1100 mg/m3 (STP) of NOx, thus the reduction rate remained as initially found at around 80%.Ammonia Water Consumption and NOx Emissions SNCR System Skövde and Slite

0 0,5

1 1,5

2 2,5

3 3,5

4 4,5

5

1994 1996 1998 2000 2002 2004 2006

Year of OperationAmmonia Water (25%) l/t of Clinker

0 200 400 600 800 1000 1200 1400NOx-Emission in mg/m3 (STP)annual average

Ammonia Water Consumption Skövde Works
Ammonia Water Consumption Slite Works

NOx-Emissions Skövde Works

NOx-Emissions Slite Works Without SNCR in Operation With SNCR in Operation since 1997

In both plants the long term NOx-Emission is around 200 mg/Nm3 since 1998. It is also shown that the ammonia water consumption (25%) in Slite works st abilised around 3,5 to 4,5 litres per ton of cement c linker produced. In Skövde it sw ayed around 2,5 l/t to 3.5 l/t. The effect of fluctuating ammonia consumption is most likely due to changed clinker sintering conditions and to lesser level also to wear of the nozzles in the system.

Remarkably is that in neither plant the nozzles had to be changed and down time form

1997 to 2005 was for three installations les s than 200 h. The performance reported illustrates once again the initia l findings of 1998, that S NCR system are BAT for NOx

abatement.

Molar Ratio (NH 3 to NOx)

In 2001 the initial molar ratio was found to be 1 – 1,2 (mol NH 3 to present mol of NOx) at Skövde. With an average 80% removal efficien cy these are computed to be 1,2 to 1,4 for removed NOx. Compared to literature sou rces this can be seen for this high removal efficiency as exceptionally good.

At Slite the ammonia ratio was as initially found to be once again in the region of 1,2 – 1,4 mol/mol (present NOx to injected NH 3 ) or 1,5 – 1,8 (reduced NOx to injected NH 3 ).

Ammonia Slip form the SNCR operation

In the initial trails ammonia slip and emission s were tested. The figures recorded in 1994 to 1996 showed that both plants had a natural ammonia emissions arising from the raw material of 10 to 30 mg/m3 (STP) in Skövde and 15 to 20 mg/m3 (STP) in Slite.In Skövde the ammonia slip, once the SNCR wa s set in operation, was 5- 10 mg/m3 (STP). In Slite the ammonia slip on top of the natural emissions is approx. 5 to 20 mg/m3 (STP).

Repeated measurement in Skövde in 2003 s howed less than 5 mg/m3 (STP) ammonia emission without SNCR and 20 mg/m3 (STP) with the SNCR, hence the ammonia slip remained as reported in 1997.

Significant for both plants is that they have ra w mills, which collect ammonia in the milling system. In Skövde almost 98% of the time t he milling systems (raw a nd coal mill) are in operation. Therefore the ammonia emiss ions found there in compound mode – mill operation – represent the average figures.

The Slite cement works has in contrast to most cement plants a SOx-Scrubber, which buffers the ammonia in the scrubber liquor – hence equalises peaks and lows. Together with the gypsum product only a small fraction of ammonia is taken to the cement milling facilities (3 kg/h). The cement mill is operated at low temper atures in a closed circuit and only very occasionally ammonia smell was detec ted in the cement silo. These however, never lead to complaints.

Still, the scrubber has an ammonia emiss ion continuous measurement since 1998 in the stack. The figures f ound there are shown below.

Ammonia Emissions and Consumption

Slite Kiln #7 and #8 main stack after Scrubber

0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00

1993 1995 1997 1999 2001 2003 2005

Year of OperationAmmonia Water (25%) - Consumption in l/tClinker

0 5 10 15 20 25 30 35 40Ammonia Emissions in mg/m3 (STP)

25%-Ammonia solution consumption Liter per ton of Clinker
Ammonia Emissions Compound Mode mg/m3 (STP, dry)

Ammonia Emissions Direct Mode mg/m3 (STP, dry)
Ammonia Emissions Averaged mg/m3 (STP, dry)
Ammonia Slip SNCR Operation mg/m3 (STP, dry) Without SNCR in Operation With SNCR in Operation since 1997

In processor period without Scrubber in Slite) t he ammonia emissions were in the region of 15 to 35 mg/Nm3. Since the scrubber is in o peration short time peaks are higher, here up to 125 mg/m3 (STP). This is due since the sc rubber liquor increases its temperature from 53°C to 59°C and the equilibrium is shifted and some accumulated ammonia is released again.With the scrubber in operation the averaged ammonia 20 – 35 mg/Nm3 level at Slite mostly

follows the ammonia water consum ption trend. This effect show s that the emphasis should remain - despite the high ef ficiency of the SNCR systems - also on primary NOx-control through optimised process combustion conditions.

Cost of operation

The cost of operating a SNCR system is predominant dependent on the ammonia water consumption. Only little pumping energy is needed and the co mbustion of ammonia in the reduction zone of 900 – 1100°C compensates the heat needed to evaporate the water (ammonia carrier).

With a cost of ~ € 100 per ton of 25% ammonia water in 1996 and 130 €/t nowadays, the reduction costs per ton of clinker produced, rose in Skövde modestly from initially 0,3 to 0,35. Accumulated cost were here then 0,4 to 0,45 €/t of clinker.

In Slite since the transport cost to the Is land Gotland is higher than on the main land (now 140 €/t), the cost fluctuated around 0,4 to 0,5 €/t. Electricity, m aintenance and depreciation accumulate to another 0,1 €/t Clinker in production cost. Here the total cost per ton of clinker remained as initially calculated around 0,5 to 0,6 €/t.

In the period of 1997 to 2005 ~ the reduction cost s add up to ~ € 11 Mil. At the same time

about 45.000 t of NOx was abated. The total co st with depreciation, capital cost, energy

and ammonia related to NOx abat ed was 250 €/t of NOx.

Special Consideration for SNCR Application

Skövde and Slite have demonstrat ed that high efficiency SNCR system work stable over a prolonged period. The achieved reduction rates of time wise above 80% are exceptionally good. However at these two cement works very favourable conditions were found such as:

• Appropriate temperature window 850 – 1100°C

• Appropriate retention time of amm onia in the correct window of > 2 sec

• Medium high raw gas NOx-values 600 – 1100 mg/Nm3 due to application of favourable (secondary) fuel

• Exceptionally stable operating cond itions in the kiln in Skövde

• Pre-Calciner kiln of Slite wi th at least two combustion points

• NOx-Emission at Slite kiln #7 and 8 are measured after the joint scrubber, hence averaged values are shown

These above mentioned effects have greatly c ontributed to positive re sults. These though might not be repeatable at all ce ment kiln installation. A case by case evaluation ought to take place.

At the Swedish installations special equipm ent was applied, which had distinct patented features. It and operated to the low NO x emission design and additional ammonia

emissions were in a tolerable level of 5 – 20 mg/Nm3. Nethertheless the ammonia slip

does fluctuate to the nature of th e cement manufacturing process. Formatiert: Englisch (Großbritannien)Summary

The cement kilns in Slite and Skövde exemplif ies that the SNCR-technique can be of high efficiency, operating at acceptable molar ratio and ammonia slip and at a reduction rate of around 80%, by using natural process pre-c onditions to achieve a competitive technique

for NOx abatement in the cem ent industry. The findings repor ted in 2001 have proved to remain in the long term, from the first experience of 1997 up to today

.Ammonia Water Consumed l/t of Clinker 3.09 Raw Gas Content NOx ppm 396 Clean Gas Content ppm 75 NOx-Removed ppm 321 Raw Gas Content NOx mg/Nm3 811.8 Clean Gas Content mg/Nm3 153.75 NOx-Removed mg/Nm3 658.05 NOx-Removal efficiency % 81.1% Ammonia Water Density kg/l 0.908 Ammonia Consumed kg/t Cl. 0.70143 Ammonia Molar Weight g/mol 17.03

NO 2 -Molar Weigth g/mol 46.0
NO-Molar Weigth g/mol 30.0 NOx-Molar Weigth g/mol 30.7 Ammonia Consumed mmol/kg Cl. 41.2

NOx-Raw Gas mmol/Nm3 17.6

NOx-Clean Gas mmol/Nm3 3.3

NOx-Removed mmol/Nm3 14.3 NOx-Raw Gas mmol/kg Cl. 40.2 NOx-Clean Gas mmol/kg Cl. 7.6 NOx-Removed mmol/kg Cl. 32.6 Gasflow at Stack (w/o) Coal Mill Nm3/h 185000

Clinker Production Rate t/d 1950 Specific Gasflow Nm3/kg Cl. 2.3

Molar Ratio Present mol/mol 1.03

Molar Ratio Removed mol/mol 1.26 

### Molar Ratio

Skövde PlantFrån 1999 till 2000 steg amoniakförbrukningen vi sätter det i samband med att vi fick tillbaka en brännare som Pargas lånat men detta är inte belagt och de skall vara lika.

Utfall produktion 1995 (referensår)

1995 månad kgNOx/ton ton klinker ton NOx ppm/månad cl-weighted

1995 jan * 2,20 27184 60 ppm mg/Nm3

1995 feb * 2,20 31994 70

1995 mars * 2,20 27472 60

1995 april * 2,20 2345 5

1995 maj 2.33 51846 121 591 30640986

1995 juni 2.37 57048 135 654 37309392

1995 juli 1.73 12026 21 433 5207258

1995 aug 4.19 1206 5 328 395568

1995 sept 2.01 57589 116 548 31558772

1995 okt 2.98 13302 40 589 7834878

1995 nov 2.32 52106 103 470 24489820

1995 dec 2.40 1139 3 545 620755

519.75 560.61199

summa mv 2,2 335257 739 mv 519 ppm

Sammanställninng Nox Utfall produktion 1997

månad kgNOx/ton ton klinker kg NOx ppm/månad mg/m3

1997 mars 0.72 42014 30417 165 338.25 6932310

1997 april 0.29 14876 4351 61 125.05 907436

1997 maj 0.52 20670 10649 155 317.75 3203850

1997 juni 0.33 41244 13493 98 200.90 4041912

1997 juli 0 0 0 0.00 0

1997 aug 0 0 0 0.00 0

1997 sept 0.56 31304 17475 149 305.45 4664296

1997 okt 0.49 51872 25308 126 258.30 6535872

1997 nov 0.33 18999 6210 67 137.35 1272933

117.2857143 124.71144 255.6584

1997 summa 0.49 220979 107903 mv 117 ppm

1998 jan 0.61 139 85 62 127.10 8618

1998 feb 0 39 21252 8244 100 205 00 2125200

. . 2125200

1998 mars 0.37 52759 19701 91 186.55 4801069

1998 april 0.39 7802 3051 81 166.05 631962

1998 maj 0.43 45929 19624 106 217.30 4868474

1998 juni 0.46 43844 20139 126 258.30 5524344

1998 juli 0.37 5314 1977 114 233.70 605796

1998 aug 0.45 13565 6161 128 262.40 1736320

1998 sept 0.34 50652 17305 95 194.75 4811940

1998 okt 0.37 13608 4977 102 209.10 1388016

1998 nov 0.37 40864 15123 90 184.50 3677760

1998 dec 0.44 25280 11110 97 198.85 2452160 Amoniak förbrukning liter 628000

1998 summa 0.40 321008 127497 mv 99 ppm 101.65373 1.956338 liter/ ton klinker

1999 jan 0.00 0 0 0 0.00 0

1999 feb 0.55 23785 13028 104 213.20 2473640

1999 mars 0.27 50474 13608 65 133.25 3280810

1999 april 0.38 20544 7728 84 172.20 1725696

1999 maj 0.32 38457 12290 88 180.40 3384216

1999 juni 0.40 49459 19718 107 219.35 5292113

1999 juli 0.00 0 0 0 0.00 0

1999 aug 0.55 7935 4335 137 280.85 1087095

1999 sept 0.41 57871 23602 119 243.95 6886649

1999 okt 0.39 8022 3148 102 209.10 818244

1999 nov 0.35 37074 12807 97 198.85 3596178

1999 dec 0.39 36444 14278 93 190.65 3389292 Amoniak förbrukning liter 642000

1999 summa 0.38 330065 124542 mv 99 96.750437 1.945071 liter/ ton klinker

månad kgNOx/ton ton klinker kg NOx ppm/månad

2000 jan 0.41 18663 7600 96 196.80 1791648

2000 feb 0.47 31864 15113 120 246.00 3823680

2000 mars 0 0 0 0.00 02000 april 0.32 54069 17043 93 190.65 5028417

2000 maj 0.22 35001 7596 63 129.15 2205063

2000 juni 0.29 50038 14500 75 153.75 3752850

2000 juli 0.67 7435 5016 64 131.20 475840

2000 aug 0 0 0 0.00 0

2000 sept 0.38 27731 10635 93 190.65 2578983

2000 okt 0.31 50837 15735 83 170.15 4219471

2000 nov 0.29 40609 11891 82 168.10 3329938

2000 dec 0.28 32211 8879 67 137.35 2158137 Amoniak förbrukning liter 923000

2000 summa 0.33 348458 114008 mv 99 84.268483 2.648813 liter/ ton klinker

2001 jan 0.00 0 0 0 0.00 0

2001 feb 0.36 24389 8693 83 170.15 2024287

2001 mars 0.32 34486 10919 70 143.50 2414020

2001 april 0.34 29300 9860 82 168.10 2402600

2001 maj 0.52 9109 4740 122 250.10 1111298

2001 juni 0.34 58311 20039 89 182.45 5189679

2001 juli 0.34 39257 13293 87 178.35 3415359

2001 aug 0.00 0 0 0 0.00 0

2001 sept 0.23 29565 6774 60 123.00 1773900

2001 okt 0.22 45529 10206 57 116.85 2595153

2001 nov 0.36 21585 7870 93 190.65 2007405

2001 dec 0.35 58285 20536 89 182.45 5187365 Amoniak förbrukning liter 1011000
summa 0.32 349816 112930 mv 83 170.56 80.388164 2.890091 liter/ ton klinker

NOx NOx NOx kg NOx / ppm mg/Nm3 ton kg/ton kli

2002 jan 87 179 2.835 0.364 247.10218

2002 feb 0.000 0

2002 mars 68 139 13.415 0.279 910.89081

2002 april 57 117 11.609 0.217 662.77407

2002 maj 100 204 3.957 0.396 394.58254

2002 juni 82 169 17.575 0.300 1448.5298

2002 juli 80 164 1.743 0.308 139.73642

2002 aug 65 133 6.895 0.240 446.99942

2002 sept 72 148 13.736 0.276 990.39047 327206 ton klinker

2002 okt 91 187 12.465 0.365 1134.9549 Amoniak förbrukning liter 914000

2002 nov 81 167 10.598 0.345 862.70233 2.793347 liter/ ton klinker

2002 dec 0.000 0

2002 summa/mv 78 161 94.829 0.290 76.334085

NOx NOx NOx NOx ppm mg/Nm3 ton kg/ton kli

2003 jan 0.000

2003 feb 82 168 11.991 0.359 985.36905

2003 mars 62 127 16.941 0.331 1051.9017

2003 april 66 135 5.324 0.344 349.75656

2003 maj 80 164 10.216 0.398 818.55905

2003 juni 72 148 15.193 0.329 1098.402

2003 juli 96 196 0.912 0.354 87.148175

2003 aug 72 148 7.370 0.324 532.93714 348725 ton klinker

2003 sept 62 127 15.055 0.277 929.84306 Amoniak förbrukning liter 943000

2003 okt 42 85 1.711 0.215 71.023655 2.704136 liter/ ton klinker

2003 nov 85 174 23.159 0.444 1966.2239

2003 dec 88 181 17.286 0.465 1525.9453

2003 summa/mv 73 150 125.158 0.359 75.241978

NOx kg NOx / ppm mg/Nm3 ton kg/ton kli
2004 jan 82 168 13.133 0.410 1075.18

2004 feb 91 186 5.330 0.470 482.78205

2004 mars 72 147 8.178 0.327 586.52617 2004 april 69 141 14.988 0.325 1030.6992 2004 maj 78 160 11.017 0.406 858.71884 2004 juni 77 158 18.624 0.364 1438.6526 2004 juli 0.000 0 2004 aug 65 134 7.269 0.348 473.75091 357360 ton klinker

2004 sept 60 124 10.604 0.299 639.56259 Amoniak förbrukning liter 1142000

2004 okt 72 148 16.807 0.363 1213.0792 3.195657 liter/ ton klinker

2004 nov 83 170 15.204 0.434 1259.9497

2004 dec 82 168 8.708 0.325 713.17553

2004 summa/mv 76 155 129.9 0.363 75.2487544006008001000120014001.522.533.544.5 N Ox-Emission in mg/m3 (STP) annual average

m monia Water (25%) l/t of ClinkerAmmonia Water Consumption and NOx EmissionsSNCR System Skövde and SliteAmmonia Water Consumption Skövde WorksAmmonia Water Consumption Slite WorksNOx-Emissions Skövde WorksWithout SNCR in Operation With SNCR in Operation since 1997020000.511994 1996 1998 2000 2002 2004 2006 N

A mYear of OperationNOxEmissionsSkövdeWorksNOx-Emissions Slite WorksSkövde plant in Sweden2000 t/d plant. FLS late 60-ies. 2-string 4 stage preheater kiln with satellite cooler and ball raw mill with conditioning towerSNCR in operation since -97 by ABC&IYearly averagesYear Clinker production Nox Nox Nox-emis Spec em NH3 consumption Total ammoTotal abated NOxton ppm mg/Nm3 ton/year kgNOx/ton Cl liter 25% NH3/ton Cl t/a t/a1995 335257 561 1150 739 2.2 019961997 220979 124 254 108 0.49 5401998 321008 102 209 127 0.4 1.96 629 6351999 330065 98 201 125 0.38 1.95 644 6252000 348458 84 172 114 0.33 2.65 923 5702001 349816 80 164 113 0.32 2.89 1011 5652002 327206 76 156 95 0.29 2.79 913 4752003 348725 75 154 125 0.36 2.7 942 6252004 357360 75 154 130 0.36 3.2 1144 6502005 409061 85 174 135 0.36 3.09 1264 6753012678 Out 1072 7469 4145Total In 5360Abated 42881520253035401.502.002.503.003.504.004.50 m monia Emissions in mg/m3 (STP)

a ter (25%) - Consumption in l/t ClinkerAmmonia Emissions and ConsumptionSlite Kiln #7 and #8 main stack after ScrubberWithout SNCR in Operation With SNCR in Operation since 199705100.000.501.001993 1995 1997 1999 2001 2003 2005 A m

Ammonia W aYear of OperationAmmonia consumption (25% NH3 solution) l/tCKAmmonia Emissions Compound Mode mg/m3 (STP, dry)Ammonia Emissions Direct Mode mg/m3 (STP, dry)Ammonia Emissions Averaged mg/m3 (STP, dry)Ammonia Emissions Slip (SNCR) mg/m3 (STP, dry)SNCR kiln 7 since mid 1999.Yearly averageYearClinkerproductionAmmoniaconsumption Gasflow OperatingNH3consumptionCompoundModeDirectModeAveragedSlip(SNCR)(25% NH3solution)t ppmmg/Nm3t/akg NOx/tCKl/tCKm3 h ton199414.3 35 16.37 019951,816,359 1076 3630 2.00 0 500,000 6748 019961,748,676 1139 4065 2.32 0 500,000 7139 019971,614,051 611 2053 1.27 1.29 500,000 6715 209019981,523,916 348 1325 0.87 4.17 530,000 7191 635319991,531,248 250 894 0.58 21 30.76 14.39 3.72 540,000 6618 569620001,854,462 247 1105 0.60 25 35.22 18.85 4.22 630,000 7104 783520011,914,804 259 1182 0.62 11.8 23.05 6.68 3.65 635,000 7197 699320021,826,501 212 910 0.50 7.6 19.31 2.94 3.53 616,000 6960 645020031,704,986 222 807 0.47 18 28.52 12.15 3.83 572,000 6361 653220041,790,491 226 915 0.51 16 26.88 10.51 3.56 616,202 6569 636820051,810,000 210 916 0.51 2.4 27.00 10.63 4.29 616,202 6569 775615,570,459 Emitted 10,107 27.25 10.88 56,073Total In 50535Cost AW 0.468161536€/t ClinkerAbated 40,428Cost Deprec0.087955018€/t ClinkerSO2-scrubber since 1999Energy 0.012745289Also kiln 7 (1300 t/d) in scrubber chimney together with kiln 8 (5500 t/d) since~june 1999Maintenance0 005394831mg/m3 (STP, dry)NOx - Emissions Ammonia EmissionsAlsokiln7(1300t/d)inscrubberchimneytogetherwithkiln8(5500t/d)since~june1999Maintenance0.005394831Total other 0.106095138Total All 0.574256674Total Cost Slite 7289490Skövd7469201650000344662Sub #######Total Abated 44,716Slite plantMonthly averagesmg/Nm32003 2004 2003 2004januari14 26 194 230februari18 20 160 220mars15 12 270 195april18 19 187 206maj16 17 210 450juni20 14 189 197juli18 13 182 184augusti19 15 159 199september17 12 177 195oktober14 13 251 182november23 14 275 191december24 16 170 19918 16 202 221NH3 Emissions NOx