CEMEX Emissions

Kiln-Flash Calciner

year

Actual Raw 

Material Usage 

[tons]

Actual Clinker 

Production [tons]

Operating 

Hours

Annual Coal 

Use [tons]

Annual Coal 

Heat Input 

[MMBtu]

Annual % 

Firing Coal

Natural Gas 

Use [mscf]

NG Heat 

Input 

[MMBtu]

SO2 [tpy]

SO2 

[lbs/ton of 

Clinker]

Average 

SO2 (lbs/hr) NOx [tpy] NOx [lbs/ton 

of Clinker]

Average 

NOx 

(lbs/hr)

% Raw 

Material Loss

2000 846,000 539,992 8020 - 14.4 0.053 3.6 1,729.6 6.41 431.3 -36.17%

2001 759,699 508,733 7893 111,677 2,702,583 96.08% 102,156 110,328 18.7 0.074 4.7 1,858.9 7.31 471.0 -33.03%

2002 738,067 472,945 7526 92,418 2,236,516 91.38% 195,375 211,005 95.0 0.402 25.3 1,747.1 7.39 464.3 -35.92%

2003 830,428 516,251 7871 99,919 2,418,040 96.14% 89,802 96,986 48.0 0.186 12.2 1,835.0 7.11 466.3 -37.83%

2004 791,866 472,053 7927 96,796 2,342,463 91.92% 190,587 205,834 26.3 0.111 6.6 1,708.9 7.24 431.2 -40.39%

2005 739,260 440,384 7641 86,730 2,098,866 93.13% 143,343 154,810 27.2 0.123 7.1 1,591.3 7.23 416.5 -40.43%

2006 734,456 466,173 7921 97,667 2,363,541 96.58% 77,411 83,604 44.7 0.192 11.3 2,011.7 8.63 508.0 -36.53%

2007 788,780 479,225 7941 89,683 2,170,329 95.81% 87,890 94,921 65.0 0.271 16.4 1,689.0 7.05 425.4 -39.24%

2008 749,325 478,520 7534 88,264 2,135,989 96.97% 62,002 66,838 55.8 0.233 14.8 1,295.5 5.41 343.9 -36.14%

2009 312,845 185,076 2990 34,914 844,919 96.36% 29,624 31,935 15.5 0.167 10.4 495.5 5.35 331.4 -0.4084

Average: 455,935 88,674 2,145,916 108,688 117,362 41 0.181 11.2 1,596.25 6.91 428.92 -37.82%

(excluding 2009) Average: 486,031 95,394

 6,160.50 6,120.47

Kiln Raw Material Usage (max feed): 967,680 (tons/year) dry basis

Kiln-Calciner: 8064 (hours/year)-condition # 10.2

Clinker Processing: 8064 (hours/year)-condition # 11.2

error reported by CEMEX, numbers are now correct

Title V Permit Limits
SO2 Emissions Control Analysis for the Kiln

Resultant SO2 

Emissions

Resultant SO2 

Emissions

Resultant SO2 

Emissions

Estimated Control 

Efficiency

SO2 Emission 

Reduction Annualized Cost Cost Effectiveness

Incremental Cost 

Effectiveness

[tons/yr] [lbs/hr] [lbs/ton of clinker] [%] [tons/yr] [$/yr] [$/ton] [$/ton]

Baseline SO2 Emissions 95.0 25.3 0.40 -

Lime Addition to Kiln Feed 71.3 19.0 0.30 25 23.8 $3,640,178 $153,271 

Fuel Substitution (coal supplemented with TDF) 57.0 15.2 0.24 40 38.0 $172,179 $4,531 ($243,368)

Dry Sorbent Injection 47.5 12.7 0.20 50 47.5 Not provided - -

Wet Lime Scrubbing (Tailpipe scrubber) 9.5 2.5 0.04 90 85.5 $2,529,018 $29,579 $49,618 

NOx Emissions Control Analysis for the Kiln

Resultant SO2 

Emissions

Resultant NOx 

Emissions

Resultant NOx 

Emissions

Estimated Control 

Efficiency

NOx Emission 

Reduction

Annualized Cost Cost 

Effectiveness

Incremental Cost 

Effectiveness

[tons/yr] [lbs/hr] [lbs/ton of clinker] [%] [tons/yr] [$/yr] [$/ton] [$/ton]

Baseline NOx Emissions 1,747.1 464.3 7.39 -

Water Injection 1,624.8 431.8 6.87 7 122.297 43,598.231 $356 128,580.55

Firing TDF 1,572.4 417.9 6.65 10 174.710 172,178.777 $986 $2,453.22 52.41 2453.219

Indirect Firing with LNB 1,397.7 371.4 5.91 20 349.4 $710,750 $2,034 $3,083 

SNCR (45% control) 960.9 255.4 4.06 45 786.2 $1,636,636 $2,082 $2,120 

SNCR (48.43% control) 901.0 239.4 3.81 48.43 846.1 $1,636,636 $1,934 $1,864 

SNCR w/LNB 786.2 208.9 3.33 55 960.9 $1,686,395 $1,755 $434 

Control Technology

Control Technology
Visibility improvement for SO2 Controls – Kiln Only

98th Percentile Improvement

(from 24-hr Max)

(Δdv) (Δdv) ($/Δdv)

24-hr Maximum (≈ 104 lbs/hr) 0.760 -

Baseline (≈ 25.3 lbs/hr)* 0.730 0.030

Lime Addition to Kiln (≈ 19.0 lbs/hr)* 0.727 0.033 $110,308,420 

Fuel Substitution (≈ 15.2 lbs/hr)* 0.726 0.034 $5,064,082 

Dry Sorbent Injection (≈ 12.7 lbs/hr)* 0.724 0.036

Wet Lime Scrubbing (≈ 2.5 lbs/hr) 0.720 0.040 $63,225,462 

Visibility improvement for NOx Controls – Kiln Only

98th Percentile Improvement

(from 24-hr Max)

(Δdv) (Δdv) ($/Δdv)

Maximum (24-hr max) 0.760

Revised Baseline* ( ≈ 464.3 lb/hr) 0.572 0.188

Original Baseline* (≈ 446.8 lb/hr) 0.555 0.205

Water Injection (≈ 431.8 lb/hr) 0.540 0.220 $198,174 

Firing TDF (≈417.9 lbs/hr) 0.526 0.234 $735,807 

Indirect Firing with LNB (≈ 371.4 lb/hr) 0.481 0.279 $2,547,493 

Original Proposed BART Limit – SNCR (≈ 268.0 lb/hr) 0.380 0.380

Proposed BART Limit – SNCR (30-day limit)** (≈ 255.3 lb/hr) 0.368 0.392 $4,175,091 

Proposed BART Limit – SNCR (annual limit)** (≈ 239.0 lb/hr) 0.352 0.408 $4,011,362 

SNCR w/LNB** (≈ 208.9 lb/hr) 0.322 0.438 $3,850,217 

Control Method 98th Percentile Impact Cost Effectiveness 

Control Method 

98th Percentile Impact Cost Effectiveness
Cemex BART Determination

Control Type Estimated 

Reduction SO2 [lb/hr] SO2 [lb/ton of clinker] SO2 [tpy] Reduction

Present SO2 BART % 48 0.80 97

Baseline - 25.3 0.40 95.0 Proposed BART limits

Lime Addition 25% 18.94 0.30 71.3 (23.8)

Fuel Substitution 40% 15.15 0.24 57.0 (38.0)

DSI 50% 12.63 0.20 47.5 (47.5)

WLS 90% 2.53 0.04 9.5 (85.5)

Control Type Estimated 

Reduction NOx [lb/hr] NOx [lb/ton of clinker] NOx [tpy] Reduction

Present NOx BART 40% 268 4.45 901

Baseline - 464.3 7.39 1,747.1

Water Injection 7% 431.8 6.87 1,624.8 (122.3)

Firing TDF 10% 417.8 6.65 1,572.3 (174.7)

LNB w/IDF 20% 371.4 5.91 1,397.6 (349.4)

SNCR 40% 278.6 4.43 1,048.2 (698.8)

SNCR (30-day roll) 45.00% 255.35 4.06 960.9 (786.2) Proposed BART limits

SNCR (annual) 48.43% 239.4 3.81 901.0 (846.1)
CEMEX Emissions

Pollutant Source

Maximum 24-hr 

Avg Emission Rate 

[lb/hr] Allowable [tpy]*

2008 Actual 

[tpy]**

2008 Actual 

[lbs/ton of 

Clinker]

SO2 Raw Materials Dryer 19.4 36.7 0.89 0.004

NOx Raw Materials Dryer 13.9 10.41 0.04

PM10 Raw Materials Dryer 22.8 5.12 0.02

CO Raw Materials Dryer 57.3 2.98 0.01

SO2 Kiln and Flash Calciner 104 1,340.0 55.8 0.23

NOx Kiln and Flash Calciner 2,649.0 1295.5 5.41

PM10 Kiln and Flash Calciner 133.0 42.04 0.18

CO Kiln and Flash Calciner 396.0 345.1 1.44

Notes: VOC Emissions not included in the BART analysis because VOC is not a significant contributor to the formation of seco

 * Allowable emissions from CEMEX Title V Operating Permit 95OPBO082 issued on 01 FEB 2000 and renewed on 01 MAR 2

 ** Actual emissions from APENs (submitted in 2009, based on 2008 production)
% Reduction (actual -

allowable )/allowable

2008 Clinker 

Production (from Kiln 

APEN) [tpy]

-97.6% 478,520

-25.1% 478,520

-77.5% 478,520

-94.8% 478,520

-95.8% 478,520

-51.1% 478,520

-68.4% 478,520

-12.9% 478,520

 to the formation of secondary organic carbon particulates

nd renewed on 01 MAR 2008
CEMEX Tire Derived Fuel (TDF) Performance Test Results

Performance test date: November 13 - 22, 2002

Performance test report date: 3/21/2003

Pollutant Fossil Fuel [ppm] TDF [ppm]

% Change (TDFFF)/FF

PM (M29 train) 8.8 9.7 10.2%

PM (M26A train) 9.5 9.1 -4.2%

NOx 517.7 391.2 -24.4%

SOx 26.2 15.7 -40.1%

THC 0.5 1.8 260.0%

CO 50.3 120.2 139.0%
Cemex Lime Addition to Kiln Feed - SO2 Cost Analysis

Direct Equipment Cost (silo & feed system) $ 2,000,000

Direct Installation Cost

Indirect Costs

Total Capital Costs $ 2,000,000

Capital Recovery Costs $ 188,786 7%, 20 years

Operating Labor

Materials (CaO-lime) $ 4,612,608 (amended by Cemex 29 JUL 2010)

Utilities

Total Annual O&M Costs $ 4,612,608

Value of extra Clinker (@$40/ton) $ 1,161,216

Total Annualized Costs: $ 3,640,178

Baseline SO2 Emissions: 95.0 [tpy]

SO2 Reduction from Lime Add: 25% (amended by Cemex 29 JUL 2010)

SO2 Reduction from Lime Add: 23.8 [tpy]

Lime Add Controlled SO2 Emissions: 71.3 [tpy]

Lime Add Control Cost: $ 153,271 [$/ton]

Capital Costs

O&M Costs
Cemex Firing w/TDF - Cost Analysis

Direct Equipment Cost $ 3,000,000

Direct Installation Cost

Indirect Costs

Total Capital Costs $ 3,000,000

Capital Recovery Costs $ 283,179 7%, 20 years

Fuel savings (300,000)

annual $ 189,000

Total O&M Costs $ (111,000)

Total Annualized Costs: $ 172,179

Baseline SO2 Emissions: 95.0 [tpy]

SO2 Reduction from Firing TDF: 40%

SO2 Reduction from Firing TDF: 38.0 [tpy]

Firing TDF Controlled SO2 Emissions: 57.0 [tpy]

Firing TDF Control Cost: $ 4,531 [$/ton]

Source: Jan. 15, 2007 Letter to J Geier from Amarjit Gill

Capital Costs

O&M Costs
Cemex Wet Lime Scrubbing - Cost Analysis

Direct Equipment Cost $ 8,482,500

Direct Installation Cost $ 7,210,125

Indirect Costs $ 2,968,875

Total Capital Costs $ 18,661,500

Capital Recovery Costs $ 1,761,514 7%, 20 years

Operating Labor $ 10,074

Maintenance Labor and Materials $ 17,520

Utilities-Electricity $ 571,180

Utilities-Limestone Slurry $ 5,235

Utilities-Water $ 103,202

Utilities-Sludge Disposal $ 60,293 corrected by Division to account for apparent er

Total O&M Costs $ 767,505

Total Annualized Costs: $ 2,529,018

Baseline SO2 Emissions: 95.0 [tpy]

SO2 Reduction from WLS: 90%

SO2 Reduction from WLS: 85.5 [tpy]

WLS Controlled SO2 Emissions: 9.5 [tpy]

WLS Control Cost: $ 29,579 [$/ton]

Original Cemex O&M Costs $ 767,505

Original Cemex Capital Recovery Costs $ 4,714,000 7%, 8 years

Original Cemex Annualized Costs $ 5,481,505

Original Baseline SO2 Emissions: 97.0 [tpy]

Original SO2 Reduction from WLS: 90%

Original SO2 Reduction from WLS: 87.3 [tpy]

Original WLS Controlled SO2 Emissions: 9.7 [tpy]

Original WLS Control Cost: $ 62,789

O&M Costs

Capital Costs
Cemex Water Injection - Cost Analysis

Direct Equipment Cost $ 250,000

Direct Installation Cost

Indirect Costs

Total Capital Costs $ 250,000

Capital Recovery Costs $ 23,598 7%, 20 years

annual $ 20,000

Total O&M Costs $ 20,000

Total Annualized Costs: $ 43,598

Baseline NOx Emissions: 1,747.1 [tpy]

NOx Reduction from Water Injection: 7%

NOx Reduction from Water Injection: 122.3 [tpy]

Water Injection Controlled NOx Emissions: 1,624.8 [tpy]

Water Injection Control Cost: $ 356 [$/ton]

Source: Jan. 15, 2007 Letter to J Geier from Amarjit Gill

Capital Costs

O&M Costs
Cemex Firing w/TDF - Cost Analysis

Direct Equipment Cost $ 3,000,000

Direct Installation Cost

Indirect Costs

Total Capital Costs $ 3,000,000

Capital Recovery Costs $ 283,179 7%, 20 years

Fuel savings (300,000)

annual $ 189,000

Total O&M Costs $ (111,000)

Total Annualized Costs: $ 172,179

Baseline NOx Emissions: 1,747.1 [tpy]

NOx Reduction from Firing TDF: 10%

NOx Reduction from Firing TDF: 174.7 [tpy]

Firing TDF Controlled NOx Emissions: 1,572.4 [tpy]

Firing TDF Control Cost: $ 986 [$/ton]

Source: Jan. 15, 2007 Letter to J Geier from Amarjit Gill

Capital Costs

O&M Costs
Cemex Indirect Firing with LNB - Cost Analysis

Direct Equipment Cost $ 7,000,000

Direct Installation Cost

Indirect Costs

Total Capital Costs $ 7,000,000

Capital Recovery Costs $ 660,750 7%, 20 years

annual $ 50,000

Total O&M Costs $ 50,000

Total Annualized Costs: $ 710,750

Baseline NOx Emissions: 1,747.1 [tpy]

NOx Reduction from IF w/LNB: 20%

NOx Reduction from IF w/LNB: 349.4 [tpy]

IF w/LNB Controlled NOx Emissions: 1,397.7 [tpy]

IF w/LNB Control Cost: $ 2,034 [$/ton]

Source: Jan. 15, 2007 Letter to J Geier from Amarjit Gill

Capital Costs

O&M Costs
Cemex SNCR - Cost Analysis

Direct Equipment Cost $ 600,000

Direct Installation Cost

Indirect Costs

Total Capital Costs $ 600,000

Capital Recovery Costs $ 56,636 7%, 20 years

annual (@50% control) $ 1,580,000

Total O&M Costs $ 1,580,000

Total Annualized Costs: $ 1,636,636

Baseline NOx Emissions: 1,747.1 [tpy]

NOx Reduction from SNCR: 48.43%

NOx Reduction from SNCR: 846.1 [tpy]

SNCR Controlled NOx Emissions: 901.0 [tpy]

SNCR Control Cost: $ 1,934 [$/ton]

Source: Jan. 15, 2007 Letter to J Geier from Amarjit Gill

Capital Costs

O&M Costs
Cemex LNB w/SNCR - Cost Analysis

Direct SNCR Equipment Cost $ 600,000

LNB Cost $ 527,150 estimated based on total annual cost provided by cemex

Indirect Costs

Total Capital Costs $ 1,127,150

Capital Recovery Costs $ 106,395 7%, 20 years

annual (@50% control) $ 1,580,000

Total O&M Costs $ 1,580,000

Total Annualized Costs: $ 1,686,395 Source: from Monica Sowders 27 OCT 2010 email

Baseline NOx Emissions: 1,747.1 [tpy]

NOx Reduction from SNCR w/LNB: 55.00% *

NOx Reduction from SNCR w/LNB: 960.9 [tpy]

SNCR w/LNB Controlled NOx Emissions: 786.2 [tpy]

SNCR w/LNB Control Cost: $ 1,755 [$/ton]

Capital Costs

O&M Costs

* Source: from Monica Sowders 27 OCT 2010, with caveat that LNB 

may actually increase NOx emissions