Meeting NESHAP Rules Through Collaboration and Analysis

Summary

Recently a cement plant customer was able to celebrate a huge "win" as a result of a collaborative strategy with Neundorfer. Following implementation, emissions levels tested at 70% below the new limit, filling the customer with a new-found confidence in their operations and helping them meet new NESHAP rules.

"Neundorfer helped a cement plant to remain economically viable and emissions compliant � gaining huge emissions improvements through low-cost upgrades."

Emissions Compliance

Cement Kiln Operation

Full Story

A multinational cement producer was clamoring to meet the new NESHAP rules for one of its operations in the Northeast United States. Its largest predicament was to achieve a significant reduction in particulate emissions on a kiln operation. Even though the kiln was in compliance with current standards, its levels were significantly greater than the new limit. Future operations hinged on the company’s ability to meet and sustain the acceptable emissions level.

This wet process kiln relied on an electrostatic precipitator (ESP) as its primary pollution control device. A number of solutions were considered including replacing the ESP with a fabric filter or the addition of a field to the ESP. However, these solutions proved not to be viable choices as their implementation would be too costly. If a cost-effective solution was not found swiftly, the plant’s future would be in jeopardy.

With limited options and an ever-shrinking window of time, the owner turned to Neundorfer to design a solution that would be both economical and sustainable. In addition, Neundorfer’s solution would have to be implemented expeditiously as the plant had no lengthy shutdowns planned.

The first step of the Neundorfer process was to apply its analytical approach and leverage its in-house process modeling capabilities to create a set of feasible solution options to be evaluated with the customer. Potential improvements were evaluated based on outage time required, cost and potential emissions reduction, then put into a sequential plan. The objective of this approach was to be able to evaluate results and determine the justification of the next incremental improvement.

An opportunity presented itself in which a very short plant shut down could be used, first to implement a portion of Neundorfer’s solution and then to measure its effectiveness. This solution was focused on the precipitator fundamental of optimizing gas velocity. A scale model of the precipitator was constructed and tested, with a full-scale solution quickly derived from the results of the model testing. Neundorfer then established a budget and created a plan that could be efficiently executed during the shut down.

The solution was quickly implemented and tested. The outcome was outstanding: the emissions levels tested at 70% below the new limit! These exceptional developments gave the owner confidence in the long-term sustainability of this approach. However, the joy didn’t stop there. The results were so promising that no additional solution phases were necessary, saving the owner substantial time and money. Furthermore, the solution did not add any additional operating expense to the plant. Thanks to Neundorfer’s unique approach to problem solving, the plant will enjoy sustainable operations providing value to its community, its owner and the employees who can continue to work there.