U.S. Cement Manufacturers Evaluate Proposed $1.14 Billion Mercury NESHAP Ruling

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Researched by Industrial Info Resources (Sugar Land, Texas)--U.S. cement manufacturers are studying the ramifications of proposed National Emissions Standards for Hazardous Air Pollutants (NESHAP), specifically mercury, at plants manufacturing Portland cement. The ruling proposes to implement emission-reduction equipment additions and recordkeeping in order to reduce and monitor mercury emissions at cement plants. Proposed equipment additions depend on the type and size of the pyroprocessing system used at any given plant, along with consideration for the type of limestone and other raw materials heated in the pyroprocessing system.

Some of the emission-reduction equipment being evaluated includes broken bag detection systems for existing baghouses, wet scrubber additions, activated carbon injection system additions and regenerative thermal oxidizer additions. Increased monitoring through the installation of continuous emissions monitoring systems, along with testing and recordkeeping, will be important aspects of the rule's implementation, as well. By 2013, the proposed equipment additions are projected to reduce mercury emissions by 81%-93%. The proposed rules will also reduce particulate, hydrocarbon, hydrochloric acid and sulfur dioxide emissions.

The Environmental Protection Agency (EPA) states in the proposal that the ruling will affect 93 cement plants and 163 cement kilns in the U.S. The EPA estimates that the capital cost of the program will be about $1.14 billion. For 163 kiln lines, that averages out to about $7 million per kiln line.

However, this is based on 2005 numbers. Today, there are 112 operational cement manufacturing plants in the U.S. Several new plants have come online in the last four years, as well as a number of new lines that have begun operation.

The estimated emission control cost for a new 1.2 million-ton-per-year cement line is $17.6 million.

For more information, see April 29, 2009, news article - EPA Proposes Regulations on Mercury Emissions from Cement Plants.

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