United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S7-86/031 Dec. 1986
x°/EPA Project Summary
Lime and Cement Industry
Particulate Emissions: Source
Category Report Volume I.
Lime Industry
John S. Kinsey
The objective of this study was to de-
velop particulate emission factors
based on cutoff size for inhalable parti-
cles for the lime industry- After review
of available information characterizing
particulate emissions from lime plants,
the data were summarized and rated in
terms of reliability. Size specific emis-
sion factors were developed from these
data for the major processes used in the
manufacture of lime. A detailed process
description was presented with empha-
sis on factors affecting the generation
of emissions. A replacement for Section
8.15 (Lime Manufacturing) of EPA re-
port AP-42, A Compilation of Air Pollu-
tant Emissions Factors, was prepared,
containing the size specific emission
factors developed during this program.
This Project Summary was devel-
oped by EPA's Air and Energy Engineer-
ing Research Laboratory, Research Tri-
angle Park, NC, to announce key
findings of the research project'that is
fully documented in a separate report
of the same title (see Project Report or-
dering information at back).
Introduction
The purpose of this program was to
summarize the best available informa-
tion on emissions of inhalable particu-
late matter in the lime industry. The
main objective of the program was to
develop reliable size specific emission
factors for the various processes used in
the production of lime. Both uncon-
trolled and controlled emission factors
are presented in the report. The uncon-
trolled factors represent emissions
which would result if the particulate
control device (baghouse, scrubber,
etc.) were bypassed, and the controlled
factors represent emissions emanating
from a particular type of control system.
The size-specific emission factors are
generally based on the results of simul-
taneous sampling conducted at the inlet
and outlet of the control device(s), utiliz-
ing a variety of particle sizing tech-
niques. Other objectives of this pro-
gram were to present current
information on the lime industry as well
as prepare a replacement for Section
8.15 in EPA report AP-42, "A Compila-
tion of Air Pollutant Emissions Factors."
The above objectives were met by a
thorough literature search which in-
cluded:
• Data from inhalable particulate
characterization program,
• Fine Particle Emissions Inventory
System (FPEIS),
• AP-42 background file at EPA's Of-
fice of Air Quality Planning and
Standards (OAQPS),
• Midwest Research Institute files,
and
• Various industry sources (e.g.. Na-
tional Lime Association).
The emission data contained in 45 ref-
erence documents were reviewed, ana-
lyzed, summarized, and ranked accord-
ing to the criteria established by
OAQPS, as published in the EPA report,
"Technical Procedures for Developing
AP-42 Emission Factors and Preparing
AP-42 Sections," April 1980. After rank-
ing the data, emission factors were cal-
culated using the highest quality data
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TABLE 1. Emission Factors for Lime Manufacturing*
Emission Factor Rating: B
Particulateb Nitrogen oxides
Carbon monoxide
Source
kg/Mg
Ib/ton
kg/Mg
Ib/ton
kg/Mg
Ib/ton
Sulfur dioxide
kg/Mg
Ib/ton
Crushers, screens, conveyors, storage
piles, unpaved roads, etc. c c Neg Neg A/eg Neg A/eg A/eg
Rotary kilnsd
Uncontrolled6 180 350 1.4 2.8 1 2 f f
Large diameter cyclone 81 160 1.4 2.8 1 2 f f
Multiple cyclone 42 83 1.4 2.8 1 2 f f
Electrostatic precipitatorS 2.4 4.8 1.4 2.8 1 2 h h
Venturi scrubber 2.4 4.8 1.4 2.8 1 2 h h
Gravel bed filters 0.53' 7.7'' 1.4 2.8 1 2 h h
Multiclone and venturi scrubbers 0.44 0.87 1.4 2.8 1 2 h h
Baghouse 0.46* 0.8&i 1.4 2.8 1 2 h h
Cyclone and baghouse 0.055 0.11 1.4 2.8 1 2 h h
Vertical kilns
Uncontrolled 4 8 NA NA NA NA NA NA
Calcimatic kilns*
Uncontrolled 25 50 0.1 0.2 NA NA NA NA
Multiple cyclone 3 6 0.1 0.2 NA NA NA NA
Secondary dust collection1 NA NA 0.1 0.2 NA NA NA NA
Fluidized bed kilns m m NA NA NA NA NA NA
Product coolers
Uncontrolled
Hydrators (atmospheric)13
Wet scrubber
Crusher, screen, hammermill
Baghouse
Final screen
Baghouse
Uncontrolled truck loading
Limestone
Open truck
Closed truck
Lime - closed truck
20"
0.05
0.0005
0.0004
0.75
0.38
0.15'
40"
0.1
0.001
0.0008
1.5
0.76
0.30'
Neg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
A/eg
a Factors for kilns and coolers are per unit of lime produced. Divide by 2 to obtain factors per unit of limestone feed to the kiln. Factors for hydrators are per unit
of hydra ted lime produced. Multiply by 1.25 to obtain factors per unit of lime feed to the hydrator. Neg = negligible. NA = not available.
b Emission Factor Rating = D.
c Factors for these operations are presented in Sections 8.20 and 11.2 of AP-42.
d For coal fired rotary kilns only.
8 No paniculate control except for settling that may occur in stack breeching and chimney base.
' Sulfur dioxide may be estimated by a material balance using fuel sulfur content.
a Combination coal/gas-fired rotary kilns only.
h When scrubbers are used, <5% of the fuel sulfur will be emitted as S02 even with high sulfur coal. When other secondary collection devices are used, about 20%
of the fuel sulfur will be emitted as S02 with high sulfur fuels, and <10% with low sulfur fuels.
1 Emission Factor Rating = E.
i Emission Factor Rating = C.
k Calcimatic kilns generally have stone preheaters. Factors are for emissions after the kiln exhaust passes through a preheater.
1 Fabric filters and venturi scrubbers have been used on calcimatic kilns. No data are available on paniculate emissions after secondary control.
m Fluidized bed kilns must have sophisticated dust collection equipment for process economics, hence paniculate emissions will depend on efficiency of the control
equipment installed.
n Some or all cooler exhaust typically is used in kiln as combustion air. Emissions will result only from that fraction not recycled to kiln.
P Typical paniculate loading for atmospheric hydrators following water sprays or wet scrubbers. Limited data suggest paniculate emissions from pressure hydrators
may be approximately 1 kg/Mg (2 Ib/ton) of hydrate produced, after wet collectors.
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available. The quality of the data used to
develop each emission factor is indi-
cated by the emission factor rating.
Process control system operating
data as well as general industry infor-
mation were also obtained and summa-
rized as general background informa-
tion. It was not part of this program to
provide detailed engineering analyses,
product specifications, or detailed eval-
uations of trends in the industry.
Summary of Results
Participate emissions are generated
from various activities at a lime plant
including stone extraction, stone proc-
essing, calcination, pulverization, and
hydration. The kiln potentially repre-
sents the largest single contribution to
process-related particulate emissions in
a lime plant. Fugitive dust emissions
from open sources (i.e., unpaved roads)
are also a major contributor but are not
specifically treated in this report except
for emissions from product loading.
Some sort of particulate control is
generally applied to most kilns. Rudi-
mentary fallout chambers and cyclone
separators are commonly used for con-
trol of larger particles. Fabric and gravel
bed filters, wet (commonly venturi)
scrubbers, and electrostatic precipita-
tors are used for secondary control. Cy-
clones, fabric filters, and wet scrubbers
have been used on product coolers for
particulate control. Hydrator emissions
are low because water sprays or wet
scrubbers are usually installed to pre-
vent product loss in the exhaust gases.
Other particulate sources in lime plants
include primary and secondary crush-
ers, mills, screens, mechanical and
pneumatic transfer operations, storage
piles, and roads.
The total mass controlled and uncon-
trolled emission factors for lime manu-
facturing are presented in Table 1. The
size-specific controlled and uncon-
trolled emission factors for rotary lime
kilns are presented in Table 2. The size-
specific uncontrolled emission factors
for product loading are presented in
Table 3. Size-specific emission factors
for other lime manufacturing processes
are not included in the report due to in-
sufficient data.
Table 2. Summary of Size Specific Emission Factors for Rotary Lime Kilns8
Emission Factor Rating: D
Cumulative mass % = stated particle sizeb
Cumulative particulate emission factor S stated size0
Particle
size Uncontrolled
(\i.mA) rotary kiln
2.5
5.0
10.0
15.0
Total mass
Rotary
kiln with
multicloned
1.4 6. 1
2.9 9.8
12 16
31 23
emission factors
Rotary
kiln
with
ESP»
14
NA
50
62
Rotary kiln
with cyclone
and baghouse1
27
NA
55
73
Uncontrolled
rotary kilns
kg/Mg
2.6
5.2
21
56
180
Ib/ton
5.2
10
42
110
350
Rotary kiln
with
multicloned
kg/Mg
2.6
4.1
6.9
9.7
42
Ib/ton
5.2
8.2
14
19
83
Rotary kiln
with ESPe
kg/Mg
0.34
NA
1.2
1.5
2.4
Ib/ton
0.68
NA
2.4
3.0
4.8
Rotary kiln
with cyclone
and baghousef
kg/Mg
0.02
NA
0.03
0.04
0.055
Ib/ton
0.03
NA
0.06
0.08
0.11
"Coal-fired rotary kilns. Numbers rounded to two significant figures. ESP = electrostatic precipitator. NA = not available.
bAerodynamic diameter.
cUnit weight of particulate matter/unit weight of lime produced.
''Emission Factor Rating = E.
"For combination coal/natural gas fired rotary kilns.
'For rotary kiln with cyclone collector followed by baghouse.
gPM10 emission factor data is not available for baghouse, venturi scrubber, simple cyclone and other control technologies used for rotary
lime kilns.
Table 3. Uncontrolled Fugitive Particulate Emission Factors For Product Loading'
Total
particulateb
Type of loading operation
Pulverized limestone into open bed
trucks
Pulverized limestone into tank trucks
Glass lime into tank trucks
kg/Mg
0.75
0.38
0.15
Ib/ton
1.5
0.76
0.30
Inhalable
paniculate0
kg/Mg
0.51
0.29
0.062
Ib/ton
1.0
0.58
0.12
Fine
particulated
kg/Mg
0.13
0.043
0.0080
Ib/ton
0.26
0.086
0.016
Emission
factor rating
D
D
E
"Factors are for mass of pollutant/mass of product loaded. Numbers rounded to two significant figures.
bParticles <~300 \i.mA (aerodynamic diameter).
cParticles < 15 \t.mA (aerodynamic diameter).
dParticles <2.5 \i.mA (aerodynamic diameter).
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John S. Kinsey is with Midwest Research Institute, Kansas City. MO 64110.
Dale L. Harmon is the EPA Project Officer (see below).
The complete report, entitled "Lime and Cement Industry Paniculate Emissions:
Source Category Report—Volume I. Lime Industry," (Order No. PB 87-103
628/AS; Cost: $22.95, subject to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
/^'N %."'"' '~'tĄ?
4-
Official Business
Penalty for Private Use $300
EPA/600/S7-86/031
0000329 PS
'GENCT
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