Emission Factor Documentation for AP-42
Section 11.6
Portland Cement Manufacturing
Final Report
For U. S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Inventory Branch
EPA Contract 68-D2-0159
Work Assignment No. 1-01
MRI Project No. 4601-01
May 18, 1994
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Emission Factor Documentation for AP-42
Section 11.6
Portland Cement Manufacturing
Final Report
For U. S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Inventory Branch
Research Triangle Park, NC 27711
Attn: Mr. Ron Myers (MD-14)
Emission Factor and Methodology
EPA Contract 68-D2-0159
Work Assignment No. 1-01
MRI Project No. 4601-01
May 18, 1994
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PREFACE
This report was prepared by Midwest Research Institute (MRI) for the Office of Air Quality
Planning and Standards (OAQPS), U. S. Environmental Protection Agency (EPA), under Contract
No. 68-D2-0159, Work Assignment No. 1-01. Mr. Ron Myers was the requester of the work. The
report was prepared by Richard Marinshaw and Dennis Wallace.
Approved for:
MIDWEST RESEARCH INSTITUTE
Roy Neulicht
Program Manager
Environmental Engineering
Department
Jeff Shular
Director, Environmental Engineering
Department
May 18, 1994
111
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iv
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CONTENTS
Page
LIST 01 FIGURES \i
LIST OF TABLES vi
1.0 INTRODUCTION 1
2.0 INDUSTRY DESCRIPTION 2
2.1 CHARACTERIZATION OF THE INDUSTRY 2
2.2 PROCESS DESCRIPTION 2
2.3 EMISSIONS 9
2.4 CONTROL TECHNOLOGY 10
3.0 GENERAL DATA REVIEW AND ANALYSIS 13
3.1 LITERATURE SEARCH AND SCREENING 13
3.2 EMISSION DATA QUALITY RATING SYSTEM 14
3.3 EMISSION FACTOR QUALITY RATING SYSTEM 15
4.0 AP-42 SECTION DEVELOPMENT 16
4.1 REVISIONS TO SECTION NARRATIVE 16
4.2 POLLUTANT EMISSION FACTOR DEVELOPMENT 16
4.2.1 Review of Specific Data Sets 46
4.2.2 Estimate of Theoretical C02 Emission Factors for
Portland Cement Kilns 74
4.2.3 Review of XATEF and SPECIATE Data Base Emission Factors 76
4.2.4 Review of Background File 75
4.2.5 Results of Data Analysis 75
4.2.6 Analysis of the Uncertainty in Kiln Emission Factors
for Portland Cement Kilns 96
5.0 AP-42 SECTION 11.6 110
APPENDIX A DERIVATION OF CRITERIA POLLUTANT EMISSION
FACTORS FOR PORTLAND CEMENT KILNS
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LIST OF FIGURES
Number Page
2-1 Process flow diagram for portland cement manufacturing 5
4-1 Boxplot of NOx emission factors for portland cement kilns 97
4-2 Boxplot of S02 emission factors for portland cement kilns 98
4-3 Boxplot of uncontrolled PM emission factors for portland
cement kilns 99
4-4 Boxplot of controlled PM emission factors for portland
cement kilns 100
LIST OF TABLES
Number Page
2-1 SUMMARY OF PORTLAND CEMENT PLANT CAPACITY INFORMATION ... 3
4-1 SUMMARY OF EMISSION TEST REPORTS AND SUMMARIES USED 17
4-2 SUMMARY OF TEST DATA FOR PORTLAND CEMENT WET PROCESS KILNS 22
4-3 SUMMARY OF TEST DATA FOR PORTLAND CEMENT LONG DRY
PROCESS KILNS 29
4-4 SUMMARY OF TEST DATA FOR PORTLAND CEMENT DRY PREHEATER
PROCESS KILNS 32
4-5 SUMMARY OF TEST DATA FOR PORTLAND CEMENT DRY PREHEATER/
PRECALCINER KILNS 34
4-6 SUMMARY OF TEST DATA FOR PORTLAND CEMENT CLINKER COOLERS . 41
4-7 SUMMARY OF TEST DATA FOR PORTLAND CEMENT OTHER PROCESSES . 43
4-8 SUMMARY OF AVERAGE PARTICLE SIZE DISTRIBUTION FOR
PORTLAND CEMENT KILNS 47
4-9 SUMMARY OF AVERAGE PARTICLE SIZE DISTRIBUTION FOR
PORTLAND CEMENT CLINKER COOLERS 47
4-10 ESTIMATED C02 EMISSION FACTORS FOR PORTLAND CEMENT KILNS ... 76
vi
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LIST OF TABLES (Continued)
Number Page
4-11 SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR
WET PROCESS KILNS 77
4-12 SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR
LONG DRY PROCESS KILNS 78
4-13 SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR
PREHEATER PROCESS KILNS 79
4-14 SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR
PREHEATER/PRECALCINER KILNS 80
4-15 SUMMARY OF NONCRITERIA POLLUTANT EMISSION FACTORS FOR
PORTLAND CEMENT KILNS 81
4-16 SUMMARY OF AVERAGE EMISSION FACTORS FOR CLINKER COOLERS ... 84
4-17 SUMMARY OF AVERAGE EMISSION FACTORS FOR OTHER PROCESSES ... 85
4-18 SUMMARY OF EMISSION FACTOR ESTIMATES 102
4-19 SUMMARY OF EMISSION FACTOR VARIABILITY 103
viii
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EMISSION FACTOR DOCUMENTATION FOR AP-42 SECTION 11.6
Portland Cement Manufacturing
1.0 INTRODUCTION
The document "Compilation of Air Pollutant Emissions Factors" (AP-42) has been published by
the U. S. Environmental Protection Agency (EPA) since 1972. Supplements to AP-42 have been
routinely published to add new emission source categories and to update existing emission factors. AP-42
is routinely updated by EPA to respond to new emission factor needs of EPA, State and local air pollution
control programs, and industry.
An emission factor relates the quantity (weight) of pollutants emitted to a unit of activity of the
source. The uses for the emission factors reported in AP-42 include:
1. Estimates of areawide emissions;
2. Estimates of emissions for a specific facility; and
3. Evaluation of emissions relative to ambient air quality.
The purpose of this report is to provide background information from test reports and other
information to support the revision of AP-42 Section 11.6, Portland Cement Manufacturing.
This background report consists of five sections. Section 1 includes the introduction to the
report. Section 2 gives a description of the portland cement industry. It includes a characterization of the
industry, an overview of the different process types, a description of emissions, and a description of the
technology used to control emissions resulting from portland cement production. Section 3 is a review of
emission data collection and analysis procedures. It describes the literature search, the screening of
emission data reports, and the quality rating system for both emission data and emission factors. Section 4
details revisions to the previous AP-42 section narrative and pollutant emission factor development. It
includes the review of specific data sets and the results of data analysis. Section 5 presents AP-42
Section 11.6.
1
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2.0 INDUSTRY DESCRIPTION12
Portland cement is a fine powder, gray or white in color, that consists of a mixture of hydraulic
cement materials comprising primarily calcium silicates. More than 30 raw materials are known to be
used in the manufacture of portland cement, and these materials can be divided into four distinct
categories: calcareous, siliceous, argillaceous, and ferrifrous. These materials are chemically combined
via pyroprocessing and subjected to subsequent mechanical processing operations to form gray and white
Portland cement. Gray portland cement is used for structural applications and is the more common type
of cement produced. White portland cement has lower iron and manganese contents than gray portland
cement and is used primarily for decorative purposes. Portland cement manufacturing plants are included
under Standard Industrial Code (SIC) Code 3241, hydraulic cement manufacturing, which also includes
natural, masonry, and pozzolanic cement. The six-digit Source Classification Code (SCC) for portland
cement plants with wet process kilns is 3-05-006, and the six-digit SCC for plants with dry process kilns is
3-05-007.
2.1 CHARACTERIZATION OF THE INDUSTRY1 4
As of December 1990, there were 112 operating portland cement plants in the United States, with
109 of these plants producing gray cement and the other 3 producing white cement. These 112 plants
operated 213 kilns with a total annual clinker capacity of 73.7 x 106 Mg (81 x 106 tons). The kiln
population included 80 wet process kilns and 133 dry process kilns. Both the number of facilities and the
industry capacity declined in 1990; two plants with a total annual clinker capacity of 492 x 103 megagrams
(Mg) (541 x 103 tons) were retired during the year. This decline continues a trend in the industry, which
has shown a reduction in clinker capacity in 8 of the last 11 years. The other major trend in the industry is
the increased use of waste fuels. In 1989, 33 plants in the United States and Canada reported using
waste fuels; the number increased to 55 plants in 1990.
The portland cement manufacturing industry is dispersed geographically throughout the
United States, with 36 States having at least one plant. Table 2-1 shows the total number of operating
plants and kilns and the total clinker capacity for each State and EPA Region.
2.2 PROCESS DESCRIPTION16
Portland cement, which consists of a mixture of the hydraulic cement minerals, calcium silicates,
aluminates and aluminoferrites, and calcium sulfates, accounts for 95 percent of the hydraulic cement
production in the United States. The balance of domestic cement production comprises primarily masonry
cement. Both of these materials are produced in portland cement manufacturing plants. A diagram of
the process, which encompasses production of both portland and masonry cement, is shown in Figure 2-1.
As shown in the figure, the process can be divided into the following primary components: raw materials
acquisition and handling, kiln feed preparation, pyroprocessing, and finished cement grinding. Each of
these process components is described briefly below. The focus of the discussion is on pyroprocessing
operations, which constitute the core of a portland cement plant.
The initial production step in portland cement manufacturing is raw materials acquisition. More
than 30 raw materials are known to be used to manufacture portland cement. Calcium, the element of
highest concentration in portland cement, is obtained from a variety of calcareous raw materials, including
limestone, chalk, marl, sea shells, aragonite, and an impure limestone known as "natural cement rock".
2
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TABLE 2-1. SUMMARY OF PORTLAND CEMENT PLANT CA
PACITY INFORMATION3
Number of plants, kilns
Capacity, 103 Mg/yr
Location
(103 tons/yr)
Region I
1(1)
414 (455)
Connecticut
0
0(0)
Maine
1(1)
414 (455)
Massachusetts
0
0(0)
New Hampshire
0
0(0)
Rhode Island
0
0(0)
Vermont
0
0(0)
Region II
4(5)
2,815 (3,097)
New Jersey
0
0(0)
New York
4(5)
2,815 (3,097)
Puerto Rico
NA
NA
Virgin Islands
NA
NA
Region III
16 (39)
9,492 (10,442)
Delaware
0
0(0)
District of Columbia
0
0(0)
Maryland
3(7)
1,691 (1,860)
Pennsylvania
11 (24)
6,039 (6,643)
Virginia
1(5)
1,015 (1,117)
West Virginia
1(3)
747 (822)
Region IV
12,599 (13,858)
Alabama
5(6)
3,873 (4,260)
Florida
6(8)
3,057 (3,363)
Georgia
2(4)
1,253 (1,378)
Kentucky
1(1)
658 (724)
Mississippi
1(1)
458 (504)
North Carolina
0
0(0)
South Carolina
3(7)
2,345 (2,579)
Tennessee
2(3)
955 (1,050)
Region V
17 (30)
10,924 (12,016)
Illinois
4(8)
2,350 (2,585)
Indiana
4(8)
2,573 (2,830)
Michigan
5(9)
4,453 (4,898)
Minnesota
0
0(0)
Ohio
4(5)
1,548 (1,703)
Wisconsin
0
0(0)
Region VI
18 (34)
11,165 (12,282)
Arkansas
2(5)
1,195 (1,314)
Louisiana
0
0(0)
New Mexico
1(2)
449 (494)
Oklahoma
3(7)
1,715 (1,887)
Texas
12 (20)
7,806 (8,587)
3
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TABL
E2-1. (continued)
Number of plants, kilns
Capacity, 103 Mg/yr
Location
(103 tons/yr)
Region VII
14 (27)
9,393 (10,332)
Iowa
4(7)
2,551 (2,806)
Kansas
4(11)
1,716 (1,888)
Missouri
5(7)
4,252 (4,677)
Nebraska
1(2)
874 (961)
Region VIII
9(14)
4,137 (4,551)
Colorado
3(5)
1,640 (1,804)
Montana
2(2)
538 (592)
North Dakota
0
0(0)
South Dakota
1(3)
696 (766)
Utah
2(3)
844 (928)
Wyoming
1(1)
419 (461)
Region IX
16 (30)
11,672 (12,840)
Arizona
2(7)
1,609 (1,770)
California
12 (20)
9,447 (10,392)
Hawaii
1(1)
239 (263)
Nevada
1(2)
377 (415)
American Samoa
NA
Virgin Islands
NA
Region X
4(4)
1,057 (1,163)
Alaska
l(0)b
0(0)
Idaho
1(2)
191 (210)
Oregon
1(1)
436 (480)
Washington
1(1)
430 (473)
NA = Data not available.
aReference 2.
bGrinding plant only.
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Figure 2-1. Process Flow Diagram for Portland Cement Manucturing.
(SCC = Source Classification Code)
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Typically, these raw materials are obtained from open-face quarries, but underground mines or dredging
operations are also used. Raw materials vary from facility to facility. The materials found in some
quarries that supply raw materials for portland cement have a high degree of calcinated limestone,
whereas the material from other limestone quarries must be blended with "cleaner" limestone to produce
an acceptable product. In addition, pockets of pyrite, which significantly increase emissions of sulfur
dioxide (S02), can be found in deposits of limestone, clays, and shales used as raw materials for portland
cement. Because a large fraction (approximately one third) of the mass of this primary material is
converted to carbon dioxide (C02) in the kiln, portland cement plants are located in close proximity to a
raw material source whenever possible. Other metallic elements included in the raw feed mix are silicon,
aluminum, and iron. These materials are obtained from ores and minerals such as sand, shale, clay, and
iron ore. Again, these materials are most commonly extracted via open-pit quarries or mines, but they
may be dredged or excavated from underwater deposits.
Either gypsum or natural anhydrite, both of which are forms of calcium sulfate, is introduced to
the process during the finish grinding operations described below. These materials are also excavated
from quarries or mines. However, they are generally purchased from an external source, rather than
obtained directly from a captive operation by the cement plant. In addition, the portland cement
manufacturing industry is relying increasingly on replacing virgin materials as described above with waste
materials or byproducts from other manufacturing operations, to the extent that such replacement can be
implemented without adversely affecting plant operations or product quality. Materials that have been
used include fly ash, mill scale, and metal smelting slags.
The second step in portland cement manufacture is preparing the raw mix or kiln feed for the
pyroprocessing operation. Raw material preparation includes a variety of blending and sizing operations
that are designed to provide a feed with appropriate chemical and physical properties. The raw material
processing operations differ somewhat for wet and dry processes, as described in the paragraphs below.
Cement raw materials are received with an initial moisture content varying from 1 to more than
50 percent. If the facility uses dry process kilns, this moisture is usually reduced to less than 1 percent
before or during grinding. Drying alone can be accomplished in impact dryers, drum dryers, paddle-
equipped rapid dryers, air separators, or autogenous mills. However, drying can also be accomplished
during grinding in ball-and-tube mills or roller mills. While thermal energy for drying can be supplied by
exhaust gases from separate, direct-fired coal, oil, or gas burners, the most efficient and widely used
source of heat for drying is the hot exit gases from the pyroprocessing system.
Materials transport associated with raw milling systems can be accomplished by a variety of
mechanisms, including screw conveyors, belt conveyors, drag conveyors, bucket elevators, air slide
conveyors, and pneumatic conveying systems. The dry raw mix is pneumatically blended and stored in
specially constructed silos until it is fed to the pyroprocessing system.
In the wet process, water is added to the raw mill during the grinding of the raw materials in ball
or tube mills, thereby producing a pumpable slip or slurry of approximately 65 percent solids. The slurry is
agitated, blended, and stored in various kinds and sizes of cylindrical tanks or slurry basins until it is fed to
the pyroprocessing system.
The heart of the portland cement manufacturing process is the pyroprocessing system. This
system transforms the raw mix into clinkers, which are gray, glass-hard, spherically shaped nodules that
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range from 0.32 to 5.1 centimeters (cm) (0.125 to 2.0 inches [in.]) in diameter. The chemical reactions
and physical processes that constitute the transformation are quite complex, but they can be viewed
conceptually as the following sequential events:
1. Evaporation of free water;
2. Evolution of combined water in the argillaceous components;
3. Calcination of the calcium carbonate (CaC03) to calcium oxide (CaO);
4. Reaction of CaO with silica to form dicalcium silicate;
5. Reaction of CaO with the aluminum and iron-bearing constituents to form the liquid phase;
6. Formation of the clinker nodules;
7. Evaporation of volatile constituents (e.g., sodium, potassium, chlorides, and sulfates); and
8. Reaction of excess CaO with dicalcium silicate to form tricalcium silicate.
This sequence of events may be conveniently divided into four stages, as a function of location
and temperature of the materials in the rotary kiln.
1. Evaporation of uncombined water from raw materials as material temperature increases to
100°C (212°F);
2. Dehydration as the material temperature increases from 100°C to approximately 430 °C
(800 °F) to form oxides of silicon, aluminum, and iron;
3. Calcination, during which carbon dioxide (C02) is evolved, between 900°C (1650°F) and
982 °C (1800°F), to form CaO; and
4. Reaction of the oxides in the burning zone of the rotary kiln to form cement clinker at
temperatures of approximately 1510°C (2750°F).
Rotary kilns are long, cylindrical, slightly inclined furnaces that are lined with refractory to protect
the steel shell and retain heat within the kiln. The raw material mix enters the kiln at the elevated end,
and the combustion fuels generally are introduced into the lower end of the kiln in a countercurrent
manner. The materials are continuously and slowly moved to the lower end by rotation of the kiln. As
they move down the kiln, the raw materials are changed to cementitious metal oxides by the direct heat
exchange. The most commonly used kiln fuels are coal, natural gas, and occasionally oil. Many cement
plants currently burn coal, but use of supplemental fuels such as waste solvents, scrap rubber, and
petroleum coke has expanded in recent years.
Five different processes are used in the portland cement industry to accomplish the
pyroprocessing step: the wet process, the dry process (long dry process), the semidry process, the dry
process with a preheater, and the dry process with a preheater/precalciner. Each of these processes
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accomplishes the physical/chemical steps defined above. However, the processes vary with respect to
equipment design, method of operation, and fuel consumption. Generally, fuel consumption decreases in
the order of the processes listed above. The paragraphs below briefly describe the process, starting with
the wet process and then noting differences in the other processes.
In the wet process and long dry process, all of the pyroprocessing activity occurs in the rotary
kiln. Depending on the process type, kilns have length-to-diameter ratios in the range of 15:1 to 40:1.
While some wet process kilns may be as long as 210 m (700 ft), many wet process kilns and all dry
process kilns are shorter. Wet process and long dry process pyroprocessing systems consist solely of the
simple rotary kiln. Usually, a system of chains is provided at the feed end of the kiln in the drying or
preheat zones to improve heat transfer from the hot gases to the solid materials. As the kiln rotates, the
chains are raised and exposed to the hot gases. Further kiln rotation causes the hot chains to fall into the
cooler materials at the bottom of the kiln, thereby transferring the heat to the load.
Dry process pyroprocessing systems have been improved in thermal efficiency and productive
capacity through the addition of one or more cyclone-type preheater vessels in the gas stream after the
rotary kiln. This system is called the preheater process. The vessels are arranged vertically, in series,
and are supported by a structure known as the preheater tower. Hot exhaust gases from the rotary kiln
pass countercurrently through the downward-moving raw materials in the preheater vessels. Compared
with the simple rotary kiln, the heat transfer rate is significantly increased, the degree of heat utilization is
more complete, and the process time is markedly reduced owing to the intimate contact of the solid
particles with the hot gases. The improved heat transfer allows the length of the rotary kiln to be
reduced. The hot gases from the preheater tower are often used as a source of heat for drying raw
materials in the raw mill. Because the catch from the mechanical collectors, fabric filters, and/or
electrostatic precipitators (ESP's) that follow the raw mill is returned to the process, these devices are
considered to be production machines as well as pollution control devices.
Additional thermal efficiencies and productivity gains have been achieved by diverting some fuel
to a calciner vessel at the base of the preheater tower. This system is called the preheater/precalciner
process. While a substantial amount of fuel is used in the precalciner, at least 40 percent of the thermal
energy is required in the rotary kiln. The amount of fuel that is introduced to the calciner is determined by
the availability and source of the oxygen for combustion in the calciner. Calciner systems sometimes use
lower-quality fuels (e.g., less-volatile matter) as a means of improving process economics.
Preheater and precalciner kiln systems often have a bypass system between the feed end of the
rotary kiln and the preheater tower to remove the undesirable volatile constituents. Otherwise, the volatile
constituents condense in the preheater tower and subsequently recirculate to the kiln. Buildup of these
condensed materials can restrict process and gas flows. In a bypass system, a portion of the kiln exit gas
stream is withdrawn and quickly cooled by air or water to condense the volatile constituents to fine
particles. The solid particles, which are removed from the gas stream by fabric filters and ESP's, are then
returned to the process.
The semidry process is a variation of the dry process. In the semidry process, the water is added
to the dry raw mix in a pelletizer to form moist nodules or pellets. The pellets then are conveyed on a
moving grate preheater before being fed to the rotary kiln. The pellets are dried and partially calcined on
the moving grate through which hot kiln exhaust gases pass.
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Regardless of the type of pyroprocess used, the last component of the pyroprocessing system is
the clinker cooler. This process step recoups up to 30 percent of the heat input to the kiln system, locks in
desirable product qualities by freezing mineralogy, and makes it possible to handle the cooled clinker with
conventional conveying equipment. The more common types of clinker coolers are (1) reciprocating
grate, (2) planetary, and (3) rotary. In these coolers, the clinker is cooled from about 1100° C to 93° C
(2000 °F to 200 °F) by ambient air that passes through the clinker and into the rotary kiln for use as
combustion air. However, in the reciprocating grate cooler, lower clinker discharge temperatures are
achieved by passing an additional quantity of air through the clinker. Because this additional air cannot be
utilized in the kiln for efficient combustion, it is vented to the atmosphere, used for drying coal or raw
materials, or used as a combustion air source for the precalciner.
The final step in portland cement manufacturing involves a sequence of blending and grinding
operations that transforms clinker to finished portland cement. Up to 5 percent gypsum or natural
anhydrite is added to the clinker during grinding to control the cement setting time, and other specialty
chemicals are added as needed to impart specific product properties. This finish milling is accomplished
almost exclusively in ball or tube mills. Typically, finishing is conducted in a closed- circuit system with
product sizing via air separation.
2.3 EMISSIONS1 •2-4"8
Particulate matter (PM and PM-10), nitrogen oxides (NOx). S02, carbon monoxide (CO), and
C02 are the primary emissions in the manufacture of portland cement. Small quantities of volatile organic
compounds (VOC), ammonia (NH3), chlorine, and hydrogen chloride (HC1), also may be emitted.
Emissions may also include residual materials from the fuel and raw materials or products of incomplete
combustion that are considered to be hazardous. Because some facilities burn waste fuels, particularly
spent solvents in the kiln and these systems also may emit small quantities of additional hazardous organic
pollutants. Also, raw material feeds and fuels typically contain trace amounts of heavy metals that may
be emitted as a particulate or a vapor.
Sources of PM at cement plants include (1) quarrying and crushing, (2) raw material storage, (3)
grinding and blending (in the dry process only), (4) clinker production, (5) finish grinding, and
(6) packaging and loading. The largest emission source of PM within cement plants is the pyroprocessing
system that includes the kiln and clinker cooler exhaust stacks. Emissions from kilns are affected by
several factors, including differences in convective patterns, material movement patterns, burner locations
and insertion lengths, heat transfer mechanisms, and the type of clinker cooler that supplies secondary air
to the kiln for combustion. In addition, operators can vary the degree of calcination that takes place
within a preheater or precalciner. Often, dust from the kiln is collected and recycled into the kiln thereby
producing clinker from the dust. However, if the alkali content of the raw materials is too high, some or
all of the dust is discarded or leached before returning it to the kiln. In many instances, the maximum
allowable cement alkali content of 0.6 percent (calculated as sodium oxide) restricts the amount of dust
that can be recycled. Bypass systems sometimes have a separate exhaust stack. Additional sources of
PM are raw material storage piles, conveyors, storage silos, and unloading facilities.
Oxides of nitrogen are generated during fuel combustion by oxidation of chemically bound
nitrogen in the fuel and by thermal fixation of nitrogen in the combustion air. As flame temperature
increases, the amount of thermally generated NOx increases, and the amount of NOx generated from fuel
increases with the quantity of nitrogen in the fuel. In the cement manufacturing process, NOx is
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generated in the burning zone of the kiln and the burning zone of a precalcining vessel. Fuel use affects
the quantity and type of NOx generated. For example, natural gas combustion with a high flame
temperature and low fuel nitrogen generates a larger quantity of NOx than does oil or coal, which have
higher fuel nitrogen but burn with lower flame temperatures. Types of fuels used vary across the
industry. Historically, some combination of coal, oil, and natural gas was used, but over the last 15 years,
most plants switched to coal, which generates less NOx than does oil or gas. However, in recent years a
number of plants have switched to systems that burn a combination of coal and waste fuel. The effect of
waste fuel use on NOx emissions is not clearly established.
Sulfur dioxide may be generated both from the sulfur compounds in the raw materials and from
sulfur in the fuel. The sulfur content of both raw materials and fuels varies from plant to plant and with
geographic location. However, the alkaline nature of the cement provides for direct absorption of S02
into the product, thereby mitigating the quantity of S02 emissions in the exhaust stream.
The C02 emissions from portland cement manufacturing are generated by two mechanisms. As
with most high-temperature, energy-intensive industrial processes, combustion of fuels to generate
process energy releases substantial quantities of C02. Substantial quantities of C02 also are generated
through calcining of limestone or other calcareous material. This calcining process thermally decomposes
CaC03 to CaO and C02. Typically, portland cement contains the equivalent of about 63.5 percent CaO.
Consequently about 1.135 units of CaC03 are required to produce 1 unit of cement, and the amount of
C02 released in the calcining process is about 500 kilograms (kg) per Mg of portland cement produced
(1,000 pounds [lb] per ton of cement).
In addition to C02 emissions, fuel combustion at portland cement plants can emit a wide range of
pollutants in smaller quantities. If the combustion reactions do not reach completion, CO and volatile
organic pollutants, which are typically measured as total organic compounds (TOC), VOC, or condensible
organic particulate, can be emitted. Incomplete combustion also can lead to emissions of specific
hazardous organic air pollutants, although these pollutants are generally emitted at substantially lower
levels than CO or TOC.
Emissions of metal compounds from portland cement kilns can be grouped into three general
classes: volatile metals, including mercury (Hg) and thallium (H); semivolatile metals, including antimony
(Sb), cadmium (Cd), lead (Pb), selenium (Se), zinc (Zn), potassium (K), and sodium (Na); and refractory
or nonvolatile metals, including barium (Ba), chromium (Cr), arsenic (As), nickel (Ni), vanadium (V),
manganese (Mn), copper (Cu), and silver (Ag). Although the partitioning of these metal groups is
affected by kiln operating conditions, the refractory metals tend to concentrate in the clinker, while the
volatile and semivolatile metals tend to be discharged via the primary exhaust stack and the by-pass stack,
respectively.
2.4 CONTROL TECHNOLOGY13
Fugitive dust sources in the industry include quarrying and mining operations, vehicular traffic
during mineral extraction and at the manufacturing site, raw materials storage piles, and clinker storage
piles. The measures used to control emissions from these fugitive dust sources are comparable to those
used throughout the mineral products industries. Vehicular traffic controls include paving and road
wetting. Controls that are applied to other open dust sources include water sprays with and without
surfactants, chemical dust suppressants, wind screens, and process modifications to reduce drop heights
10
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or enclose storage operations. Additional information on these control measures can be found in Chapter
11 of AP-42.
Process fugitive emission sources include materials handling and transfer, raw milling operations
in dry process facilities, and finish milling operations. Typically, emissions from these processes are
captured by a ventilation system and collected in fabric filters. Some facilities use an air pollution control
system comprising one or more mechanical collectors with a fabric filter in series. Because the dust from
these units is returned to the process, they are considered to be process units as well as air pollution
control devices. The industry uses shaker, reverse air, and pulse jet filters as well as some cartridge units,
but most newer facilities use pulse jet filters. For process fugitive operations, the different systems are
reported to achieve typical outlet PM loadings of 45 milligrams per cubic meter (mg/m3) (0.02 grains per
actual cubic foot [gr/acf]).
In the pyroprocessing units, PM emissions are controlled by fabric filters (reverse air, pulse jet, or
pulse plenum) and ESP's. Typical control measures for the kiln exhaust are reverse air fabric filters with
an air-to-cloth ratio of 0.41:1 meter per minute (m/min) (1.5:1 acfm/ft2) and ESP's with a net SCA of
1,140 to 1,620 square meters per thousand m3 (m2/l,000 m?) (350 to 500 square feet per thousand ft3
[ft2/l,000 ft3]). These systems are reported to achieve outlet PM loadings of 45 mg/m3 (0.02 gr/acf).
Clinker cooler systems are controlled most frequently with pulse jet or pulse plenum fabric filters. A few
gravel bed filters also have been used to control clinker cooler emissions. Typical outlet PM loadings are
identical to those reported for kilns.
Cement kiln systems have highly alkaline internal environments that can absorb up to 95 percent
of potential S02 emissions. However, in systems that have sulfide sulfur (pyrites) in the kiln feed, the
sulfur absorption rate may be as low as 50 percent without unique design considerations or changes in
raw materials. The cement kiln system itself has been determined to provide substantial S02 control.
Fabric filters on cement kilns are also reported to absorb S02. Generally, substantial control is not
achieved. An absorbing reagent (e.g., CaO) must be present in the filter cake for S02 capture to occur.
Without the presence of water, which is undesirable in the operation of a fabric filter, CaC03 is not an
absorbing reagent. It has been observed that as much as 50 percent of the S02 can be removed from the
pyroprocessing system exhaust gases when this gas stream is used in a raw mill for heat recovery and
drying. In this case, moisture and calcium carbonate are simultaneously present for sufficient time to
accomplish the chemical reaction with S02.
REFERENCES FOR SECTION 2
1. W. L. Greer, et al., "Portland Cement", Air Pollution Engineering Manual, A. J. Buonicore and
W. T. Davis (eds.), Von Nostrand Reinhold, New York 1992.
2. Written communication from Walter Greer, Ash Grove Cement Company, Overland Park,
Kansas, to R. Myers, U. S. Environmental Protection Agency, Research Triangle Park, NC,
September 30, 1993.
3. U. S. and Canadian Portland Cement Industry Plant Information Summary, December 31,
1990, Portland Cement Association, Washington, DC, August 1991.
11
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4. "Chapter 11.6, Portland Cement Manufacturing, Compilation of Air Pollutant Emission
Factors, AP-42, U. S. Environmental Protection Agency, Research Triangle Park, NC,
September 1991.
5. Written communication from John Wheeler, Capitol Cement, San Antonio, Texas, to R. Myers, U.
S. Environmental Protection Agency, Research Triangle Park, NC, September 21, 1993.
6. Written communication from F. L. Streitman, ESSROC Materials, Incorporated, Nazareth,
Pennsylvania, to R. Myers, U. S. Environmental Protection Agency, Research Triangle Park, NC,
September 29, 1993.
7. Written communication from Robert W. Crolius, Portland Cement Association, to Ron Myers, U.
S. Environmental Protection Agency, Research Triangle Park, NC. March 11, 1992.
8. Dellinger, H.B., D.W. Pershing, and A.F. Sarofim. Evaluation of the Origin, Emissions and
Control of Organic and Metal Compounds from Cement Kilns Fired with Hazardous
Wastes. Science Advisory Board on Cement Kiln Recycling. June 1993.
12
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3.0 GENERAL DATA REVIEW AND ANALYSIS
3.1 LITERATURE SEARCH AND SCREENING
Data for this investigation were obtained from a number of sources within the Office of Air
Quality Planning and Standards (OAQPS) and from outside organizations. The AP-42 Background Files
located in the Emission Inventory Branch (EIB) were reviewed for information on the industry, processes,
and emissions. The Crosswalk/Air Toxic Emission Factor Data Base Management System (XATEF) and
VOC/PM Speciation Data Base Management System (SPECIATE) data bases were searched by SCC
code to identify potential pollutants emitted and emission factors for those pollutants. A general search of
the Air CHIEF CD-ROM also was conducted to supplement the information from these two data bases.
Information on the industry, including number of plants, plant location, and annual production capacities
was obtained from industry reports recently prepared by the Portland Cement Association (PCA).
A number of sources of information were investigated specifically for emission test reports and
data. A search of the Test Method Storage and Retrieval (TSAR) data base was conducted to identify
test reports for sources within the portland cement industry. Copies of these test reports were obtained
from the files of the Emission Measurement Branch (EMB). The EPA library was searched for
additional test reports. A list of plants that have been tested within the past 5 years was compiled from
the AIRS data base. Using this information, State and Regional offices were contacted about the
availability of test reports. However, the information obtained from these offices was limited.
Publications lists from the Office of Research and Development (ORD) and Control Technology Center
(CTC) were also searched for reports on emissions from the portland cement industry. In addition, the
PCA was contacted for assistance in obtaining information about the industry and emissions, and
information supplied by PCA for the 1989 AP-42 revision was received.
To screen out unusable test reports, documents, and information from which emission factors
could not be developed, the following general criteria were used:
1. Emission data must be from a primary reference:
a. Source testing must be from a referenced study that does not reiterate information from
previous studies.
b. The document must constitute the original source of test data. For example, a technical
paper was not included if the original study was contained in the previous document. If
the exact source of the data could not be determined, the document was eliminated.
2. The referenced study must contain test results based on more than one test run.
3. The report must contain sufficient data to evaluate the testing procedures and source
operating conditions (e.g., one-page reports were generally rejected).
A final set of reference materials was compiled after a thorough review of the pertinent reports,
documents, and information according to these criteria.
13
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3.2 EMISSION DATA QUALITY RATING SYSTEM
As part of the analysis of the emission data, the quantity and quality of the information contained
in the final set of reference documents were evaluated. The following data were excluded from
consideration:
1. Test series averages reported in units that cannot be converted to the selected reporting units;
2. Test series representing incompatible test methods (i.e., comparison of EPA Method 5 front
half with EPA Method 5 front and back halves);
3. Test series of controlled emissions for which the control device is not specified;
4. Test series in which the source process is not clearly identified and described; and
5. Test series in which it is not clear whether the emissions were measured before or after the
control device.
Test data sets that were not excluded were assigned a quality rating. The rating system used
was that specified by EIB for preparing AP-42 sections. The data were rated as follows:
A~Multiple tests that were performed on the same source using sound methodology and reported
in enough detail for adequate validation. These tests do not necessarily conform to the methodology
specified in EPA reference test methods, although these methods were used as a guide for the
methodology actually used.
B~Tests that were performed by a generally sound methodology, but lack enough detail for
adequate validation.
C~Tests that were based on an untested or new methodology or that lacked a significant amount
of background data.
D~Tests that were based on a generally unacceptable method but may provide an order-of-
magnitude value for the source.
The following criteria were used to evaluate source test reports for sound methodology and
adequate detail:
1. Source operation. The manner in which the source was operated is well documented in the
report. The source was operating within typical parameters during the test.
2. Sampling procedures. The sampling procedures conformed to a generally acceptable
methodology. If actual procedures deviated from accepted methods, the deviations are well documented.
When this occurred, an evaluation was made of the extent to which such alternative procedures could
influence the test results.
14
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3. Sampling and process data. Adequate sampling and process data are documented in the
report, and any variations in the sampling and process operation are noted. If a large spread between test
results cannot be explained by information contained in the test report, the data are suspect and are given
a lower rating.
4. Analysis and calculations. The test reports contain original raw data sheets. The
nomenclature and equations used were compared to those (if any) specified by EPA to establish
equivalency. The depth of review of the calculations was dictated by the reviewer's confidence in the
ability and conscientiousness of the tester, which in turn was based on factors such as consistency of
results and completeness of other areas of the test report.
3.3 EMISSION FACTOR QUALITY RATING SYSTEM
The quality of the emission factors developed from analysis of the test data was rated utilizing the
following general criteria:
A-Excellent: Developed only from A-rated test data taken from many randomly chosen facilities
in the industry population. The source category is specific enough so that variability within the source
category population may be minimized.
B-Above average: Developed only from A-rated test data from a reasonable number of
facilities. Although no specific bias is evident, it is not clear if the facilities tested represent a random
sample of the industries. The source category is specific enough so that variability within the source
category population may be minimized.
C-Averase: Developed only from A- and B-rated test data from a reasonable number of
facilities. Although no specific bias is evident, it is not clear if the facilities tested represent a random
sample of the industry. In addition, the source category is specific enough so that variability within the
source category population may be minimized.
D-Below average: The emission factor was developed only from A- and B-rated test data from
a small number of facilities, and there is reason to suspect that these facilities do not represent a random
sample of the industry. There also may be evidence of variability within the source category population.
Limitations on the use of the emission factor are noted in the emission factor table.
E-Poor: The emission factor was developed from C- and D-rated test data, and there is reason
to suspect that the facilities tested do not represent a random sample of the industry. There also may be
evidence of variability within the source category population. Limitations on the use of these factors are
always noted.
The use of these criteria is somewhat subjective and depends to an extent upon the individual
reviewer. Details of the rating of each candidate emission factor are provided in Chapter 4 of this report.
15
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REFERENCES FOR SECTION 3
1. Technical Procedures for Developing AP-42 Emission Factors and Preparing AP-42
Sections, EPA-454/B-93-050, Office of Air Quality Planning and Standards, U.S. Environmental
Protection Agency, Research Triangle Park, NC, October 1993.
16
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4.0 AP-42 SECTION DEVELOPMENT
4.1 REVISIONS TO SECTION NARRATIVE
The revised AP-42 section described in this report replaces the September 1991 portland cement
manufacturing section of AP-42. The process description and emissions and controls discussion in the
previous version had major flaws. Specifically, components of the process other than pyroprocessing
were not described (although emission factors were presented for other operations), the different types of
dry processes (long dry kiln, dry kiln with preheater, and dry kiln with preheater/precalciner) were not
clearly delineated, and the use of waste fuels by the industry was not discussed. Information contained in
the recently updated Air Pollution Engineering manual and materials supplied by the PCA on industry
characteristics and C02 emissions were used to update the discussion.
4.2 POLLUTANT EMISSION FACTOR DEVELOPMENT
A total of 80 documents were reviewed in the process of developing emission factors for this
revision to the AP-42 section on portland cement manufacturing. Emission factors were developed from
the data presented in 62 of these references. A list of the references used to develop emission factors is
presented in Table 4-1. The majority of these documents were emission test reports. However, several
test report summaries and other technical reports containing emission data also were reviewed.
Approximately 40 of the references were provided by the PCA for the 1991 update of the portland
cement kiln S02 and NOx emission factors in AP-42. These references were a combination of full test
reports, excerpts from test reports, and tabular data summaries, and the level of supporting data on testing
procedures and process operations varied considerably among these references. Many of the remaining
reports were taken from the existing background file for the AP-42 section. Other references reviewed
include reports of tests sponsored by EPA to determine the emission characteristics of burning hazardous
waste in cement kilns; tests to demonstrate compliance with the boiler and industrial furnace (BIF)
regulations of 40 CFR Part 266 for using hazardous waste as a supplemental fuel; and a test to satisfy the
requirements of California AB 2588 ("Hot Spots").
The data compiled and the emission factors developed from the data are presented in Tables 4-2
to 4-7, which summarize the data on wet process kilns, long dry process kilns, preheater kilns,
preheater/precalciner kilns, clinker coolers, and other processes, respectively. These tables specify the
type of pollutant; control device; number of test runs; minimum, maximum, and average emission factors
for each test; data rating; and reference number for each set of test data reviewed. No data were
available on emissions from semidry process kilns.
As has been the practice in previous versions of AP-42, the emission factors for portland cement
kilns presented in Tables 4-2 to 4-5 are expressed in units of mass of pollutant emitted in kg (lb) per mass
of clinker produced in Mg (ton). Nine of the 56 references from which kiln emission factors were
developed provided process rates in terms of clinker production; 25 references provided process rates in
terms of both raw material feed and clinker production; and the remaining 22 references provided process
rates on the basis of raw material feed. From those references in which both feed and production rates
are provided, an average feed-to-production ratio was determined for each type of kiln. These average
feed-to-production ratios are as follows: 1.69 for wet process kilns, 1.63 for long dry process kilns, 1.72
for dry preheater process kilns, and 1.70 for dry preheater/precalciner process kilns. These ratios were
rounded to 1.6 for long dry process kilns and 1.7 for the other three types of kilns. For the kiln emission
17
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factors developed from references for which only feed rates were provided, these ratios were used to
convert emission factors from a feed basis to a clinker production basis. Emission factors for processes
other than kilns are presented in Tables 4-6 and 4-7 in units of mass of pollutant emitted per mass of
material feed.
Particle size data for portland cement manufacturing processes have not been revised from the
previous version of AP-42 because new data were not available, and no problems were found with the
methodology and analysis used to develop the particle size data for the previous version of AP-42. A
detailed discussion of how the particle size data were developed for the section can be found in
Reference 79, which is the background report for the October 1986 revision to the PM emission factors
for the portland cement manufacturing section of AP-42. Tables 4-8 and 4-9 summarize the particle size
data from Reference 79 for portland cement kilns and clinker coolers, respectively. These particle size
data also were used to develop PM-10 emission factors for kilns and clinker coolers.
4.2.1 Review of Specific Data Sets
This section includes descriptions of each reference that was reviewed as part of this revision to
AP-42 Section 11.6. A list of the references used to develop emission factors is presented in Table 4-1.
4.2.1.1 Reference 1. This report documents measurements of filterable PM, condensible
inorganic PM, C02, and NOx emissions from a gas-fired rotary kiln, and filterable PM and condensible
inorganic PM emissions from a clinker cooler. A trace metal analysis was also conducted on the total
PM catches from one of the kiln runs and one of the clinker cooler runs. The emission test was
sponsored by EPA as part of the development of new source performance standards (NSPS) for portland
cement plants and was conducted in 1971. The plant uses the wet process, and process rates were
provided on the basis of slurry feed rate. Kiln and clinker cooler emissions are controlled with ESP's, and
only controlled emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back half), and NOx
emissions were measured using Method 7. Carbon dioxide emissions were measured using an infrared
analyzer. The report does not specify the type of analysis used to quantify trace metal concentrations,
although it does state that the analysis was conducted by EPA. Three PM runs and four NOx runs were
conducted.
Emission factors were developed for PM and NOx emissions and for emissions of the following
trace metals: beryllium, (Be), V, Mn, Ni, Cr, iron (Fe), Cu, and strontium (Sr). The PM samples also
were analyzed for cadmium, arsenic, antimony, and lead, but these elements were not detected.
Insufficient information was available to develop emission factors for C02 emissions. The test report
noted that a number of upsets occurred during the testing of the kiln.
The clinker cooler emission data for filterable and condensible PM are rated B. The test
methodology was sound, and no problems were reported, but the report lacked adequate documentation
for a higher rating. The kiln PM and NOx emission data are rated C. Although the methodology was
sound, because of the upsets that occurred during testing and the lack of adequate documentation, a
higher rating is not justified. The trace metal data are unrated because only one run was conducted and
the analytical method was not specified.
28
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TABLE 4-1. SUMMARY OF EMISSION TEST REPORTS AND SUMMARIES USED
Type of
process
wet
Company name
Maule Industries
Ideal Cement
Ideal Cement
Dragon Cement
Ideal Cement
Giant Portland Cement
Oregon Portland Cement
Ideal Cement
Arizona Portland Cement
Monarch Cement
Ideal Basic Industries
Lone Star Industries
Plant location
Hiahleah, FL
Seattle, WA
Castle Hayne, NC
Northampton, PA
Houston, TX
Harleyville, SC
Lake Oswego, OR
Tijeras, NM
Rillito, AZ
Humboldt, KS
Ada, OK
Nazareth, PA
wet
wet
dry
wet
wet
wet
dry
NA
preheater
wet
dry
Sources tested
clinker cooler
kiln
clinker cooler
kiln
finish mill air
separator
finish grinding mill
kiln
clinker cooler
finish grinding mill
kiln
kiln
raw mill weigh
hopper
raw mill
raw mill air
separator
finish mill weigh
hopper
finish mill
finish mill air
separator
primary crushing
primary screening
limestone transfer
secondary screening
and crushing
kiln
kiln
kiln
Pollutants
PM, metals
PM, metals
PM, metals
PM, metals
PM
PM
PM, SOx, Hg, C02
PM
PM
PM, S02, NOx, Hg
PM,S02
PM, metals
PM, metals
PM, metals
PM, metals
PM
PM, metals
PM
PM
PM
PM
PM
PM
PM,S02
Ref.
Year No.
1971 1
1971
1971
1971
1971
1971
1971
1971
1974
1981
1981
1977
2
3
4
5
6
7
8
10
11
12
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TABLE 4-1. (continued)
Type of
Ref.
Company name
Plant location
process
Sources tested
Pollutants
Year
No.
Lone Star Industries
Greencastle, IN
wet
kiln
PM,S02
1979
13
Lone Star Cement
Roanoke, VA
dry, wet
kiln
PM,C02
1980
14
Oklahoma Cement
Pryor, OK
dry
clinker cooler
PM
1980
15
Oklahoma Cement
Pryor, OK
dry
kiln
PM, S02, C02
1980
16
Lone Star Industries
Sweetwater, TX
preheater
kiln
S02, S03, C02
1980
17
Lone Star Industries
New Orleans, LA
wet
kiln
PM, S02, S03, NH4,
1980
18
CI, K, Na, S04, C02
Lone Star Industries
Bonner Springs, KS
wet
kiln
PM, S02, NOx, C02
1981
19
Lehigh Portland Cement
Mason City, IO
dry
clinker cooler
PM,C02
1983
20
California Portland Cement
Mojave, CA
precalciner
kiln
S02, NOx, CO, C02
1983
21
Lehigh Portland Cement
Waco, TX
NS
kiln
PM, S02, NOx, C02
1983
23
clinker cooler
PM
California Portland Cement
Mojave, CA
precalciner
kiln
PM, S02, S03, NOx
1984
24
CO, C02, TOC
clinker cooler
PM
Leeds Portland Cement
Leeds, AL
preheater
kiln
PM,C02
1984
25
clinker cooler
PM,C02
Lehigh Portland Cement
Cementon, NY
wet
kiln
PM, S02, C02
1984
26
CalMatCo
Mojave, CA
precalciner
kiln
PM, S02, S03, NOx
1985
27
CO, C02, TOC
clinker cooler
PM
Lonestar Florida Holding
Miami, FL
wet
kiln
PM, S02, NOx, C02
1985
28
Lonestar Florida/Pennsuco
Miami, FL
wet
kiln
PM, S02, NOx, C02
1981
29
Lonestar Florida/Pennsuco
Miami, FL
wet
kiln
PM, S02, NOx, C02
1981
30
Lone Star Cement
Davenport, CA
precalciner
kiln
PM, S02, NOx, CO
1985
31
C02
CalMatCo
Colton, CA
dry
kiln
NOx
1987
35
Riverside Cement
Crestmore, CA
dry
kiln
S02, NOx, CO
1981
36
NOx
1985
Lafarge Corp.
Alpena, Ml
dry
kiln
PM, S02, NOx, TOC
1989
37
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TABLE 4-1. (continued)
Company name
Southwestern Portland Cement
Alpha Portland Cement
Lone Star Industries
Plant location
Black Mountain, CA
Cementon, NY
New Orleans, LA
Type of
process
dry
wet
wet
Lone Star Industries
New Orleans, LA
wet
Lone Star Industries
New Orleans, LA
wet
Southwestern Portland Cement
Ash Grove Cement West
Calaveras Cement
Texas Cement
Southwestern Portland Cement
Florida Mining and Materials
Victorville, CA
Durkee, OR
Redding, CA
Buda, TX
Fairborn, OH
Brooksville, FL
wet
precalciner
precalciner
precalciner
preheater
preheater
Southwestern Portland Cement
Kosmosdale, KY
preheater
Southwestern Portland Cement
Odessa, TX
preheater
Ash Grove Cement West
Leamington, UT
precalciner
Ref.
Sources tested
Pollutants
Year
No.
kiln
S02, NOx, CO, C02
1984
39
kiln
PM, S02, HCI
1982
40
kiln
PM, S02, S04, NH4,
1982
42
CI, K, Na,
kiln
PM, S02, S04, NH4,
1982
43
CI, K, Na, F, NOx
kiln
PM, S02, S04, NH4,
1982
44
CI, Na, C02
kiln
S02, NOx, CO, C02
1980
48
kiln
NOx
1987
49
kiln
S02, NOx
1981
50
kiln
PM, S02, NOx
1986
51
kiln
PM, S02, C02
1986
52
kiln
PM, S02, NOx
1982
53
PM,S02
1983
PM, S02, NOx
1984
PM, S02, NOx
1985
PM, S02, NOx, C02
1986
PM, S02, NOx
1987
PM, NOx, C02
1988
PM, S02, NOx, C02
1989
kiln
PM, S02, NOx, CO
1989
54
C02, TOC, HCI
kiln
PM, S02, S03, NOx
1983
55
C02
kiln
PM, S02, NOx, C02
1989
56
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TABLE 4-1. (continued)
Type of
Company name Plant location process
CalMatCo Colton, CA precalciner
Marquette Cement
Lone Star Industries
Ash Grove Cement West
Southwestern Portland Cement
Cape Girardeau, MO
Cape Girardeau, MO
Leamington, UT
Victorville, CA
precalciner
precalciner
precalciner
precalciner
Southwestern Portland Cement Victorville, CA
precalciner
Southwestern Portland Cement Victorville, CA
Southwestern Portland Cement Victorville, CA
precalciner
precalciner
Ref.
Sources tested
Pollutants
Year
No.
kiln
PM, S02, NOx
1983
57
PM, S02, NOx, CO
1984
S04, TOC
PM, S02, NOx, CO
1985
S04, TOC
PM, S02, NOx, CO
1986
S04, TOC
PM, S02, NOx, CO
1987
S04, TOC
PM, S02, NOx, CO
1988
S04, TOC
PM, S02, NOx, CO
1989
S04, TOC
kiln
S02
1982
58
kiln
S02
1983
59
kiln
PM, NOx, C02
1985
60
kiln
PM, S02, NOx,
1985
61
CO, C02, TOC
clinker cooler
PM
raw mill
PM
finish mill
PM
kiln
PM, S02, NOx,
1985
62
CO, C02
raw mill
PM
raw mill feed belt
PM
finish mill
PM
finish mill feed belt
PM
kiln
PM, S02, NOx,
1987
63
CO, C02
kiln
PM, S02, NOx, CO
1987
64
C02, NH3, HCI
-------
TABLE 4-1. (continued)
Type of
Ref.
Company name
Plant location
process
Sources tested
Pollutants
Year
No.
Ash Grove
Louisville, NE
precalciner
kiln
NOx, CO, C02,
20 organics
1990
65
Continental
Hannibal, MO
wet
kiln
S02, NOx, CO, C02,
25 organics
1990
66
Lonestar Florida/Pennsuco
Miami, FL
wet
kiln
PM,C02
1980
67
Lone Star Industries
Sweetwater, TX
preheater
kiln
PM,C02
1980
69
Kaiser Cement
Walnut Creek, CA
precalciner
kiln
HCI, C02, 6 metals,
24 organics
1990
74
Lone Star Industries
Cape Girardeau, MO
precalciner
kiln
PM, CO, C02, TOC,
HCI, CI, 11 metals
1992
76
Essrock Materials
Frederick, MD
wet
kiln
PM, S02, NOx, CO
THC, 7 metals,
15 organics
1991
77
Lone Star Industries
Oglesby, IL
dry
kiln
PM, S02, NOx, CO
THC, HCI, 12 metals,
14 organics
1984
78
-------
TABLE 4-2. SUMMARY OF TEST DATA FOR PORTLAND CEMENT WET PROCESS KILNS
Type of No. of sion factor, kg/Mg Emission factor, lb/ton Data Ref.
Pollutant control runs(a) Minimum Maximum Average Minimum Maximum Average rating No.
COAL-FIRED ROTARY KILNS
filterable PM
none
4
550
700
630
1,100
1,400
1,250
D
11
filterable PM
none
6
63
73
65
125
145
130
B
13
filterable PM
none
4
55
75
65
110
150
130
B
19
filterable PM
none
3a
100
230
180
200
450
350
C
30
filterable PM
ESP
2
0.053
0.086
0.069
0.11
0.17
0.14
C
11
filterable PM
ESP
3a
0.034
0.079
0.050
0.068
0.16
0.10
C
67
filterable PM
ESP
3
0.00049
0.19
0.075
0.00098
0.38
0.15
C
13
filterable PM
ESP
3b
0.13
0.26
0.18
0.26
0.51
0.36
B
18
filterable PM
ESP
3c
0.17
0.20
0.19
0.34
0.41
0.37
B
18
filterable PM
ESP
7d
0.14
1.6
0.70
0.27
3.2
1.4
B
19
filterable PM
ESP
14
0.22
1.1
0.60
0.44
2.1
1.2
B
19
filterable PM
ESP
4d
0.17
0.95
0.42
0.33
1.9
0.83
B
19
filterable PM
ESP
3e
0.070
0.10
0.075
0.14
0.19
0.15
C
26
filterable PM
ESP
3a
0.10
0.13
0.12
0.20
0.26
0.23
B
28
filterable PM
ESP
3a
0.080
0.13
0.10
0.16
0.26
0.20
C
29
filterable PM
ESP
3a
0.060
0.13
0.10
0.12
0.26
0.19
C
30
filterable PM
ESP
3e
0.50
0.55
0.55
1.0
1.1
1.1
C
40
filterable PM
ESP
3b
0.018
0.37
0.16
0.04
0.73
0.32
B
42
filterable PM
ESP
3c
0.038
0.15
0.11
0.08
0.31
0.22
B
42
filterable PM
ESP
3b
0.22
0.29
0.25
0.44
0.58
0.49
B
43
filterable PM
ESP
3c
0.065
0.10
0.084
0.13
0.20
0.17
B
44
filterable PM
FF
3
0.21
0.26
0.23
0.43
0.53
0.46
C
7
filterable PM
(b)
2
0.034
0.17
0.10
0.07
0.33
0.20
C
14
condensible inorg. PM
ESP
3
0.050
0.17
0.11
0.10
0.33
0.21
B
13
condensible inorg. PM
FF
3
0.026
0.25
0.10
0.053
0.49
0.20
C
7
condensible inorg. PM
(b)
2
0.10
0.19
0.14
0.20
0.37
0.29
C
14
S02
none
3a
2.1
3.9
3.0
4.2
7.7
6.0
C
30
S02
ESP
3f
0.55
2.4
1.2
1.1
4.7
2.3
B
13
1
2
3
6
6.5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
24
25
28
30
31
34
-------
TABLE 4-2. (Continued)
Type of
No.
sion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
S02
ESP
3f
5.5
7.0
S02
ESP
3c
1.8
3.1
S02
ESP
3b
0.26
1.8
S02
ESP
6d
2.1
15
S02
ESP
16
2.0
11
S02
ESP
8d
3.5
10
S02
ESP
3e
8.0
10
S02
ESP
3a
2.1
2.3
S02
ESP
3a
2.2
3.5
S02
ESP
3a
1.9
3.3
S02
ESP
3e
1.3
1.6
S02
ESP
3c
2.2
3.2
S02
ESP
3b
2.1
3.6
S02
ESP
3c
6.8
8.5
S02
ESP
1
NA
NA
S02
FF
4
0.085
0.42
NOx
ESP
6d
0.24
2.1
NOx
ESP
12
1.7
4.7
NOx
ESP
2d
2.5
2.7
NOx
ESP
3a
3.2
3.5
NOx
ESP
12a
1.6
4.2
NOx
ESP
12a
2.5
4.7
NOx
ESP
3b
1.7
2.9
NOx
ESP
12c
1.4
2.7
NOx
ESP
1
NA
NA
CO
ESP
1
NA
NA
C02
ESP
3c
1,100
1,100
C02
ESP
3a
290
320
C02
ESP
3b
950
1,000
Emission factor,
b/ton
Data
Ref.
rage
Minimum
Maximum
Average
rating
No.
6.0
11
14
12
B
13
35
1
2.6
3.6
6.3
5.3
C
18
36
1
1.0
0.53
3.6
2.0
C
18
37
1
11
4.1
30
21
B
19
38
1
5.5
3.9
22
11
B
19
39
1
6.0
6.9
20
12
B
19
40
1
9.0
16
20
18
C
26
41
1
2.2
4.2
4.5
4.4
B
28
42
1
2.8
4.4
6.9
5.5
C
29
43
1
2.7
3.8
6.5
5.4
C
30
44
1
1.4
2.5
3.1
2.8
C
40
45
1
2.8
4.4
6.5
5.6
C
42
46
1
2.8
4.3
7.1
5.6
C
42
47
1
8.0
13.6
17
16
C
44
48
1
13
NA
NA
25
NR
65
0.20
0.17
0.83
0.41
D
7
51
1
0.90
0.47
4.1
1.8
B
19
3.0
3.4
9.3
6.0
B
19
2.6
4.9
5.3
5.1
C
19
3.4
6.3
6.9
6.7
B
28
53
1
3.2
3.2
8.4
6.4
C
29
54
1
3.4
4.9
9.3
6.8
C
30
55
1
2.1
3.4
5.8
4.3
B
43
56
1
1.9
2.9
5.4
3.7
B
43
57
1
10
NA
NA
20
NR
65
1.3
NA
NA
2.7
NR
65
1,100
2,100
2,200
2,200
B
18
59
0
310
578
630
610
C
67
59.5
1
1,000
1,900
2,000
2,000
B
18
60
1
{HOME}
@round(
,-2)~
-------
TABLE 4-2. (Continued)
Type of No. sion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
C02
ESP
4f
1,100
1,500
C02
ESP
8f
1,200
2,600
C02
ESP
8
650
2,200
C02
ESP
3e
800
950
C02
ESP
3a
1,000
1,200
C02
ESP
3a
410
450
C02
ESP
6a
410
490
C02
ESP
3c
1,100
1,300
C02
ESP
1
NA
NA
C02
(b)
2
26
950
Be
ESP
1
NA
NA
Cd
ESP
1
NA
NA
CI
ESP
3b
0.12
0.23
CI
ESP
3c
0.15
0.29
CI
ESP
3b
0.15
0.48
CI
ESP
3c
0.42
0.62
CI
ESP
3c
ND
ND
CI
ESP
3c
0.37
0.50
Cr
ESP
1
NA
NA
Cu
ESP
1
NA
NA
F
ESP
3c
ND
ND
Fe
ESP
1
NA
NA
HCI
ESP
3
0.016
0.036
K
ESP
3b
0.013
0.026
K
ESP
3c
0.016
0.025
K
ESP
3b
0.00060
0.00082
K
ESP
3c
6.8E-005
0.0012
K
ESP
3c
ND
ND
Mn
ESP
1
NA
NA
Emission factor,
lb/ton
Data
Ref.
Average
Minimum
Maximum
Average
rating
No.
1,250
2,200
2,900
2,500
B
19
1,700
2,400
5,100
3,300
B
19
1,100
1,300
4,400
2,200
B
19
900
1,600
1,900
1,800
C
26
1,100
2,000
2,300
2,100
B
28
430
820
890
850
C
29
450
810
970
890
C
30
1,200
2,200
2,500
2,300
C
44
2,200
NA
NA
4,400
NR
65
490
51
1,900
970
D
14
2.2E-006
NA
NA
4.4E-006
NR
2
0.00019
NA
NA
0.00037
NR
2
0.17
0.24
0.46
0.34
C
18
0.25
0.31
0.58
0.49
C
18
0.31
0.31
0.97
0.61
C
42
0.52
0.83
1.2
1.0
C
42
0.55
ND
ND
1.1
C
43
0.44
0.73
1.0
0.88
C
44
0.00011
NA
NA
0.00022
NR
2
0.00022
NA
NA
0.00044
NR
2
0.00045
ND
ND
0.00090
C
43
0.017
NA
NA
0.033
NR
2
0.024
0.031
0.071
0.047
C
40
0.020
0.026
0.053
0.041
B
18
0.020
0.032
0.049
0.041
B
18
0.00068
0.0012
0.0016
0.0014
B
42
0.00047
0.00014
0.0024
0.00094
B
42
0.00060
ND
ND
0.0012
C
43
0.00022
NA
NA
0.00044
NR
2
61
62
63
64
65
67
68
69
70
71
72
73
74
75
77
79
80
82
84
85
86
87
88
89
91
-------
TABLE 4-2. (Continued)
Type of
No.
sion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
NH4
ESP
3c
0.010
0.023
NH4
ESP
3b
0.0065
0.0094
NH4
ESP
3b
0.026
0.053
NH4
ESP
3c
0.084
0.13
NH4
ESP
3
ND
ND
NH4
ESP
3
0.11
0.14
N03
ESP
3
ND
ND
Na
ESP
3
0.015
0.027
Na
ESP
3
0.022
0.024
Na
ESP
3
0.00020
0.0045
Na
ESP
3
3.7E-003
0.0057
Na
ESP
3
ND
ND
Na
ESP
3
0.052
0.094
Ni
ESP
1
NA
NA
Pb
ESP
1
NA
NA
S03
ESP
3c
0.026
0.085
S03
ESP
3b
0.016
0.029
S04
ESP
3b
0.071
0.082
S04
ESP
3c
0.010
0.022
S04
ESP
3b
0.16
0.22
S04
ESP
3c
0.094
0.16
S04
ESP
3c
ND
ND
S04
ESP
3c
0.025
0.037
V
ESP
1
NA
NA
Zn
ESP
1
NA
NA
Acrolein
ESP
1
NA
NA
Acetone
ESP
1
NA
NA
Methylene chloride
ESP
1
NA
NA
Acrylonitrile
ESP
1
NA
NA
Emission factor, lb/ton
Average
Minimum
Maximum
0.015
0.020
0.046
0.0078
0.013
0.019
0.037
0.053
0.11
0.11
0.17
0.26
0.094
ND
ND
0.12
0.22
0.29
0.0023
ND
ND
0.021
0.031
0.054
0.023
0.044
0.048
0.0016
0.0004
0.0090
0.0044
0.0073
0.011
0.0010
ND
ND
0.077
0.10
0.19
0.00022
NA
NA
0.0044
NA
NA
0.064
0.053
0.17
0.020
0.032
0.058
0.076
0.14
0.16
0.017
0.020
0.044
0.19
0.32
0.44
0.12
0.19
0.32
0.12
ND
ND
0.030
0.049
0.073
6.7E-005
NA
NA
0.0094
NA
NA
0.00094
NA
NA
0.0012
NA
NA
0.00043
NA
NA
0.0016
NA
NA
Data
Average
rating
0.031
C
0.016
C
0.073
B
0.22
B
0.19
C
0.24
C
0.0046
C
0.043
B
0.046
B
0.0032
B
0.0088
B
0.0020
C
0.15
C
0.00044
NR
0.0088
NR
0.13
C
0.041
C
0.15
B
0.034
B
0.37
B
0.24
B
0.24
C
0.060
C
0.00013
NR
0.019
NR
0.0019
NR
0.0024
NR
0.00085
NR
0.0032
NR
Ref.
No.
18 92
18 93
42 94
42 95
43 96
44 97
43 98
18 99
18 100
42 101
42 102
43 103
44 104
2 106
2 108
18 109
18 110
18 111
18 112
42 113
42 114
43 115
44 116
2 119
2 120
65 0.00055
65 0.00072
65 0.00025
65 0.00093
-------
TABLE 4-2. (Continued)
Type of
No.
sion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
t-1,2-Dichloroethane
ESP
1
NA
NA
1,1 Dichloroethane
ESP
1
NA
NA
Methyl ethyl ketone
ESP
1
NA
NA
Chloroform
ESP
1
NA
NA
1,1,1-Trichloroethane
ESP
1
NA
NA
Carbon tetrachloride
ESP
1
NA
NA
Benzene
ESP
1
NA
NA
1,2-Dichloroethane
ESP
1
NA
NA
Trichloroethene
ESP
1
NA
NA
1,2-Dichloropropane
ESP
1
NA
NA
p-Dioxane
ESP
1
NA
NA
Bromodichloromethane
ESP
1
NA
NA
Toluene
ESP
1
NA
NA
t-1,3-Dichloropropene
ESP
1
NA
NA
1,1,2-Trichloroethane
ESP
1
NA
NA
Tetrachloroethene
ESP
1
NA
NA
Dibromochloromethane
ESP
1
NA
NA
Chlorobenzene
ESP
1
NA
NA
Ethylbenzene
ESP
1
NA
NA
Bromoform
ESP
1
NA
NA
1,1,2,2-Tetrachrloroethane
ESP
1
NA
NA
Benzyl alcohol
ESP
1
NA
NA
Benzoic acid
ESP
1
NA
NA
Naphthalene
ESP
1
NA
NA
2-Methylnaphthalene
ESP
1
NA
NA
Phenanthrene
ESP
1
NA
NA
CDD/CDF (total)
ESP
1
NA
NA
GAS-FIRED ROTARY KILNS
filterable PM
ESP
3
0.54
1.5
Emission factor,
lb/ton
Data
Ref.
Average
Minimum
Maximum
Average
rating
No.
2.4E-007
NA
NA
4.8E-007
NR
65
0.0000001
1.2E-006
NA
NA
2.3E-006
NR
65
0.0000007
0.00026
NA
NA
0.00051
NR
65
0.00015
5.3E-005
NA
NA
0.00011
NR
65
0.000031
4.6E-005
NA
NA
9.2E-005
NR
65
0.000027
2.9E-006
NA
NA
5.8E-006
NR
65
0.0000017
0.0029
NA
NA
0.0058
NR
65
0.0017
2.0E-005
NA
NA
4.1 E-005
NR
65
0.000012
2.0E-005
NA
NA
4.1 E-005
NR
65
0.000012
2.9E-006
NA
NA
5.8E-006
NR
65
0.0000017
0.00016
NA
NA
0.00032
NR
65
0.000093
2.9E-005
NA
NA
5.8E-005
NR
65
0.000017
0.00094
NA
NA
0.0019
NR
65
0.00055
1.7E-006
NA
NA
3.4E-006
NR
65
0.000001
2.0E-005
NA
NA
4.1 E-005
NR
65
0.000012
1.1E-005
NA
NA
2.1 E-005
NR
65
0.0000062
3.6E-006
NA
NA
7.1 E-006
NR
65
0.0000021
0.00019
NA
NA
0.00037
NR
65
0.00011
0.00015
NA
NA
0.00030
NR
65
0.000089
6.5E-006
NA
NA
1.3E-005
NR
65
0.0000038
5.8E-005
NA
NA
0.00012
NR
65
0.000034
0.0041
NA
NA
0.0082
NR
65
0.0024
0.0058
NA
NA
0.012
NR
65
0.0034
0.00085
NA
NA
0.0017
NR
65
0.0005
0.00029
NA
NA
0.00058
NR
65
0.00017
0.00012
NA
NA
0.00024
NR
65
0.000072
6.3E-007
NA
NA
1.3E-006
NR
65
0.0000004
1.0
1.1
3.1
2.0
C
1
4
-------
TABLE 4-2. (Continued)
Type of
No.
sion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
filterable PM
ESP
2
0.72
0.78
filterable PM
FF
1
NA
NA
condensible inorg. PM
ESP
3
0.054
0.16
condensible inorg. PM
ESP
2
0.063
0.09
S02
FF
2
4.8
6.4
NOx
ESP
4
0.71
2.2
NOx
FF
2
1.6
4.3
Cr
ESP
1
NA
NA
Cu
ESP
1
NA
NA
Fe
ESP
1
NA
NA
Hg
FF
1.3E-005
2.6E-005
Mn
ESP
1
NA
NA
Ni
ESP
1
NA
NA
Pb
ESP
1
NA
NA
Sr
ESP
1
NA
NA
V
ESP
1
NA
NA
OIL-FIRED ROTARY KILNS
condensible inorg. PM
FF
1
NA
NA
S02
none
1
NA
NA
S02
FF
2
7.2
11
COAL- AND OIL-FIRED ROTARY KILNS
filterable PM
ESP
3
0.35
0.46
condensible inorg. PM
ESP
3
0.021
0.025
S02
ESP
3
0.55
2.0
NOx
ESP
3
8.5
11
CO
ESP
3
0.046
0.080
C02
ESP
3
1,300
1,400
TOC
ESP
3
0.014
0.015
Ba
ESP
3
0.00014
0.00025
Emission factor, lb/ton
Average
Minimum
Maximum
0.75
1.4
1.6
0.46
NA
NA
0.10
0.11
0.32
0.075
0.13
0.17
5.6
9.7
13
1.4
1.4
4.4
3.0
3.2
8.5
0.0020
NA
NA
0.00015
NA
NA
0.0062
NA
NA
2.0E-005
2.6E-005
5.3E-005
7.7E-005
NA
NA
0.0013
NA
NA
0.00048
NA
NA
0.0017
NA
NA
8.2E-005
NA
NA
0.57
NA
NA
16
NA
NA
8.9
14
21
0.42
0.69
0.91
0.024
0.042
0.050
1.2
1.1
4.0
10
17
22
0.060
0.092
0.16
1,300
2,500
2,700
0.014
0.027
0.029
0.00018
0.00027
0.00049
Data
Ref.
Average
rating
No.
1.5
C
2
5
2
gas-fired
0.92
NR
6
23
2
gas
0.20
C
1
26
2
gas-fired
0.15
C
2
27
2
gas-fired
11
D
6
49
2
gas
2.9
C
1
52
2
gas-fired
6.0
D
6
58
2
gas
0.0039
NR
1
76
2
gas-fired
0.00031
NR
1
78
2
gas-fired
0.012
NR
1
81
2
gas-fired
3.9E-005
D
6
83
2
gas
0.00015
NR
1
90
2
gas-fired
0.0026
NR
1
105
2
gas-fired
0.00097
NR
1
107
2
gas-fired
0.0034
NR
1
117
2
gas-fired
0.00016
NR
1
118
2
gas-fired
1.1
NR
6
29
3
oil
32
NR
6
32
3
oil
18
D
6
50
3
oil
0.84
B
77
1
4
coal/oil-fired
0.047
B
77
2
4
coal/oil-fired
2.3
B
77
3
4
coal/oil-fired
20
B
77
4
4
coal/oil-fired
0.12
B
77
5
4
coal/oil-fired
2,600
B
77
6
4
coal/oil-fired
0.028
B
77
6.5
4
coal/oil-fired
0.00035
B
77
7
4
coal/oil-fired
-------
TABLE 4-2. (Continued)
Type of
No.
sion factor, kg/Mg
Emission factor,
b/ton
Data
Ref.
Pollutant
control
runs(a)
Minimum
Maximum
Average
Minimum
Maximum
Average
rating
No.
Cd
ESP
3
2.7E-006
6.5E-006
4.2E-006
0.0000054
0.000013
0.0000083
B
77
7
4
coal/oil-fired
Cr
ESP
2
1.6E-006
6.0E-006
3.9E-006
0.0000032
0.000012
0.0000077
C
77
7
4
coal/oil-fired
Hg
ESP
3
7.5E-005
0.00014
0.00011
0.00015
0.00027
0.00022
B
77
7
4
coal/oil-fired
Ni
ESP
1
NA
NA
1.4E-005
NA
NA
0.000027
NR
77
7
4
coal/oil-fired
Pb
ESP
3
0.00021
0.00048
0.00036
0.00042
0.00096
0.00071
B
77
7
4
coal/oil-fired
Zn
ESP
3
0.00019
0.00037
0.00027
0.00038
0.00073
0.00054
B
77
7
4
coal/oil-fired
2-butanone
ESP
3
3.7E-006
2.9E-005
2.0E-005
0.0000073
0.000058
0.000039
B
77
8
4
coal/oil-fired
acetone
ESP
3
4.7E-005
0.00033
0.00019
0.000093
0.00065
0.00037
B
77
8
4
coal/oil-fired
benzene
ESP
3
0.0014
0.0019
0.0016
0.0027
0.0037
0.0031
B
77
8
4
coal/oil-fired
benzoic acid
ESP
3
0.0014
0.0021
0.0018
0.0028
0.0042
0.0035
B
77
8
4
coal/oil-fired
bis(2-ethylhexyl)phthalate
ESP
3
3.1 E-005
7.0E-005
4.8E-005
0.000061
0.00014
0.000095
B
77
8
4
coal/oil-fired
bromomethane
ESP
2
1.5E-005
2.9E-005
2.2E-005
0.000029
0.000058
0.000043
C
77
8
4
coal/oil-fired
carbon disulfide
ESP
3
5.0E-005
6.0E-005
5.5E-005
0.00010
0.00012
0.00011
B
77
8
4
coal/oil-fired
chlorobenzene
ESP
2
5.5E-006
1.1 E-005
8.0E-006
0.000011
0.000021
0.000016
C
77
8
4
coal/oil-fired
chloromethane
ESP
3
8.5E-005
0.00029
0.00019
0.00017
0.00057
0.00038
B
77
8
4
coal/oil-fired
di-n-butylphthalate
ESP
3
1.5E-005
2.4E-005
2.1 E-005
3.0E-005
0.000047
0.000041
B
77
8
4
coal/oil-fired
ethylbenzene
ESP
3
5.5E-006
1.5E-005
9.5E-006
0.000011
0.000029
0.000019
B
77
8
4
coal/oil-fired
naphthalene
ESP
3
6.0E-005
0.00015
0.00011
0.00012
0.00029
0.00022
B
77
8
4
coal/oil-fired
phenol
ESP
3
4.5E-005
6.0E-005
5.5E-005
0.000089
0.00012
0.00011
B
77
8
4
coal/oil-fired
toluene
ESP
3
0.00060
0.0014
0.00010
0.0012
0.0028
0.00019
B
77
8
4
coal/oil-fired
xylenes
ESP
3
2.0E-005
0.00012
0.00007
4.0E-005
0.00023
0.00013
B
77
8
4
coal/oil-fired
ESP = electrostatic precipitator.
FF = fabric filter.
TOC = total organic compounds.
NA = not applicable.
NR = not rated.
(a) Multiple tests conducted on the same kiln indicated by a-e.
(b) Cooling tower with multiclone and ESP.
-------
TABLE 4-3. SUMMARY OF TEST DATA FOR PORTLAND CEMENT LONG DRY PROCESS KILNS
Type of No. of Emission factor, kg/Mg Emission factor, lb/ton
Pollutant
control
runs
Minimum
Maximum
Average
Minimum
Maximum
Average
filterable PM
ESP
3
0.12
0.46
0.24
0.24
0.92
0.48
filterable PM
ESP
3
0.065
0.16
0.10
0.13
0.33
0.21
filterable PM
ESP
2
0.600
1.35
0.95
1.2
2.7
1.9
filterable PM
FF
2
0.044
0.049
0.046
0.088
0.10
0.093
filterable PM
FF
3
0.090
0.10
0.10
0.18
0.21
0.20
filterable PM
FF
3
ND
ND
0.10
ND
ND
0.19
filterable PM
(a)
6
0.55
0.80
0.65
1.1
1.6
1.3
filterable PM
(a)
6
0.28
2.0
0.85
0.56
4.0
1.7
filterable PM
(a)
6
0.50
0.80
0.65
1.0
1.6
1.3
condensible inorg. PM
ESP
3
0.18
0.70
0.41
0.37
1.4
0.82
condensible inorg. PM
ESP
3
0.10
0.18
0.13
0.20
0.35
0.26
condensible inorg. PM
FF
2
0.088
0.10
0.10
0.18
0.19
0.19
condensible inorg. PM
FF
3
0.42
0.48
0.44
0.85
0.97
0.89
condensible inorg. PM
(a)
6
0.090
0.20
0.14
0.18
0.39
0.29
condensible inorg. PM
(a)
6
0.0026
0.20
0.10
0.0051
0.41
0.21
condensible inorg. PM
(a)
6
0.10
0.20
0.16
0.20
0.40
0.33
S02
ESP
12
11
17
14
22
33
27
S02
ESP
2
0.080
0.011
0.046
0.16
0.022
0.092
S02
FF
3
1.8
3.5
2.7
3.7
7.0
5.4
S02
FF
3
0.080
0.40
0.19
0.16
0.81
0.38
S02
FF
3
0.13
0.27
0.20
0.26
0.54
0.40
S02
FF
6
1.9
5.0
3.4
3.8
10
6.7
S02
FF
5
0.010
0.45
0.12
0.019
0.90
0.24
NOx
FF
2
0.96
1.9
1.4
1.9
3.8
2.9
NOx
FF
3
7.0
7.5
7.0
14
15
14
NOx
FF
3
2.2
7.0
4.6
4.5
14
9.2
NOx
FF
(b)
NA
NA
2.9
NA
NA
5.8
-------
TABLE 4-3. (Continued)
Type of No. of Emission factor, kg/Mg Emission factor, lb/ton
Pollutant
control
runs
Minimum
Maximum
Average
Minimum
Maximum
Average
NOx
FF
3
1.7
2.9
2.2
3.4
5.8
4.3
NOx
FF
6
2.2
3.6
2.8
4.5
7.3
5.5
NOx
ESP
2
3.0
3.3
3.2
6.0
6.6
6.3
NOx
FF
3
3.2
3.4
3.4
6.5
6.9
6.7
NOx
FF
81
1.7
5.0
3.4
3.4
10
6.7
CO
ESP
2
0.10
0.12
0.11
0.20
0.24
0.22
CO
FF
3
0.10
0.10
0.10
0.20
0.20
0.20
CO
FF
1
NA
NA
0.44
NA
NA
0.87
C02
ESP
2
950
1,000
1,000
1,900
2,000
2,000
C02
FF
2
360
470
420
720
940
830
C02
FF
3
850
950
900
1,700
1,900
1,800
C02
FF
6
750
1,400
1,000
1,500
2,800
2,000
C02
(a)
6
750
1,200
900
1,500
2,300
1,800
C02
(a)
6
850
1,400
1,100
1,700
2,800
2,100
C02
(a)
6
950
1,200
1,100
1,900
2,300
2,100
VOC
FF
3
ND
ND
0.22
ND
ND
0.45
TOC
FF
3
ND
ND
0.024
ND
ND
0.048
TOC
ESP
2
0.0042
0.0046
0.0044
0.0083
0.0093
0.0088
HC1
ESP
2
0.019
0.031
0.025
0.038
0.062
0.050
A1
ESP
2
0.0036
0.0090
0.0065
0.0073
0.018
0.013
As
ESP
2
5.5e-06
7.0e-06
6.5e-06
0.000011
0.000014
0.000013
Ca
ESP
2
0.085
0.16
0.12
0.17
0.31
0.24
Cd
ESP
2
1.6e-05
2.8e-05
2.2e-05
0.000031
0.000056
0.000043
Cr
ESP
1
NA
NA
0.00012
NA
NA
0.00025
Fe
ESP
2
0.0065
0.010
0.0085
0.013
0.021
0.017
Hg
ESP
2
1.6e-06
3.0e-06
2.3e-06
0.0000032
0.0000059
0.0000046
Hg
FF
3
9.6e-06
2.2e-05
1.4e-05
1.9e-05
4.3e-05
2.9e-05
-------
TABLE 4-3. (Continued)
Type of
No. of
Emission factor, kg/Mg
Emission factor, lb/ton
Pollutant
control
runs
Minimum
Maximum
Average
Minimum
Maximum
Average
Mn
ESP
2
0.00032
0.00055
0.00043
0.00063
0.0011
0.00086
Pb
ESP
2
5.0e-05
l.le-04
8.0e-05
0.00010
0.00021
0.00016
Se
ESP
2
5.0e-05
0.00010
7.5e-05
0.00010
0.00020
0.00015
Ti
ESP
2
3.2e-04
4.8e-05
0.00018
0.00063
0.000096
0.00037
Zn
ESP
2
7.0e-05
3.4e-05
5.0e-05
0.00014
0.000068
0.00010
fireon 113
ESP
2
2.3e-05
2.8e-05
2.5e-05
0.000045
0.000055
0.00005
toluene
ESP
2
9.5e-05
0.00016
0.00013
0.00019
0.00033
0.00026
methyl ethyl ketone
ESP
2
8.0e-06
1.2e-05
1.0e-05
0.000016
0.000023
2.0e-05
1,1,1, trichloroethylene
ESP
1
NA
NA
2.2e-06
NA
NA
0.0000043
methylene chloride
ESP
2
0.00010
0.00039
0.00024
0.00021
0.00078
0.00049
styrene
ESP
2
3.6e-07
l.le-06
7.5e-07
0.00000072
0.0000022
0.0000015
ethylbenzene
ESP
2
3.6e-07
5.5e-07
4.6e-07
0.00000072
0.0000011
0.0000009
C3 benzenes
ESP
2
2.3e-06
3.6e-07
1.3e-06
0.0000045
0.0000007
0.0000026
C4 benzenes
ESP
2
3.6e-07
5.5e-06
3.0e-06
0.00000072
0.000011
6.0e-06
C6 benzenes
ESP
2
3.6e-07
5.5e-07
4.6e-07
0.00000072
0.0000011
0.0000009
biphenyl
ESP
2
2.2e-06
3.9e-06
3.1e-06
0.0000043
0.0000078
0.0000061
benzaldehyde
ESP
2
2.9e-06
2.2e-05
1.2e-05
0.0000057
0.000043
0.000024
naphthalene
ESP
2
3.6e-06
2.0e-05
1.2e-05
0.0000072
0.00004
0.000024
methylnaphthalene
ESP
2
1.5e-06
2.8e-06
2.1e-06
0.0000029
0.0000056
0.0000042
ESP = electrostatic precipitator.
FF = fabric filter.
TOC = total organic compounds.
ND = no data.
NR = not rated.
NS = not specified.
(a) Cooling tower with multiclone and ESP.
(b) Multiple CEM readings.
-------
TABLE 4-4. SUMMARY OF TEST DATA FOR PORTLAND CEMENT DRY PREHEATER PROCESS KILNS
Type of
No. of
Emission factor, kg/Mg
Emission factor, lb/ton
Data
Ref.
Pollutant
control
runs
Minimum
Maximum
Average
Minimum
Maximum
Average
rating
No.
filterable PM
none
4
120
130
125
240
260
250
A
10
11
F/P
filterable PM
ESP
4
0.10
0.15
0.13
0.20
0.31
0.26
B
25
1
F
filterable PM
FF
2
0.37
0.52
0.45
0.74
1.0
0.89
C
10
2
F/P
filterable PM
FF
3
0.085
0.12
0.10
0.17
0.23
0.19
B
52
4
F/P
filterable PM
FF
7
0.025
0.10
0.050
0.049
0.19
0.10
C
53
5
F/P
filterable PM
FF
3
0.022
0.045
0.031
0.044
0.090
0.063
C
69
6
F
filterable PM
FF
2
0.065
0.077
0.071
0.13
0.15
0.14
C
69
7
F
filterable PM
FF
3
0.071
0.074
0.072
0.14
0.15
0.14
C
69
8
F
filterable PM
FF
9
0.055
0.16
0.11
0.11
0.31
0.22
B
54
9
F/P
filterable PM
FF
3
0.13
0.16
0.14
0.25
0.31
0.28
B
55
10
F/P
condensible inorg. PM
FF
3
0.010
0.023
0.017
0.020
0.045
0.033
B
55
12
F/P
S02
FF
3
1.0
1.1
1.0
1.9
2.2
2.0
B
52
14
F/P
S02
FF
10
0.0080
0.085
0.042
0.016
0.17
0.083
C
53
15
F/P
S02
FF
8
0.028
0.11
0.055
0.055
0.22
0.11
B
54
17
F/P
S02
FF
3
0.0025
0.0027
0.0026
0.0050
0.0053
0.0052
C
55
18
F/P
NOx
FF
9
0.55
3.0
1.2
1.1
6.0
2.4
C
53
21
F/P
NOx
FF
9
2.5
3.3
2.9
5.0
6.5
5.8
B
54
23
F/P
NOx
FF
3
2.7
3.3
3.1
5.4
6.5
6.2
B
55
24
F/P
CO
FF
9
0.26
1.2
0.49
0.52
2.4
0.98
B
54
25
F/P
C02
ESP
4
850
850
850
1,700
1,700
1,700
B
25
26
F
C02
FF
3
850
950
900
1,700
1,900
1,800
B
17
27
F
C02
FF
3
950
1,050
1,000
1,900
2,100
2,000
B
17
28
F
C02
FF
3
1,000
1,000
1,000
2,000
2,000
2,000
B
17
29
F
C02
FF
3
900
900
900
1,800
1,800
1,800
B
52
30
F/P
C02
FF
3
485
950
800
970
1,900
1,600
C
53
31
F/P
C02
FF
2
850
1,100
950
1,700
2,100
1,900
C
69
32
F
C02
FF
3
750
800
800
1,500
1,600
1,600
B
69
33
F
C02
FF
3
600
950
750
1,200
1,900
1,500
B
69
34
F
0
1
1
1
1
1
1
1
1
1
2
3
3
3
3
4
4
4
5
6
6
6
6
6
6
6
6
6
-------
TABLE 4-4. (Continued)
Type of
No. of
Emission factor, kg/Mg
Emission factor, lb/ton
Data
Ref.
Pollutant
control
runs
Minimum
Maximum
Average
Minimum
Maximum
Average
rating
No.
C02
FF
9
800
1,000
900
1,600
2,000
1,800
B
54
35
F/P
6
C02
FF
3
1,100
1,100
1,100
2,100
2,200
2,100
C
55
36
F/P
6
TOC
FF
9
0.070
0.13
0.090
0.14
0.25
0.18
B
54
37
VOC
FF
9
0.055
0.19
0.13
0.11
0.37
0.25
D
54
37
F/P
7
S03
FF
3
0.0057
0.017
0.011
0.011
0.034
0.022
B
17
38
F
8
S03
FF
3
0.0094
0.026
0.016
0.019
0.053
0.032
B
17
39
F
8
S03
FF
3
0.0054
0.0060
0.0057
0.011
0.012
0.011
B
17
40
F
8
S03
FF
3
0.0025
0.0064
0.0039
0.0050
0.0128
0.0077
C
55
41
F/P
8
HCI
FF
9
0.010
0.029
0.018
0.019
0.058
0.035
D
54
42
F/P
9
ESP = electrostatic precipator.
FF = fabric filter.
TOC = total organic compounds.
NS = not specified.
NA = not applicable.
-------
TABLE 4-5. SUMMARY OF TEST DATA FOR PORTLAND CEMENT DRY PREHEATER/PRECALCINER KILNS
Type of
No.
ssion factor, kg/Mg
Emission factor, lb/ton
Data
Ref.
Pollutant
control
runs(a)
Minimum
Maximum
Average
Minimum Maximum
Average
rating
No.
ilterable PM
ESP
3
0.017
0.034
0.024
0.034
0.068
0.048
B
31
1
F
ilterable PM
FF
3a
0.018
0.038
0.026
0.036
0.077
0.053
B
24
2
ilterable PM
FF
3a
0.010
0.017
0.014
0.020
0.034
0.029
B
27
3
ilterable PM
FF
3
0.090
0.13
0.10
0.18
0.25
0.20
C
51
ilterable PM
FF
3b
0.042
0.055
0.050
0.083
0.11
0.099
C
57
4
P
ilterable PM
FF
3b
0.041
0.050
0.046
0.082
0.10
0.091
C
57
5
P
ilterable PM
FF
3b
0.025
0.037
0.029
0.049
0.073
0.058
C
57
6
P
ilterable PM
FF
3b
0.033
0.043
0.039
0.066
0.086
0.077
C
57
7
P
ilterable PM
FF
2b
0.049
0.060
0.055
0.097
0.12
0.11
C
57
8
P
ilterable PM
FF
3b
0.023
0.041
0.033
0.046
0.081
0.066
C
57
9
P
ilterable PM
FF
3b
0.012
0.022
0.018
0.024
0.043
0.036
C
57
10
P
ilterable PM
FF
3c
0.0094
0.014
0.011
0.019
0.027
0.022
B
61
11
F
ilterable PM
FF
3c
0.0085
0.034
0.018
0.017
0.067
0.035
B
62
12
F/P
ilterable PM
FF
3c
0.014
0.018
0.017
0.028
0.036
0.033
B
63
13
F/P
ilterable PM
FF
6c
0.0028
0.0080
0.0060
0.0055
0.016
0.012
B
64
14
F/P
ilterable PM
FF
3d
0.12
0.46
0.26
0.24
0.91
0.52
B
56
15
P
ilterable PM
FF
2d
0.12
0.13
0.13
0.24
0.25
0.25
D
60
16
F/P
ilterable PM
FF
3
0.11
0.14
0.12
0.21
0.27
0.24
A
76
condensible inorg. PM
ESP
3
0.13
0.17
0.14
0.26
0.34
0.29
B
31
17
F
condensible inorg. PM
FF
3a
0.0020
0.0094
0.0045
0.0039
0.019
0.0090
B
24
18
condensible inorg. PM
FF
3a
0.0029
0.0076
0.0055
0.0058
0.015
0.011
B
27
19
condensible inorg. PM
FF
3
0.016
0.035
0.024
0.032
0.070
0.047
B
64
20
F/P
condensible inorg. PM
FF
3d
0.12
0.19
0.14
0.23
0.37
0.28
B
56
21
P
condensible inorg. PM
FF
2d
0.065
0.070
0.065
0.13
0.14
0.13
D
60
22
F/P
S02
ESP
3
0.29
0.32
0.31
0.58
0.65
0.63
B
31
23
F
S02
ESP
3
1.4
1.5
1.4
2.7
3.1
2.9
B
58
24
F
S02
FF
3a
0.43
0.43
0.43
0.85
0.85
0.85
C
21
25
-------
TABLE 4-5. (Continued)
Type of No. of ssion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
S02
FF
3a
0.53
0.55
S02
FF
3a
0.13
0.14
S02
FF
3
0.50
1.1
S02
FF
3b
0.24
0.30
S02
FF
3b
0.48
0.50
S02
FF
3b
0.50
0.55
S02
FF
3b
0.12
0.13
S02
FF
3b
0.70
0.75
S02
FF
3b
0.29
0.43
S02
FF
3b
0.36
0.40
S02
FF
6c
0.013
0.045
S02
FF
3c
0.034
0.075
S02
FF
3c
0.015
0.019
S02
FF
3c
0.020
0.023
S02
FF
3d
0.0030
0.0032
S02
ST
(b)
ND
ND
S02
ST+ESP
(b)
ND
ND
S02
NS
NS
NA
NA
NOx
ESP
3
1.0
1.1
NOx
ESP
5
1.8
3.3
NOx
ESP
1
NA
NA
NOx
FF
3a
1.4
1.6
NOx
FF
3a
1.8
1.9
NOx
FF
3a
2.1
2.1
NOx
FF
3
1.9
2.0
NOx
FF
3b
1.3
1.5
NOx
FF
3b
1.7
1.8
NOx
FF
3b
2.0
2.0
Emission factor, lb/ton
Data
Ref.
Average
Minimum
Maximum
Average
rating
No.
0.54
1.1
1.1
1.1
B
24
26
0.14
0.26
0.27
0.27
B
27
27
0.75
1.0
2.2
1.5
C
51
0.27
0.47
0.59
0.53
C
57
28
P
3
0.50
0.95
1.0
1.0
C
57
29
P
3
0.50
0.99
1.1
1.0
C
57
30
P
3
0.13
0.24
0.25
0.3
C
57
31
P
3
0.75
1.4
1.5
1.5
C
57
32
P
3
0.35
0.58
0.85
0.70
C
57
33
P
3
0.39
0.72
0.79
0.8
C
57
34
P
3
0.025
0.025
0.090
0.050
B
61
35
F
3
0.055
0.068
0.15
0.11
B
62
36
F/P
3
0.017
0.029
0.037
0.033
B
63
37
F/P
3
0.021
0.039
0.045
0.042
B
64
38
F/P
3
0.0031
0.0060
0.0063
0.0061
D
56
39
P
3
0.60
ND
ND
1.2
C
59
40
P
3
0.40
ND
ND
0.79
C
59
41
P
3
0.43
NA
NA
0.85
D
50
1.1
2.0
2.2
2.2
B
31
42
F
4
2.5
3.5
6.6
5.0
B
49
1.6
NA
NA
3.2
NR
65
1.5
2.9
3.2
3.1
C
21
43
1.9
3.6
3.7
3.7
B
24
44
2.1
4.3
4.3
4.3
B
27
45
1.9
3.7
3.9
3.8
C
51
1.4
2.6
3.0
2.8
C
57
46
P
4
1.7
3.3
3.6
3.4
C
57
47
P
4
2.0
3.9
3.9
3.9
C
57
48
P
4
-------
TABLE 4-5. (Continued)
Type of
No. of
ssion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
NOx
FF
3b
1.8
3.0
NOx
FF
3b
0.80
0.90
NOx
FF
3b
2.7
2.7
NOx
FF
3b
2.4
3.2
NOx
FF
6c
1.6
2.5
NOx
FF
3c
3.4
3.8
NOx
FF
3c
2.9
3.7
NOx
FF
3c
3.2
3.4
NOx
FF
3d
2.0
2.6
NOx
FF
2d
4.6
4.9
NOx
NS
NS
ND
ND
CO
ESP
3
1.0
1.2
CO
ESP
1
NA
NA
CO
FF
3a
0.52
0.64
CO
FF
3a
0.60
0.65
CO
FF
3b
0.24
0.33
CO
FF
3b
0.55
1.1
CO
FF
3b
0.46
0.60
CO
FF
3b
0.26
0.34
CO
FF
6c
0.47
1.62
CO
FF
3c
0.20
0.38
CO
FF
3c
1.5
1.8
CO
FF
3c
2.1
2.7
CO
FF
3
3.5
5.5
C02
ESP
3
800
850
C02
ESP
1
NA
NA
C02
FF
3a
900
950
C02
FF
3a
900
1,000
Emission factor, lb/ton
age
Minimum
Maximum
2.3
3.6
6.0
0.85
1.6
1.8
2.7
5.3
5.4
2.8
4.7
6.3
2.1
3.2
5.0
3.6
6.8
7.5
3.3
5.7
7.4
3.3
6.4
6.7
2.2
4.0
5.1
4.8
9.2
9.7
0.17
ND
ND
1.1
2.0
2.4
0.32
NA
NA
0.58
1.0
1.3
0.62
1.2
1.3
0.30
0.48
0.66
0.85
1.1
2.1
0.55
0.92
1.2
0.29
0.51
0.67
0.85
0.94
3.2
0.26
0.39
0.76
1.7
3.0
3.5
2.3
4.2
5.3
4.4
6.9
11
800
1,600
1,700
500
NA
NA
900
1,800
1,900
950
1,800
2,000
Data Ref.
Average rating No.
4.5
C
57
49
P
4
1.7
C
57
50
P
4
5.3
C
57
51
P
4
5.5
C
57
52
P
4
4.1
B
61
53
F
4
7.1
B
62
54
F/P
4
6.5
B
63
55
F/P
4
6.6
B
64
56
F/P
4
4.4
D
56
57
P
4
9.5
C
60
58
F/P
4
0.34
D
50
2.2
B
31
59
F
5
0.63
NR
65
1.2
C
21
60
1.2
B
24
61
0.59
C
57
62
P
5
1.7
C
57
63
P
5
1.1
C
57
64
P
5
0.57
C
57
65
P
5
1.7
B
61
66
F
5
0.52
B
62
67
F/P
5
3.3
B
63
00
CD
F/P
5
4.6
C
64
69
F/P
5
8.7
A
76
1,600
B
31
70
F
6
1,000
NR
65
1,800
C
21
71
1,900
B
24
72
-------
TABLE 4-5. (Continued)
Type of No. of ssion factor, kg/Mg
Pollutant
control runs(a)
Minimum
Maximum
C02
FF 3a
950
950
C02
FF 3c
800
900
C02
FF 3c
950
1,000
C02
FF 3c
1,000
1,100
C02
FF 3c
970
1,000
C02
FF 3d
1,050
1,400
C02
FF 12d
1,350
1,400
C02
FF 2
700
950
C02
FF 6
960
980
TOC
FF 3a
0.048
0.094
TOC
FF 3a
0.032
0.040
TOC
FF 3b
0.070
0.075
TOC
FF 3b
0.0060
0.014
TOC
FF 3b
0.030
0.037
TOC
FF 3b
0.044
0.080
TOC
FF 3b
0.035
0.060
TOC
FF 3b
0.017
0.025
TOC
FF 3
0.036
0.085
TOC
FF 3
0.16
0.20
sulfate
FF 3a
0.0066
0.0069
sulfate
FF 3a
1.2E-006
2.0E-006
sulfate
FF 3b
0.0017
0.0031
sulfate
FF 3b
0.0030
0.0055
sulfate
FF 3b
0.0040
0.0055
sulfate
FF 3b
0.0008
0.0022
sulfate
FF 3b
0.0060
0.0065
sulfate
FF 3b
0.0023
0.0031
Emission factor, lb/ton
Data
Ref.
Average
Minimum
Maximum
Average
rating
No.
950
1,900
1,900
1,900
B
27
73
850
1,600
1,800
1,700
B
61
74
F
6
950
1,900
2,000
1,900
B
62
75
F/P
6
1,100
2,000
2,200
2,100
B
63
76
F/P
6
1,000
1,900
2,000
2,000
B
64
77
F/P
6
1,200
2,100
2,800
2,400
D
56
78
P
6
1,400
2,700
2,800
2,800
C
60
79
F/P
6
800
1,400
1,900
1,600
D
74
970
1,900
2,000
1,900
A
76
0.064
0.10
0.19
0.13
B
24
80
0.036
0.065
0.080
0.071
B
27
81
0.075
0.14
0.15
0.15
C
57
82
P
7
0.010
0.012
0.027
0.019
C
57
83
P
7
0.033
0.059
0.074
0.066
C
57
84
P
7
0.060
0.088
0.16
0.12
C
57
85
P
7
0.045
0.069
0.12
0.090
C
57
86
P
7
0.020
0.033
0.050
0.040
C
57
87
P
7
0.054
0.071
0.17
0.11
B
61
88
F
7
0.18
0.31
0.39
0.35
A
76
0.0068
0.013
0.014
0.014
B
24
89
1.7E-006
0.00000238
0.0000039
3.4E-006
B
27
90
0.0026
0.0033
0.0062
0.0052
C
57
91
P
8
0.0044
0.0059
0.011
0.0087
C
57
92
P
8
0.0047
0.0080
0.011
0.0094
C
57
93
P
8
0.0014
0.0016
0.0043
0.0027
C
57
94
P
8
0.0065
0.012
0.013
0.013
C
57
95
P
8
0.0026
0.0045
0.0062
0.0051
C
57
96
P
8
-------
TABLE 4-5. (Continued)
Type of No. of ssion factor, kg/Mg
Pollutant
control
runs(a)
Minimum
Maximum
S03
FF
3
0.0020
0.0069
HCI
FF
3
0.13
0.14
HCI
FF
3
0.00094
0.0016
HCI
FF
3
0.0024
0.0095
CI
FF
3
6.5E-004
1.5E-003
NH3
FF
3
0.0050
0.0052
Ag
FF
3
3.0E-007
3.2E-007
As
FF
3
5.0E-006
7.0E-006
Ba
FF
3
0.00011
0.00049
Be
FF
3
1.9E-007
5.0E-007
Cd
FF
3
3.7E-006
1.5E-005
Cd
FF
3
9.5E-007
1.3E-006
Cr
FF
3
4.8E-005
0.00011
Cu
FF
3
0.00011
0.0077
Hg
FF
3
8.5E-005
0.00014
Hg
FF
3
9.0E-006
1.3E-005
Pb
FF
3
1.4E-005
6.3E-005
Pb
FF
3
3.5E-005
4.0E-005
Se
FF
3
8.5E-005
0.00013
Th
FF
3
2.3E-006
3.5E-006
Zn
FF
3
0.00020
0.00039
Zn
FF
3
0.00010
0.00029
acenaphthalene
FF
3
5.3E-006
0.00015
acenaphthene
FF
1
NA
NA
acetone
ESP
1
NA
NA
anthracene
FF
1
NA
NA
benzene
FF
3
0.0057
0.0094
Emission factor, lb/ton
Average
Minimum
Maximum
0.0053
0.0041
0.0138
0.14
0.26
0.29
0.0013
0.0019
0.0032
0.0060
0.0048
0.019
1.1E-003
0.0013
0.0029
0.0051
0.010
0.010
3.1 E-007
5.9E-007
6.3E-007
6.0E-006
1.0E-005
1.4 E-005
0.00023
0.00021
0.00098
3.3E-007
3.8E-007
9.9E-007
7.9E-006
7.3E-006
3.1 E-005
1.1E-006
0.0000019
0.0000025
7.0E-005
0.000096
0.00022
0.0026
0.00022
0.015
0.00010
0.00017
0.00027
1.0E-005
1.8E-005
2.5E-005
3.4E-005
2.9E-005
0.00013
3.8E-005
0.000069
8.0E-005
0.00010
0.00017
0.00026
2.7E-006
0.0000046
0.0000069
0.00028
0.00041
0.00078
0.00017
0.00020
0.00058
5.9E-005
1.1 E-005
0.00031
1.0E-005
NA
NA
2.5E-005
NA
NA
6.5E-006
NA
NA
0.0080
0.011
0.019
Data Ref.
Average rating No.
9
10
{EDIT}*1,7~
0.00020
D
74
2.0E-005
A
76
6.8E-005
D
74
0.000075
A
76
0.00020
D
74
0.0000054
A
76
0.00056
D
74
0.00034
A
76
0.00012
D
74
2.0E-005
NR
74
4.9E-005
NR
65
1.3E-005
NR
74
0.016
D
74
0.0105
B
24
0.27
B
64
0.0026
D
74
0.012
A
76
0.0021
A
76
0.010
D
64
6.1 E-007
A
76
1.2E-005
A
76
0.00046
A
76
6.6E-007
A
76
1.6E-005
D
74
0.0000022
A
76
0.00014
A
76
0.0053
D
74
-------
TABLE 4-5. (Continued)
Type of
No. of
ssion factor, kg/Mg
Emission factor, lb/ton
Data
Pollutant
control
runs(a)
Minimum
Maximum
Average
Minimum
Maximum
Average
rating
benzene
ESP
1
NA
NA
0.00043
NA
NA
0.00086
NR
benzo(a)anthracene
FF
3
2.0E-008
2.5E-008
2.1 E-008
3.9E-008
4.9E-008
4.3E-008
D
benzo(a)pyrene
FF
3
4.9E-008
8.5E-008
6.5E-008
9.9E-008
1.7 E-007
1.3E-007
D
benzo(b)fluoranthene
FF
3
6.5E-008
6.6E-007
2.8E-007
1.3 E-007
1.3 E-006
5.6E-007
D
benzo(g,h,i)perylene
FF
3
2.5E-008
4.7E-008
3.9E-008
4.9E-008
9.4E-008
7.8E-008
D
benzo(k)fluoranthene
FF
3
6.3E-008
9.4E-008
7.7E-008
1.3 E-007
1.9 E-007
1.5E-007
D
bis(2-ethylhexyl)phthalate
ESP
1
NA
NA
0.00011
NA
NA
0.00021
NR
chrysene
FF
3
5.4E-008
1.0E-007
8.1 E-008
1.1 E-007
2.0E-007
1.6E-007
D
dibens(a,h)anthracene
FF
3
2.4E-008
3.9E-008
3.1 E-007
4.8E-008
7.8E-008
6.3E-007
D
1,1-dichloroethene
ESP
1
NA
NA
8.0E-007
NA
NA
1.6E-006
NR
ethylbenzene
ESP
1
NA
NA
6.5E-005
NA
NA
0.00013
NR
fluoranthene
FF
3
1.7E-006
6.5E-006
4.4E-006
3.4E-006
1.3E-005
8.8E-006
D
fluorene
FF
3
1.1 E-006
1.7E-005
9.4E-006
2.2E-006
3.4E-005
1.9E-005
D
formaldehyde
FF
3
0.00022
0.00027
0.00023
0.00044
0.00054
0.00046
D
indeno(1,2,3-cd)pyrene
FF
3
2.4E-008
6.3E-008
4.3E-008
4.8E-008
1.3 E-007
8.7E-008
D
methylene chloride
ESP
1
NA
NA
0.00023
NA
NA
0.00046
NR
monochlorobenzene
ESP
1
NA
NA
4.7E-006
NA
NA
9.4E-006
NR
naphthalene
FF
3
8.2E-005
0.0020
0.00085
0.00016
0.0039
0.0017
D
phenanthrene
FF
3
2.8E-005
0.00044
0.00020
5.6E-005
0.00088
0.00039
D
pyrene
FF
3
7.7E-007
3.5E-006
2.2E-006
1.5 E-006
7.0E-006
4.4E-006
D
tetrachloroethene
ESP
1
NA
NA
2.2E-006
NA
NA
4.3E-006
NR
toluene
ESP
1
NA
NA
0.00041
NA
NA
0.00082
NR
trichloroethene
ESP
1
NA
NA
2.6E-006
NA
NA
5.2E-006
NR
trichlorofluoromethane
ESP
1
NA
NA
3.3E-005
NA
NA
6.5E-005
NR
1,1,1-trichloroethane
ESP
1
NA
NA
4.0E-007
NA
NA
8.0E-007
NR
total HpCDD
FF
3
1.8E-010
2.1 E-010
2.0E-010
3.6E-010
4.3E-010
3.9E-010
D
total OCDD
FF
3
8.5E-010
1.3E-009
1.0E-009
1.7E-009
2.6E-009
2.0E-009
D
Ref.
No.
65
74
74
74
74
74
65
74
74
65
65
74
74
74
74
65
65
74
74
74
65
65
65
65
65
74
74
-------
TABLE 4-5. (Continued)
Type of No. of ssion factor, kg/Mg Emission factor, lb/ton Data Ref.
Pollutant
control
runs(a)
Minimum
Maximum
Average
Minimum
Maximum
Average
rating
No.
total PCDD
FF
3
1.2E-009
1.5E-009
1.4E-009
2.4E-009
3.1 E-009
2.7E-009
D
74
total PCDF
FF
2
1.1E-010
1.9E-010
1.4E-010
2.2E-010
3.7E-010
2.9E-010
D
74
total TCDF
FF
2
1.1E-010
1.9E-010
1.4E-010
2.2E-010
3.7E-010
2.9E-010
D
74
CDD/CDF
ESP
1
NA
NA
1.2E-009
NA
NA
2.3E-009
NR
65
1,2,3,4,6,7,8 HpCDD
FF
3
1.1E-010
1.1E-010
1.1E-010
2.2E-010
2.2E-010
2.2E-010
D
74
ESP = electrostatic precipitator.
FF = fabric filter.
ST = spray tower.
TOC = total organic compounds.
NA = not applicable.
NR = not rated.
(a) Multiple tests on same kiln indicated by a-d.
(b) Average CEM readings over 3-day period.
-------
TABLE 4-6. SUMMARY OF TEST DATA FOR PORTLAND CEMENT
CLINKER COOLERS
Type of
No. of
Emission factor, kg/Mg
Emission factor, lb/ton
Pollutant
control
runs(a)
Mnimum
Maximum
Average
Mnimum
Maximum
Average
filterable PM
ESP
3
0.040
0.055
0.048
0.08
0.11
0.096
filterable PM
FF
3
0.20
0.27
0.24
0.41
0.54
0.47
filterable PM
FF
3
0.012
0.022
0.017
0.025
0.045
0.034
filterable PM
FF
3
0.0036
0.010
0.0060
0.0071
0.020
0.012
filterable PM
FF
3a
0.0032
0.0044
0.0036
0.0064
0.0087
0.0072
filterable PM
FF
3a
0.010
0.010
0.010
0.020
0.020
0.020
filterable PM
GBF
3
0.075
0.090
0.080
0.15
0.18
0.16
filterable PM
GBF
3
0.032
0.070
0.055
0.064
0.14
0.11
filterable PM
C/GFB
2
0.060
0.085
0.070
0.12
0.17
0.14
filterable PM
C/GFB
3
0.16
0.24
0.18
0.32
0.48
0.35
condensible
ESP
3
0.0026
0.0044
0.0038
0.0052
0.0088
0.0075
inorg. PM
condensible
FF
3
0.0050
0.014
0.0090
0.010
0.027
0.018
inorg. PM
condensible
FF
3
0.010
0.020
0.016
0.021
0.04
0.031
inorg. PM
condensible
FF
3
0.0000
0.0010
0.00034
0.0000
0.0020
0.00067
inorg. PM
condensible
GBF
3
0.0024
0.0070
0.0050
0.0048
0.014
0.010
inorg. PM
condensible
GBF
3
0.0027
0.0060
0.0040
0.0054
0.012
0.0079
inorg. PM
Be
ESP
1
NA
NA
4.0e-07
NA
NA
8.0e-07
Be
FF
1
NA
NA
0.0000004
NA
NA
8.7e-07
Cd
FF
1
NA
NA
0.0000085
NA
NA
1.7e-05
-------
TABLE 4-6. (Continued)
Cr
ESP
1 NA
NA
Cr
FF
1 NA
NA
Cu
ESP
1 NA
NA
Cu
FF
1 NA
NA
Fe
ESP
1 NA
NA
Fe
FF
1 NA
NA
Mn
ESP
1 NA
NA
Mn
FF
1 NA
NA
7.5e-05
NA
NA
0.00015
0.00018
NA
NA
0.00037
1.3e-05
NA
NA
2.6e-05
0.00011
NA
NA
0.00022
0.0014
NA
NA
0.0027
0.0070
NA
NA
0.014
1.7e-05
NA
NA
3.4e-05
8.5e-05
NA
NA
0.00017
-------
TABLE 4-6. (Continued)
Type of No. Emission factor, kg/Mg
Pollutant
control
runs(a) Mnimum
Maximum
Ni
ESP
1 NA
NA
Ni
FF
1 NA
NA
Pb
FF
1 NA
NA
Sb
FF
1 NA
NA
Sr
ESP
1 NA
NA
Sr
FF
1 NA
NA
V
ESP
1 NA
NA
Zn
FF
1 NA
NA
ESP = electrostatic precipitator.
FF = fabric
filter.
C = cylcone.
GBF = gravel bed filter.
NA = not applicable.
NR = not rated.
(a) Multiple tests on same clinker cooler indicated by a.
Emission factor, lb/ton
Average
Mnimum
Maximum
Average
7.5e-05
NA
NA
0.00015
0.00011
NA
NA
0.00022
6.5e-05
NA
NA
0.00013
0.0000215
NA
NA
4.3e-05
0.00022
NA
NA
0.00043
0.00044
NA
NA
0.00087
l.le-05
NA
NA
2.2e-05
0.00085
NA
NA
0.0017
-------
TABLE 4-7. SUMMARY OF TEST DATA FOR PORTLAND CEMENT OTHER PROCESSES
Type of
No. of
Emission factor, kg/Mg
Emission factor, lb/ton
Data
Ref.
Pollutant control
runs
Minimum
Maximum
Average
Minimum
Maximum
Average
rating
No.
RAW MILL
filterable PM FF
2
0.0080
0.0090
0.0085
0.016
0.018
0.017
C
8
filterable PM FF
3
0.0041
0.0048
0.0045
0.0081
0.0096
0.0089
B
61
filterable PM FF
3
0.0043
0.0060
0.0055
0.0086
0.012
0.011
B
62
Sb FF
1
NA
NA
9.5E-007
NA
NA
0.0000019
NR
8
Cr FF
1
NA
NA
9.5E-007
NA
NA
0.0000019
NR
8
Cu FF
1
NA
NA
4.7E-006
NA
NA
0.0000094
NR
8
Fe FF
1
NA
NA
4.7E-005
NA
NA
0.000094
NR
8
Mn FF
1
NA
NA
3.8E-006
NA
NA
0.0000075
NR
8
Sr FF
1
NA
NA
1.9E-005
NA
NA
0.000038
NR
8
Zn FF
1
NA
NA
1.9E-006
NA
NA
0.0000038
NR
8
RAW MILL FEED BELT
filterable PM FF
2
0.0012
0.0020
0.0016
0.0023
0.0039
0.0031
C
62
RAW MILL WEIGH HOPPER
filterable PM FF
2
0.0075
0.012
0.010
0.015
0.023
0.019
C
8
Be FF
1
NA
NA
1.3E-008
NA
NA
2.5E-008
NR
8
Cr FF
1
NA
NA
3.8E-006
NA
NA
0.0000076
NR
8
Cu FF
1
NA
NA
3.8E-006
NA
NA
0.0000076
NR
8
Fe FF
1
NA
NA
1.3E-005
NA
NA
0.000025
NR
8
Pb FF
1
NA
NA
2.6E-006
NA
NA
0.0000051
NR
8
Mn FF
1
NA
NA
6.5E-006
NA
NA
0.000013
NR
8
Ni FF
1
NA
NA
5.0E-006
NA
NA
1.0E-005
NR
8
Zn FF
1
NA
NA
2.6E-006
NA
NA
0.0000051
NR
8
RAW MILL AIR SEPARATOR
filterable PM FF
2
0.014
0.019
0.016
0.027
0.038
0.032
C
8
Cd FF
1
NA
NA
4.5E-007
NA
NA
8.9E-007
NR
8
Cu FF
1
NA
NA
7.5E-006
NA
NA
1.5E-005
NR
8
Fe FF
1
NA
NA
2.1 E-005
NA
NA
4.1 E-005
NR
8
aped POLLUTAN APCD
1
-------
TABLE 4-7. (Continued)
Type of No. Emission factor, kg/Mg
Pollutant
control runs
Minimum
Maximum
Average
Pb
FF
1
NA
NA
1.5E-006
Mn
FF
1
NA
NA
7.5E-006
Zn
FF
1
NA
NA
9.0E-006
FINISH GRINDING MILL
filterable PM
FF
3
0.0065
0.0070
0.0065
filterable PM
FF
3
0.0060
0.010
0.0080
filterable PM
FF
2
0.0030
0.0030
0.0030
filterable PM
FF
3
0.00044
0.0021
0.0015
filterable PM
FF
3
0.00110
0.0033
0.0020
FINISH GRINDING MILL FEED BELT
filterable PM
FF
3
0.0012
0.0014
0.0012
FINISH GRINDING MILL WEIGH HOPPER
filterable PM
FF
3
0.0046
0.0048
0.0047
Cd
FF
1
NA
NA
7.5E-007
Cr
FF
1
NA
NA
2.3E-006
Cu
FF
1
NA
NA
5.5E-006
Fe
FF
1
NA
NA
1.8E-004
Mn
FF
1
NA
NA
3.8E-006
Ni
FF
1
NA
NA
6.0E-006
Zn
FF
1
NA
NA
3.1 E-005
FINISH GRINDING MILL AIR SEPARATOR
filterable PM
FF
3
0.018
0.021
0.020
filterable PM
FF
2
0.0080
0.0085
0.0085
Cd
FF
1
NA
NA
1.3E-006
Cu
FF
1
NA
NA
1.6E-005
Fe
FF
1
NA
NA
1.3E-004
Mn
FF
1
NA
NA
4.9E-006
Ni
FF
1
NA
NA
1.6E-006
Zn
FF
1
NA
NA
6.5E-005
Emission factor, lb/ton
Data
Ref.
Minimum
Maximum
Average
rating
No.
pollutant
aped
NA
NA
3.0E-006
NR
8
F
NA
NA
1.5E-005
NR
8
F
NA
NA
1.8E-005
NR
8
F
0.013
0.014
0.013
B
3
F
1
0.012
0.020
0.016
B
5
F
1
0.0060
0.0060
0.0060
C
8
F
1
0.00088
0.0041
0.0029
B
61
0.0022
0.0065
0.0040
B
62
0.0023
0.0027
0.0024
B
62
0.0092
0.0095
0.0094
C
8
F
NA
NA
0.0000015
NR
8
F
NA
NA
0.0000045
NR
8
F
NA
NA
0.000011
NR
8
F
NA
NA
0.00036
NR
8
F
NA
NA
0.0000076
NR
8
F
NA
NA
0.000012
NR
8
F
NA
NA
0.000061
NR
8
F
0.035
0.042
0.039
B
3
F
1
0.016
0.017
0.017
C
8
F
1
NA
NA
0.0000026
NR
8
F
NA
NA
0.000032
NR
8
F
NA
NA
0.00026
NR
8
F
NA
NA
0.0000097
NR
8
F
NA
NA
0.0000032
NR
8
F
NA
NA
0.00013
NR
8
APCD
-------
TABLE 4-7. (Continued)
Type of No. Emission factor, kg/Mg
Emission factor, lb/ton
Data Ref.
Pollutant control runs Minimum Maximum Average Minimum Maximum Average rating No. pollutant
PRIMARY LIMESTONE CRUSHING
0.00040 0.00070
0.00050
9.0E-005 0.00013 0.00011
filterable PM FF
PRIMARY LIMESTONE SCREENING
filterable PM FF
LIMESTONE TRANSFER
filterable PM FF 3 8.5E-006 2.1E-005 1.5E-005
SECONDARY LIMESTONE SCREENING AND CRUSHING
filterable PM FF 3 8.5E-005
FF = fabric filter.
NA = not applicable.
NR = not rated.
0.00021
0.00016
0.00079 0.0014 0.0010 B 9 F
0.00018 0.00026 0.00022 C 9 F
1.7E-005 4.1E-005 2.9E-005 B 9 F
0.00017 0.00041 0.00031 B 9 F
aped POLLUTAN APCD
-------
TABLE 4-8. SUMMARY OF AVERAGE PARTICLE SIZE DISTRIBUTION
FOR PORTLAND CEMENT KILNS3
Particle
size, |im
Cumulative mass percent equal to or less than stated size
Uncontrolled
Controlled
Wet process
Dry process
Wet process
with ESP
Dry process
with FF
2.5
7
18
64
45
5.0
20
ND
83
77
10.0
24
42
85
84
15.0
35
44
91
89
20.0
57
ND
98
100
aReference 79.
TABLE 4-9. SUMMARY OF AVERAGE PARTICLE SIZE DISTRIBUTION
FOR PORTLAND CEMENT CLINKER COOLERS3
Particle size, |im
Cumulative mass percent equal to or less than stated size
Uncontrolled
With gravel bed filter
2.5
0.54
40
5.0
1.5
64
10.0
8.6
76
15.0
21
84
20.0
34
89
aReference 79.
29
-------
TABLE 4-10. ESTIMATED C02 EMISSION FACTORS FOR
PORTLAN
D CEMENT KILNS3
Kiln process
Fuel
requirements,
j/Mg
(MMBtu/ton)
CO, emission factor
Fuel combustion,
for
CaC03,
Total,
kg/]
(lb/MMBtu)
kg/Mg
(lb/ton)
kg/Mg
(lb/ton)
kg/Mg
(lb/ton)
Coal-fired
Wet
6.00 x 109
(5.14)
0.100 x 10"6
(233)
600
(1,200)
500
(1,000)
1,100
(2,200)
Dry
5.59 x 109
(4.82)
0.100 x 10"6
(233)
560
(1,100)
500
(1,000)
1,100
(2,100)
Preheater
4.24 x 109
(3.65)
0.100 x 10"6
(233)
430
(850)
500
(1,000)
930
(1,900)
Gas-fired
Wet
6.00 x 109
(5.14)
0.603 x 10"6
(140)
360
(720)
500
(1,000)
860
(1,700)
Dry
5.59 x 109
(4.82)
0.603 x 10"6
(140)
340
(680)
500
(1,000)
840
(1,700)
Preheater
4.24 x 109
(3.65)
0.603 x 10"6
(140)
260
(510)
500
(1,000)
760
(1,500)
aReference 80.
59
-------
TABLE 4-11. SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR WET PROCESS KILNS
Pollutant
filterable PM
filterable PM
filterable PM
filterable PM
condensible inorg. PM
condensible inorg. PM
condensible inorg. PM
filterable PM-10
filterable PM-10
S02
NOx
CO
C02
Type of
control
none
ESP
FF
CT/MC/ESP
ESP
FF
CT/MC/ESP
none
ESP
none
none
none
none
TOC none
ESP = electrostatic precipitator.
FF = fabric filter.
CT = cooling tower.
MC = multiclone.
TOC = total organic compounds.
(a) Based on a single particle size test.
(b) Based on two particle size tests.
No. of No. of rage emission factor
tests kilns kg/Mg
2 2 65
20 11 0.38
1 1 0.23
1 1 0.10
4 4 0.076
1 1 0.10
1 1 0.14
(a) 1 16
(b) 2 0.33
17 8 4.1
7 6 3.7
1 1 0.060
12 7 1,100
1 1 0.014
lb/ton
130
0.77
0.46
0.20
0.15
0.20
0.29
31
0.65
8.2
7.4
0.12
2,100
0.028
Factor
rating
D
C
E
E
D
E
E
D
D
D
D
C
References
13,19
1,2,11,13,18,19,26,28,
29,30,40,42,43,44,67,77
1,2,13,77
19,79
1,2,11,13,18,19,26,28,29,
30,40,42,43,44,67,77,79
13,18,19,26,28,29,30,
40,42,44,77
19,28,29,30,43,77
18,19,26,28,29,30,44,
67,77
-------
TABLE 4-12. SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR LONG DRY PROCESS KILNS
Type of
No. of
srage emission factor
Factor
Pollutant
control
tests
kg/Mg
lb/ton
rating
References
filterable PM
ESP
5
0.50
1.00
D
12,14
filterable PM
FF
1
0.10
0.20
D
condensible inorg. PM
ESP
5
0.19
0.38
D
12,14
condensible inorg. PM
FF
1
0.45
0.89
D
filterable PM-10
FF
(a)
0.084
0.17
D
16,79
S02
none
5
4.9
10
D
4,12,36,37
NOx
none
7
3.0
6.0
D
4,35,36,37,78
CO
none
2
0.11
0.21
E
36,78
C02
none
6
900
1,800
D
4,14,16,78
TOC
none
2
0.014
0.028
E
37,78
ESP = electrostatic precipitator.
FF = fabric filter.
CT = cooling tower.
MC = multiclone.
TOC = total organic compounds.
(a) Based on two particle size tests.
-------
TABLE 4-13. SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR PREHEATER PROCESS KILNS
Type of
No. of
•age emission factors
Factor
Pollutant
control
tests
kg/Mg
lb/ton
rating
References
filterable PM
none
1
130
250
D
10
filterable PM
ESP
1
0.13
0.26
D
25
filterable PM
FF
8
0.13
0.25
C
10,52,53,54,55,69
condensible inorg. PM
FF
1
0.017
0.033
D
55
S02
none
4
0.27
0.55
D
52,53,54,55
NOx
none
3
2.4
4.8
D
53,54,55
CO
none
1
0.49
0.98
D
54
C02
none
11
900
1,800
C
17,25,52,53,54,55,69
TOC
none
1
0.090
0.18
D
54
ESP = electrostatic precipator.
FF = fabric filter.
TOC = total organic compounds.
-------
TABLE 4-14. SUMMARY OF CRITERIA POLLUTANT EMISSION FACTORS FOR PREHEATER/PRECALCINER KILNS
Type of
Pollutant control
filterable PM ESP
filterable PM FF
condensible inorg. PM controlled
S02 none
S02 ST
NOx none
CO none
C02 none
TOC none
ESP = electrostatic precipator.
FF = fabric filter.
ST = spray tower.
TOC = total organic compounds.
No. of
tests
1
8
5
9
2
9
7
11
4
No. of age emission factors
kilns
1
4
4
4
2
4
4
11
2
kg/Mg
0.024
0.10
0.078
0.54
0.50
2.1
1.8
900
0.059
lb/ton
0.048
0.21
0.16
1.1
1.0
4.2
3.7
1,800
0.12
Factor
rating References
D
D
D
D
E
D
D
E
D
31
24,27,56,61,62,63,64,76
24,27,31,56,64
21,24,27,31,58,61,62,
63,64
59
21,24,27,31,49,61,62,
63,64
21,24,31,61,62,63,76
17,25,52,53,54,55,69
24,27,61,76
-------
TABLE 4-15. SUMMARY OF NONCRITERIA POLLUTANT EMISSION FACTORS FOR PORTLAND CEMENT KILNS
Type of
No. of
No. of
srage emission factor
Factor
Pollutant
control
tests
kilns
kg/Mg
lb/ton
rating
References
Ag
FF
1
1
3.1 E-007
6.1 E-007
D
Al
ESP
1
1
0.0065
0.013
E
As
ESP
1
1
6.5E-006
0.000013
E
As
FF
1
1
6.0E-006
1.2E-005
D
Ba
ESP
1
1
0.00018
0.00035
D
Ba
FF
1
1
0.00023
0.00046
D
Be
FF
1
1
3.3E-007
6.6E-007
D
Ca
ESP
1
1
0.12
0.24
E
Cd
ESP
1
1
4.2E-006
0.0000083
D
Cd
FF
1
1
1.1E-006
0.0000022
D
CI
ESP
6
2
0.34
0.68
E
18,42,43,44
CI
FF
1
1
0.0011
0.0021
D
Cr
ESP
1
1
3.9E-006
0.0000077
E
Cr
FF
1
1
7.0E-005
0.00014
D
Cu
FF
1
1
0.0026
0.0053
E
F
ESP
1
1
0.00045
0.00090
E
Fe
ESP
1
1
0.0085
0.017
E
HCI
ESP
2
2
0.025
0.049
E
40,78
HCI
FF
2
2
0.073
0.14
D
64,76
Hg
ESP
1
1
0.00011
0.00022
D
Hg
FF
2
2
1.2E-005
2.4E-005
D
4,76
K
ESP
5
2
0.0090
0.018
D
18,42,43
Mn
ESP
1
1
0.00043
0.00086
E
NH3
FF
1
1
0.0051
0.010
E
NH4
ESP
6
2
0.054
0.11
D
18,42,43,44
N03
ESP
1
1
0.0023
0.0046
E
Na
ESP
6
2
0.020
0.038
D
18,42,43,44
Pb
ESP
1
1
0.00036
0.00071
D
Pb
FF
1
1
3.8E-005
0.000075
D
76
78
78
76
77
76
76
78
77
76
76
77
76
74
43
78
77
78
64
43
77
76
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-------
TABLE 4-15. (Continued)
Type of No. of No. of Average emission factor Factor
Pollutant control tests kilns kg/Mg lb/ton rating References
chlorobenzene
ESP 1
1 8.0E-006
0.000016
D
chloromethane
ESP 1
1 0.00019
0.00038
E
chrysene
FF 1
1 8.1 E-008
1.6E-007
E
di-n-butylphthalate
ESP 1
1 2.1 E-005
0.000041
D
dibenz(a,h)anthracene
FF 1
1 3.1 E-007
6.3E-007
E
ethylbenzene
ESP 1
1 9.5E-006
0.000019
D
fluoranthene
FF 1
1 4.4E-006
8.8E-006
E
fluorene
FF 1
1 9.4E-006
1.9E-005
E
formaldehyde
FF 1
1 0.00023
0.00046
E
freon 113
ESP 1
1 2.5E-005
5.0E-005
E
indeno(1,2,3-cd)pyrene
FF 1
1 4.3E-008
8.7E-008
E
methyl ethyl ketone
ESP 1
1 1.5E-005
3.0E-005
E
methylene chloride
ESP 1
1 0.00025
0.00049
E
methylnaphthalene
ESP 1
1 2.1 E-006
0.0000042
E
naphthalene
FF 1
1 0.00085
0.0017
E
naphthalene
ESP 1
1 0.00011
0.00022
D
phenanthrene
FF 1
1 0.00020
0.00039
E
phenol
ESP 1
1 5.5E-005
0.00011
D
pyrene
FF 1
1 2.2 E-006
4.4E-006
E
styrene
ESP 1
1 7.5E-007
0.0000015
E
toluene
ESP 1
1 0.00010
0.00019
D
total HpCDD
FF 1
1 2.0E-010
3.9E-010
E
total OCDD
FF 1
1 1.0E-009
2.0E-009
E
total PCDD
FF 1
1 1.4E-009
2.7E-009
E
total PCDF
FF 1
1 1.4E-010
2.9E-010
E
total TCDF
FF 1
1 1.4E-010
2.9E-010
E
xylenes
ESP 1
1 6.5E-005
0.00013
D
ESP = electrostatic precipitator.
FF = fabric filter.
77
77
74
77
74
77
74
74
74
78
74
78
78
74
77
74
77
74
78
77
74
74
74
74
74
77
-------
TABLE 4-16. SUMMARY OF AVERAGE EMISSION FACTORS FOR CLINKER COOLERS
Type of
No. of
srge emission factors
Factor
Pollutant
control
tests
kg/Mg
lb/ton
rating
References
filterable PM
ESP
1
0.048
0.096
D
1
filterable PM
FF
5
0.068
0.13
D
2,5,20,24,27
filterable PM
GBF
3
0.11
0.21
D
15,23,25
condensible inorg.
PM
ESP
1
0.0038
0.0075
D
1
condensible inorg.
PM
FF
3
0.0084
0.017
D
2,5,24
condensible inorg.
PM
GBF
2
0.0045
0.090
D
15,23
filterable PM-10
GBF
1
0.084
0.16
D
15,23,25,79
ESP = electrostatic precipitator.
FF = fabric filter.
GBF = gravel bed filter.
-------
TABLE 4-17. SUMMARY
FACTORS FOR OTHER
V OF AVERAGE EMISSION
PROCESSES
Type of
No. of
Average emission factor,
Factor
Pollutant
control
tests
kg/Mg
lb/ton
rating
Refs.
RAW MILL
filterable PM
FF
3
0.0062
0.012
D
8,61,62
RAW MILL FEED BELT
filterable PM
FF
1
0.0016
0.0031
E
62
RAW MILL WEIGH HOPPER
filterable PM
FF
1
0.010
0.019
E
8
RAW MILL AIR SEPARATOR
filterable PM
FF
1
0.016
0.032
E
8
FINISH GRINDING MIL!
filterable PM
FF
5
0.0042
0.0080
D
3,5,8,61,62
FINISH GRINDING MIL!
L FEED BE
LT
filterable PM
FF
1
0.0012
0.0024
E
62
FINISH GRINDING MIL
L WEIGH F
IOPPER
filterable PM
FF
1
0.0047
0.0094
E
8
FINISH GRINDING MILL AIR
SEPARATOR
filterable PM
FF
2
0.014
0.028
D
38
PRIMARY LIMESTONE CRUSHING
filterable PM
FF
1
0.00050
0.0010
E
9
PRIMARY LIMESTONE SCREENING
filterable PM
FF
1
0.00011
0.00022
E
9
LIMESTONE TRANSFER
filterable PM
FF
1
1.5e-05
2.9e-05
E
9
SECONDARY LIMESTONE SCREENING AND
CRUSHING
filterable PM
FF
1
0.00016
0.00031
E
9
FF = fabric filter.
NA = not applicable.
NR = not rated.
In addition to the tables for this chapter is a Lotus 1,2,3 spreadsheet file (Cementr6.wk4) that contains
summary statistical information about emission factors presented in the AP-42 section and background
report. This information is not contained in the background report or the final AP-42 section and can be
used for uncertainty estimates. To obtain this file, download it from
http://www.epa.gov/ttn/chief/fbgdocs/blls06.zip Unzip the file and open Cementr6.wk4
-------
4.2.1.2 Reference 2. This report documents measurements of filterable PM, condensible
inorganic PM, and C02 emissions from a gas-fired rotary kiln and a clinker cooler. A trace metal
analysis was also conducted on the total PM catches for one run of the kiln and cooler tests. The
emission test was conducted in 1971 and was sponsored by EPA as part of the development of an NSPS
for portland cement plants. The plant uses the wet process, and process rates were provided on the basis
of the slurry feed rate. Emissions from the kiln are controlled with an ESP, and clinker cooler emissions
are controlled with a fabric filter. Only controlled emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back half); no information
was provided on the method used to measure C02 emissions. The report states that the trace metal
analysis was performed using spectroscopy, but no other details are provided. Two PM runs were
conducted on the kiln stack and three runs were conducted on the clinker cooler stack. The tests on the
kiln were interrupted due to inclement weather, but the data were considered to be representative.
Emission factors were developed for filterable and condensible PM emissions and for the
emissions of 12 trace metals, including Sb, Be, Cd, Cr, Cu, Fe, Pb, Mn, Ni, Sr, V, and Zn. The samples
also were analyzed for arsenic but the concentration was below the detection limit. There was
insufficient information to develop emission factors for C02 emissions.
The clinker cooler emission data for filterable and condensible PM are rated B. The test
methodology was sound and no problems were reported, but the report lacked adequate documentation
for a higher rating. The kiln PM test data are rated C because only two test runs were conducted. The
trace metal emission data are unrated because only a single run was conducted, and details on the
analytical procedure are not provided in the report.
4.2.1.3 Reference 3. This report documents measurements of filterable PM and condensible
inorganic PM emissions from an air separator and a finishing mill, and S02, NOx, and gaseous mercury
emissions from an oil-fired rotary kiln. The emission test was sponsored by EPA as part of the
development of an NSPS for portland cement plants. The test was conducted in 1971. The plant uses
the wet process, and process rates were provided on the basis of slurry feed rate. Air separator
emissions are controlled by two fabric filters in parallel, and the finishing mill emissions are controlled by a
single fabric filter. Only controlled emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back half). Although
back half PM catches are reported in the results of the tests on the finishing mill and air separator, these
two processes should not emit condensible PM. Therefore, it is assumed that the back half catch is the
result of an anomaly in the sampling and analytical procedures used. The test report does not include
adequate information to determine the origin of this apparent anomaly.
Emissions of S02 and NOx were measured using continuous monitors. Gaseous mercury
emissions were measured by bubbling kiln stack gas through impingers containing an acidic solution of
iodine monochloride. Three PM runs were conducted on the air separator and finishing mill stacks, three
mercury, one S02, and one NOx runs were conducted on the kiln.
Emission factors were developed for filterable PM emissions from the air separator and the
finishing mill. The report indicates concentrations of S02, NOx, and gaseous mercury emissions but does
30
-------
not provide volumetric flow rates for the kiln stack. Therefore, inadequate information was available to
calculate emission factors for S02, NOx. and gaseous mercury emissions.
The air separator and finishing mill emission data for filterable PM are rated B. The test
methodology was sound, and no problems were reported, but the report lacked adequate documentation
for a higher rating.
4.2.1.4 Reference 4. This report documents measurements of filterable PM, condensible
inorganic PM, S02, NOx, C02, and gaseous mercury emissions from two coal-fired rotary kilns that are
ducted to a common stack. A trace metal analysis also was conducted on the total PM catch for run 1 of
the kiln test. The emission test was sponsored by EPA as part of the development of an NSPS for
Portland cement plants. The test was conducted in 1971. The plant uses the dry process, and process
rates were provided on the basis of feed rate. The kiln emissions are controlled by two fabric filters in
parallel, each preceded by a multiclone. Only controlled emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back half). Emissions of
S02 and NOx were measured using continuous monitors, but no details are provided on the methods and
instruments used. Gaseous mercury emissions were measured by bubbling kiln stack gas through
impingers containing an acidic solution of iodine monochloride. Carbon dioxide emissions were quantified
using Orsat. The report states that the trace metal analysis was performed using spectroscopy, but no
other details are provided. Three runs were conducted on the kiln for PM, S02, NOx. and mercury; two
C02 runs were conducted. All measurements were taken on the duct that collects gases from both fabric
filters. The PM sample collected during the first run had to be discarded due to contamination of the
sample, and the impinger water from the second and third PM runs was mistakenly mixed together.
Emission factors were developed for filterable and condensible PM from the two valid test runs
and for S02, NOx, C02, and gaseous mercury emissions from all three test runs on the kilns. Because the
trace metal analysis was performed on the catch of run 1, which was not valid, no trace metal emission
factors were developed. Because of the problems described above and the lack of adequate
documentation, the PM emission data are rated C. The S02 and NOx data are rated D because of the
nonstandard method used and the general lack of documentation in the report. The mercury emission
data are rated C due to the lack of adequate documentation, and the C02 emission data are rated C
because data from only two test runs are provided.
4.2.1.5 Reference 5. This report documents measurements of filterable PM and condensible
inorganic PM from a clinker cooler and a finishing grinding mill. A trace metal analysis was also
conducted on the total PM catch from one run on each of the sources tested. The emission test was
sponsored by EPA as part of the development of an NSPS for portland cement plants. The test was
conducted in 1971. The plant uses the wet process, and process rates were provided on the basis of
slurry feed rate. The clinker cooler and finishing mill emissions are controlled with fabric filters, and only
controlled emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back half), and three PM
runs were conducted. Although back half PM catches are reported in the results of the test on the
finishing mill, this process should not emit condensible PM. Therefore, it is assumed that the back half
catch is the result of an anomaly in the sampling and analytical procedures used. The test report does not
include adequate information to determine the origin of this apparent anomaly.
31
-------
Trace metal analyses of the PM catches also were performed using spark source mass
spectroscopy and optical emission spectroscopy.
Emission factors were developed for filterable and condensible inorganic PM emissions from the
clinker cooler and for filterable PM emissions from the finishing mill. Because of a discrepancy in the
total catches indicated for the trace metal analyses and the corresponding total PM catches, emission
factors were not developed for trace metal emissions. However, the report indicated that the following
metals were detected in the sample: Sb, As, boron (B), Cr, Cu, Fe, Pb, lithium (Li), Mn, Hg, Ni, Se, Ag,
Sr, tin (Sn), V, and Zn. The samples also were analyzed for Be, but the concentration of this element was
below the detection limit.
The clinker cooler and finish grinding mill emission data for filterable and condensible PM are
rated B. The test methodology was sound and no problems were reported, but the report lacked adequate
documentation for a higher rating.
4.2.1.6 Reference 6. This report documents measurements of filterable PM, condensible
inorganic PM, S02, NOx, and gaseous Hg emissions from a rotary kiln that was fired with natural gas and
No. 6 fuel oil. A trace metal analysis also was conducted on the PM filter catch from one run. The
emission test was sponsored by EPA as part of the development of an NSPS for portland cement plants.
The test was conducted in 1971. The plant uses the wet process, and process rates were provided on the
basis of the slurry feed rate. The kiln emissions are controlled by a fabric filter that exhausts to 12 stacks
in parallel. Both uncontrolled and controlled S02 emissions were measured, but only controlled PM, NOx,
and mercury emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back half), inlet S02
emissions were measured using Method 6, and outlet S02 and NOx emissions were measured using
Methods 7 and 8, respectively. Gaseous Hg emissions were measured by bubbling kiln stack gas through
impingers containing an acidic solution of iodine monochloride. The trace metal analyses were performed
using spark source mass spectrography and optical emission spectrography. However, emission factors
could not be developed for trace metals because of the lack of details on total PM catch.
One PM run was conducted on each pair of stacks (for six pairs, total) for natural gas and fuel oil
separately. One inlet and two outlet S02 runs were conducted for each type of fuel. Two NOx runs
were conducted for natural gas firing, and one run for fuel oil firing. Two Hg runs were conducted for
gas-firing. Emission factors were developed for filterable and condensible PM, S02, NOx, and gaseous
Hg emissions from the kiln fired with natural gas and for filterable and condensible PM, S02, and NOx
from the kiln fired with fuel oil.
For all tests, the testing methodology was sound. However, the data were downrated because of
a lack of detail in documentation and for the following reasons. The PM data are rated D. Although six
measurements were made (one per pair of stacks), the six measurements constitute only one run of the
entire emission stream. The inlet S02 data for both gas and fuel oil firing, and the NOx data for fuel oil
firing are unrated because only one run was conducted for each of the tests. The outlet S02 data and the
NOx data for gas-firing are rated C because only two runs were conducted and the report lacked
adequate documentation. The Hg data are rated D because the report does not provide process or
volumetric flow rates for the Hg runs; the Hg emission factors were developed using average process and
32
-------
flow rates from the other tests. In addition, a nonstandard method was used to measure Hg emissions.
4.2.1.7 Reference 7. This report documents measurements of filterable PM, condensible
inorganic PM, C02, and S02 emissions from a gas-fired rotary kiln. The emission test was sponsored by
EPA as part of the development of an NSPS for portland cement plants. The test was conducted in
1971. The plant uses the wet process, and process rates were provided on the basis of the slurry feed
rate. Kiln emissions are controlled with a fabric filter, and only controlled emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back halves), and S02
emissions were measured using Method 8. The report does not specify the method used to quantify C02
emissions. Three PM runs and four SOx runs were conducted.
Emission factors were developed for PM and S02 emissions; insufficient information was
available to develop emission factors for C02 emissions. The test report noted that process operation was
interrupted several times during the test due to excessive pressure drop across the fabric filter, visible
emissions from leaking filter bags, and breakdown of dust removal equipment.
The emission data for filterable and condensible inorganic PM are rated C. Although the test
methodology was sound, a higher rating is not justified due to lack of adequate documentation and
recurring process upsets during the test. The S02 emission data also are rated D for the same reasons
stated above for the PM test. In addition, process and volumetric flow rates for two of the four S02 runs
were not provided and average rates had to be used to develop emission factors.
4.2.1.8 Reference 8. This report documents measurements of filterable PM and condensible
inorganic PM emissions from a raw mill weigh hopper, a raw mill, a raw mill air separator, a finishing mill
weigh hopper, a finishing mill, and a finishing air separator. Trace metal analyses also were conducted on
the total PM catches from one run on each of the six sources. The emission test was sponsored by EPA
as part of the development of an NSPS for portland cement plants. The test was conducted in 1971. The
plant uses the dry process, and process rates were provided on the basis of the feed rate.
All six sources tested are controlled with fabric filters, and only controlled emissions were
measured. Particulate matter emissions were measured using Method 5 (front and back half), and two
test runs were conducted on the each of the six sources. Although back half PM catches are reported in
the results of the tests on all of the sources, these processes should not emit condensible PM. Therefore,
it is assumed that the back half catch is the result of an anomaly in the sampling and analytical procedures
used. The test report does not include adequate information to determine the origin of this apparent
anomaly.
The report states that the trace metal analyses were performed using emission spectroscopy, but
no other details are provided. The samples were analyzed for Sb, As, Be, Cd, Cr, Cu, Fe, Pb, Mn, Ni, Sr,
V, and Zn. Emission factors were developed for filterable PM emissions from the six sources tested.
Emission factors also were developed for all of the trace metals listed above with the exception of arsenic
and vanadium, which were below the detection limit in all samples.
The PM emission data are rated C. The test methodology was sound and no problems were
reported, but only two test runs were conducted, and the report lacked adequate documentation for a
33
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higher rating. The trace metal emission data are unrated because only a single run was conducted, and
details on the analytical procedure are not provided in the report.
4.2.1.9 Reference 9. This report documents measurements of filterable PM and condensible
inorganic PM emissions from primary limestone crushing, primary limestone screening, primary limestone
transfer (conveyor discharge), and secondary screening and crushing combined. The emission test was
sponsored by EPA as part of the development of an NSPS for stone crushing operations. The test was
conducted in 1974. Process rates were provided on the basis of feed rate.
All four sources tested for PM emissions are controlled with fabric filters, and only controlled
emissions were measured. Particulate matter emissions were measured using Method 5 (front and back
half). Four test runs were conducted on the primary limestone crushing and screening, and three test runs
were conducted on primary limestone transfer and secondary screening and crushing. Although back
half PM catches are reported in the results of the tests on all of the sources, these processes should not
emit condensible PM. Therefore, it is assumed that the back half catch is the result of an anomaly in the
sampling and analytical procedures used. The test report does not include adequate information to
determine the origin of this apparent anomaly.
One of the four runs on the primary crusher was not conducted under the acceptable limits (90 to
110 percent) for isokinetic conditions. All four runs on the primary screen were interrupted by process
upsets that resulted in anisokinetic conditions. No problems were reported for the tests on the primary
limestone transfer and secondary screening and crushing. Emission factors were developed for filterable
PM emissions from the four sources tested.
The PM emission data for primary crushing, primary limestone transfer, and secondary screening
and crushing are rated B. The test methodology was sound and no problems were reported, but the
report lacked adequate documentation for a higher rating. The emission data for primary screening are
rated C due to anisokinetic sampling conditions.
4.2.1.10 Reference 10. This report documents measurements of filterable PM and particle size
distribution from a dry rotary kiln that is equipped with a suspension preheater. The emission test was
sponsored by EPA as part of a study to characterize emissions of inhalable PM emissions from the
cement industry. The test was conducted in 1981. Process rates were provided on the basis of feed rate
and clinker production rate. The kiln is fired with a combination of coal and coke.
Emissions from the kiln are controlled with a fabric filter. Both uncontrolled and controlled
emissions were measured. Uncontrolled PM emissions were measured using Method 5 (front half only),
and controlled PM emissions were measured using Method 17. Four test runs were conducted on the
fabric filter inlet and two test runs on the fabric filter outlet. Emission factors were developed for
uncontrolled and controlled filterable PM emissions from the kiln.
Particle size distribution was measured on the uncontrolled and controlled emissions using
cascade impactors with a preseparator. The particle size distribution measurements were taken
concurrently with the Method 5 and Method 17 PM measurements. The results of the particle size tests
are described in more detail in Reference 79.
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The uncontrolled PM and particle size distribution data are rated A. The test methodology was
sound, and the report includes adequate documentation. The controlled PM data are downrated to C
because only two runs were conducted.
4.2.1.11 Reference 11. This report documents measurements of filterable PM and particle size
distribution from a rotary kiln with preheat supplied from the clinker cooler. The emission test was
sponsored by EPA as part of a study to characterize emissions of inhalable PM emissions from the
cement industry. The test was conducted in 1981. Process rates were provided on the basis of dry feed
rate and clinker production rate. The kiln is fired with pulverized coal and uses the wet process.
Emissions from the kiln are controlled with an ESP. Both uncontrolled and controlled emissions
were measured. Uncontrolled PM emissions were measured using Method 5 (front half only), and
controlled PM emissions were measured using Method 17. Four test runs were conducted on the ESP
inlet and two test runs on the ESP outlet.
Particle size distribution was measured on the uncontrolled and controlled emissions using
cascade impactors with a preseparator. The particle size distribution measurements were taken
concurrently with the Method 5 and Method 17 PM measurements. The results of the particle size tests
are described in more detail in Reference 79.
Due to a dust layer in the inlet duct to the ESP, the sampling points locations had to be adjusted.
Although it was not known what effect this modification had on the tests, the unusually high uncontrolled
emission rates indicate that the data are biased high. Emission factors were developed for uncontrolled
and controlled filterable PM emissions from the kiln; size-specific emission factors also were developed.
The inlet PM data and particle size distribution data are rated D due to the problem described
above. The outlet PM and particle size distribution data are rated C. The test methodology was sound,
and the report includes adequate documentation, but only two runs were conducted.
4.2.1.12 Reference 12. This report documents measurements of filterable PM, condensible
inorganic PM, and S02 emissions from four coal-fired rotary kilns. The emission test was conducted to
demonstrate compliance with State regulations. The test was conducted in 1977. The plant uses the dry
process, and process rates were provided on the basis of raw material feed and clinker production rates.
The sulfur content of the coal was reported as 2.84 percent. The plant has two stacks, each of which
serves two of the kilns. Each of the stacks is equipped with a multiclone and an ESP to control kiln
emissions, and only controlled emissions were measured.
Particulate matter emissions were measured using Method 5 (front and back half), and S02
emissions were measured using Method 8. Three PM runs were conducted on each of the two stacks.
Eight S02 runs were conducted on one of the stacks, and four S02 runs were conducted on the other
stack. Emission factors were developed for controlled PM and S02 emissions. Because of the relatively
high S02 emission rates measured, the data were combined and treated as a measurement of S02
emissions from one kiln.
The kiln emission data for PM and S02 are rated B. The test methodology was sound, and no
problems were reported, but the report lacked adequate documentation for a higher rating.
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4.2.1.13 Reference 13. This report documents measurements of filterable PM, condensible
inorganic PM, and S02 emissions from a coal-fired rotary kiln. The emission test was conducted to
demonstrate compliance with State regulations. The test was conducted in 1977. The plant uses the wet
process, and process rates were provided on the basis of raw material (dry solids) feed and clinker
production rates.
Emissions are controlled with an ESP, and both uncontrolled and controlled emissions were
measured. Particulate matter emissions were measured using Method 5 (front and back half), and S02
emissions were measured using Method 8. Six uncontrolled and 12 controlled PM runs were conducted.
For three of the uncontrolled and controlled runs, an insufflation rate of 6 tons/hr was reported, and for
three uncontrolled and controlled runs, an insufflation rate of 12 tons/hr was reported. The kiln normally
operates with a 6-ton/hr insufflation rate. Six S02 runs were conducted. The sulfur content of the coal
was 2.44 percent for the first three runs and 2.98 percent for the last three runs. Emission factors were
developed for uncontrolled and controlled PM and for uncontrolled S02 emissions. The PM emission
factors developed for the kiln operating at both insufflation rates were comparable.
The kiln emission data for PM and S02 are rated B. The test methodology was sound and no
problems were reported, but the report lacked adequate documentation for a higher rating.
4.2.1.14 Reference 14. This report documents measurements of filterable PM, condensible
inorganic PM, and C02 emissions from four coal-fired rotary kilns. The emission tests were conducted in
1979 to demonstrate compliance with State regulations. Three of the kilns (Nos. 1, 3, and 4) tested use
the dry process, and the fourth kiln (No. 5) uses the wet process. Process rates were provided on the
basis of feed and clinker production rates.
Emissions from each of kilns 1, 3, and 4 first pass through a cooling tower and then through a
combination of multiclone with ESP. Kiln No. 5 is operated with a preheater/pelletizer system; emissions
from the preheater are controlled with a double-chamber ESP. Only controlled emissions measurements
were documented in the report. Particulate matter emissions were measured using Method 5 (front and
back half), and C02 emissions were measured using Orsat. Six runs were conducted on each of the four
kilns. However, for one of the kilns, the data needed to develop emission factors were provided for only
two runs. Emission factors were developed for controlled PM and for uncontrolled C02 emissions.
Additional runs also were conducted on kiln 5 with the exhaust gas bypassing the ESP to either one or
two raw mills. However, emission factors were not developed for these runs because the gas sampled
did not represent all of the kiln emissions.
The data for PM and C02 emissions from kilns 1, 3, and 4, are rated B. The test methodology
was sound and no problems were reported, but the report lacked adequate documentation for a higher
rating. The emission data for kiln 5 are rated C because only two test runs were conducted.
4.2.1.15 Reference 15. This report documents measurements of filterable PM and condensible
inorganic PM from a clinker cooler. The emission test was conducted in 1980 to demonstrate compliance
with State regulations. The plant has three dry process coal-fired rotary kilns, all of which feed a
common clinker cooler. Process rates were provided on the basis of kiln feed and clinker cooler feed
rates.
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Emissions from the clinker cooler are controlled with a wet gravel bed filter. Only controlled
emissions were measured. Particulate matter emissions were measured using Method 5 (front and back
half), and three test runs were conducted. Emission factors were developed for controlled filterable and
condensible inorganic PM.
The clinker cooler PM emission data are rated A. The test methodology was sound and no
problems were reported.
4.2.1.16 Reference 16. This report documents measurements of filterable PM, condensible
inorganic PM, S02, and C02 from a dry process coal-fired rotary kiln. The emission tests were
conducted in 1980 to demonstrate compliance with State regulations. Process rates were provided on the
basis of kiln feed and clinker cooler production rates.
Emissions from the kiln are controlled with a combination of cyclone and fabric filter. Only
controlled emissions were measured. Particulate matter emissions were measured using Method 5 (front
and back half), and S02 emissions were measured using Method 6. The method used to measure C02
emissions was not specified, although the report states that all testing was conducted in accordance with
EPA reference test methods. Three test runs were conducted. Emission factors were developed for
controlled filterable and condensible inorganic PM, S02, and C02 emissions.
The PM data are rated A. The test methodology was sound, no problems were reported, and the
documentation was adequate. The C02 data are rated C because the test method was not specified.
The S02 data are rated D because the wide range in emission rates (26.9 lb/hr for the first run and 5.3
lb/hr for the last two runs) is indicative of testing problems.
4.2.1.17 Reference 17. This report documents measurements of S02, S03, and C02 from three
dry process coal-fired rotary kilns. The kilns are equipped with suspension preheaters. The emission
tests were conducted in 1980 to demonstrate compliance with State regulations. Process rates were
provided on the basis of kiln feed rates.
The kilns are equipped with fabric filters to control emissions, and only controlled emissions were
reported. Emissions of S02 and S03 were measured using Method 6, and C02 emissions were measured
by Orsat. Three test runs were conducted on each of the three kilns. Emission factors were developed
for S03 and C02 emissions. For six of the nine S02 runs, S02 emissions are reported as zero.
Therefore, emission factors were not developed for S02 emissions.
The emission data for S03 and C02 emissions are rated B. The test methodology was sound, and
no problems were reported. However, the documentation was inadequate to warrant a higher rating.
4.2.1.18 Reference 18. This report documents measurements of filterable PM, S02, S03, C02,
ammonium (NH4+), chloride (CI ), K, Na, and sulfate (S04~2) from two wet process coal-fired rotary kilns.
The emission tests were conducted in 1981 to demonstrate compliance with State regulations. Process
rates were provided on the basis of kiln feed rates. The sulfur content of the coal was 1.06 percent.
The kilns are equipped with ESP's, and only controlled emissions were reported. Emissions of
filterable PM were measured using Method 5; C02 emissions were measured by Orsat; emissions of
NH4+, K, Na, and S04 2 were quantified from the Method 5 PM catch; and emissions of S02, S03, and
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chloride were measured by analyzing the back half of the Method 5 sampling train. To quantify S02
emissions, one of the impingers was filled with a 6 percent solution of hydrogen peroxide. Three test runs
were conducted on both of the kilns. Emission factors were developed for filterable PM, S02, S03, C02,
NH4+, CI", K, Na, and S04 2.
The PM, C02, K, Na, and S04 2 emission data are rated B. The test methodology was sound,
and no problems were reported. However, the documentation was inadequate to warrant a higher rating.
The emission data for S02, S03, and CI" are rated C because nonstandard test methods were used.
4.2.1.19 Reference 19. This report documents measurements of filterable PM, S02, NOx, and
C02 from four wet process coal-fired rotary kilns. The emission tests were conducted in 1981 to
demonstrate compliance with State regulations. Process rates were provided on the basis of kiln feed and
clinker production rates. The sulfur content of the coal was reported as 3.55 percent.
Three of the kilns (Nos. 1, 2, and 3) are ducted to a common stack (stack 2) and are controlled
with an ESP. Kiln 4 is ducted to a separate ESP and stack (stack 4). Controlled emissions from stack 2,
and both uncontrolled and controlled emissions from stack 4 were measured. Emissions of PM were
measured using Method 5, S02 emissions were measured using Method 6, NOx emissions were measured
using Method 7, and C02 emissions were measured by Orsat. The number of valid test runs conducted
included 29 for PM, 30 for S02, 20 for C02, and 20 for NOx. Emission factors were developed for
filterable PM, SO... NOx, and C02 emissions.
The filterable PM, SOx, NOx, and C02 emission data are rated B. The test methodology was
sound, and no problems were reported. However, the documentation was inadequate to warrant a higher
rating.
4.2.1.20 Reference 20. This report documents measurements of filterable PM emissions from a
coal-fired rotary kiln and a clinker cooler. The type of process was not specified in the report. The
emission tests were conducted in 1983 to demonstrate compliance with State regulations. Process rates
were provided on the basis of the kiln and clinker cooler feed rate.
The kiln emissions are ducted to an ESP and fabric filters in parallel; the clinker cooler emissions
are ducted to a fabric filter. Three runs were conducted on each source, and only controlled emissions
were measured. Emission factors were developed for filterable PM emissions from the clinker cooler.
However, because of the unusual configuration of control devices on the kiln, the test data are not useful
for developing kiln emission factors.
The emission data are rated B. The test methodology was sound, and no problems were
reported. However, the documentation was inadequate to warrant a higher rating.
4.2.1.21 References 21 and 22. Reference 21 is an emission test report that documents
measurements of filterable PM, S02, NOx, CO, and C02 emissions from a dry process coal-fired rotary
kiln that is equipped with a suspension preheater/flash calciner. An unspecified crusher and a grate-type
clinker cooler also were tested for PM emissions. The emission tests were conducted in 1983 to
demonstrate compliance with State regulations. The process rates included in the report tables were
indicated as production rates, but no other information was provided. The report does not include a
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process description. However, Reference 22, which is a technical paper about the facility, includes a
process description of the facility.
Emissions from the kiln, crusher, and clinker cooler are each controlled with a separate fabric
filter. Method 5 was used to measure PM emissions, and continuous monitors were used to quantify
emissions of S02, NOx, CO, and C02. Three runs were conducted on each source, and only controlled
emissions were measured. Due to negative filter weights on most of the runs, emission factors were not
developed for PM emissions from the kiln and clinker cooler. In addition, due to a lack of information,
emission factors also were not developed for crusher emissions.
The S02, NOx, CO, and C02 emission data are rated C due to the poor documentation of the test
methods and the basis for the process rates.
4.2.1.22 Reference 23. This report documents measurements of PM, S02, and NOx emissions
from a coal-fired rotary kiln and PM emissions from a clinker cooler. The type of process was not
specified in the report. The emission test were conducted in 1983 as part of a State source survey.
Process rates were provided on the basis of kiln feed and clinker production.
Emissions from the kiln are controlled with a fabric filter. Only controlled kiln emissions were
measured. Particulate matter emissions were measured using Method 5 (front and back half); the report
states that S02, NO... and C02 emissions were measured in accordance with standard EPA test methods
but does not indicate the methods used. Three test runs were conducted. Emission factors were
developed for controlled filterable PM, condensible inorganic PM, S02, NOx, and C02 emissions from the
kiln.
Emissions from the clinker cooler are controlled with a gravel bed filter. Three runs were
conducted on the clinker cooler and only controlled emissions were measured. Emission factors were
developed for filterable PM and condensible inorganic PM emissions from the clinker cooler.
The emission data from the kiln test were not rated because the type of process was not
specified. The clinker cooler data are rated B. The test methodology appeared to be sound, no problems
were reported, and the documentation was inadequate to warrant a higher rating. Because
3. fyrite may have been used to measure C02 concentrations, the C02 data are rated C.
4.2.1.23 Reference 24. This report documents measurements of filterable PM, condensible
inorganic PM, S02, S03, S04 2, NOx, CO, TOC, and C02 from a dry process coal-fired rotary kiln. The
kiln is equipped with a suspension preheater/flash calciner, and the facility is the same as the facility
tested in Reference 21. An unspecified crusher and a grate-type clinker cooler were also tested. The
emission tests were conducted in 1984 to demonstrate compliance with State regulations. Process rates
were provided on the basis of kiln feed rate for the kiln test and clinker feed rate for the test on the
clinker cooler. Due to the lack of adequate information, the crusher test data were discarded.
Emissions from the kiln and clinker are controlled by separate fabric filters, and only controlled
emissions were measured. Emissions of PM (front and back half) were measured using Method 5;
sulfate emissions were measured using Method 8; and TOC emissions were measured with a gas
chromatograph-flame ionization detector (GC-FID) procedure. Emissions of S02, NOx, CO, and C02
were measured with continuous monitors in accordance with California Air Resources Board (CARB)
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Method 1-100. This method is comparable to EPA Methods 6C, 7E, 10, and 3A for measuring S02, NOx,
CO, and C02, respectively. However, CARB Method 1-100 uses separate instrument analyzers
connected in parallel with a manifold to simultaneously sample for different types of gases.
The emission data are rated B. The test methodology was sound, and no problems were
reported. However, the documentation was inadequate to warrant a higher rating.
4.2.1.24 Reference 25. This report documents measurements of filterable PM and C02 from a
dry process coal-fired rotary kiln that is equipped with a suspension preheater. The report also documents
emissions from a Loesche-type raw mill and a grate-type clinker cooler. The emission tests were
conducted in 1984 to demonstrate compliance with State regulations. Process rates were provided for the
kiln and the clinker cooler on the basis of kiln feed rate for the kiln test only.
Because the raw mill is ducted to the same stack as the kiln, the emission data measured while
the kiln were operating are of little use. However, measurements also were made with the raw mill not
operating, and the data from those runs should be representative of kiln emissions.
Emissions from the kiln and raw mill are controlled with an ESP, and clinker cooler emissions are
controlled with a combination of a cyclone and gravel bed filter in series. Only controlled emissions were
measured. Emissions of filterable PM were measured using Method 5, and C02 emissions were
quantified by Orsat. Using the measurements made while the raw mill was not operating, emission
factors were developed for filterable PM and C02 emissions from the kiln. Emission factors also were
developed for filterable PM emissions from the clinker cooler.
The emission data are rated B. The test methodology was sound, and no problems were
reported. However, the documentation was inadequate to warrant a higher rating.
4.2.1.25 Reference 26. This report documents measurements of filterable PM, S02, and C02
from a wet process coal-fired rotary kiln. The emission tests were conducted in 1984 to demonstrate
compliance with State regulations. Process rates were provided on the basis of kiln feed rate in gallons
per minute of slurry. The report also states that the capacity of the kiln is 400 gal/min, which corresponds
to approximately 1,500 tons/day of clinker. The sulfur content of the coal was reported as 2.50 percent.
Emissions from the kiln are controlled with an ESP, and only controlled emissions were measured.
Emissions of filterable PM were measured using Method 5; S02 emissions were measured using
Method 6; and C02 emissions were quantified by Orsat. Emission factors were developed for filterable
PM, S02, and C02 emissions from the kiln.
Although the test methodology was sound, and no problems were reported, the emission data are
rated C due to a lack of adequate documentation and the uncertainty in process rates.
4.2.1.26 Reference 27. This report documents an emission test at the same facility as in
References 21 and 24. The emission tests included measurements of filterable PM, condensible inorganic
PM, S02, S03, S04 2, NOx, CO, TOC, and C02 from a dry process coal-fired rotary kiln. The kiln is
equipped with a suspension preheater/flash calciner. An unspecified crusher and a grate-type clinker
cooler also was tested. The emission tests were conducted in 1985 to demonstrate compliance with State
regulations. Process rates were provided on the basis of kiln feed rate for the kiln test and clinker feed
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rate for the test on the clinker cooler. Due to the lack of adequate information, the crusher test data were
discarded.
Emissions from the kiln and clinker are controlled by separate fabric filters, and only controlled
emissions were measured. Emissions of PM (front and back half) were measured using Method 5;
sulfate emissions were measured using Method 8; emissions of S02, NOx, CO, and C02 were measured
with continuous monitors in accordance with CARB Method 1-100; and TOC emissions were measured
with a GC-FID procedure.
The emission data are rated B. The test methodology was sound, and no problems were
reported. However, the documentation was inadequate to warrant a higher rating.
4.2.1.27 Reference 28. This report documents measurements of filterable PM, S02, NO... and
C02 from a wet process coal-fired rotary kiln. The emission tests were conducted in 1985 to
demonstrate compliance with State regulations. Process rates were provided on the basis of kiln feed and
clinker production rates. The sulfur content of the coal was reported as 1.78 percent.
Emissions from the kiln are controlled with an ESP, and only controlled emissions were measured.
Emissions of filterable PM were measured using Method 5; S02 emissions were measured using
Method 6; NOx emissions were quantified using Method 7; and C02 emissions were quantified by Orsat.
Emission factors were developed for filterable PM, S02, NO... and C02 emissions from the kiln.
The emission data are rated B. The test methodology was sound, and no problems were
reported. However, the documentation was inadequate to warrant a higher rating.
4.2.1.28 Reference 29. This report documents measurements of filterable PM, S02, NO.., and
C02 from a wet process coal-fired rotary kiln. The emission tests were conducted in 1981 to
demonstrate compliance with State regulations. Process rates were provided on the basis of kiln feed and
clinker production rates. The sulfur contents of the coal and raw material were reported as 1.33 percent
and 0.08 percent, respectively.
Emissions from the kiln are controlled with an ESP, and only controlled emissions were measured.
Emissions of filterable PM were measured using Method 5; S02 emissions were measured using
Method 6; NOx emissions were quantified using Method 7; and C02 emissions were quantified by Orsat.
Three runs of PM and S02, 6 runs of C02, and 12 runs of NOx emissions were conducted. Emission
factors were developed for filterable PM, S02, NOx, and C02 emissions from the kiln.
The emission data are rated C. Although the test methodology was sound, the report does not
include a process description and generally is lacking in details.
4.2.1.29 Reference 30. This report documents measurements of filterable PM, S02, NO.., and
C02 from the same wet process coal-fired rotary kiln for which emission measurements were
documented in Reference 29. The emission tests were conducted in 1981 to demonstrate compliance
with State regulations. Process rates were provided on the basis of kiln feed and clinker production rates.
The sulfur content of the coal was reported as 1.33 percent.
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Emissions from the kiln are controlled with an ESP. Uncontrolled and controlled PM emissions
were measured, ESP inlet and outlet S02 emissions were measured, and uncontrolled NOx and C02
emissions were measured. Emissions of filterable PM were measured using Method 5; S02 emissions
were measured using Method 6; NOx emissions were quantified using Method 7; and C02 emissions were
quantified by Orsat. Six runs of PM and S02 emissions were performed (3 at the ESP inlet and 3 at the
ESP outlet), as were 6 runs of C02 emissions, and 12 runs of NOx emissions. Emission factors were
developed for uncontrolled and controlled filterable PM emissions and for uncontrolled S02, NOx, and
C02 emissions from the kiln.
The emission data are rated C. Although the test methodology was sound, the report does not
include a process description and generally is lacking in details.
4.2.1.30 Reference 31. This report documents measurements of filterable PM, condensible
inorganic PM, S02, NOx, CO, and C02 from a precalciner dry process coal-fired rotary kiln. The
emission tests were conducted in 1985 to demonstrate compliance with State regulations. Process rates
were provided on the basis of kiln feed.
Emissions from the kiln are controlled with an ESP, and only controlled emissions were measured.
Emissions of filterable PM were measured using Method 5; S02, NOx, CO, and C02 emissions were
measured with continuous monitors in accordance with CARB Method 1-100. Three runs were
conducted. Emission factors were developed for filterable PM, condensible inorganic PM, S02, NOx,
CO, and C02 emissions from the kiln.
The emission data are rated B. The test methodology was sound, and no problems were
reported. However, the documentation was inadequate to warrant a higher rating.
4.2.1.31 References 32. 33. and 34. These reports document measurements of filterable PM
emissions from two coal-fired kilns and a clinker cooler (Reference 32), measurements of filterable PM,
S02, and sulfuric acid emissions from two coal-fired kilns (Reference 33), and measurements of filterable
PM and S02 emissions from three coal-fired kilns (Reference 34). The emission tests were conducted in
1976 and 1978 to demonstrate compliance with State regulations. The reports do not specify the type of
process used, and process rates are not included in the reports. Therefore, the reports could not be used
to develop emission factors.
4.2.1.32 Reference 35. This document consists primarily of summary tables of measurements of
NOx from two dry process coal-fired rotary kilns. The emission tests were conducted in 1987. Process
rates were provided on the basis of clinker production. The report states that low-sulfur coal was used but
does not specify the sulfur content of the coal.
Emissions from the kiln are controlled with a fabric filter. Only controlled emissions of NOx were
measured, using continuous emission monitoring, and data were provided for daily NOx emission levels for
three consecutive months. Emission factors were developed for NOx emissions.
The NOx data are rated C due to the general lack of adequate documentation.
4.2.1.33 Reference 36. This reference is a four-volume report on the demonstration of the
feasibility of reducing NOx emissions from a portland cement rotary kiln, which is controlled with a fabric
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filter. The report includes continuous emission monitor (CEM) data on NOx emissions from a coal-fired
dry process kiln for a 14-month period in 1984 and 1985 following process modifications to reduce NOx
emissions. The process changes consist of using more secondary air from the clinker cooler for
combustion; using redesigned heat exchange equipment to reduce fuel consumption; using an indirect coal
firing system; using a redesigned burner pipe to improve flame control; and using improved
instrumentation, raw material chemical uniformity, flame control, and personnel training to improve kiln
stability.
The report describes the instruments used and the quality assurance procedures developed during
the course of the project. However, it is not clear from the report if the sampling and analytical methods
were comparable to standard EPA methods.
Process operating rates are not provided, but the report includes NOx emission factors in units of
lb/ton of clinker at 6-minute intervals with hourly and daily averages for the entire 14-month period. The
overall average NOx emission factor for the test period was reported as 5.8 lb/ton. Based on the results
of eight emission tests conducted between 1974 and 1981, the process modifications achieved a
26 percent reduction in NOx emissions. The NOx CEM data are rated B. Although the methodology was
sound, data on process operating rates is limited.
Attachment C of the report includes reports for two of the eight previous emission tests
referenced in the document. The first of these reports includes data on CO and NOx emissions. Samples
were collected in a mylar bag, evacuated to a grab bulb, and analyzed. These data are rated D due to the
nonstandard test methodology. In the second test report included in Attachment C of the reference, S02
and NOx emissions were measured using Methods 6 and 7 (instrument analyzers). These data are rated
B.
4.2.1.34 Reference 37. This report documents measurements of filterable PM, S02, NOx, TOC,
and VOC from a dry process coal-fired rotary kiln. The emission test was conducted in 1989 to quantify
emissions of various pollutants. The report includes hand-written process rates on the basis of clinker
production.
Emissions from the kiln are controlled with a fabric filter. Only controlled emissions were
measured. Particulate matter emissions were measured using the Michigan Department of Natural
Resources Method 5B. Sulfur dioxide and NOx emissions were measured using a continuous analyzer.
Methods 25 and 25A were used to measure VOC and TOC, respectively, which were reported on a
molecular weight basis as methane. Three test runs were conducted. Emission factors were developed
for filterable PM, S02, NO.,. TOC, and VOC.
The S02 and NOx data are rated B. The test methodology was sound, no problems were
reported, and the documentation was adequate. The PM, TOC, and VOC data are rated C because the
report did not include data for individual runs.
4.2.1.35 Reference 38. This reference consists of selected pages from a report of an emission
test conducted on a wet process rotary kiln. The kiln was being co-fired with coal and waste fuel at the
time of the test. Results of S02 emissions are reported, but process rates are not included. Therefore,
emission factors were not developed from the data.
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4.2.1.36 References 39. This reference consists of summaries of several test reports and
includes data summaries and other test documentation for measurements of S02, NOx, CO, and C02 from
three dry process coal-fired rotary kilns. Two of the kilns are located at the Southwestern Portland
Cement Victorville Plant, and the third kiln is located at the Southwestern Portland Cement Black
Mountain Plant. Emissions from the kilns at both locations are controlled with fabric filters. The sulfur
contents of the coal for two of the tests are reported as 0.71 percent and 0.81 percent.
The only data for the Victorville facility are from a single-run test conducted on each kiln in 1980.
Because only one test run was performed on each kiln, the data from the Victorville Plant were not used
to develop emission factors.
Test data for the Black Mountain facility are included for one test conducted in 1980 and three
tests conducted in 1984. The test summaries include data on one test run for S02, NOx, CO, and C02
emissions; data on one test run from a second test for NOx and C02 emissions; data on one test run from
a third test for S02, NOx, and C02 emissions; and data on three test runs from a fourth test for S02, NOx,
and C02 emissions. Nitrogen oxide and S02 emissions were measured using EPA Methods 7 and 8,
respectively. Carbon monoxide was analyzed using gas chromatography, and C02 emissions were
quantified using Orsat.
The data from tests that consist of a single run generally are not used for emission factor
development. However, because several one-run tests and one three-run test were conducted on the
same kiln, the data were combined for the purposes of developing average emission factors.
The SOx, NOx, and C02 test data from the Black Mountain Plant are rated D for a combination
of reasons. The documents included little documentation; average, rather than run-specific process rates
were provided; and volumetric flow rates were based on fuel analysis rather than on direct measurement.
The CO emission data are unrated because the results of only a single run are reported.
4.2.1.37 Reference 40. This document consists of selected pages from a test report that
documents measurements of PM, hydrochloric acid (HC1), S02, and C02 from a wet process kiln fired
with coal. The kiln is that the same kiln for which emission measurements were documented in
Reference 26. Emissions from the kiln are controlled with an ESP. The test included measurements of
emissions while the same kiln was fired with a combination of coal and waste fuel, but data on that test
were not included in the reference. The sulfur content of the coal was reported as 2.72 percent.
The test method used to measure PM emissions was not indicated in the reference. Method 6
was used to quantify S02. Hydrochloric acid emissions were quantified using a modified Method 5
sampling train. The first two impingers contained a solution of sodium hydroxide, the third impinger was
empty, and the fourth impinger contained silica gel. The samples were analyzed with the mercuric nitrate
method. Emission factors were developed for emissions of filterable PM, S02 and HC1 emissions. No
information is provided on the method used to measure C02, and the reference does not include adequate
information for developing C02 emission factors.
The test data are rated C because of the lack of adequate documentation.
4.2.1.38 Reference 41. This report documents measurements of filterable PM, NO^ and S02
emissions from a coal-fired wet process rotary kiln. The emission test was conducted in 1985 to
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demonstrate compliance with State regulations. The report does not include process rates and could not
be used to develop emission factors.
4.2.1.39 References 42 and 43. These reports document measurements of filterable PM, NOx,
S02, S04 2, NH4+, CI", K, Na, nitrates (N03), and fluoride (F) from two wet process coal-fired rotary
kilns. These kilns are the same kilns for which emission measurements are documented in Reference 18.
The purpose of the tests was to identify the pollutants that were causing a detached plume of 100 percent
opacity that formed within a short distance of the stacks. Reference 42 documents emission tests on both
kilns for filterable PM, NOx. S02, S04"2, NH4+, CI", K, and Na, and Reference 43 documents an emission
tests for on one of the kilns for filterable PM, NOx, S04 2, NH4+, CI", K, Na, N03, and F using an
experimental procedure. The tests were conducted in 1982. Process rates were provided on the basis of
kiln feed rate.
Emissions from the kilns are controlled with ESP's, and only controlled emissions were measured.
In the initial tests (Reference 42), filterable PM emissions were measured using a combination of
Methods 5 and 17 sampling trains in series. The other compounds were quantified by analyzing either the
front half or the back half of the PM sampling train; details on the testing and analytical methods are not
provided. Three test runs were conducted on each kiln.
For the experimental test, a modified Method 17 sampling train was used. The train was modified
to introduce dilution air into the gas stream to cool the gas temperature. An analytical procedure similar to
the procedure used in the initial test was used to quantify emissions of S02, S04 2, NH4+, CI", K, and Na.
Three test runs were conducted.
Nitrogen oxide emissions were measured using Method 7. Twelve NOx runs were conducted on
each kiln. These tests were documented in Reference 18.
Emission factors were developed for controlled filterable PM, NOx, S02, S04 2, NH4+, CI", K, Na,
N03, and F. The PM and NOx data are rated B. The methodology was sound, but the documentation
was not in adequate detail to warrant a higher rating. The emission data for the other compounds are
rated C due to the lack of adequate documentation and the nonstandard test methods used.
4.2.1.40 Reference 44. This report documents measurements of filterable PM, S02, S04 2,
NH4+, CI", K, and Na from a wet process coal-fired rotary kiln. The facility is the same as that in
References 18, 42, and 43. The stated purpose of the test was to determine the concentrations of the
target pollutants in the stack emissions. The test was conducted in 1982. Process rates were provided on
the basis of the kiln feed rate.
Emission from the kiln are controlled with an ESP, and only controlled emissions were measured.
Method 5 was used to measure PM emissions. The other compounds were quantified by analyzing the
back half of the PM sampling train. The back half of the sampling train included an impinger containing
deionized water to absorb NH4+, CI", K, and Na; an impinger containing 80 percent isopropyl alcohol to
absorb S03; and an impinger containing a 6 percent solution of hydrogen peroxide to absorb S02. Three
test runs were conducted.
Emission factors were developed for controlled filterable PM, S02, S04 2, NH4+, CI", and Na.
The PM data are rated B. The methodology was sound, but the documentation was not in adequate detail
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to warrant a higher rating. The emission data for the other compounds are rated C due to the lack of
adequate documentation and the nonstandard test methods used.
4.2.1.41 References 45 and 46. These references include only a table of SOx and NOx emission
factors developed from several tests conducted on a coal-fired wet process kiln. Due to the lack of
information on test methods and control devices, the data were not considered for this revision of AP-42.
4.2.1.42 Reference 47. This reference consists of a single sheet of handwritten notes on an
emission test conducted on a dry process rotary kiln. The facility is the same facility for which emission
tests were documented in Reference 39. Because data are presented for a single run only and the
reference lacks information on test methods and other aspects of the test, emission factors were not
developed.
4.2.1.43 Reference 48. This reference documents measurements of NO^ CO, C02, and S02
from three coal-fired wet process rotary kilns. The facility is the same as that in References 39 and 47.
However, the tests were conducted on kilns other than those for which tests are documents in those
references. The emission tests were conducted in 1980 as part of the application requirements for an
operating permit for the kilns. Process rates were provided on the basis of the clinker production rate.
The report does not specify the type of control device used on the kiln stacks. The S02 emission
test consisted of a single run on each kiln, and a nonstandard sampling train was used. Nitrogen oxide and
CO samples were collected in a Tedlar bag connected to the dry gas meter. Three NOx samples and one
CO sample were collected from each of the kiln stacks. A single C02 measurement was taken using
Orsat. Emission factors were developed for S02, NOx, CO, and C02 emissions. The S02, CO, NOx, and
C02 data are unrated because only a single run was conducted.
4.2.1.44 Reference 49. This report documents measurements ofNOx emissions from a
preheater/precalciner coal-fired rotary kiln. The emission test was conducted in 1987 to demonstrate
compliance with State regulations. Process rates were provided on the basis of kiln feed and clinker
cooler production rates.
Emissions from the kiln are controlled with an ESP. Nitrogen oxide emissions were measured
using Method 7, and five runs were conducted. Emission factors were developed for NOx emissions from
the kiln.
The NOx data are rated B. The test methodology was sound, and no problems were reported, but
the documentation was inadequate to warrant a higher rating.
4.2.1.45 Reference 50. This reference consists of a letter that includes S02 and NOx emission
factors developed from the results of an emission test conducted on a coal-fired preheater/precalciner kiln
in 1981. The letter states that Method 6 was used to measure S02 emissions and Method 7 was used to
quantify NOx emissions. The letter does not indicate the number of test runs conducted.
Due to the lack of documentation, the emission data are rated D.
4.2.1.46 Reference 51. This reference includes selected pages from a report that documents
measurements of filterable PM, NOx, and S02 from a coal-fired preheater/precalciner kiln. The emission
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test was conducted in 1986 to demonstrate compliance with State regulations. Process rates were
provided on the basis of kiln feed and clinker production rate.
Emissions from the kiln are controlled with a fabric filter. Only controlled emissions were
measured. The document states that all tests were conducted in accordance with standard EPA methods,
but no information is included on sampling and analytical procedures. Three test runs were conducted.
Emission factors were developed for filterable PM, S02, and NOx emissions. The emission data are
rated C due to the general lack of adequate documentation.
4.2.1.47 Reference 52. This reference includes selected pages from a report that documents
measurements of filterable PM, S02, and C02 emissions from a preheater process coal-fired rotary kiln.
The emission test was conducted in 1986 to demonstrate compliance with State regulations. Process
rates were provided on the basis of kiln feed and clinker production rate. The sulfur content of the coal
was reported as 1.5 percent.
Emissions from the kiln are controlled with two fabric filters, one for the kiln stack and one for the
alkali bypass stack. Only controlled emissions were measured. Method 5, Method 6, and Orsat were
used to measure emissions of filterable PM, S02, and C02, respectively. Three test runs were
conducted. Emission factors were developed for filterable PM and S02 emissions based on the combined
emissions from both stacks.
The emission data are rated B. Although standard test methods were used, the document lacked
adequate information to warrant a higher rating.
4.2.1.48 Reference 53. This reference consists of a cover letter with summary tables for a
series of emission tests for filterable PM, S02, NOx, and C02 emissions from a preheater process coal-
fired rotary kiln. The emission tests were conducted between 1982 and 1989 to demonstrate compliance
with State regulations. Process rates were provided on the basis of kiln feed and clinker production rate.
Emissions from the kiln are controlled with two fabric filters, and only controlled emissions were
measured. Method 5, Method 6, Method 7, and Orsat were used to measure emissions of filterable PM,
S02, NOx, and C02, respectively. Seven PM tests, 10 S02 tests, and 9 NOx tests were conducted. In
addition, data on C02 emissions from three tests are presented in the tables. The number of runs per test
is not specified in the document. Emission factors were developed for filterable PM, S02, NOx, and C02
emissions from the kiln.
The emission data are rated C. Although standard test methods were used, the document lacked
adequate information to warrant a higher rating.
4.2.1.49 Reference 54. This reference consists of selected pages from a report that documents
three emission tests on a preheater process coal-fired rotary kiln. The kiln was tested for emissions of
filterable PM, S02, NOx, CO, C02, TOC, VOC, and HC1 in 1989 to demonstrate compliance with State
regulations. Process rates were provided on the basis of kiln feed and clinker production rate. Emissions
from the kiln are controlled with a fabric filter, and it is assumed that emissions were measured at the
outlet of the control device only.
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The test methods used were Method 5 for PM, Method 6C for S02, Method 7E for NOx,
Method 10 for CO, Method 25A for TOC, and Orsat for C02. The methods used to test for HC1 and
VOC were not specified in the document. Three runs were conducted during each of the three tests.
Emission factors were developed for filterable PM, S02, NOx, CO, C02, TOC, VOC, and HC1 emissions
from the kiln.
The PM, S02, NOx, CO, C02, and TOC emission data are rated B. Although standard test
methods were used, the document lacked adequate information to warrant a higher rating. The HC1 and
VOC data are rated D because the test method is not specified.
4.2.1.50 Reference 55. This report documents measurements of filterable PM, condensible
inorganic PM, S02, S03, NOx, and C02 from a preheater process coal-fired rotary kiln. The purpose of
the test was to demonstrate compliance with State regulations. The test was conducted in 1983. Process
rates were provided on the basis of the kiln feed and clinker production rates. The sulfur content of the
coal was reported as 0.48 percent. Emissions from the kiln are controlled with a fabric filter.
Method 5 was used to measure PM emissions. Emissions of S02 and S03 were quantified by
analyzing the back half of the PM sampling train. The back half of the sampling train included an
impinger containing 80 percent isopropyl alcohol to absorb sulfur trioxide; and an impinger containing a
6 percent solution of hydrogen peroxide to absorb S02. Method 7 was used to measure NOx emissions.
The method used to measure C02 concentrations was not specified. Three test runs were conducted.
Emission factors were developed for controlled filterable and inorganic condensible PM, S02, S03, C02,
and NOx emissions.
The PM, NOx, and C02 data are rated B. The methodology was sound, but the documentation
was not in adequate detail to warrant a higher rating. The emission data for C02 are rated C because the
test method was not specified. The emission data for S02 and S03 are rated C due to the lack of
adequate documentation and the nonstandard test methods used.
4.2.1.51 Reference 56. This reference consists of selected pages from a report that documents
an emission test on a coal-fired preheater/precalciner kiln. Measurements were made of emissions of
filterable PM, condensible inorganic PM, S02, NOx, and C02 from the main kiln stack and the alkali
bypass stack. The test was conducted in 1980 to demonstrate compliance with State regulations.
Process rates were provided on the basis of kiln feed and clinker production rate. Emissions from the kiln
are controlled with a fabric filter.
The test methods used to measure emissions were not specified in the reference. Three runs
were conducted during each of the three tests. Emission factors were developed for filterable PM,
condensible inorganic PM, S02, NOx, and C02 emissions from the kiln.
The PM, S02, NOx, and C02 emission data are rated D because the test methods were not
specified, and the reference lacked other details on the testing and process.
4.2.1.52 Reference 57. This reference consists of summary data from seven compliance tests
on a preheater/precalciner kiln between 1983 and 1989. Data on emissions of PM, S04 2, S02, NO... CO,
and TOC are included. Coal was burned during three of the tests; a combination of gas and coal was
burned during three of the tests; and a combination of gas, coal, and oil was burned during the remaining
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test. Average clinker production rates were provided for each of the tests. Kiln emissions are controlled
by means of a fabric filter, and only controlled emissions were measured.
Methods 5 and 8 were used to measure PM and S02; CARB Method 1-100 was used to
measure NOx and CO; and TOC emissions were quantified used GC-FID. Three runs were conducted
during each test. Emission factors were developed for filterable PM, S04 2, S02, NOx. CO, and TOC
emissions.
Due to a lack of documentation, all of the emission data from this reference are rated C.
4.2.1.53 Reference 58. This report documents measurements of filterable PM and S02 from a
coal-fired preheater/precalciner kiln. The test was conducted in 1981 to demonstrate compliance with
State regulations. Process rates were provided on the basis of the kiln feed rate. Emissions from the kiln
are controlled with an ESP.
Method 5 was used to measure PM emissions. However, the PM data were missing from the
report. Emissions of S02 were quantified using Method 6, and three test runs were conducted. Emission
factors were developed for controlled S02 emissions.
The S02 emission data are rated B. The methodology was sound, and no problems were
reported. However, the report lacked adequate documentation to warrant a higher rating.
4.2.1.54 Reference 59. This reference includes selected pages from a report documenting
measurements of S02 from a coal-fired preheater/precalciner kiln. The test was conducted in 1983, and
the purpose was to determine the effect of a PM emissions control device on S02 emissions. Process
rates were provided on the basis of the clinker production rate.
Emissions from the kiln pass through a spray tower, and then through an ESP. Concentrations of
S02 were measured before and after the ESP using a CEM over a 3-day period. However, the emission
rates were determined using the average S02 concentration and a single volumetric flow rate
measurement. Emission factors were developed for S02 emissions before and after the ESP. The S02
emission data are rated C because they are based on a single volumetric flow measurement.
4.2.1.55 Reference 60. This report documents an emission test on a coal-fired
preheater/precalciner kiln. The kiln tested is the same kiln for which an emission test was documented in
Reference 56. Measurements were made of emissions of filterable PM, condensible inorganic PM, NOx,
and C02 from the main kiln stack and the alkali bypass stack. The test was conducted in 1984 to
demonstrate compliance with State regulations. Process rates were provided on the basis of kiln feed.
Emissions from the kiln are controlled with a fabric filter.
Method 5 was used to measure PM emissions, and Method 7 was used to measure emissions of
NOx. Concentrations of C02 were measured using Orsat. Three runs were conducted on each of the
kiln sources. However, the final test run was not completed due to a kiln shutdown. Emission factors
were developed for filterable PM, condensible inorganic PM, NOx, and C02 emissions from the kiln (main
stack and alkali bypass stack combined).
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The N0X and C02 emission data are rated C. Although the test methodologies were sound, only
two test runs were completed. The PM data are rated B. Although the methodologies were sound, the
report lacked adequate documentation to warrant a higher rating.
4.2.1.56 Reference 61. This report documents emission tests on a coal-fired
preheater/precalciner kiln, clinker cooler, raw mill, and finish mill. Measurements were made of
emissions of filterable PM, S02, NOx, CO, TOC and C02 from the kiln. The clinker cooler, raw mill, and
finish mill were tested for PM emissions. The tests were conducted in 1985 to evaluate the performance
of newly installed equipment. Process rates were provided on the basis of kiln feed.
Emissions from the kiln and mills are controlled with separate fabric filters, and emissions from
the clinker cooler are controlled with a gravel filter bed. Method 5 was used to measure PM emissions,
and CEM's were used in accordance with CARB Method 1-100 to measure emission concentrations of
S02, NO,, CO, TOC, and C02.
Three runs were conducted on each of the four sources. Emission factors were developed for
filterable PM, S02, NOx, CO, TOC, and C02 emissions. The results of Run 1 on the clinker cooler PM
test are suspect due to contamination of the sampling train probe. Therefore, the clinker cooler emission
factor is based only on Runs 2 and 3.
With the exception of the clinker cooler test, the emission data are rated B. The methodology
was sound and no problems were noted, but the report lacked adequate documentation to warrant a
higher rating. The clinker cooler PM emission data are rated C because only two of the test runs were
valid.
4.2.1.57 Reference 62. This report documents emission tests on a coal-fired
preheater/precalciner kiln, raw mill, raw mill feed belt, finish mill, and finish mill feed belt. Measurements
were made of emissions of filterable PM, S02, NOx, CO, and C02 from the kiln. The raw mill, raw mill
feed belt, finish mill, and finish mill feed belt were tested for PM emissions. The tests were conducted in
1985 to evaluate the performance of newly installed equipment. The kiln, raw mill, and finish mill are the
same as those for which emission measurements were documented in Reference 61. Process rates were
provided on the basis of kiln feed and production.
Emissions from the kiln, mills, and mill feed belts are controlled with separate fabric filters.
Method 5 was used to measure PM emissions, and CEM's were used in accordance with CARB
Method 1-100 to measure emission concentrations of S02, NOx, CO, and C02. Three runs were
conducted on each of the four sources. Emission factors were developed for filterable PM, S02, NOx,
CO, and C02 emissions.
With the exception of the raw mill feed belt data, the emission data are rated B. The
methodology was sound and no problems were noted, but the report lacked adequate documentation to
warrant a higher rating. The raw mill feed belt data are rated C because only two test runs were
conducted.
4.2.1.58 Reference 63. This report documents an emission test on a coal-fired
preheater/precalciner kiln. Measurements were made of emissions of filterable PM, S02, NOx, CO, and
C02 from the kiln. The tests were conducted in 1987 to demonstrate compliance with State regulations.
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The kiln is the same one for which emission measurements were documented in References 61 and 62.
Process rates were provided on the basis of kiln feed rates.
Emissions from the kiln are controlled with a fabric filter. Method 5 was used to measure PM
emissions, and CEM's were used in accordance with CARB Method 1-100 to measure emission
concentrations of S02, NO.,. CO, and C02. Three runs were conducted on each of the four sources.
Emission factors were developed for filterable PM, S02, NOx, CO, and C02 emissions.
The emission data are rated B. The methodology was sound and no problems were noted, but the
report lacked adequate documentation to warrant a higher rating.
4.2.1.59 Reference 64. This report documents an emission test on a coal-fired
preheater/precalciner kiln. Measurements were made of emissions of filterable PM, S02, NOx, CO, C02,
NH3, and HC1 from the kiln. The tests were conducted in 1987 to demonstrate compliance with State
regulations and to determine NH3 and HC1 emission rates. Emissions from the kiln are controlled with a
fabric filter. The kiln is the same one for which emission measurements were documented in References
61, 62, and 63. Process rates were provided on the basis of kiln feed rates.
Method 5 was used to measure PM emissions. Continuous monitors were used in accordance
with CARB Method 1-100 to measure emission concentrations of NOx, CO, and C02. Emissions of S02
were quantified using Method 8, and NH3 and HC1 emissions were measured using modified Method 5
sampling trains. To test for NH3, the Method 5 train was modified to include two impingers (impingers 1
and 2) containing 100 milliliters (ml) of 0.1 normal (N) HC1. In the HC1 test, the Method 5 train was
modified to include two impingers (impingers 1 and 2) containing 100 ml of 0.1 N sodium hydroxide.
Three runs of each of the sampling trains were conducted. In general, the tests were completed
without a problem. However, the calibration sheets indicated a consistent problem in calibrating the CEM
for CO. Emission factors were developed for filterable PM, S02, NOx, CO, C02, NH3, and HC1
emissions.
The emission data for PM, S02, NOx, TOC, HC1, and C02 are rated B. The methodology was
sound and no problems were noted, but the report lacked adequate documentation to warrant a higher
rating. The CO emission data are rated D because of the problems in calibrating the CEM for CO. The
NH3 data are rated D because the method used was inappropriate.
4.2.1.60 Reference 65. This report documents emissions from a wet process kiln cofired with
waste fuels and coal. The test, which was sponsored by EPA's Office of Solid Waste, was conducted to
compare emissions from the kiln during cofiring to those generated at baseline when only fossil fuels were
fired. The test was conducted in 1990.
The kiln is operated with a clinker capacity of about 1,700 Mg/day (1,870 tons/day) and fires a
combination of coal and liquid waste fuels, which typically consist of a combination of waste solvents and
thinners. Emissions from the kiln are controlled by a mechanical collector and a four-field ESP in series.
A series of tests, sponsored by EPA, was conducted at the ESP exhaust to compare emissions under
different fuel-firing scenarios. Originally, the protocol called for two scenarios-coal-only baseline and
coal/liquid waste cofiring. However, the system could not maintain stable operations during the coal-only
baseline run, which makes results from this single run suspect. Consequently, the final test sequence
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included a coal-only baseline (1 run), a coal/diesel fuel baseline (2 runs), and the coal/liquid waste
condition (3 runs). The purpose of the coal/diesel baseline runs was to overcome the problems associated
with the coal only baseline run by simulating the plant's standard firing condition of coal and liquid waste
firing with coal and a liquid fossil fuel (diesel).
The test protocol called for quantitation of a variety of criteria and noncriteria pollutants. Criteria
pollutants measured were CO (Method 10) and TNMOC (Method 25). Noncriteria pollutant
measurements included C02 (by CEM), semivolatile organic compounds (Method 010), VOC (VOST-
Method 030), and HC1 (Modified Method 5). Emission factors were developed from the results of the
baseline run (coal only). These baseline data are unrated because only one test run was conducted and
the process was not operating normally during the run.
Emission factors were not developed from the data from the coal/diesel runs because this
combination of fuels is not representative of the plant's standard operating practice; emission factors
were not developed from the coal- and liquid waste fuel-fired runs because the emission characteristics
would likely be a function of the amount and chemical constituents of liquid waste used, and therefore
may not be of use in estimating emissions from other kilns in the industry.
4.2.1.61 Reference 66. This report documents emissions from a preheater/precalciner process
kiln cofiring waste fuels and coal. The test, which was sponsored by EPA's Office of Solid Waste, was
conducted to compare emissions from the kiln during cofiring to those generated at baseline when only
fossil fuels were fired. The test was conducted in 1990.
The kiln is operated with a clinker capacity of about 1,640 Mg/d (1,800 tons/d). The system
typically fires a combination of fossil fuels (coal, natural gas, or No. 2 fuel oil) and liquid organic waste to
the kiln and a combination of pulverized coal and liquid or solid organic waste in the pyroclone precalciner.
The exhaust gases from both the main kiln stack and the alkali bypass stack are exhausted through ESP's
to the atmosphere. This series of tests, which was sponsored by EPA, measured emissions from both the
main kiln stack and the alkali by-pass stack. Because the test sequence was designed to compare
emissions from fossil fuel and waste firing, emissions were measured under three operating conditions-
coal only (1 run), liquid waste only (2 runs), and a coal/liquid waste mixture(2 runs)~fired to the kiln.
During all conditions pulverized coal was fired to the pyroclone precalciner.
The test protocol involved quantitation of a range of criteria and noncriteria pollutants. Criteria
pollutants measured included CO (Method 10), TOC (Method 25A) and S02 and NOx with plant CEM
monitors. Noncriteria pollutant measurements included C02 (by CEM), VOC organic screen (VOST-
Method 030), a semivolatile organic screen method (Method 030) that included quantitation of chlorinated
dibenzo-p-dioxins and chlorinated dibenzofurans (CDD/CDF), and HC1 (MM5). Both organic sampling
methods are integrated extractive sampling procedures with analysis by GC/MS.
Emission factors were developed from the results of the baseline run (coal only). These baseline
data are unrated because only one test run was conducted. Emission factors were not developed from
the waste fuel-fired runs because the emission characteristics would likely be a function of the amount
and chemical constituents of waste used, and therefore may not be of use in estimating emissions from
other kilns in the industry.
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4.2.1.62 Reference 67. This report documents measurements of filterable PM and C02 from a
wet process coal-fired rotary kiln. The emission test was conducted in 1980 to demonstrate compliance
with State regulations. The kiln tested is the same kiln emissions of which are documented in
Reference 29. Process rates were provided as the total dry kiln feed and insufflated dust feed rate.
Emissions from the kiln are controlled with an ESP, and only controlled emissions were measured.
Emissions of filterable PM were measured using Method 5, and C02 emissions were quantified by Orsat.
Three runs of PM were conducted. Emission factors were developed for filterable PM and C02
emissions from the kiln.
The emission data are rated C. Although the test methodology was sound, the report does not
include a process description and generally is lacking in details.
4.2.1.63 Reference 68. This report documents measurements of filterable PM from a clinker
cooler. The emission test was conducted at the same facility simultaneously with the kiln emission test
that is documented in Reference 67. The purpose of the test was to demonstrate compliance with State
regulations. Process rates were provided on the basis of clinker cooler feed rate. However, the clinker
cooler feed rate reported is identical to the kiln feed rate reported in Reference 67 for the same test
period. For this reason, it appears that the cooler feed rate is incorrect, and emission factors were not
developed from this report.
4.2.1.64 Reference 69. This report documents measurements of PM and C02 from three dry
process coal-fired rotary kilns. The kilns are equipped with suspension preheaters. The emission test
were conducted in 1979 to determine differences in emission rates for the same kilns fueled with natural
gas. Process rates were provided on the basis of kiln feed rates and included raw material and insufflated
dust feed rates.
The kilns are equipped with fabric filters to control emissions, and only controlled emissions were
reported. Emissions of PM were measured using Hi-Vol samplers positioned in three of the six fabric
filter compartments. Concentrations of C02 were measured by Orsat. Three test runs were conducted
on kilns 1 and 3, and two test runs were conducted on kiln 2. Emission factors were developed for
filterable PM and C02 emissions.
The PM emission data are rated C because of problems reported in calibrating the Hi-Vol
samplers. The C02 data for kilns 1 and 3 are rated B. The test methodology was sound, and no
problems were reported. However, the documentation was inadequate to warrant a higher rating. The
C02 data for kiln 2 are rated C because only two runs were conducted.
4.2.1.65 Reference 70. This report documents a determination of visible emissions from kilns at
four portland cement plants. Because the report does not contain emission data, it could not be used to
develop emission factors.
4.2.1.66 Reference 71. This report documents measurements of filterable PM, NOx, and S02
from a kiln and emissions of filterable PM from a clinker cooler. The emission test was conducted in
1983 to demonstrate compliance with State regulations. The report does not specify the type of kiln or
control device tested. In addition, clinker cooler feed rates are not provided. For these reasons, emission
factors were not developed from the report.
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4.2.1.67 Reference 72. This report documents measurements of filterable PM from a dry
process rotary kiln fired with coal. The emission test was conducted in 1983 to demonstrate compliance
with State regulations. Emissions from the kiln are controlled with a combination of an ESP and a series
of fabric filters in parallel. Emission factors were not developed from the report because of the atypical
control device configuration.
4.2.1.68 Reference 73. This report documents measurements of filterable PM, NOx, and S02
from a kiln and emissions of filterable PM from a clinker cooler. The emission test was conducted in
1982 to demonstrate compliance with State regulations. The facility is the same plant for which emission
measurements were documented in Reference 71. The report does not specify the type of kiln or control
device tested. In addition, clinker cooler feed rates are not provided. For these reasons, emission factors
were not developed from the report.
4.2.1.69 Reference 74. This report documents measurements of emissions from a coal-fired
preheater/precalciner process kiln. The test was conducted to satisfy the requirements of AB 2588 ("Hot
Spots") of the State of California and included measurements of dioxins and furans, polycyclic aromatic
hydrocarbons (PAH), multiple metals, hexavalent chromium (Cr+6) and total Cr, formaldehyde, HC1, and
benzene, and C02. Process rates were provided on the basis of the kiln feed.
Emissions from the kiln are first ducted to the raw and coal mills and then to a 32-compartment
fabric filter. However, the test was conducted with the raw mill not operating. Emissions were measured
in only one stack (of 32, apparently) of the fabric filter. Although not specified in the reference, it
assumed that the fabric filter had multiple stacks because the filter was a positive pressure type.
Emissions of dioxins and furans were measured using a modified Method 5, as described in
CARB Method 428; PAH emissions were measured using CARB Method 429; emissions of multiple
metals were quantified with EPA Method 0012; Cr+6 and total Cr emissions were measured using CARB
Method 425; formaldehyde emissions were quantified with CARB Method 430; Emissions of HC1 were
measured using CARB Method 421; and benzene emissions were quantified with CARB Method 410.
Three runs were conducted with each sampling train.
Emission factors were developed for six metals, heptachlorinated dibenzo-p-dioxin (HpCDD),
octochlorinated dibenzo-p-dioxin (OCDD), pentachlorinated dibenzo-p-dioxin (PCDD), tetrachlorinated
dibenzo-furan (TCDF), pentachlorinated dibenzo-furan (PCDF), HC1, C02, and 18 organic pollutants.
Because emissions were sampled from only 1 of 32 stacks, emission rates were multiplied by 32 when
developing emission factors from the test data.
The emission data are rated D because only 1 of 32 fabric filter stacks were sampled and total
emissions had to be extrapolated over the entire fabric filter in order to develop emission factors from the
data.
4.2.1.70 Reference 75. This reference consists of selected pages of a test report that documents
emissions from a preheater/precalciner rotary kiln. The purpose of the tests was to determine the effects
on emission characteristics of burning tire chips as a supplemental fuel. A portion of the exhaust stream
from the kiln is ducted to a raw mill prior to the air pollution control device. However, the control device
is not specified.
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The tests were conducted under four conditions: (1) burning coal with the raw mill on (three
runs); (2) burning coal with the raw mill off (one run); (3) burning coal and tire chips with the raw mill off
(one run); and (4) burning coal and tire chips with the raw mill on (three runs). Run-by-run data are
provided for conditions 1 and 4 only. The data were not used to develop emission factors because the
control device is not specified and emissions measured with the raw mill operating are of little use without
information on the percentage of exhaust gas ducted to the raw mill.
4.2.1.71 Reference 76. This report documents emission tests on a coal-and waste fuel-fired
preheater/precalciner rotary kiln. Emissions from the kiln are controlled with a fabric filter. The tests
were conducted to satisfy the requirements of the BIF regulations. Three baseline runs (Phase I) were
conducted during which the kiln was fired with coal only, and three runs (Phase II) were conducted
during which the kiln was fired with a combination of coal, tires, and solid and liquid hazardous waste.
Emissions were sampled for filterable PM (Method 5), HC1 and chlorine (CI) (Method 0050),
multiple metals (Method 0012), semivolatile organic compounds (Method 0010), VOC (Method 0030), CO
(Method 10), C02 (Method 3A), and TOC (Method 25A). Three runs were conducted during both
phases (baseline and hazardous waste cofiring) of testing, and no problems were reported. The baseline
Method 0030 samples were analyzed for perchloroethylene, trichlorofluoromethane, 1,1,2 trichloroethane,
and 1,1,1 trichloroethane, all of which were below the detection limit.
Emission factors were developed, from the baseline data only, for emissions of filterable PM, CI,
HC1, CO, C02, TOC, and 11 metals. The emission data are rated A. Emission factors were not
developed from the coal- and waste fuel-fired runs because the emission characteristics would likely be a
function of the amount and chemical constituents of waste used, and therefore may not be of use in
estimating emissions from other kilns in the industry.
4.2.1.72 Reference 77. This report documents emission tests on two wet process rotary kilns
(Nos. 1 and 2) that are ducted to a common ESP. The tests were conducted to satisfy the requirements
of the BIF regulations for using hazardous waste as a supplemental fuel. The kilns were tested under two
operating conditions. For condition I, kiln 1 was fired with coal and oil, and kiln 2 was fired with coal and
tires. For condition II, kiln 1 was fired with coal and oil, and kiln 2 was fired with coal only. Three runs
were conducted for each operating condition.
Emissions were sampled for filterable PM (Method 5), multiple metals (Method 0012),
semivolatile organic compounds (Method 0010), dioxins and fiirans, VOC (Method 0030), S02
(Method 6), NOx (Method 7E), CO (Method 10), C02 (Method 3 A), and TOC (Method 25 A), and no
problems were reported. Emissions of seven metals and 15 organic compounds were found to be above
the detection limit.
Only the baseline (condition II) data were used to develop emission factors. Emission factors
were developed for emissions of filterable PM, condensible inorganic PM, S02, NOx, CO, C02, TOC, 7
metals, and 15 organic compounds. The emission data are rated B. The methodologies were sound, and
no problems were reported. However, the report lacked adequate documentation to warrant a higher
rating.
4.2.1.73 Reference 78. This report documents emission tests on a coal-fired dry process rotary
kiln. The tests were sponsored by EPA in order to determine the destruction and removal efficiency of
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several inorganic and inorganic pollutants in kilns burning hazardous waste. The kilns were tested under
two operating conditions: two baseline runs were conducted during which the kiln was fired with coal
only, and three runs were conducted during which the kiln was fired with a combination of coal and waste
fuel. Emissions from the kiln are controlled with an ESP. However, the ESP was malfunctioning during
the entire test period.
Emissions were sampled for filterable PM (Method 5), HC1 using the Method 6 midget impinger
train, semivolatile organic compounds (modified Method 5), VOC (Method 0030), S02 (Method 6C), NOx
(Method 7E), CO (Method 10), C02 (Method 3A), and TOC (Method 25A). In addition, the Method 5
PM catch was analyzed for multiple metals using atomic absorption and inductively coupled argon plasma
techniques. Because of the problem with the ESP, the PM, metals, and semivolatile organic compound
data are highly suspect.
Only the baseline (condition II) data were used to develop emission factors. Emission factors
were developed for emissions of filterable PM, S02, NOx, CO, C02, TOC, HC1, 12 metals, and 5 VOC,
and 9 semivolatile organic compounds.
The emission data for PM, metals and semivolatile organic compounds are rated D because only
two runs were conducted and the control device malfunctioned during the tests. The emission data for
1,1,1 trichloroethylene are unrated because the concentrations measured were above the detection limit
for only one run. The emission data for the other four VOC are rated C because only two test runs were
conducted.
4.2.1.74 Reference 79. This reference is the background report for the 1986 revisions to the PM
emission factors for AP-42 Section 11.6. With the exception of a few references that could not be
located for this revision to Section 11.6, the references used in the preparation of Reference 79 also were
reviewed and described in this background report. As explained in Section 4.2 of this report, the average
particle size distribution data presented in Reference 79 were retained in the proposed revision to AP-42
Section 11.6 without change. These data are presented in Table 4-8. In addition, these particle size data
were used to develop average PM-10 emission factors from the average PM emission factors developed
for the proposed revision to the section.
4.2.1.75 Reference 80. This secondary reference provides a theoretical and empirical evaluation
of metal and organic compound emissions from portland cement kilns firing both traditional fossil fuels and
waste derived fuel including both hazardous waste and waste tires. The study focuses on three major
issues-the partitioning of metal compounds in the various kiln discharge streams, the destruction and
removal efficiency of the hazardous organic constituents in the waste fuels, and the formation of organic
products of incomplete combustion for both conventional fossil fuels and waste-derived fuels. All
emission data presented in the report were secondary data, and little information was provided on either
the sampling and analysis methodology used to generate the data or the processes tested. In particular, no
process operating rates were presented for any of the kilns during the test period. Consequently, emission
factors could not be calculated from the data presented.
While emission factors were not generated from the report, several findings from this study may
be useful for analyses of metal and organic compound data from portland cement kilns. First, this study
found that metal compounds could be grouped into three general classes-volatile metals (Hg and Tl),
semivolatile metals (Sb, Cd, Pb, Se, Zn, K, and Na), and refractory or nonvolatile metals (Ba, Be, Cr, As
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[which acts as a refractory metal even though it is relatively volatile because it tends to form arsenates in
the kiln], Ni, V, Mn, Cu, and Ag). Although the partitioning of these groups is affected by kiln operating
conditions, the refractory metals tend to concentrate in the clinker, while the volatile and semivolatile
metals tend to be discharged via the primary exhaust stack and the by-pass stack, respectively. Details
on the partitioning of the different metals and the effects of operating parameters on this partitioning are
supplied in the report. Relative to organic constituents, the study indicated that the formation of
chlorinated dibenzo-p-dioxins, chlorinated dibenzofurans, and other chlorinated compounds, particularly
chlorinated benzenes, appeared to be related to the chlorine content of waste fuels. However, the data
presented in the report were insufficient to quantify the relationship.
4.2.2 Estimate of Theoretical CCK Emission Factors for Portland Cement Kilns81
Carbon dioxide is emitted from portland cement manufacturing kilns by two mechanisms: the
reduction of carbonate (C03 2) in the feed material to CaO and the oxidation of carbon in the fuel.
Portland cement typically contains the equivalent of 63.5 percent CaO, which corresponds to the release
of approximately 500 kg of C02 per Mg (1,000 lb/ton) of cement produced. The amount of C02 released
as a result of the second mechanism depends on the energy efficiency of the kiln and the type of fuel
used. The fuel required produce to 1 Mg (1 ton) of portland cement is estimated to be 5.42 x 109 joules (j)
(5.14 million British thermal units [MMBtu]) for wet process kilns, 5.09 x 109 j (4.82 MMBtu) for dry
process kilns, and 3.85 x 109 j (3.65 MMBtu) for preheater kilns. Fuel requirements for
preheater/precalciner kilns were not available. However, because of increased efficiency,
preheater/precalciner kilns should have lower energy requirements than preheater kilns.
Using a C02 emission factor of 0.100 kg/j (233 lb/Btu) for coal and 0.603 kg/j (140 lb/MMBtu)
for gas, the emission factors for C02 emissions from fuel combustion can be estimated in units of mass of
cement produced. The C02 emission factor for both mechanisms can be combined to yield estimates of
the total C02 emission factors for portland cement kilns. These estimated emission factors are presented
in Table 4-10.
4.2.3 Review of XATEF and SPECIATE Data Base Emission Factors
The XATEF data base contains emission factors for manganese, nickel, beryllium, cadmium, and
chromium for most of the portland cement manufacturing PM sources described earlier. However, when
the emission factors were traced back to the original reference, they were found to be based on the
application of a fraction of metal in dry cement dust to earlier AP-42 emission factors. No actual
emission data were referenced. Consequently, these emission factors do not satisfy the minimum criteria
for inclusion in AP-42.
The SPECIATE data base also includes emission factors for most portland cement plant PM
sources. The SPECIATE documentation notes that two sets of factors are based on cement kiln
emission tests and the others are based on unknown methods. To date, the original references for the test
data have not been obtained, so the emission factors do not meet minimum criteria for inclusion in AP-42.
However, the references are being pursued, and additional metals emission factors may be included in a
subsequent draft.
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4.2.4 Review of Background File
The references reviewed for this revision included all test reports and relevant information
included in the AP-42 background file for portland cement manufacturing. These references are
described in Section 4.2.1. of this report.
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4.2.5 Results of Data Analysis
This section discusses the analysis of the data and describes how the data were used to develop
average emission factors for portland cement manufacturing. These average emission factors are listed
in Tables 4-11 to 4-17. As described in Section 4.2, emission factors for kilns are presented in units of
mass of pollutant emitted per mass of clinker produced.Emission factors for clinker coolers and other
sources are presented in units of mass of pollutant emitted per mass of material processed. The following
paragraphs describe how the emission data from individual test reports were used to develop the average
emission factors for portland cement manufacturing. Emission factors for emissions of criteria pollutants
(PM, PM-10, S02, NOx. CO, and VOC's) and C02 from portland cement kilns are discussed in the
following order: wet process kilns, long dry process kilns, dry preheater process kilns, and dry
preheater/precalciner process kilns. Following the discussions of specific types of kilns, general emission
factors for emissions of other pollutants (metals, other inorganics, and organics) from portland cement
kilns are discussed. Finally, emission factors for emissions from clinker coolers and other portland cement
manufacturing processes are discussed.
The emission factor ratings assigned to each of the average emission factors developed for
portland cement manufacturing are based on the emission data ratings and the number of tests conducted.
Of the 553 data sets from which emission factors were developed, 21 were A-rated, 180 were B-rated,
112 were C-rated, 109 were D-rated, and 131 were unrated. In general, A- and B-rated data are not
supposed to be averaged with C- and D-rated data. However, because of the relatively large number of
C-rated data sets reviewed, emission factors based on C-rated data were averaged with B-rated data if
no A-rated data were available for that particular combination of source, control, and pollutant, and the
number of C-rated tests were relatively large in comparison to the number of B-rated tests. D-rated data
were used only when A- or B-rated data were not available.
A number of the references described in Section 4.2.1 document multiple emission tests on the
same kiln. In such cases, the emission factors based on the results of all of the emission tests on the
same kiln were averaged first. For these average emission factors, data ratings were assigned as follows.
If the data from the individual tests were assigned the same rating, the average data set for that kiln was
assigned that rating. If the data from the individual tests were assigned two different ratings, the average
data set was assigned the higher of the two ratings if there were at least as many individual data sets
rated at the higher rating than individual data sets rated at the lower rating. For example, if there were
four tests conducted on the same kiln, two (or more) were rated B, and two (or less) were rated C, the
average data set for the kiln was assigned a rating of B. If one B-rated tests and three C-rated tests
were obtained for the same kiln, the average data set was assigned a rating of C. With few exceptions
the individual tests on the same kiln were rated B or C. In a few cases, individual D-rated data sets were
combined with C-rated data sets. After the average kiln emission factors were determined, they were
combined with the emission factors developed for other kilns as described previously in this section and in
Sections 3.2 and 3.3 of this report. Appendix A provides additional information on how the emission
factors were derived for criteria pollutant emissions from portland cement kilns.
4.2.5.1 Wet Process Kilns. Of the 81 data sets from which emission factors were developed for
criteria pollutant emissions from wet process kilns, none were rated A, 33 were rated B, 35 were rated C,
6 were rated D, and 7 were not rated. The majority of the tests documented were conducted on coal-
fired wet process kilns. However, some data were available on emissions from gas- and oil-fired wet
process kilns, and one test report documented emissions from a wet process kiln fired with a combination
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of coal and oil. For kilns fired with fuels other than coal, the number of documented tests were so few
that emission factors developed from the data are not likely to be representative of emissions from kilns
using alternatives to coal as fuel. Therefore, the data from kilns fired with gas and oil were combined
with the coal-fired kiln emission data. The average criteria pollutant emission factors developed for wet
process kilns are summarized in Table 4-11. The following paragraphs describe how these average
emission factors for wet process kilns were developed.
Filterable PM For uncontrolled emissions of filterable PM from wet process kilns, data from two
B-rated, one C-rated, and one D-rated test were available. The emission factor developed from the
B-rated tests averaged 65 kg/Mg (130 lb/ton), the emission factor developed from the C-rated test
averaged 180 kg/Mg (350 lb/ton), and the emission factor developed from the D-rated data averaged
630 kg/Mg (1,300 lb/ton). The C- and D-rated data were discarded, and the B-rated data were used for
the average emission factor for uncontrolled filterable PM emissions from wet process kilns. This
emission factor is rated D.
For filterable PM emissions controlled with an ESP, a total of 20 data sets were available. After
combining the results of multiple tests on the same kiln, the number of data sets was reduced to 11. Five
of these data sets were rated B, and six of the data sets were rated C. The emission factors developed
from the B-rated data ranged from 0.13 kg/Mg (0.25 lb/ton) to 0.60 kg/Mg (1.2 lb/ton) and averaged 0.38
kg/Mg (0.76 lb/ton). The emission factors developed from the C-rated data ranged from 0.069 kg/Mg
(0.14 lb/ton) to 1.0 kg/Mg (2.0 lb/ton) and averaged 0.39 (0.77 lb/ton). The B- and C-rated data were
combined for an average emission factor for ESP-controlled filterable PM emissions from coal-fired wet
process kilns of 0.38 kg/Mg (0.77 lb/ton). This average emission factor is assigned a rating of C.
A single test was available on emissions from a coal-fired wet process kiln controlled with a
combination of cooling tower, multiclone, and ESP. The data from this test were rated C, and were used
to develop an E-rated emission factor of 0.10 kg/Mg (0.20 lb/ton).
For fabric filter-controlled filterable emissions from a coal-fired wet process kiln, data from one
C-rated and one unrated test were available. The data from the C-rated test yielded an E-rated emission
factor of 0.23 kg/Mg (0.46 lb/ton).
Emission factors for filterable PM-10 emissions from uncontrolled wet process kilns, and ESP-
controlled wet process kilns also were developed by multiplying the cumulative mass percent less than
10 fim presented in Reference 79 by the average emission factors described in the preceding paragraphs.
Condensible inorganic PM For condensible inorganic PM emissions from wet process kilns, data
from eight emission tests were available: two B- and two C-rated tests on ESP-controlled kilns, one
C-rated and two unrated tests on fabric filter-controlled kilns, and a C-rated test on a kiln controlled with a
combination of cooling tower, multiclone, and ESP. For ESP-controlled condensible inorganic PM
emissions, emission factors developed from B-rated data were 0.11 kg/Mg (0.21 lb/ton) and 0.024 kg/Mg
(0.047 lb/ton), and emission factors developed from the C-rated data were 0.10 kg/Mg (0.20 lb/ton) and
0.075 kg/Mg (0.15 lb/ton). The B- and C-rated data were combined to yield an average emission factor
of 0.076 kg/Mg (0.15 lb/ton) for condensible inorganic PM emissions from an ESP-controlled wet process
kiln. For fabric filter-controlled condensible inorganic PM emissions, an E-rated emission factor of
0.10 kg/Mg (0.20 lb/ton) was developed from the C-rated test data, and for condensible inorganic
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emissions controlled with a combination of cooling tower, multiclone, and ESP, an E-rated emission factor
of 0.14 kg/Mg (0.29 lb/ton) was developed.
Sulfur dioxide. For S02 emissions from wet process kilns, a total of 22 data sets were available.
Two of the data sets consists of measurements of S02 emissions prior to a control device, 17 tests were
conducted on ESP-controlled kilns, and 3 tests were conducted on fabric filter-controlled kilns. Because
ESP's are expected to have negligible effects on S02 emissions, the ESP-controlled kiln data sets were
treated as measurements of uncontrolled S02 emissions. Fabric filters also are considered to have
negligible effects on S02 emissions, and the emission factors developed from the fabric filter-controlled
kiln tests were comparable in magnitude to the emission factors developed from the other test data.
Therefore, the results of the fabric filter-controlled tests also were treated as measurements of
uncontrolled S02 emissions. After combining the results of multiple tests on the same kiln, the number of
data sets was reduced to 13. Four of these data sets were rated B, four of the data sets were rated C,
three of the data sets were rated D, and two data sets were unrated. The emission factors developed
from the B-rated data ranged from 1.2 kg/Mg (2.3 lb/ton) to 8.3 kg/Mg (17 lb/ton) and averaged
4.7 kg/Mg (9.5 lb/ton). The emission factors developed from the C-rated data ranged from 1.9 kg/Mg
(3.8 lb/ton) to 5.2 kg/Mg (10 lb/ton) and averaged 3.6 kg/Mg (7.0 lb/ton). The D- and unrated data were
discarded, and the B- and C-rated data were combined for an average emission factor for uncontrolled
S02 emissions from wet process kilns of 4.1 kg/Mg (8.2 lb/ton). This average emission factor is assigned
a rating of C.
Nitrogen oxides. For NOx emissions from wet process kilns, a total of 12 data sets were
available, 11 of which are from tests conducted on ESP-controlled kilns; the remaining data set is from a
fabric filter-controlled kiln. Because ESP's and fabric filters are expected to have negligible effects on
NOx emissions, all data sets were treated as measurements of uncontrolled NOx emissions. After
combining the results of multiple tests on the same kiln, the number of data sets was reduced to nine.
Five of these data sets were rated B, two data sets were rated C, one data set was rated D, and one data
set was unrated. The emission factors developed from the B-rated data ranged from 1.7 kg/Mg
(3.5 lb/ton) to 10 kg/Mg (20 lb/ton) and averaged 3.7 kg/Mg (7.4 lb/ton). The emission factors developed
from the C-rated data were determined to be 3.3 kg/Mg (6.6 lb/ton) and 1.4 kg/Mg (2.9 lb/ton). The
D-rated and unrated data were discarded. Because the number of C-rated tests was relatively small in
comparison to the number of B-rated tests, the C-rated data were discarded and only the B-rated data
were used. This average emission factor is assigned a rating of D.
Carbon monoxide. For CO emissions from wet process kilns, the only rated data available consist
of the results of a single test on an ESP-controlled wet process kiln. Because ESP's are expected to have
negligible effects on CO emissions, the data were treated as measurements of uncontrolled CO emissions.
These data are rated B and were used to develop a D-rated emission factor of 0.060 kg/Mg (0.12 lb/ton).
Carbon dioxide. For C02 emissions from wet process kilns, a total of 14 data sets were available
on measurements of C02 emissions from ESP-controlled kilns. Because ESP's are expected to have
negligible effects on C02 emissions, all data sets were treated as measurements of uncontrolled C02
emissions. One of the tests was rated D and one of the tests was unrated; both of these data sets were
discarded. After combining the results of multiple tests on the same kiln, the number of data sets were
reduced to seven. Five of these data sets were rated B, and two of the data sets were rated C. The
emission factors developed from the B-rated data ranged from 980 kg/Mg (2,000 lb/ton) to 1,500 kg/Mg
(2,900 lb/ton) and averaged 1,200 kg/Mg (2,400 lb/ton). The emission factors developed from the C-rated
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data were 570 kg/Mg (1,100 lb/ton) and 890 kg/Mg (1,800 lb/ton) and averaged 730 kg/Mg (1,500 lb/ton).
Because the theoretical average emission factor for C02 emissions from wet process kilns as discussed in
Section 4.2.2 is 1,100 kg/Mg (2,200 lb/ton), the B-rated data appear to be biased high. Therefore, the B-
and C-rated data were combined for an average emission factor for uncontrolled C02 emissions from
coal-fired wet process kilns of 1,100 kg/Mg (2,100 lb/ton). In comparison to the theoretical average
emission factor for C02 emissions from coal-fired wet process kilns, the magnitude of this average
emission factor appears to be reasonable. This average emission factor is assigned a rating of C.
Volatile Organic Compounds. For wet process kilns, data were available from one test of TOC
emissions. The test was conducted on an ESP-controlled kiln. Because ESP's should have negligible
effects on VOC emissions, the results were treated as uncontrolled emissions. The data were rated B,
and the emission factor developed from the data is rated D.
4.2.5.2 Long Dry Process Kilns. Of the 46 data sets from which emission factors were
developed for long dry process kiln emissions, 2 were rated A, 21 were rated B, 15 were rated C, 7 were
rated D, and 1 was not rated. All of the tests documented were conducted on coal-fired dry process kilns.
The average emission factors developed from these data sets are provided in Table 4-12. The following
paragraphs describe how these average emission factors for long dry process kilns were developed.
Filterable PM For filterable PM emissions from long dry process kilns controlled with an ESP, a
total of three data sets were available. Two of these data sets were rated B, and one of the data sets
was rated D. The D-rated data were discarded. Data were available from three tests conducted on
emissions from a dry process kiln controlled with a combination of cooling tower, multiclone, and ESP.
The data from all three tests were rated B, and ranged from 0.65 kg/Mg (1.3 lb/ton) to 0.85 kg/Mg
(1.7 lb/ton). These emission factors for the five tests were combined to yield a D-rated average emission
factor of 0.50 kg/Mg (1.0 lb/ton) for filterable PM emissions from an ESP-controlled dry process kiln.
For fabric filter-controlled filterable emissions from a dry process kiln, data from one A-rated test
and two C-rated tests were available. The emission factors for the C-rated tests, which ranged from
0.046 kg/Mg (0.093 lb/ton) to 0.10 kg/Mg (0.19 lb/ton), were discarded. The A-rated data yielded a
D-rated emission factor of 0.10 kg/Mg (0.20 lb/ton).
Emission factors for filterable PM-10 emissions from uncontrolled long dry process kilns, and
fabric filter-controlled long dry process kilns were developed by multiplying the cumulative mass percent
less than 10 fim presented in Reference 79 by the average emission factors described in the preceding
paragraphs.
Condensible inorganic PM For condensible inorganic PM emissions from long dry process kilns,
data from seven emission tests were available: two B-rated tests on ESP-controlled kilns; three B-rated
tests on a kilns controlled with a combination of cooling tower, multiclone, and ESP; and one A-rated and
one C-rated test on fabric filter-controlled kilns. Each of these data sets were used to develop an average
emission factor. For ESP-controlled condensible inorganic PM emissions, the factors developed from the
two tests were 0.13 kg/Mg (0.26 lb/ton) and 0.41 kg/Mg (0.82 lb/ton) and averaged 0.27 kg/Mg
(0.54 lb/ton). For condensible inorganic emissions controlled with a combination of cooling tower,
multiclone, and ESP, the emission factors developed from the three B-rated tests ranged from 0.11 kg/Mg
(0.21 lb/ton) to 0.17 kg/Mg (0.33 lb/ton). The average for the five tests is 0.19 kg/Mg (0.38 lb/ton). This
average emission factor is rated D.
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For fabric filter-controlled condensible inorganic PM emissions, a D-rated emission factor of
0.45 kg/Mg (0.89 lb/ton) was developed was developed from the A-rated test data; the C-rated data were
discarded.
Sulfur dioxide. For S02 emissions from long dry process kilns, a total of seven data sets were
available. Two of the data sets consist of measurements of S02 emissions from ESP-controlled kilns, and
the remaining five data sets consist of measurements of S02 emissions from fabric filter-controlled dry
kilns. Because the average emission factor developed from the ESP-controlled emission tests is four
times the average of the fabric filter-controlled kiln test emission factors, the data appear to indicate that
ESP's and fabric filters affect S02 emissions differently. However, the fabric filter data all fall within the
range of the ESP test data. In addition, both types of control devices are expected to have negligible
effects on S02 emissions. Therefore, all data sets were treated as measurements of uncontrolled S02
emissions. Five of the data sets were rated B, one of the data sets was rated C, and two of the data sets
were rated D. The D-rated data were discarded. The emission factor developed from the C-rated test
was 0.046 kg/Mg (0.092 lb/ton). The emission factors developed from the B-rated tests ranged from
0.20 kg/Mg (0.40 lb/ton) to 14 kg/Mg (28 lb/ton) and averaged 4.9 kg/Mg (10 lb/ton). The C-rated data
were discarded because there were substantially more B-rated data sets. The average emission factor
developed from the B-rated data is rated D.
Nitrogen oxides. For NOx emissions from long dry process kilns, nine data sets were available.
Two of the tests were conducted on kilns with unspecified emission controls, one of the tests was
conducted on an ESP-controlled kiln, and six of the tests were conducted on kilns controlled with fabric
filters. Because ESP's and fabric filters are expected to have negligible effects on NOx emissions, all
data sets were treated as measurements of uncontrolled NOx emissions. Three of these data sets were
rated B, four of the data sets were rated C, and two of the data sets were rated D. The D-rated data
were discarded. The emission factors developed from the B-rated data ranged from 2.2 kg/Mg
(4.3 lb/ton) to 4.6 kg/Mg (9.2 lb/ton) and averaged 3.2 (6.4 lb/ton). The emission factors developed from
the C-rated data ranged from 1.4 kg/Mg (2.9 lb/ton) to 3.4 kg/Mg (6.7 lb/ton) and averaged 2.9 kg/Mg
(5.7 lb/ton). The B- and C-rated data were combined for an average emission factor for uncontrolled
NOx emissions from dry process kilns of 3.0 kg/Mg (6.0 lb/ton). This average emission factor is assigned
a rating of D.
Carbon monoxide. For CO emissions from a long dry process kilns, the results from three
emission tests were available. The data from one of the tests was unrated and were discarded. The
remaining data consist of the results of a C-rated test on an ESP-controlled kiln (0.11 kg/Mg [0.22 lb/ton])
and a D-rated test on a fabric filter-controlled kiln (0.10 kg/Mg [0.20 lb/ton]). Because ESP's and fabric
filters are expected to have negligible effects on CO emissions, the data were treated as measurements of
uncontrolled CO emissions. The emission factors from both tests were combined to yield an E-rated
emission factor of 0.11 kg/Mg (0.21 lb/ton) for CO emissions from long dry process kilns.
Carbon dioxide. For C02 emissions from long dry process kilns, a total of seven data sets were
available on measurements of C02 emissions from kilns controlled with various control devices, none of
which are expected to have significant effects on C02 emissions. Therefore, all data sets were treated as
measurements of uncontrolled C02 emissions. One of the tests was rated D and was discarded. Three
of the data sets were rated B, and the other three data sets were rated C. The emission factors
developed from the B-rated data ranged from 900 kg/Mg (1,800 lb/ton) to 1,100 kg/Mg (2,100 lb/ton) and
averaged 1,000 (2,000 lb/ton). The emission factors developed from the C-rated data ranged from
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420 kg/Mg (830 lb/ton) to 1,000 kg/Mg (2,000 lb/ton) and averaged 780 kg/Mg (1,500 lb/ton). The B- and
C-rated data were combined for an average emission factor for uncontrolled C02 emissions from long dry
process kilns of 900 kg/Mg (1,800 lb/ton). In comparison to the theoretical average emission factor for
C02 emissions (1,100 kg/Mg [2,100 lb/ton]) from coal-fired dry process kilns discussed in Section 4.2.2,
the magnitude of this average emission factor appears to be reasonable. This average emission factor is
assigned a rating of D.
Volatile Organic Compounds. For long dry process kilns, data were available from two tests of
TOC emissions and one test of TNMOC emissions. The tests were conducted on kilns with dry PM
controls (ESP's or fabric filters), which should have negligible effects on VOC emissions, and all three
tests were rated C. The TOC data were 0.024 kg/Mg (0.048 lb/ton) and 0.0044 kg/Mg (0.0088 lb/ton)
and averaged 0.014 kg/Mg (0.028 lb/ton). The results of the TNMOC test were 0.23 kg/Mg (0.45 lb/ton),
which are considerably higher than the emission factors developed from the TOC tests. Because TOC
emissions should be higher, the emission factor developed from the TNMOC data was not incorporated
into the revised AP-42 section. The TOC emission factor is rated E.
4.2.5.3 Drv Preheater Kilns. Of the 32 data sets from which criteria pollutant emission factors
were developed for dry preheater kiln emissions, 1 was rated A, 19 were rated B, 11 were rated C, and 1
was rated D. All of the tests documented were conducted on coal-fired dry preheater process kilns. The
average emission factors developed from these data sets are provided in Table 4-13. The following
paragraphs describe how these average emission factors for dry preheater process kilns were developed.
Filterable PM For filterable PM emissions from uncontrolled dry preheater kilns, one A-rated
data set was available. The results from this test were used to develop a D-rated emission factor.
For filterable PM emissions controlled with an ESP, a single B-rated data set was available. The
results from this test also were used to develop a D-rated emission factor.
For filterable PM emissions from a dry preheater kiln controlled with a fabric filter, data from
three B-rated tests and five C-rated tests were available. The emission factors developed from the
B-rated data ranged from 0.10 kg/Mg (0.19 lb/ton) to 0.14 kg/Mg (0.28 lb/ton) and averaged 0.12 kg/Mg
(0.23 lb/ton). The emission factors developed from the C-rated data ranged from 0.031 kg/Mg
(0.063 lb/ton) to 0.45 kg/Mg (0.89 lb/ton) and averaged 0.13 kg/Mg (0.26 lb/ton). The emission factors
develop from all eight tests were combined to yield an average emission factor of 0.13 kg/Mg (0.25 lb/ton)
for filterable PM emissions from dry preheater kilns controlled with fabric filters. Because of the
relatively large number of tests upon which it is based, this emission factor is rated C.
Condensible inorganic PM For condensible inorganic PM emissions from dry preheater kilns
controlled with fabric filters, data from a single B-rated test were available. These data were used to
develop a D-rated emission factor of 0.017 kg/Mg (0.033 lb/ton).
Sulfur dioxide. For S02 emissions from dry preheater kilns, four data sets were available. All
four data sets consist of measurements of S02 emissions from fabric filter-controlled dry preheater
process kilns. These data were treated as measurements of uncontrolled S02 emissions. Two of the
data sets were rated B and two of the data sets were rated C. The emission factors developed from the
B-rated data were 0.055 kg/Mg (0.11 lb/ton) and 1.0 kg/Mg (2.0 lb/ton) and averaged 0.53 kg/Mg
(1.1 lb/ton). The emission factors developed from the C-rated data were 0.0026 kg/Mg (0.0052 lb/ton)
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and 0.042 kg/Mg (0.083 lb/ton) and averaged 0.022 kg/Mg (0.044 lb/ton). The emission factors develop
from all four tests were combined to yield an average emission factor of 0.27 kg/Mg (0.55 lb/ton) for S02
emissions from dry preheater process kilns controlled with fabric filters. This average emission factor is
assigned a rating of D.
Nitrogen oxides. For NOx emissions from dry preheater kilns, three data sets were available. All
three of the tests were conducted on kilns controlled with fabric filters. Because fabric filters are
expected to have negligible effects on NOx emissions, all data sets were treated as measurements of
uncontrolled NOx emissions. Two of these data sets were rated B, and the remaining data set was rated
C. The emission factors developed from the B-rated data were 2.9 kg/Mg (5.8 lb/ton) and 3.1 kg/Mg
(6.2 lb/ton) and averaged 3.0 kg/Mg (6.0 lb/ton). The emission factor developed from the C-rated data
was 1.2 kg/Mg (2.4 lb/ton). The B- and C-rated data were combined for an average emission factor for
uncontrolled NOx emissions from dry preheater kilns of 2.4 kg/Mg (4.8 lb/ton). This average emission
factor is assigned a rating of D.
Carbon monoxide. For CO emissions from dry preheater kilns, data from a single B-rated test
were available. These data were used to develop a D-rated emission factor of 0.49 kg/Mg (0.98 lb/ton).
Carbon dioxide. For C02 emissions from dry preheater process kilns, 11 data sets were available
on measurements of C02 emissions from kilns controlled with various control devices, none of which are
expected to have significant effects on C02 emissions. Therefore, all data sets were treated as
measurements of uncontrolled C02 emissions. Eight of the data sets were rated B, and the other three
data sets were rated C. The emission factors developed from the B-rated data ranged from 770 kg/Mg
(1,500 lb/ton) to 1,000 kg/Mg (2,000 lb/ton) and averaged 890 (1,800 lb/ton). The emission factors
developed from the C-rated data ranged from 790 kg/Mg (1,600 lb/ton) to 1,100 kg/Mg (2,100 lb/ton) and
averaged 950 kg/Mg (1,900 lb/ton). The B- and C-rated data were combined for an average emission
factor for uncontrolled C02 emissions from dry preheater process kilns of 900 kg/Mg (1,800 lb/ton). In
comparison to the theoretical average emission factor for C02 emissions (930 kg/Mg [1,900 lb/ton]) from
coal-fired preheater kilns discussed in Section 4.2.2, the magnitude of this average emission factor
appears to be reasonable. Because of the relatively large number of tests upon which it is based, this
emission factor is rated C.
Volatile Organic Compounds. For preheater kilns, data were available from one test of TOC
emissions and one test of VOC emissions. Both tests were conducted on the same fabric filter controlled
kiln. Because fabric filters should have negligible effects on VOC emissions, the results were considered
to be measurements of uncontrolled emissions. The TOC emission factor, which is based on B-rated
data, is rated D. Because the VOC emission factor was developed from D-rated data, it was not
incorporated into the revised AP-42 section.
4.2.5.4 Preheater/Precalciner Kilns. Of the 102 data sets from which emission factors were
developed for preheater/precalciner kiln emissions, 4 were rated A, 42 were rated B, 43 were rated C, 10
were rated D, and 3 were not rated. All of the tests documented were conducted on coal-fired
preheater/precalciner kilns. The average emission factors developed from these data sets are included in
Table 4-14. The following paragraphs describe how these average emission factors for
preheater/precalciner kilns were developed.
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Filterable PM For filterable PM emissions controlled with an ESP, data from a single B-rated
test were available. These data were used to develop a D-rated emission factor of 0.24 kg/Mg
(0.48 lb/ton).
For fabric filter-controlled filterable emissions from a preheater/precalciner kiln, data were
available from 17 tests. After combining the results of multiple tests on the same kiln, the number of data
sets was reduced to seven. One of these data sets was rated A, three of the data sets were rated B, two
of the data sets was rated C, and the remaining data set was rated D. The C- and D-rated data were
discarded. The A-rated data were used to develop an emission factor of 0.12 kg/Mg (0.24 lb/ton). The
emission factors developed from the B-rated data ranged from 0.0062 kg/Mg (0.012 lb/ton) to 0.26 kg/Mg
(0.52 lb/ton) and averaged 0.099 kg/Mg (0.19 lb/ton). The A- and B-rated data were combined for an
average emission factor for fabric filter-controlled filterable PM emissions from dry preheater/precalciner
process kilns of 0.10 kg/Mg (0.21 lb/ton). This average emission factor is assigned a rating of D.
Condensible inorganic PM For condensible inorganic PM emissions from preheater/precalciner
kilns, data from six emission tests were available: a B-rated test on an ESP-controlled kiln, four B-rated
tests on fabric filter-controlled kilns, and one D-rated test on a fabric filter-controlled kilns. For fabric
filter-controlled condensible inorganic PM emissions, the D-rated data set was discarded. Two of the
B-rated tests were conducted on the same kiln and resulted in an emission factor of 0.0050 kg/Mg
(0.010 lb/ton). The data from the remaining B-rated tests resulted in an emission factors of 0.023 kg/Mg
(0.047 lb/ton) and 0.14 kg/Mg (0.28 lb/ton). When combined, these emission factors yield an average
emission factor of 0.056 kg/Mg (0.11 lb/ton) for condensible inorganic PM emissions from dry
preheater/precalciner process kilns controlled with fabric filters. This emission factor is significantly
lower than the emission factor developed from the ESP-controlled kiln test (0.14 kg/Mg [0.29 lb/ton]).
Because it is unlikely that the difference in condensible PM emissions control achieved by ESP's and
fabric filters is so pronounced, and due to the overall sparsity of test data, the results of all tests were
combined. The data yield an average controlled emission factor for condensible inorganic PM emissions
of 0.078 kg/Mg (0.16 lb/ton). This emission factor is rated D.
Sulfur dioxide. For S02 emissions from dry preheater/precalciner process kilns, a total of 21 data
sets were available. Two of the data sets consist of measurements of S02 emissions from an ESP-
controlled kiln, one of the tests was conducted on a kiln controlled with a spray tower, one of the tests
was conducted on a kiln controlled with both a spray tower and ESP, and the remaining 17 tests were on
fabric filter-controlled kilns.
Because ESP's and fabric filters are expected to have negligible effects on S02 emissions, the
results of these tests were treated as measurements of uncontrolled S02 emissions. The results of one of
the tests were rated D and were discarded. Combining the results of multiple tests on the same kiln,
reduced the number of data sets to five B-rated data sets and two C-rated data sets. The emission
factors developed from the B-rated data ranged from 0.016 kg/Mg (0.033 lb/ton) to 1.4 kg/Mg (2.9 lb/ton)
and averaged 0.54 kg/Mg (1.1 lb/ton). The emission factors developed from the C-rated data were
0.75 kg/Mg (1.5 lb/ton) and 0.43 kg/Mg (0.85 lb/ton). The C-rated data were discarded because of the
relatively large number of B-rated data sets available. The average emission factor developed from the
B-rated data is assigned a rating of D.
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The test data on the spray tower-controlled kilns both were rated C. The emission factors
developed from the results of these two tests were 0.40 kg/Mg (0.79 lb/ton) and 0.60 kg/Mg (1.2 lb/ton)
and averaged 0.50 kg/Mg (1.0 lb/ton). This average emission factor is rated E.
Nitrogen oxides. For NOx emissions from dry preheater/precalciner process kilns, a total of
20 data sets were available. Two of the tests was conducted on a kiln controlled with an ESP, one test
was conducted on a kiln with an unspecified control device, and the remaining 16 tests were conducted on
fabric filter-controlled kilns. Because ESP's and fabric filters are expected to have negligible effects on
NOx emissions, all data sets were treated as measurements of uncontrolled NOx emissions; the
unspecified control device test was rated D and discarded. After combining the results of multiple tests
on the same kiln, the number of data sets was reduced to five B-rated data sets and two C-rated data
sets. The emission factors developed from the B-rated data ranged from 1.1 kg/Mg (2.2 lb/ton) to
3.6 kg/Mg (7.1 lb/ton) and averaged 2.1 kg/Mg (4.2 lb/ton). The emission factors developed from the
C-rated data ranged from 1.5 kg/Mg (3.1 lb/ton) to 4.8 kg/Mg (9.5 lb/ton) and averaged 3.4 kg/Mg
(6.7 lb/ton). Only the B-rated data were used. The average emission factor developed from the B-rated
data is assigned a rating of D.
Carbon monoxide. For CO emissions from preheater/precalciner kilns, data were available from
12 tests on 6 kilns. One of the tests was conducted on a kiln controlled with an ESP and the remaining 11
tests were conducted on fabric filter-controlled kilns. Because ESP's and fabric filters are expected to
have negligible effects on CO emissions, all data sets were treated as measurements of uncontrolled CO
emissions. After combining the results of multiple tests on the same kiln, the number of data sets was
reduced to one A-rated test, three B-rated data sets, and one C-rated data set. The results of the A-rated
test yielded an emission factor of 4.4 kg/Mg (8.7 lb/ton). The emission factors developed from the
B-rated data ranged from 0.60 kg/Mg (1.2 lb/ton) to 1.3 kg/Mg (2.5 lb/ton) and averaged 0.86 kg/Mg
(1.7 lb/ton). The C-rated data yielded an average emission factor of 0.50 kg/Mg (0.99 lb/ton). The
C-rated data were discarded and an average emission factor of 1.8 kg/Mg (3.7 lb/ton) was developed
from the combined A- and B-rated data. This emission factor is rated D.
Carbon dioxide. For C02 emissions from preheater/precalciner kilns, 12 data sets were available
for ESP- or fabric filter-controlled kilns. All data sets were treated as measurements of uncontrolled C02
emissions. After combining the results of multiple tests on the same kiln, the number of data sets was
reduced to six. One of these data sets was rated A, three of the data sets were rated B, one data set
was rated C, and one of the data sets was rated D. The A-rated data resulted in an emission factor of
970 kg/Mg (1,900 lb/ton). The emission factors developed from the B-rated data ranged from 820 kg/Mg
(1,600 lb/ton) to 1,000 kg/Mg (2,100 lb/ton) and averaged 900 (1,800 lb/ton). An emission factor of
1,400 kg/Mg (2,800 lb/ton) was developed from the C-rated data. The A- and B-rated data were
combined for an average emission factor for uncontrolled C02 emissions from preheater/precalciner kilns
of 920 kg/Mg (1,800 lb/ton). This average emission factor is higher than the average CO2 emission factor
for preheater kilns. However, because preheater/precalciner kilns are more efficient than preheater kilns,
the average C02 emission factor for preheater/precalciner kilns should be lower than the C02 emission
factor for preheater kilns. Therefore, it is recommended that the average C02 emission factor for
preheater kilns be used as an upper estimate for the emission factor for preheater/precalciner kilns.
Because this emission factor is not based on preheater/precalciner kiln test data, it is assigned a rating of
E.
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Volatile Organic Compounds. For preheater/precalciner kilns, data were available from ten tests
of TOC emissions conducted on three kilns all of which were controlled with fabric filters. After
combining the results of multiple tests on the same kiln, the number of data sets was reduced to three, one
A-rated, one B-rated, and one C-rated tests. Because fabric filters should have negligible effects on
VOC emissions, the results were considered to be measurements of uncontrolled emissions. The C-rated
data were discarded, and the results of the A- and B-rated tests were combined to yield an average
emission factor of 0.059 kg/Mg (0.12 lb/ton) for uncontrolled TOC emissions from preheater/precalciner
kilns. This emission factor is rated D.
4.2.5.5 Noncriteria Pollutant Emissions From Portland Cement Kilns. The remaining data sets on
emissions from portland cement kilns consist of measurements of a number of inorganic and organic
compounds. For the majority of these compounds, data are available from only one or two emission
tests. In addition, the data do not appear to indicate significant differences in emissions of the same
compounds from different types of pyroprocesses. Therefore, the data from all four types of kilns (wet
process, dry process, dry preheater process, and preheater/precalciner process) were combined to yield
generic emission factors for portland cement kilns. These emission factors are summarized in Table 4-15.
Due to the large number of compounds and the relatively small number of data sets on each type
of compound, a discussion of how data for each of these compounds were combined to yield average
emission factors is not presented. In general, data were combined using the methodology described above
for criteria pollutant emission factors. When available, only A- and B-rated data were used to develop
average emission factors. C-rated data were combined with B-rated data if the number of C-rated data
sets was significant in comparison to the number of B-rated data sets. D-rated data were used, alone or
in combination with C-rated data, only if no A- or B-rated data were available, and all unrated data sets
were discarded. Emission factors are reported only if the majority of runs for a test were above detection
limits. In those cases, only runs above the detection limits were considered in the average.
4.2.5.6 Clinker Coolers. Of the 35 data sets from which emission factors were developed for
clinker cooler emissions, 2 were rated A, 13 were rated B, 1 was rated C, and 19 were not rated. The
unrated data consist of the results of metal analyses for a single Method 5 run filter catch. All unrated
data were eliminated from consideration for inclusion in AP-42. The remaining data sets consist of the
results of measurements of filterable PM (10 tests) and condensible inorganic PM (6 tests) emissions.
The average emission factors developed from the data are summarized in Table 4-16. The following
paragraphs highlight how these emission factors were developed.
Filterable PM For clinker cooler controlled with ESP's, a single B-rated test report was
available. The data resulted in an emission factor of 0.048 kg/Mg (0.096 lb/ton). This emission factor is
rated D.
For clinker coolers controlled with fabric filters, the results of five tests were available. The
results of all five tests were rated B, and two of the tests were conducted on the same clinker cooler.
The emission factor developed from the data ranged from 0.0060 kg/Mg (0.012 lb/ton) to 0.24 kg/Mg
(0.47 lb/ton) and averaged 0.068 kg/Mg (0.13 lb/ton). This emission factor is rated D.
For clinker coolers controlled with gravel bed filters, data from four emission tests were available.
The results of one of the tests was rated A (0.080 kg/Mg [0.16 lb/ton]), the results of two of the tests
were rated B (0.055 kg/Mg [0.11 lb/ton] and 0.18 kg/Mg [0.35 lb/ton]), and the results of the remaining
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test was rated C (0.070 kg/Mg [0.14 lb/ton]). The C-rated data were discarded and an average emission
factor of 0.11 kg/Mg (0.21 lb/ton) was developed from the A- and B-rated data. This emission factor is
rated D.
Emission factors for PM-10 emissions from gravel bed filter-controlled clinker coolers also were
developed using the particle size data presented in Reference 79 and the average emission factors
described in the preceding paragraphs.
Condensible inorganic PM The condensible inorganic PM data consist of the results of one
A-rated test and five B-rated tests. One of the B-rated tests was conducted on a clinker cooler
controlled with an ESP. The results of this test were used to develop a D-rated emission factor of
0.0038 kg/Mg (0.0075 lb/ton). Three of the B-rated tests were conducted on clinker coolers controlled
with fabric filters. The results of these tests yielded a D-rated average emission factor of 0.0084 kg/Mg
(0.017 lb/ton). The A-rated and remaining B-rated tests were conducted on clinker coolers controlled
with gravel bed filters. The data from these tests resulted in a D-rated average emission factor of
0.0045 kg/Mg (0.0090 lb/ton).
4.2.5.7 Other Processes. A total of 53 data sets were available for measurements of emissions
from portland cement manufacturing processes other than kilns and coolers. These other processes
included raw and finished material crushing, grinding, screening, and transfer. Eleven of the data sets
were rated B and eight data sets were C-rated. All of these data sets consist of measurements of
filterable PM emissions. Table 4-17 summarizes the average emission factors developed from these data.
The results of a single B- or C-rated test were available for the following sources: raw mill feed
belt, raw mill weigh hopper, raw mill air separator, finishing mill feed belt, finishing mill weigh hopper,
primary limestone crushing, primary limestone screening, limestone transfer, and secondary limestone
screening and crushing. The emission factors developed from these tests are presented directly in
Table 4-17. The results of two to five B- or C-rated tests were available for raw mills, finishing mills, and
finishing mill air separators. Average emission factors for these sources were developed by averaging
the results of all of the emission tests. The average emission factors based on C-rated data were rated E.
The average emission factors based on multiple B-rated data sets were rated D. However, the average
emission factors based on a single B-rated data set were rated E. Because of difficulty in measuring
emissions from such sources, the results are likely to be less representative of average emissions.
The remaining 34 data sets consist of unrated results of measurements of trace metal emissions
from various sources. Because these data were unrated, emission factors developed from the data were
not included in the revised AP-42 section.
4.2.6 Analysis of the Uncertainty in Kiln Emission Factors for Portland Cement Kilns
Because a substantial quantity of data is available on NOx. S02, and PM emissions from portland
cement plants, these data were analyzed statistically to develop a better understanding of the uncertainty
in the emission factors. The objectives of this uncertainty analysis were to evaluate the precision in
calculated average emission factors and to characterize the plant-to-plant variability in plant-specific
emission factors. The analyses were conducted in three stages. First, the data were examined
graphically in a series of box plots to gain insight about the variability of emissions as a function of kiln
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type, air pollution control device (APCD), and data quality rating. Next, "average" emission factors were
obtained for different groupings of cement kiln types for two sets of data (A-, B-, and C-rated data and
A- and B-rated data only) using a least squares analysis procedure. This procedure is very similar to the
averaging procedure typically used to generate AP-42 emission factors, but it has certain advantages for
the uncertainty analysis because it provides estimates of the precision of the calculated emission factors.
The final stage of the analysis used variance components analysis procedures to develop final estimates of
the precision of the calculated emission factors and to estimate the plant-to-plant variability in emission
factors. The paragraphs below discuss these analyses further and present the results of the analyses.
Figures 4-1 through 4-4 present box plots of the run-specific emission factors for NOx, S02,
uncontrolled PM, and controlled PM, respectively. The emission factors in the figures are presented in
units of lb/ton. For each particular configuration of kiln type, APCD, and data rating, the box plot
identifies the interquartile range of the data (i.e., the 25th to 75th percentiles) with a box, with a horizontal
bar in each box identifying the median of the data. The mean of the data is identified with an asterisk, and
outliers are identified as moderate and extreme with a diamond and a box, respectively. The width of
each box is proportional to the logarithm of the number of data points used to construct the box. For the
NOx emission data in Figure 1, plots are developed for each type of kiln and data rating. For the S02
emission data in Figure 2 and the controlled PM emission data in Figure 4, separate plots are developed
for each combination of kiln type, APCD, and data rating. In the kiln group identifiers in Figures 2 and 4,
the first letter represents kiln type (W=wet, D=dry, H=preheater, and C=preheater/precalciner); the
second letter represents APCD (U=uncontrolled, E=Esp, and F=fabric filter); and the third letter
represents the data rating for the group of tests. Note that for all plots, only A-, B-, and C-rated data
were plotted. Figure 3 shows plots of the uncontrolled kiln PM emission data as a function of kiln type
and data rating.
Based on a visual examination, there appears to be no consistent pattern of differences between
emission factors as a function of data rating, but patterns do exist for some pollutants. The NOx data in
Figure 1 and the controlled PM data in Figure 4 show little variation between the B- and C-rated data,
and, for the case in which the box locations do differ, there is no consistent pattern of one of the ratings
yielding the greater emission factor. However, the S02 data in Figure 2 do exhibit a general pattern of the
C-rated data having substantially lower levels than do the B-rated data. Because the some of the
differences are quite large, further examination of the S02 data is warranted. Other important
observations from the box plots are that the NOx emission factors show little variability across kiln types;
the emission factors for S02 are substantially lower for preheater and preheater/precalciner kilns than for
wet and dry kilns; there is a slight pattern of lower S02 emission factors with fabric filters than with
ESP's or no controls but the difference may not be significant; and there is a substantial difference
between controlled and uncontrolled PM emissions but there are no apparent differences in the controlled
emissions as a function of either kiln type or control device.
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Boxplot: NGx Emission Data
30
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Figure 4-1, Boxplol of NOx emission lacum Jut Portland cemem feiijis.
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Figure 4-2. Raxplct of SQj emission factors for portend eemem kilns.
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500
Boxplot: PM Emission Data - Uncontrolled
400
I 300
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200
100
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Kiln Group
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figure 4-J. btoxpfot of unccnicioJLed PM emission factors for portlaed dsmenl. kilns,
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Roxplut; PM Emission Data—Controlled
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DFA DPB DFC DEB CFA CFB CEB HTB HFC HEB WFC WEB WEC
Kiln Group
Figure +4, BospJof of conrrollcd PM emission f'ncfori for portlaM cement kilns.
-------
Based on the observations from the graphical analyses, the decision was made to develop
emission factor estimates for a variety of kiln type/APCD/data rating groupings. The estimates were
calculated using a general linear model (GLM) procedure that obtained the final estimates by weighing
each facility tested within the group of interest equally and by weighing all runs within each facility
equally. For all groupings of interest, estimates were calculated based on all A-, B-, and C-rated data and
on A- and B-rated data only. Because the primary interest in this analysis was on the uncertainty in the
emission factors, only those groups with more than two facilities were evaluated. The results of the
analysis are shown in Table 4-18. The calculated AP-42 emission factors are also presented for
comparison. For the GLM results, both the estimate and the standard errors of the estimates are
presented. In general, the estimates generated with the A-, B-, and C-rated data agree closely with those
generated by the A- and B-rated data only, and the results do not appear to differ statistically, although
formal statistical tests were not conducted. The two groups for which there are major differences are
uncontrolled PM and S02 emission factors for wet process kilns. Because these differences are so large,
there appears to be an advantage to using only the A- and B-rated data for these groups. For the other
groups, the use of A-, B-, and C-rated data appears to be warranted because it results in little change in
the point estimate and provides a more precise estimate as evidenced by the lower standard error. These
results indicate that with a few exceptions, the standard errors of the emission factors are reasonably
small (10 percent of the estimate), which indicates that the 95 percent confidence interval for most
population mean emission factors is in the range of ±20 percent of the estimate.
The final stage of the analysis focused on characterizing emission factor variability. Because the
earlier analyses suggest that variability was consistent across some kiln type/APCD groupings, further
grouping was done for these analyses in order to provide more stable variance estimates. Estimates of
the between-plant and within-plant variance were obtained using a restricted maximum likelihood variance
components procedure. The results of these analyses are presented in Table 4-19, which shows
estimates of both between-plant and within-plant variances (the variance is the square of the standard
deviation) for each grouping of interest.
There are three results of note in Table 4-19. First, for all possible groupings, the plant-to-plant
variability is substantially larger than the within-plant variability. Furthermore, for all of the groupings
except FF/ESP-controlled PM emissions, the between-plant standard deviation is on the same order of
magnitude as the mean emission factor estimate. This result indicates that the emission factor for any
particular plant within the categories modelled can vary substantially from the mean emission factor for
that category. Second, the NOx results indicate that the plant-to-plant variability with all kiln types
averaged together (variance of 18) is smaller than the between-plant variance averaged across kiln types
when separate emission factors are developed for each kiln type. These results suggest that
consideration be given to developing a single average emission factor for NOx. Finally, the plant-to-plant
variance for uncontrolled PM and S02 emissions is so large that AP-42 readers should show care in
applying the average emission factor to specific facilities. On the other hand, because a small number of
plants are involved in both variance calculations, the variance results should be interpreted cautiously.
76
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TABLE 4-18. SUMMARY OF EMISSION FACTOR ESTIMATES
Pollutant
Kiln type
APCD
Revised AP-
42 emission
factor, lb/ton
A-, B-, C- data
A-,B-
data
Emission
factor, lb/ton
Standard error
Emission
factor, lb/ton
Standard
error
NOx
Wet
-
7.4
6.5
0.21
7.2
0.25
Dry
--
6.0
6.0
0.32
6.7
0.61
Preheater
--
4.8
4.8
0.34
6.0
0.50
Precalciner
--
4.2
4.8
0.23
4.2
0.33
Combined
--
5.7
0.13
6.1
0.18
so2
Wet
Uncontrolled
13
1.3
21
1.7
ESP
7.4
0.53
7.5
0.82
Combined
8.2
8.4
0.52
8.2
0.84
Dry
ESP
14
1.4
27
1.2
FF
4.5
1.4
4.5
1.5
Combined
10
8.4
1.0
10.1
1.0
Preheater
FF
0.55
0.56
0.89
1.1
1.4
Precalciner
FF
0.78
0.70
0.31
0.98
Combined
1.1
1.1
0.83
1.0
1.0
PM
Wet
Uncontrolled
130
210
18
130
4.4
ESP
0.77
0.68
0.056
0.61
0.071
FF
0.46
a
a
Dry
ESP
1.0
1.2
0.083
1.2
0.095
FF
0.2
0.16
0.17
0.20
0.27
Preheater
Uncontrolled
250
a
a
ESP
0.26
a
a
FF
0.25
0.25
0.082
0.23
0.14
Precalciner
ESP
0.048
a
a
FF
0.21
0.16
0.071
0.17
0.10
All
UNC
220
14
170
3.6
ESP
0.73
0.044
0.72
0.054
FF
0.22
0.053
0.20
0.077
"Not calculated due to small data set.
77
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TABLE 4-19. SUMMARY OF EMISSION FACTOR VARIABILITY
Pollutant
Kiln
Control
Variance
Between Plant
Within Plant
NOx
All
--
18a
0.031
13b
0.031
so2
Allc
Uncontrolled11
23,000
1,500
FFd
2.8
0.062
ESPd
411
13
All
Combined6
PM
All
Uncombined
8.5 x 107
1.4 x 106
FF/ESP
0.0043
0.00028
aBased on model for kiln-specific emission factors.
bBased on emission factor averaged across kiln types.
cSeparate estimates obtained by kiln type so variance estimates are related to variability within a kiln type.
dBased on using data for only specific controls.
eBased on use of all data in a single model with emission factors specific to control method.
78
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REFERENCES FOR SECTION 4
1. Emissions From Wet Process Cement Kiln and Clinker Cooler atMaule Industries, Inc., ETB
Test No. 71-MM-01, U.S. Environmental Protection Agency, Research Triangle Park, NC, March
1972.
2. Emissions From Wet Process Cement Kiln and Clinker Cooler at Ideal Cement Company, ETB
Test No. 71-MM-03, U.S. Environmental Protection Agency, Research Triangle Park, NC, March
1972.
3. Emissions From Wet Process Cement Kiln and Finish Mill Systems at Ideal Cement Company,
ETB Test No. 71-MM-04, U.S. Environmental Protection Agency, Research Triangle Park, NC,
March 1972.
4. Emissions From Dry Process Cement Kiln at Dragon Cement Company, ETB Test No.
71-MM-05, U.S. Environmental Protection Agency, Research Triangle Park, NC, March 1972.
5. Emissions From Wet Process Clinker Cooler and Finish Mill Systems at Ideal Cement
Company, ETB Test No. 71-MM-06, U.S. Environmental Protection Agency, Research Triangle
Park, NC, March 1972.
6. Emissions From Wet Process Cement Kiln at Giant Portland Cement, ETB Test No. 71-MM-07,
U.S. Environmental Protection Agency, Research Triangle Park, NC, March 1972.
7. Emissions From Wet Process Cement Kiln at Oregon Portland Cement, ETB Test No.
71-MM-15, U.S. Environmental Protection Agency, Research Triangle Park, NC, March 1972.
8. Emissions From Dry Process Raw Mill and Finish Mill Systems at Ideal Cement Company, ETB
Test No. 71-MM-02, U.S. Environmental Protection Agency, Research Triangle Park, NC, April
1972.
9. Part I, Air Pollution Emission Test: Arizona Portland Cement, EPA Project Report No. 74-STN-
1, U.S. Environmental Protection Agency, Research Triangle Park, NC, June 1974.
10. Characterization of Inhalable Particulate Matter Emissions From a Dry Process Cement Plant,
EPA Contract No. 68-02-3158, Midwest Research Institute, Kansas City, MO, February 1983.
11. Characterization of Inhalable Particulate Matter Emissions From a Wet Process Cement Plant,
EPA Contract No. 68-02-3158, Midwest Research Institute, Kansas City, MO, August 1983.
12. Particulate Emission Testing at Lone Star Industries' Nazareth Plant, Lone Star Industries, Inc.,
Houston, TX, January 1978.
13. Particulate Emissions Testing at Lone Star Industries' Greencastle Plant, Lone Star Industries,
Inc., Houston, TX, July 1977.
79
-------
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
(las Process Survey at Lone Star Cement, Inc. 's Roanoke No. 5 Kiln System, Lone Star Cement,
Inc., Cloverdale, VA, October 1979.
Test Report: Stack Analysis for Particulate Emissions: Clinker Coolers/Gravel Bed Filter,
Mease Engineering Associates, Port Matilda, PA, January 1993.
Source Emissions Survey of Oklahoma Cement Company's Kiln Number 3 Stack, Mull ins
Environmental Testing Co., Inc., Addison, TX, March 1980.
Source Emissions Survey of Lone Star Industries, Inc.: Kilns 1, 2, and 3, Mull ins
Environmental Testing Co., Inc., Addison, TX, June 1980.
Source Emissions Survey of Lone Star Industries, Inc., Mullins Environmental Testing Co., Inc.,
Addison, TX, November 1981.
Stack Emission Survey and Precipitator Efficiency Testing at Bonner Springs Plant, Lone Star
Industries, Inc., Houston, TX, November 1981.
NSPSParticulate Emission Compliance Test: No. 8 Kiln, Interpoll, Inc., Blaine, MN, March 1983.
Annual Compliance Test: Moiave Plant, Pape & Steiner Environmental Services, Bakersfield,
CA, May 1983.
Sid Levine, "New Mojave Plant of California Portland Under Computer Control", Pit & Quarry, pp.
82-87, July 1983.
Source Emissions Survey of Lehigh Portland Cement Company, Mullins Environmental Testing
Co., Inc., Addison, TX, August 1983.
Annual Compliance Test: Mojave Plant, Pape & Steiner Environmental Services, Bakersfield,
CA, May 1984.
Particulate Compliance Test: Lehigh Portland Cement Company, CH2M Hill, Montgomery, AL,
October 1984.
Compliance Test Results: Particulate & Sulfur Oxide Emissions at Lehigh Portland Cement
Company, KVB, Inc., Irvine, CA, December 1984.
Annual Compliance Test: Moiave Plant, Pape & Steiner Environmental Services, Bakersfield,
CA, May 1985.
Stack Tests for Particulate, S02, NOx and Visible Emissions at Lone Star Florida Holding, Inc.,
South Florida Environmental Services, Inc., West Palm Beach, FL, August 1985.
Compliance Stack Test at Lone Star Florida/Pennsuco, Inc., South Florida Environmental
Services, Inc., West Palm Beach, FL, July 1981.
80
-------
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Preliminary Stack Test at Lone Star Florida/Pennsuco, Inc., South Florida Environmental
Services, Inc., West Palm Beach, FL, July 1981.
Quarterly Testing for Lone Star Cement at Davensport, California, Pape & Steiner
Environmental Services, Bakersfield, CA, September 1985.
Stack Sampling at Trinity Division of General Portland, Fort Worth, Texas, Texas Air Control
Board, Fort Worth, TX, July 1976.
Stack Sampling at General Portland Cement, Trinity Division, Fort Worth, Texas, Texas Air
Control Board, Fort Worth, TX, January 1977.
Stack Sampling at General Portland, Inc., Trinity Division, Fort Worth, Texas, Texas Air
Control Board, Fort Worth, TX, February 1979.
Written Communication from David S. Cahn, CalMat Co., El Monte, CA, to Frank Noonan, U.S.
Environmental Protection Agency, Research Triangle Park, NC, June 2, 1987.
Technical Report on the Demonstration of the Feasibility ofNOx Emissions Reduction at
Riverside Cement Company, Crestmore Plant (Parts I-V), Riverside Cement Company, Riverside,
CA, and Quantitative Applications, Stone Mountain, GA, January 1986.
Emission Study of the Cement Kiln No. 20 Baghouse Collector at the Alpena Plant, Great
Lakes Division, Lafarge Corporation, Clayton Environmental Consultants, Inc., Novi, MI, March
1989.
Emission Testing of Dust Collectors on Kiln No. 1 at Lafarge Corporation, Paulding, Ohio,
Clayton Environmental Consultants, Inc., Novi, MI, July 1989.
Test Report of Kiln Exhaust Emissions from Southwestern Portland Cement Company, Kilns
Nos. 5 and 8 at the Victorville Plant and Kiln No. 1 at the Black Mountain Plant, Truesdail
Laboratories, Inc., Los Angeles, CA, September 1980.
Baseline and Solvent Fuels Stack Emissions Test at Alpha Portland Cement Company in
Cement on, New York, Energy & Resource Recovery Corp., Albany, NY, January 1982.
Lehigh Portland Cement Company White Kiln Coke Conversion Emission Compliance Report,
Tenerex Corporation, Friendswood, TX, December 1985.
Stationary Source Sampling Report of Lone Star Industries, New Orleans, Louisiana, Entropy
Environmentalists, Inc., Research Triangle Park, NC, May 1982.
Stationary Source Sampling Report of Lone Star Industries, New Orleans, Louisiana, Entropy
Environmentalists, Inc., Research Triangle Park, NC, May 1982.
Source Emissions Survey of Kiln No. 1 at Lone Star Industries, Inc., New Orleans, Louisiana,
Mullins Environmental Testing Company, Inc., Addison, TX, March 1984.
81
-------
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
Written Communication from Don Sinkular, Gifford-Hill Cement Company of Texas, Midlothian, TX,
to John Croom, Quantitative Applications, Inc., Stone Mountain, GA, December 18, 1989.
Written Communication from Gerald Young, St. Mary's Peerless Cement, Detroit, MI, to John
Croom, Quantitative Applications, Inc., Stone Mountain, GA, December 13, 1989.
Anonymous Written Communication, Truesdail Laboratories, Incorporated, Results of tests
conducted on Southwestern Portland Cement, Black Mountain, California, Kilns 5 and 8, October 9,
1980.
Written Communication from Douglas Maclver, Southwestern Portland Cement Company,
Victorville, CA, to Walter Mook, San Bemadino County Air Pollution Control District, San
Bernadino, CA, August 22, 1980.
Written Communication from Richard Cooke, Ash Grove Cement West, Inc., Durkee, OR, to Frank
Noonan, U.S. Environmental Protection Agency, Research Triangle Park, NC, May 13, 1987.
Written Communication from Stan Cramer, Calveras Cement Company, Redding, CA, to Frank
Noonan, U.S. Environmental Protection Agency, Research Triangle Park, NC, May 13, 1987.
Source Emissions Survey of Texas Cement Company of Buda, Texas, Mullins Environmental
Testing Co., Inc., Addison, TX, September 1986.
Determination of Particulate and Sulfur Dioxide Emissions from the Kiln and Alkali Baghouse
Stacks at Southwestern Portland Cement Company, Pollution Control Science, Inc., Miamisburg,
OH, June 1986.
Written Communication from Doug Maclver, Southwestern Portland Cement Company, Victorville,
CA, to John Croom, Quantitative Applications, Inc., Stone Mountain, GA, October 23, 1989.
Source Emissions Survey of Southwestern Portland Cement Company, KOSMOS Cement
Division, MetCo Environmental, Dallas, TX, June 1989.
Written Communication from John Mummert, Southwestern Portland Cement Company, Amarillo,
TX, to Bill Stewart, Texas Air Control Board, Austin, TX, April 14, 1983.
Written Communication from Stephen Sheridan, Ash Grove Cement West, Inc., Portland, OR, to
John Croom, Quantitative Applications, Inc., Stone Mountain, GA, January 15, 1980.
Written Communication from David Cahn, CalMat Co., Los Angeles, CA, to John Croom,
Quantitative Applications, Inc., Stone Mountain, GA, December 18, 1989.
Source Emissions Compliance Test Report on the Kiln Stack at Marquette Cement
Manufacturing Company, Cape Girardeau, Missouri, Performance Testing & Consultants, Inc.,
Kansas City, MO, February 1982.
82
-------
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
Assessment of Sulfur Levels at Lone Star Industries in Cape Girardeau, Missouri, KVB,
Elmsford, NY, January 1984.
Written Communication from Douglas Maclver, Southwestern Portland Cement Company, Nephi,
UT, to Brent Bradford, Utah Air Conservation Committee, Salt Lake City, UT, July 13, 1984.
Performance Guarantee Testing at Southwestern Portland Cement, Pape & Steiner
Environmental Services, Bakersfield, CA, February 1985.
Compliance Testing at Southwestern Portland Cement, Pape & Steiner Environmental Services,
Bakersfield, CA, April 1985.
Emission Tests on Quarry Plant No. 2 Kiln at Southwestern Portland Cement, Pape & Steiner
Environmental Services, Bakersfield, CA, March 1987.
Emission Tests on the No. 2 Kiln Baghouse at Southwestern Portland Cement, Pape & Steiner
Environmental Services, Bakersfield, CA, April 1987.
Emissions Testing of a Precalciner Cement Kiln at Louisville, Nebraska, U.S. Environmental
Protection Agency, Washington, D.C., November 1990.
Emissions Testing of a Wet Cement Kiln at Hannibal, Missouri, U.S. Environmental Protection
Agency, Washington, D.C., December 1990.
Compliance Stack Test on Kiln No. 3 at Lone Star Florida, Inc., South Florida Environmental
Services, Inc., Belle Glade, FL, July 1980.
Compliance Stack Test of Cooler No. 3 at Lone Star Florida, Inc., South Florida Environmental
Services, Inc., Belle Glade, FL, July 1980.
Stack Emissions Survey of Lone Star Industries, Inc., Portland Cement Plant at Maryneal,
Texas, Ecology Audits, Inc., Dallas, TX, September 1979.
Visible Emission Testing at Four Portland Cement Plants, EPA Report No. 75-CEM-l, U.S.
Environmental Protection Agency, Research Triangle Park, NC, August 1974.
Field Data Source Test of Lone Star Industries at Davenport, California, Chemecology Corp.,
Pittsburg, CA, August 1983.
NSPS Particulate Emission Compliance Test on the No. 8 Kiln at the Lehigh Portland Cement
Plant in Mason City, Iowa, Interpoll, Inc., Circle Pines, MN, July 1983.
Field Data Source Test at Lone Star Industries, Davenport, California, Chemecology, CA, May
1982.
Emissions Testing Report Conducted at Kaiser Cement, Coupertino, California, for Kaiser
Cement, Walnut Creek, California, TMA Thermo Analytical, Inc., Richmond, CA, April 30, 1990.
83
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75. Source Emissions Survey ofBoxcrow Cement Company Kiln Stack, Midlothian, Texas, TACB
Permit C-8996, Volume I, Metco Environmental, October 1991.
76. Certification of Compliance Stack Emission Test Program at Lone Star Industries, Inc., Cape
Girardeau, Missouri, April & June 1992, Air Pollution Characterization and Control, Ltd., Tolland,
CT, January 1993.
77. Source Emissions Survey of EssrockMaterials, Inc., Eastern Division Cement Group, Kilns
Number 1 and 2 Stack, Frederick, Maryland, Volume I (Draft), Metco Environmental, Addison,
TX, November 1991.
78. M. Branscome et al., Evaluation of Waste Combustion in a Dry-Process Cement Kiln at Lone
Star Industries, Oglesby, Illinois, Research Triangle Institute, Research Triangle Park, NC,
December 1984.
79. J. Kinsey, Lime and Cement Industry Particulate Emissions: Source Category Report, Volume
II., Cement Industry, EPA-600/7-87-007, U.S. Environmental Protection Agency, Research
Triangle Park, NC, February 1987.
80. Dellinger, H.B., D.W. Pershing, and A.F. Sarofim. Evaluation of the Origin, Emissions and
Control of Organic and Metal Compounds from Cement Kilns Fired with Hazardous Wastes.
Science Advisory Board on Cement Kiln Recycling. June 1993.
81. Written communication from Robert W. Crolius, Portland Cement Association, to Ron Myers, U. S.
Environmental Protection Agency, Research Triangle Park, NC. March 11, 1992.
84
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5.0 PROPOSED AP-42 SECTION 11.6
A proposed revision of the existing AP-42 Section 8.6, Portland Cement Manufacturing, is
presented in the following pages as it would appear in the document.
85
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APPENDIX A
DERIVATION OF CRITERIA POLLUTANT EMISSION FACTORS
FOR PORTLAND CEMENT KILNS
-------
APPENDIX A.
DERIVATION OF CRITERIA POLLUTANT EMISSION FACTORS
FOR PORTLAND CEMENT KILNS
The following tables present the derivation of the average emission factors for emissions of
criteria pollutants (PM, S02, NO,., CO, TOC, and C02) from portland cement kilns, as presented in Tables
4-11 to 4-14 of this background report and Tables 11.6-1, 11.6-2, 11.6-5, and 11.6-7 of the AP-42 section.
The data for wet process kilns, dry process kilns, preheater kilns, and preheater/precalciner kilns are
presented in Tables A-l, A-2, A-3, and A-4, respectively. These tables include the results from each test
report from which an emission factor could be developed for the pollutants listed above. For each test,
the tables list the type of control (Column 2), average emission factor in kg/Mg and lb/ton (Columns 3 and
4), the data rating (Column 5), and the reference number (Column 9) as designated in Chapter 4 of this
background report. The emission factors that were used to calculate the average emission factor for a
specific pollutant and type of kiln are listed in the second set of emission factors (Columns 6 and 7) in the
tables. The ratings (Column 8) assigned to these average emission factors also are indicated in the tables.
The comment column in the tables indicates if the test data were discarded.
For wet process and preheater/precalciner kilns, data were available (and emission factors were
developed) for multiple tests on some kilns. In such cases, the kilns were arbitrarily labeled (A, B, C, etc.
[Column 1]), the average emission factor for each of those kilns was calculated, and an average data
rating was assigned. These kiln-specific average emission factors then were used to determine the
overall average emission factor for a specific pollutant, control device, and kiln type.
A-l
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