Cement is the main ingredient of concrete, which is the most common building material in the world. The cement industry is one of the biggest CO2 emission producers mainly due to the huge production capacities and calcination process, which is an important part of cement production. Cement manufacturers need to monitor these emissions continuously according to local emission regulations. Read about our solutions to the cement industry!
Waste Incineration in Cement Kilns
The cement industry is actively seeking to increase the use of alternative fuels for cement production. Both to decrease energy dependence on conventional fossil fuels and to mitigate negative environmental impact.
One of these alternatives is waste-to-energy. Many cement plants generate energy through the incineration of waste. Hazardous waste can be incinerated at specific waste-to-energy plants but also at plants with permission for co-incineration of waste.
The downside is that waste incineration in cement kilns releases toxic emissions into the air containing mercury, lead, cadmium and thallium, and other heavy metals.
Cement Plants’ Emissions Monitoring
Cement plants, in general, follow their own emissions monitoring standards. In cement plants, the flue gas generally includes carbon dioxide (CO2), nitrous oxides (NOx), sulphur dioxide (SO2), mercury, and dust. SO2 emissions are mostly derived from the raw material, whereas more than half of the CO2 emissions are coming from the limestone calcination process and rest are related to the used fuel and efficiency of the combustion process.
If a cement plant acts as a co-incineration plant and incinerates waste, it is subject to strict emissions regulations. All waste burning plants have to meet at least the stringent emissions limit, monitoring, waste reception and treatment standards brought in under the Waste Incineration Directive (2000/76/EC), which has been recast into the Industrial Emissions Directive (2010/75/EU).
To learn more about monitoring emissions, download our Emissions Monitoring Handbook.
The Waste Incineration Directive subjects co-incineration plants to the continuous measurement of for example hydrochloric acid (HCl), hydrogen fluoride (HF) and mercury (Hg). Measuring of total organic carbon (TOC) is also mandatory.
Our Solution: Monitoring Systems for Demanding Measurements
Our continuous emissions monitoring systems are certified systems designed for demanding emission monitoring measurements.
The Continuous Emissions Monitoring System CEMS II e offers TÜV and MCERTS certified solution (QAL1) for a wide range of demanding emission monitoring applications. The CEMS II e system utilizes Fourier Transform Infrared Spectroscopy FTIR technology. CEMS II e can also be equipped with a ZrO2 oxygen analyzer which is designed for continuous oxygen measurement of wet or dry flue gas. Gasmet CEMS II e is generally used to simultaneously measure the following 16 gases: H2O, CO2, CO, N2O, NO, NO2, SO2, HCl, HF, NH3, CH4, C2H6, C3H8, C2H4 and CH2O.
The Continuous Mercury Monitoring systems CMM AutoQAL and CMM have the lowest certified range in the world (0-5 µg/m3). CMM AutoQAL has an automatic and integrated QAL3 validation tool. Systems are perfect for monitoring mercury continuously from hot, wet and corrosive gas streams. The systems utilize Cold Vapor Atomic Fluorescence (CVAF) technology.
Why choose Gasmet as your CEMS partner?
Gasmet is an ideal partner for the cement industry. Here are the top 5 reasons why you should choose us as your CEMS partner:
- Reduce risks with equipment that satisfy all regulatory requirements
- Save money with minimal maintenance, operational costs and calibration
- Gain longevity of investment with a long lifetime expectancy
- Future-proof your investment. With Gasmet FTIR, if additional requirements emerge, new compounds can be added to the measurement setup without costly hardware changes.
- Gasmet has a reputation for providing analytical expertise, supplying quality products and services
In 2017, Best Available Techniques Conclusions for Large Combustion Plants (LCP BREF) was published. The document specifies new measuring requirements and emission limits for LCPs with a total rated thermal input exceeding 50MW. Gasmet has made a summary of the document: Changes and New Methods in Emission Monitoring and Control in Accordance with LCP BREF 2017
Case: Thetford Power Station
“Individual gas readings are displayed in almost real-time in the control room,” says Plant Manager Andrew Corbyn