Cement Industry Environmental Consortium

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A casual observer of the American environmental arena could easily compare the activities therein with those which have been recorded by historians as occurring in the Roman Coliseum. The ongoing confrontation between the regulated community, the regulators, and the various environmental groups had been well documented in court records and by the media. However, a glimmer of hope for a solution to this endless, nonproductive struggle was reported in a small Southern California newspaper in 1992. The article described the formation of the Cement Industry Environmental Consortium, a small nonprofit corporation for the public benefit according to their California Articles of Incorporation. The Consortium's goal was set to develop much needed environmental control systems for the Portland cement manufacturing industry.

The concept for this unique organization originated in the city of Pasadena at the Office of Competitive Technology, California Department of Commerce (now Trade & Commerce Agency). Mr. E. J. Moscaret, a Program Manager, and his associates became concerned about the eroding industrial base in the State due in part to the rigorous environmental regulations being imposed on the manufacturing sector. Following a comprehensive evaluation of various remedies, the State invited a large group of Southern California businessmen to the founding meeting of the Joint Venture for Environmental Compliance Assistance. The meeting was held in Ventura on July 10-12, 1991. The letter of invitation stated that "the new enterprise holds great promise for the future of environmental technology advancement and cost-effective compliance in California and the Nation". At the meeting, many details were developed including tile administration of State funds which would be leveraged by participating companies. These fiends would be principally allocated toward environmental technology development.

Following that meeting, it became apparent that the wide diversity of industry in Southern California would make a single organization unwieldy. Mr. M. A. Yannone, representing the Cement Manufacturers Association, began to interest the members of his organization in this new venture- a nonprofit organization partially funded by the State and devoted to environmental technology development for the cement industry. The first informal meeting for that purpose was held on February 6, 1992. Those attendees would later form the Cement Industry Environmental Consortium. Oil November 5, 1992, the "Organizational Meeting of tile Incorporators" was held and CIEC became an official entity. Founding members were Southwestern Portland Cement Company (now Southdown, Inc.), Riverside Cement Company, Mitsubishi Cement Corporation, San Bernardino County Air Pollution Control District (now

Mojave Desert AQMD), and the Office of Competitive Technology, California Department of Commerce (now Office of Strategic Technology, California Trade & Commerce Agency). Eventually, two major electric utilities joined CEEC as Associate Members- Pacific Gas & Electric Corporation and Southern California Edison. Both organizations have been active members of the CIEC Technology Committee, the group with the responsibility for technology development.

Because State funds were being utilized in addition to cement company contributions, the California State University Foundation (CSUF) was selected as the fiscal agent in 1992. CSUF was established in 1962 as a nonprofit, auxiliary organization to enhance the educational mission of the university system and its twenty campuses. One of its activities is to develop, manage, and administer State grants and contracts such as that awarded to CIEC. On December 31, 1996, CIEC terminated its relationship with CSUF because additional State funds were no longer available and the original grant funds were depleted.

In October, 1992, the Articles of Incorporation were issued by the California Secretary of State. Earlier that year, the founding members had selected the reduction of nitrogen oxides (NO,,) from the cement kilns as its first project. With regulations on NO,, emissions from cement kilns expected to be promulgated by the US EPA in the near future, there was concern that the cement companies would not be able to comply in a timely manner. The technologies that were being used by other combustion processes had not been successfully proven in the cement industry. Also, there was another restriction on technology selection. CIEC not only had to develop an efficient NO,, reduction process, but this process would hopefully generate income since the State of California was not expected to provide additional funding.

Very little information was known about NO., abatement for cement kilns. Accordingly, magazine ads were placed in six domestic and foreign trade magazines. The ads requested interested parties to submit technology concepts for NO,, reduction which could be commercialized with a joint effort. Responses were received from within the United States and around the world. The Technology Committee carefully evaluated each proposal and recommended two technologies to the CIEC Board of Directors for funding. One of these was the use of Wastewater Treatment Plant sludge (biosolids) for kiln NO,, reduction. The Committee believed that the ammonia precursors in biosolids might achieve a reaction similar to that seen in Selective Non-Catalytic Reaction processes. After the CIEC Board approved the project, Radian Corporation, headquartered in Austin, TX, and having offices in Southern California, was selected as the Project Leader.

In late 1993 Radian completed an extensive Feasibility Study. Some concern had developed that the nitrogen compounds in biosolids would be destroyed rather than be decomposed into ammonia when exposed to tile kiln heat. However, both i-nodeling and laboratory tests indicated that if the proper temperature window could be maintained, ammonia would be produced. The Feasibility Study was followed by the Engineering Phase and then by the Procurement/installation Phase. All purchased equipment had to be modified, some more than others, and several units were designed and fabricated at the plant. Ultimately, in January February, 1994, a pilot test was made.

This pilot test would, hopefully, answer a number of questions raised since the project began. These were:

I .What would be the effect of tile high water content (75%) on the kiln process.

2. Would the equipment provide a uniform, well-dispersed feed at the injection point.

3. Was the injection point positioned properly to achieve the correct temperature window.

4. Would odor from the biosolids be objectionable to the plant employees.

5. Could the trucker supply the required tonnage from the supply point some 75 miles away.

6. Would the pathogens in biosolids cause a plant hygiene problem which would require protective equipment.

7. Would excessive buildups in the kiln system be a problem.

8. Would the combustion of the solids offset the heat required to vaporize the inherent moisture in biosolids.

9. What would be the effect on plant neighbors concerning the technology and the increased truck traffic.

I 0. Would ammonia slip or visible particle or aerosol emission be detected.

I 1. Finally, from the environmental perspective, would the technology reduce NO,, emissions sufficiently to make the project a success.

Data from three days of steady operation were analyzed. Because tile plant was using TDF (Tire-Derived Fuel), it was necessary to include this baseline variable in all evaluations.

The conclusions from this pilot test were as follows:

At a sludge injection rate of 20 tph (wet), and using TDF, it was observed that fuel consumption was reduced 3-6% over baseline values, NO,, emissions were reduced 15-30%, and further modifications were required to the equipment. Also, it was agreed by all parties that additional testing would be done after equipment modifications were made.

No adverse industrial hygiene effects were reported by the employees. This was consistent with tile earlier CIEC survey of employees of area wastewater treatment plants. The small increase in truck traffic did not cause a problem. With the exception of a production problem that caused a brief blue haze, no adverse comments from plant neighbors were received. After a thorough critique of the pilot test, planning began for an extended plant test.

The contribution of the Technology Committee to the progress of CIEC is worthy of comment at

this time. All members of the Committee are volunteer professionals with full time jobs in the member organizations. Notwithstanding tile demands of their regular 'jobs, attendance at the monthly meetings has been nonpareil as has their support of all CIEC activities. The CIEC Board of Directors also deserves kudos for their faith in CIEC and, of course, the financial input by the member organizations was (and is) essential.

When the responses to the CIEC Request for Proposal for NO,, Reduction began to arrive in the CIEC office in early 1993, the Technology Committee developed a comprehensive evaluation plan. With over 40 proposals to examine, this plan provided a convenient method to compare dissimilar technologies. Chaired by H. 0. (Bud) Biggs of Mitsubishi Cement Corporation, the Committee not only recommended the BSI Technology to the Board as their top priority, but also ranked the remaining technologies for later consideration. Many of these appeared to have potential for reducing NO,, from cement kilns and will be revisited as the need arises.

In April, 1994, Mr. F. T. Sheets, 111, of Riverside Cement Company assumed the Chair of the Technology Committee. Bud Biggs was elevated to the CIEC Board replacing Michael W. Jasberg of Mitsubishi Cement Corporation. With data from the recent pilot test now available, the Committee began to investigate the concept of drying biosolids using waste kiln/cooler heat. The high water content of biosolids is a negative factor for the cement kiln operator, and considering the waste heat available from a typical kiln, possibilities exist to exploit this idea. Various laboratory tests were performed to determine the effect of drying as it relates to NO,, reduction potential. As planning for the extended test continued, the Committee began to search for funding to commercialize this technology.

Recognizing that the utilization of biosolids for NO,, reduction from cement kilns and other combustion operations could be a patentable technology, the CIEC Board contacted a legal firm for advice. Their research confirmed this idea and the long patent process began with the application dated March 16, 1994. This was followed with a Continuation-in-Part filed in December, 1996, relating to the sludge feeding and handling equipment. On December 24, 1996, the U. S. Patent &Trademark Office issued Patent No. 5,586,510 titled METHOD AND SYSTEM FOR CONTROLLING POLLUTANT EMISSIONS IN COMBUSTION OPERATIONS, assigned to the Cement Industry Environmental Consortium. The Continuation in-Part will also generate a patent. By early January, 1995, the Mitsubishi plant was ready for the extended biosolids test. Plant modifications were in place and had been tested, a new blosolids supplier with greater capacity had been selected, and the consulting engineers were on site.

The startup went well and by late February an emissions source test was conducted for the purpose of amending the Permit to Operate to include the use of biosolids. The test data included was taken during the period February 27- March 3, 1995. NO,, reduction continued to show a decrease over the baseline period and no adverse results were noted. Of significant interest was a decrease in dioxins and furans. On August 8,1995, the Mojave Desert Air Quality

Management District issued a new Permit to Operate which included the use of biosolids, an extended test continued until September, 1995, when tile plant entered a major maintenance

1996, the plant was operated fully on TDF and Biosolids and these period. By January, acting uneven

materials are still being used today.

The financial arrangement between Mitsubishi, a founding member of the Consortium, and CIEC is that tipping fees (money received by the plant for biosolids disposal) are being split by the two organizations. When CIEC has been reimbursed fully for research and development costs incurred on the project, Mitsubishi will then receive all tipping fees. CIEC will use its share for future technology development. This project has been described as a Win-Win operation. The State of California has set goals for solid waste reduction in order to conserve the limited landfill space. By utilizing biosolids in an environmentally safe manner and simultaneously reducing kiln NO,, emissions, two major goals have been achieved. In recognizing this achievement, Renew America, a prestigious organization which honors notable achievements in many fields of endeavor, gave an award to CIEC in 1996. In 1997, the Mojave Desert Air Quality Management District bestowed its EXEMI?LAR award on CIEC for the same technology development.

In looking to the future, CEEC has two major projects under development. As discussed earlier, the drying of blosolids utilizing waste heat appears to have great potential. The plant experience in handling and feeding this waste material into the kiln, along with extensive laboratory testing, verifies the feasibility of the project. Secondly, CEEC is conducting a major survey to determine industry interest in the Beneficiation of Cement Kiln Dust (CKD). Upcoming EPA regulations covering this byproduct from cement production will determine how the industry must react. However, it would appear that, regardless of these regulations, our industry is ill-prepared for the challenge.

The Cement Industry Environmental Consortium continues to be a unique organizations medium where the regulators and the regulated can meet in a spirit of cooperation for the purpose of solving mutual environmental problems. The victims of the Romans would have greatly benefited froi-n this concept.

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