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1 SURVEY OF CHEMICAL EMISSIONS Worrell and Galitsky [15] did a study of energy efficiency in the cement industry. According to their report, the energy costs for cement production is very high. There are significant opportunities to reduce these costs through energy capture of waste-derived fuels. Coal and coke are predominantly used as fuels, followed by natural gas and waste fuels. The role of carbon-intensive fuels, such as coal and coke, increased due to the higher prices of natural gas and crude oil. This increase in carbon intensity was offset by increased efficiency; therefore, the total carbon intensity actually dropped. From 1985- 1999, use of waste-derived fuels for energy generation has risen from 0-17%, a very positive trend. Between 1970 and 1999, the primary energy intensity for cement production dropped from 7.3 MBtu/short ton to 5.3 MBtu/short ton, while the carbon dioxide intensity dropped from 0.31 tons C/ton cement to 0.26 tons C/ton cement. The production of cement results in the emission of CO2 from both fuel consumption and calcinations of limestone. The U.S. cement industry is made up of either cement plants that produce clinker and grind it to finished cement, or clinker-grinding plants that grind clinker produced in other plants. Clinker production consists of a high-temperature burn in a kiln of limestone with smaller amounts of siliceous, aluminous, and ferrous materials. More than 90% of cement produced in the United States in 1999 was Portland cement, while ~ 5% of cement production was masonry cement. There were 117 cement plants in the United States in 1999, distributed across 39 states and Puerto Rico, and owned by 42 companies. Production rates per plant varied from 0.5-3.1 million metric tons per year, with total production in 1997 ~ 86 Mtons. Clinker production from the wet process decreased from a 60% share in 1970 to a 25% share in 1999. Raw materials production requires 25-35 kWh/tonne in the form of electricity. Unless electricity is generated in-house, emissions from this process cannot be addressed, since the electricity is generated in a remote utility. However, by using the process integration approach described in this report, thermal energy from other process streams can be captured to produce electricity in-house. Clinker production (by pyro-processing in large kilns) accounts for > 90% of total industry energy use, and almost all of the fuel use. Most of the emissions occur in this process. These kilns evaporate water in the raw material, calcine the carbonate, and form cement minerals. Fuel consumption in a wet kiln ranges from 5.3-7.1 GJ/tonne clinker, while for a dry kiln, it varies from 3.2-3.5 GJ/tonne clinker. Once the clinker is formed, it is cooled and transported to a finish mill to produce powdered cement by grinding with additives using roller or ball mills. This process is electricity intensive, using 50-70 kWh/tonne in older mills and 32-37 kWh/tonne in modern mills. 40PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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