Minutes Manufacturing Technical Committee Portland Cement

Minutes
Manufacturing Technical Committee
Portland Cement Association
Intercontinental Chicago Hotel
Chicago, Illinois
August 25, 2008
The meeting of the Manufacturing Technical Committee of the Portland Cement
Association was held on August 25, 2008 at the Intercontinental Chicago Hotel in
Chicago, Illinois.
A list of participants is attached (Attachment I).
Call to Order
Satish Sheth, Committee Chairman, called the meeting to order and directed the
attention of those present to the Antitrust and Competition Act Statements. The
meeting agenda is an attachment to these minutes (Attachment II).
Chairman Sheth welcomed the committee members and guests attending the meeting.
Introduction of New Associate Member
Chairman Sheth recognized Mr. Robin Riester and Mr. Aleksander Kaszubowski of
Mikropul as representatives of the newest Associate Member. Mr. Riester presented a
brief overview of the services provided by Mikropul.
Approve May 19, 2008 Meeting Minutes
The minutes of the May 19, 2008 meeting were approved as distributed. [Secretary’s
Note: Mr. Andy Edwards later noted that the presentation by Margret Walsh,
Dalhousie University, was not included in the minutes.]
DOE Industrial Assessment Center Overview
Mr. Bohan noted that representatives of the DOE Industrial Assessment Center would
not be available for the scheduled presentation.
Information Services Capabilities Update
Ms. Connie Field, PCA Information Services Manager, provided a brief overview of
the services available to PCA and Associate Members related to PCA’s information
services capabilities. Ms. Field provided a variety of examples of assistance that the
information services group provided in support of ongoing MTC research activities,
MTC member requests, literature search capabilities, and other services.
SNCR and SCR Update
Mr. Bob Schreiber and Ms. Christa Russell of Schreiber and Yonley Associates
presented an update on selective non-catalytic and selective catalytic reduction
techniques used in the cement industry. Their presentation reviewed the final results
of project M07 01 Selective Non-Catalytic Reduction (now published as PCA Serial
Number Report SN 3046) and their personal observations of selective catalytic
reduction installations at Solnhofen, Cementeria di Sarche di Calavino, and
Cementeria di Monselice.
Materials Preparation and Finishing Task Committee Items
Mr. Jeff Bump, Task Committee Chairman, noted that the committee previously
approved the meeting minutes. He recommended that committee members identify
potential research suggestions for the coming year during the research suggestion
breakout groups.
Pyroprocessing Task Committee Items
Mr. Andy Edwards, Task Committee Chairman, noted that the committee previously
approved the meeting minutes. He then invited Mr. Arron Heinerikson, Trinity
Consultants, to provide a progress report on project M07 02 AFR Permitting Manual.
Following Mr. Heinerikson’s presentation, the task committee chairman solicited
recommendations for a task group to review the upcoming final report. The task
group was identified and includes: Mr. Jeff Bump, Mr. Mark Morgan, Mr. Michele
Maranzana, and Mr. Greg Mayes. Mr. Edwards, as task committee chairman, will
also participate.
Mr. Edwards noted that project M07 03 Mercury CEMS would be discussed during
Mr. Ty Wilson’s update regarding the PCA Environment and Energy Committee
update. Mr. Edwards also noted that project M06 04 CKD for Biological Wastewater
Treatment was updated at the recent spring meeting and would not be reported on at
this meeting.
Mr. Bohan noted that project M07 12 CO2 Control Technology Effectiveness would
be discussed at the steering committee meeting later that afternoon. Mr. Bohan also
noted that the fellowship projects, F06 05 CKD for Reconstruction of Pavements, and
F06 06 CKD for Artificial Soil, when complete, would result in serial number reports.
Mr. Alan Gee suggested that some clarification regarding the definition of CKD may
be appropriate. He observed that CKD traditionally collected in the bypass was not
chemically similar to the CKD that might be obtained through collection at the
preheater tower. There was brief discussion regarding the definition of CKD although
no further action was taken.
Auxiliary and Control Equipment Task Equipment Committee Items
Mr. Phil Gaynor, Task Committee Vice Chairman, noted that the committee did not
have any actionable items at this meeting.
Environment and Energy Committee Update
Mr. Ty Wilson updated the committee on a variety of regulatory issues. Additionally,
Mr. Wilson reviewed Environment and Energy Committee sponsored research
projects including: 07-20 Mercury Continuous Emissions Monitoring Profile, 08-11
AFR Emission Profile and Risk Assessment, 08-12 Auto Shredder Residue as Fuel,
08-13 Mercury Control Through Process Control Baghouse Dust, and others.
Occupational Health and Safety Committee Update
Mr. Wilson also updated the committee on a variety of occupational health and safety
regulatory issues.
Research Audit
Mr. Bohan briefly reviewed the current research audit and noted that three MTC
projects were included in the audit.
Research Suggestion Breakout Groups
The committee divided into four separate groups to generate research suggestions. A
list of the suggestions is attached as an appendix to these minutes.
Education Activities Update
Mr. Bohan updated the committee on PCA’s current offering of manufacturing
related educational programming.
Fall Technical Session Preview
The scheduled fall technical session will include:
• Acoustic Cleaning Applications: A Real World Cement Plant Case Study Corrine Prince
• Oxy-Fuel Fired Cement Production - Stefan Laux
• XP4i : Innovative Technology - Pierre Stouffs and Olivier Hancotte
• Waste Heat Recovery for Industrial Processes - Dan Wishnick
• The Reduced Emission Oxygen Kiln- Frank Zeman
• Biodiesel: Background, Issues and Opportunities - Richard Nelson
Establish Date of Next Meeting
The next meeting will be held in conjunction with the 2009 IEEE-IAS/PCA Cement
Industry Technical Conference scheduled May 31-June 4, 2009 at the Desert Springs
JW Marriott, Palm Desert, California.
Adjourn
There being no further business, the task committee adjourned at approximately 2:45
p.m.
R. P. Bohan
Secretary
Attachment I
MANUFACTURING TECHNICAL COMMITTEE MEETING
AUGUST 25, 2008
ATTENDEES
Name
Bob Hunter
Kevin Regan
Arron Heinerikson
Robert Shenk
Michele Maranzana
Jason Crowther
Chris Sprunger
Harvey Buckley
Kenny Miller
Ron Vidergar
Corinne Prince
Mark Morgan
Dave Hankins
Patrick Brady
Robin Riester
Aleksander Kaszubowski
Phil Gaynor
Dan Fritz
Chris Taylor
Jeff Bump
Andy Edwards
Satish Sheth
Rick Bohan
C. Thom Martin
Andy Winston
Vernon Christensen
Mike Knoflicek
Tom Luepke
Guido Tenaglia
Rafael Martinez
Steven Miller
Neil Ballantyne
Uwe Eschenhorst
Stefan Laux
Scott Grossbauer
Lars Hansen
Scott Hunsicker
Ken Derksen
Bruno de Robert
John Kline
Bob Schreiber
Christa Russell
Dave Norris
Company
___________
Refratechnik
Refratechnik
Trinity Consultants
FLSmidth, Inc
Buzzi Unicem USA
TXI
TXI
Monarch Cement
Monarch Cement
Ash Grove Cement
GE Energy
Holcim (US) Inc.
Siemens
Siemens
Mikropul
Mikropul
TXI
Suwannee American
Magotteaux
Lafarge NA
Ash Grove Cement
Cemex
PCA
GE Energy
GE Energy
Penta Engineering
Humboldt-Wedag
Metso Minerals
St. Mary’s Cement
FLSmidth, Inc.
FLSmidth, Inc.
Polysius
Polysius
Praxair
Donaldson
Solios Environment
River Consulting
Cadence Recycling
Lafarge NA
Lafarge NA
Scheiber Yonley Associates
Scheiber Yonley Associates
TXI
Stephen Arment
Steve Regis
Frank Romano
Andy Woodford
Doug Kunik
Takafumi Hino
ZK Zarif
Ty Wilson
Alan Gee
Blaz Jurko
Aris Papadopoulos
TXI
California Portland Cement
Air Products & Chemicals
MAC Equipment
MAC Equipment
California Portland Cement
Vezer’s PIC
PCA
Lehigh Portland Cement
Gebr. Pfeiffer
Titan America LLC
Attachment II
PORTLAND CEMENT ASSOCIATION
MEETING OF THE MANUFACTURING TECHNICAL COMMITTEE
INTERCONTINENTAL CHICAGO HOTEL
CHICAGO, ILLINOIS
August 25, 2008
8:00 a.m.–3:30 p.m.
AGENDA
I. CALL TO ORDER
II. ANTITRUST/COMPETITION ACT STATEMENTS
III. SELF-INTRODUCTIONS
IV. INTRODUCTION OF NEW ASSOCIATE MEMBER
V. APPROVE MAY 19, 2008 MEETING MINUTES
VI. DOE INDUSTRIAL ASSESSMENT CENTER OVERVIEW
a. Evaluation of LEED certification programs for buildings
VII. INFORMATION SERVICES CAPABILITIES UPDATE
VIII. SNCR AND SCR UPDATE
IX. MATERIALS PREPARATION AND FINISHING TASK COMMITTEE
ITEMS
a. Approve May 19, 2008 Meeting Minutes
X. PYROPROCESSING TASK COMMITTEE ITEMS
a. Approve May 19, 2008 Meeting Minutes
b. M07 02 AFR Permitting Manual
c. M07 03 Mercury CEMS
d. M07 12 CO2 Control Technology Effectiveness
e. M06 04 CKD for Biological Wastewater Treatment
f. F06 05 CKD for Reconstruction of Pavements
g. F06 06 CKD for Artificial Soil
XI. AUXILIARY AND CONTROL EQUIPMENT TASK COMMITTEE ITEMS
a. Approve May 19, 2008 Meeting Minutes
XII. ENVIRONMENT AND ENERGY COMMITTEE UPDATE
XIII. OCCUPATIONAL HEALTH AND SAFETY COMMITTEE UPDATE
XIV. RESEARCH AUDIT
XV. RESEARCH SUGGESTION BREAKOUT GROUPS
XVI. EDUCATION ACTIVITIES UPDATE
XVII. FALL TECHNICAL SESSION PREVIEW
XVIII. ESTABLISH DATE OF NEXT MEETING
XIX. ADJOURN
Attachment III
Research Suggestions from Breakout Groups
MTC Fall Meeting
August 25, 2008
Items discussed:
1.
2.
3.
4.
5.
Idiots’ Guide to Hex Chrome – Compilation of background data
Greenfield technologies to retrofit for mercury remediation
Feasibility of co-generation
Quantify benefit of analyzers
Effects of residence temp time: SNCR (liquid to gas)
CO2 Æ Currently on TAP: CO2 from combustion or calcinization production
Î Carbon neutral/ Bio fuels
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
mercury
Crystalline silica
THC
Hex Chrome
Emission Issues: NOX, CO2 combustion, Calcinization, Carbon neutral
respirable dust
mineralizer as NOx reduction
Better way to handle moisture in VRM circuits
Does hi-eff have any benefit on VRMs with moisture issues?
Reducing emissions
Power, costs
Research alternative fuels & raw materials, optimization for energy reduction, power generation
(co-generation)
Is it possible to co-generate power cost effectively?
Study around co-generation w/ heat temps and how effects process
Are there subsidized projects/ money available from the government for energy saving projects at
plant?
Is waste to energy plants concept a potential to operate at cement plants?
CO2 off-gas feed to algae – creation of biodiesel ÆglycerinÆ natural gas? (energy)
Where are sources of biomass (potential fuel in kiln) oxygen from process can reduce CO2?
Research on facilities utilizing CO2 off-gas, algae, etc. Search other means of creating energy &
decreasing CO2
Reliability – vibration analysis – what are newest techniques – what are other industries doing?
Lubrication – what is current state of the art?
Air leakage – reducing & best practices
Statistical analysis methods – Using same methods with all the information coming out &
measurements. How do you fully use, analyze, etc. to make best decision? What is cutting edge
in other industries?
How can major power-consuming pieces of equipment be optimized?
Balancing production, electrical consumption/ efficiency / peak/ off-peak rates
State of the Art report on uses/ effectiveness of grinding aid
Î Product classes used in market (TEA, glycol….)
Î Impact of product classes
Î Consumption per T Cement
Î (get grinding aid and mill company to chair)
32. Effectiveness of down hole drill analysis (in-situ)
Î Products available
Î Results/ impacts of use
Î Impact on plant operation
33. Testing for Bio/ Synthetic Fuel using C14
i. Repeatability
ii. Accuracy
iii. Influence on CO2 tax/ credit
Î Issue is Bio versus synthetic rubber in tires
i. For CO2 tax in Canada and Calif, tires may have two types or material in them.
Paper presented in Europe [ECRA]?
34. Update on 1990s paper on metals content of cement
i. NSF proposing 0.3 ppb limit on cesium
ii. State agencies tracking lead on cement
Î Marketplace wants current data
35. Definition of CKD
i. Pre-heater dust
ii. Long kiln dust
iii. By-pass dust
36.
37.
38.
39.
classify by LOI, ALK, CL, S, CaCO3, OR ????
Waste heat recovery
Operating efficiency vs. energy efficiency (overall)
Increasing efficiency in the process through things like VRM installations
Quantify the benefits of instrumentation like PGGNA, free CaO, Online BSA analyzers…
consider equipment costs, energy requirements, and emission measurement requirements

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