BridgeGap Engineering Blog » General Business Posts

CO2 emissions a good thing?

Lehigh Ben — Fri, 06 Jan 2012 14:45:36 +0000

Among other emissions, Carbon dioxide is a headache for many cement producers. Finding the right balance between environmental-responsibility and financial-stability is difficult. For industrial plants shifting towards carbon capture and sequestration (CCS), economic performance suffers due to the high cost of installing and running the necessary equipment. However, a way of offsetting those costs is now in development at Sandia National Laboratories.

A new type of turbine, utilizing supercritical carbon dioxide (S-CO₂) instead of traditional steam, is being tested at Sandia. These turbines use the S-CO₂ compressed at 73 bar and at 33 °C and run on the Brayton Cycle (where steam turbines utilize the Rankine Cycle). The benefits of this new type of system lie in footprint in the plant along with initial investment. The use of the Brayton Cycle allows for a drastic reduction in turbine size. A 300 MWe S-CO2 turbine has an outside diameter of approximately 1 meter and needs only three stages of turbomachinery. The corresponding steam turbine would require a diameter of five meters with 22-30 stages of turbomachinery. This reduction in size translates to a decrease in the initial investment on the system.

Any plant that could employ this system successfully should see the device pay for itself over a short interval of time. Depending on the turbine size chosen, a plant could remove itself from the grid by generating all its own power needs and perhaps even sell power back to the utility companies. With the ever-changing technology, what was once a headache for the cement industry might turn out to be a godsend for the financial competitiveness.

Information gathered for this article appears in the January 2012 issue of Mechanical Engineering, the official magazine of ASME. The article was entitled, “Mighty Mite” and was authored by Steven Wright.

Waste Heat Recovery from Cement Pyroprocess in Turkey

Lehigh Ben — Thu, 24 Nov 2011 15:27:53 +0000

Aķcansa Cement, a joint venture of HeidelbergCement and Sabanci Holding, recently announced the installation of a $24 million waste heat recovery unit at their Çannakale, Turkey, plant. Aķcansa, which produces 6.5 tonnes of clinker and 9 million tonnes of cement annually in three plants within Turkey, is a major producer of both cement and ready-mixed concretes.

The new unit will have approximately 15.2 MW of capacity, drawing enough radiant heat from the clinker production process than for an annual energy savings of 105 million kWh. This equates to about 30% of the plant’s current energy needs. This installation now gives the Çannakale plant the distinction of being the largest facility in Europe with a functional heat recovery unit. Additionally, the new unit will allow the plant to reduce their carbon dioxide emissions by 60 thousand tons annually, taking a stride forward for a cleaner, healthier globe.

Possible Relief for Cement Sector?

Lehigh Ben — Thu, 18 Aug 2011 16:22:53 +0000

Is relief is on the horizon for the cement industry? Recently, two representatives introduced a bill titled “Cement Sector Regulatory Relief Act of 2011.” If passed, this legislation will require the Environmental Protection Agency (EPA) to re-propose three rules aimed at the portland cement industry. These rules were targeting the solid waste incineration initiatives started by many companies.

The president and CEO of the Portland Cement Association (PCA) Brian McCarthy said, “The bill introduced…by Reps. Sullivan and Ross will allow the industry to continue its dialogue with the EPA with the goal of crafting rational and feasible emission standards. We are not shying away from environmental regulations. We take our environmental stewardship seriously and have a long history of investing in continuous improvements that preserve U.S. manufacturing capacity and the economy.” If current regulations remain in place, approximately a fifth of domestic plants could be forced to close and cost the industry $3.4 billion over three years.

Cement Demand to Increase with Rebuilding of Infrastructure

Hannah — Thu, 16 Jun 2011 22:06:41 +0000

With America’s infrastructure crumbling and the economy still struggling to recover from its nosedive, a game of passing the buck has begun. The federal government has no money to foot the enormous bill of rebuilding and expanding roads, bridges, water and waste treatments systems, etc. Just recently a group of senators has drafted a bill that will give about $56 billion a year towards highway and transit construction. While this is a step in the right direction, America’s infrastructure needs hundreds, not tens of billions of dollars of work. Thus, much of the responsibility of finding funding is passed off to the state government. These men, in turn, look at the trillions of dollars of debt they face, and pass the responsibility on to more local governing bodies. Where will it stop? At some point it must. Indeed, maintaining and rebuilding the country’s infrastructure is necessary for the operation and safety of society, much less for America to keep up in the global race of technology and expansion. Given that America cannot ignore the state of its infrastructure, what does this mean for cement companies who produce one of the primary materials needed for this massive renovation project? Whether America attacks the problem – beginning with the passing of this new bill – or waits until the last minute in each situation, there will be an enormous need for quality cement. It may come as a slow but steady need, or in the form of mass contracts – only time and the government will tell.

EPA Introduces New Sulfur Dioxide NAAQS

Lehigh Ben — Tue, 15 Jun 2010 09:41:50 +0000

On June 2, the Environmental Protection Agency unveiled new sulfur dioxide (SO₂) primary national ambient air quality standards (NAAQS). The EPA’s main reason for revoking the former standards is the public health risk posed by sulfur oxides, which SO₂ is a part. They claim that sulfur oxides react with compounds in the atmosphere to form particulates that pose health risks to intensify existing heart conditions or may cause and worsen certain respiratory conditions. EPA estimates show the cost of the new ruling will be approximately $1.5 billion; however, it estimates the health benefits between $13 and $33 billion. Power generation sites and cement plants will be particularly affected by the EPA’s new ruling. These plants are known for temporary SO₂ spikes, especially during the start-up and shutdown of combustion equipment.

The particulars of the regulation require that plants maintain a level of no more than 75 parts per billion (ppb) of SO₂ evaluated over a one hour period compared with the former rule of 140 ppb evaluated over a twenty-four hour period. This new ruling also overturns the other standard of maintaining a level of no more than 30 ppb evaluated over a year. The second part of the new regulation also revises the ambient air monitoring system. The EPA feels that 41 new monitoring stations will need to be established for operation beginning the first of January, 2013. These new sites will use air quality modeling and air dispersion monitoring to designate the areas that meet or fail the new standards, designated “attainment” and “non-attainment” areas. All sites must meet the new standards no later than August 2017. Secondary SO₂ standards will be addressed in a separate ruling.

One immediate effect of this action is that Prevention of Significant Deterioration (PSD) permits issued after the effective date of the new NAAQS must include a compliance demonstration with respect to the new NAAQS.

EPA Proposes Coal Ash Regulations

Lehigh Ben — Tue, 11 May 2010 19:08:39 +0000

With almost 900 ash-containing landfills nationwide, the proper disposal of coal ash was a problem that could be avoided no longer.

Early last week, the Environmental Protection Agency finally announced a new proposed set of regulations on coal ash, the first time this by product is being nationally regulated. The main concern with this coal power plant after product lies in its contents of potentially hazardous contaminants, such as mercury, arsenic, and cadmium. Because the ash is commonly stored in liquid form, seepage of these heavy metals into groundwater has been a concern that the EPA is working to eliminate. EPA administrator Lisa Jackson said, “The time has come for common-sense national protections to ensure the safe disposal of coal ash. We’re proposing strong steps to address the serious risk of groundwater contamination and threats to drinking water and we’re also putting in place stronger safeguards against structural failures of coal ash impoundments. The health and the environment of all communities must be protected.”

Despite its desire to control the waste material, the EPA has yet to decide on the final course to pursue, which are open to public comment for 90 days. The first option is drawn from the Resource Conservation and Recovery Act (RCRA) which would create an extensive program of federally enforceable requirements. The second option, drawn from another part of the RCRA, would create standards for the proper waste management and would be primarily enforced through civil lawsuits. The EPA has published a comparison of the two options for public review.

Fortunately, in order to keep from alienating support in industry, the EPA announced that it will leave the Bevill exemption in place under the new rules. This exemption allows different industries to recycle the ash into other useful products that do not present health hazards. The assistant administrator of the office overseeing the regulations, Mathy Stanislaus said, “EPA supports the legitimate beneficial use of coal combustion residuals. Environmentally sound beneficial uses of ash conserve resources, reduce greenhouse gas emissions, lessen the need for waste disposal units, and provide significant domestic economic benefits. This proposal will clearly differentiate these uses from coal ash disposal and assure that safe beneficial uses are not restricted and in fact are encouraged.”

The long awaited rules are definitely a step in the right direction and fortunately the legitimate, beneficial uses of the waste material are preserved.

US Climate Bill Faces Opposition and Possibly Delays

Lehigh Ben — Fri, 23 Apr 2010 13:35:46 +0000

Senators John Kerry (D-Ma), Lindsey Graham (R-SC), and Joseph Liebermann (I-CT) have been working on a sweeping climate change bill for months and are expected to reveal the bill in session on Monday, April 26. The senators have been pulled in twenty different directions by varied lobbyist groups, industry, environmental activists, and fellow colleagues on the Hill. The main concerns being voiced over the bill regard a possible ‘gas tax,’ control over new offshore drilling, and the effect of the bill on recovering American industry.

As a major emitter of carbon dioxide, the cement industry is anxious over what the new legislation will mean for them. Carbon pricing or a cap-and-trade system might well sink an industry that is still struggling to keep its head above water during the economic downturn. To alleviate fears in energy intensive industries, energy adviser to President Obama Carol Browner predicted that “a final bill will be very, very mindful of the needs of these particular sectors of the economy.” Also, if other countries do not enact similar legislation, companies fear that carbon taxes will prohibit them from competing successfully with overseas firms. The cement and steel lobbyists propose a border tax to keep competition fair, but lawmakers reject this idea over the risk of starting a trade war with countries like China and India.

All in all, the trio of senators has been working through various drafts of the bill in what has turned out tougher than expected. According to Reuters.com, arranging the multiple facets needed for a successful bill is like “the skill needed to solve a Rubik’s Cube puzzle — move one set of items the wrong way and the lawmakers you thought you had lined up are out of place — and good luck getting them back.” Despite progress made, hopes are not high for sweeping climate legislation to be passed anytime during 2010.

Lagging Behind: America’s Green Technology

Lehigh Ben — Sun, 28 Mar 2010 02:12:09 +0000

Michael Rock, an economics professor at Bryn Mawr College, held a lecture this past week concerning America’s lack of continued green technology development. He fears that we are on the way to losing our place as the forerunner of this industry just as we did in the automobile industry. Daniel Weiss, director of a DC-based climate think-tank, said “China, Germany and Spain are far ahead of us in creating green energy technology.”

Along with China, other Asian nations such as Korea and Japan are leveling off and reducing their CO₂ emissions while US emission levels continue to rise. China is taking the lead in developing electric vehicles, wind turbines, and solar panels in an effort to reduce their overall carbon footprint. Chinese car producers have plans in place to export electric vehicles to the US by the end of the year at nearly half the price of comparable US-made models.

What has America been doing in response? Not a whole lot. Despite the fact that clean energy-related jobs grew nearly three times as much as traditional jobs over the last decade, America is still falling behind in renewable energy. America’s solution so far has been to try and pass legislation limiting carbon emissions. Such a bill failed in Congress about a year ago and another similar bill (proposing either a cap-and-trade system or a carbon tax) is being formulated by a tri-partisan Senate committee now.

Is legislation by itself enough to help reduce our carbon footprint? That is hard to answer. However, DuPont has decided to not sit around and wait for laws to be passed. They have actively committed their company to reduce their carbon footprint and develop new technologies to stimulate green industry, including developing new solar panel materials, biofuels research, and environmentally-friendly refrigerants. DuPont has the right attitude in taking an aggressive approach at improving our world. If America continues to remain relatively passive about climate change and greenhouse emissions, we will be left in the energy “dark ages” by countries that have taken a proactive role in changing the status quo. All industries in America, from small businesses to the giant cement industry, should be looking for ways to improve their energy efficiencies in order to help keep the US on the forefront of clean energy technology.

From Trash to Treasure: Turning Waste into Fuel

Lehigh Ben — Thu, 11 Mar 2010 00:02:46 +0000

The Japanese have been trying to implement a method of converting refuse organic waste into usable fuel for some time now, but have encountered formidable barriers in their path. Their refuse-derived fuel (RDF) is produced from raw garbage, an adhesive, and lime in pellet form. However, the heat output of the RDF is very low compared to traditional fuels such as coal. In most cases, oil or other combustibles are combined with the RDF for improved usage. Plants producing the RDF also run the risk of fires from methane build-up and increased cost to recover the lime in the ash created during the process. With these barriers, RDF plants have not been as successful breaking into the market as possible.

Takeshi Sako and a group of fellow researchers are looking to change this. They claim to have found a way to create fuel from discarded plastic containers and the non-edible portions of agricultural goods. Their process involves extreme temperature and pressure, mimicking Mother Nature’s own process. Sako mixes the waste products with superheated water at two hundred degrees Celsius and at a pressure roughly twenty times normal atmospheric pressure. The organic materials bond to broken down plastic particles to form a powdered fuel which can be compressed into pellets.

The main benefit of Sako’s product over RDF lies in its heat output. During trials, Sako recorded values of 6,250 to 7,000 kilocalories per kilogram; the same range as coal. Also, the Sako product, when burned, produces no sulfur dioxide and the output of nitrogen oxide and dioxins is well below government standards for power plants. Sako and fellow researchers hope to have their method put into practical use within three years.

This new Sako fuel holds promise for the entire world, but especially to the cement industry. As a major greenhouse gas emitter, the cement industry is spending billions on pollution controls and alternative fuels. Sako’s research is a windfall for the industry, as garbage is the one by-product of civilization that will never cease to be produced. By harnessing this resource and time, companies will be able to expand their horizons for a healthier and “greener” bottom line.

Postponement of EPA Greenhouse Gas Regulations

Lehigh Ben — Wed, 24 Feb 2010 20:40:21 +0000

EPA administrator Lisa Jackson announced Monday that the agency would not push through regulations against large greenhouse gas emitters until 2011. Also, Ms. Jackson announced that the agency would raise the threshold for the Clean Air Act on regulating carbon dioxide emissions.

The delay comes after multiple groups, including eight Senate Democrats, expressed concern on the potential economic impact of the new regulations. Another concern was raised over the inability of state regulators to cope with the impending flood of permit applications had the regulations been passed. Ms. Jackson stated that the regulations will begin taking effect in limited amounts during the first half of next year.