t

Dr Magnus Amajirionwu Inspector Environmental Licencing Programme Office of Climate, Licencing, Resource and Research Environmental Protection Agency PO Box 3000 Johnstown Castle Estate County Wexford

30fh May 2017

Dear Dr Amajirionwu -

lrfph Cement Umlted Platin Drogheila Co. Louth Telephone: 041-987 6000 Facsimile: 041-987 6400 . E-mail: Info@lrishcement.le www.lrishcementle

I wish to submit additional information to support an application under the BAT licence review (POO30-05) to increase the gas volume in Kiln 3 at Platin Works. The proposed increase in gas volume is in the context of the existing Kiln 3 configuration w.r:t. to site layout, fuel inputs etc. and is consistent with efficiencies and optimization of kiln systems as outlined in BAT #7, BAT #10 and BAT #19 of the Cement BAT conclusions.

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Or. Peter Rosholm, FL Smidth, has prepared a report on behalf of Irish Cement which outlines the improvement in clinker production (tonne per day) and the associated energy saving (kcal per kg of clinker) benefit that an increase in Kiln 3 gas volume to 477,878 Nm3/hr (from the existing limit of 410,000Nm3/hrj could achieve. A copy of the report is attached for reference.

I

I Background :

A" review of the BAT conclusions for the cement industry was undertaken, following a request from the EPA. It was determined that the existing Kiln 3 system can be optimized by increasing kiln gas flow to achieve an increase in clinker production with a higher energy efficiency. The following BAT conditions were reviewed in this context:

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BAT 7: In order to reduce /minimise electrical energy consumption, BAT is to use one or a combination of the following techniques: ai Applying improved and optimised kiln systems and a 'smooth and stable *kiln process ...

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EPA Export 14-06-2017:03:18:12

BAT 10: In order to reduce / minimise electrical energy consumption, BAT is to U

one or a combination of the following techniques: e. Process control optimisation

A table outlining the benefits of process control optimization (the increase gas flow) as summarised from the FL Smidth report attached is given as follows:

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As can be seen above the increase in Kiln 3 gas volume to 477,878 Nm3 / hr yields an increase of 1,250 t of clinker per day, whidh annualised could yield up to an increase of ca. 400,000 tonnes of clinker per year.

The decrease in specific heat consumption a t 5,000 t clinker per 24 hr. compared to ~

3750 t clinker per 24 hr. is due to the relative reduction in kiln' radiation losses a t the i , higher production. The improvement in specific heat consumption is 11 kcal / kg clinker or 11,000 kcal / t clinker. This equates to a saving of 12.8 kWh / t clinker (1 ,I kcal = 0.00116 kWh). The World Business Council for Sustainable Development ; (WBCSD) describes in its CO2 protocol that the CO2 per power unit produced 1 externally is 0.43 kg CO2 / kWh. Therefore the energy saving can be also be expressed as a reduction of 5.5 kg of CO2 per tonne of clinker produced a t the higher ' gas volume.

In the context of optimizing the process by increasing Kiln 3 gas volume, a review of air emissions w.r.t BAT #19 from the Cement BAT conclusions was undertaken.

BAT 19: In order to reduce emissions of NOx from the flue-gases of kiln firing and/or '1 reheating/precalcinating processes, BAT is to use one or a combination of the following techniques:

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a. Process optimisation

In the table below the Kiln 3 NO, emission (kg / t clinker) is calculated for the current 'I and proposed scenarios. As can be seen in the table below there is a reduction in the NO, emission rate for the current and proposed gas volumes of the order of 0.01 Kg !I NO, / t clinker. Based on this it is expected that similar reductions will be achieve3 1

' I 'l for other ELVs (particulate, SO, etc.)

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EPA Export 14-06-2017:03:18:12

3750 5000

362656 477878

500 500

3Limmat-v: I I

A report has been prepared by Dr. Peter Rosholm on behalf of Irish Cement which outlines the improvement in clinker production (1250 clinker tonne per day) and the a$sociated improvement in energy efficiency (11 kcal per kg of clinker) that an increase in Kiln 3 gas volume to 477,878 Nm3/hr could achieve.

Additionally, it has been demonstrated that with the increase in Kiln 3 gas volume the emission rate of NO, in terms of kg NO,/ t clinker is reduced. Based on this it is expected that similar reductions will be achieved for other ELVs (particulate, SO, etc.). Air dispersion modelling of emissions of NO, and other pollutants a t much higher flow rates has been previously submitted. The air dispersion modelling has shown that Air Quality Standards and Guidelines are easily met in respect of all regulated substances.

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q n this basis, Irish Cement is seeking an increase in the volumetric flow rate limit of k l n 3 from 410,000Nm3/hr to 477,878 Nm3/hr. Irish Cement is not applying for a cpange t o the volumetric flow rate limits for Kiln 2 and Cement Mill 1 at this time.

I trust that the above addresses the queries raised. Should you need any further !

information please don't hesitate to contact the undersigned.

Yours Sincerely, I

Seamus Breen Hiead of Quality and Sustainability Ir-ish Cement Ltd.

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EPA Export 14-06-2017:03:18:12

~ m c e s t design FLSmidth A/S Vigerslev All6 77 - 2500 Valby . Denmark Tel +45 36181000 . Fax +45 36301820 www.flsrnidth.com I. DK reg.no. 15 02 8882

To Seamus Breen - Platln Cement works, Irish Cement; Ireland

Ronan Breslin - Platin Cement Works, Irish Cement, Ireland

David O'Brlen - Platin cement works, Irlsh Cement, Ireland

'

Copies to

From PROS

Filing

Subject

Memo-93/Platln/PH gas Flow in Stack/PRos/2017/05/25

Production simulation a t 3750 and 5000 tpd clinker - estlmatlon of PH exit gas In

6tack expressed as Nm'/h (dry) gas 6 10% 0 2 .

.

Kiln 3 a t Ir ish Cement Platin works is currently producing around 3750 tpd clinker with less than 410000 Nm3 (dry)/h@'lO% 0 2 preheater exit gas in the stack. Due to increased market demand Irish cement is con- sidering increasing the production capacity of kiln 3 at Platin Cement works. The maximum achievable production capacity is evaluated to be around 500.0 tpd cligker.

The operational parameters of kiln 3 at Platin Cement work have been simulated at 2 different production levels for worst case fuel scenario. The simulations are shown in:

0 Enclosure 1: simulation of the operational parameters at a produc- tion capacity of 3750 tpd clinker.

0 Enclosure 2: Simulation of the operational parametek at a produc- tion ca.pacity of 5000 tpd clinker.

3750 <tDddinker 'ienclosure 11 c

The simulation shows a specific heat consumption on 860 kcal/kg clinker.

The preheater exit gas is simulated to 2.498 kg gas/kg clinker with a density of 1.352 kg/Nm3 corresponding to 1.848 Nm3 (wet) gasjkg clinker with a moisture content of 0.110 kg HzO/kg dry gas.

The amount of dry preheater gas is calculated as 2.498/1.11 = 2.250 kg dry gas/kg clinker.

The amount of moisture in the preheater exit gas is calculated to 2.498- 2.250=0.248 kg HzO/kg clinker or 0.310 Nm3/kg clinker and the volume of dry preheater gas is calculated to 1.848 - 0.310 =1.538 Nm3 dry gas/kg clinker with 4.4% 0 2 , 27.8% CO2 and 67.8% N2.

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EPA Export 14-06-2017:03:18:12

Process deslgn FLSmidth AVS Vlgerslev All6 77 . 2500 Valby . Denmark Tel +45 36181000 Fax +45 36301820 www.flsmidth.com . DK regno. 15 02 88 82

The 1.538 Nm3/kg clinker (dry) preheater exit gas at 4.4% 0 2 is con- verted to 10% 0 2 by 1.538*(1+ (10-4.4)/ (21-10)) = 2.321 Nm3/kg clinker dry gas @ 10%02.

The predicted preheater exit flow a t 3750 tpd clinker is 3750/24ton/h*1000kg/ton*2.321 Nm3/kg clinker dry gas @ 10% 0 2

=362656 Nm3/h dry gas @ 10% 0 2 .

500'0 tod clinker f enclosure 21

T i e simulation shows a specific heat consumption on 849 kcal/kg I cli,nker., 1

i i The decrease in specific heat consumption at 5000 tpd clinker compared to,at 3750 tpd clinker is due to the relative reduction in kiln radiation losses a t the higher production.

The preheater exit gas is simulated to 2.471 kg gas/kg clinker with a density of 1.353 kg/Nm3 corresponding to 1.826 Nm3 (wet) gas/kg clinker with a moisture content of 0.11 kg HzO/kg dry gas.

The amount of dry preheater gas is calculated as 2.471/1.11 = 2.226 kg dry gaslkg clinker.

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The amount of moisture in the preheater exit gas is calculated to 2.471- 2.226=0.245 kg HzO/kg clinker or 0.306 Nm3/kg clinker and the volume of dry preheater gas is calculated to 1.826 - 0.306=1.520 Nm3 dry gas/kg clinker with 4.4% 0 2 , 28.0% CO2 and 67.6% N2.

T i e 1.520 Nm3/kg clinker (dry) preheater exit gas at 4.3% 0 2 is con- verted tp 10% 0 2 by 1.520*(1+ (10-4.4)/ (21-10)) = 2.294 Nm3/kg clinker dry gas @ 10%02.

The predicted preheater exit gad flow at 5000 tpd clinker is 5000/24ton/h*1000kg/ton*2.294 Nm3/kg clinker dry gas @ 10% 0 2 = 477878-Nm3/h dry gas @ 10% 0 2

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Corn Da r ison

,

I (dry) gas -@10%0~. - - " -

Nm3/h@lO%O; 362656 477878

*SHC is the specific heat consumption

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EPA Export 14-06-2017:03:18:13

Process design FLSrnidthNS . Vlgenlev All6 77 2500 Valby Denmark Tel +45 36181000 Fax +45 36301820 www.flsrnldth.com DK regmo. 15 02 88 82

Chem. Engr. (Ph.D, MSc) a

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EPA Export 14-06-2017:03:18:13

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EPA Export 14-06-2017:03:18:13

i ii Project number Increased PA and 30% moisture in RDF

Production: 3750 tpd Preheater: ILC, 5 stages Bypass (%): 10 0

Case 1

Kiln

30 0

Excess O2

Heat balance relative to 0 'C Firing

1 Heat inp8'$s$f$s{$$mct@ 0;;fO Glkgcl p) ~ ~ f v $ f @ ( k f i . Fuel tyae

+ Heat in bypass gas,+.dustb 3 +&&.3 Net-heatyalue [kcallkg) + Radiation loss frofklpreheater 164 39.1 Fuel moisture [%/.I t=r + Radiation loss from kiln 126 30.1 + Heat of reaction excl combustibles 1740 415 + Free water 19.5 4.67

+ Heat of clinker at ambient temperature 13.1 3.13 - Heat in raw meal, air and fuel 152 36.3

+ Cooler loss (VDZ) 350 83.7

- Combustibles in raw meal 32.8 7.85 = Net heat consumption 3600 860 ( O h ) kglh of fuel

Firing in Calciner K-string 2340 560 65.1 38400 1.350

Total firing 3600 860 Firing in kiln 1260 300 34.9 11100 1.200

Combustion aidgas Airlgas flow Temperature Rel. press. Density Clinker dust Primaly air includes transport air kglkgcl Nm'ls 'C Pa kglNm' kglkgcl Kiln inlet

Drimarv air 0.1 12 3.78 30 0 1.284 secondary'aiu 0'402 n13 59 On 0 1284 0020 n 3 14 lO#O

tertiary air 0 937 31 67 879 -1000 1 2&4 0 047 kiln gas 0 617 20 97 954 -300 1277

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EPA Export 14-06-2017:03:18:13

Project Platin Pyro process system Project number Operating .

09/05/2017 Edition Fuels '

70% Page 2 of 6 Ambient temperature 20 "C Relative humidity

~ m ' D T H ~ Date

Case 1'

Fuels as feeds

Free moisture I Ash C H S N 0 CO2 '

Density (gas only) [kglNm'] I Consumption [kglh] I

Production: 3750 tpd Preheater: ILC, 5 stages Bypass (%): 10.0

0 p(g l'a g 0 (3 k;pJ 1 k-j 3 0 0 . cr 30 0 28 1 7 7 25 8 42 8 3 5 . 5 8 0 2 0 2 0 4 0 3 15 0 15 0 0 0 0 0

38400 11 100

Fuels as fired Designation Combustion heat [kJlkg] r) Composition [kg / 100 kg we

Free moisture Ash

H S N 0

c ,

' CO2 , Density (gas only) [kg/Nm'l Consumption [kglh] I I -

Kiln Calciner K-string

17600

30.0 ' 7.7

42.8 5.8 0.2 0.3 15.0 0.0

30.0 28.1 25.8 ,-

3.5 0.2 0.4 15.0 0.0

11100 I 38400 " n n

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EPA Export 14-06-2017:03:18:13

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6'PZ Z'9 OZZ'O "P.ZL Z 9 Z ' i LSL'O - LEO'E SLL OS1 OE6L- OOP . , . . JaMO1 ~U!UO!I!PUO~ uo 6u!uo!i!puoz~ se9

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E'E l 9's POL'O LS'Z LLZ'L E8Z'O - 690'0 S'OL PS6 'OOE- - %o'o 1 :ssed& E'EL 9's POL'O L'EZ u z ' t E'ez.0 EX Li9.o S . P ~ P S ~ OOE- o ad!d Jas!a

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EPA Export 14-06-2017:03:18:13

I - I Project Platin I Pyro process system \ Operating Project number

Date 09/05/2017 Edition Mat flows and misc Ambient temperature 20 "C . Relative humidity 70% Page 4 of 6

m, DTH

Case 1 : Production: 3750 tpd Preheater: ILC, 5 stages Bypass ("A): 10.0

Total raw meal - Total raw mealcomposition [dry % w/w]- Heat of reaction'excl.comb. heat [kJIkgCl]

Moisture [wet % w/w] d 2.60 False air [kglkg] 0.0 Sulphur in pyrite 0.05

Silica module (MS) 2.50 Silicium dioxide SiOz 11.30

Heat of r e a i t a 2&'cl'cbkb\ 6G> $&$c@ Amount ( d ~ . h i a w ~ ; ; ; i e a l l f a ~ t ~ ~ ) : [ k ~ ~ ~ c l ] ~ \za

Lime saturation factor (LSF) [ O h ] 95.0 Organic carbon ' 0.11

Alumina module (MA) 1.60 Silica combined calcium oxide CaO 0.00

Raw meal streams Material flow (dry) Temperature LO1 Gas flow kglkgcl t/h "C Yo mYs t/h

Dust from K-stnng 0 0879 13 7 435 35 34 224 390 Feed to K-string 1 56 243 60 35 80 0 0

- Net raw meal consumption 147 229

Material flows (outlets), K-string Stage Flow (dry) Temperature LO1

Uh k g I k g c I 'C % 1 261 1670 430 35 3

Kiln loads

Burning zone residence time [min] Burning zone filling degree [%I

Burning zone load [MW/m2] 3 3 Burning zone load [Gcal/hlmz] 2 8 Volumetnc load [Udlm'] 3 8

9 8 25 8

1

K-string Calciner; Outlet gas velocity [mls] 8 3 (UP draft part) Residence time [SI 3 3 Kiln fans Case GC off GC on

Rotor speed [rpm] 1170 916 Expected power consumption 2848 2020

Downcomer Gas bypassing kiln fan [t/h] 0 0

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EPA Export 14-06-2017:03:18:13

Case 1 Production: 3750 tpd Preheater: ILC, 5 stages Bypass (%): 10 0

Kiln Kcalc.

164 30 0 + Radiation loss from kiln 126 30 1 + Heat of reaction excl combustibles 1740 415 Kiln loads + Free water 19 5 4 67 Burning zone load [MWlmz] 3 3 + Cooler loss (VDZ) 350 83 7 Burning zone load [Gcallhlmz] 2 8 + Heat of clinker at ambient temperature 13 1 3 13 Volumetric load [tpdlm'] 3 8 - Heat in raw meal air and fuel 152 36 3

32 8 7.85 I ' B E i i l l

- Combustibles in raw meal = Net heat consumption 3600 860 (Oh) kglh of fuel Excess O2 Primary air [kglkg A-min]

Firing in Calciner K-string 2340 560 65.1 38400 1350 OlOOi 111 Firing in kiln 1260 300 349 11100 1200 02501 I [

3600 860 (primary air includes tiadsport air) Total tiring 1 i l I

Gas flow point Type I Size Mat LO1 AP Re1 press Temperature Gas flow Velocity Density Dryp

Preheater K-stnng (outlet gas) % Pa Pa 'C Nm'lkgcl mls kglm' VOI Yo

' II Staae 1 HR+ 7200 35 3 1580 -7330 435 1.848 19 4 0 483 I 4.91 Stage 2 17 5 Stage 3

Stage 5 900 19 3

0 313 I 3,4, 11 1 Calciner 0 7 5 x h 27.6 - 600 -1600 905 1.724 8.3 Tertiary air duct 4 50 m2 - 1000 -1000 879 0 730 30 0 0 301 '2llO

; ' ill 1

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Riser pipe 3 89 m2 0 -300 954 0 483 24 3 0 283 5 6 Bypass 10 0 % 0 - 1 0 % -300 954 0 054 0 283 5 'd Kiln ROTAX-25 00 X 600 - 300 -300 954 0 537 6 3 1 0283 Cooler SF (Cross bar)

Secondarv air 0 897 0 313 897. n 0729 Total tertiary-air - n -

I 1 -

8 3 -

Calciner Outlet'gas velocity [mls] (up draft part) Residence time [SI 3 3 I /

____.---- GC on

Expected power consumption 2848 2020 1 j i Kiln fans Case GC off

Rotor speed [rpm] 1170 916

11 Downcomer Gas bypassing kiln fan [tlh] 0 0 Water injected [kgls] 12 90 None

Mat flow Feed to [kglkgcl] (dry) 1556 [ I Dust from [kglkgcl] (dry) 0 088 i I

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EPA Export 14-06-2017:03:18:13

Project Platin Pyro process system Operating Project number

Date 09/05/2017 Edition Summary Diagram Ambient temperature 20 "C Relative humidity 70% Page 6 of 6

,,, , DTH

Case 1

Equipment

Production: 3750 tpd Preheater: ILC. 5 stages Bypass (%): 10.0

Kiln ROTAX-2 5 00 x 60 0

Pre-heater E h gas "C Pa mYs

Stage 1 HR+ 7200 435 -7330 224

Stage 3 LP-CE-S 7500 785 -4610 31 1 Stage 4 LP-CE-S 7500 878 -3560 331

Stage 2 LP-CC-S 7200 643 -5750 278

Stage 5 LP-CE 7500 900 -2420 333

Material flow rates Uh Gross feed 243 Dust from pre-heater 13 7 Net feed 229 Production 156

Firing kJ/kgcl kcallkgcl Total Kiln

3600 860 1260 ' 300 . .

Calciner 2340 560 Kiln fan GCon GCoff

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EPA Export 14-06-2017:03:18:13

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' Project Enclosure 2 to Memo-9YPlatinlPros Pyro process system I I

Operating; Project number Increased PA and 30% Moisture 09/05/2017 Edition

Ambient temperature 20 "C Relative humidity

Heat balai$el l ' 1 70% Page 1 of 6 1 ,

Brn'''' Date

Case 1 Production: 5000 tpd Preheater: ILC, 5 Stages I Bypass ("A): 10.0 $1

L ! Heat balance relative to 0 "C Kiln Kcalc. I :

164 30 0 + Radiation loss from kiln 94 6 22 6 + Heat of reaction excl combustibles 1740 415 + Freewater 19 6 4 68

+ Heat of clinker at ambient temperature 13 1 3 13 I

- Heat in raw meal, air and fuel 151 36 1

+ Cooler loss (VDZ) 359 85 8 I

32 9 7 86 I t

I ' - Combustibles in raw meal = Net heat consumption 3550 849 (%) kglh of fuel Excess O2 Primary air [kglkg

Firing in Calciner K-string 2300 549 64.7 50200 1.350 Firing in kiln 1260 300 35 3 14900 1 200 0 2501

(primary air includes transr i

Total firing 3560 849

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EPA Export 14-06-2017:03:18:13

Platin I Pyro process system I

Ash C H S N

CO2 1

0 ,

Density (gas only) [kglNma] Consumption [kglh]

I IAmbient temperature 20 "C I Relative humidity

20 1 ' 7 7 25 8 42 0 3 5 5 0 0 2 0 2 0 4 0 3 15 0 15 0 0 0 0 0

50200 14900

Case 1

Mix on combustion heat basis Kiln Calciner K-stnng

Mix on mass basis [kg I 100 kt Kiln Calciner K-stnrg

F u e l u s e d [ I ( ~ l h / h J , / n \ I ~ / ~ ~ ~ ~ ~ ~ \ ~ \ ~ I Kiln ' U Calciner ,K-stnng

I

Production: 5000 tpd Preheater: ILC, 5 stages Bypass (%): 10.0

:kJ I 100 kJ mix] 0 0 100 0

100 0 0 0

mix] 0 0 100 0

l h w m h 3 m f i m ~ f i 1 ~ a r : 3 s + ; m f i f l qeh I

- ~ ~ / l u ~ ~ ~ - ~ l \LlfI I Iitul \'/ (ui 14 \ l J l \ b a l - U0 tj 14900

50200 0

Fuels as fired

Combustion heat [kJlkg] (') Designation

Composhon [kg I 100 kg wet] Free moisture Ash C H S N O [ CO2

Density (gas only) [kglNm'] Consumption [kglh]

Fuel mixes

Kiln PW

17600

30 0 7 7 .

42 0 50 0 2 0 3 15 0 0 0

14900

Calciner K-string I SRF

. 9550 '

30.0 20.1

. 25.0 3.5 0.2 0.4 15.0 0.0

50200

r) Combustion heyat'is'the l a e r !@tag value at 0 'C ExpeISIIed operating watlues .. . - - . ... . - .. ~ . .-

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EPA Export 14-06-2017:03:18:13

I

Project Platin Pyro process Sys Project number

Ambient temperature 20 "C Relative humidity

Operating', D

09/05/2017 Edition * Gas flo4s' 70% Page 3 of 6

mmlDTH Date

a~~ , ,

Case 1 . ) . Production: 5000 tpd Preheater: ILC, 5 stages , Bypass (%): 10.0

Flow Velocity Density Dust H20 Dry O2 Dry C,021?i WaforouUew),. . - ,Pa. ,?a, 'CJ mYs. .kg/kgcl. ,mls,kg/m.: ,kg/NrnL,' ffh, kglkgfl ,~ol,%~vol-%'f k( nP7 . , - AP Ret. P Temp. Gas. flow point . _

Stage 2 Stage 3 1930 -7010 781 419 2.380 24.2 0.329' 1.365 55.4 0.100 4.0 28.8. Stage 4 2050 -5090 877 443 2:356 25.6 0.308 1.365 69.2 0,101 3.8 29.2 ' C

1430 -3030 900 441 2.362 25.5 0.310 1.371 84.1 O I l O O 3.6 30.3

600 -1600 905 432 2.338 9.6 0.313. 1.372 336 0.101 3.3 30.7 t 'I Stage 5

$ Calciner Tertiary air duct 1000 -1000 885 177 0.916 30.0 0.300 1.284 9.54 0.010 21.0 0.0 I C

. : . I . . . . ... .

Riser pipe 0 , -300 988 129 0617 250 0276 1277 308 0 104 5 6 - -300 988 1 4 4 0069 - 0276 1277 342 0 104 5 6

Downcomer Gas bypassing kiln fan Gas conditioning on

Conditioning tower

Kiln fan damper Kiln fan

Gas conditioning off Conditioning tower Kiln fan damper Kiln fan

0 429 0 0;OOO ' : 0.526 0.000 0 Oil10 4.4 28.0 1 400 -12580 . 150 247 , 3:050. , - . 0.715 , , 1.265 16.5 0.212 6.5 24.4 f ' C

150 -12730 147 253 3.147 -- . 0.720, 1.266 16.5 Oj204' 7.1 23.4 ###### -200 163 234 3.197 - 0.791 1.266 ' i16.5 0.201 7.4 22.9

. . > - . - . . 'J

~ 9 . ' I ! i 7 1

400 -12580 395 328 2.734 ' - 0.482, 1.345 16.5 0.099 6.3 24.7 1 f 150 -12730 385 335 2,820 '- . 0.487, 1.343 16.5 0.096 6.9 23.8 C

MW## -200 407 308 2.865 - 0.538' 1.343 16.5 0.095 7.1 23.4 $

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I False air IS the kiln inlet seal false air ** False air at kiln hood

3' 3 air

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EPA Export 14-06-2017:03:18:13

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EPA Export 14-06-2017:03:18:13

Case 1 Production: 5000 tpd I ' I

Preheater: ILC, 5 stages Bypass (%): 10.0

Kiln

164 39 1 Fuel moisture [%] 30 0 30 0 + Radiation loss from kiln 94 6 22 6 + Heat of reaction excl combustibles 1740 415 Kiln loads + Free water 19 6 4 68 Burning zone load [MWlrnl] + Cooler loss (VDZ) 359 85 8 Burning zone load [Gcallhlm'] + Heat of clinker at ambient temperature 13 1 3 13 Volumetric load [tpdlm'] - Heat in raw meal, air and fuel 151 36 1

6

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- Combustibles in raw meal 32.9 7.86 = Net heat consumption 3550 849 (%) kglh of fuel Ekess O2 Primary air [kglkg A-min]

,! !

Firing in kiln 1260 300 35.3 . 14900 1.200 0.250 11 ; Firing in Calciner K-string 2300 549 64.7 50200 1.350 0.100 ';,

Total tiring 3560 849 .' (primary air includes transp6rl air) ;j j

Gas flow point Type I Size Mat. LO1 AP Rel. press. Temperature Gas flow Velocity .Density . DdqT (outlet gas) YO Pa Pa "C NmYkgcl mls kglm' VOllYO

Staae 1 HR+ 7200 35.3 2900 -11980 431 1.826 26.8 ' 0.463 4 1'4; .i )

Preheater K-string - . , , I

Stage 4 Stage 5 900 17.22

I

Y Calciner 0 8 0 x h 31 6 - 600 -1600 905 1704 9 6 0 313 3.3' Tertiary air duct 5 89 m2 - 1000 -1000 885 0 713 30 0 0 300 21t0 -

I t 1 14

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Riser pipe 5.19 m' 0 -300 988 0.483 25.0 0.276 5?6

Kiln

Bypass: 10.0 YO 0-10% -300 988 0.054 0.276 5!6 ROTAX-2 5.00 x 60.0 - 300 -300 988 0.537 8.7 0.276 5 3

Cooler SF (Cross bar) , r

Secondaw air 0 904 0.313 ' - 0.298 211.0 1 6 !

904. n 0713 Total tertiacy-air - n -

- 9 6 I Calciner Outlet-gas velocity [mls]

(up drafl part) Residence time [SI 3 3 I,

Expected power consumption 6653 4731 ti Downcomer Gas bypassing kiln fan [t/h] 0 0 I! 1

Water injected [kgls] 16 56 None L Mat flow Feed to [kglkgcl] (dry) 1558 I\ 1

Dust from [kglkgcl] (dry) 0 088 /I I

, '1 Kiln fans Case GC off GC on

Rotor speed [rpm] 1561 1227

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EPA Export 14-06-2017:03:18:13

Project Platin Pyro process system Operating Project number

Date 09/05/2017 Edition Summary Diagram Ambient temperature 20 "C Relative humidity 70% Page 6 of 6

,,, , DT

Case 1

Equipment

Production: 5000 tpd Preheater: ILC. 5 stages Bypass (%): 10.0

Kiln ROTAX-2 5 00 x 60 0

Pie-heater U

'C Pa m% Stage 1 HR+ 7200 431 -1 1980 309

Stage 3 LP-CE-S 7500 781 -701 0 419

Stage 5 LP-CE 7500 900 -3030 44 1

Stage 2 LP-CC-S 7200 638 -9080 377

Stage 4 LP-CE-S 7500 877 -5090 443

Material flow rates ffh Gross feed 325 Dust from me-healer 18.3 Net feed 306 Production

Firing kJlkgcl kcallkgcl Total 3560 849 Kiln 1260 300 Calciner 2300 549

Kiln fan GCon GCoff Ql Power [kWJ 4731 6653

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EPA Export 14-06-2017:03:18:13

.. . I

Dorota Richards

Subject: Attachments:

FW: Emailing: Kiln 3 gas flow increase-final Platin K3 Gas flow increase.pdf

-----Original Message----- - - - - From: Breen, Seamus1 _ _ _ - - _ _ Sent: 30 May 2017 17:38 To: Magnus Amajirionwu Subject: FW: Emailing: Kiln 3 gas flow increase-final

Hi Magnus !

Sorry for the delay in getting this document to you -

I can't submit on the BAT platform as with the previous Platin application as it is no longer available -

Any questions on the submission please come back to me -

Kind regards ;

Seamus.

Attention , This message and any attachments may contain propriety, confidential or trade secret information. It is intended solely for the use of the addressee. If you are not the intended recipient and have received this message in error, please notify the sender and delete this message from your system. Any unauthorised reading, distribution, copying or other use of this message or i ts attachments is strictly prohibited.

Website: http://www.irishcement.ie

This email has been scanned by the Symantec Email Security.cloud service. For more information please visit http://www.symanteccloud.com

1

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EPA Export 14-06-2017:03:18:13