Overview
The U.S. Environmental Protection Agency (EPA) has finalized its National Emission Standards for Hazardous Air Pollutants (NESHAP) to regulate emissions from lime manufacturing plants. These standards specifically address hazardous air pollutants (HAPs) such as heavy metals particulate matter, mercury, and hydrochloric acid. By setting stringent limits on these emissions, the NESHAP mandates that lime manufacturing facilities adopt effective emission control systems, perform regular performance testing, and comply with rigorous monitoring and reporting requirements. This ensures that facilities operate in an environmentally responsible manner while minimizing their impact on air quality.
Why is it important to Lime Manufacturers?
Adhering to the NESHAP standards necessitates that non-compliant facilities develop and implement effective emission control strategies. These strategies must incorporate proven technologies to reduce pollutants and ensure compliance with regulatory requirements, while simultaneously not adversely affecting the production of lime products.
UCC NESHAP Solution
At UCC, we take pride in developing comprehensive emissions control solutions, meticulously designed to meet every aspect of the emissions regulations outlined by NESHAP. From controlling HCl to managing mercury emissions, each contaminant is addressed with precision to ensure compliance. Our commitment goes beyond regulatory adherence; it also reflects our dedication to providing proven, reliable solutions that minimize capital and operating costs for our customers.
Meeting the NESHAP Compliance Timeline
Navigating the compliance timeline outlined by the EPA’s NESHAP regulations requires experience and foresight. UCC understands that meeting these deadlines is crucial for regulatory adherence and avoiding potential operational penalties or disruptions. Our expertise in environmental engineering, dry sorbent injection (DSI) and regulatory compliance offer tailored solutions to ensure customers meet their obligations within the required timeframe. From conducting sophisticated predictive modeling and on-site trials to validate removal rates, sorbent consumption, and balance of plant effects, to optimizing operational practices, we work closely with our customers to develop customized strategies that streamline the compliance process. By partnering with us, customers can be confident that their compliance needs will be met promptly, allowing them to focus on their core business activities with peace of mind.
UCC Technical Solution
Ecopod™
Modular Dry Sorbent Injection System For Acid Gas Control in Lime Kilns
The ecopod is a compact, modular unit designed to provide cost-effective hydrated lime injection. Its stand-alone design can accommodate a legged silo or external hopper for sorbent storage. The ecopod incorporates both the sorbent metering and conveying equipment. A six-door configuration allows for easy and safe access to all equipment and instrumentation. Its small footprint allows for installation on existing slabs or platforms.
Benefits
• Compact design for smaller footprint and easy installation
• Pre-piped and pre-wired module eliminates need for most of the field installation, offering substantial construction savings.
*A typical ecopod installation versus a traditional Dry Sorbent Injection System installation can generate a savings of $250 – $300k.
Operational Savings
• Highest removal efficiency for short residence time
• UCC’s patented COBRA™ Lances are considered best-in-class for pollutant removal in short residence-time configurations like those typically found in hydrated lime kiln exhaust ductwork. Their innovative design reduces sorbent usage by up to 30% providing significant cost savings over the life of the system. For lime kilns in particular, this allows sites to consume less hydrated lime for control and allow them to sell more product.
• Design Flexibility
• Flexible system design can accommodate multiple feed trains to control multiple emission points, such as multiple kilns on one site, and/or allow redundancy, if required.
• In-house Computational Fluid Dynamic (CFD) modeling of plant duct flows to predict and enhance sorbent distribution in flue gas, thereby maximizing performance and minimizing sorbent usage.
• Variable operation to meet site-specific injection rates
* Based on typical lime kiln applications with an injection rate of 100 lbs/hr, the expected sorbent savings can range from 100,000 to 250,000 lbs/year per kiln.
Maintenance Savings
• Automated system is safer and less labor intensive than bulk bag unloaders, requiring less operational and maintenance support
• The standard ecopod system design allows for parts to be shared across the entire fleet, enhancing cost-efficiency, reducing inventory requirements and making it an economical solution.
*Traditional systems can require constant maintenance for three, eight-hour shifts per day, versus only occasional maintenance for an ecopod, providing a typical labor savings of 5,000 hours per year or more.
UCC REFERENCES
UCC’s expertise allows us to navigate the complexities involved and provide customers with practical strategies that ensure compliance, operational efficiency, and cost effectiveness. Our extensive DSI reference list includes over 125 full-scale on-site tests, 175 permanent installations, and over 65 retrofitted competitor systems. UCC’s DSI systems have the well-earned reputation of the most reliable systems in the industry.
Installation Savings
Operational Savings
Maintenance Savings
How can we help?
Our team of experts are happy to help answer any questions you have about UCC’s air solutions.
