Advancements in Meeting New Regulations With Activated Carbon: Results From Full-Scale Cement Plant Field Tests

Throughout 2011-2012, Norit (now part of Cabot Corporation) performed five full-scale field trials at cement plants within North America. Despite differences in kiln configuration, raw mix composition, activated carbon injection (ACI) location, flue gas temperature, and particulate control systems, results show that test activated carbons significantly reduced mercury emissions. The test programs discussed in this report were developed to assist cement plants in meeting pending regulations for mercury emissions in a cost-effective and reliable manner. Several new carbon sorbents were evaluated with either improved mercury removal performance, concrete compatible characteristics, or both. Depending on the plant locations, EPA Method 30B and/or mercury CEMS were used to determine the mercury removal across the particulate control system. All carbon sorbents tested in the United States reduced mercury emissions to less than 55-lb mercury per million tons of clinker for all cases, thus meeting the cement emissions regulations for existing kilns. Carbon sorbents tested outside of the United States targeted mercury reduction requirements as mandated by the applicable regulating body.