Mass balance of dioxins over a cement kiln in China

Free radical formation via BDE-209 thermolysis in the precalciner of a cement kiln: Simulation and DFT study

To deeply understand the formation mechanism of polybrominated dibenzo-p-dioxins/furans (PBDD/Fs) in the thermal disposal process of polybrominated diphenyl ether (PBDE)-containing waste, this paper studied the formation pathways of key intermediates (free radicals, FRs) in the formation process of PBDD/Fs. BDE-209, the most common PBDE in the environment, was selected as the object of study to analyze FR formation by simulating the key conditions such as temperature (850 °C) and Fe-based materials when PBDE-containing waste entering cement kiln precalciner. Electron paramagnetic resonance (EPR) spectroscopy and density functional theory (DFT) calculations were used to study the reaction. The result of simulation experiments revealed carbon-centered radicals, and DMPO-OH analysis further confirmed the generation of FRs. The findings confirmed previous calculations predicting the existence of radical intermediates during the formation of PBDD/Fs from BDE-209. DFT calculations revealed the existence of an inner ortho-position CBr bond in BDE-209. The priority order of the bond breaking of BDE-209 was ether bond, inner ortho-position CBr bond, and outside ortho-position CBr bond. BDE-209 can further form three kinds of FRs, namely, oxygen-centered radicals of single benzene rings, carbon-centered radicals of single benzene rings, and carbon-centered radicals of double benzene rings. The specific processes of FR formation were inferred: high-temperature homogeneous cleavage of chemical bonds, electron transfer, and chemisorption, where electron transfer and chemisorption may be more important pathways. The proposed inner ortho-position cleavage within BDE-209 provides new insights into the degradation of PBDEs and the formation of PBDD/Fs; the results regarding BDE-209 generation radicals further elucidate the synthesis mechanism of dioxins, which is important for controlling dioxin generation and emission during the treatment and disposal of waste containing PBDEs.

A mechanistic and kinetic investigation on the oxidative thermal decomposition of decabromodiphenyl ether

The thermal processes of materials containing decabromodiphenyl ether (BDE-209) normally result in the exposure of BDE-209 to high-temperature environments, generating a series of hazardous compounds. However, the evolution mechanisms of BDE-209 during oxidative thermal processes remain unclear. Thus, this paper presents a detailed investigation on the oxidative thermal decomposition mechanism of BDE-209 by utilizing density functional theory methods at the M06/cc-pVDZ theoretical level. The results show that the barrierless fission of the ether linkage dominates the initial degradation of BDE-209 at all temperatures, with branching ratio over 80%. The decomposition of BDE-209 in oxidative thermal processes is mainly along BDE-209 → pentabromophenyl and pentabromophenoxy radicals → pentabromocyclopentadienyl radicals → brominated aliphatic products. Additionally, the study results on the formation mechanisms of several hazardous pollutants indicate that the ortho-phenyl-type radicals created by ortho-C-Br bond fission (branching ratio reached 15.1% at 1600 K) can easily be converted into octabrominated dibenzo-p-dioxin and furan, which require overcoming the energy barriers of 99.0 and 48.2 kJ/mol, respectively. The O/ortho-C coupling of two pentabromophenoxy radicals also acts as a non-negligible pathway for the formation of octabrominated dibenzo-p-dioxin. The synthesis of octabromonaphthalene involves the self-condensation of pentabromocyclopentadienyl radicals, followed by an intricately intramolecular evolution. Results presented in this study can enhance our understanding of the transformation mechanism of BDE-209 in thermal processes, and offer an insight into controlling the emissions of hazardous pollutants.

PCNs, PCBs, and PCDD/Fs in Soil around a Cement Kiln Co-Processing Municipal Wastes in Northwestern China: Levels, Distribution, and Potential Human Health Risks

To evaluate the impact of the first cement kiln co-processing municipal wastes in northwest China on the surrounding environment, the concentrations of polychlorinated naphthalenes (PCNs), polychlorinated biphenyls (PCBs), and polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) were determined in 17 soil samples collected around the plant. The concentration ranges of PCNs, PCBs, and PCDD/Fs were 132-1288, 10.8-59.5, and 2.50-5.95 pg/g, and the ranges of toxic equivalents (TEQ) were 1.98-20.8, 2.36-48.0, and 73.2-418 fg/g, respectively. The concentrations of PCNs, PCBs, and PCDD/Fs in this study were generally lower than those in soil around municipal waste incinerators and industrial parks in other areas. An exponential function equation was applied for the relationship between the concentration of the target compounds and the distance from the cement kiln stack, the results showed that PCN and PCB concentrations declined with the increasing of distance from the stack. Furthermore, it was found that the effect of the cement kiln on surrounding soil contaminations with PCNs and PCBs was stronger than that of PCDD/Fs by comparing the PCN, PCB, and PCDD/F homologue profiles in the fly ash sample from the plant and soil samples at different distances. The total carcinogenic risks (CR) of PCNs, PCBs, and PCDD/Fs for children and adults in soil were 1.65 × 10^-8-8.93 × 10^-8 and 1.70 × 10^-8-9.16 × 10^-8, respectively, which was less than the risk threshold (CR = 1 × 10^-6), and there was no health risk.

Dioxin emission and distribution from cement kiln co-processing of hazardous solid waste

Cement kiln collaborative disposal technology can not only dispose of hazardous waste but also provide energy for the cement industry. However, the addition of hazardous waste may promote the formation of dioxins in cement kilns. In this study, typical hazardous solid wastes, such as solidified fly ash, electroplating sludge, and industrial residue, were co-processed in a cement kiln with different feeding positions and different feeding amounts. The concentrations of dioxins in the flue gas, clinker, and precalciner furnace slag were investigated. The effect of adding mixed hazardous solid waste on the formation of dioxin was also studied. The results showed that the concentration of dioxin in the flue gas without added hazardous waste was 1.57 ng/m³, and the concentration varied from 1.03 to 6.49 ng/m³ after the addition of hazardous waste. In addition, the concentration of dioxin in the flue gas and solid samples increased substantially when the co-processing ratio doubled. The large amount of Cu in solidified fly ash promoted the formation of dioxins, while the higher S content in the electroplating sludge suppressed the formation of dioxins. Compared with the addition of single hazardous waste, the concentration of dioxin in precalciner furnace slag increases by about 300%. Furthermore, the distributions of isomers in the clinker and precalciner furnace slag were similar. 1,2,3,4,6,7,8-HpCDD and OCDD accounted for a large proportion of the mass concentration, and the contribution rate ranged from 48.7 to 82.0%. Most importantly, correlation analysis showed that the concentration of dioxin was closely related to the copper content, hazardous waste types and additive proportion, with correlation coefficients of 0.79, 0.83, and 0.89, respectively. This study provides a basis for exploring the high environmental benefits of disposing of hazardous solid waste by co-processing in cement kilns.

Disposal of hazardous industrial waste in cement kiln - A pilot study of acid tar sludge

Acid tar sludge (ATS) is a hazardous waste generated in steel plants as a process by-product. ATS disposal is a major challenge for the steel industry around the world and specifically for developing nations. Hazardous wastes are usually disposed of in a dedicated expensive thermal treatment plant as per existing rules. Due to inadequate capacity of treating the total amount of hazardous waste, study of other economical options are required. India generates over 7.2 million metric tonnes of hazardous waste annually as per Central Pollution Control Board (CPCB), Government of India. Thus, co-processing of ATS in cement plant as an alternative means of disposal was studied based on a number of trials. During the five trials of 5 day each, feed rate of ATS was maintained at 0.4 tonne per hour (TPH) with an average coal feed rate of 10 TPH. No incremental variations in emissions were observed during the trials. The analysis further revealed insignificant impact on clinker quality, leach behaviour and cement property. The study also showed negligible impact on ambient air quality based on NOx, SO₂, RSPM, SPM measurement at varying location around the cement plant. Thus, co-processing of hazardous waste such as ATS in cement plant can be an effective way to address the hazardous waste disposal problem in developing countries such as India.

Removal and transformation of unconventional air pollutants in flue gas in the cement kiln-end facilities

To understand the removal and transformation behaviors of unconventional air pollutants (polycyclic aromatic hydrocarbons, heavy metals and carbonyl compounds) in the flue gas in cement kiln-end facilities, including SP boiler, a slide stream SCR-DeNO_x system, raw mill and baghouse filter, the gas and particle matter samples at the inlets and outlets of each kiln-end installation were collected and the contents of the unconventional air pollutants were measured. The results showed that the concentrations of the polycyclic aromatic hydrocarbons (PAHs) in particulate and gas-phase, heavy metals in the particulate matter were 17.5 μg m^-3, 48.7 μg m^-3 and 3113.1 μg m^-3 at the inlet of the SP boiler, and decreased to 0.6 μg m^-3, 17.7 μg m^-3 and 39.7 μg m^-3, respectively, while the concentrations of carbonyl compounds in gas-phase increased from 1988.5 μg m^-3 to 2844.5 μg m^-3 after flue gas successively passed through the kiln-end facilities. The cooling of flue gas and the precipitation of coarse particulate matter in the SP boiler resulted in a significant decrease of PAHs concentration in both gas-phase and particulate-phase, as well as the heavy metal concentration in the particulate-phase, while the SP boiler hardly had any influence on the removal and transformation of carbonyl compounds. Grinding and heat exchange in the raw mill accelerated the volatilization of compounds with the low boiling point in the raw meal, which increased concentrations of gas-phase PAHs and carbonyl compounds. When flue gas passed through the baghouse filter, almost all particulate-phase PAHs, heavy metals and most of the gas-phase PAHs, were removed while the carbonyl compounds concentration maintained unchanged. Furthermore, some portion of gas-phase PAHs and carbonyl compounds were removed by the SCR-DeNO_x system.

Modeling the air pollutant concentration near a cement plant co-processing wastes

In this study, for the first time, we conducted full life-cycle studies on pollutants in a cement plant co-processing hazardous waste (HW) via the combined use of thermodynamic equilibrium calculations and the American Meteorological Society/Environmental Protection Regulatory Model. Results showed that the potential toxic elements (PTEs) can be classified into three categories: (1) non-volatized elements, Co; (2) semi-volatized elements, Cr and Ni; and (3) volatized elements, Cd, Pb and As. Besides, the spatial distributions of pollutants were strongly influenced by the prevalent wind direction and the size of the particulate matter they were absorbed on. The highest concentrations of most pollutants tended to be centralized at a distance in the range of 400 to 800 m away from the cement plant. Finally, validated results indicated that there is good agreement between the simulated and observed concentrations in this study. These findings can facilitate and assist local government authorities and policy makers with the management of urban air quality.

Emission and migration of PCDD/Fs and major air pollutants from co-processing of sewage sludge in brick kiln

The annual output of sewage in China is increasing rapidly and continues to grow, so there is an urgent need for a treatment other than landfills. Among various treatment methods, brick production coprocessing of sewage sludge is technically and economically advantageous. The emission characteristics of typical brick kiln coprocessing of sewage sludge with an annual production of 60 million bricks were studied. The major air pollutants and PCDD/Fs in gas and soil were determined. Particulate matter and SO₂ contributed most before treatment, with concentrations of (1.017 ± 0.089) × 10⁴ mg/Nm³ and (2.770 ± 0.251) × 10³ mg/Nm³, respectively. After cleaning, the average emitted concentrations of major air pollutants were permissive and homogeneous: 58.13 ± 5.51 mg/Nm³ for NO_x, 30.15 ± 9.12 mg/Nm³ for HCl, 28.63 ± 14.33 mg/Nm³ for SO₂, 23.76 ± 3.31 mg/Nm³ for particulate matter, and 356.8 ± 99.1 for odor. The PCDD/Fs in the exhaust gas and ambient air showed similar distributions and fingerprint characteristics. The annual emission amounts of the PCDD/Fs were 0.265 g/year and 0.0393 g TEQ/year. Moreover, correlation analysis indicated that PCDD/Fs were most relevant to HCl, and particulate matter might be important to SO₂ and fluoride. Further relativity studies showed that the brick kiln was a source of PCDD/Fs but not a main source of major air pollutants to the surrounding environment. All the above pollutants from the brick kiln were permissive with relevant national standards. The results could help with pollution inventories for the brick and tile industry and sewage sludge disposal process.

Ca2+ mediated mechanism of octa-brominated dioxin/furan formation via BDE-209 thermolysis: Introducing the Mayer bond order difference

Polybrominated dibenzo-p-dioxins/dibenzofurans (PBDD/Fs) that form during industrial thermal processes, such as the cement kiln co-processing of BDE-209, are highly toxic contaminants. Nevertheless, the formation mechanisms of octa-brominated dioxins/furans (OBDD/Fs), most PBDD/F congeners, and one precursor of the more toxic lower PBDD/Fs from BDE-209 have received little attention. In cement kiln co-processes, the Ca²⁺-mediated regulation of OBDD/F formation is still debated. In this study, simulation experiments revealed that the average brominating degree of PBDD/Fs was 7.8, indicating that OBDD/Fs are dominant congeners (93.6 % median). Density functional theory (DFT) calculations found a new transition state (TS1) with a lower energy barrier than that found in a previous study. Three major OBDD/F formation reactions suggested that the presence of Ca²⁺ was thermodynamically beneficial to the formation of OBDD/Fs. This promotion effect can be attributed to the transfer of electron density leading to a change in the Mayer bond order (MBO) among elements when Ca²⁺ was bound. Intriguingly, in the transition state structures of the Ca²⁺-bound and Ca²⁺-free systems, the MBO difference among the old and new bonds can reveal the difficulty of Ca²⁺-mediated OBDD/F formation reactions from BDE-209.

Variations of PCDD/Fs emissions from secondary nonferrous smelting plants and towards to their source emission reduction

Polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) are cancerogenic organic pollutants that priority controlled by Stockholm Convention with globally 183 signatories now. Secondary nonferrous smelting plants are confirmed to be important sources in China due to its large industrial activities and high emissions of PCDD/Fs. It is important to prioritize source to achieve source emission reduction by conducting field monitoring on typical case plants. Here, the emission profiles and levels of PCDD/Fs were investigated in 25 stack gas samples collected from three secondary copper production (SeCu), two secondary zinc production (SeZn) and two secondary lead production (SePb). Both average mass concentration and toxic equivalency quantity (TEQ) concentrations of PCDD/Fs all generally decreased in the order: SeCu > SeZn > SePb. It is noteworthy that the mean TEQ concentration in stack gas from SeCu with oxygen-enrich melting furnace technology, at 2.7 ng I-TEQ/Nm³, was much higher than the concentrations of other smelting processes. The average emission factors and annual release amounts of PCDD/Fs from SeCu, SePb and SeZn investigated were 28.4, 1.5, 10.4 μg I-TEQ/t and 1.03, 0.023, 0.17 g I-TEQ/year, respectively. The ratios of 2,3,7,8-TCDF to 1,2,3,7,8-PeCDF and OCDD to 1,2,3,7,8,9-HxCDD varied to large extent for three metal smelting, which could be used as diagnostic ratios of tracing specific PCDD/Fs sources. Addition of copper-containing sludge into the raw materials might lead to higher PCDD/Fs emissions. It is important to emphasize and reduce the PCDD/Fs emissions from oxygen-enrich melting furnace from secondary copper productions.

Spatial and temporal variation, source profile of PCDD/Fs in the atmosphere of a municipal waste incinerator in China

The mass concentrations, toxic equivalent quantity (TEQ) concentrations and congener profiles of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) in the stack flue gas and ambient air of municipal solid waste incinerator (MSWI) were monitored in this study to evaluate the levels, emission characteristics, seasonal variation and emission sources of PCDD/Fs. Thirty-one ambient air samples were collected from four sites around MSWI during 2016-2017, and twelve stack flue gas samples were collected from one MSWI. Results showed that the PCDD/Fs concentrations of the stack flue gas ranged from 0.0077 to 0.021 ng I-TEQ/Nm³, with an average value of 0.016 ng I-TEQ/Nm³. The ambient air samples collected in 2016 and 2017 ranged from 0.017 to 0.27, and 0.035-0.27 pg I-TEQ/Nm³, with an average value of 0.078 and 0.10 pg I-TEQ/Nm³, respectively. The 2, 3, 4, 7, 8-PCDF always contributes most to toxicity both in stack flue gas and ambient air samples. PCDD/Fs in the ambient air of the study area showed significant seasonal differences, and the total concentration of PCDD/Fs was highest in winter, which was about 3.5-7.5 times that of summer. Principal component analysis (PCA) and hierarchical cluster analysis (HCA) were used to determine the correlation between MSWI emissions and PCDD/Fs in ambient air. It is worth mentioning that MSWI is not the main source of PCDD/Fs in ambient air.

Unintentional persistent organic pollutants in cement kilns co-processing solid wastes

Co-processing solid waste in cement kilns has become increasingly widespread in recent years. Persistent organic pollutants (POPs) can be unintentionally produced and emitted from cement kilns, especially kilns in which solid waste is co-processed. Unintentionally produced POP formation and emission by cement kilns co-processing solid waste therefore need to be studied in detail to allow the potential risks posed by cement kiln co-processing techniques to be assessed. Many field studies and laboratory simulation experiments have been performed to investigate the formation and release of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs). However, the formations, characteristics and emission factors of various emerging unintentionally produced POPs have not been comprehensively reviewed. Here, emissions of well-known unintentionally produced POPs (PCDD/Fs and polychlorinated biphenyls) and emerging unintentionally produced dioxin-like POPs (polybrominated dibenzo-p-dioxins and dibenzofurans, polychlorinated naphthalenes, and chlorinated and brominated polycyclic aromatic hydrocarbons) in cement kilns co-processing solid waste are reviewed, focusing on formations and influencing factors of those unintentional POPs. Data from field studies indicated that the main stages in which POPs are unintentionally produced in cement kilns co-processing solid waste are the cyclone preheater outlet, suspension preheater boiler, humidifier tower, and back-end bag filter. The raw material composition, chlorine and bromine contents, and temperature are the most important factors affecting POP formation. The homolog distributions and congener profiles of POPs formed unintentionally in cement kilns were compared, and it was found that larger amounts of less-chlorinated homologs than more-chlorinated homologs are emitted. Emission factors for various unintentionally produced POPs for cement kilns co-processing solid waste were summarized, and could be useful for compiling global emission inventories for pollutants covered by the Stockholm Convention. This comprehensive review improves our understanding of unintentional production and emissions of POPs by cement kilns co-processing solid waste.

Characterization of PCDD/Fs and dioxin-like PCBs in flue gas from thermal industrial processes in Vietnam: A comprehensive investigation on emission profiles and levels

The emission profiles and levels of unintentionally produced persistent organic pollutants (U-POPs) comprising polychlorinated dibenzo-p-dioxins/furans (PCDD/Fs) and dioxin-like polychlorinated biphenyls (dl-PCBs) were comprehensively investigated in flue gas released from 20 facilities belonging to 11 thermal industrial processes in Vietnam. Levels and patterns of PCDD/Fs and dl-PCBs in flue gas samples varied widely between sectors and different facilities in the same sector, suggesting different formation mechanisms involved. Flue gas concentrations of PCDD/Fs and dl-PCBs generally decreased in the order: industrial waste incinerator > secondary zinc production > coal fired craft boiler > coal fired power plant ≈ medical waste incinerator > steel production ≈ cement production > secondary copper production > coal fired industrial boiler > secondary tin production ≈ municipal waste incinerator. Results obtained from diagnostic ratio and fingerprint analysis have revealed that the stack emissions of PCDD/Fs and dl-PCBs were probably attributed to the de novo formation and incomplete destruction of input materials containing technical PCB oils or paints. The average emission factors of PCDD/Fs and dl-PCBs ranged from 0.011 to 374 μg WHO-TEQ tonne^-1 for the studied facilities. A total emission amount of 4.89-11.4 g WHO-TEQ year^-1 was estimated for the 20 facilities investigated in our study. This is the first comprehensive investigation on the unintentional emissions of PCDD/Fs and dl-PCBs from a wide range of industrial sectors in Vietnam.

PAHs and heavy metals in the surrounding soil of a cement plant Co-Processing hazardous waste

The Chinese government is encouraging domestic cement producers to move from traditional coal power sources to the co-processing of waste as the primary energy source for the industry. In this study, 32 samples collected from the soil surrounding a cement plant in Beijing were analyzed for the presence of 16 U.S. EPA priority polycyclic aromatic hydrocarbons (PAHs) and 12 heavy metals. Ten samples were selected for polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans (PCDD/Fs) analysis. The pollution distribution patterns, sources, and potential risks to human health and the environment were investigated and evaluated. The highest concentrations of PCDD/Fs occurred 1200 m downwind from the cement plant. The levels of ∑16 PAHs ranged from 130.6 to 1134.3 μg kg^-1 in the sampled soils. Source identification analysis suggested that the cement plant was the most likely source of PAH contamination. The concentrations of most of the heavy metals detected in the sampled soils were close to background levels, except for the levels of cadmium (Cd) and mercury (Hg), which were, on average, two times and six times higher than background values, respectively. The co-incineration of sludge, coal, and hazardous waste in the cement plant is a major contributing cause for the high levels of Hg in the surrounding soil. Risk assessment models, both the incremental lifetime cancer risks (ILCRs) for PAHs and the potential ecological risk index (RI) for heavy metals, indicate potential risks to the population and the environment surrounding the cement plant.

Spatial variation of PCDD/F and PCB emissions and their composition profiles in stack flue gas from the typical cement plants in China

Cement production processes are important sources of unintentionally produced persistent organic pollutants (UP-POPs), such as polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs), and polychlorinated biphenyls (PCBs). The emissions of PCDD/Fs and PCBs in the stack flue gases from eight typical cement plants in China were investigated in this study, including one wet process rotary kiln, three dry process rotary kilns and four vertical shaft kilns. PCBs exhibited relatively higher mass concentrations with the dioxin-like (dl) and indicator PCBs of 0.14-17.36 and 0.42-12.90 ng/Nm³, respectively. However, PCDD/Fs contributed most to the total toxic equivalent concentrations, with the proportions exceeding 90%. The international toxicity equivalency (I-TEQ) concentrations of PCDD/Fs varied greatly from 0.01 to 0.46 ng I-TEQ/Nm³ in stack gases, two of which exceeded the exhaust gas concentration limit of 0.1 ng I-TEQ/Nm³ established by the European Union Directive. In weight units, 1,2,3,4,6,7,8-HpCDF was the most abundant congener in the stack gases from various types of cement kilns, with the factions of 17.0-27.8%. TCDFs and PeCDFs were the first two most abundant homologue groups. 2,3,4,7,8-PeCDF was the largest contributor to the total I-TEQ. The emission factors of PCDD/Fs and PCBs in the eight cement kilns were estimated to be 0.01-1.35 μg I-TEQ/t clinker and 8.20 × 10^-4∼8.23 × 10^-2 μg World Health Organization TEQ (W-TEQ)/t clinker, respectively. No obvious differences of the PCDD/F and PCB emission factors were found among the varied cement production technologies.

Thermal reaction characteristics of dioxins on cement kiln dust

Cement kiln dust is commonly recycled back into the production process. This results in elevated concentrations of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) in the flue gases of cement plants. The present study investigated the effects the reaction temperature, oxygen content, and origin of kiln dust had on the thermal reaction characteristics of PCDD/Fs. The concentration of 2,3,7,8-PCDD/Fs that were desorbed from the kiln dust decreased as the reaction temperature was increased and the higher temperature facilitated the degradation of PCDD/Fs. However, the oxygen content, which ranged from 6–21%, had only a minor impact on the thermal reaction characteristics of PCDD/Fs. Finally, the thermal reaction characteristics of PCDD/Fs were largely affected by the origin of the kiln dust; 1.2 pg I-TEQ g⁻¹ was desorbed from kiln dust originating from a cement plant that co-processed refuse-derived fuel (RDF) and 47.5 pg I-TEQ g⁻¹ was desorbed from kiln dust originating from a cement plant that co-processed hazardous waste. The study also found that PCDD/F formation pathways were dependent on the origin of the kiln dust; precursor synthesis dominated PCDD/F formation on the kiln dust collected from a cement plant that co-processed RDF, while de novo synthesis dominated the formation of PCDD/Fs on the remaining samples of kiln dust.

Cement kiln dust is commonly recycled back into the production process.

Evaluation of dioxins and dioxin-like compounds from a cement plant using carbide slag from chlor-alkali industry as the major raw material

Carbide slag produced from chlor-alkali industry contains high amounts of calcium compounds and can potentially be used as raw material for cement production; however, it contains large amounts of chlorine so it is essential to evaluate the emissions of chlorinated organic pollutants, including polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs), polychlorinated biphenyls (PCBs), and polychlorinated naphthalenes (PCNs). A field study of the emission profiles of these pollutants in a cement plant using such slag was performed. The average concentrations of PCDD/Fs, PCBs, and PCNs in stack gases collected at the kiln back end were 6.31, 1.07, and 31.89pg TEQ m^-3, respectively. PCDFs dominated over PCDDs in particulate samples. Di- to pentachlorinated biphenyls were dominant homologs in the particulate samples. MonoCBs were the dominant homolog in stack gases from the kiln back end, and homolog concentrations decreased with increasing chlorine numbers. Mono- and diCNs accounted for 48-98% of PCNs. The estimated toxic equivalents of stack gas emissions of PCNs, classified as new persistent organic pollutants under Stockholm Convention, were unexpectedly higher than those of PCDD/Fs and PCBs. A mass balance indicated that all of the toxic equivalents were reduced by this cement kiln system. The highest 2,3,7,8-PCDD/F output is with clinker.

Emissions of PCDD/Fs, PBDD/Fs, dioxin like-PCBs and PAHs from a cement plant using a long-term monitoring system

The aim of the present work was to assess the emission of different persistent organic pollutants from a cement plant over a period of one year, under normal operational conditions. Thus, a long-term sampling device was installed in the clinker kiln stack of the cement plant. The factory uses petroleum coke as primary fuel, but also alternative fuels such as solid recovered fuel (SRF), automotive shredder residue (ASR), sewage sludge, waste tires, and meat and bone meal (MBM) wastes, with an energy substitution level of about 40%. Both PCDD/Fs (together with dl-PCBs) and PBDD/Fs were continuously sampled, with a total of ten samples collected in 2-4week periods. Also, PAHs were sampled during one-week periods, in order to evaluate their emissions in three different samples. The emission levels throughout the year were much lower than the set legal limits in all substances, being <10pgI-TEQ/Nm(3) in the case of PCDD/Fs. The data obtained allowed calculation of updated emission factors for the cement sector, which were 8.5ng I-TEQ/ton clinker for PCDD/Fs and 3.2ng WHO-TEQ/ton clinker for PCBs. With respect to the congener distribution, 2,3,7,8-TCDF accounts for 60 to 68% of the total toxicity for PCDD/Fs, and in PBDD/F emissions, a clear predominance of octa-substituted species (both dioxin and furan) was found.

Recycling ash into the first stage of cyclone pre-heater of cement kiln

Fly ash collected from the bag filter could be recycled into the first stage of the cyclone pre-heater of the cement kiln, resulting in the possible enrichment of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs). In this study, soxhlet fly ash (SFA) and raw meal (RM) were selected as the basis for the PCDD/F formation experiments. The levels of 2,3,7,8-PCDD/Fs formed on the SFA and RM were observed to be 2550pg/g (157pg I-TEQ/g) and 1142pg/g (55pg I-TEQ/g), respectively. While less 2,3,7,8-PCDD/Fs was detected when SFA was mixed with RM, suggesting that recycling cement kiln ash would not largely increase the concentration of PCDD/Fs in flue gas. Furthermore, the possible influencing factors on the PCDD/F formation were also investigated. The formation of 2,3,7,8-PCDD/Fs was up to 10,871pg/g (380pg I-TEQ/g) with the adding of CuCl2, which was much higher than the results of CuO and activated carbon. Most importantly, the homologue, congener and gas/particle distribution of PCDD/Fs indicated that de novo synthesis was the dominant PCDD/F formation pathway for SFA. Lastly, principal component analysis (PCA) was also conducted to identify the relationship between the compositions of reactant and the properties of PCDD/Fs produced.

Effects of bypass system on PCDD/F emission and chlorine circulation in cement kilns

A bypass at the kiln inlet allows the effective reduction of alkali chloride cycles and thus perhaps affects the emission of PCDD/Fs. Effects of bypass system on PCDD/F emission and chlorine circulation were studied in two typical dry cement kilns with 5000 ton/day clinker capacity in China and named CK1 and CK2, respectively. Firstly, the emission level of PCDD/Fs with the operation of bypass system was estimated in CK1, to certify that bypass system has a perfect adaption to the cement kiln regarding the PCDD/F emission even with the refuse derived fuel (RDF) as the replacement of fuel. On the other hand, the operating conditions in the CK2 were scrutinised by monitoring the concentrations of SO2, NH3 and HCl. In addition, the characteristics of raw meal, clinker, bag filter ash and bypass ash were also investigated by Energy Dispersive Spectrometer (EDS), metal and chlorine analysis. The balance of chlorine showed that 18 % of the possible accumulated chlorine could be ejected from the cement kiln system when 2 % of kiln exhaust gas was extracted. Furthermore, the emission level of PCDD/Fs in the main flue gas also decreased from 0.037 ± 0.035 ng I-TEQ/Nm(3) to 0.019 ± 0.007 ng I-TEQ/Nm(3) with a reduction efficiency of 48.2 %. Most importantly, PCDD/F emission from the bypass system was proven to have rather minor effect on the total emission factor. The congener distributions of PCDD/Fs were also analysed in the flue gas and fly ash, before and after application of bypass system, to find cues to the formation mechanism.

Variations and factors that influence the formation of polychlorinated naphthalenes in cement kilns co-processing solid waste

Pilot studies of unintentionally produced pollutants should be performed before waste being co-processed in cement kilns. Polychlorinated naphthalene (PCN) formation and emission from cement kilns co-processing sorted municipal solid waste, sewage sludge, and waste acid, however, have not previously been studied. Here, PCNs were analyzed in stack gas samples and solid samples from different stages of three cement production runs. PCN destruction efficiencies were higher when waste was co-processed (93.1% and 88.7% in two tests) than when waste was not co-processed (39.1%), so co-processing waste would not increase PCN outputs. The PCN concentrations were higher in particle samples from the C1 preheater and stages at back end of kiln than in particle samples from other stages, suggesting that cyclone preheater and back end of kiln should be focused for controlling PCN emissions. Besides that, based on the variation of PCN concentrations and corresponding operating conditions in different stages, the temperature, feeding materials, and chlorine content were suggested as the main factors influencing PCN formation. The PCN homologue and congener profiles suggested chlorination and dechlorination were the main PCN formation and decomposition pathways, and congeners CN-23, CN-46, and CN-59 appear to be appropriate indicators of PCNs emitted from coal-burning sources.

Emission and distribution of PCDD/Fs and CBzs from two co-processing RDF cement plants in China

An analysis of the emission and distribution characteristics of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) and chlorobenzenes (CBzs) from two cement kilns (CK1 and CK2) is done. Six measurements in CK1 showed an increase of PCDD/F emission from 76 to 97 pg I-TEQ/Nm(3) after feeding 10 ton/h RDF (refuse derived fuel). For CK2, the effect of increasing the RDF substitution rates from 0 to 21 t/h on the emission of PCDD/Fs was investigated. The correlation analysis indicated that replacing parts of the conventional fuel with RDF could not increase the emission of PCDD/Fs. Furthermore, the gas/particle partitions of PCDD/Fs and CBzs in stack gas were investigated, indicating that PCDD/Fs and CBzs were more associated in gas phase, especially for the lower chlorinated ones. Moreover, the bag filter fly ash was characterized by its particle distribution, XRD- and EDS-analysis. Additionally, the level of PCDD/Fs in outflowing fly ash escalates for smaller particle size. In order to evaluate the environmental effect on inhabitants, the levels of PCDD/Fs were also determined in samples of ambient air collected in the vicinity of CK2 (~200 m).

Field pilot study on emissions, formations and distributions of PCDD/Fs from cement kiln co-processing fly ash from municipal solid waste incinerations

A pilot study was performed to evaluate formation, distribution and emission of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) from cement kilns that co-process fly ash from municipal solid waste incineration (MSWI). Stack gas and particulate samples from multiple stages in the process were collected and analyzed for PCDD/Fs. Stack emissions of PCDD/Fs were below the European Union limit for cement kilns (0.1 ng TEQ m(-3)). PCDD/F concentrations in particulates from the cyclone preheater outlet, suspension preheater boiler, humidifier tower, and back-end bag filter were much higher than in other samples, which suggests that these areas are the major sites of PCDD/F formation. Comparison of PCDD/F homolog and congener profiles from different stages suggested that tetra- and penta-chlorinated furans were mainly formed during cement kiln co-processing of MSWI fly ash. Three lower chlorinated furan congeners, including 2,3,7,8-tetrachlorodibenzofuran, 1,2,3,7,8-pentachlorodibenzo-p-dioxin and 2,3,4,7,8-pentachlorodibenzofuran, were identified as dominant contributors to the toxic equivalents (TEQ) of the PCDD/Fs. The concentration of PCDD/Fs in particulates was correlated with chloride content, which is consistent with its positive effect on PCDD/F formation. This could be mitigated by pretreating the feedstock to remove chloride and metals. Mass balance indicated that cement kilns eliminated about 94% of the PCDD/F TEQ input from the feedstock.

Review of the current state and main sources of dioxins around the world

Polychlorinated dibenzo-p-dioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs) are a group of dangerous compounds, emitted mostly from anthropogenic sources, that have negative effects on human health. Therefore, it is interesting to analyze the emission patterns of dioxins proceeding from different sources around the world, to observe the actual trend of the transmission of dioxins and furans into the atmosphere.For that reason, the main objective of the present document is to provide a general assessment about the dioxin problematic, analyzing the main parameters that influence the ambient concentration of dioxins worldwide, and describing the most characteristic features of the fingerprint from different sources, while making emphasis in the importance that non-industrial sources are gaining over the last years in front of the decreasing tendency of industrial sources. The description of the most important abatement technologies for dioxins is also included in this review.

IMPLICATIONS

Given the negative effects of dioxins in human health, it is important to depict and locate the main sources of these dangerous compounds. Emissions proceeding from industrial facilities have decreased over the last years; however, other zones where nonindustrial sources used to be relevant contributors do not show the same decreasing tendency because it is more difficult to control this type of emissions. For that reason, future studies should focus on measuring and regulating this highly uncontrolled source of dioxins.