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An assessment of gas-side fouling in cement plants

The cement industry is the most energy-intensive industry in the United States in terms of energy cost as a percentage of the total product cost. An assessment of gas-side fouling in cement plants with special emphasis on heat recovery applications is provided. In the present context, fouling is defined as the buildup of scale on a heat-transfer surface which retards the transfer of heat and includes the related problems of erosion and corrosion. Exhaust gases in the cement industry which are suitable for heat recovery range in temperature from about 100 to 1300 K, are generally dusty, may be highly abrasive, and are often heavily laden with alkalies, sulfates, and chlorides. Particulates in the exhaust streams range in size from molecular to about 100 micrometers in diameter and come from both the raw feed as well as the ash in the coal which is the primary fuel used in the cement industry. The major types of heat-transfer equipment used in the cement industry include preheaters, gas-to-air heat exchangers, waste heat boilers, and clinker coolers. At the present time, the trend in this country is toward suspension preheater systems, in which the raw feed is heated by direct contact with the hot kiln exit gases, and away from waste heat boilers as the principal method of heat recovery. The most important gas-side fouling mechanisms in the cement industry are those due to particulate, chemical reaction, and corrosion fouling.

Marner, W. J.

Applications of thermal energy storage in the cement industry

In the manufacture of cement, literally trillions of Btu's are rejected to the environment each year. The purpose of this feasibility study program was to determine whether thermal energy storage could be used to conserve or allow alternative uses of this rejected energy. This study identifies and quantifies the sources of rejected energy in the cement manufacturing process, established use of this energy, investigates various storage system concepts, and selects energy conservation systems for further study. Thermal performance and economic analyses are performed on candidate storage systems for four typical cement plants representing various methods of manufacturing cement. Through the use of thermal energy storage in conjunction with waste heat electric power generation units, an estimated 2.4 x 10 to the 13th power Btu/year, or an equivalent on investment of the proposed systems are an incentive for further development.

Jaeger, F. A.

Detection of particulate air pollution plumes from major point sources using ERTS-1 imagery

The Earth Resources Technology Satellite (ERTS-1) launched by NASA in July 1972 has been providing thousands of high resolution multispectral images of interest to geographers, cartographers, hydrologists, and agroculturists. It has been found possible to detect the long-range (over 50 km) transport of suspected particulate plumes from the Chicago-Gary steel mill complex over Lake Michigan. The observed plumes are readily related to known steel mills, a cement plant, refineries, and fossil-fuel power plants. This has important ramifications when discussing the interregional transport of atmospheric pollutants. Analysis reveals that the Multispectral Scanner Band 5 (0.6 to 0.7 micrometer) provides the best overall contrast between the smoke and the underlying water surface.

Lyons, W. A.

Thermal energy storage systems using fluidized bed heat exchangers

The viability of using fluidized bed heat exchangers (FBHX) for thermal energy storage (TES) in applications with potential for waste heat recovery was investigated. Of the candidate applications screened, cement plant rotary kilns and steel plant electric arc furnaces were identified, via the chosen selection criteria, as having the best potential for successful use of FBHX/TES system. A computer model of the FBHX/TES systems was developed and the technical feasibility of the two selected applications was verified. Economic and tradeoff evaluations in progress for final optimization of the systems and selection of the most promising system for further concept validation are described.

Ramanathan, V.

Valve For Extracting Samples From A Process Stream

Valve for extracting samples from process stream includes cylindrical body bolted to pipe that contains stream. Opening in valve body matched and sealed against opening in pipe. Used to sample process streams in variety of facilities, including cement plants, plants that manufacture and reprocess plastics, oil refineries, and pipelines.

Callahan, Dave

Analyzing Carbon Dioxide and Methane Emissions in California Using Airborne Measurements and Model Simulations

Greenhouse gas (GHG) concentrations have increased over the past decades and are linked to global temperature increases and climate change. These changes in climate have been suggested to have varying effects, and uncertain consequences, on agriculture, water supply, weather, sea-level rise, the economy, and energy. To counteract the trend of increasing atmospheric concentrations of GHGs, the state of California has passed the California Global Warming Act of 2006 (AB-32). This requires that by the year 2020, GHG (e.g., carbon dioxide (CO2) and methane (CH4)) emissions will be reduced to 1990 levels. To quantify GHG fluxes, emission inventories are routinely compiled for the State of California (e.g., CH4 emissions from the California Greenhouse Gas Emissions Measurement (CALGEM) Project). The major sources of CO2 and CH4 in the state of California are: transportation, electricity production, oil and gas extraction, cement plants, agriculture, landfills/waste, livestock, and wetlands. However, uncertainties remain in these emission inventories because many factors contributing to these processes are poorly quantified. To alleviate these uncertainties, a synergistic approach of applying air-borne measurements and chemical transport modeling (CTM) efforts to provide a method of quantifying local and regional GHG emissions will be performed during this study. Additionally, in order to further understand the temporal and spatial distributions of GHG fluxes in California and the impact these species have on regional climate, CTM simulations of daily variations and seasonality of total column CO2 and CH4 will be analyzed. To assess the magnitude and spatial variation of GHG emissions and to identify local “hot spots”, airborne measurements of CH4 and CO2 were made by the Alpha Jet Atmospheric eXperiment (AJAX) over the San Francisco Bay Area (SFBA) and San Joaquin Valley (SJV) in January and February 2013 during the Discover-AQ-CA study. High mixing ratios of GHGs were observed in-flight with a high degree of spatial variability. To provide an additional method to quantify GHG emissions, and analyze AJAX measurement data, the GEOS-Chem CTM is used to simulate SFBA/SJV GHG measurements. A nested-grid version of GEOS-Chem will be applied and utilizes varying emission inventories and model parameterizations to simulate GHG fluxes/emissions. The model considers CO2 fluxes from fossil fuel use, biomass/biofuel burning, terrestrial and oceanic biosphere exchanges, shipping and aviation, and production from the oxidation of carbon monoxide, CH4, and non-methane volatile organic carbons. The major sources of CH4 simulated in GEOS-Chem are domesticated animals, rice fields, natural gas leakage, natural gas venting/flaring (oil production), coal mining, wetlands, and biomass burning. Preliminary results from the comparison between available observations (e.g., AJAX and CALGEM CH4 emission maps) and GEOS-Chem results will be presented, along with a discussion of CO2 and CH4 source apportionment and the use of the GEOS-Chem-adjoint to perform inverse GHG modeling.

Johnson, Matthew S.

Thermal energy storage systems using fluidized bed heat exchangers

A rotary cement kiln and an electric arc furnace were chosen for evaluation to determine the applicability of a fluid bed heat exchanger (FBHX) for thermal energy storage (TES). Multistage shallow bed FBHX's operating with high temperature differences were identified as the most suitable for TES applications. Analysis of the two selected conceptual systems included establishing a plant process flow configuration, an operational scenario, a preliminary FBHX/TES design, and parametric analysis. A computer model was developed to determine the effects of the number of stages, gas temperatures, gas flows, bed materials, charge and discharge time, and parasitic power required for operation. The maximum national energy conservation potential of the cement plant application with TES is 15.4 million barrels of oil or 3.9 million tons of coal per year. For the electric arc furnance application the maximum national conservation potential with TES is 4.5 million barrels of oil or 1.1 million tons of coal per year. Present time of day utility rates are near the breakeven point required for the TES system. Escalation of on-peak energy due to critical fuel shortages could make the FBHX/TES applications economically attractive in the future.

Weast, T.

Nitrogen fixation studies, lead detection in living plants, and solar wind analysis

Progress is reported for research on the following: (1) magnetically shielded test facility studies; (2) electrochemistry of B10C2H12, B9CH10(-), and preparation of tumor specific boron containing materials for use in cancer therapy; (3) histochemical method for determining lead in living plant tissue; (4) diamond cementing; (5) analysis of solar wind using the washings of lunar fines; and (6) environmental engineering.

Libby, W. F.

Arroyo el Mimbral, Mexico, K/T unit: Origin as debris flow/turbidite, not a tsunami deposit

Coarse, spherule-bearing, elastic units have been discovered at 10 marine sites that span the K/T boundary in northeastern Mexico. We examined one of the best exposed sites in Arroyo el Mimbral, northwest of Tampico. The Mimbral outcrop displays a layered elastic unit up to 3 m thick enclosed by marly limestones of the Mendez (Latest Maastrichian) and Velasco (Earliest Danian) Formations. At its thickest point, this channelized elastic unit is comprised of 3 subunits: (1) a basal, poorly-sorted, ungraded calcareous spherule bed 1 m thick containing relict impact glass and shocked mineral grains, (2) a massive set of laminated calcite-cemented sandstones up to 2 m thick with plant debris at its base, (3) capped by a thin (up to 20 cm) set of rippled sandstone layers separated by silty mudstone drapes containing a small (921 pg/g) iridium anomaly. This tripartite elastic unit is conformably overlain by marls of the Velasco Formation. We also visited the La Lajilla site east of Ciudad Victoria; its stratigraphy is similar to Mimbral's, but its elastic beds are thinner and less extensive laterally. The Mimbral elastic unit has been interpreted previously as being deposited by a megawave or tsunami produced by an asteroid impact on nearby Yucatan (Chicxulub crater). However, a presumed 400-m paleodepth of water at the Mimbral site, channeling of the spherule subunit into the underlying Mendez Formation marls, and the overtopping of the basal, spherule-bearing subunit by the laminated sandstone subunit, all suggest a combined debris flow/turbidite origin for this elastic unit similar to that proposed for Upper Pleistocene sand/silt beds occurring elsewhere in the Gulf of Mexico. In this latter model, the sediment source region for the elastic unit is the lower continental shelf and slope escarpment. For the K/T unit at Mimbral, we propose that thick ejecta blanket deposits composed mostly of spherules were rapidly loaded onto the lower shelf and slope from an impact-generated ejecta curtain.

Bohor, Bruce F.

A technical analysis for cogeneration systems with potential applications in twelve California industrial plants

In a study sponsored by the State of California Energy Resources Conservation and Development Commission, 12 industrial plants in five utility districts were surveyed to assess the potential applications of the cogeneration of heat and electricity in California industry. Thermodynamic calculations were made for each plant in determining the energy required to meet the existing electrical and steam demands. The present systems were then compared to conceptual cogeneration systems specified for each plant. Overall energy savings were determined for the cogeneration applications. Steam and gas turbine topping cycle systems were considered as well as bottoming cycle systems. Types of industries studied were: pulp and paper, timber, cement, petroleum refining, enhanced oil recovery, foods processing, steel and glass

Moretti, V. C.

Applications for special-purpose minerals at a lunar base

Maintaining a colony on the Moon will require the use of lunar resources to reduce the number of launches necessary to transport goods from the Earth. It may be possible to alter lunar materials to produce minerals or other materials that can be used for applications in life support systems at a lunar base. For example, mild hydrothermal alteration of lunar basaltic glasses can produce special-purpose minerals (e.g., zeolites, smectites, and tobermorites) that in turn may be used in life support, construction, waste renovation, and chemical processes. Zeolites, smectites, and tobermorites have a number of potential applications at a lunar base. Zeolites are hydrated aluminosilicates of alkali and alkaline earth cations that possess infinite, three-dimensional crystal structures. They are further characterized by an ability to hydrate and dehydrate reversibly and to exchange some of their constituent cations, both without major change of structure. Based on their unique absorption, cation exchange, molecular sieving, and catalytic properties, zeolites may be used as a solid support medium for the growth of plants, as an adsorption medium for separation of various gases (e.g., N2 from O2), as catalysts, as molecular sieves, and as a cation exchanger in sewage-effluent treatment, in radioactive waste disposal, and in pollution control. Smectites are crystalline, hydrated 2:1 layered aluminosilicates that also have the ability to exchange some of their constituent cations. Like zeolites, smectites may be used as an adsorption medium for waste renovation, as adsorption sites for important essential plant growth cations in solid support plant growth mediums (i.e., 'soils'), as cation exchangers, and in other important application. Tobermorites are cystalline, hydrated single-chained layered silicates that have cation-exchange and selectivity properties between those of smectites and most zeolites. Tobermorites may be used as a cement in building lunar base structures, as catalysts, as media for nuclear and hazardous waste disposal, as exchange media for waste-water treatment, and in other potential applications. Special-purpose minerals synthesized at a lunar base may also have important applications at a space station and for other planetary missions. New technologies will be required at a lunar base to develop life support systems that are self-sufficient, and the use of special-purpose minerals may help achieve this self-sufficiency.

Ming, Douglas W.

Paleobiology of the Mesoproterozoic-Neoproterozoic transition: the Sukhaya Tunguska Formation, Turukhansk Uplift, Siberia

Silicified carbonates of the latest Mesoproterozoic Sukhaya Tunguska Formation, northwestern Siberia, contain abundant and diverse permineralized microfossils. Peritidal environments are dominated by microbial mats built by filamentous cyanobacteria comparable to modern species of Lyngbya and Phormidium. In subtidal to lower intertidal settings, mat-dwelling microbenthos and possible coastal microplankton are abundant. In contrast, densely woven mat populations with few associated taxa characterize more restricted parts of tidal flats; the preservation of vertically oriented sheath bundles and primary fenestrae indicates that in these mats carbonate cementation was commonly penecontemporaneous with mat growth. Eoentophysalis mats are limited to restricted environments where microlaminated carbonate precipitates formed on or just beneath the sediment surface. Most microbenthic populations are cyanobacterial, although eukaryotic microfossils may occur among the simple spheroidal cells interpreted as coastal plankton. Protists are more securely represented by large (up to 320 micrometers in diameter) but poorly preserved acritarchs in basinal facies. The Sukhaya Tunguska assemblage contains 27 species in 18 genera. By virtue of their stratigraphic longevity and their close and predictable association with specific paleoenvironmental conditions, including substrates, Proterozoic cyanobacteria support a model of bacterial evolution in which populations adapt rapidly to novel environments and, thereafter, resist competitive replacement. The resulting evolutionary pattern is one of accumulation and stasis rather than the turnover and replacement characteristic of Phanerozoic plants and animals.

NASA Discipline Exobiology