11.

17 Lime Manufacturing

11.17.1 Process Description1-5

Lime is the high-temperature product of the calcination of limestone. Although limestone

deposits are found in every state, only a small portion is pure enough for industrial lime
manufacturing. To be classified as limestone, the rock must contain at least 50 percent calcium
carbonate. When the rock contains 30 to 45 percent magnesium carbonate, it is referred to as
dolomite, or dolomitic limestone. Lime can also be produced from aragonite, chalk, coral, marble, and
sea shells. The Standard Industry Classification (SIC) code for lime manufacturing is 3274. The six-
digit Source Classification Code (SCC) for lime manufacturing is 3-05-016.

Lime is manufactured in various kinds of kilns by 1 of the following reactions:

CaCO3 + heat → CO2 + CaO (high calcium lime)

CaCO3 MgCO3 + heat → 2CO2 + CaO MgO (dolomitic lime)

In some lime plants, the resulting lime is reacted (slaked) with water to form hydrated lime. The basic
processes in the production of lime are: (1) quarrying raw limestone; (2) preparing limestone for the
kilns by crushing and sizing; (3) calcining limestone; (4) processing the lime further by hydrating; and
(5) miscellaneous transfer, storage, and handling operations. A generalized material flow diagram for
a lime manufacturing plant is given in Figure 11.17-1. Note that some operations shown may not be
performed in all plants.

The heart of a lime plant is the kiln. The prevalent type of kiln is the rotary kiln, accounting
for about 90 percent of all lime production in the United States. This kiln is a long, cylindrical,
slightly inclined, refractory-lined furnace, through which the limestone and hot combustion gases pass
countercurrently. Coal, oil, and natural gas may all be fired in rotary kilns. Product coolers and kiln
feed preheaters of various types are commonly used to recover heat from the hot lime product and hot
exhaust gases, respectively.

The next most common type of kiln in the United States is the vertical, or shaft, kiln. This
kiln can be described as an upright heavy steel cylinder lined with refractory material. The limestone
is charged at the top and is calcined as it descends slowly to discharge at the bottom of the kiln. A
primary advantage of vertical kilns over rotary kilns is higher average fuel efficiency. The primary
disadvantages of vertical kilns are their relatively low production rates and the fact that coal cannot be
used without degrading the quality of the lime produced. There have been few recent vertical kiln
installations in the United States because of high product quality requirements.

Other, much less common, kiln types include rotary hearth and fluidized bed kilns. Both kiln
types can achieve high production rates, but neither can operate with coal. The "calcimatic" kiln, or
rotary hearth kiln, is a circular kiln with a slowly revolving doughnut-shaped hearth. In fluidized bed
kilns, finely divided limestone is brought into contact with hot combustion air in a turbulent zone,
usually above a perforated grate. Because of the amount of lime carryover into the exhaust gases, dust
collection equipment must be installed on fluidized bed kilns for process economy.

Another alternative process that is beginning to emerge in the United States is the parallel flow
regenerative (PR) lime kiln. This process combines 2 advantages. First, optimum

1/95 Mineral Products Industry 11.17-1

 Figure 11.17-1. Process flow diagram for lime manufacturing.4
(SCC = Source Classification Code.)

11.17-2 EMISSION FACTORS 1/95

heating conditions for lime calcining are achieved by concurrent flow of the charge material and
combustion gases. Second, the multiple-chamber regenerative process uses the charge material as the
heat transfer medium to preheat the combustion air. The basic PR system has 2 shafts, but 3 shaft
systems are used with small size grains to address the increased flow resistance associated with smaller
feed sizes.

In the 2-shaft system, the shafts alternate functions, with 1 shaft serving as the heating shaft
and the other as the flue gas shaft. Limestone is charged alternatively to the 2 shafts and flows
downward by gravity flow. Each shaft includes a heating zone, a combustion/burning zone, and a
cooling zone. The 2 shafts are connected in the middle to allow gas flow between them. In the
heating shaft, combustion air flows downward through the heated charge material. After being
preheated by the charge material, the combustion air combines with the fuel (natural gas or oil), and
the air/fuel mixture is fired downward into the combustion zone. The hot combustion gases pass from
the combustion zone in the heating shaft to the combustion zone in the flue gas shaft. The heated
exhaust gases flow upward through the flue gas shaft combustion zone and into the preheating zone
where they heat the charge material. The function of the 2 shafts reverses on a 12-minute cycle. The
bottom of both shafts is a cooling zone. Cooling air flows upward through the shaft countercurrently
to the flow of the calcined product. This air mixes with the combustion gases in the crossover area
providing additional combustion air. The product flows by gravity from the bottom of both shafts.

About 15 percent of all lime produced is converted to hydrated (slaked) lime. There are
2 kinds of hydrators: atmospheric and pressure. Atmospheric hydrators, the more prevalent type, are
used in continuous mode to produce high-calcium and dolomitic hydrates. Pressure hydrators, on the
other hand, produce only a completely hydrated dolomitic lime and operate only in batch mode.
Generally, water sprays or wet scrubbers perform the hydrating process and prevent product loss.
Following hydration, the product may be milled and then conveyed to air separators for further drying
and removal of coarse fractions.

The major uses of lime are metallurgical (aluminum, steel, copper, silver, and gold industries),
environmental (flue gas desulfurization, water softening, pH control, sewage-sludge destabilization, and
hazardous waste treatment), and construction (soil stabilization, asphalt additive, and masonry lime).

11.17.2 Emissions And Controls1-4,33

Potential air pollutant emission points in lime manufacturing plants are indicated by SCC in
Figure 11.17-1. Except for gaseous pollutants emitted from kilns, particulate matter (PM) is the only
dominant pollutant. Emissions of filterable PM from rotary lime kilns constructed or modified after
May 3, 1977 are regulated to 0.30 kilograms per megagram (kg/Mg) (0.60 pounds per ton [lb/ton]) of
stone feed under 40 CFR Part 60, subpart HH.

The largest ducted source of particulate is the kiln. The properties of the limestone feed and
the ash content of the coal (in coal-fired kilns) can significantly affect PM emission rates. Of the
various kiln types, fluidized beds have the highest levels of uncontrolled PM emissions because of the
very small feed rate combined with the high air flow through these kilns. Fluidized bed kilns are well
controlled for maximum product recovery. The rotary kiln is second worst in uncontrolled PM
emissions because of the small feed rate and relatively high air velocities and because of dust
entrainment caused by the rotating chamber. The calcimatic (rotary hearth) kiln ranks third in dust
production primarily because of the larger feed rate and the fact that, during calcination, the limestone
remains stationary relative to the hearth. The vertical kiln has the lowest uncontrolled dust emissions
due to the large lump feed, the relatively low air velocities, and the slow movement of material

1/95 Mineral Products Industry 11.17-3

through the kiln. In coal-fired kilns, the properties of the limestone feed and the ash content of the
coal can significantly affect PM emissions.

Some sort of particulate control is generally applied to most kilns. Rudimentary fallout
chambers and cyclone separators are commonly used to control the larger particles. Fabric and gravel
bed filters, wet (commonly venturi) scrubbers, and electrostatic precipitators are used for secondary
control.

Carbon monoxide (CO), carbon dioxide (CO2), sulfur dioxide (SO2), and nitrogen oxides
(NOx) are all produced in kilns. Sulfur dioxide emissions are influenced by several factors, including
the sulfur content of the fuel, the sulfur content and mineralogical form (pyrite or gypsum) of the
stone feed, the quality of lime being produced, and the type of kiln. Due to variations in these factors,
plant-specific SO2 emission factors are likely to vary significantly from the average emission factors
presented here. The dominant source of sulfur emissions is the kiln’s fuel, and the vast majority of the
fuel sulfur is not emitted because of reactions with calcium oxides in the kiln. Sulfur dioxide
emissions may be further reduced if the pollution equipment uses a wet process or if it brings CaO and
SO2 into intimate contact.

Product coolers are emission sources only when some of their exhaust gases are not recycled
through the kiln for use as combustion air. The trend is away from the venting of product cooler
exhaust, however, to maximize fuel use efficiencies. Cyclones, baghouses, and wet scrubbers have
been used on coolers for particulate control.

Hydrator emissions are low because water sprays or wet scrubbers are usually installed to
prevent product loss in the exhaust gases. Emissions from pressure hydrators may be higher than from
the more common atmospheric hydrators because the exhaust gases are released intermittently, making
control more difficult.

Other particulate sources in lime plants include primary and secondary crushers, mills, screens,
mechanical and pneumatic transfer operations, storage piles, and roads. If quarrying is a part of the
lime plant operation, particulate emissions may also result from drilling and blasting. Emission factors
for some of these operations are presented in Sections 11.19 and 13.2 of this document.

Tables 11.17-1 (metric units) and 11.17-2 (English units) present emission factors for PM
emissions from lime manufacturing calcining, cooling, and hydrating. Tables 11.17-3 (metric units)
and 11.17-4 (English units) include emission factors for the mechanical processing (crushing,
screening, and grinding) of limestone and for some materials handling operations. Section 11.19,
Construction Aggregate Processing, also includes stone processing emission factors that are based on
more recent testing, and, therefore, may be more representative of emissions from stone crushing,
grinding, and screening. In addition, Section 13.2, Fugitive Dust Sources, includes emission factors
for materials handling that may be more representative of materials handling emissions than the
emission factors in Tables 11.17-3 and 11.17-4.

Emission factors for emissions of SO2, NOx, CO, and CO2 from lime manufacturing are
presented in Tables 11.17-5 and 11.17-6. Particle size distribution for rotary lime kilns is provided in
Table 11.17-7.

11.17-4 EMISSION FACTORS 1/95

1/95

Table 11.17-1 (Metric Units). EMISSION FACTORS FOR LIME MANUFACTURING CALCINING,
COOLING, AND HYDRATINGa

Filterableb Condensable PMc

EMISSION EMISSION EMISSION EMISSION
FACTOR FACTOR FACTOR FACTOR
Source PM RATING PM-10 RATING Inorganic RATING Organic RATING
Coal-fired rotary kiln 180d D 22e D 0.67f D 0.51g E
(SCC 3-05-016-18)
Coal-fired rotary kiln with large diameter
cyclone (SCC 3-05-016-18) 60h D ND ND ND
Coal-fired rotary kiln with fabric filter 0.14j D 0.077k D 0.19m E ND
(SCC 3-05-016-18)
Coal-fired rotary kiln with ESP 4.3h D 2.2n D ND ND
Mineral Products Industry

(SCC 3-05-016-18)
Coal-fired rotary kiln with venturi scrubber 0.72p D ND 0.14q D ND
(SCC 3-05-016-18)
Gas-fired rotary kiln with ESP 0.086r E ND 0.11r E ND
(SCC 3-05-016-19)
Gas-fired rotary kiln with gravel bed filter 0.51s E ND 0.24s E ND
(SCC 3-05-016-19)
Coal- and gas fired rotary kiln 40t E ND ND ND
(SCC 3-05-016-20)
Coal- and gas-fired rotary kiln with venturi
scrubber (SCC 3-05-016-20) 0.44t D ND 0.041t D ND
Coal- and coke-fired rotary kiln with venturi
scrubber (SCC 3-05-016-21) 0.83u D ND ND ND
Coal-fired rotary preheater kiln with multiclone 42v E ND 0.040v E ND
(SCC 3-05-016-22)
Coal-fired rotary preheater kiln with gravel bed
filter (SCC 3-05-016-22) 0.59w E ND ND ND
Coal-fired rotary preheater kiln with
multiclone, water spray, and fabric filter 0.56x E ND 0.57x E 0.076x E
(SCC 3-05-016-22)
11.17-5
11.17-6

Table 11.17-1 (cont.).

Filterableb Condensable PMc

EMISSION EMISSION EMISSION EMISSION
FACTOR FACTOR FACTOR FACTOR
Source PM RATING PM-10 RATING Inorganic RATING Organic RATING
Gas-fired calcimatic kiln (SCC 3-05-016-05) 48y E ND 0.14y E ND
Gas-fired parallel flow regenerative kiln with
fabric filter (SCC 3-05-016-23) 0.051z D ND ND ND
Atmospheric hydrator with wet scrubber 0.033aa D ND 0.0067aa D ND
(SCC 3-05-016-09)
Product cooler 3.4y E ND 0.011y E ND
(SCC 3-05-016-11)
a Factors represent uncontrolled emissions unless otherwise noted. All emission factors in kg/Mg of lime produced unless noted. ND = no
EMISSION FACTORS

data. SCC = Source Classification Code.

b Filterable PM is that PM collected on or prior to the filter of an EPA Method 5 (or equivalent) sampling train.
c Condensable PM is that PM collected in the impinger portion of a PM sampling train.
d References 9-10.
e References 4,9-10.
f References 9,11.
g Reference 9.
h Reference 10.
j References 10,18,29,31.
k References 4,10,18,29,31.
m References 7,18-21,31.
n References 4,10.
p References 8,26-27.
q References 8,13-14.
r Reference 12.
s References 15,30.
t Reference 17.
u Reference 28.
v Reference 11.
w Reference 16.
x Reference 32.
y Reference 23.
z Reference 34.
1/95

aaReference 22; units are kg/Mg of hydrated lime produced.

1/95

Table 11.17-2 (English Units). EMISSION FACTORS FOR LIME MANUFACTURING CALCINING,
COOLING, AND HYDRATINGa

Filterableb Condensable PMc

EMISSION EMISSION EMISSION EMISSION
FACTOR FACTOR FACTOR FACTOR
Source PM RATING PM-10 RATING Inorganic RATING Organic RATING
Coal-fired rotary kiln 350d D 42e D 1.3f D 1.0g E
(SCC 3-05-016-18)
Coal-fired rotary kiln with large diameter
cyclone (SCC 3-05-016-18) 120h D ND ND ND
Coal-fired rotary kiln with fabric filter 0.28j D 0.15k D 0.38m E ND
(SCC 3-05-016-18)
Coal-fired rotary kiln with ESP 8.5h D 4.3n D ND ND
Mineral Products Industry

(SCC 3-05-016-18)
Coal-fired rotary kiln with venturi scrubber 1.4p D ND 0.28q D ND
(SCC 3-05-016-18)
Gas-fired rotary kiln with ESP 0.17r E ND 0.22r E ND
(SCC 3-05-016-19)
Gas-fired rotary kiln with gravel bed filter 0.99s E ND 0.48s E ND
(SCC 3-05-016-19)
Coal- and gas fired rotary kiln 80t E ND ND ND
(SCC 3-05-016-20)
Coal- and gas-fired rotary kiln with venturi
scrubber (SCC 3-05-016-20) 0.87t D ND 0.082t D ND
Coal- and coke-fired rotary kiln with venturi
scrubber (SCC 3-05-016-21) 1.7u D ND ND ND
Coal-fired rotary preheater kiln with multiclone 84v E ND 0.081v E ND
(SCC 3-05-016-22)
Coal-fired rotary preheater kiln with gravel bed
filter (SCC 3-05-016-22) 1.2w E ND ND ND
Coal-fired rotary preheater kiln with
multiclone, water spray, and fabric filter 1.1x E ND 1.1x E 0.15x E
(SCC 3-05-016-22)
Gas-fired calcimatic kiln 97y E ND 0.27y E ND
(SCC 3-05-016-05)
11.17-7
11.17-8

Table 11.17-2 (cont.).

Filterableb Condensable PMc

EMISSION EMISSION EMISSION EMISSION
FACTOR FACTOR FACTOR FACTOR
Source PM RATING PM-10 RATING Inorganic RATING Organic RATING
Gas-fired parallel flow regenerative
kiln with fabric filter (SCC 3-05-016-23) 0.026z D ND ND ND
Atmospheric hydrator with wet scrubber 0.067aa D ND 0.013aa D ND
(SCC 3-05-016-09)
Product cooler 6.8y E ND 0.023y E ND
(SCC 3-05-016-11)
a Factors represent uncontrolled emissions unless otherwise noted. Factors are lb/ton of lime produced unless noted. ND = no data.
SCC = Source Classification Code.
EMISSION FACTORS

b Filterable PM is that PM collected on or prior to the filter of an EPA Method 5 (or equivalent) sampling train.
c Condensable PM is that PM collected in the impinger portion of a PM sampling train.
d References 9-10.
e References 4,9-10.
f References 9,11.
g Reference 9.
h Reference 10.
j References 10,18,29,31.
k References 4,10,18,29,31.
m References 7,18-21,31.
n References 4,10.
p References 8,26-27.
q References 8,13-14.
r Reference 12.
s References 15,30.
t Reference 17.
u Reference 28.
v Reference 11.
w Reference 16.
x Reference 32.
y Reference 23.
z Reference 34.
aa Reference 22; units are lb/ton of hydrated lime produced.
1/95
 Table 11.17-3 (Metric Units). EMISSION FACTORS FOR LIME MANUFACTURING
RAW MATERIAL AND PRODUCT PROCESSING AND HANDLINGa

Filterableb
EMISSION EMISSION
FACTOR FACTOR
Source PM RATING PM-10 RATING
c
Primary crusher 0.0083 E ND
(SCC 3-05-016-01)
Scalping screen and hammermill (secondary crusher)c 0.31 E ND
(SCC 3-05-016-02)
Primary crusher with fabric filterd 0.00021 D ND
(SCC 3-05-016-01)
Primary screen with fabric filtere 0.0030 D ND
(SCC 3-05-016-16)
Crushed material conveyor transfer with fabric filterf 4.4x10-5 D ND
(SCC 3-05-016-24)
Secondary and tertiary screen with fabric filterg 6.5x10-5 D ND
(SCC 3-05-016-25)
Product transfer and conveying 1.1 E ND
(SCC 3-05-016-15)h
Product loading, enclosed truck 0.31 D ND
(SCC 3-05-016-26)h
Product loading, open truck 0.75 D ND
(SCC 3-05-016-27)h
a Factors represent uncontrolled emissions unless otherwise noted. Factors are kg/Mg of material
processed unless noted. ND = no data. SCC = Source Classification Code.
b Filterable PM is that PM collected on or before the filter of an EPA Method 5 (or equivalent)
sampling train.
c Reference 6; units of kg/Mg of stone processed.
d Reference 34. Emission factors in units of kg/Mg of material processed. Includes scalping
screen, scalping screen discharges, primary crusher, primary crusher discharges, and ore
discharge.
e Reference 34. Emission factors in units of kg/Mg of material processed. Includes primary
screening, including the screen feed, screen discharge, and surge bin discharge.
f Reference 34. Emission factors in units of kg/Mg of material processed. Based on average of
three runs each of emissions from two conveyor transfer points on the conveyor from the
primary crusher to the primary stockpile.
g Reference 34. Emission factors in units of kg/Mg of material processed. Based on sum of
emissions from two emission points that include conveyor transfer point for the primary
stockpile underflow to the secondary screen, secondary screen, tertiary screen, and tertiary
screen discharge.
h Reference 10; units of kg/Mg of product loaded.

1/95 Mineral Products Industry 11.17-9

 Table 11.17-4 (English Units). EMISSION FACTORS FOR LIME MANUFACTURING
RAW MATERIAL AND PRODUCT PROCESSING AND HANDLINGa

Filterableb
EMISSION EMISSION
FACTOR FACTOR
Source PM RATING PM-10 RATING
c
Primary crusher 0.017 E ND
(SCC 3-05-016-01)
Scalping screen and hammermill (secondary crusher)
(SCC 3-05-016-02)c 0.62 E ND
d
Primary crusher with fabric filter 0.00043 D ND
(SCC 3-05-016-01)
Primary screen with fabric filtere 0.00061 D ND
(SCC 3-05-016-16)
Crushed material conveyor transfer with fabric filterf 8.8x10-5 D ND
(SCC 3-05-016-24)
Secondary and tertiary screen with fabric filterg 0.00013 D ND
(SCC 3-05-016-25)
Product transfer and conveying 2.2 E ND
(SCC 3-05-016-15)h
Product loading, enclosed truck 0.61 D ND
(SCC 3-05-016-26)h
Product loading, open truck 1.5 D ND
(SCC 3-05-016-27)h
a Factors represent uncontrolled emissions unless otherwise noted. Factors are lb/ton of material
processed unless noted. ND = no data. SCC = Source Classification Code.
b Filterable PM is that PM collected on or before the filter of an EPA Method 5 (or equivalent)
sampling train.
c Reference 6; factors are lb/ton.
d Reference 34. Factors are lb/ton of material processed. Includes scalping screen, scalping
screen discharges, primary crusher, primary crusher discharges, and ore discharge.
e Reference 34. Factors are lb/ton of material processed. Includes primary screening, including
the screen feed, screen discharge, and surge bin discharge.
f Reference 34. Factors are lb/ton of material processed. Based on average of three runs each of
emissions from two conveyor transfer points on the conveyor from the primary crusher to the
primary stockpile.
g Reference 34. Emission factors in units of kg/Mg of material processed. Based on sum of
emissions from two emission points that include conveyor transfer point for the primary
stockpile underflow to the secondary screen, secondary screen, tertiary screen, and tertiary
screen discharge.
h Reference 10; units are lb/ton of product loaded.

11.17-10 EMISSION FACTORS 1/95

1/95

Table 11.17-5 (Metric Units). EMISSION FACTORS FOR LIME MANUFACTURINGa

EMISSION EMISSION EMISSION EMISSION EMISSION

FACTOR FACTOR FACTOR FACTOR FACTOR
Source SO2b RATING SO3 RATING NOx RATING CO RATING CO2c RATING
d e f
Coal-fired rotary kiln 2.7 D ND 1.6 C 0.74 D 1,600g C
(SCC 3-05-016-18)
Coal-fired rotary kiln with fabric filter 0.83h D ND ND ND ND
(SCC 3-05-016-18)
Coal-fired rotary kiln with wet scrubber 0.15j D 0.11k E ND ND ND
(SCC 3-05-016-18)
Gas-fired rotary kiln (SCC 3-05-016-19) ND ND 1.7m E 1.1m E ND
Coal- and gas-fired rotary kiln with
1.4n 0.41n 1,600n
Mineral Products Industry

venturi scrubber (SCC 3-05-016-20) ND ND D D D

Coal- and coke-fired rotary kiln with
venturi scrubber (SCC 3-05-016-21) ND ND ND ND 1,500p D
Coal-fired rotary preheater kiln
with dry PM controls 1.1q E ND ND ND ND
(SCC 3-05-016-22)
Coal-fired rotary preheater kiln with
multiclone, water spray, and fabric
filter (SCC 3-05-016-22) 3.2r E ND ND 3.2r E 1,200r E
s s
Gas-fired calcimatic kiln ND ND 0.076 D ND 1,300 E
(SCC 3-05-016-05)
Gas-fired parallel flow regenerative kiln
with fabric filter (SCC 3-05-016-23) 0.0060t D ND 0.12t D 0.23t D ND
Product cooler (SCC 3-05-016-11) ND ND ND ND 3.9s E
a Factors represent uncontrolled emissions unless otherwise noted. Factors are kg/Mg of lime produced unless noted. ND = no data.
SCC = Source Classification Code.
b Mass balance on sulfur may yield a more representative emission factor for a specific facility.
c Mass balance on carbon may yield a more representative emission factor for a specific facility.
d References 9,18.
e References 9,11,18,29,31.
f
11.17-11

References 18,25.
g References 8-9,24-27,29.
11.17-12

Table 11.17-5 (cont.).

h References 18,29,31.
j Reference 25.
k Reference 13.
m Reference 12.
n Reference 17.
p Reference 28.
q References 16,24.
r Reference 32.
s Reference 23.
t Reference 34.
EMISSION FACTORS
1/95
1/95

Table 11.17-6 (English Units). EMISSION FACTORS FOR LIME MANUFACTURINGa

EMISSION EMISSION EMISSION EMISSION EMISSION

FACTOR FACTOR FACTOR FACTOR FACTOR
Source SO2b RATING SO3 RATING NOx RATING CO RATING CO2c RATING
Coal-fired rotary kiln 5.4d D ND 3.1e C 1.5f D 3,200g C
(SCC 3-05-016-18)
Coal-fired rotary kiln with fabric filter 1.7h D ND ND ND ND
(SCC 3-05-016-18)
Coal-fired rotary kiln with wet scrubber 0.30j D 0.21k E ND ND ND
(SCC 3-05-016-18)
Gas-fired rotary kiln (SCC 3-05-016-19) ND ND 3.5m E 2.2m E ND
Coal- and gas fired rotary kiln with
Mineral Products Industry

venturi scrubber (SCC 3-05-016-20) ND ND 2.7n D 0.83n D 3,200n D

Coal- and coke-fired rotary kiln with
venturi scrubber (SCC 3-05-016-21) ND ND ND ND 3,000p D
Coal-fired rotary preheater kiln with dry
PM controls (SCC 3-05-016-22) 2.3q E ND ND ND ND
Coal-fired rotary preheater kiln with
multiclone, water spray, and fabric filter
(SCC 3-05-016-22) 6.4r E ND ND 6.3r E 2,400r E
s s
Gas-fired calcimatic kiln ND ND 0.15 D ND 2,700 E
(SCC 3-05-016-05)
Gas-fired parallel flow regenerative kiln
with fabric filter (SCC 3-05-016-23) 0.0012t D ND 0.24t D 0.45t D ND
Product cooler ND ND ND ND 7.8s E
(SCC 3-05-016-11)
a Factors represent uncontrolled emissions unless otherwise noted. Factors are lb/ton of lime produced unless noted. ND = no data.
SCC = Source Classification Code.
b Mass balance on sulfur may yield a more representative emission factor for a specific facility.
c Mass balance on carbon may yield a more representative emission factor for a specific facility.
d References 9,18.
e References 9,11,18,29,31.
11.17-13

f References 18,25.
g References 8-9,24-27,29.
11.17-14

Table 11.17-6 (cont.).

h References 18,29,31.
j
Reference 25.
k Reference 13.
m Reference 12.
n Reference 17.
p Reference 28.
q References 16,24.
r Reference 32.
s Reference 23.
t Reference 34.
EMISSION FACTORS
1/95
 Table 11.17-7. AVERAGE PARTICLE SIZE DISTRIBUTION FOR ROTARY
LIME KILNSa

Cumulative Mass Percent Less Than Stated Particle Size

Particle Size Uncontrolled Rotary Kiln With Rotary Kiln Rotary Kiln With
(µm) Rotary Kiln Multiclone With ESP Fabric Filter
2.5 1.4 6.1 14 27
5.0 2.9 9.8 ND ND
10.0 12 16 50 55
15.0 31 23 62 73
20.0 ND 31 ND ND
a Reference 4, Table 4-28; based on A- and C-rated particle size data. Source Classification Codes 3-
05-016-04, and -18 to -21. ND = no data.

Because of differences in the sulfur content of the raw material and fuel and in process
operations, a mass balance on sulfur may yield a more representative emission factor for a specific
facility than the SO2 emission factors presented in Tables 11.17-5 and 11.17-6. In addition, CO2
emission factors estimated using a mass balance on carbon may be more representative for a specific
facility than the CO2 emission factors presented in Tables 11.17-5 and 11.17-6. Additional
information on estimating emission factors for CO2 emissions from lime kilns can be found in the
background report for this AP-42 section.

References For Section 11.17

1. Screening Study For Emissions Characterization From Lime Manufacture, EPA Contract
No. 68-02-0299, Vulcan-Cincinnati, Inc., Cincinnati, OH, August 1974.

2. Standards Support And Environmental Impact Statement, Volume I: Proposed Standards Of

Performance For Lime Manufacturing Plants, EPA-450/2-77-007a, U. S. Environmental
Protection Agency, Research Triangle Park, NC, April 1977.

3. National Lime Association, Lime Manufacturing, Air Pollution Engineering Manual,

Buonicore, Anthony J. and Wayne T. Davis (eds.), Air and Waste Management Association,
Van Nostrand Reinhold, New York, 1992.

4. J. S. Kinsey, Lime And Cement Industry--Source Category Report, Volume I: Lime Industry,
EPA-600/7-86-031, U. S. Environmental Protection Agency, Cincinnati, OH, September 1986.

5. Written communication from J. Bowers, Chemical Lime Group, Fort Worth, TX, to R.
Marinshaw, Midwest Research Institute, Cary, NC, October 28, 1992.

6. Air Pollution Emission Test, J. M. Brenner Company, Lancaster, PA, EPA Project
No. 75-STN-7, U. S. Environmental Protection Agency, Office of Air Quality Planning and
Standards, Research Triangle Park, NC, November 1974.

1/95 Mineral Products Industry 11.17-15

7. D. Crowell et al., Test Conducted at Marblehead Lime Company, Bellefonte, PA, Report on
the Particulate Emissions from a Lime Kiln Baghouse, Marblehead, Lime Company, Chicago,
IL, July 1975.

8. Stack Sampling Report of Official Air Pollution Emission Tests Conducted on Kiln No. 1 at J.
E. Baker Company, Millersville, OH, Princeton Chemical Research, Inc., Princeton, NJ, March
1975.

9. W. R. Feairheller, and T. L. Peltier, Air Pollution Emission Test, Virginia Lime Company,
Ripplemead, VA, EPA Contract No. 68-02-1404, Task 11, (EPA, Office of Air Quality
Planning and Standards), Monsanto Research Corporation, Dayton, OH, May 1975.

10. G. T. Cobb et al., Characterization of Inhalable Particulate Matter Emissions from a Lime
Plant, Vol. I, EPA-600/X-85-342a, Midwest Research Institute, Kansas City, MO, May 1983.

11. W. R. Feairheller et al., Source Test of a Lime Plant, Standard Lime Company, Woodville,
OH, EPA Contract No. 68-02-1404, Task 12 (EPA, Office of Air Quality Planning and
Standards), Monsanto Research Corporation, Dayton, OH, December 1975.

12. Air Pollution Emission Test, Dow Chemical, Freeport, TX, Project Report No. 74-LIM-6,
U. S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, NC, May 1974.

13. J. B. Schoch, Exhaust Gas Emission Study, J. E. Baker Company, Millersville, OH, George D.
Clayton and Associates, Southfield, MI, June 1974.

14. Stack Sampling Report of Official Air Pollution Emission Tests Conducted on Kiln No. 2
Scrubber at J. E. Baker Company, Millersville, OH, Princeton Chemical Research, Inc.,
Princeton, NJ, May 1975.

15. R. L. Maurice and P. F. Allard, Stack Emissions on No. 5 Kiln, Paul Lime Plant, Inc.,
Engineers Testing Laboratories, Inc., Phoenix, AZ, June 1973.

16. R. L. Maurice, and P. F. Allard, Stack Emissions Analysis, U.S. Lime Plant, Nelson, AZ,
Engineers Testing Laboratories, Inc., Phoenix, AZ, May 1975.

17. T. L. Peltier, Air Pollution Emission Test, Allied Products Company, Montevallo, AL, EPA
Contract No. 68-02-1404, Task 20 (EPA, Office of Air Quality Planning and Standards),
Monsanto Research Corporation, Dayton, OH, September 1975.

18. T. L. Peltier, Air Pollution Emission Test, Martin-Marietta Corporation, Calera, AL, (Draft),
EMB Project No. 76-LIM-9, U. S. Environmental Protection Agency, Office of Air Quality
Planning and Standards, Research Triangle Park, NC, September 1975.

19. Report on the Particulate Emissions from a Lime Kiln Baghouse (Exhibit 1 supplied by the
National Lime Association), August 1977.

20. Report on the Particulate Emissions from a Lime Kiln Baghouse (Exhibit 2 supplied by the
National Lime Association), May 1977.

11.17-16 EMISSION FACTORS 1/95

21. Report on the Particulate Emissions from a Lime Kiln Baghouse (Exhibit 3 supplied by the
National Lime Association), May 1977.

22. Air Pollution Emission Test, U.S. Lime Division, Flintkote Company, City of Industry, CA,
Report No. 74-LIM-5, U. S. Environmental Protection Agency, Office of Air Quality Planning
and Standards, Research Triangle Park, NC, October 1974.

23. T. L. Peltier and H. D. Toy, Particulate and Nitrogen Oxide Emission Measurements from
Lime Kilns, EPA Contract No. 68-02-1404, Task No. 17, (EPA, National Air Data Branch,
Research Triangle Park, NC), Monsanto Research Corporation, Dayton, OH, October 1975.

24. Air Pollution Emission Test, Kilns 4, 5, and 6, Martin-Marietta Chemical Corporation,
Woodville, OH, EMB Report No. 76-LIM-12, U. S. Environmental Protection Agency, Office
of Air Quality Planning and Standards, Research Triangle Park, NC, August 1976.

25. Air Pollution Emission Test, Kilns 1 and 2, J. E. Baker Company, Millersville, OH, EMB
Project No. 76-LIM-11, U. S. Environmental Protection Agency, Office of Air Quality
Planning and Standards, Research Triangle Park, NC, August 1976.

26. Particulate Emission Tests Conducted on the Unit #2 Lime Kiln in Alabaster, Alabama, for
Allied Products Corporation, Guardian Systems, Inc., Leeds, AL, October 1990.

27. Particulate Emission Tests Conducted on #1 Lime Kiln in Alabaster, Alabama, for Allied
Products Corporation, Guardian Systems, Inc., Leeds, AL, October 1991.

28. Mass Emission Tests Conducted on the #2 Rotary Lime Kiln in Saginaw, Alabama, for SI Lime
Company, Guardian Systems, Inc., Leeds, AL, October 1986.

29. Flue Gas Characterization Studies Conducted on the #4 Lime Kiln in Saginaw, Alabama, for
Dravo Lime Company, Guardian Systems, Inc., Leeds, AL, July 1991.

30. R. D. Rovang, Trip Report, Paul Lime Company, Douglas, AZ, U. S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, NC, January
1973.

31. T. E. Eggleston, Air Pollution Emission Test, Bethlehem Mines Corporation Annville, PA,
EMB Test No. 74-LIM-1, U. S. Environmental Protection Agency, Office of Air Quality
Planning and Standards, Research Triangle Park, NC, August 1974.

32. Air Pollution Emission Test, Marblehead Lime Company, Gary, Indiana, Report No.
74-LIM-7, U. S. Environmental Protection Agency, Office of Air Quality Planning and
Standards, Research Triangle Park, NC, 1974.

33. Written communication from A. Seeger, Morgan, Lewis & Bockius, to R. Myers, U. S.
Environmental Protection Agency, RTP, NC, November 3, 1993.

34. Emissions Survey Conducted at Chemstar Lime Company, Located in Bancroft, Idaho,
American Environmental Testing Company, Inc., Spanish Fork, Utah, February 26, 1993.

1/95 Mineral Products Industry 11.17-17