Cement Manufacturing Process

Service Description

Gossman Consulting, Inc. provides assistance in cement manufacturing process trouble-shooting and process improvement. Our experienced team of professionals have an intimate understanding of the chemical processes in cement manufacture and can assist in the selection of alternate fuels and feed stocks or in determining a raw materials specification and blending ratio. GCI's wide experience in assisting clients who utilize a number of different clinker production processes has given us a unique understanding of the cement manufacturing process. This understanding and experience, coupled with our strong sampling and analytical skills and our equally strong production management experience, create a combination of skills that can be widely utilized by cement manufacturers wishing to improve their process.

Experience

David Gossman

• Acted as QA/QC manager for one of the first comprehensive RCRA Trial Burns at a cement plant.
• Performed a comprehensive review of a proposed update to SW-846.
• Assisted in the review of a cement plant's waste water run off plans.
• Provides hardware support and maintenance for in-house state of the art network system including the networking of the latest 486 and pentium based computer technology, high-end laser printing, CD-ROM, and optical character and voice recognition technology.
• Prepared an analysis of existing metal emission data from cement kilns and incinerators burning hazardous waste, and recommended technology based metal emission standards which have been presented in a petition for rule making to the USEPA by the Cement Kiln Recycling Coalition.
• Prepared a study of recycling opportunities utilizing cement kiln technology for refineries in Venezuela.
• Performed technical and market evaluations to determine the suitability and made recommendations regarding the resource recovery opportunities available to various cement plants throughout the United States as well as Great Britain, Venezuela, and South East Asia.
• Performed comprehensive laboratory based study, including field sampling, of cement kiln dust and cement clinker stored and generated at cement plants throughout the country.
• Performed a comprehensive evaluation of the potential for utilizing spent aluminum potliner as a fuel in cement kilns. Evaluation included facility design criteria and concepts based on the study's technical findings.
• Evaluated various resource recovery opportunities for client companies relative to technical feasibility, worker health and safety impact, environmental impact, and regulatory requirements.
• Performed a study of various alternatives for the introduction of solid hazardous wastes into cement kilns including the potential for pyrolysis or thermal separation prior to cement kiln introduction.
• Performed the first comprehensive, published study on the fate of trace metals in the cement manufacturing process. The study provided special insight on how recirculating loads, as well as the point of introduction, can effect the fate of metals in cement kilns.
• Developed the first comprehensive HWF specification which met the needs of product (cement) quality, environmental protection and personal health & safety in 1980.
• Assisted in the development of a dynamic computer model for predicting emissions and recirculating loads on volatile constituents such as Hg and alkali chlorides in cement kilns.

Qualification Statements

David Gossman, and Susan Gossman

Relevant Publications

GCI has prepared a number of papers on cement manufacturing process. (If a link to a paper title is not yet available please e-mail with your fax number for a copy.)

• Metal Equilibration and Process Capture Efficiencies in Cement Kilns
• The Fate of Trace Metals In The Wet Process Cement Kiln
• The Effect of Process Differences on System Removal Efficiencies (SREs) and the Fate of Metals in Cement Kilns
• A Comparison of Normal and Worst Case Cement Plant Emissions
• Observations and Comments on EPA/DOE Mercury CEMs Demonstration at Holnam's Holly Hill, SC Facility
• The Design of A Custom Database System for Storing and Accessing Point Source Emission Test Data and Associated Process Conditions
• GCI Tech Notes "Why All Cement Kilns Should Test Their CKD" June-97
• GCI Tech Notes "Working together in Plant Operations" Dec-96
• GCI Tech Notes "The Impact of CKD Recycling on "HCl" Emissions from the Wet Process Cement Kiln", Aug-96
• GCI Tech Notes "The Potential for CKD Insufflation to Impact Metals Emissions from Cement Kilns", Sept-95
• HWF Notes "CKD Report to Congress Comments", Feb-94
• HWF Notes "The Clean Air Act and Cement Kiln NOx Emissions", June-93
• HWF Notes "THE MSHA Hazard Communication Standard", Nov-91

If you have questions or wish to set up a meeting please contact David Gossman at (563) 652-2822 or via e-mail.

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