CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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CCUS in cement industry: CLEANKER technology,
progress and project perspectives
Martina Fantini
Laboratorio Energia e Ambiente
Piacenza – LEAP s.c.a r.l.
Martina.fantini@polimi.it
www.cleanker.eu –
www.leap.polimi.it
Summary
Main technologies for CO2 capture in cement plants:
oPost-combustion solvent systems
oOxyfuel
oExternally heated calcination
oCalcium looping
CLEANKER project
oProject objectives
oThe consortium
oCaL integrated configuration
oCLEANKER demo system
oCLEANKER project timeline
oCLEANKER Opening event
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
CO2 emission reduction from
cement kilns
CO2 capture in cement industry:
• Cement industry is the hardest industry to decarbonize without CCS
• 60% of CO2 emissions derive from CaCO3 calcination and cannot be reduced by
fuel switch, fuel decarbonization or energy efficiency
Reduction by:
Increase of energy efficiency
Alternative fuels use
Reduction of clinker share
CCS
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
Main technologies for CO2
capture in cement plants
Post-combustion capture by sovents:
• Most mature technology for full-scale
applications. Large scale units operating on
power plant flue gases.
• Extensive experience for application in power
plants
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
Main technologies for CO2
capture in cement plants
Oxyfuel combustion:
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
Main technologies for CO2
capture in cement plants
Oxyfuel combustion:
Partial oxyfuel: oxyfuel pre-calciner with air-fired rotary kiln and air-cooled clinker
cooler
C. Paxton, M. Weichinger, 2008. Patent WO2008059378 A2.
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
Main technologies for CO2
capture in cement plants
Externally heated calcination
www.project-leilac.eu/
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
Main technologies for CO2
capture in cement plants
Calcium Looping:
CO2-rich gas to
CO2-lean flue gas sequestration
CALCINATION
CARBONATION CaCO3
CaCO3→CaO+C
Heat CaO+CO2→CaCO3 O2 Heat
~ 650ºC CaO ~ 900ºC
(FR)
CaCO3 CaO
Flue gas (CO2)
make-up purge
(FCO2)
(F0)
CaO + CO2 CaCO3 ΔH298 K=-178 kJ/mol (or 4.04 MJ/kgCO2)
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
Main technologies for CO2
capture in cement plants
Calcium Looping:
Tail-end Calcium looping:
o Post-combustion capture configuration -> highly suitable for retrofit
o High fuel consumption (double calcination for the mineral CO2 captured)
o Heat from fuel consumption recovered in efficient (~35% efficiency) steam cycle for power generation
o CFB CaL reactors: d50=100-250 μm, vs. particle size for clinker production d50=10-20 μm -> CaL purge
milled in the raw mill at low temperature
Arias et al., 2017.
Ind. Eng. Chem.
Res., 56, 2634–
2640;
Hornberger et al.,
CaCO3 -> CaO+CO2 2017. Energy
CaO+CO2 –> CaCO3 Procedia, 114,
6171–6174;
De Lena et al.,
2017. Int. J. Greenh
Gas Control, 67, 71-
92.
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
Main technologies for CO2
capture in cement plants
Calcium Looping: Fresh raw CO2-lean
CO2-rich meal flue gas
gas to CPU Fresh raw
meal
Integrated CaL:
o CaL carbonator highly integrated within the
Carbonator
Raw meal
preheater, captures CO2 from rotary kiln gas preheater
o CaL calciner coincides with the cement kiln pre- Raw meal
preheater
calciner -> no double calcination, lower fuel II
consumption CO2 recycle
Calcined
o Calcined raw meal as CO2 sorbent in the raw meal to Raw
carbonator meal
carbonator instead of high purity limestone recycle
o Sorbent has small particle size (d50=10-20 μm) ->
Calciner
Fresh raw
entrained flow reactors meal
Raw meal III Air
preheater
III
Fuel Calcined
raw meal to
rotary kiln Rotary kiln
Fuel
Alonso et al., 2018. Energy & Fuels, 31, 13955–13962. O2 Recarbonated /
fresh sorbent
Turrado et al., 2018. Ind Eng Chem Res, 57, 13372-13380. to calciner
De Lena et al., 2019. Int J Greenh Gas Control, 82, 244-260.
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020Technology comparison
Post- Oxyfuel Calcium Externally
combustion looping heated
solvents calcination
Direct CO2
emissions
Direct fuel
consumption ?
Electricity
consumption
Increase
rate
Indirect fuel depends
consumption and on electric
CO2 emissions grid mix
Capital costs
?
Need of steam generation may increase emissions and fuel consumption in the cement kiln battery limit
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020Main technologies for CO2
capture in cement plants
• Optimal CO2 capture technologies for industry is very sector-specific.
• For cement plants, different CO2 capture technologies can compete. The
optimal technology may be site dependent, as CO2 avoidance cost
depends on: (i) cost of fuel and availability of alternative fuels; (ii) cost of
utilities; (iii) needed purity of CO2; (iv) financial framework, advantaging
technologies with partial CO2 capture and lower investment costs; (v)….?
• Retrofitability of existing plants is crucial for a CO2 capture technology,
especially in mature economies where many new industrial plants are
unlikely to be built.
• The experience acquired in the first large-scale plants will contribute
determining the winning technologies.
• Calcium looping is one of the (best) players on the ground!
• … but for the integrated CaL process, pilot scale demonstration and more
accurate scale-up study is needed to answer some research questions
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
The ultimate objective of CLEANKER is advancing the integrated Calcium-looping process for
CO2 capture in cement plants.
VERNASCA
PLANT
This fundamental objective will be achieved by pursuing the following primary targets:
• Demonstrate the integrated CaL process at TRL 7, in a new demo system connected to the
operating cement burning line of the Vernasca 1.300.000 ton/y cement plant, operated by
BUZZI in Italy.
• Demonstrate the technical-economic feasibility of the integrated CaL process in retrofitted
large scale cement plants through process modelling and scale-up study.
• Demonstrate the storage of the CO2 captured from the CaL demo system, through
mineralization of inorganic material in a pilot reactor of 100 litres to be built in Vernasca, next
to the CaL demo system.
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
Starting date: October 1st 2017
Duration: 4 years
Total budget: € 9.237.851,25
UE co-financing: € 8.972.201,25
Chinese governement founding: 265.650 €
Partner: 13 from 5 EU member states +
Switzerland and China
WP1 - Management
WP2 – Demonstration system WP3 – Demonstration of CaL
design process
WP4 – Comparative WP5 – Process integration and
characterization of raw meals
for CaL modelling
WP7 – Transport and storage WP6 – Scale up, economics, LCA
WP8 – Exploitation
WP9 - Dissemination
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
Integrated CaL configuartion
CaL cement plant
Flue gas (with CO2) to environment Calciner: Carbonator:
CaCO3 (fresh + from carbonator) + heat -> CaO (from calciner) + CO2 (from kiln fuel) ->
CO2
Raw meal CaO + CO2 (to storage) CaCO3 (to calciner) + heat
CO2
CaCO3
CO2
Flue gas (poor in
CO2 to storage or Raw meal CO2) to the
utilization CaCO3 environment
Existing pre-heating tower CO2
CO2
CO2
Raw meal
Carbonator
Calcined preheater
CO2 from: raw meal to
carbonator
calciner fuel (CaO-rich)
CO2
Calciner
CO2
fresh raw meal
CO2
Pre-calciner: kiln fuel
CaCO3 + heat -> CaO Recarbonated sorbent
CO2 (CaCO3 - rich) + fresh
+ CO2 preheated raw meal
III Air
Fuel III Air Fuel to calciner
Clinker cooler Calcined raw meal Rotary kiln:
to rotary kiln (CaO CaO (from calciner) + heat -> clinker + flue gas
Fuel Clinker rich)
O2
Air Clinker cooler
Rotary kiln: CaO + heat -> clinker
Fuel Clinker
Air
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
CLEANKER demo system
Flue gas
CO2 rich flue gas CO2 poor
to storage/utilization flue gas
Existing pre-heating tower
Carbonator (Vernasca)
Calciner 650-700°C
920°C
Flue gas
from
cement kiln
CaO
CaCO3
Fuel Raw
meal Tertiary air
O2
Solids Pre-calciner
Fuel
Air
Demonstrator Rotary kiln Clinker
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
CLEANKER demo system BASIC FLOWSHEET FOR
THE APPLICATION
FINAL FLOWSHEET
OF THE TEST RIG
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
CLEANKER demo system
Preheater tower
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
CLEANKER timeline
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER project
CLEANKER timeline
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020CLEANKER Save the
date!!
Opening event 15th and
16th of May
When: Friday 15th and Saturday 16th
Where: Vernasca cement plant
What:
Friday 15th: official event (cut of
the ribbon)
Saturday 16th: activities for local
communities
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020Acknowledgments
This project has received funding from the European Union's Horizon 2020 research
and innovation programme under Grant Agreement n. 764816
This work is supported by the China Government (National Natural Science
Foundation of China) under contract No.91434124 and No.51376105
www.cleanker.eu
Twitter: @CLEANKER_H2020
LinkedIn: www.linkedin.com/company/14834346
Disclaimer: The European Commission support for the production of this publication does not constitute endorsement of the contents which reflects the views only of the authors, and the
Commission cannot be held responsible for any use which may be made of the information contained therein
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020Main technologies for CO2
capture in cement plants
Post-combustion capture by chilled ammonia:
• Most mature technology for full-scale
applications. Large scale units operating on
power plant flue gases.
• Extensive experience for application in power
plants
La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020Main technologies for CO2
capture in cement plants
Regulatory and social framework:
• All CO2 capture technologies are capital intensive industrial projects
need clear and stable regulatory framework and stably high carbon tax to
be economically justified.
• It is crucial that carbon pricing mechanisms are coupled with measures
that protect the market from imports of high-emission cement.
• Logistic issue may be critical for cement plants, which are built in the
vicinity of quarries and are mostly traded on regional markets. Logistics
with respect to CO2 transport and storage infrastructure may affect the
survival or the repowering of existing kilns.
• Social acceptance of CO2 transport and storage may be a decisive factor
for the success of CCS projects in a specific region. Social/political
acceptance will represent a bottleneck for CCS projects in Europe.
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