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 - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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
CCUS in cement industry: CLEANKER technology, progress and project perspectives - Martina Fantini - Desarc-Maresanus
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 2020
Technology 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 2020
Main 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 2020
CLEANKER 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 2020
CLEANKER 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 2020
CLEANKER 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 2020
CLEANKER 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 2020
CLEANKER 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 2020
CLEANKER project
 CLEANKER demo system

Preheater tower

        La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
CLEANKER project
CLEANKER timeline

      La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
CLEANKER project
CLEANKER timeline

      La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
CLEANKER                                                      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 2020
Acknowledgments

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 2020
Main 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 2020
Main 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.

       La rimozione di CO2 dall’atmosfera e il progetto Desarc-Maresanus - 4-5 febbraio 2020
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