Post on 14-Oct-2020
TCCS-10 17-19th June 2019, Trondheim
Matteo Romano Politecnico di Milano, Department of Energy
CLEANKER – Clean clinker by calcium looping process for low-CO2 cement production – Overview and current stage
Technology for a better society 2
Calcium looping for CO2 capture: history and process fundamentals
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CARBONATION
CaO+CO2→CaCO3
~ 650ºC
Heat
Flue gas (CO2) (FCO2)
CO2-lean flue gas
CaCO3
CaO (FR)
CO2-rich gas to sequestration
CaCO3 make-up
(F0)
CaO purge
CALCINATION
CaCO3→CaO+CO2
~ 900ºC
Heat
• Originally proposed by Shimizu et al., 1999. A twin fluid-bed reactor for removal of CO2. Chem. Eng. Res. Des., 77.
• Continuously developed since 1998, mainly for application in power plants
• Several fluidized bed pilot facilities - demonstrated at size > 1 MW (La Pereda, Oviedo, ES; Darmstadt University, D)
Technology for a better society 3
«Tail-end» CaL configuration
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• Carbonator removes CO2 from cement plant flue gas highly suitable for retrofit
• CaO-rich purge from CaL calciner used as feed for the cement kiln
• High fuel consumption due to double calcination of the mineral CO2 (air-blown precalciner + oxy-blown CaL calciner)
clinker
Ca
lcin
erCaCO3
fuelO2
Ca
rbo
na
tor
CO2 depleted
flue gas
CO2 to CPU
CEMENT
kiln
Raw
meal
CaO
Flue gas
Arias et al., 2017. CO2 Capture by CaL at Relevant Conditions for Cement Plants: Experimental Testing in a 30 kW Pilot Plant. Ind. Eng. Chem. Res., 56, 2634–2640.
Hornberger et al., 2017. CaL for CO2 Capture in Cement Plants – Pilot Scale Test. Energy Procedia, 114, 6171–6174.
De Lena et al., 2017. Process integration of tail-end CaL in cement plants. Int J Greenh Gas Control 67, 71-92.
Technology for a better society 4
«Integrated» CaL configuration
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CaL cement plant
CO2 to storage or utilization
Rotary kiln: CaO + heat -> clinker
Pre-calciner: CaCO3 + heat -> CaO
+ CO2
Fuel ClinkerAir
Flue gas (with CO2) to environment
Existing pre-heating tower
Raw mealCaCO3
Raw mealCaCO3
Raw meal preheater
Flue gas (poor in CO2) to the
environment
O2
Carbonator: CaO (from calciner) + CO2 (from kiln fuel) ->
CaCO3 (to calciner) + heat
Calciner: CaCO3 (fresh + from carbonator) + heat ->
CaO + CO2 (to storage)
Recarbonated sorbent (CaCO3 - rich) + fresh preheated raw meal
to calciner
Calcined raw meal to rotary kiln (CaO
rich)
Calcined raw meal to carbonator (CaO-rich)
Rotary kiln:CaO (from calciner) + heat -> clinker + flue gas
Car
bon
ator
Cal
cine
r
CO
2
Clinker cooler
ClinkerAir
Clinker cooler
III Air
Fuel
FuelFuel III Air
CO2 from:
calciner fuel
fresh raw meal
kiln fuel
CO2
CO2
CO
2
CO2
CO2
CO
2
CO
2
CO
2
CO
2
Conventional cement kiln Integrated CaL cement kiln
CO
2
Technology for a better society 5
«Integrated» CaL configuration
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• CaL carbonator integrated in the preheater, treats the rotary kiln gas only
• CaL calciner coincides with the cement kiln pre-calciner single calcination step and reduced fuel consumption
• Calcined raw meal as CO2 sorbent in the carbonator
• Sorbent has small particle size (d50=10-20 μm) entrained flow reactors
Fresh raw meal
Raw meal preheater
II
CO2-lean flue gas
Fuel
O2
Car
bon
ato
r
CO2-rich gas to CPU
Fuel
Cal
cine
r
Recarbonated / fresh sorbent
to calciner
Calcined raw meal to rotary kiln
Calcined raw meal to carbonator
Rotary kiln
CO2 recycle
Fresh raw meal
Raw meal preheater
III Air
Fresh raw meal
Raw meal preheater
III
Raw meal
recycle
Alonso et al., 2018. Capacities of Cement Raw Meals in Calcium Looping Systems. Energy & Fuels, 31, 13955–13962.
Spinelli et al., 2018. One-dimensional model of entrained-flow carbonator for CO2 capture in cement kilns by calcium looping process. Chemical Engineering Science, 191, 100-114.
De Lena et al., 2019. Techno-economic analysis of Calcium Looping processes for low CO2 emission cement plants. Int J Greenh Gas Control, 82, 244-260.
Technology for a better society 6
Tail-end vs. Integrated CaL configurations
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De Lena et al., 2019. Techno-economic analysis of Calcium Looping processes for low CO2 emission cement plants. Int J Greenh Gas Control, 82, 244-260.
Cement plant w/o capture
Tail-end CaL (20% integration)
Tail-end CaL (50% integration)
Integrated CaL
Carbonator CO2 capture efficiency [%] -- 88.8 90.0 82.0
Total fuel consumption [MJLHV/tclk] 3240 8720 7100 5440
Rotary kiln fuel consumption [MJLHV/tclk] 1230 1220 1220 1150
Pre-calciner fuel consumpt. [MJLHV/tclk] 2010 1550 850 4290
CaL calciner fuel consumpt. [MJLHV/tclk] -- 5950 5040
ASU electric consumption [kWh/tcem] -- 85 73 62 CPU electric consumption [kWh/tcem] -- 110 101 89 Steam turbine production [kWh/tcem] -- 413 260 150 Other auxiliaries consumption [kWh/tcem] 97 137 128 116 Net electricity consumpt. [kWhel/ tcem] 97 -81 42 117 Direct CO2 emissions [kgCO2/tclk] 865 119 79 55 Indirect CO2 emissions [kgCO2/tclk] 35 -29 15 46 Equivalent CO2 emissions [kgCO2/tclk] 900 90 94 101 Equivalent CO2 avoided [%] -- 90.0 89.5 88.8 SPECCA [MJLHV/kgCO2] -- 4.42 4.07 3.16
Technology for a better society 7
-30
-20
-10
0
10
20
30
40
50
60
70
80
Co
st o
f CO
2av
oid
ed, €
/tC
O2
Fuel Electricity Other var. Opex Fixed Opex Capex
Tail End CaL (IL=20%) Tail End CaL (IL=50%) Integrated CaL
Total CCA
Tail-end vs. Integrated CaL configurations
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De Lena et al., 2019. Techno-economic analysis of Calcium Looping processes for low CO2 emission cement plants. Int J Greenh Gas Control, 82, 244-260.
Technology for a better society 8
Primary project objectives
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The ultimate objective of CLEANKER is advancing the integrated Calcium-looping process for CO2 capture in cement plants.
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.
VERNASCA PLANT
Technology for a better society 9
The consortium
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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
WP3 – Demonstration of CaLprocess
WP4 – Comparative characterization of raw meals
for CaL
WP2 – Demonstration systemdesign
WP5 – Process integration and modelling
WP6 – Scale up, economics, LCA
WP8 – Exploitation
WP1 - Management
WP9 - Dissemination
WP7 – Transport and storage
Technology for a better society 10
Vernasca kiln preheater and rendering of CaL pilot
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Preheater tower
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CLEANKER pilot plant configuration
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Rotary kiln
Raw Meal Inlet
Raw Meal Preheater
Flue gas
Fuel input 1
Carbonator
CO2-rich gas to filters
Fuel Inlet
Calciner
Carbonated sorbent to
calciner
Fresh raw mealto CaL Calciner
Calcined raw meal to
carbonator
Pneumatic transport air
Pre-calciner
Raw meal to preheater
1
3
5
7
9
2
4
6
8
10
11
1315
17
21
12
14
16
19
20Flue gas
to carbonator
Air leakAir leak
O2 Inlet18
Tertiary air
HX 3
Cooling Air
CO2 lean flue gas
Control Air
23
24
CO2 recycle
26
25
22
Fuel input 2
27
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CLEANKER pilot 3D
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CLEANKER pilot 3D
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CLEANKER pilot 3D
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CLEANKER pilot 3D
15
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CLEANKER pilot 3D
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CLEANKER pilot 3D
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CLEANKER pilot 3D
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CLEANKER pilot 3D
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CLEANKER pilot 3D
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CLEANKER timeline
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2021 2020 2019 2018 2017
1st
Oct
ob
er 2
01
7
30
th S
epte
mb
er
20
21
17-18 October 2017 Kick-off meeting
July 2018 Pilot Plant H&M balances defined
December 2019 Erection completed
March 2020 Running tests and data analysis
September 2021 Strategic conclusions
April 2021 Casting concrete results
and full economic analysis of cement plant with CaL
March 2019 Fabrication begins
January 2020 Inspection
July 2018 Raw meal
characterization
June 2018 Measuring points
and instrumentation defined
Technology for a better society 22
Acknowledgments
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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
CCUS in cement industry: CLEANKER project - CO2GeoNet Open Forum - S.Servolo, Venice - 6-9 May 2019
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