CO2-Capture from Cement Plants Applying Oxyfuel Concepts
Transcript of CO2-Capture from Cement Plants Applying Oxyfuel Concepts
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CO2-Capture from Cement
Plants Applying Oxyfuel
Concepts
S Oberhauser
Institute of
Energy Systems
A Kather
2nd International Conference on Energy
Process Engineering
20.06.2011 - 22.06.2011
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2Motivation
Why Applying CCS to the Cement Industry ?
CO2 Emissions from Stationary Sources
(Metz, Bert et al, 2005)
Others 15%
Power Industry 78%
Cement
Industy
7% • Large Development of CCS applied
to power plants during the past several
years
• Cement Industry second largest
stationary CO2 source
• No possibility to avoid CO2 emitted
by the raw material
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3
CO2-Sources in the Cement Industry
H2O
SiO2 CaCO3
MgCO3
Al2O3
Fe2O3
H2O CaOFe2O3
SiO2
calcination reaction:
CaCO3 CaO + CO2
MgCO3 MgO + CO2
Others
Motivation
1/3 of emitted CO2Fossil Fuel
2/3 of emitted CO2 not possible to avoid !
Al2O3
MgO
2/3 of emitted CO2
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4
Conventional Cement Plant with Calciner
Conventional Cement Production
Rotary Kiln
Fuel
Cooling Air
Calciner
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment FuelRaw
Material
Raw
Material
Flu
eG
as
~860°C
Flue
Gas
Treat-
ment
Waste Air
Waste Air
Treatment
Cooler
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5
Conventional Cement Plant with Calciner
Conventional Cement Production
Rotary KilnCooler
Fuel
Cooling Air
Calciner
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment FuelRaw
Material
Flu
eG
as
~860°C
Flue
Gas
Treat-
ment
Fixed Parameters for Simulation:
• Fixed raw meal composition
• Calcination of 90% in calciner
• Clinker after rotary kiln: 1400°C
• Air Excess: kiln: 1.15
calciner: 1.30
• Reaction behaviour according to
to pseudo-equilibrium investigated by
experiments
Waste Air
Waste Air
Treatment
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6
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Raw
Material
Conventional Cement Production
Flu
eG
as
~860°C
Modifications to Full Oxyfuel (Case A-0)
Calciner
Flue
Gas
Treat-
ment
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7
Modifications to Full Oxyfuel (Case A-0)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Full Oxyfuel
Flu
eG
as
~860°C
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8
Modifications to Full Oxyfuel (Case A-0)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Full Oxyfuel
ASU
Cooling WFGD GPUCooling Hot ESP
Recirculation Rate:
Calciner: equal solid loading
Rotary kiln: equal TadiabaticWa
ste
Air
ASU: 99.5% Oxygen Purity
GPU: 95% CO2 Purity
~900°C
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100
27.5
30.8
95.6
11,2
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113.1
91.8
373
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
9
Evaluation of First Full Oxyfuel Case
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
according to
German power mix (2010):
0.575 kgCO2/kWh
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10
Full Oxyfuel (Avoiding Air-In Leakages, Before)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
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11
Full Oxyfuel (Avoiding Air-In Leakages, After)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
X
X
X
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
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100
27,5
30.8
95.6
11.2
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113.1
91.8
373
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
12
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
Evaluation of Avoiding Air-In Leakages (Before)
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100
20.9 19.6 18,6
95.6
4.6 4.1 4.9
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113.1
92
371 352 319
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
13
Evaluation of Avoiding Air-In Leakages (After)
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
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14
Full Oxyfuel (Case A-HX)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
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15
Full Oxyfuel (Case A-HX)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Gas-Gas
Heat Exchanger
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
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100
20.9 19.6 18,6
95.6
4.6 4.1 4.9
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113
92
371 352 319
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
16
Evaluation of Different Heat Recovery Systems
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
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17
Full Oxyfuel (Case A-Direct)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
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18
Full Oxyfuel (Case A-Direct)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
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100
20.9 19.6 18,6
95.6
4.6 4.1 4.9
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113
92
371 352 319
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
19
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
Evaluation of Different Heat Recovery Systems
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20Concepts to Apply Full Oxyfuel
Influences of recirculation rate:
• Flue gas temperature of preheater
• Solid Loading in the Calciner
• Air-in leakage
• Heat recovered from cooler
Lowest heat demand at a
recirculation rate, were solid loading
of calciner is ~1.15 times
solid loading of base case
Influences of Recirculation Rate
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
ClinkerFuel
Waste Air
Treatment
ASU
Cooling WFGD GPUCooling Hot ESP
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100
38.6
18.5
95.6
26.7
4.50
20
40
60
80
100
120
140CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
10095
92
100
270318
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-EnergyGPUASUElectrical Power
21
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Ele
ctr
ica
lEnerg
yD
em
an
d P
el/ P
el,B
ase
in %
Base
Case
Case
B-Direct
Case
A-DirectBase
Case
Case
B-Direct
Case
A-Direct
Evaluation of Best Case for Full Oxyfuel Operation
Concepts to Apply Full Oxyfuel
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22
Modification to Partial Oxyfuel (Before)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Partial Oxyfuel
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Cooler
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23
Modification to Partial Oxyfuel (After, Case B-0)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Partial Oxyfuel
ASU
Cooling WFGD GPUCooling Hot ESP
Preheater 2
(Air)
Flu
e
Gas
Cooler
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24
Partial Oxyfuel (Case B-HX)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Flu
e
Gas
Preheater 2
(Air)
Gas-Gas
Heat Exchanger
Cooler
Concepts to Apply Partial Oxyfuel
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25
Partial Oxyfuel (Case B-Direct)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Preheater 2
(Air)
Cooler
Concepts to Apply Partial Oxyfuel
Flu
e
Gas
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100
38.6
18.5
95.6
26.7
4.50
20
40
60
80
100
120
140CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
10095
92
100
270318
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-EnergyGPUASUElectrical Power
26
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Ele
ctr
ica
lEnerg
yD
em
an
d P
el/ P
el,B
ase
in %
Base
Case
Case
B-Direct
Case
A-DirectBase
Case
Case
B-Direct
Case
A-Direct
Concepts to Apply Oxyfuel
Evaluation of Best Cases of Full and Partial
Oxyfuel Operation
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27
Conclusion
• Two main concepts for oxyfuel operation in a cement plant have been evaluated
• Different subconcepts for heat recovery from clinker cooler have been compared
• Uncertainties:
- Effect of CO2-rich fluegas in kiln on clinker quality
- Effect of CO2-rich recirculation gas in clinker cooler on
clinker quality
- Air-in leakage into cooler
• Advantages/disadvantages of best subconcepts:
• In spite of remaining uncertainties concepts become more and more CONCRETE
Concept Fuel Demand Electrical Energy
Demand
CO2-Emission Risk
Base Case o o o o
Partial Oxyfuel
Concepts+ - + -
Full Oxyfuel
Concepts+ - - + + - -
Conclusion
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THANK YOU FOR YOUR ATTENTION !