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CO2 capture from cement production

Deliverables

CaL reactor modelling and process simulations

This report will cover final CaL process simulations results. The carbonator-calciner system will be modelled and simulated for different operating conditions. The process simulations will include the results of mass and energy balances of the two CaL processes assessed in this WP. The content of the deliverable will also be a basis for the process design achtivities in Task 12.4.

Analysis of oxyfuel clinker cooler operational performance

Due to the changed gas atmosphere the cooling performance could be changed which is directly influencing the product composition. Therefore the overall aim of this work package is the experimental testing of an oxyfuel cooler in an industrial surrounding in order to ensure a sufficient cooling performance (efficiency) and the product quality. The cooler performance will be evaluated based on the experimental data and the product quality on analysis of the gained samples.

CEMCAP framework for comparative techno-economic analysis of CO2 capture from cement plants

With the progress of the project the framework will be updated to be in line with the requirements identified within the experimental CEMCAP work packages. A public framework report will be delivered, which provides transparency to the comparative analysis undertaken in WP2.2 = 4.

Optimized operation of an oxyfuel cement plant

A Report describing the full-scale optimized oxyfuel cement plant incorporating experimental results from WP7, WP8, WP9 will be delivered. Due to the changed atmosphere and additional parameters the operation will be more complex. Therefore the report will include procedure instructions about start-ups, shut-downs and optimal operational settings. A section will also include recommendations about training of operators

Design and performance of CEMCAP cement plant with MEA post combustion capture

In analogy with D4.1, a techno-economic study is provided of the CEMCAP reference cement plant when equipped with CO2 capture using MEA. Stream data, additional energy consumption with CO2 capture, CO2 emissions, and estimated costs will be provided.

Results from 30 kWth CFB experiments

This report will cover the results of experiments under synthetic cement plant exhaust compositions delivering input to 200kWth tests. This will include results of experimental testing of different limestones, raw meals and operating windows for calcium looping in cement plant at a 30 kWth CFB bench scale plant.

Retrofitability study for CO2 capture technologies in cement plants

A description of to what the consequences are (footprint, influence on production process and product quality, extent of necessary construction work etc.) when retrofitting different CO2 capture technologies to cement plants, and to what extent retrofit is feasible.

Assessment of calciner test results

Assessment, and compilation of WP8 results for further use in WP6 oxyfuel process simulations. In this deliverable report results obtained in task 8.3 will be evaluated in respect to large scale application of suspension calcination under oxyfuel conditions. Moreover, key parameters and findings from experiments will be compiled to a concise chapter aiming to support designers of industrial scale oxyfuel suspension calciners. The deliverable will also provide input data and information from for the oxyfuel process simulation and optimisation in WP6.

Case study of communication and public acceptance of CO2 capture in the cement industry

This deliverable will explore the Norcem approach to communication about on-site testing of CO2 capture in Brevik, Norway, including how local inhabitants and other stakeholders perceive different economic, social and environmental risks and benefits with CO2 capture in their own local community.

Cost of critical components in CO2 capture processes

A description of the calculations of Size and cost of process components required for CO2 capture from cement plants. This provides the necessary basis for the techno-economic evaluation in D4.6

Experimental investigation of CO2 liquefaction for CO2 capture from cement plants

Description of the undertaken CO2 liquefaction tests at low temperatures with gas composition input determined by Task 11.1. Documentation of experimental results such as retention time vs. separation efficiency, separator temperature vs. separation efficiency and CO2 product purity.

Status-report on Calciner Technology

Description of industrially relevant boundary conditions for cement plant calciners. This report shall summarize the current state-of-the-art of different industrial cement calciner designs and expected alterations when operating those under oxyfuel conditions. It aims to be a comprehensive basis for the design of oxy-fuel calciner experiments in task 8.3.

Feasibility study and CAP process scale-up

This deliverable evaluates how to proceed with CAP process to on-site pilot/demo testing. Aim of the document is to provide strategic guidelines for a project follow-up and CAP progress to TRL7-8 for cement plants.

Oxyfuel burner prototype performance tests

Report on the burner modifications and the results from oxyfuel tests with different solid fuels. The report will summarize details on the optimum burner design for oxy-fuel application to cement kilns as well as experimental results from 500 kW oxy-fuel burner tests and their evaluation. It will also provide input data and information from demonstration tests for the oxyfuel process simulation and optimisation in WP6.

Post capture CO2 management – options for the cement industry

An overview of different options to dispose of CO2 captured from cement plants and potential for generating business case(i.e. technical-economic evaluation). Based on the potential, dedicated roadmaps will be made.

Results of entrained flow carbonator/calciner tests

This report covers the experimental work with entrained flow carbonator and calciner for an integrated calcium looping process. The report will summarize conducted experiments and results with respect to the operation and performance of entrained flow carbonation and suspension calcination under various relevant conditions and cement plant specific particle sizes.

Calcium Looping CO2 capture for the cement industry – Demonstration of fluidized bed CaL at 200 kW scale and research on entrained flow CaL

The first and main part of the report summarizes the results of fluidized bed Calcium Looping (CaL) process demonstration trials under industrially relevant conditions at USTUTT’s 200 kWth pilot rig. In these pilot scale Calcium Looping demonstration trials, process conditions were adapted to cement specific requirements (e.g. use of cement specific flue gas and sorbent make-up, etc.) to demonstrate the technology at TRL 6. Optimum process conditions for the application of CaL to the cement process are key results presented in the report and will enable energetic evaluation. The second part of the deliverable presents final results from investigations on Calcium Looping CO2 capture in entrained flow environments (TRL=4). Special focus will be given to the sorbent performance results from additional experiments that have been conducted at the CSIC´s 30kWth carbonator reactor operated in entrained mode, after completion of D12.2.

Membrane-assisted CO2 liquefaction for CO2 capture from cement plants

Optimized simulation results and design for pilot- and full-scale membrane-assisted CO2-liquefaction; provides input to WP6. Process design for CO2 liquefaction unit, simulation results for CO2 liquefaction based on different input compositions from Task 11.1, optimised cases for each input composition and process parameters for minimum overall capture cost.

CEMCAP comparative techno-economic analysis of CO2 capture in cement plants

This deliverable describes process simulation results of the four different CO2 capture technologies and their integration into the CEMCAP reference cement plant, as well as the estimated costs associated with each technology. All technologies are analysed and compared from point of view of the KPIs defined in WP3.

Design of post combustion capture and integrated calcium looping cement plant systems (M32)

The report will present a Full-scale process design and sizing, based on experimental work and using the finalized CaL process model, also outlining how to proceed with the CaL development for on-site testing to reach TRL 7-8.

Plan for dissemination, exploitation and communication of results

The CEMCAP plan for communication will describe when, how, by whom communication actions will be undertaken and towards whom they are direced, . Plans for other dissemination activities (CEMCAP internal and CEMCAP/ECRA) and plans for exploitation of results will be described

Oxyfuel suspension calciner test results

Summary report on conducted oxyfuel calcination tests. The report will summarize conducted experiments and results in respect to the operation and performance of oxyfuel suspension calcination under various relevant oxy-fuel conditions.

Design and performance of CEMCAP cement plant without CO2 capture

Atechno-economic study of the CEMCAP reference cement plant without CO2 capture is provided with process stream data, energy consumption, fuel and power input, CO2 emissions, cement production rate and estimated costs.

CAP Process optimisation and comparison with pilot plant tests

The deliverable will report the results achieved with the optimisation of the CAP process model. Pilot plant test results will be taken into account. Aim of the document is to assess the CAP performance and to provide the input for the plant integration investigated in WP4. Mass and heat balance for each stream and component of the optimal process will be reported.

Oxyfuel CFD-burner and large kiln simulations

Report on oxyfuel CFD simulations of the tested burner and on full-scale cement plant. The report will summarize results in respect to CFD model adaption and validation with experimental data obtained in WP7, as well as the results of the simulations of a large scale oxy-fuel cement kiln, including a results evaluation. The document will also provide input data and information from CFD simulations for the oxyfuel process simulation and optimisation in WP6.

CEMCAP Strategic conclusions – progressing CO2 capture from cement plants towards demonstration

This deliverable is the final public CEMCAP document, and will that summarize the work and draws the strategic conclusions for further development and deployment of CCS in the cement industry.

Membrane-assisted CO2-liquefaction scale up to TRL7-8

Describes the technical solutions required to proceed to on-site testing of membrane-assisted CO2 liquefaction on site at a cement plant. Preliminary design for combined membrane and CO2 liquefaction test plant for operating on-site at TRL7-8, taking user requirements into account. Includes process flow diagrams (PFDs)

CEMAP website

The website will be the online source to all public information and results from CEMCAP. Alerts about website updates will be spread via Twitter and Facebook.

CEMCAP Newsletter 3

The newsletters will contain highlights and other CEMCAP updates, and will be distributed via e-mail and posted on the website, alerts about new newsleters will be spread via Twitter and Facebook.

CEMCAP Newsletter 5

The newsletters will contain highlights and other CEMCAP updates, and will be distributed via e-mail and posted on the website, alerts about new newsleters will be spread via Twitter and Facebook.

CEMCAP Newsletter 4

The newsletters will contain highlights and other CEMCAP updates, and will be distributed via e-mail and posted on the website, alerts about new newsleters will be spread via Twitter and Facebook.

CEMCAP Newsletter 1

The newsletters will contain highlights and other CEMCAP updates, and will be distributed via e-mail and posted on the website, alerts about new newsleters will be spread via Twitter and Facebook.

CEMCAP Newsletter 2

The newsletters will contain highlights and other CEMCAP updates, and will be distributed via e-mail and posted on the website, alerts about new newsleters will be spread via Twitter and Facebook.

CEMCAP Newsletter 7

The newsletters will contain highlights and other CEMCAP updates, and will be distributed via e-mail and posted on the website, alerts about new newsleters will be spread via Twitter and Facebook.

CEMCAP Newsletter 6

The newsletters will contain highlights and other CEMCAP updates, and will be distributed via e-mail and posted on the website, alerts about new newsleters will be spread via Twitter and Facebook.

Clinker cooler film

This is a video describing the oxyfuel clinker cooler installation and operation in WP9, at the HeidelC plant in Hannover. The film is a dissemination Activity and the work is therefore carried out by WP2 (Task 2.3). VDZ is responsible for storyboard and filming, while SINTEF-ER will do the final editing.

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Publications

CEMCAP – Making CO 2 Capture Retrofittable to Cement Plants

Author(s): Kristin Jordal, Mari Voldsund, Sigmund Størset, Kristina Fleiger, Johannes Ruppert, Reinhold Spörl, Matthias Hornberger, Giovanni Cinti
Published in: Energy Procedia, Issue 114, 2017, Page(s) 6175-6180, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.03.1755

Techno-economic Analysis of MEA CO 2 Capture from a Cement Kiln – Impact of Steam Supply Scenario

Author(s): Simon Roussanaly, Chao Fu, Mari Voldsund, Rahul Anantharaman, Maurizio Spinelli, Matteo Romano
Published in: Energy Procedia, Issue 114, 2017, Page(s) 6229-6239, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.03.1761

Oxy-fuel burner investigations for CO2 capture in cement plants

Author(s): Francisco Carrasco-Maldonado, Jørn Bakken, Mario Ditaranto, Nils E.L. Haugen, Øyvind Langørgen, Simon Grathwohl, Jörg Maier
Published in: Energy Procedia, Issue 120, 2017, Page(s) 120-125, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.07.160

Membrane-assisted CO2 Liquefaction: Performance Modelling of CO2 Capture from Flue Gas in Cement Production

Author(s): Richard Bouma, Frank Vercauteren, Peter van Os, Earl Goetheer, David Berstad, Rahul Anantharaman
Published in: Energy Procedia, Issue 114, 2017, Page(s) 72-80, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.03.1149

Integration of Ca-Looping Systems for CO2 Capture in Cement Plants

Author(s): M. Spinelli, I. Martínez, E. De Lena, G. Cinti, M. Hornberger, R. Spörl, J.C. Abanades, S. Becker, R. Mathai, K. Fleiger, V. Hoenig, M. Gatti, R. Scaccabarozzi, S. Campanari, S. Consonni, M.C. Romano
Published in: Energy Procedia, Issue 114, 2017, Page(s) 6206-6214, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.03.1758

Screening CO2 Capture Test for Cement Plants Using a Lab Scale Calcium Looping Pilot Facility

Author(s): Mónica Alonso, Borja Arias, Alberto Méndez, Fernando Fuentes, J.Carlos Abanades
Published in: Energy Procedia, Issue 114, 2017, Page(s) 53-56, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.03.1146

Calcium Looping for CO2 Capture in Cement Plants – Pilot Scale Test

Author(s): M. Hornberger, R. Spörl, G. Scheffknecht
Published in: Energy Procedia, Issue 114, 2017, Page(s) 6171-6174, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.03.1754

Application of a Chilled Ammonia-based Process for CO2 Capture to Cement Plants

Author(s): José-Francisco Pérez-Calvo, Daniel Sutter, Matteo Gazzani, Marco Mazzotti
Published in: Energy Procedia, Issue 114, 2017, Page(s) 6197-6205, ISSN 1876-6102
DOI: 10.1016/j.egypro.2017.03.1757

Process integration study of tail-end Ca-Looping process for CO 2 capture in cement plants

Author(s): E. De Lena, M. Spinelli, I. Martínez, M. Gatti, R. Scaccabarozzi, G. Cinti, M.C. Romano
Published in: International Journal of Greenhouse Gas Control, Issue 67, 2017, Page(s) 71-92, ISSN 1750-5836
DOI: 10.1016/j.ijggc.2017.10.005

One-dimensional model of entrained-flow carbonator for CO2 capture in cement kilns by Calcium looping process

Author(s): Maurizio Spinelli, Isabel Martínez, Matteo C. Romano
Published in: Chemical Engineering Science, Issue 191, 2018, Page(s) 100-114, ISSN 0009-2509
DOI: 10.1016/j.ces.2018.06.051

Carbonation of Fine CaO Particles in a Drop Tube Reactor


Published in: ISSN 0888-5885
DOI: 10.1021/acs.iecr.8b02918

Pilot Tests and Rate-Based Modelling of CO2 Capture in Cement Plants Using an Aqueous Ammonia Solution

Author(s): José-Francisco Pérez-Calvo, Daniel Sutter, Federico Milella, Matteo Gazzani, Marco Mazzotti
Published in: Chemical Engineering Transactions, Issue 69, 2018, Page(s) 145-150, ISSN 2283-9216
DOI: 10.3303/CET1869025

Experimental investigations of oxyfuel burner for cement production application

Author(s): Francisco Carrasco, Simon Grathwohl, Jörg Maier, Johannes Ruppert, Günter Scheffknecht
Published in: Fuel, Issue 236, 2019, Page(s) 608-614, ISSN 0016-2361
DOI: 10.1016/j.fuel.2018.08.135

CO 2 Carrying Capacities of Cement Raw Meals in Calcium Looping Systems


Published in: ISSN 0887-0624
DOI: 10.1021/acs.energyfuels.7b02586

State-of-the-art Paper No. 6: Carbon Capture and Storage (CCS): Long-term perspective for application in the cement industry

Author(s): Johannes Ruppert, Helmut Hoppe, Volker Hoenig, Martin Schneider
Published in: Development of State of the Art-Techniques in Cement Manufacturing: Trying to Look Ahead; CSI/ECRA-Technology Papers 2017, 2017