CO Capture and Storage: Options and Challenges For The Cement Industry

CO2 Capture and Storage: Options and
Challenges for the Cement Industry

Martin Schneider, Dsseldorf, Germany
CSI Workshop
Beijing, 16 17 November 2008
CO2 abatement costs will tremendously increase

Global cost curve for greenhouse gas abatement measures beyond business as usual;
greenhouse gases measured in GtCO2e1
Source:
McKinsey-Quarterly 1/2007
CO2 abatement costs will tremendously increase

Global cost curve for greenhouse gas abatement measures beyond business as usual;
greenhouse gases measured in GtCO2e1
1.
2.
3.
4.
5.
GtCO2e=Giga tonnes of CO2 equivalent, business as usual based on emission growth driven mainly by increasing demand for energy
tCO2e= tonne of CO2 equivalent
Measures costing more than 40$ were not the focus of this study
Atmosperic concentrations of all greenhouse gases recalculated into CO2e in ppm
Source:
Marginal costs of avoiding 1tonne of CO2e in each abatement scenarion
McKinsey-Quarterly 1/2007
CO2 Capture and Storage:

Options and Challenges for the Cement Industry
1. Introduction
2. The cement clinker burning process
3. General CO2 capture technologies
4. Applicability of CO2 capture technologies to the
clinker burning process ECRA research project
5. CO2 transport and storage
6. Summary and outlook
CO2 Emissions from Large Stationary Sources

Process
Emissions [Mt CO2/yr] *
Power Plants
10,539
Cement Production
932
Refineries
798
Iron and Steel Industry
646
Petrochemical Industry
379
Oil and Gas Processing
50
Other Sources
33
*IPCC Special Report Carbon Dioxide Capture and Storage (2005)

1. Introduction
clinker burning process - ECRA research project
The cement clinker burning process

preheater exit
gas
kiln feed
cooler exhaust gas
fuel
tertiary air
secondary air
primary
air
fuel
clinker
cooling air
CO2 emissions from the clinker burning process
Calcination of raw material:

CaCO3
CaO + CO2
0,5250,555 kg CO2/kg clinker
Fuel combustion
0,2800,415 kg CO2/kg clinker
Electricity use
Electricity
use
6%
Fuel
combustion
38%
Decarbonisation
56%
Options to control the CO2 emissions from the clinker

burning process
Conventional technologies
Reduction of clinker / cement ratio
Decarbonated raw materials
Utilization of biomass
Limited reduction
potential left
Energy efficiency measures

CO2 capture technologies
CO2 capture at large stationary sources
Transport of CO2 to appropriate storage sites
Long-term underground storage of CO2
Not state of the art

and very expensive

1. Introduction
General CO2 capture technologies
Pre-combustion capture
Oxy-fuel combustion capture
Post-combustion capture
Others (e.g. carbonate looping, ....)
Pre-combustion technologies (1)
natural
gas
reforming
process
coal
gasification
process
biomass
H2
combustion process
CO2
storage
H2
combustion process
CO2
storage

Scheme of gasification process:
Partial oxidation for heat supply
CH4 + O2 CO + H2
Gasification of solid carbonaceous matter
2 C + O2
2 CO
C + H2O
CO + H2
CO shift for hydrogen synthesis
CO + H2O CO2 + H2

Level of implementation:
Steam reforming is the predominant technology for H2 production

worldwide
IGCC (Integrated Gasification Combined Cycle) demonstration

plants since the 1970s
IGCC can be realized with or without CO2 capture

Several full-scale IGCC projects with CO2 capture are being
planned in the power sector
Oxy-fuel combustion
Elimination of nitrogen from the flue gas

Combustion in pure oxygen or a mixture of oxygen and a
CO2-rich recycled flue gas
Flue gas consists mainly of CO2 and water vapour

Flue gas cooling to condense the water
Concentrated CO2 stream is compressed, dried
and purified before delivery into a pipeline for storage
General scheme of Oxy-fuel combustion processes
air
air separation
N2
atmosphere
exhaust gas
recirculation
O2
fuel
combustion
process
exhaust
gas
(CO2 enriched)
Post-combustion technologies
Flue gas from combustion processes is passed through

equipment which separates most of the CO2
Impurities in the flue gas stream are very important for the
design of the plant and affect the costs significantly
(low dust, NO2 and SO2 concentration required)
End-of-pipe technology
Commercially available (absorption technologies)
Retrofit to existing plants possible
Different types of post-combustion technologies
Absorption technologies:
- Chemical absorption
- Physical absorption
Membrane processes
Solid sorbent processes:
- Physisorption processes
- Mineral carbonation
- Carbonate looping
Absorption technologies are most developed today

Chemical absorption:
- Amines (e.g. MEA) or inorganic salt
solutions (e.g. K2CO3) as absorbent
- High energy demand for solvent
regeneration
- Very low dust, SO2 and NO2
concentration required
- CO2 capture costs for new coal-fired
power plants: 29-51 $/t CO2
Physical absorption:
- Solvents as absorbent
(e.g. methanol)
- High CO2 content required
CO2 capture by chemical absorption

(fertilizer plant in Malaysia)
Simplified flow sheet

of chemical absorption process for CO2 capture

1. Introduction
ECRA research project on CCS

Carbon Capture technology
Options and Potentials for the Cement Industry
Phase I: Literature and scoping study (2007)

Phase II: Study about technical and financial aspects of CCS
projects, concentrationg on oxy-fuel and post-combustion
(autumn 2007- summer 2009)
Phase III: Laboratory-scale / small-scale research activities

(autumn 2009 summer 2011)
Phase IV: Pilot-scale research activities (time-frame: 2-3 years)
Assessment of CO2 Capture Technologies

Fuel generated Raw material
CO2
generated CO2
Effects on
burning
process
Applicable to
the clinker
burning
process ?
PreCombustion
yes
no
Oxy-fuel
yes
new plants
PostCombustion
no
new plants,
retrofit
Applicability of pre-combustion technologies to the

clinker burning process (1)
Hydrogen from syngas of gasification processes
as fuel for cement kiln burners?
Hydrogen has different properties

as actual fuels:
- handling/feeding must be solved
- pure H2 cannot be used in
kiln firing
H2 flames have low heat transfer
by radiation
- temperature profile in the kiln
- injection of raw meal or clinker
dust

Hydrogen from syngas of gasification processes
as fuel for cement kiln burners?
New combustion technologies

required:
- non-carbonaceous flame
ingredients
- new burner technologies
for increasing heat transfer
Only abatement of fuel CO2
is captured
1/3 of total CO2 emissions
Hardly promising for clinker burning process

air
air separation
atmosphere
N2
exhaust gas
recirculation
O2
exhaust
gas
fuel
raw material
(CO2 enriched)
clinker burning
process
clinker

On-site oxygen production required (air separation plant)

New combustion technologies required, e.g.:
Oxy-fuel burner
Waste gas recirculation
Modification of plant design, e.g.:

Dimension of kiln, cooler, preheater
Gas recirculation including dedusting, cooling
Impact on reactions (e.g. decarbonation) and clinker quality
Influence of CO2 partial pressure on decarbonation

kiln meal 2
1,0
degree of decarbonation
pCO2 = 0,2 bar
The equilibrium
temperature of the
decarbonation of
calcium carbonate
and cement raw
meals will be
increased
by 50 70 K
pCO2 = 0,4 bar
0,8
pCO2 = 0,6 bar

pCO2 = 0,8 bar
0,6
pCO2 = 0,97 bar

0,4
0,2
0,0
650
700
750
800
850
temperature [C]
900
950
1000
Modeling of the clinker burning process

clinker burning process (dry)
chemical / mineralogical reactions
heat transfer
process technology
energy and material balances
(approximately 1000 balance spaces)
balance spaces
The gas temperature profile in the rotary kiln will be

changed by higher CO2 concentration in combustion air
2400
temperature [C]
2200
2000
1800
1600
1400
1200
1000
kiln length
0 Vol-% CO2
30 Vol-% CO2
60 Vol-% CO2
reference
10 Vol-%
40 Vol-%
70 Vol-%
CO2
CO2
CO2
20 Vol-% CO2
50 Vol-% CO2
79 Vol-% CO2
The maximum temperature of flame gases and raw meal in

the sintering zone will be decreased by oxy-fuel operation
2200
temperature [C]
2000
1800
kiln feed
gas
1600
1400
1450C
10
20
30
40
50
60
70
80
CO2 concentration in tertiary-/secondary air" [Vol-%]
The energy balance of a cement kiln will be significantly

affected by the oxy-fuel operation
88
70
84
68
66
80
64
76
62
60
72
10
20
30
40
50
60
70
CO2 concentration in combustion air [Vol-%]
preheater
cooler
80
degree of efficiency [%]
degree of efficiency [%]
72
Applicability of post-combustion capture to the clinker

burning process
CO2
air
fuel
raw material
clinker
burning
process
CO2
absorption
transport,
storage
exhaust gas
(CO2 poor)
clinker
Application of CO2 capture with amine absorption in a

Norwegian 3000 t/d cement plant (pilot study)
Technical requirements:
NOx abatement with SNCR
SO2 abatement with wet
scrubber
waste heat recovery boiler
CO2 capture amine absorption
Amine recovery with stripper
Gas fired boiler
2006 data
Investment costs in mio

thereof:
- waste gas cleaning
- waste heat recovery boiler
- CO2 capture
- CO2 drying and compression
- boiler
Operating costs in mio /year
Total costs in /t CO2
110
8
7
32
28
28
32
45

1. Introduction
clinker burning process ECRA research project
CCS: CO2 capture, transport and storage
Transport of CO2 is state of the art but for

considerably smaller quantities
CO2 transport ship
CO2 pipeline
Transport costs through pipelines are determined by

distance and mass flow rate
Storage Options for CO2
CO2 enhanced oil recovery

CO2 enhanced gas recovery
CO2 enhanced coal-bed methane recovery (ECBM)
Storage in depleted oil and gas fields
Storage in deep saline aquifers
Other storage options
Storage Options for CO2
CO2 storage with enhanced oil recovery (EOR)
recycled CO2
production
well
CO2 injection
CO2
water
oil
Source: IEA 2004
International CO2 Storage projects
Exhaust gas composition effect on CCS

Impurities
Known effects on
SO2
density of compressed CO2
NOx
compressibility
H2S
water solubility
H2O
flow rate
No significant difference between CO2 from cement plants and

power plants
Small impact of efficiency
Criteria for storage site selection

Trapping mechanisms:
Physical: statigraphic and structual
Physical: hydrodynamic
Geochemical
Others
Source: Baele, J.-M., 2008
Suitable storage formation - Belgium, an example
Campine Basin:
Potential sequestration
in coal seams
Subsequent coal bed
methane production
Source: P.C.H., 2001

1. Introduction
Criteria for the application of CCS

ecology/risk assessment
evidence has to be mainly provided
for long-term secure storage
technology
acceptance
is already available in principle,

but has to be further developed for
CO2 capture, transport and storage
(mainly for very high mass flows)
has to be assured in
society (especially for
long-term storage)
costs
have to be reduced significantly
Potential future application of CCS in the cement

industry
Short-term: no relevance due to
- Very high costs (> 50 $/t CO2 avoided)
- Not existing availability of capture technologies
Medium-term: depends on policy decisions and technical developments

- International climate policy
- Cost reductions due to technical developments (target value: 20-30 $/t CO2)
Long-term: high relevance possible if

- Other options are exhausted
- Worldwide comparable costs for cement production would be introduced
Summary and outlook

CO2 capture technologies are not technically available for the cement
industry
Pre-combustion technologies are not promising because only fuel CO2

would be captured
Oxy-fuel combustion is state-of-the-art in a few other industry sectors and

seems to be promising for new kilns
Post-combustion capture is state-of-the-art in other industrial sectors, but

on relatively small scale
From a today's point of view CCS is by far too expensive for the cement
industry
Huge research efforts would be/are necessary to develop CO2 capture

technologies for the cement production process
ECRA research project shall enable the cement industry to give

scientifically based reliable answers to political requirements in the future

CO Capture and Storage: Options and Challenges For The Cement Industry

Uploaded by

Copyright:

Available Formats

CO Capture and Storage: Options and Challenges For The Cement Industry

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CO Capture and Storage: Options and Challenges For The Cement Industry

Uploaded by

Copyright:

Available Formats

CO2 Capture and Storage: Options and

Challenges for the Cement Industry

CO2 abatement costs will tremendously increase

CO2 abatement costs will tremendously increase

CO2 Capture and Storage:

CO2 Emissions from Large Stationary Sources

Emissions [Mt CO2/yr] *

Iron and Steel Industry

Oil and Gas Processing

*IPCC Special Report Carbon Dioxide Capture and Storage (2005)

CO2 Capture and Storage:

The cement clinker burning process

cooler exhaust gas

CO2 emissions from the clinker burning process

Calcination of raw material:

0,5250,555 kg CO2/kg clinker

Options to control the CO2 emissions from the clinker

Energy efficiency measures

Not state of the art

CO2 Capture and Storage:

General CO2 capture technologies

Pre-combustion technologies (1)

Pre-combustion technologies (2)

Pre-combustion technologies (3)

Steam reforming is the predominant technology for H2 production

IGCC (Integrated Gasification Combined Cycle) demonstration

IGCC can be realized with or without CO2 capture

Elimination of nitrogen from the flue gas

Flue gas consists mainly of CO2 and water vapour

General scheme of Oxy-fuel combustion processes

Flue gas from combustion processes is passed through

Different types of post-combustion technologies

Absorption technologies are most developed today

CO2 capture by chemical absorption

Simplified flow sheet

CO2 Capture and Storage:

ECRA research project on CCS

Phase I: Literature and scoping study (2007)

Phase III: Laboratory-scale / small-scale research activities

Phase IV: Pilot-scale research activities (time-frame: 2-3 years)

Assessment of CO2 Capture Technologies

Applicability of pre-combustion technologies to the

Hydrogen has different properties

Applicability of pre-combustion technologies to the

New combustion technologies

Only abatement of fuel CO2

Applicability of pre-combustion technologies to the

Applicability of pre-combustion technologies to the

On-site oxygen production required (air separation plant)

Modification of plant design, e.g.:

Impact on reactions (e.g. decarbonation) and clinker quality

Influence of CO2 partial pressure on decarbonation

pCO2 = 0,2 bar

pCO2 = 0,4 bar

pCO2 = 0,6 bar

pCO2 = 0,97 bar

Modeling of the clinker burning process

The gas temperature profile in the rotary kiln will be

The maximum temperature of flame gases and raw meal in