Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
17th October 2018, Brussel - Belgium ECRA/CEMCAP/CLEANKER Workshop “Carbon Capture Technologies in the Cement Industry”
EU research project CLEANKER Technology, progress and project perspectives
Martina Fantini
Summary
The CLEANKER project
2
• Project objectives
• The demo plant
• The consortium
• Work packages and main activities
• CLEANKER project timeline
Primary project objectives
The CLEANKER project
3
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 900.000 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 location
The CLEANKER project
4
VERNASCA PLANT
Primary project objectives
The CLEANKER project
5
• TRL 1 – basic principles observed
• TRL 2 – technology concept formulated
• TRL 3 – experimental proof of concept
• TRL 4 – technology validated in lab
• TRL 5 – technology validated in relevant environment (industrially relevant environment in the case of key enabling technologies)
• TRL 6 – technology demonstrated in relevant environment (industrially relevant environment in the case of key enabling technologies)
• TRL 7 – system prototype demonstration in operational environment
• TRL 8 – system complete and qualified
• TRL 9 – actual system proven in operational environment (competitive manufacturing in the case of key enabling technologies; or in space)
Schematic of the integrated CaL concept
6 The CLEANKER project
Calcination:
CaCO3 + O2 + fuel (CH) CaO + CO2 + CO2 + H2O (920°C)
+ CO2 (650°C)
Rotary kiln
Calc
iner
92
0°C
ASU
CaO
CaCO3
Raw meal
Clinker
Fuel
Fuel
Air
O2
Air
CO2 rich flue gas
FGR
Flue gas from kiln
CO2 poor flue gas
Carb
onato
r
65
0°C
CO2 to utilization
or storage
CPU
N2
Integrated CaL concept
The CLEANKER project
7
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
Indicative configuration of the CLEANKER pilot
The CLEANKER project
8
Rotary kiln
Carbonator650-700°CCalciner
920°C
CaO
Pre-calciner
CaCO3
Tertiary air
SolidsFuel
Clinker
Air
O2
CO2 poor flue gas
Fuel
CO2 rich flue gas to storage/utilization
Flue gas
Existing pre-heating tower (Vernasca)
Raw meal
Demonstrator
Flue gasfrom
cement kiln
Project targets
The CLEANKER project
9
*SPECCA = Specific primary energy consumption for CO2 avoided
Objective Key indexes Target
CO2 emissions
CO2 capture efficiency CO2 specific emissions
Cement plant CO2 capture efficiency >90% Negative direct CO2 emissions by biomass co-
firing (Bio-CCS) Reduction of total CO2 specific emissions (kgCO2
per ton of cement) >85%*
Energy efficiency Fuel consumption Electricity consumption Specific primary energy
consumption for CO2 avoided
(SPECCA*)
increase of total fuel consumption with respect to
state of the art plants <40%* increase of electric consumption with respect to
state of the art plants <20%* SPECCA* < 2 MJLHV per kg of CO2 avoided SPECCA* at least 10% lower than that of
benchmark full oxyfuel cement plants
Economics
Cost of cement Cost of CO2 avoided
Increase of cement cost < 25 €/tcement Cost of CO2 avoided <30 €/tCO2
Minimum carbonator efficiency required?
CLEANKER Project 10
generation of CO2 from fuel oxidation: C CO2
generation of CO2 from fuel oxidation: C CO2
generation of CO2 from calcination: CaCO3 CaO + CO2
Fuel
CO2 out
1t clinker
854 kg CO2
Fuel
126 kg CO2
Raw meal
540 kg CO2
Fuel
188 kg CO2
Minimum carbonator efficiency required?
CLEANKER Project 11
Raw meal
540 kg CO2
Flue gas from kiln
126 + 54 = 180 kg CO2 CaO
54 kg CO2
(10% - raw meal)
Carbonator efficiency:
769 – 486 – 188 =
95 kg CO2
95 / 180 ~ 53%
CO2 rich flue gas
486 kg CO2 (90% - raw meal)
+
188 kg CO2 (100% calciner fuel)
Rotary kiln
Calc
iner
CaO
CaCO3
Air
O2
FGR
CO2 poor flue gas
Carb
onato
r
Fuel
126 kg CO2
1t clinker
Target:
854 * 90% =
769 kg CO2
Fuel
188 kg CO2
CO2 to
utilization or
storage
CPU
Vernasca kiln preheater and rendering of CaL pilot
The CLEANKER project
12
The consortium
The CLEANKER project
13
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
The WPs structure
The CLEANKER project
14
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
CLEANKER timeline
The CLEANKER project
15
2021 2020 2019 2018 2017
1st
Oct
ob
er 2
01
7
30
th S
ep
tem
ber
20
21
17-18 October 2017 Kick-off meeting (Piacenza)
July 2018 Final Plant layout
December 2019 Erection
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 Main items fabrication
January 2020 Inspection
July 2018 Raw meal
characterization
June 2018 Measuring points
and instrumentation
Acknowledgments
16
This project has received funding from the European Union's Horizon 2020 Framework 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
The CLEANKER project
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