eu research project cleanker technology, progress and ...€¦ · primary project objectives the...

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


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


4

VERNASCA PLANT

Primary project objectives


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


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


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


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


12

The consortium


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


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


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


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

eu research project cleanker technology, progress and ...€¦ · primary project objectives the...

Documents