Carbon capture in cement production and its reuse

Transcription

1 Remi CHAUVY Carbon capture in cement production and its reuse Lionel DUBOIS, Diane THOMAS, Guy DE WEIRELD Faculty of Engineering (FPMs), UMONS, Mons, Belgium ECRA/CEMCAP/CLEANKER workshop - Brussels 17/10/2018

2 Cement industry ECRA CO 2 Capture & Purification CO 2 Conversion Full oxy-fuel CO 2 capture y CO2 > 70% CO 2 Purification Unit (CPU) De-SOx/De-NOx Sour Compression Unit (SCU) Partial oxy-fuel 35 < y CO2 < 70% Postcombustion y CO2 < 35% Absorption-Regeneration CO 2 capture Process: Conventional & Demixing solvents Other configurations Modeling Experiments Techno-economic analysis CO 2 to X: Methanol Methane Modeling Techno-economic Environmental analysis University of Mons Collaborative team work between 4 PhD, 1 Post Doc Remi CHAUVY ECRA/CEMCAP/CLEANKER workshop 17/10/2018 2

3 Context: Carbon Capture & Utilization (CCUS) CCS/CCU CCU CO 2 capture and purification Amine scrubbing Membrane Pressure Swing Adsorption etc. Capture and Storage (CCS) Sequestration Geological storage Saline aquifers Capture and Utilization (CCU) Conversion Chemicals Mineralization Biological etc. Fuels Organic chemicals Carbonates Polymers Microalgae Non exhaustive 3

4 Technology Readiness Level for main CO 2 -based products Commercialized Demonstration scale TRL 7-9 Development scale TRL 4-6 R & D TRL 1-3 4

5 Size of CO 2 utilization (non-exhaustive) No Equivalent of cement plants: Potential of CO2 reduction CO2 emissions of 1 BAT cement plant [Mt y] [Mt y] With: CO 2 emissions of 1 BAT cement plant = 0.74 Mt/y eq. to 120 cement plants eq. to 35 cement plants 5

6 Selection of CO 2 -based conversion pathways Identification > 100 conversion pathways Pre-selection Reduction of the panel Selection Multicriteria assessment Methodological selection [1] CO 2 -based compound CO 2 -conversion process Interest Methanol Hydrogenation ***** Methane Hydrogenation ***** Dimethyl carbonate Organic synthesis ***** Calcium carbonates Mineral carbonation ***** Microalgae Biological process **** Polycarbonates Organic synthesis **** Sodium carbonates Mineral carbonation *** Ethanol Microbial process ** Syngas Dry reforming ** Formic acid CO 2 Electroreduction * CO 2 conversion alternatives [1] Chauvy R, et al. Selecting emerging CO 2 utilization products for short to mid-term deployment (2018) University of Mons Remi CHAUVY ECRA/CEMCAP/CLEANKER workshop 17/10/2018 6

7 CO 2 to methanol: Global Chain Technological metrics of the CO 2 capture and conversion units normalized to the production of one-ton methanol Emissions water / air / solid wastes Infrastructure & Raw materials Electricity Fuels Electricity Steam Electricity Steam Water Carbon free electricity 0.1 MWh 6.7 GJ 0.01 MWh 4 GJ 0.33 MWh 0 GJ 1830 kg 11 MWh 1.4 GJ System boundary Cement plant Pre-treated Flue gas 1644 kg CO 2 CO 2 capture 14 kg water 1479 kg CO 2 Methanol synthesis 203 kg H 2 Production of hydrogen 125 kg CO kg 165 kg CO kg 1000 kg 1626 kg Indirect emissions Clinker Purified flue gas Excess water Methanol Oxygen 7

8 CO 2 to methanol: Economics Project Capital Costs for CO 2 Capture & Conversion 60 M Global CAPEX Project Investment CO 2 Capture (37 %) CO 2 Conversion (63 %) H 2 production CAPEX: 438 M Cost Estimations of Operational Expenses (per ton methanol) /ton methanol Methanol selling O2 selling CO2 credit tax Hydrogen Production CO2 Capture CO2 Conversion Amortized CAPEX TOTAL O 2 Selling: 86 CO 2 Credit Tax: 20 CO 2 Capture: 30 Global OPEX CO 2 Conversion: 24 CAPEX: 8 90 per ton CO 2 8

9 CO 2 to methanol: Carbon footprint Comparison between the environmental impacts of reference system and CO 2 -based alternative Reference system Integrated CO 2 -based alternative Infrastructure & Raw materials Emissions water / air / solid wastes Cement plant Methanol synthesis (SMR) Renewable energy production Clinker Methanol Carbon free electricity Clinker production CO 2 conversion unit H 2 production CO 2 capture unit CO 2 inlet Reference system Maximum Reduction by 50% of CO 2 emissions! Need of additional scenarios 9

10 Concluding remarks Economic viability of CCU process highly dependent on the assumptions (e.g. price of electricity) CO 2 reduction may be possible only if renewable energy use as input Mitigation potential of CCU to methanol: 50% of the original emissions of the reference system without CCU Need to perform additional scenarios CCU is NOT in competition with CCS: COMPLEMENTARY approach for CO 2 mitigation CO 2 to methanol, CO 2 to methane (Power to gas), CO 2 to formic acid : study cases in progress Propose environmentally friendly, integrated and optimized CO 2 conversion processes applied to the cement sector! 10

11 Thank you for your attention We gratefully acknowledge the ECRA for its technical and financial support More information of the ECRA Chair at: Remi CHAUVY, Lionel DUBOIS, Diane THOMAS, Guy DE WEIRELD ECRA/CEMCAP/CLEANKER workshop - Brussels 17/10/2018