EU research project CLEANKER Technology, progress and project perspectives

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1 17 th 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

2 Summary Project objectives The demo plant The consortium Work packages and main activities CLEANKER project timeline 2

3 Primary project objectives The ultimate objective of CLEANKER is advancing the integrated Calcium-looping process for CO 2 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 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 CO 2 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. 3

4 Vernasca plant location VERNASCA PLANT 4

5 Primary project objectives 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) 5

6 Calciner 920 C Carbonator 650 C Schematic of the integrated CaL concept CPU CO 2 rich flue gas Raw meal CO 2 poor flue gas CO 2 to utilization or storage CaCO 3 FGR CaO Air O 2 ASU Flue gas from kiln Rotary kiln Air N 2 Clinker Calcination: CaCO 3 + O 2 + fuel (CH) CaO + CO 2 + CO 2 + H 2 O (920 C) + CO 2 (650 C) 6

7 Calciner Carbonator Integrated CaL concept CaL cement plant Raw meal CaCO 3 Flue gas (with CO 2 ) to environment CO 2 CO2 CO2 Existing pre-heating tower Calciner: CaCO 3 (fresh + from carbonator) + heat -> CaO + CO 2 (to storage) CO 2 to storage or utilization CO 2 Carbonator: CaO (from calciner) + CO 2 (from kiln fuel) -> CaCO 3 (to calciner) + heat Raw meal CaCO 3 Flue gas (poor in CO 2) to the environment CO 2 CO2 CO 2 from: calciner fuel Calcined raw meal to carbonator (CaO-rich) Raw meal preheater CO2 fresh raw meal CO2 CO 2 Pre-calciner: CaCO 3 + heat -> CaO + CO 2 III Air kiln fuel CO2 Recarbonated sorbent (CaCO3 - rich) + fresh preheated raw meal to calciner III Air Rotary kiln: CaO + heat -> clinker Clinker cooler Clinker Air O 2 Calcined raw meal to rotary kiln (CaO rich) Rotary kiln: CaO (from calciner) + heat -> clinker + flue gas Clinker cooler Clinker Air 7

8 Indicative configuration of the CLEANKER pilot Flue gas CO 2 rich flue gas to storage/utilization CO 2 poor flue gas Calciner 920 C CaO Carbonator C Flue gas from cement kiln Existing pre-heating tower (Vernasca) CaCO 3 O 2 Demonstrator Raw meal Solids Pre-calciner Rotary kiln Tertiary air Air Clinker 8

9 Project targets Objective Key indexes Target CO 2 emissions CO 2 capture efficiency CO 2 specific emissions Cement plant CO 2 capture efficiency >90% Negative direct CO 2 emissions by biomass cofiring (Bio-CCS) Reduction of total CO 2 specific emissions (kg CO2 per ton of cement) >85%* Energy efficiency Economics consumption Electricity consumption Specific primary energy consumption for CO 2 avoided (SPECCA*) Cost of cement Cost of CO 2 avoided 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 MJ LHV per kg of CO 2 avoided SPECCA* at least 10% lower than that of benchmark full oxyfuel cement plants Increase of cement cost < 25 / tcement Cost of CO 2 avoided <30 /t CO2 *SPECCA = Specific primary energy consumption for CO 2 avoided 9

10 Minimum carbonator efficiency required? CO 2 out 854 kg CO2 Raw meal 540 kg CO2 generation of CO 2 from calcination: CaCO 3 CaO + CO kg CO2 generation of CO 2 from fuel oxidation: C CO 2 1t clinker generation of CO 2 from fuel oxidation: C CO kg CO2 CLEANKER Project 10

11 Minimum carbonator efficiency required? Calciner Carbonator CPU CO 2 to utilization or storage Target: 854 * 90% = 769 kg CO2 CO 2 rich flue gas 486 kg CO2 (90% - raw meal) kg CO2 (100% calciner fuel) 188 kg CO2 FGR O 2 Raw meal 540 kg CO2 CaCO 3 CaO CO 2 poor flue gas Carbonator efficiency: = 95 kg CO2 95 / 180 ~ 53% Flue gas from kiln = 180 kg CO2 CaO 54 kg CO2 (10% - raw meal) 126 kg CO2 Rotary kiln Air 1t clinker CLEANKER Project 11

12 Vernasca kiln preheater and rendering of CaL pilot 12

13 The consortium Starting date: October 1 st 2017 Duration: 4 years Total budget: ,25 UE co-financing: ,25 Chinese governement founding: Partner: 13 from 5 EU member states + Switzerland and China 13

14 The WPs structure WP1 - Management WP2 Demonstration system design WP3 Demonstration of CaL process WP4 Comparative characterization of raw meals for CaL WP5 Process integration and modelling WP7 Transport and storage WP6 Scale up, economics, LCA WP8 Exploitation WP9 - Dissemination 14

15 1 st October 2017 CLEANKER timeline 30 th September October 2017 Kick-off meeting (Piacenza) July 2018 Raw meal characterization December 2019 Erection March 2020 Running tests and data analysis June 2018 Measuring points and instrumentation January 2020 Inspection April 2021 Casting concrete results and full economic analysis of cement plant with CaL July 2018 Final Plant layout March 2019 Main items fabrication September 2021 Strategic conclusions 15

16 Acknowledgments This project has received funding from the European Union's Horizon 2020 Framework Programme under Grant Agreement n This work is supported by the China Government (National Natural Science Foundation of China) under contract No and No 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 16