Harnessing CO2. The CO2 and the Cement Industry: Uses & Needs OCTAVIUS / IFPEN Rueil, November Michel Gimenez

Transcription

1 Harnessing CO2 The CO2 and the Cement Industry: Uses & Needs OCTAVIUS / IFPEN Rueil, November 2015 Michel Gimenez

2 This is a Cement Plant! 2

3 CO 2 Emission of a Cement Plant Combustion 0,20 t CO 2 0,60 t CO 2 0,1 t Fuel Calcination 0,40 t CO 2 Additions 0,253 t e.g. ~ 600 kg CO 2 /t cement Raw material Cement Clinker c/k = 1,34 1,15 t 0,747 t 1 t 3 4

4 Breakthrough Levers New low CO 2 intensive products (cement and concrete): Low burning: - 30 % CO 2 /t Mineral carbonation: ~ - 70 % CO 2 /t Carbonated aggregates by CO 2 applications: we favor direct flue gas capture & uses: Mineral carbonation: see above + Skyonic example in Texas Some chemistry with low concentration CO 2? High concentration CO 2 capture (>99 %) is still expensive = /t and can be used for EOR, high value added applications and geological storage. No business model is established today for CCS 4

5 Which CO 2 Uses in the Cement Industry? The birth of a new type of binders LafargeHolcim is developing a new type of binder through a collaboration with the start up company SOLIDIA, based in New Jersey (USA) Industrial productions, 2 x 5000 t, made year 2014 in USA and in 2015 in Hungary 5

6 Which CO 2 Uses in the Cement Industry? The birth of a new type of binders Many trials have been performed with SOLIDIA at customer sites (concrete precast) Market development started in North America and Europe ( ) Up to 70 % CO 2 reduction is expected by using the SOLIDIA binder as compared to usual Portland cement but application segments still need to be developed: today nonstructural precast only 6

7 Applications Railroad Sleepers Concrete Block Products AAC Block Concrete Pavers / Hardscape Products 7

8 CO 2 Needs Capture & logistics The amount of CO 2 potentially available in our plants is generally exceeding by far the needs (ratio ~ 1 to 10) CO 2 source is present in our cement plants but is still very expensive to capture and cost is critical to the business model (50 /t 75 /t) There is a need for cheap & small size CO 2 capture plants i.e. 50,000 t/y 100 kt/y Logistics is critical in most CO 2 applications because it implies liquefaction 8

9 CO 2 Needs And then? CO 2 is not necessarily emitted where it is needed Capture can be partial and thus, not synonymous to storage Choosing the partial capture means going for the postcombustion technologies Energy integration may be envisioned in most cement plants due to waste heat availability CO 2 utilizations will not trigger the development of full capture to storage chain, while the other way round may be true (you can plug on a CO2 pipe and use the quantity you need for your specific use) 9

10 CO 2 Uses vs CO 2 Storage There are differences in Business Models Volume of CO 2 needed for use is by far smaller than the CO 2 emitted CO 2 uses will not enable storage because the business model are not the same (while the other way round could be true) They will develop in parallel and not sequentially CO 2 Uses 2050 CO 2 Capture & Storage 10

11 CO 2 Uses & Mitigation Effect Which CO 2 Applications? Chemical applications are small but rewarding (e.g., polymers) Mineral carbonation is bigger but not too rewarding (e.g., building materials) Direct applications (algae growth, greenhouses ) are local Fuel making meets a big market (e.g. power to gas) but requires a reducing agent (e.g., H 2 ) produced from low carbon power and expensive and scarce 11

12 Market Size of the CO 2 Applications Concrete We are here Source Market Size World Wide per Year Product Value Addition ( /t) 12

13 CO 2 Needs Quantities Chemical uses may be compared to lab scale: 10 Mt CO 2 /y Mineral carbonation to pilot scale one: 100 Mt CO 2 /y Storage to industrial scale: 1Bt CO 2 /y An average cement plant is emitting 750 kt CO 2 per year and the CO 2 needs for carbonation might be 75 kt/y, i.e. 10% (70 kt to 100 kt is the standard size CO 2 production plant in Europe today) We thus need cheap, well located & small-sized CO 2 capture plants Credit 13

14 CO 2 Needs Cost The CO 2 on the market today is in limited quantity and devoted to its market demand; its specifications are not adapted to mineral carbonation (too pure ) Investing a full-size capture plant and using only 10 % of it is not sound regarding capture cost, thus preventing CO 2 uses to develop Small capture plants will be less expensive than full size ones but the CO 2 captured more expensive, both due to size effect The more concentrated the CO 2, the cheaper the capture thus, selected sources of CO 2 will be the first concerned e.g. biogas plants, fermentation plants, SMR (when not captured yet) No pipelines are requested for shipping but only refrigerated truck, and liquid CO 2 storage on utilization sites 14

15 The Biogas, the CO 2, the Concrete and the GIS All plants Biogas & Precast and Nat. Gas Pipes 15

16 CO 2 Cost versus Capture Plant Size Needs between 50,000 tco 2 /y and 100,000 tco 2 /y /t CO 2 (MEA plant) 50,000 t/y< CO 2 needs for carbonation < 100,000 t/y t CO 2 /y LafargeHolcim CO 2 Uses & Needs

17 Summary Learning on Capture Technologies % CO 2 Captured DMX Solvent (99% vol ) [2] [1] MEA Solvent (99%vol) Oxycombustion (80%-99%vol) [3] [4] Separated calcination (80%-99%vol) CO 2 from Flue Gas (15%-25% vol ) [5] [1] From the ACACIA project with IFPEN ( ) [2] From the ACACIA project with IFPEN ( ) [3] Estim. by LAFARGE-AL-FLS Oxycomb. Project (2013) [4] Estim. by LAFARGE IPC-LEC (2013) [5] Estim. LAFARGE IPC-LEC (2015) CO 2 Capture Cost /t CO2 17

18 CO 2 Uses in the Frame of the Cement Industry Progress conclusion We do sell minerals! Therefore, mineralization appears to be the most adapted to our industry; we do close the loop, provided the final product can be sold SOLIDIA or Carbon8 experiences are good examples of low CO 2 products, even if the final market still needs to be extended to more application segments CO 2 source is present in our plants but is still very expensive and critical to the business model We need cheap adapted local CO 2 in limited quantity Logistics is critical in most CO 2 applications 18

19 Thank you for your attention 19