CCUS Projects at LafargeHolcim Focus on Oxycombustion. Michel GIMENEZ, ECRA/CEMCAP Workshop Düsseldorf, 16 September 2015

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1 CCUS Projects at LafargeHolcim Focus on Oxycombustion Michel GIMENEZ, ECRA/CEMCAP Workshop Düsseldorf, 16 September 2015

2 Why Studying CO 2 Capture into the Cement Plant? As one potential additional lever to mitigate CO 2 emissions To ensure that the cement plant flue gas specifications are addressed within capture technologies development To understand how all this works and find technologies adapted to our process To better integrate capture process into the cement plant To make the proof of concept and technical-economic feasibility studies of selected technologies 2

3 CO 2 Capture into the Cement Plant CO 2 capture is tricky e.g., post-combustion amine scrubbing (MEA), is not integrated to the cement plant and is very energy intensive (in terms of both kwh & GJ) CO 2 capture appears to be technically feasible into the cement plant but there is no viable business model identified today; the more integrated to the cement process, the cheaper the capture Once captured, CO 2 needs to be used or geologically stored Harnessing CO2 September 21st,

4 The Oxycombustion Project A collaborative project between 3 major companies from Cement, OEM and Gas & Combustion Technologies Supplier 4

5 The Oxy-Combustion Project ( ) collaboration, lead by LAFARGE In 2009 Air Liquide, FLSmidth and LAFARGE decided to cooperate and jointly study the calciner Oxy-Combustion technology, including performing pilot trials at FLSmidth R&D pilot plant in Dania, Denmark The project included several phases: Feasibility paper study (performed by LAFARGE & Air Liquide) Pilot trials to prove the technical feasibility of the technology (LAFARGE, FLSmidth, AL) The study of the retrofit of Le Havre Cement Plant / France with cost estimation for CO 2 capture shipping and storage in the North Sea (LAFARGE, FLSmidth, Air Liquide) Possible application to the EC NER300 program 5

6 The Oxy-Combustion Project ( ) The aim was to integrate the CO 2 capture technology into the cement plant by implementing the oxy-combustion at calciner Air is replaced by oxygen injection at calciner while the combustion gases get partially recycled to the calciner We wanted to reach a better integration (process & energy) into the cement making process and thus a lower cost for the CO 2 capture than the reference post-combustion amine scrubbing technology 6

7 The Pilot Trials 7 test campaigns have been performed over 2011 and 2012 with a raw meal feed rate of 2 t/h i.e. 1 t CO 2 /h The FLSmidth pilot plant in DANIA / Denmark has been modified to oxycombustion at precalciner 7

8 Main Results from the Pilot campaigns No safety issues regarding oxygen have been experienced during the trials Stable operation was achieved Measured CO 2 concentration in calciner was limited to 66 % vol. dry below target 78 % due to false air and limited raw feed rate Calcined raw meal showed no difference between air and oxycombustion i.e., no expected impact on cement quality Results showed that an existing preheater or calciner cement kiln line can be retrofitted to oxycombustion 8

9 Why Converting Le Havre plant Normandy France? Eligible to the European NER300 funding program Adapted to the oxy-retrofit: no calciner, space for ASU & CPU It is on the seashore, liquid CO 2 can be shipped to off shore storage or EOR sites Pooling opportunities with the 14 Mt/y CO 2 emitted in the Le Havre harbor area Air Liquide has an existing O 2 production plant that can deliver 300 t/d, located 300 m away from the cement plant 9

10 The Retrofitted Le Havre Plant 10

11 CAPEX and OPEX Evaluation of the Retrofitted Plant Le Havre CAPEX (M ) (8,5 % money discount rate, 15 years) OPEX (M /y) 22 /t CO 2 Captured 40 /t CO 2 Captured Full Cost is 62 /t CO 2 Captured i.e. 36 /t Cement 11

12 Foot Print of the ASU & CPU + Power Station Liquid CO 2 Storage 12

13 Improvement Levers to Reduce CO 2 Capture Cost Treat more CO 2 at calciner 627,450 t/y of liquid CO 2-5 /t CO 2 capture cost Reduce the false air ingress 84% (vol. dry) CO 2 concentration in flue gases decreased CPU power consumption - 5 /t CO 2 Produce CO 2 at supercritical state for pipeline transport lower CPU power consumption - 4 /t CO 2 Total CO 2 capture cost cut down to around 50 /t 13

14 Project Conclusions No safety issues have been identified/experienced on the pilot plant The technical feasibility of the Oxycombustion technology has been demonstrated on the FLSmidth R&D Centre Dania pilot plant The retrofit of a LAFARGE cement plant was shown possible A full cost of this technology made for Le Havre plant is 62 /t CO 2 captured, incl. CO 2 compression, liquefaction and liquid storage Optimization levers have been identified to cut the expected CO 2 capture cost down to 50 /t for a new plant There is no viable business model today for CCS on cement plants This new technology is now ready for FEED study & demonstration 14

15 Other CCUS Projects 15

16 The CO 2 Projects Partnerships ( ) 16

17 The CCUS Projects at LAFARGE ( ) CapCO 2 Project, studying the MEA scrubbing of CO 2 ( ), ACACIA Project, studying breakthrough technologies like Enzymes, Ionic Liquids, Clathrates, Demixing Amines ( ), Algae Pilot experimentation into a cement plant (France) with Salata Gmbh (2009) MANTRA CO 2 electroreduction to produce formic acid (CANADA) (started 2009 on going) Oxy-Combustion Project with Air Liquide and FLSmidth ( ) France Nord Project to find a CO 2 storage in a deep saline aquifer North of France ( ) IPMC (in plant mineral carbonation), LAFARGE (2010) Separated Calcination Project with Chem. Eng. Dpt. (2010 on going) And now: SOLIDIA new low CO 2 binder using mineral carbonation of industrial ecology (since 2013) 17

18 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 The CO2 and the Cement Industry, July 21 st,

19 Which CO 2 for which Applications in the Cement Industry? The CO2 and the Cement Industry, July 21st,

20 Thank you for your attention 20

21 BACK UP SLIDES BACK UP SLIDE 21

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23 Which Levers to Mitigate the CO 2 Emissions in the Cement Industry? The usual levers of the Cement Industry are the following: Cement on clinker ratio (c/k) i.e., allows producing more cement in using additions to clinker (Blast Furnace Slag, Fly Ash, limestone ) Control of the specific heat consumption of the kiln, Use of alternative fuels, especially from biomass Between , Lafarge has decreased its specific CO 2 emissions by 24 % (from 785 to 597 kg CO 2 /t cement) i.e. a reduction of ~23 Mt CO 2 /y LAFARGE has committed to 33 % in 2020 (base 1990) using those levers We are studying many other levers to mitigate further our CO 2 emissions 23