5 Laboratory-scale similar-system validation in a relevant environment The basic technological components are integrated so that the system configuration is similar to (matches) the final application in almost all respects. Prototype is defined as < 1 tpd clinker scale (e.g., complete technology
at a scale equivalent to ≥ 18 Nm3 and actual raw materials). Table 2: CO2 capture from the cement industry: technology comparisons Attribute scrubbing* Calcium looping Full Partial Direct capture Capital cost (€2013) 213 M for 2 Mtpa RF (China)18 440 – 540 for 1 Mtpa NB32 245 – 350 for 1 Mtpa RF32 269 M NB (inc cement cost) for 1 Mtpa35 125 M NB (capture plant only) for 1 Mtpa35 291 M for 1 Mtpa NB32 104 M for 1 Mtpa RF32 97 – 107 M for 1 Mtpa RF35 85 M for 1 Mtpa RF32 275 M for 1 Mtpa NB32 Unknown. Overall cost, avoided (€2013/t CO2) 46 – 57 NB @ DR 6 – 16 %18 75 – 85 RF @ DR 10 %15 18 NB35 39 NB @ DR 8 %32 49 NB @ DR 8 %32 Unknown
51 NB @ DR 7 %48 107 NB @ DR 10 %58 52 – 104 @ DR 8 %32 143 – 187 RF @ DR 10 %15 172 – 333 86 53 RF18 31 NB59 41 RF @ DR 8 %32 54 RF @ DR 8 %32 12 NB35 54 – 69 RF37 58 RF32 62 RF36 Typical capture rate > 90 % > 90 % > 90 % 65 % 60 % Complexity Low: mature end-of-pipe technology, Medium: integration should be simple but High: Increased design and maintenance Medium: Increased design and maintenance Low: Operational knowledge of direct capture
but extensive FG is required before capture fluidised bed combustor operation is outside cement industry knowledge complexity; operation of the plant changes, especially in kiln and cooler. Kiln stop likely if O2 supply fails. complexity (although less than full operation of the should be relatively similar to unabated cement in cement industry currently non-existent except for one company but kiln/cooler section identical to before. Major changes to cement process None Precalciner replaced with dual fluidised beds (or, for HECLOT, one fluidised bed and a rotary kiln), steam cycle New preheaters and precalciner necessary. Changes to kiln burner and cooler designs necessary. New preheaters and precalciner necessary. Precalciner replaced with direct capture unit (DCU) tower.
and associated equipment air flow reduction requires altered designs of units Capture plant footprint Large because of installation of SCR & FGD systems as well as capture plant26 Possibly slightly larger than partial oxy-fuel but smaller than full oxy-fuel. CO2 processing unit required to remove chlorides & water. A steam cycle Relatively large - air separation, waste heat recovery and CO2 processing units will take up space. Medium (0.5 ha) – air separation, waste heat recovery, FG recycling and CO2 processing units will take up space, but lower capture rate and O2 demand means they Small. DCU tower likely to be shorter but wider than a preheater tower; gas treatment plant will be small due to low capture rate and inherent purity of
shutdown period. Space for capture plant may be an issue on many sites. of kiln will cause a long shutdown. As with full practicality of gas-tight rotary kilns must be demonstrated existing units should enable some prefabrication and reduce construction times on site Current Technology Readiness Level (TRL) with respect to cement manufacture 6 0.125 Nm3/s real FG scrubbed28 (ca. 0.2% of full size) 6 3.1 tph FG (0.7 Nm3/s FG) HECLOT PP in operation in Taiwan59 but results not yet published (1.2% of full size) 4 Lab-scale tests undertaken, but no PP built yet20 6 2 – 3 tph RM (1.3 – 2 tph) pilot plant in Denmark operated successfully37 4-5 One-tube (10 tph RM, 6.6 tph/160 tpd) tests undertaken, but not at a cement plant with only with RM.
Heat integration not tested43. TRL expected in 2020 assuming successful completion of current plans 6 No new amine scrubbing PP projects in cement sector are currently known 8 ITRI plans to build a 30 MWt (11 Nm3/s, 20% of full size) HECLOT PP in 201759 4 ECRA plans to build a 2 tph PP seem to be on hold so unlikely to be completed by 2020 6 Consortium not progressing with FEED because of lack of viable business model37 7 20 tph RM (ca. 13 tph/320 tpd clinker, 10 % of full size) PP to be in 2018 – 2020. Time until wide availability 10 – 15 10 – 15 15 – 25 years 10 – 20 years 10 – 15 RF = retrofit. Includes only cost of capture NB = New-build. Includes cost of cement plant (usually about 150 M€ in Europe). DR = discount rate. RM = raw meal. FG = flue gas. PP = pilot plant. Full size = 3 000 tpd clinker (1 Mtpa), or 55 Nm3/s flue gas. *Includes the cost of CHP for heat provision.
3: Technology-specific considerations for designing capture-ready cement plants Aspect of plant scrubbing Calcium looping Direct capture Oxy-fuel Partial Full Raw materials & fuel handling; utility If a CHP plant is to be built, the fuel supply should be considered. This may include a natural gas pipeline connection. More fuel (ca. 50%) will be required on site so storage & handling facilities could be designed to accommodate this from the start. Combustion If necessary, a source of purer (i.e. low-Cl) raw materials should be identified A larger electricity connection should installed so that electricity can be to run the ASU and capture equipment
the kiln and preheaters should be appropriate for to the CaL calciner (‘replacement’ and ‘HECLOT’ designs) calciner is necessary. Kiln No action necessary. The kiln should be as airtight as possible. The region around the burner,
Plant footprint A very large amount of land will be required to build the capture facilities. This should be close to the preheater exhaust. The CHP plant should be built close by to reduce the The cement plant may require a different layout to ensure that a CaL system can be fitted between the preheaters and kiln or within the preheater train. Space for the ASU and steam cycle should be provided relatively close to the A small amount of land will be required to accommodate the DCU and flash condenser. A significant amount of land will be required for an ASU and the recirculation loop. Land for the gas clean-up plant should be made available close to the preheater tower.
distance that the steam has to be transported CaL plant location, and gas clean-up and compression should not be too far away from the calciner. Other Gypsum will be produced on-site from the FGD plant; disposal or sale of this should be considered Purification & compression plant for partial plant (1 Mtpa) would require 0.5 ha.