The cement industry’s approach to carbon capture ECRA’s approach from basic research towards an industrial implementation of carbon capture • All low-carbon roadmaps require a significant reduction of CO 2 , also in the cement sector. • Correspondingly and according to CEMBUREAU approx. 60% of cement plants in the EU should be equipped with CCS technology by 2050. • Based on the need to develop this breakthrough technology, ECRA is investigating its technical and economic feasibility in its CCS research project. • A focus is also being placed on CO 2 reuse in cooperation with the University of Mons. • In the current phase IV of the project an oxyfuel pilot plant is being prepared, taking economic and technical issues into account. Study about oxyfuel and post-combustion technology (summer 2007 – summer 2009) Phase I Literature study (January - June 2007) Laboratory-scale / small-scale research activities (autumn 2009 – autumn 2011) Prepare pilot plant (time-frame: 2 - 3 years) Build and operate pilot plant (time-frame: 3-5 years) Phase II Phase III Phase IV Phase V Phase VI Demonstration plant (time-frame: 3-5 years) Post-Combustion: Tail-end separation of CO 2 from flue gas by e.g. chemical absorption, adsorption, membranes or Calcium Looping. • A very energy-intensive technology. • Important projects: Norcem‘s Brevik project (pilot testing), CEMCAP (prototype testing). Oxyfuel Technology: Combustion with pure oxygen instead of air in combination with flue gas recirculation to increase the CO 2 concentration. • Requires process and design adaptations. • Important projects: ECRA (complete oxyfuel), LafargeHolcim / AirLiquide / FLSmidth (pilot testing of partial oxyfuel), CEMCAP (prototype testing). Post-Combustion and Oxyfuel Technology as potential capture solutions for the cement industry Pilot project Finan- cing Consor- tium Project scope Plant design Busi- ness case Suitable location Legal struc- ture Envisaged next steps towards an industrial-scale oxyfuel cement kiln Potential sites for the oxyfuel demo project 0 20 40 60 80 100 120 140 160 180 Breakthrough techn. like CCS/U Decarb. power Transport efficiency Clinker substitution/ new cements Energy efficiency/ fuel mix 1990 Mton CO 2 2050 Major contribution from carbon capture technologies expected to fulfil climate target 1990 2050 1990 • Demonstration of technical and economic feasibility in an industrial surrounding. • Designs: Brownfield (new installation using the infrastructure of existing line) or blackfield (retrofitting existing line). • Size: Industrial-scale > 500 t/d • Two potential locations (blackfield) have been selected. • Projects costs estimated at up to 80 M €. • Project includes engineering/construction, training and operation/scientific evaluation. • Project requires significant funding which might only be available in 2019/20. Colleferro Plant: • HeidelbergCement Group (Italcementi Plant) • Plant located in Italy, close to Rome • Kiln not used for daily production • Petcoke as fuel; no alternative fuels • Kiln currently on stand-by • Lowest CAPEX / medium OPEX Retznei Plant: • LafargeHolcim Group • Plant located in the south-east of Austria • 100 % alternative fuels goal • Currently operated at maximum production • Low CAPEX / high OPEX 0 20 40 60 80 100 120 2020 2025 2030 EUR/t CO2 long -term Post- combustion Oxyfuel technology Successful demonstration EUR/ t CO 2 Cooler design Burner design CO 2 conditioning unit Future oxygen supply systems CO 2 reuse Plant operation and false air reduction Refractory durability/ material conversion Post-Combustion Oxyfuel Technology Time schedule of ECRA‘s CCS project, so far fully industry-funded. Multiple paths to emission reduction Source: CEMBUREAU: the role of cement in the 2050 low carbon economy Estimated costs for carbon capture and its corresponding implementation horizon. Source: ECRA CCS Project: Report on Phase III, 2012 Production cost increase of up to 100% uncertainty Finalisation of the most important research packages Source: ECRA CCS Project : Reports on phase III, 2012 and phase IV.A, 2015 Contact ECRA: www.ecra-online.org Email: [email protected] Phone: +49 (0) 211 23 98 380 New calciner for the Colleferro Kiln New calciner for the Colleferro Kiln Layout of the modified Retznei Kiln