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Advanced Indirectly HeatedCarbonate Looping Process
This project ANICA is funded through the ACT programme (Accelerating CCS Technologies, Horizon2020 Project No 294766). Financial contributions
made from the German Federal Ministry of Economic Affairs and Energy, the Department for Business, Energy and Industrial Strategy of the United
Kingdom and the Greek General Secretariat for Research and Technology.
Integration of the IHCaL Process into Cement Plants
Dr.-Ing. Viktoria Erfurt (VDZ), 6. October 2021
1
Cement process
Viktoria Erfurt, ANICA Workshop, October 2021
2
Reference plant (BAT)
cement kiln1450 °C
clinker cooler
Cal
cin
er8
60
°C
Pre
he
ater
tertiary
secondary
silo
primary
raw gas
200 000 kg/h
232 000 Nm³/h
125 000 kg/h
exhaust
3
Reference plant (BAT)
cement kiln1450 °C
clinker cooler
Cal
cin
er8
60
°C
Pre
he
ater
tertiary
secondary
silo
primary
raw gas
200 000 kg/h
232 000 Nm³/h
125 000 kg/h
exhaustCalcination:𝐶𝑎𝐶𝑂3 → 𝐶𝑎𝑂 + 𝐶𝑂2
Formation of
clinker phases
supply with oxygen and
heat recuperation
4
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
exhaust
Concept for the integration of the IHCaL process
Calcination:𝐶𝑎𝐶𝑂3 → 𝐶𝑎𝑂 + 𝐶𝑂2
Carbonation:𝐶𝑎𝑂 + 𝐶𝑂2 → 𝐶𝑎𝐶𝑂3
5
Concept for the integration of the IHCaL process
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
exhaust
Remark:
1. More fuel is needed in calciner.
2. Kiln fuel feed has to be decreased.
3. Recycled mass has to be cooled.
Indirect heated calciner
100 % CO2
calcination shifts from 860 °C to 920 °C
6
Concept for the integration of the IHCaL process
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
120 000 kg/h, 920 °C 143 000 kg/h, 920 °C
54 000 Nm³/h
exhaust
7
Concept for the integration of the IHCaL process
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
120 000 kg/h, 920 °C 143 000 kg/h, 920 °C
heat ex-changer
120 000 kg/h, 650 °C
54 000 Nm³/h
exhaust
more sorbent
more fuel
more heat
demandmore CO2
exhaust
8
Concept for the integration of the IHCaL process
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
120 000 kg/h, 920 °C 143 000 kg/h, 920 °C
heat ex-changer
120 000 kg/h, 650 °C
54 000 Nm³/h
44 000 Nm³/h, 854 °C
29 000 Nm³/h, 1140 °C
exhaust
98 000 Nm³/h
70 000 Nm³/h, < 650 °C
9
Concept for the integration of the IHCaL process
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
120 000 kg/h, 920 °C 143 000 kg/h, 920 °C
heat ex-changer
120 000 kg/h, 650 °C
54 000 Nm³/h
44 000 Nm³/h, 854 °C
29 000 Nm³/h, 1140 °C
exhaust
98 000 Nm³/h
70 000 Nm³/h, < 650 °C
54 000 Nm³/h, 1010 °C
44 000 Nm³/h, 1080 °C
Challenges:
• Calcination in preheater 1
• CO2 release outside the calciner
• formation of belit in preheater 1
• recirculation of inactive phases
kiln combustor
44
00
0 N
m³/
h
10
80
°C
preheater 1 (< 25 % CO2)
54
00
0 N
m³/
h
10
10
°C
kiln
44
00
0 N
m³/
h
10
80
°C
calciner
11
200
0 N
m³/
h
< 9
00
°C
preheater 1
BAT:
10
Concept for the integration of the IHCaL process
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
120 000 kg/h, 920 °C 143 000 kg/h, 920 °C
heat ex-changer
120 000 kg/h, 650 °C
54 000 Nm³/h
44 000 Nm³/h, 854 °C
29 000 Nm³/h, 1140 °C
exhaust
< 650 °C
54 000 Nm³/h, 1010 °C
44 000 Nm³/h, 1080 °C
1020 °Cevap. cooler
< 750 °C
+ 12 000 kg/h
103 000 Nm³/h363 °C
Solution: evaporation cooler
- efficiency loss
+ positive influence of water vapour
on carbonation
solution: cooling the combustion gas
from 1020 °C to < 750 °C
technical limitations due to high
temperature and erosive dust load
currently no appropriate heat exchangers
and turbines available
11
Concept for the integration of the IHCaL process
Because of erosive dust load a filter is
needed between clinker cooler and the
combustor.
tertiary air < 450 °C !
+ enough oxygen
+ no need of an additional oxygen input
- more air to heat up in the combustor
- need of a preheating zone in the lower
part of combustor
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
120 000 kg/h, 920 °C 143 000 kg/h, 920 °C
heat ex-changer
120 000 kg/h, 650 °C
54 000 Nm³/h
29 000 Nm³/h, 1140 °C
exhaust
< 650 °C
1010 °C
44 000 Nm³/h, 1080 °C
1020 °Cevap. cooler
< 750 °C
+ 12 000 kg/h
103 000 Nm³/h363 °C
166 000 Nm³/h, < 450 °C
12
Concept for the integration of the IHCaL process
com
bu
sto
r
cement kiln clinker cooler
Cal
cin
er
tertiary
silo
carb
on
ato
r
Pre
hea
ter
2
Pre
hea
ter
1
CO2
primary
primary
raw gas
125 000 kg/h
232 000 Nm³/h
200 000 kg/h
120 000 kg/h, 920 °C 143 000 kg/h, 920 °C
heat ex-changer
120 000 kg/h, 650 °C
54 000 Nm³/h
29 000 Nm³/h, 1140 °C
exhaust
< 650 °C
1010 °C
44 000 Nm³/h, 1080 °C
1020 °Cevap. cooler
< 750 °C
+ 12 000 kg/h
103 000 Nm³/h363 °C
166 000 Nm³/h, < 450 °C
13
Thank you for your attention!
www.act-anica.euViktoria Erfurt, ANICA Workshop, October 2021
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