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  • 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 CO2, 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 CO2 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 CO2 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 CO2 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

    2050

    Breakthrough techn. like CCS/U

    Decarb. power

    Transport efficiency

    Clinker substitution/ new cements

    Energy efficiency/ fuel mix

    1990

    Mton CO2

    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 langfrist.

    E U

    R /t

    C O

    2

    long -term

    Post-

    combustion

    Oxyfuel

    technology

    S u

    c c

    e s

    s fu

    l d

    e m

    o n

    s tr

    a ti

    o n

    E U

    R / t

    C O

    2

    Cooler design

    Burner design

    CO2 conditioning

    unit

    Future oxygen

    supply systems

    CO2 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: info@ecra-online.org

    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 

    http://www.ecra-online.org/ http://www.ecra-online.org/ http://www.ecra-online.org/ mailto:info@ecra-online.org mailto:info@ecra-online.org mailto:info@ecra-online.org