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
Suitablelocation
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
Majorcontribution 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.
EU
R/t
CO
2
long -term
Post-
combustion
Oxyfuel
technology
Su
cc
es
sfu
l d
em
on
str
ati
on
EU
R/ t
CO
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: [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
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