CaReCI - Carbon Emissions Reduction in the Cement Industry · CaReCI Project Seminar:...

CaReCI Project Seminar: “Sustainable and efficient carbon capture for the cement industry”

October 8, 2019

CaReCI - Carbon Emissions Reduction in the Cement Industry

PTDC/AAGMAA/6195/2014

Carla Costa [email protected]

CaReCI Project Seminar: “Sustainable and efficient carbon capture for the cement industry”2

CO2 Emissions Reduction

✓ Reducing energy intensity:Requires efficient use of energy.

✓ Reducing carbon intensity:Use of carbon-free fuel, requires switchingto using non-fossil fuels such as hydrogen and renewable energy.

✓ Large scale CO2 capture:Essential step of CO2 supply chain forcarbon dioxide utilization (CCUS)..


For Utilization

or storage

Calcination – endothermic reactionTemperature: 800 - 900 °C

Carbonation – exothermic reactionTemperature: 600 - 700 °C

Reversible Reaction: carbonation-calcination

Main Advantages:• High adsorption capacity (Max. 0.78 g

CO2/g CaO )

• High CO2 selectivity • Spent sorbent used as raw material in

the cement industry• Low cost sorbents (natural, wastes,

etc)• Economically and environmentally

viable compared to other processes

In industrial realistic conditions Ca-looping

generates a flow with high CO2 concentration that can be used as raw matter for CO2 conversion processes

Main drawback of CaL sorbents:• Sorbent deactivation due

sintering and pores blockage• Energy penalty

Calcium Looping Process (CaL)


Main Advantages:• High capture capacity (Max. 1 mol

CO2/1 mol CaO )

• High CO2 selectivity • Spent sorbent used as raw material in

the cement industry• Low cost sorbents (natural, wastes,

etc)• Economically and environmentally

viable compared to other processes

Molten Salts

CO2 capture Capacity (g CO2/g)

Homogeneous Double Double Modified

0.009 – 0.57 0.04 – 0.15 0.08 – 0.56

Amina Source

CO2 capture Capacity (g CO2/g)

DETA TEPA PEI APTES

0.04 - 0.05 0.07 - 0.13 0.06 - 0.10 0.08

Maximum CO2 capture capacity : 0.78 g CO2/g CaO

Ca-Looping:

Petroleum 3 (2017) 37-50Journal of Energy Chemistry 26 (2017) 830-838

Ca-Looping for CO2 capture in the cement industry


Post-Combustion Calcium Looping

Technology


Cement Plant with Calcium Looping

System

Source: Rodriguez, N., Murillo, R., Abanades, J.C., Environmental science and Technology, 46 (2012) 2460-2466.

Synergy with the cement industry: the deactivated carbonate minerals

used in the Ca-looping can be used as raw material in cement industry!


Ca-Looping for CO2 capture: Energy

Penalty

Calcium looping process currently being tested experimentally in bench- and pilot-scale plants worldwide:

• Promising alternative to amine scrubbing approach (efficiency penalty 8-12.5%), as it leads to the projectedefficiency penalty of 6–8% upon integration to the power plant (Hanak et al., 2015).

• The average cost of CO2 avoided is estimated to be $29–50/t-CO2 which is more than 50% less than for amine scrubbing (Hanak et al., 2015)


Ca-Looping European Projects for CO2 capture in cement industry:

CLEANKER- Low Emissions Intensity Lime And Cement (2017-2021)

Prototype demonstration (TRL 7) in operational environment(Vernasca 1300 kton/year cement plant, Italy)


Ca-Looping Pilot Plant for CO2 capture in cement industry - Taiwan

Experimental Testing of a 1.9MWth Calcium Looping Pilot Plant

Carbonator (bubbling fluidized bed)

Carbonation conversion: 20-40%CO2 capture efficiency: 80-95%Initial sorbent: 10 ton CaOMake-up of limestone: 0.2 ton/h

Calciner (directly fired rotary kiln)Efficiency: 80-95%

ITRI - Industrial Technology Research Institute of Taiwan - Calcium Looping Pilot

Energy Procedia 63 ( 2014 ) 2100 – 2108


CEMCAP – CO2 capture from cement industry (2015-2018)

Energy Procedia 114 ( 2017 ) 6171 – 6174

30 kWth test facility at INCAR-CSIC

(National Coal Institute – Spain)

200 kWth pilot plant in CFB-CFB at Institute of Combustion and Power

Plant Technology (University of Stuttgart – Germany)

Ind. Eng. Chem. Res. 2017, 56, 2634−2640

Ca-Looping European Projects for CO2 capture in cement industry:


CaReCI proposal

• Submission of CaReCI FCT project proposal: February 2015

• Approval of CaReCI project: October 2015

• Paris Agreement: December 2015

• Starting of CaReCI FCT contract: May 2016• End of CaReCI project: 31st October 2019


Is CO2 post-combustion capture by Ca-looping

cycle technology a potential sustainable and

efficient option for the cement industry if:

CaReCI Project Main Goal: answer the question

• Alternative fuels are used?

• Inexpensive natural and waste sorbents are used,

• Energy efficient techniques with waste heat recovery are used,


Marble Production and…

13

Large amount of Waste Marble Powder (WMP) generated by each producer during cutting and polishing procedures:

hundreds to thousands of tonnes of powder/year !!...

Environmental threat: nearly 20% of the total weight of the marble processed results into WMP!


Marble Production and…

14

Innovative idea for WMP:Possible source of inexpensive solid sorbents for Ca-looping

Cycle CO2 Capture???


Strategies to meet carbon footprint reduction target for sustainable cement production

Modeling and simulation of the industrial cement plant

Natural sorbents reactivity for Ca-looping cycle CO2 capture

Modelling and simulation of CO2 capture by Ca-looping cycle

Simulation and economic assessment of CO2 capture integrated in the industrial cement plant

Task 1

Task 2

Task 3

Task 4

Task 5

CaReCI Project Tasks


Objectives: ➢To estimate the carbon footprint (CFP) of cement

production using industrial plant data.

➢To identify hotspots and determine potential strategiesto meet carbon footprint (CFP) reduction target forsustainable cement production.

CaReCI Project TasksTask 1: Strategies to meet carbon footprint reduction target for sustainable cement production


Objective:

➢An integrated equation based model that will be used for processsimulation and optimization of the industrial cement plant.

Task 2: Modeling and simulation of the industrial cement plant


Task 3: Natural sorbents reactivity for Ca-looping cycle CO2

capture

Objectives: ➢ To select and test a set of portuguese natural and synthetic

sorbents (supported or not) with appropriated formulationand characteristics suitable for CO2 capture in terms ofreactivity decay and carbonation capacity for industrialoperation.

➢ To obtain experimental data for parameters estimation andmodels validation in Task 4.


Task 4: Modelling and simulation of CO2 capture by Ca-looping cycle

Objectives:➢ To develop and validate a first principles novel model for the

estimation of natural CaO-based sorbents carbonationreactivity decay during Calcium Looping (CaL) carbonation-calcination cycles.

➢ Scale up and modeling of an industrial fluidized bed reactor CO2

capture plant integrated with a cement plant.


Task 5: Simulation and economic assessment of CO2 capture and utilization integrated in the industrial cement plant

Objectives:➢ Energy efficient scenarios based on use of alternative fuels,

process optimization and process integration and assessment onprocess alternatives to the utilization of CO2.

➢ To simulate and optimize some alternatives for the CO2

conversion integrated in a CO2 capture and utilization process inthe cement plant.


CARECI Project Team

IST-ID/CQE/CATHPRO

IST-ID/CERENA/ProfEET

MármoresGalrão

CIMPOR


CaReCI Team Members

➢IR: Carla Costa Pinheiro (CO2 Team@CQE/IST)

➢Maria Filipa Ribeiro (CO2 Team@CQE/IST)

➢João Miguel Silva (CQE/ISEL)

➢Henrique Matos (CERENA/ISEL)

➢Rui Filipe (CERENA/ISEL)


CaReCI Research Fellowships

➢ Paula Teixeira (Ph.D.): Tasks 3, 4

➢ João Marcos (MSc.): Tasks 1, 2

➢ Miguel Abreu Torres (MSc.): Task 4

➢ Ismail Mohamed (MSc): Task 3

➢Diogo Santos (MSc.): Tasks


Companies that collaborate:

➢CIMPORTEC: to provide data and process informationfrom the Alhandra production center and to providerequired industrial know-how and perspectives.

➢MÁRMORES GALRÃO S.A.: to provide samples of WasteMarble Powders (WMP).


CaReCI Publications

25

Papers in International Journals:• Teixeira, Paula; Mohamed, Ismail; Fernandes, Auguste; Silva, João; Ribeiro, Filipa; Pinheiro, Carla. “Enhancement of

sintering resistance of CaO-based sorbents using industrial waste resources for Ca-looping in the cement industry”, Separation and Purification Technology , 235 (2020) 116190; DOI: 10.1016/J.SEPPUR.2019.116190.

• Torres, Miguel; Teixeira, Paula; Filipe, Rui; Domingues, Luis; Pinheiro, Carla; Matos, Henrique. “Modeling the deactivation of CaO-based sorbents during multiple Ca-Looping cycles for CO2 post-combustion capture”, Computers and Chemical Engineering , 134 (2020) 106679; DOI: 10.1016/j.compchemeng.2019.106679 .

• P. Teixeira, C. Pinheiro, A. Fernandes, M. Ribeiro, “Tailoring Synthetic Sol-Gel CaO Sorbents with High Reactivity or High Stability for Ca-Looping CO2 Capture“, Industrial & Engineering Chemistry Research, 58 (2019) 8484-8494; DOI: 10.1021/acs.iecr.8b05311.

• Teixeira, Paula; Fernandes, Auguste; Ribeiro, Filipa; Pinheiro, Carla. 2018. "Sustainable use of natural geological materials and marble wastes as promising calcium looping sorbents for CO2 capture in the cement industry: a comparative study". 14th Greenhouse Gas Control Technologies Conference Melbourne, Australia, 21-26 October 2018 (GHGT-14); https://ssrn.com/abstract=3332630. (Open Access)

• Carla I. C. Pinheiro, Auguste Fernandes, Catia Freitas, Edgar T. Santos, and Maria F. Ribeiro, “Waste Marble Powders asPromising Inexpensive Natural CaO-Based Sorbents for Post-Combustion CO2 Capture”, Industrial & Engineering Chemistry Research, 55(29) (2016) 7860−7872. DOI: 10.1021/acs.iecr.5b04574.

https://doi.org/10.1016/j.compchemeng.2019.106679

https://ssrn.com/abstract=3332630


CaReCI Publications

26

Papers in International Books:• Torres, Miguel; Teixeira, Paula; Filipe, Rui; Domingues, Luis; Pinheiro, Carla, Matos, Henrique.

“Modelling Full Cycles of Carbonation-Calcination for Calcium Looping Process Simulation” Computer Aided Chemical Engineering-ESCAPE29, 2019, 46: 1009-1014.

• Carla I.C. Pinheiro, Rui Filipe, Miguel Abreu Torres, João M. Silva, Henrique A. Matos, "Multi-scalemodelling and simulation of Ca-looping cycle process for CO2 post-combustion capture", ComputerAided Chemical Engineering, Vol. 43: Proceedings of the 28th European Symposium on Computer AidedProcess Engineering –ESCAPE 28, Edited by Anton Friedl, Jirí J. Klemeš, Stefan Radl, Petar S. Varbanov, Thomas Wallek, Elsevier B.V., pp. 291-292, 2018. (ISBN: 978-0-444-64235-6)

Papers in International Journals:• P. Teixeira, C.I.C. Pinheiro, A. Fernandes, M. Ribeiro, “Blending wastes of marble powder and dolomite

sorbents for Calcium-Looping CO2 capture under more realistic calcination conditions”, (2020) (undersubmission).

• D. Santos, M. Abreu, R. Filipe, C.I.C. Pinheiro, H.A. Matos, “Technical and Economic Evaluation of Ca-Looping Process for CO2 Capture in the Cement Industry”, (2020) (To be submitted)


CaReCI Publications

27

International Conferences:

1. Joana F. Hipólito, Auguste Fernandes, Carla I.C. Pinheiro, Maria F. Ribeiro, “Use of activated carbon in the synthesis of highly active and stable sol-gel CaO sorbents for CO2 capture”, 14th International Conference on Carbon Dioxide Utilisation - ICCDU XIV, Sheffield, UK, 11-15 September 2016. (Oral presentation)

2. Teixeira, P., Pinheiro, C.I.C., Fernandes, A., Ribeiro, M. “Sustainable utilization of bi-ecofriendly materials for CO2

capture”.The Energy & Materials Research Conference – EMR 2017, Lisboa, 5 -7 April 2017 (Oral presentation)

3. João Marcos, Carla I.C. Pinheiro, Rui Filipe, Henrique Matos, “Strategies to meet carbon footprint reduction target for sustainable cement production”, 10th World Congress of Chemical Engineering, Barcelona, 1-5 October 2017. (Oral presentation)

4. Miguel A. Torres, Rui M. Filipe, Carla I.C. Pinheiro. Modelling and simulation of the calcium looping cycle sorbentperformance for CO2 capture. Advanced Process Modelling Forum, Londres, Inglaterra, 17 a 18 de Abril 2018. (Poster presentation) https://www.psenterprise.com/events/uk/2018/apmf/overview.

5. Carla I. C. Pinheiro, Rui M. Filipe, Miguel Abreu Torres, João M. Silva, Henrique A. Matos. Multi-scale modelling andsimulation of Ca-looping cycle process for CO2 post-combustion capture. 28th European Symposium on Computer-Aided Process Engineering (ESCAPE 28), Graz, Áustria, 10 a 13 de Junho 2018. (Poster presentation) https://escape28.tugraz.at/.

https://www.psenterprise.com/events/uk/2018/apmf/overview

https://escape28.tugraz.at/



6. Teixeira, P., Pinheiro, C., Fernandes, A., Ribeiro, M. Sustainable use of natural geological materials and marble wastesas promising Calcium Looping sorbents for CO2 capture in the cement industry: comparative study. Greenhouse GasControl Technologies (GHGT), Melbourne, Australia, 21 a 26 de Outubro de 2018. (Poster presentation) http://www.ghgt.info/ghgt-14.

7. Paula Teixeira, Carla I.C. Pinheiro, Auguste Fernandes, Maria F. Ribeiro, “Sustainable Use of Dolomites and WasteMarble Powders as Calcium Looping Sorbents for CO2 Capture in the Cement Industry”, 15th InternationalConference on Carbon Dioxide Utilisation - ICCDU XV, Shanghai, 17-21 July 2017.

8. Teixeira, Paula; Mohamed, Ismail; Fernandes, Auguste; Ribeiro, Filipa; Pinheiro, Carla. 2019. "Improvement of CaOsorbents stability for Ca-Looping capture in the cement industry using coal fly ashes and spent FCC catalysts". ICCDU XVII, 23-27 June 2019, Aechen, Germany.

9. Teixeira, Paula; Mohamed, Ismail; Fernandes, Auguste; Ribeiro, Filipa; Pinheiro, Carla. 2019. "Waste materialsutilization of Calcium Looping CO2 capture for the production of eco-cements". ANQUE - ICCE - CIBIQ 2019, Santander, Spain, 19-21 June 2019.

CaReCI Publications

http://www.ghgt.info/ghgt-14



10. Teixeira, Paula; Pinheiro, Carla; Fernandes, Auguste; Ribeiro, Filipa. 2017. "Sustainable utilization of bi-ecofriendlymaterials for CO2 capture". Energy & Materials Research Conference, April 5-7, 2017, Lisbon, Portugal.

11. Carla Pinheiro, Rui Filipe, Henrique Matos, "Strategies to meet carbon footprint reduction target for sustainablecement production", 10th World Congress of Chemical Engineering, Barcelona, Spain, 1- 5 October 2017. URL: http://www.wcce10.org/.

12. Rui Filipe, Carla I.C. Pinheiro, João M. Silva, Henrique A. Matos, "Multi-scale modelling and simulation of Ca-looping cycle process for CO2 post-combustion capture", 28th European Symposium on Computer Aided Process Engineering – ESCAPE 28, Graz, Austria, 10-13 June 2018.

13. Torres, Miguel; Teixeira, Paula; Filipe, Rui; Domingues, Luis; Pinheiro, Carla, Matos, Henrique. “Modelling Full Cyclesof Carbonation-Calcination for Calcium Looping Process Simulation”. 29th European Symposium on Computer-Aided Process Engineering, Eindhoven, June 2019.

CaReCI Publications


CaReCI Publications

30

National Conferences:

1. Pinheiro, C.I.C., Teixeira, P., Fernandes, A., Ribeiro, M. “Utilização promissora e sustentavel de recursos geológicos e resíduos de pó de mármore para captura de CO2”. Green Business Week 2017, Centro Congressos de Lisboa, Lisboa, 15 -17 March 2017. (Oral presentation)

2. Teixeira, P., Pinheiro, C.I.C., Fernandes, A., Ribeiro, M. F. “Natural and synthetic sorbent materials performance for CO2 capture: a comparative study”. MATERIAIS 2017, Aveiro, 9 -12 April 2017. (Oral presentation)

3. C.I.C. Pinheiro, A. Fernandes, M.F. Ribeiro, "Textural properties of waste marble powder samples used as cheap CaObased sorbents for calcium looping cycle CO2 capture process", Reunião Ibérica de Adsorção, 5-7 September 2016, Évora, Portugal. (Poster presentation) http://www.40ria.uevora.pt/index.php?/event/Apresentacao.

4. Teixeira, P., Pinheiro, C., Fernandes, A., Ribeiro, M. Sustainable use of natural materials as Calcium Looping sorbentsfor CO2 capture in the cement industry. Green Business Week 2018, Lisboa, Portugal, 11 a 13 de abril de 2018 (Poster presentation). http://greenbusinessweek.fil.pt/.

5. Miguel A. Torres, Rui M. Filipe, Carla I. C. Pinheiro. Modelling and simulation of CO2 capture by calcium looping cycleusing gPROMS®. 5º Fórum de Engenharia Química e Biológica, ISEL, Lisboa, Portugal, 8 a 10 de Maio 2018. (Poster presentation) http://coifeqb.wixsite.com/i-feqb.

6. Teixeira, Paula; Mohamed, Ismail; Fernandes, Auguste; Ribeiro, Filipa; Pinheiro, Carla. 2019. "Performance of CaO-based sorbents for Calcium-Looping CO2 capture: waste resources, natural and synthetic materials". CQE days Spring meeting 2019.

http://greenbusinessweek.fil.pt/

http://www.40ria.uevora.pt/index.php?/event/Apresentacao

http://greenbusinessweek.fil.pt/

http://coifeqb.wixsite.com/i-feqb


CaReCI Master Thesis

31

Master Thesis:

1. November 2018 - ISMAIL SALAH AHMED MOHAMED, "Waste Resources Utilization as Stable Supports for SinteringResistant CaO-Based Sorbents for Calcium Looping CO2 Capture in Cement Industry", Master Thesis in ChemicalEngineering, Instituto Superior Técnico.

2. November 2018 - Ana Patrícia de Pádua Leal Figueiredo, “Estratégias de Redução das Emissões de CO2 na Indústria do Cimento”, Master Thesis in Chemical Engineering, Instituto Superior Técnico.

3. September 2017 - Magdalena Iwona Trzcionka, "Dolomites as Promising Natural CaO-based Sorbents for Ca-Looping Cycle CO2 Capture", Master Thesis in Chemical Engineering, Instituto Superior Técnico.

4. December 2016 - João Miguel Monteiro Marcos, "Modelling of naphtha cracking for olefins production", Master Thesis in Chemical Engineering, Instituto Superior Técnico .

5. July 2016 - Daniela Carla Moreira de Souza, “Modelling and Simulation of a Saline Aquifer for CO2 Injection andStorage”, Master Thesis in Chemical Engineering, Instituto Superior Técnico.


➢ Financial support: FCT – Portuguese Foundation for Science and Technology through projects UID/QUI/00100/2019, UID/ECI/04028/2019 and

CaReCI - PTDC/AAG-MAA/6195/2014.

➢ Cement Producer: CIMPOR – Cimentos de Portugal

➢ Marble producer: Mármores Galrão Company.

AKNOWLEDGEMENTS

➢ IR: Carla C. Pinheiro (IST/CQE)

➢Maria Filipa Ribeiro (IST/CQE)

➢ João Miguel Silva (ISEL/CQE)

➢Henrique Matos (IST/CERENA)

➢Rui Filipe (ISEL/CERENA)

➢Paula Teixeira (CQE)

➢Miguel A. Torres (Research Fellow)

➢Diogo Santos (Research Fellow)

➢ Ismail Mohamed (Research Fellow)

➢ João Marcos (Research Fellow)

➢Auguste Fernandes (CQE)


THANK YOU FOR YOUR ATTENTION

The authors gratefully acknowledge the financial support by the Portuguese Foundation for Science and Technology I.P. through Research Projects UID/ECI/04028/2019, UID/QUI/00100/2019 and Carbon Emissions Reduction in the

Cement Industry (PTDC/AAG-MAA/6195/2014)

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