CO2-Capture from Cement Plants Applying Oxyfuel Concepts
28
CO 2 -Capture from Cement Plants Applying Oxyfuel Concepts S Oberhauser Institute of Energy Systems A Kather 2 nd International Conference on Energy Process Engineering 20.06.2011 - 22.06.2011
Transcript of CO2-Capture from Cement Plants Applying Oxyfuel Concepts
CO2-Capture from Cement
Plants Applying Oxyfuel
Concepts
S Oberhauser
Institute of
Energy Systems
A Kather
2nd International Conference on Energy
Process Engineering
20.06.2011 - 22.06.2011
2Motivation
Why Applying CCS to the Cement Industry ?
CO2 Emissions from Stationary Sources
(Metz, Bert et al, 2005)
Others 15%
Power Industry 78%
Cement
Industy
7% • Large Development of CCS applied
to power plants during the past several
years
• Cement Industry second largest
stationary CO2 source
• No possibility to avoid CO2 emitted
by the raw material
3
CO2-Sources in the Cement Industry
H2O
SiO2 CaCO3
MgCO3
Al2O3
Fe2O3
H2O CaOFe2O3
SiO2
calcination reaction:
CaCO3 CaO + CO2
MgCO3 MgO + CO2
Others
Motivation
1/3 of emitted CO2Fossil Fuel
2/3 of emitted CO2 not possible to avoid !
Al2O3
MgO
2/3 of emitted CO2
4
Conventional Cement Plant with Calciner
Conventional Cement Production
Rotary Kiln
Fuel
Cooling Air
Calciner
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment FuelRaw
Material
Raw
Material
Flu
eG
as
~860°C
Flue
Gas
Treat-
ment
Waste Air
Waste Air
Treatment
Cooler
5
Conventional Cement Plant with Calciner
Conventional Cement Production
Rotary KilnCooler
Fuel
Cooling Air
Calciner
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment FuelRaw
Material
Flu
eG
as
~860°C
Flue
Gas
Treat-
ment
Fixed Parameters for Simulation:
• Fixed raw meal composition
• Calcination of 90% in calciner
• Clinker after rotary kiln: 1400°C
• Air Excess: kiln: 1.15
calciner: 1.30
• Reaction behaviour according to
to pseudo-equilibrium investigated by
experiments
Waste Air
Waste Air
Treatment
6
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Raw
Material
Conventional Cement Production
Flu
eG
as
~860°C
Modifications to Full Oxyfuel (Case A-0)
Calciner
Flue
Gas
Treat-
ment
7
Modifications to Full Oxyfuel (Case A-0)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Full Oxyfuel
Flu
eG
as
~860°C
8
Modifications to Full Oxyfuel (Case A-0)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Full Oxyfuel
ASU
Cooling WFGD GPUCooling Hot ESP
Recirculation Rate:
Calciner: equal solid loading
Rotary kiln: equal TadiabaticWa
ste
Air
ASU: 99.5% Oxygen Purity
GPU: 95% CO2 Purity
~900°C
100
27.5
30.8
95.6
11,2
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113.1
91.8
373
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
9
Evaluation of First Full Oxyfuel Case
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
according to
German power mix (2010):
0.575 kgCO2/kWh
10
Full Oxyfuel (Avoiding Air-In Leakages, Before)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
11
Full Oxyfuel (Avoiding Air-In Leakages, After)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
X
X
X
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
100
27,5
30.8
95.6
11.2
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113.1
91.8
373
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
12
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
Evaluation of Avoiding Air-In Leakages (Before)
100
20.9 19.6 18,6
95.6
4.6 4.1 4.9
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113.1
92
371 352 319
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
13
Evaluation of Avoiding Air-In Leakages (After)
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
14
Full Oxyfuel (Case A-HX)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
15
Full Oxyfuel (Case A-HX)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Gas-Gas
Heat Exchanger
Concepts to Apply Full Oxyfuel
Raw Meal
Pretreating,
Gas Treating
100
20.9 19.6 18,6
95.6
4.6 4.1 4.9
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113
92
371 352 319
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
16
Evaluation of Different Heat Recovery Systems
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
17
Full Oxyfuel (Case A-Direct)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
18
Full Oxyfuel (Case A-Direct)
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
Treatment
Flue
Gas
Treat-
ment
Raw
Material
Preheater
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Concepts to Apply Full Oxyfuel
100
20.9 19.6 18,6
95.6
4.6 4.1 4.9
0
20
40
60
80
100CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
100
127
113
92
371 352 319
100
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-Energy
GPU
ASU
Electrical Power
19
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Base
Case
Case
A-0
Case
A-HX
Case
A-Direct
Ele
ctr
ica
lEn
erg
yD
em
an
d P
el/ P
el,B
ase
in %
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Concepts to Apply Full Oxyfuel
Evaluation of Different Heat Recovery Systems
20Concepts to Apply Full Oxyfuel
Influences of recirculation rate:
• Flue gas temperature of preheater
• Solid Loading in the Calciner
• Air-in leakage
• Heat recovered from cooler
Lowest heat demand at a
recirculation rate, were solid loading
of calciner is ~1.15 times
solid loading of base case
Influences of Recirculation Rate
Rotary KilnCooler
Fuel
Cooling Air
Waste Air
Cement
ClinkerFuel
Waste Air
Treatment
ASU
Cooling WFGD GPUCooling Hot ESP
100
38.6
18.5
95.6
26.7
4.50
20
40
60
80
100
120
140CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
10095
92
100
270318
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-EnergyGPUASUElectrical Power
21
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Ele
ctr
ica
lEnerg
yD
em
an
d P
el/ P
el,B
ase
in %
Base
Case
Case
B-Direct
Case
A-DirectBase
Case
Case
B-Direct
Case
A-Direct
Evaluation of Best Case for Full Oxyfuel Operation
Concepts to Apply Full Oxyfuel
22
Modification to Partial Oxyfuel (Before)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Partial Oxyfuel
ASU
Cooling WFGD GPUCooling Hot ESP
Wa
ste
Air
Cooler
23
Modification to Partial Oxyfuel (After, Case B-0)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
Concepts to Apply Partial Oxyfuel
ASU
Cooling WFGD GPUCooling Hot ESP
Preheater 2
(Air)
Flu
e
Gas
Cooler
24
Partial Oxyfuel (Case B-HX)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Flu
e
Gas
Preheater 2
(Air)
Gas-Gas
Heat Exchanger
Cooler
Concepts to Apply Partial Oxyfuel
25
Partial Oxyfuel (Case B-Direct)
Rotary Kiln
Fuel
Cooling Air
Waste Air
Cement
Clinker
Ra
wM
ea
l
Raw
Material
Treatment Fuel
Waste Air
TreatmentFlue
Gas
Treat-
ment
Raw
Material
Preheater 1
(Oxyfuel)
Raw Meal
Pretreating,
Gas Treating
Ca
lcin
er
ASU
Cooling WFGD GPUCooling Hot ESP
Preheater 2
(Air)
Cooler
Concepts to Apply Partial Oxyfuel
Flu
e
Gas
100
38.6
18.5
95.6
26.7
4.50
20
40
60
80
100
120
140CO2-Emission Incl. Elec. Power
CO2-Emission Excl. Elec. Power
10095
92
100
270318
0
200
400
600
800
1000
1200
1400
1600
1800
0
20
40
60
80
100
120
140Fuel-EnergyGPUASUElectrical Power
26
Fu
el D
em
an
d Q
F/Q
F, B
ase in
%
CO
2-E
mis
sio
n R
atio
in
%
Ele
ctr
ica
lEnerg
yD
em
an
d P
el/ P
el,B
ase
in %
Base
Case
Case
B-Direct
Case
A-DirectBase
Case
Case
B-Direct
Case
A-Direct
Concepts to Apply Oxyfuel
Evaluation of Best Cases of Full and Partial
Oxyfuel Operation
27
Conclusion
• Two main concepts for oxyfuel operation in a cement plant have been evaluated
• Different subconcepts for heat recovery from clinker cooler have been compared
• Uncertainties:
- Effect of CO2-rich fluegas in kiln on clinker quality
- Effect of CO2-rich recirculation gas in clinker cooler on
clinker quality
- Air-in leakage into cooler
• Advantages/disadvantages of best subconcepts:
• In spite of remaining uncertainties concepts become more and more CONCRETE
Concept Fuel Demand Electrical Energy
Demand
CO2-Emission Risk
Base Case o o o o
Partial Oxyfuel
Concepts+ - + -
Full Oxyfuel
Concepts+ - - + + - -
Conclusion
THANK YOU FOR YOUR ATTENTION !
