Norcem CO2 Capture Project Status and Results

Liv Bjerge | Norcem CO2 Capture Project Manager Workshop NRC - 18. March 2015

Background – Why CCS?

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850 °C

1450 °C

- Cement industry major emitter of CO2: 5 % (1,9 Gt/ y) Two sources: 1) 2/3 Main raw material (limestone) 2) 1/3 Fuels to keep the high temperature in cyclone tower and kiln - HeidelbergCement: 100 cement plant 50 mill tons CO2/y - Norcem Brevik: Approx. 800 000 t CO2/ y

Norcem CO2 capture project - Project Manager Liv Bjerge

The Project

Small scale test centre at Norcem Brevik 4 post-combustion CO2-capture technologies Small scale testing full scale perspective Kicked off in May 2013 – scheduled for 3,5 years

Partners:

• Norcem • HeidelbergCement • ECRA (European Cement Research Academy)

Project on behalf of the cement industry in Europe!

Total budget: 93 mill. NOK (11,7 M€) Gassnova / Climit-Program: 75% support

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Mandate and Main Objectives

■ Study and compare various CO2-capture technologies on real conditions

■ Qualification of technologies – Determine how suitable these are for implementation at modern cement kiln

systems

■ Focus on CO2 Capture – Transport and storage is not part of the study

■ Technology Performance due to:

– Capture rate – Energy consumption – Impact from flue gas impurities – Costs (CAPEX/ OPEX)

■ Full Scale/ Commercial Scale Perspective – Utilization of waste heat – Full scale not necessarily 100 % capture

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Benchmark Study | Commercial Scale Perspective

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Benchmark Report – Project Milestone Delivery

Benchmark Study - 3 Commercial Cases

■ Case 1: – Full-size (min 85%) cleaning, no waste heat

■ Case 2:

– Full-size (min 85%) cleaning, waste heat as per Norcem Brevik

■ Case 3: – Reduced-size cleaning, based on cost-optimal utilization of waste heat

as per Norcem Brevik. In this case the technology provider will decide which capture ratio is cost-optimal

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Aker Solution | Results from Long Term Testing

■ Amine technology: Solvent S26 ■ 6 months test program completed (May – Oct 2014) ■ Long term testing: 2700 test hours/ 300 t CO2 captured

■ Promising test results

■ More than 90 % capture rate ■ Energy consumption (RBD) in the range of 2,7-2,8 MJ/ kg CO2 ■ Low degradation and consumption of amine ■ Low emissions of amines and degradation products detected

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Aker Solution | Commercial scale capture at Norcem

■ Feasibility Study: – Capture incl. CO2 handling for transport (pipeline 100 bar)

■ Benchmark Study: Input to all 3 cases ■ What is identified (first estimates)?

– Process description, layout, equipment list, space requirement – Energy consumption (incl. waste heat recovery) – Utilities & consumables (Sea water, el-power, amine, caustic) – Waste streams (DCC, reclaimer) – CO2 avoided – Life Cycle Costs; CAPEX, OPEX

■ Case 3

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RTI - Research Triangle Institute| Testing Phase I

Phase I (Apr – Jun 2014): – Cyclic thermal-swing, absorption-

desorption process – Sorbent material is based on a CO2-philic

poly-ethylene-imine, PEI – Dual fluidized, moving-bed reactor design – Bench-scale; flue gas capacity: 6-10 slpm

Results:

– 300 absorption/ regeneration cycles with capture loading between 5-7 wt %

– Sorbent exhibited no critical failure in CO2 capture performance

– Presence of contaminants reduce performance pre-treatment system required

– First estimates of full-scale capture plants (based on the 3 cases)

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RTI - Research Triangle Institute| Phase II

3-floor pilot: – Flue Gas capacity: 500-1500 slpm – Detail engineering on-going

Long term testing (2016):

– Investigating new sorbent materials expected capture loading: 9-11 wt%

– Economic analysis of full scale capture plant (3 cases) incl CO2 handling for shipment (piping)

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DNV GL, NTNU & Yodfat Engineers | Membrane Technology Phase I: May – Oct 2014:

– One stage membrane module – Flat sheet polysulfon membranes with a

top layer of poly-vinyl-amine (PVAm) – Feed flow: ~ 25 m3/h

Results:

– Pre-treatment system is required to remove water and contaminants

– Good separation performance with permeate purity of 70 % CO2

– First LCC estimates (Case 1 and 3) available for commercial scale capture using the membrane technology in Brevik

Project terminated after Phase I

– Design/ Concept Phase II module too immature

Norcem CO2 capture project - Project Manager Liv Bjerge

Slide 11 Mar 2015

Alstom Power │Calcium-Looping 1 year study completed:

– Characterization of local materials (limestones from Norway)

– Confirmation of sorbent performance through pilot testing

Pilot testing at IFK (Stuttgart University) – Sorbent reactivity, degradation over time – Circulation pattern between reactors – close

material balance

Results:

– Limestone from Verdal highest reactivity – Sorbent deactivated more quickly with

thermal cycles than expected – Input from field testing used as input to

modelling of various full-scale integration cases

Norcem CO2 capture project - Project Manager Liv Bjerge Slide 12 Mar 2015

Status

Focus the coming months:

■ Evaluation of project results – Based on field testing & input to benchmark study

■ Compare technologies and evaluation of commercial scale

perspective

■ Before summer 2015 Norcem will have much more knowledge regarding the realism of industrial carbon capture; especially in the cement industry

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Further contribution towards CCS realization

■ Further testing at site using the MTU – Long term testing (will achieve 5000 testing hours) – Part of the Solvit R&D-project – Optimize technical aspects and investigate new solvents

■ Concept Study:

– Identify most optimal integration of a 400 000 t CO2 capture amine plant including CO2 handling for shipment in Brevik

– Best waste heat recovery (Norcem Brevik, capture plant/ compression train) – Identify necessary re-constructions/ replacement of equipment – Cost-estimate (Capture and further handling) – Identify possible showstoppers/ possible risk elements

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Summary Norcem CO2 Capture Project

■ Important project to understand the realism of deployment of carbon capture in the cement industry.

■ We have tested several technologies on REAL condition and the technologies manages to capture the CO2 at expected level.

■ Our view is that Aker Solutions amine technology can be defined as available technology.

■ Further step is to identify optimal integration of a commercial scale

capture plant including CO2 handling, based on Aker Solutions amine technology, at site in Brevik.

■ We need a system for transport and storage/ reuse of the CO2

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Thank you for your attention!

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