A bottom-up model for synchronising carbon capture application with major process plant shutdowns and application to the UK cement sector Thomas Hills, Nicholas Florin & Paul S. Fennell

Supporting information

Table of Contents

Item Item numberUK kiln capacities and ages. Appendix Table S1Historical and projected UK cement sector properties Appendix Table S2

Properties of the UK cement sector decarbonisation scenarios, 2012 – 2055 Appendix Table S3Calculation of thermal efficiencies for new cement kilns, 2012 – 2055 Appendix S4Assumptions regarding fuels in the top-down and bottom-up models developed in this paper

Appendix Table S5

Information about construction and closure durations for cement plants, refineries and blast furnaces.

Appendix Table S6

Construction times for carbon capture plants Appendix Table S7UK cement sector thermal energy demand for different carbon capture technologies in the 2020 – 2055 period for the ‘Renovation CCS’ scenario

Fig. S1

UK cement sector net direct CO2 emissions with application of calcium looping in different scenarios over the 2020 - 2055 period

Fig. S2

UK cement sector net direct CO2 emissions for different carbon capture technologies in the 2020 – 2055 period for the ‘Large Plants’ scenario

Fig. S3

UK cement sector net direct CO2 emissions for different carbon capture technologies in the 2020 – 2055 period for the ‘Delayed Roll-out’ scenario

Fig. S4

UK cement sector net direct CO2 emissions for different carbon capture technologies in the 2020 – 2055 period for the ‘Pipeline’ scenario

Fig. S5

References Pages 20 – 22Abbreviations Page 23

1

Appendix Table S1. UK kiln capacities and ages.

Kiln name Current owner Kiln start

Assumed clinker capacity (Mt/y)

South Ferriby A2

Cemex 1967 0.25

South Ferriby A3

Cemex 1978 0.25

Cookstown A1 Lafarge 1968 0.48Hope B1 Hope 1970 0.65Hope B2 Hope 1970 0.65

Aberthaw A6 Lafarge 1975 0.50Ribblesdale A7 Hanson 1983 0.75

Cauldon B1 Lafarge 1985 0.90Dunbar A3 Lafarge 1986 0.90Ketton A8 Hanson 1986 1.00Rugby A7 Cemex 2000 1.50

Tunstead A2 Lafarge 2004 1.10Padeswood A4 Hanson 2005 0.82

Where there are two kilns on one site (South Ferriby & Hope), it is assumed that each has half of the total reported site capacity. This information comes from http://www.cementkilns.co.uk/ (Moore, 2016)

2

Appendix Table S2. Historical and projected UK cement sector properties

Year Cementitious material production

Clinker-to-cement ratio

Clinker production

Unabated plant energy intensity (historical)

Direct CO2

emissionsSpecific CO2

intensity of clinker (MPA)

Specific CO2 intensity of clinker (DECC/BIS)

Mt/y t/t Mt/y MJ/t clinker Mt/y t CO2/t clinker1990 13.9 0.95 13.2 4800 13.32000 13.4 0.83 11.1 4270 10.62010 9.4 0.73 6.8 3810 6.0 0.832012 8.5 0.70 5.9 3900 5.02015 9.1 0.69 6.3 0.802020 10.0 0.69 6.9 0.96 0.752025 10.0 0.68 6.8 0.752030 10.0 0.68 6.8 0.90 0.672035 10.0 0.68 6.8 0.622040 10.0 0.68 6.8 0.512045 10.0 0.68 6.8 0.432050 10.0 0.68 6.8 0.39 0.33

3

Appendix Table S3. Properties of the UK cement sector decarbonisation scenarios, 2012 – 2055.

Property Unit Scenario 1 Scenario 2 Scenario 3 Scenario 4 Scenario 5 Scenario 6CCS properties Base case Large

plantsDelayed Biomass Renovation Pipeline

Minimum plant size for CCS Mt/y clinker 0 1 0Amine scrubbing availability date Year 2020 2020 2030 2020 2020 2020Calcium looping availability date Year 2030 2030 2040 2030 2030 2030Partial oxy-fuel availability date Year 2030 2030 2040 2030 2030 2030Full oxy-fuel availability date Year 2035 2035 2045 2035 2035 2035Direct capture availability date Year 2025 2025 2035 2025 2025 2025Amine scrubbing capture rate t/t 0.9 0.9 0.9 0.9 0.9 0.9Calcium looping capture rate t/t 0.9 0.9 0.9 0.9 0.9 0.9Partial oxy-fuel capture rate t/t 0.65 0.65 0.65 0.65 0.65 0.65Full oxy-fuel capture rate t/t 0.9 0.9 0.9 0.9 0.9 0.9Direct capture capture rate t/t 0.6 0.6 0.6 0.6 0.6 0.6

Amine scrubbing energy intensity MJ/t CO2 captured 2000 2000 2000 2000 2000 2000Calcium looping energy intensity MJ/t CO2 captured 2000 2000 2000 2000 2000 2000

Partial oxy-fuel thermal demand factor MJ/MJ 0.08 0.08 0.08 0.08 0.08 0.08Full oxy-fuel thermal demand factor MJ/MJ 0 0 0 0 0 0Direct capture thermal demand factor MJ/MJ 0.02 0.02 0.02 0.02 0.02 0.02

CHP thermal efficiency MJ/MJ 0.5 0.5 0.5 0.5 0.5 0.5Calcium looping calciner thermal efficiency MJ/MJ 0.85 0.85 0.85 0.85 0.85 0.85

Plant propertiesKiln effective lifetime Years 50 50 50 50 25 50

Efficiency factor A MJ/t 3660 3660 3660 3660 3660 3660Efficiency factor B MJ/t/y -11.795 -11.795 -11.795 -11.795 -16.923 -11.795Efficiency factor C %/y 0.999 0.999 0.999 0.999 0.999 0.999

4

Efficiency and CCS assumptions are for the bottom-up model. Thermal demand factors are the fractional increase in thermal energy demand due to applying CCS

Appendix S4. Calculation of thermal efficiencies for new cement kilns, 2012 – 2055

ηbase=A+B(t kilnopen−2011)

η=ηbase∗C (kilnage )

Where tkiln open is the year the kiln is built and (kiln age) is in years, and η is measured in MJ/t clinker.

5

Appendix Table S5. Assumptions regarding fuels in the top-down and bottom-up models developed in this paper (Rahman et al., 2015)

Property Fossil fuel (coal)

Biomass (wheat straw) Alternative fuel (refuse-derived fuel) Natural gas

Units

Fossil carbon fraction 1 0 0.5 1 mol/molEnergy content 21 475 17 000 21 200 N/A MJ/tOverall carbon intensity

81.5 98.1 80.9 52.1 t CO2/TJ

N/A: The data for natural gas were given as an overall carbon intensity without an energy content in MJ/t, thus a value for that is not given here.

6

Appendix Table S6. Information about construction and closure durations for cement plants, refineries and blast furnaces. All links correct as of 15 th January 2016

Industry Location Activity Unit Length of time SourceCement Umm Bab, Qatar Construction New line, 5 800 tpd “20 months from mobilisation to

first flame in kiln”(FLSmidth, 2014a)

Cement Mangrol plant, India

Construction New line, 5 000 tpd 12 months construction activity“Signing of the contract: 1st Aug 12; Site mobilisation (mechanical): 1st April 13; Expected commissioning: 2Q 2014”

(FLSmidth, 2014b)

Cement Sumbe, Angola Construction New plant, 4 200 tpd 3-4 years (“a complex project lasting from 2009 to 2013”)

(FLSmidth, 2014c)

Cement Sarbottam, Nepal Construction New plant1200 tpd

Total project: 26 months; installation: 7 months“Effective date of contract: 15 October 2012; Completion of engineering: 30 December 2013; Supply of major equipment: 6 May 2014; Expected commissioning: December 2014”

(FLSmidth, 2014d)

Cement Sidhi, India Construction Brownfield construction (5000 tpd) 16 months for equipment erection & commissioning“Equipment erection commenced in May 2011…the plant produced the first clinker in September 2012”

(FLSmidth, 2013a)

Cement Karnatka, India Construction Greenfield (6 000 tpd) 28 months (commissioning after 25)“FLSmidth began installing the equipment…in October 2010…the first phase of the plant was commissioned in November 2012, and the plant began commercial

(FLSmidth, 2013b)

7

operations in January 2013”Cement Manikgarh

Cement, IndiaConstruction Brownfield 8000 tpd 39 months between completion of

engineering and plant commissioning“26 May 2010: Contract signed; May 2011: completion of engineering; November 2011: Site mobilisation (mechanical); September 2012: Supply of major equipment; 17 August 2014: Plant commissioning”

(FLSmidth, 2015)

Cement Platin Works, Republic of Ireland

Construction Kiln 3 Preheat tower installation “Contract duration: 5 months” (“Kiln Replacement,” n.d.)

Cement Shitou & CUCC Jiyuan

Renovation New cross-bar coolers “Installation was completed within 60 days”

(FLSmidth, 2014e)

Cement Andhra Pradesh, India

Renovation 3-phase modernisation of pyroprocessing

Phases 2&3: 18 monthsPhase 1: unknown

(FLSmidth, 2014f)

Cement Nobsa, Colombia Renovation Cooler upgrade 20 days (during planned maintenance shutdown)“The shutdown, from flame-off to flame-on, lasted 20 days”

(FLSmidth, 2014g)

Cement Sebryakovcement, Russia

Renovation New cross-bar coolers “In the autumn of 2010 Kiln No. 6… was stopped for 37 days”

(FLSmidth, 2011)

Cement Tunstead Annual shutdown “Tunstead cement plant undertakes an annual maintenance shutdown lasting about a month. Over 200 contractors employing a range of specialist skills are used during the shutdown.”

(“Managing major cement plant shutdown with 20 contracting companies,” 2011)

Cement Göllheim, Germany

Annual shutdown 1 month max“...Dyckerhoff’s annual maintenance stop in January 2013, with production planned to start again at the beginning of

(FLSmidth, 2013c)

8

February 2013.”Refinery (shale)

North Dakota Construction Greenfield Around 2 years“Break ground first-half 2016, enter operation sometime in 2018”

(Brelsford, 2015a)

Refinery Duqm, Oman Construction Greenfield (site prep only) 1 year“ …began during second-quarter 2015 and is scheduled to be completed in second-quarter 2016”

(Brelsford, 2015b)

Refinery Sitra, Bahrain Construction Phased renovation 6 years“Initiated in 2012 and planned for execution in a series of phases over 6 years”

(Brelsford, 2015c)

Refinery Buseruka, Uganda Construction Greenfield Around 2 years“…final project agreement within 60 days…March negotiations…first phase commissioned in 2018, with the plant due to reach its full capacity by 2020”

(Brelsford, 2015d)

Refinery Gdansk, Poland Upgrade Delayed coker (DCU), coker naphtha hydrotreater (CNHT), and hydrogen generation unit (HGU)

2.5 – 3.75 years“Q4 2014: Execution of contracts…Q2 2017:…completion of OGU…3Q 2018: Completion of tests and full commissioning of all EFRA units”

(Brelsford, 2015e)

Refinery Northland, NZ Greenfield expansion

2 M bbl/y increase in petrol production capacity

4 years“the project, which took 4 years to complete”

(Brelsford, 2015f)

Refinery Northland, NZ Maintenance Catalytic cracking reformer Every 6 years (Brelsford, 2015f)

9

“CCR unit designed for planned maintenance every 6 years as compared with the decommissioned platformer’s required maintenance shutdown every 18 months”

Refinery Minatitlan , Mexico

Modification and upgrade

Hydrodesulphurisation, sulphur recovery, hydrogen plant

27 months“a 14 month-long construction and installation”

(“Pemex advances low-sulfur fuels project at Minatitlan refinery,” 2015)

Refinery Baku, Azerbaijian Phased modernisation & expansion

Hydrotreaters, desulphurisation 4 years“Designed to be implemented in stages during 2015-19”

(Brelsford, 2015g)

Refinery Saint Nazaire, France

Modernisation & overhaul; upgrade & expand

Gasoline; VGO HDS (vacuum gas oil hydrodesulfurisation)

Full contract & construction: 2 years“contracts for construction of new units to follow in 2017…due for startup sometime in 2019”

(Brelsford, 2015h)

Refinery St Petersburg, Russia

Greenfield expansion

New water treatment plant 2 years(Article Oct 30 2015) “Once fully commissioned in 2017”

(“Gazprom Neft’s Moscow refinery due treatment plant,” 2015)

Refinery Rotterdam, NL Expansion Hydrocracker 2 years“receive final permits in early 2016, with construction to start soon after…plans to commission the expanded unit in 2018”

(Brelsford, 2015i)

Methanol plant

Louisiana, USA Greenfield construction by a refiinery

Methanol plant 2 years“…expects to begin construction on the project during second-quarter 2016…scheduled to be

(Brelsford, 2015j)

10

commissioned by yearend 2018”

Refinery Cartagena, Colombia

“Long-planned expansion and modernisation project”

Everything 18 months for full overhaul; total closure for > 7 months“The first hydrocarbons were introduced into the new unit for processing on Oct. 21 … Shuttered since Mar. 5, 2014 …Scheduled to become fully operational during second-quarter 2016”

(Brelsford, 2015k)

Refinery Al-Zour, Kuwait Greenfield construction

Refinery complex 45 months“The consortium’s scope of work under the contract, which is to last 45 months”

(Brelsford, 2015l)

Refinery Piura, Peru Modernisation & expansion

All 55 months“Slated to be completed within 55 months from the start of construction”

(Brelsford, 2015m)

Refinery Navodari, Romania Maintenance turnaround (no total shutdown)

> 1 Month“…the refinery’s more than month-long planned shutdown for execution of turnaround activities”

(Brelsford, 2015n)

Refinery Mt Vernon, USA Maintenance turnaround

16 days“During the previous year’s turnaround, which lasted 16 days”

(Brelsford, 2015o)

Refinery Vadinar, India Maintenance turnaround (complete shutdown)

30 days“The refinery resumed operations on Oct. 17 following completion of activities related to the scheduled turnaround, which started on Sept. 18 and required a full shutdown of the site”

(Brelsford, 2015p)

Refinery St John, Canada (complete 6 weeks (“Irving Oil starts

11

shutdown) “Irving Oil Ltd. has started 6 weeks of scheduled maintenance on several processing units at its 250,000-b/d St. John refinery”

turnaround at St. John refinery,” 2014)

Refinery Porvoo, Finland (complete shutdown)

8 weeks“Neste Oil Corp. will begin a 2-month planned maintenance turnaround”

(Brelsford, 2015q)

Oil sands upgrader

Alberta, Canada (complete shutdown)

5 months(Article published June 8th)“it has completed the maintenance turnaround… which started in March”

(“Shell completes Athabasca Oil Sands Project turnaround,” 2010)

Oil sands Ft McMurray, Canada

Maintenance turnaround (complete shutdown)

Coker only 2 months“The turnaround will take 2 months to complete”

(“Syncrude begins coker turnaround,” 2009)

Refinery Durban, SA Maintenance turnaround (complete shutdown)

4 weeks“Engen Petroleum Ltd. has restarted its 125,000-b/d Enref refinery…following a 4-week period of planned maintenance activities”

(Brelsford, 2015r)

Refinery Gujarat, India Maintenance turnaround (complete shutdown)

Crude oil distillation unit 4 weeks“ RIL…will undertake a month-long, planned maintenance turnaround”

(Brelsford, 2015s)

Gas-to-liquid (GTL) plant

Ras Laffan, Qatar Maintenance turnaround (complete shutdown)

One of two gas-to-liquid (GTL) trains

2 months“Planned maintenance activities at the train…will continue for about 2 months”

(Brelsford, 2015t)

Refinery Dung Quat, Vietnam

(complete shutdown)

“the repair of defects for thermal expansion joints in the refinery’s residue fluidized catalytic cracking unit and the connection of awaiting

57 days“The scheduled turnaround, which shuttered the refinery for 2 months beginning on May 19,

(“Vietnam’s Dung Quat refinery wraps maintenance,” 2014)

12

ends for a second sulfur recovery unit (SRU) at the site”

lasted 57 days”

Refinery St Nazaire, France Maintenance turnaround (complete shutdown)

All units 2 months“The maintenance shutdown is scheduled to begin on May 4 and will conclude on June 25, during which time all units will be shuttered”

(Brelsford, 2015u)

Ironmaking Taranto, Italy Replacement Hot blast stoves, blast furnace top gas cleaning plant, granulated slag condensation system, de-dusting system in stockhouse

12 months“A challenging schedule foresees project completion…within 12 months.”

(“New BF5 at Taranto will use Best Available Technologies,” 2015)

Ironmaking Gijon, Spain Replacement Coke oven batteries 2 years“The refurbishment work will start in mid-2016… expected to produce the first batch of coke in the first half of 2018”

(“ArcelorMittal to invest over €100 million in the refurbishment of the Coke Oven Batteries in Gijón,” 2015)

Ironmaking Odisha, India Blast furnace construction

Complete blast furnace system 5 years in total“Engineering, supplies and construction of the Furnace have taken five years.”

(Smith, 2013)

13

Appendix Table S7. Construction times for carbon capture plants

Plant name Capture process

Industry Construction time Status Source

Boundary Dam, Canada

Amine scrubbing

Renovated coal-fired electricity generation

13 months Completed (Axton, 2013)

Quest, Canada New-build refinery 2.5 years construction plus 6 months commissioning“Construction started in the fall of 2012 and finished in March [2015]. After the commissioning phase was completed in August, the testing phase began.”

Completed (Howell, 2015)

Kemper County Energy Facility, USA

Pre-combustion capture

New-build Integrated Gasification Combined Cycle (IGCC) electricity generation

Foundations, earthworks: ca. 1 yearAbove ground construction: ca. 2 years

In commissioning

(“Kemper County Energy Facility - Facts,” n.d.)

Emirates Steel, United Arab Emirates

New-build blast furnace-route steel production

2.5 years from signing of Engineering Procurement & Construction (EPC) Contract to completion

In construction (“Taking carbon capture and storage a step further,” n.d.)

Note: The duration of construction of capture plants on new-build facilities may be shorter than those stated here because durations tend to encompass all construction on site.

14

Fig. S1. UK cement sector thermal energy demand for different carbon capture technologies in the 2020 – 2055 period for the ‘Renovation CCS’ scenario

15

Fig. S2. UK cement sector net direct CO2 emissions with application of calcium looping in different scenarios over the 2020 - 2055 period

16

Fig. S3. UK cement sector net direct CO2 emissions for different carbon capture technologies in the 2020 – 2055 period for the ‘Large Plants’ scenario

17

Fig. S4. UK cement sector net direct CO2 emissions for different carbon capture technologies in the 2020 – 2055 period for the ‘Delayed Roll-out’ scenario

18

Fig. S5. UK cement sector net direct CO2 emissions for different carbon capture technologies in the 2020 – 2055 period for the ‘Pipeline’ scenario

19

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refinery-wraps-maintenance.html (accessed 2.9.16).

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Abbreviations

Abbreviation Meaning

BAT Best Available TechnologyBIS/DECC The pathway published jointly by the UK’s Departments for Business, Innovation &

Skills and Energy & Climate ChangeCaCO3 Calcium carbonateCCR Clinker-to-cement ratioCCS Carbon Capture & StorageCEM 1 The European standard for ordinary Portland cementCHP Combined heat and power plantCSI GNR The Cement Sustainability Initiative’s ‘Getting the Numbers Right’ databaseEU European UnionIEA International Energy AgencyMPA UK Mineral Products AssociationMt Million (metric) tonnesSCM Supplementary Cementitious Materialtpa (Metric) tonnes per annumtpd (Metric) tonnes per dayUK United Kingdom

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