ccus projects at lafargeholcim focus on oxycombustion · the ccus projects at lafarge (2005-2015)...

© LafargeHolcim 2015

CCUS Projects at LafargeHolcimFocus on Oxycombustion

Michel GIMENEZ, ECRA/CEMCAP WorkshopDüsseldorf, 16 September 2015

© LafargeHolcim 2015ECRA - CO2 Capture 16 September 2015 2

Why Studying CO2 Capture into the Cement Plant?

• As one potential additional lever to mitigate CO2 emissions

• To ensure that the cement plant flue gas specifications are addressed within capture technologies development

• To understand how all this works and find technologies adapted to our process

• To better integrate capture process into the cement plant

• To make the proof of concept and technical-economic feasibility studies of selected technologies

© LafargeHolcim 2015Harnessing CO 2 September 21st, 2015 3

CO2 Capture into the Cement Plant

• CO2 capture is tricky• e.g., post-combustion amine scrubbing (MEA), is not integrated to the cement

plant and is very energy intensive (in terms of both kWh & GJ)

• CO2 capture appears to be technically feasible into the cement plant but there is no viable business model identified today; the more integrated to the cement process, the cheaper the capture

• Once captured, CO2 needs to be used or geologically stored

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© LafargeHolcim 2015ECRA - CO2 Capture 16 September 2015

The Oxycombustion Project

A collaborative project between 3 major companies from Cement, OEM and Gas & Combustion Technologies Supplier

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The Oxy-Combustion Project (2009-2014)

collaboration, lead by LAFARGE

• In 2009 Air Liquide, FLSmidth and LAFARGE decided t o cooperate and jointly study the calciner Oxy-Combustion technolog y, including performing pilot trials at FLSmidth R&D pilot plant in Dania, Denmark

• The project included several phases:

• Feasibility paper study (performed by LAFARGE & Air Liquide)• Pilot trials to prove the technical feasibility of the technology (LAFARGE,

FLSmidth, AL)• The study of the retrofit of Le Havre Cement Plant / France with cost

estimation for CO2 capture shipping and storage in the North Sea (LAFARGE, FLSmidth, Air Liquide)

• Possible application to the EC NER300 program

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The Oxy-Combustion Project (2009-2014)

• The aim was to integrate the CO2 capture technology into the cement plant by implementing the oxy-combustion at calciner

• Air is replaced by oxygen injection at calciner while the combustion gases get partially recycled to the calciner

• We wanted to reach a better integration (process & energy) into the cement making process and thus a lower cost for the CO2 capture than the reference post-combustion amine scrubbing technology

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The Pilot Trials

• 7 test campaigns have been performed over 2011 and 2012 with a raw meal feed rate of 2 t/h i.e. 1 t CO2/h

• The FLSmidth pilot plant in DANIA / Denmark has been modified to oxycombustion at precalciner

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Main Results from the Pilot campaigns

• No safety issues regarding oxygen have been experienced during the trials

• Stable operation was achieved

• Measured CO 2 concentration in calciner was limited to 66 % vol. dry below target 78 % due to false air and limited raw feed rate

• Calcined raw meal showed no difference between air and oxy-combustion i.e., no expected impact on cement quality

• Results showed that an existing preheater or calciner cement kiln line can be retrofitted to oxycombustion

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Why Converting Le Havre plant – Normandy –France?

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• Eligible to the European NER300 funding program

• Adapted to the oxy-retrofit: no calciner, space for ASU & CPU

• It is on the seashore, liquid CO2 can be shipped to off shore storage or EOR sites

• Pooling opportunities with the 14 Mt/y CO2 emitted in the Le Havre harbor area

• Air Liquide has an existing O2 production plant that can deliver 300 t/d, located 300 m away from the cement plant


The Retrofitted Le Havre Plant

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• CAPEX (M€) (8,5 % money discount rate, 15 years)

CAPEX and OPEX Evaluation of the Retrofitted Plant Le Havre

• OPEX (M€/y)

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22 €/t CO2 Captured 40 €/t CO 2 Captured

Full Cost is 62 €/t CO 2 Captured i.e.

36 €/t Cement


Foot Print of the ASU & CPU + Power Station

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Liquid CO 2 Storage


Improvement Levers to Reduce CO 2 Capture Cost

• Treat more CO2 at calciner � 627,450 t/y of liquid CO2 � - 5 €/t CO2 capture cost

• Reduce the false air ingress � 84% (vol. dry) CO2 concentration in flue gases � decreased CPU power consumption �� - 5 €/t CO2

• Produce CO2 at supercritical state for pipeline transport � lower CPU power consumption �� - 4 €/t CO2

Total CO2 capture cost cut down to around 50 €/t

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Project Conclusions

• No safety issues have been identified/experienced on the pilot plant

• The technical feasibility of the Oxycombustion technology has been demonstrated on the FLSmidth R&D Centre Dania pilot plant

• The retrofit of a LAFARGE cement plant was shown possible

• A full cost of this technology made for Le Havre plant is 62 €/t CO2captured, incl. CO2 compression, liquefaction and liquid storage

• Optimization levers have been identified to cut the expected CO2capture cost down to 50 €/t for a new plant

• There is no viable business model today for CCS on cement plants

• This new technology is now ready for FEED study & demonstration

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Other CCUS Projects

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The CO2 Projects Partnerships (2005-2015)


The CCUS Projects at LAFARGE (2005-2015)

• CapCO2 Project , studying the MEA scrubbing of CO2 (2005-2008),

• ACACIA Project , studying breakthrough technologies like Enzymes, Ionic Liquids, Clathrates, Demixing Amines (2008-2012),

• Algae Pilot experimentation into a cement plant (France) with Salata Gmbh (2009)

• MANTRA CO2 electroreduction to produce formic acid (CANADA) (started 2009 – on going )

• Oxy-Combustion Project with Air Liquide and FLSmidth (2009-2014)

• France Nord Project to find a CO2 storage in a deep saline aquifer North of France (2009-2014)

• IPMC (in plant mineral carbonation), LAFARGE (2010)

• Separated Calcination Project with Chem. Eng. Dpt. (2010 – on going )

And now:

• SOLIDIA new low CO2 binder using mineral carbonation of industrial ecology (since 2013 )

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Summary Learning on Capture Technologies

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% CO2 Captured

CO2 Capture Cost€/t CO2

DMX™ Solvent (99%vol)

MEA Solvent (99%vol)

Oxycombustion (80%-99%vol)

Separated calcination (80%-99%vol)

CO2 from Flue Gas (15%-25%vol)

[1] From the ACACIA project with IFPEN (2009-2012)

[2] From the ACACIA project with IFPEN (2009-2012)

[3] Estim. by LAFARGE-AL-FLS Oxycomb. Project (2013)

[4] Estim. by LAFARGE IPC-LEC (2013)

[5] Estim. LAFARGE IPC-LEC (2015)

[1][2]

[3]

[4]

[5]

The CO2 and the Cement Industry, July 21 st, 2015


Which CO 2 for which Applications in the Cement Industry?

The CO2 and the Cement Industry, July 21st, 2015 19

Thank you for your attention

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BACK UP SLIDE

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BACK UP SLIDES


Which Levers to Mitigate the CO2 Emissions in the Cement Industry ?

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LAFARGE has committed to – 33 % in 2020 (base 1990) using those levers

• The usual levers of the Cement Industry are the following:• Cement on clinker ratio (c/k) i.e., allows producing more cement in

using additions to clinker (Blast Furnace Slag, Fly Ash, limestone…) • Control of the specific heat consumption of the kiln, • Use of alternative fuels, especially from biomass

• Between 1990-2014, Lafarge has decreased its specific CO2emissions by 24 % (from 785 to 597 kg CO2/t cement) i.e. a reduction of ~23 Mt CO2/y

• We are studying many other levers to mitigate further our CO2emissions

ccus projects at lafargeholcim focus on oxycombustion · the ccus projects at lafarge (2005-2015)...

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