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CLIMIT-Forskning, utvikling og demo av CO2-håndtering

Accelerating Carbon Capture using Oxyfuel technology in Cement production

Awarded: NOK 7.9 mill.

In AC2OCem, pilot-scale experiments, as well as analytical studies, have been performed to bring the key components of oxyfuel cement plants to TRL6 with the aim of reducing the time to market of the oxyfuel technology in the cement sector. AC²OCem is exploring the 1st generation oxyfuel for retrofitting, focusing on optimization of the oxyfuel calciner operation and advancing the kiln burner technology for combusting up to 100% alternative fuels with high biogenic share to bring this Bio-CCS solution to TRL6. Experimental investigations are being complemented by retrofitability analysis to support the technology transfer from TRL6-TRL8, considering boundary conditions from two real cement plants. The Lägerdorf plant in Germany (Holcim) and the Slite plant in Sweden (Cementa/HeidelbergMaterials) have been selected for this purpose, and the process designs for oxyfuel integration of each of these plants are nearly finished. The techno-economic evaluations highlighted cost parameters and presented guideline for retrofitting oxyfuel in existing cement plants. Moreover, within AC²OCem, the innovative 2nd gen. oxyfuel technology for new-build cement plants, in which the flue gas recycle loop is excluded, has seen its TRL promoted from TRL2 at the beginning of the project for key components. An unprecedented oxyfuel kiln burner for up to pure oxygen combustion is for the first time developed, and first tests in a pilot-scale facility that replicates cement kiln conditions have been performed. CFD simulations work has been undertaken at SINTEF, in parallel with the pilot testing at USTUTT, to aid the design and development of the process at TKIS, VDZ and SINTEF. The first tests and simulations of the new 2nd generation burner have highlighted on the one hand the technical feasibility of the concept, on the other hand the challenges to overcome. The overall process design was also optimized and subsequently assessed economically through a techno-economic feasibility study. The outcome of the techno-economic benchmarking comparing 1st and 2nd generation oxyfuel technology best available technology cement plants supports the cement industry on how to proceed with decarbonization of the cement sector using the oxyfuel technology. In addition, AC²OCem encompassed the environmental sustainability aspects of oxyfuel technologies for retrofitted and new-build cement plants by conducting life cycle assessments.

A retrofitability analysis considering real boundary condition of two cement plants for the 1st generation oxyfuel technology was performed. The techno-economic evaluation highlighted different cost factors and updated the cost estimates performed in previous projects, eg. CEMCAP. In addition, the performance and costs of 1st generation and 2nd generation oxyfuel technology for new built plants were compared. These tasks were highly interdisciplinary and increased research collaboration between the applied research institutes SINTEF and VDZ, and the industrial partners, stakeholders over the whole chain: Holcim, Heidelberg Materials, and TITAN as cement producers, Total Energies, ThyssenKrupp, and Air Liquide as technology and gas providers. In fact, Holcim announced in 2022 that in one of the cement plants in Germany studied in the AC2OCem project, a 2nd generation oxyfuel kiln will be installed. Moreover, Heidelberg Materials announced that BECCS will be implemented in the plant studied in the AC2OCem project by 2030. Therefore, AC2OCem helped the stakeholders from the cement industry in strategic decision-making to reduce their environmental impact and transition towards a cleaner and more sustainable industry where CO2 capture will play a central role. Besides, the first pilot testing and simulations of the innovative 2nd generation burner and kiln system are of critical importance in order to develop further the technology to be implemented as planned.

In AC²OCem, pilot-scale experiments, as well as analytical studies, will be performed to bring the key components of oxyfuel cement plants to TRL6 with the aim of reducing the time to market of the oxyfuel technology in the cement sector. AC²OCem will explore the 1st generation oxyfuel for retrofitting, focusing on optimization of the oxyfuel calciner operation and advancing the kiln burner technology for combusting up to 100 % alternative fuels with high biogenic share to bring this Bio-CCS solution to TRL6. The experimental investigations will be complemented by retrofitability analysis to support the technology transfer from TRL6-TRL8, considering real boundary conditions from 2 cement plants that are selected by ECRA as potential oxyfuel demo plants. Ultimately, the techno-economic evaluations will prepare a guideline for retrofitting oxyfuel in existing cement plants. Moreover, within AC²OCem, the innovative 2nd gen. oxyfuel technology for new-build cement plants, in which the flue gas recycle loop is excluded, will be promoted from TRL2-TRL6 in key components. An unprecedented oxyfuel kiln burner for highly enriched up to pure oxygen combustion will be for the first time developed and tested in a pilot-scale facility that replicates cement kiln conditions. A novel process design for the 2nd gen. oxyfuel technology, associated with high cost-saving potentials, will be introduced. This process design will be optimized and subsequently assessed economically through a techno-economic feasibility study. The outcome of this techno-economic benchmarking will support the cement industry on how to proceed with decarbonization of the cement sector using the oxyfuel technology. AC²OCem will encompass the environmental sustainability aspects of oxyfuel technologies for retrofitted and new-build cement plants by conducting life cycle assessments. Results will be exploited and disseminated within the CCS community and the cement industry to maximize the project's impact.

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CLIMIT-Forskning, utvikling og demo av CO2-håndtering