Displaying items by tag: European Cement Research Academy

Germany: The European Cement Research Academy (ECRA) has elected Eric Bourdon as the chair of its Technical Advisory Committee. Hendrik Möller, Schwenk Deutschland and Samir Cairae, Titan Cement have also joined the organisation’s board of directors

Bourdon is the Deputy CEO, the Head of Industry and the Chief Climate Officer of Vicat. He joined the group in 2002 after working for thyssenkrupp Polysius. He is a graduate in engineering from the Ecole Nationale Supérieure d’Arts et Métiers in Paris.

ECRA was founded in 2003. It supports and shares research by the cement sector in Europe. It is steered by its technical committee. Bourdon will work with ECRA managing director Martin Schneider on strengthening its work in strategic areas, including CO₂ capture and related technologies, as well as grinding and kiln technologies.

Germany/UK: The Global Cement and Concrete Association (GCCA) and the European Cement Research Academy (ECRA) have announced a formal partnership agreement. The strategic alliance is aimed at fostering innovation in the cement and concrete sectors and across their value chain partners.

Under the terms of the agreement, the GCCA and ECRA have granted each other mutual membership in order to aid collaboration. In addition, ECRA’s managing director will join the GCCA’s Partnership Council and the GCCA’s cement director will join ECRA’s Technical Advisory Council. The two parties will share their current work programs and identify key areas for future collaboration and input.

“ECRA’s mission to advance innovation in the cement industry within the context of sustainable development, as well as communicating key knowledge and research findings in technology, fits perfectly with the GCCA’s aim of driving advances in sustainable construction,” said Benjamin Sporton, the chief executive officer (CEO) of the GCCA.

Austria/Germany/Italy: The European Cement Research Academy (ECRA) has launched its oxyfuel carbon capture pilot projects at HeidelbergCement’s Colleferro plant in Italy and LafargeHolcim’s Retznei plant in Austria. The two locations were chosen form a shortlist of five sites. The pilots will test oxyfuel technology on an industrial scale. The test phase of the research is expected to cost Euro80m and the cement industry has contributed Euro25m towards this. ‘Substantial’ funding from European or national research schemes is being sought.

“The technical feasibility of oxyfuel technology can only be proven in real-scale application, but we have sufficient information from our research to believe that we will obtain a positive result after the trials” said Daniel Gauthier, chairman of ECRA.

Switzerland: The Cement Sustainability Initiative (CSI) has published a technology review on current and anticipated developments that can be used to mitigate CO₂ emissions in cement production. The report includes 52 individual papers on existing technologies and seven additional summary papers

The CSI initiated a review of its original technology papers, which were originally developed in 2009, when the sector issued the first ever low-carbon technology roadmap in partnership with the International Energy Agency (IEA), following the United Nations Framework Convention on Climate Change (UNFCCC) Paris Agreement. The European Cement Research Academy (ECRA) and a stakeholder consultant processes have also supported the project.

Key technological fields covered in the current review include: thermal energy efficiency, electric energy efficiency, use of alternative fuels, materials and biomass, reduction of the clinker content in cement, new binding materials, CO₂ capture and storage (CCS), and CO₂ use (CCU). The report also includes an assessment of the level of possible implementation, the challenges and costs of these technologies in future scenarios for 2030 and 2050.

“The publication of these revised and new technical papers sets robust foundations for the overall exercise of updating our 2009 roadmap. It is also a major step in the implementation of commitments made by the cement sector in Paris through the Cement Low Carbon Technology Partnerships initiative (LCTPi) and it demonstrates that the business is more than ever focused on supporting the implementation of the Paris Agreement,” said Philippe Fonta, managing director of the CSI.

The CSI and IEA plan to share the initial results of the updated global technology roadmap for the cement sector at COP 23 in Bonn, Germany.

One highlight from the cement industry news over the last month was Skyonic's announcement that it has opened a commercial-scale carbon capture unit at the Capitol Aggregates cement plant in Texas, US. Details were light, but the press release promised that the unit was expected to generate US$48m/yr in revenue for an outlay of US$125m. Potentially, the implications for the process are profound, so it is worth considering some of the issues here.

Firstly, it is unclear from the public information released whether the process will actually make a profit. The revenue figures for the Skyonic unit are predictions and are dependent on the markets that the products (sodium biocarbonate, hydrogen and chlorine) will be sold into. Skyonic CEO and founder, Joe Jones, has said in interview that the sodium-based product market by itself could only support 200 - 250 plants worldwide using this process. Worldwide there are over 2000 integrated cement plants. Since Jones is selling his technology his market prediction might well be optimistic. It is also uncertain how existing sodium biocarbonate producers will react to this new source of competition.

Secondly, Skyonic is hoping to push the cost of carbon capture down to US$20/t. Carbon dioxide (CO₂) capture and transportation varies between industries depending on the purity and concentration of the by-product. For example, in 2011 the US Energy Information Administration estimated the cost for CO₂ capture to range from US$36.10/t for coal and biomass-to-liquids conversion up to US$81.08/t for cement plants. The difference being that capturing CO₂ from cement plant flue gas emissions requires more cleaning or scrubbing of other unwanted chemicals such as mercury.

With these limitations in mind, Skyonic is placing itself in competition with the existing flue gas scrubbing market rather than the carbon capture market, since the level of CO₂ removal can be scaled to local legislation. Plus, SO_x, NO₂, mercury and other heavy metals can be removed in the process.

Back on carbon capture, Skyonic is securing finance for a process it calls Skycycle, which will produce calcium-based products from CO₂, with a pilot plant planned at Capitol Aggregates for late 2015. This puts Skyonic back amongst several other pilot projects that are running around the world.

Taiwan Cement and the Industrial Technology Research Institute inaugurated their calcium looping project pilot in mid-2013. It was last reported to have a CO₂ capture rate of 1t/hr.

The Norcem cement plant in Brevik, Norway started in early 2014 to test and compare four different types of post-combustion carbon capture technologies at its pilot unit. These are Aker Solutions Amine Technology, RTI Solid Sorbent Technology, DNV GL/ NTNU/ Yodfat Engineers Membrane Technology and Alstom Power Regenerative Calcium Cycle. The project in conjunction with HeidelbergCement and the European Cement Research Academy (ECRA) is scheduled to run until 2017.

St Marys Cement in St Marys, Canada started its bioreactor pilot project in July 2014. This process uses flue gas to grow algae that can then be used for bio-oil, food, fertiliser and sewage treatment.

If Skyonic is correct then its sodium biocarbonate process in Texas is a strong step towards cutting CO₂ emissions in the cement industry. Unfortunately, it looks like it can only be a step since the market won't support large-scale adoption of this technology. Other pilots are in progress but they are unlikely to gather momentum until legislation forces cement producers to adopt these technologies or someone devises a method that pays for the capture cost.

Norway: Oil and gas industry engineering firm Aker Solutions has won a contract to test and study the capture of CO₂ from flue gas emitted at Norcem's cement plant in Brevik, Norway. The award from the HeidelbergCement subsidiary, in cooperation with the European Cement Research Academy (ECRA) marks the first time technology to capture CO₂ will be used at a cement production plant.

Aker Solutions will perform long-term testing on the actual flue gas to select optimum chemical solvent for high content CO₂ flue gas at the plant. Tests will be performed with Aker Solutions' in-house developed Mobile Test Unit (MTU). The MTU is a CO₂ capture plant that includes all processes and functions found in a large scale commercial plant.

ECRA members chose Norcem Brevik as the site for ECRA operational CO₂-capture test project. The project is supported and partly financed by the CLIMIT programme, which is managed by Gassnova in cooperation with the Research Council of Norway.

Aker Solutions has developed CO₂-technology solutions since the early 1990s. A separate company, Aker Clean Carbon, was established in 2007 as a company under Aker ASA to commercialise carbon capture technology. Aker Solutions took full ownership of Aker Clean Carbon in 2012 and carbon capture and storage activities are an integrated part of Aker Solutions.