Displaying items by tag: carbon capture

Coolbrook has been in the news recently with collaboration deals struck with Cemex and UltraTech Cement. First the Finland-based company officially launched its Roto Dynamic Heater (RDH) technology with a memorandum of understanding signed with Cemex in May 2022. Then, this week, it signed a similar agreement with UltraTech Cement.

The specifics of either agreement are unknown but the target is clearly to build an industrial pilot of an electric kiln – or something like it - at a cement plant. Coolbrook says it has run a pilot of its RDH technology in Finland. Further tests are now scheduled to continue for two years starting from September 2022 at the Brightlands Chemelot Campus at Geleen in the Netherlands. Commercial scale demonstrations are scheduled from 2022 with the hope of commercial use from 2024. Links with Cemex and UltraTech Cement seem to suggest progress. At the same time Coolbrook will be testing its RotoDynamic Reactor (RDR) technology, which promises to electrify the steam cracking process used in plastic manufacturing.

Publically available details on the RDH technology are light. In its promotional material Coolbrook says that it can achieve process temperatures of up to around 1700°C. This is crucial to achieve full clinker formation in a cement kiln. Reaching this temperature with non-combustion style kilns, such as solar reactors, has previously been a problem. Notably, Synhelion and Cemex said in February 2022 that they had managed to produce clinker using concentrated solar radiation. Retrofit possibilities and compact equipment size are also mentioned in the promotional material for the RDH. The former is an obvious attraction but size of equipment footprint is increasingly emerging as a potential issue for cement plants looking to reduce their CO₂ emissions. Rick Bohan from the Portland Cement Association (PCA) presented a summary of the potential and problems of emerging carbon capture and utilisation/storage (CCUS) technologies for cement plants in the US at the Virtual Global CemCCUS Seminar that took place on 14 June 2022. He noted that installing CCUS equipment makes cement plants start to look different (more like petrochemical plants in the view of Global Cement Weekly) and that they may require more space to install it all.

Coolbrook hasn’t been the only organisation looking at kiln electrification. The installation with the most available information on kiln electrification has been the Decarbonate project, led by the VTT, formerly known as the Technical Research Centre of Finland. The project has built a pilot rotary kiln with a length of 8m inside a shipping container. It has a production capacity of around 25kg/hr. The system reportedly uses fixed radiant heating coils around the kiln, surrounded by insulation materials. Early results presented to the 1st Virtual Global CemPower Seminar in late 2021 were that the kiln started up, sufficient calcination was occurring and the system was operated continuously for three days at a temperature of 1000°C with no problems reported. Further research was scheduled to carry on into 2022 with longer trials planned for three different materials.

HeidelbergCement’s subsidiary in Sweden, Cementa, completed a feasibility study on implementing electrified cement production at its Slite plant in 2019. It then said that it was conducting further study with electricity producer Vattenfall as part of CemZero project. This consists of three projects running to 2025. Namely: heat transfer with plasma in rotary kilns; direct separation of carbon dioxide from calcination of carbonate-based raw materials in the production of cement clinker and burnt lime; and carbon dioxide-free products with electrified production - reactivity of cement clinker with secondary additives. HeidelbergCement has since announced plans to build a full scale 1.8Mt/yr carbon capture and storage (CCS) plant at the Slite cement plant by 2030.

How this would fit with any kiln electrification plans is unknown. However, one attraction of moving to an electrical kiln, for all of the projects above, is to cut out the 40 – 50% of a cement plant’s CO₂ emissions that arise from the fuel that is burnt. Taking a kiln electric also makes CO₂ capture easier. Much of the remainder of the CO₂ released comes from the decomposition of limestone during calcination when clinker is created. Substitute out fossil or alternative fuels and the flue gas becomes much purer CO₂.

It is early days for cement kiln electrification but progress is happening both commercially and scientifically. The next step to watch out for will be the first pilot installation at a cement plant. One point to finish with is a comment that Rick Bohan made at the IEEE-IAS/PCA Cement Industry Technical Conference that took place in May 2022: carbon capture is expected to double a cement plant’s energy consumption. Kiln electrification is one potential route for cement production to reach net zero. CCUS is another. If one or both occur then a low carbon future could be a high energy one also.

Watch out for Global Cement’s forthcoming interview with Coolbrook in the September 2022 issue of Global Cement Magazine

For more on CCUS, download the proceedings pack for the Virtual Global CemCCUS Seminar 2022

For more on Synhelion and Cemex read the interview in the December 2020 issue of Global Cement Magazine interview

UK: The UK Department for Business, Energy and Industrial Strategy (BEIS) has granted Carbon Clean Euro701,000 under its Carbon Capture, Utilisation and Storage (CCUS) Innovation 2.0 programme. Carbon Clean says that it will partner with energy engineering company Doosan Babcock and Newcastle University to develop carbon capture systems which apply non-aqueous solvent (NAS) and rotating packed bed (RPB) technology together for the first time. The partners seek to overcome the challenges of scale and cost in order to advance the widespread deployment of CCUS systems.

The CCUS Innovation 2.0 programme is part of the UK government’s Euro1.17bn Net Zero Innovation Portfolio scheme.

Germany: ThyssenKrupp Industrial Solutions’ Polysius division says that it has been commissioned by Buzzi Unicem, HeidelbergCement, Schwenk Zement and Vicat to build a pure oxyfuel kiln system at the Mergelstetten cement plant as part of the Cement Innovation for Climate (CI4C) project. No dates of the start of construction or final project commissioning of the industrial trial have been disclosed. CI4C was originally formed in 2019.

The Polysius pure oxyfuel process is a new type of clinker production process in which the otherwise normal ambient air is replaced by pure oxygen in the kiln combustion process. One advantage of the technology is that atmospheric nitrogen is eliminated from the clinker burning process leading to much higher concentrations of CO₂ in the exhaust gas compared to a conventional kiln. As such the process aims to concentrate, capture and reuse almost 100% of the CO₂ produced in a cost-effective manner. The medium-term goal is to further process the captured CO₂ with the help of renewable energy into products such as kerosene for air traffic.

Sweden: HeidelbergCement says that it will establish a 1.8Mt/yr carbon capture and storage (CCS) plant at its Slite cement plant in Gotland. It aims to achieve full-scale capture of the plant’s CO₂ emissions by 2030. In conjunction with the CCS plant project, Cementa will increase the share of biomass in the Slite plant’s fuel mix.

Chair Dominik von Achten said “Just a few days ago, we published new sustainability targets, underlining the importance of carbon capture, utilisation and storage (CCUS) as one key lever to almost halve our CO₂ footprint by 2030 compared to 1990, and achieve Net Zero by 2050 at the latest.” He continued “Slite CCS is the largest CCUS project yet in our group and the cement industry, and a model for what will be achievable with CCUS also beyond 2030. As this initiative contributes considerably to the climate ambitions of Sweden, and is a unique project for us in terms of scale, we are keen to make it happen.”

UK: Hanson plans to install a C-Capture solvent-based carbon capture system at its Ketton cement plant in Rutland. The producer says that the technology reduces energy requirements per tonne of CO₂ by 40% compared to other capture systems.

Chief executive officer Simon Wills said “Carbon capture is a critical part of our strategy to decarbonise cement production, and essential if we are to reach net zero carbon by 2050. If successful, the C-Capture process has the potential to be rolled-out across other sites across the HeidelbergCement Group.”

US: The US Department of Energy has granted Solidia Technologies US$2.1m in funding for the development and testing of carbonation methods for its Solidia Cement. Solidia will research synthetic supplementary cementitious materials (SCMs) production methods using direct CO₂ capture and utilisation.

CEO Russell Hill said “We are proud to partner with the US Department of Energy to continue innovating and ultimately deliver on our mission to provide commercially viable decarbonisation technologies and sustainable solutions for the global construction and building materials industries. The funding will advance our carbon capture, utilisation and storage (CCUS) technologies and synthetic SCMs that can be easily integrated into Portland cement-based concrete formulations, offering manufacturers a solution that is sustainable environmentally and economically.”

UK: Carbon capture systems developer Carbon Clean has raised US$150m in its largest funding round to date. US-based energy company Chevron Corporation led the round, with participation from Cemex venture capital subsidiary Cemex Ventures, Marubeni Corporation, WAVE Equity Partners, AXA IM Alts, Samsung Ventures, Saudi Aramco Energy Ventures and TC Energy.

As a result of the new funding, Carbon Clean says that it will now scale the production of its CycloneCC fully modular carbon capture technology, increase investment in research and development grow its team to meet ‘exponential’ demand growth for its products.

Germany: Holcim Deutschland says that the preliminary test phase of a new CO₂ separation unit at its Höver cement plant in Lower Saxony has delivered positive results. Plant manager Stephan Hinrichs said that the company was “delighted” with the results so far. In late 2021 Cool Planet Technologies and Hereon signed a memorandum of understanding with Holcim Deutschland to deliver a carbon capture system for a carbon capture and storage (CCS) trial at the plant based on Hereon’s PolyActive membrane technology.

The next stage of the project will start in August 2022 and it will last until late 2024. This will include a one-year active test phase, in which the system is to be examined in long-term operation, planned to start in September 2023. If the results are good enough then the carbon capture unit will be expanded step-by-step so that after the final expansion stage it can separate around 90% of the CO₂ emissions and deliver high-purity CO₂ in liquid form for sequestration or further use. The ultimate aim of the project is to demonstrate performance, economy and operational behaviour on a larger scale in order to check whether the technology can be used at both Höver and other cement plants. Continued funding for the scheme is dependent on an application to the Competence Centre on Climate Change Mitigation in Energy-Intensive Industries (KEI) as part of the Decarbonisation in Industry program.

France: Lhoist and Air Liquide have signed a memorandum of understanding with the aim to build a carbon capture unit at Lhoist’s Réty lime plant in Hauts-de-France. Air Liquide wants to build and operate a unit from 2028 using its Cryocap FG (Flue Gas) technology to capture and purify 95% of the lime plant’s CO₂ emissions. The companies have jointly applied for the European Innovation Fund large scale support scheme to pay for the project. This partnership is a step towards the creation of a low-carbon industrial ecosystem in the Dunkirk area.

Lhoist’s ‘Chaux et Dolomies du Boulonnais’ plant in Réty is France’s largest lime production plant. A potential carbon capture unit at the plant could potentially reduce the CO₂ emissions of the plant by more than 600,000t/yr. Captured CO₂ would then be transported to a multimodal CO₂ export hub in Dunkirk, currently under development, and sent to be sequestered in the North Sea as part of the D’Artagnan project, which has received the PCI (Project of Common Interest) label from the European Commission. The implementation of the project will be possible as public funding from European and/or French schemes supporting decarbonisation become available.

World: The Global Cement and Concrete Association (GCCA) has named its first six startups to receive backing under the inaugural Innovandi Open Challenge. The startups have partnered with GCCA members to help increase cement’s sustainability towards achieving net zero CO₂ concrete production by 2050. This will lead to the formation of six consortia to further test, develop and deploy their new technologies.

Carbon capture, utilisation and storage (CCUS) startups CarbonOrO, MOF Technologies and Saipem, all based in Europe, are among the participants. GCCA members are currently involved in dozens of pilot projects and aim to have 10 industrial-scale carbon capture plants installed by 2030. Other startups Carbon Upcycling Technologies and Fortera, from Canada and the US respectively, use captured CO₂ to produce low-carbon cement and cementitious materials, while UK-based Coomtech has developed a low-cost drying technology using turbulent air.

GCCA CEO Thomas Guillot said “It’s a proud moment to see the industry coming together to support such innovative start-ups on their journey. Our member companies were greatly impressed by their ambition to be a key part of the climate solution. The programme is another big step forward towards unlocking innovation to help us achieve our net zero goal.” He continued “As the need for resilient and sustainable communities to support a growing global population becomes more pressing , cement and concrete will be essential to providing the infrastructure and buildings that society needs. Achieving net zero concrete relies on a number of different groups playing their part, and as an industry we’re looking outwards as well as inwards, to see how start-ups like these can support our goals.”