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Carbon Capture and Storage in the Cement Industry

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Antea Group
Antea Group

Heidelberg Cement presented on carbon capture and storage/ utilization as part of the recent Antea Group-sponsored EHS&S workshop for the chemical industry at the Brightlands Chemelot campus in the Netherlands.

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Christoph Reißfelder Global Environmental Sustainability Brightlands Campus, 11th October 2016 HeidelbergCement driving Carbon Capture and Storage/Utilisation
HeidelbergCement in the world Number 1 in aggregates, number 2 in cement, and number 3 in ready-mixed concrete HeidelbergCement Italcementi HeidelbergCement and Italcementi
Expanded HeidelbergCement Group in figures  63,000 employees  Core business – Aggregates – Cement – Downstream activities: ready-mixed concrete and asphalt  3,030 locations in around 60 countries (incl. joint ventures) – 620 production sites for sand, gravel, and crushed rock – 161 cement and grinding plants – 1,740 ready-mixed concrete plants – 114 asphalt plants  Cement capacity 197 million tonnes (incl. joint ventures)  Aggregates reserves 19 billion tonnes
Contents 1. Climate change & cement 2. Carbon Capture 3. CO2 utilization 4. Concluding remarks
Cement manufacturing explained in 1 minute Limestone CaCO3 Calcining to CaO Sintering to clinker Grinding to cement 1,6 ton limestone + 0,1 ton coal = 1 ton cement + 0,8 ton CO2
We reached the turning point: coal fired power is out!
Mandatory to deploy CCS/CCU to reach our goals! 4 levers to reduce CO2 Energy efficiency 27% Alternative fuels 19% Clinker substitution 9% Carbon Capture & S/U 46% 2016
The cement sector will face one of the highest costs for carbon capture (excluding the power sector) Iron & steel Cement 500 Mt/y 1.500 Mt/y 70 €/t 40 €/t AFR & Clinker substitution Technology
HeidelbergCement beliefs & strategy (I)  Carbon Capture and Storage (CCS) is required for a full de-carbonization of cement industry  CCS needs financial supporting mechanisms to be competitive* feasible *imports/steel  CCS lacking public acceptance in mainland EU, sufficiently accepted in Scandinavia and Canada  Carbon Capture & Utilization (CCU) commercial today for small high-value-end-products  CCU potential to significant contribute to CCS/U targets for cement industry  in focus Reliable technology Financially sound Public acceptance
HeidelbergCement beliefs & strategy (II)  CCS and CCU are mainly in pre-competitive phase  HeidelbergCement encourages and initiates collective approaches – within the cement industry  WBCSD-CSI  ECRA – and beyond  lime-industry  automotive industry  start-ups
Carbon Capture
Large Scale Carbon Capture Norway  Test program 12 m€ final end 2016 – 75% funding government – Amine scrubbing most reliable technology  Feasibility study done – 40% CO2 capture using waste heat Brevik – > 100m€ investment needed (+/- 30%) – OPEX: > 40 €/t clinker – CO2 from fertilizer industry + refinery will be combined for shared storage  Next steps – Evaluate to which extend Government of Norway can finance CAPEX and OPEX to avoid competitive out ruling of Norcem – Evaluate how much HC can “bare” to remain competitive – 1½-2 years to finalize this phase
CEMCAP 9 mio € EU funding September 2015 Econsense Berlin Slide13 Oxyfuel Cement Kiln Cooler Prototype: HC-Hannover Calciner prototype: HC-Italcementi Burner prototype University of Stuttgart CO2-enrichment: Oxyfuel Project for Cement Kilns Funding in progress Slite 7 qualified as demoplant
 Consortium  Indirect heating raw meal: – Separate process CO2 – Calix MgO proven process  10 tph demonstration plant, Lixhe-Belgium – Cement & Lime applications – www.leilac.org.uk LEILAC: CO2 separation@calcining (12 m€ EU-Horizon 2020)
Carbon Capture and Utilization
Technology supplier  Design + supply equipment  Part of CAPEX Energy-company  Construction + Operation  Power control market  Part of CAPEX CO2 and H2 (made by excess renewable energy) to CH4  CO2-supply  Electricity supply  Part of CAPEX  Owner of the facility Cement plant HC CO2 Automobile company  E-gas offtake  Status of e-gas  Marketing of e-gas cars
CCU with cyano bacteria and micro-algae Modified bacteria to ethanol Strategic Partnership with Joule Ltd  Large space required and solar radiation  EU funding not approved  Audi cooperation partner with Joule  Pilot test possible in combination with micro-algae Microalgae for fish & fowl feed Sweden & Turkey  Microalgae are reacting positively to the flue-gas of cement kilns  Algal biomass can be a base material for fishmeal and animal feed
Market – interesting for cement-industry Fishmeal Partner 2020 commercial Ethanol as fuel Partner Joule (+Audi) 2025 commercial
Carbon8: carbonating CaO rich ashes to light weight aggregates Flue gas 20% CO2 85% of flow 15% of flow CKD, sand oil shale ash
Concluding remarks  The cement industry set ambitious targets on CO2 reduction in the CSI-Roadmap 2050  Carbon Capture requires intensive cooperation in our industry and HeidelbergCement is demonstrating leadership in this domain  In its operations worldwide HC is testing and developing (commercial) use of CO2 from our stacks applying various technologies
CO2 will become a valuable asset….. Christoph Reißfelder Assistant Biodiversity & Public Affairs Global Environmental Sustainability jan.theulen@heidelbergcement.com +31 62 9097 354 Contacts:

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Carbon Capture and Storage in the Cement Industry

  • 1. Christoph Reißfelder Global Environmental Sustainability Brightlands Campus, 11th October 2016 HeidelbergCement driving Carbon Capture and Storage/Utilisation
  • 2. HeidelbergCement in the world Number 1 in aggregates, number 2 in cement, and number 3 in ready-mixed concrete HeidelbergCement Italcementi HeidelbergCement and Italcementi
  • 3. Expanded HeidelbergCement Group in figures  63,000 employees  Core business – Aggregates – Cement – Downstream activities: ready-mixed concrete and asphalt  3,030 locations in around 60 countries (incl. joint ventures) – 620 production sites for sand, gravel, and crushed rock – 161 cement and grinding plants – 1,740 ready-mixed concrete plants – 114 asphalt plants  Cement capacity 197 million tonnes (incl. joint ventures)  Aggregates reserves 19 billion tonnes
  • 4. Contents 1. Climate change & cement 2. Carbon Capture 3. CO2 utilization 4. Concluding remarks
  • 5. Cement manufacturing explained in 1 minute Limestone CaCO3 Calcining to CaO Sintering to clinker Grinding to cement 1,6 ton limestone + 0,1 ton coal = 1 ton cement + 0,8 ton CO2
  • 6. We reached the turning point: coal fired power is out!
  • 7. Mandatory to deploy CCS/CCU to reach our goals! 4 levers to reduce CO2 Energy efficiency 27% Alternative fuels 19% Clinker substitution 9% Carbon Capture & S/U 46% 2016
  • 8. The cement sector will face one of the highest costs for carbon capture (excluding the power sector) Iron & steel Cement 500 Mt/y 1.500 Mt/y 70 €/t 40 €/t AFR & Clinker substitution Technology
  • 9. HeidelbergCement beliefs & strategy (I)  Carbon Capture and Storage (CCS) is required for a full de-carbonization of cement industry  CCS needs financial supporting mechanisms to be competitive* feasible *imports/steel  CCS lacking public acceptance in mainland EU, sufficiently accepted in Scandinavia and Canada  Carbon Capture & Utilization (CCU) commercial today for small high-value-end-products  CCU potential to significant contribute to CCS/U targets for cement industry  in focus Reliable technology Financially sound Public acceptance
  • 10. HeidelbergCement beliefs & strategy (II)  CCS and CCU are mainly in pre-competitive phase  HeidelbergCement encourages and initiates collective approaches – within the cement industry  WBCSD-CSI  ECRA – and beyond  lime-industry  automotive industry  start-ups
  • 12. Large Scale Carbon Capture Norway  Test program 12 m€ final end 2016 – 75% funding government – Amine scrubbing most reliable technology  Feasibility study done – 40% CO2 capture using waste heat Brevik – > 100m€ investment needed (+/- 30%) – OPEX: > 40 €/t clinker – CO2 from fertilizer industry + refinery will be combined for shared storage  Next steps – Evaluate to which extend Government of Norway can finance CAPEX and OPEX to avoid competitive out ruling of Norcem – Evaluate how much HC can “bare” to remain competitive – 1½-2 years to finalize this phase
  • 13. CEMCAP 9 mio € EU funding September 2015 Econsense Berlin Slide13 Oxyfuel Cement Kiln Cooler Prototype: HC-Hannover Calciner prototype: HC-Italcementi Burner prototype University of Stuttgart CO2-enrichment: Oxyfuel Project for Cement Kilns Funding in progress Slite 7 qualified as demoplant
  • 14.  Consortium  Indirect heating raw meal: – Separate process CO2 – Calix MgO proven process  10 tph demonstration plant, Lixhe-Belgium – Cement & Lime applications – www.leilac.org.uk LEILAC: CO2 separation@calcining (12 m€ EU-Horizon 2020)
  • 15. Carbon Capture and Utilization
  • 16. Technology supplier  Design + supply equipment  Part of CAPEX Energy-company  Construction + Operation  Power control market  Part of CAPEX CO2 and H2 (made by excess renewable energy) to CH4  CO2-supply  Electricity supply  Part of CAPEX  Owner of the facility Cement plant HC CO2 Automobile company  E-gas offtake  Status of e-gas  Marketing of e-gas cars
  • 17. CCU with cyano bacteria and micro-algae Modified bacteria to ethanol Strategic Partnership with Joule Ltd  Large space required and solar radiation  EU funding not approved  Audi cooperation partner with Joule  Pilot test possible in combination with micro-algae Microalgae for fish & fowl feed Sweden & Turkey  Microalgae are reacting positively to the flue-gas of cement kilns  Algal biomass can be a base material for fishmeal and animal feed
  • 18. Market – interesting for cement-industry Fishmeal Partner 2020 commercial Ethanol as fuel Partner Joule (+Audi) 2025 commercial
  • 19. Carbon8: carbonating CaO rich ashes to light weight aggregates Flue gas 20% CO2 85% of flow 15% of flow CKD, sand oil shale ash
  • 20. Concluding remarks  The cement industry set ambitious targets on CO2 reduction in the CSI-Roadmap 2050  Carbon Capture requires intensive cooperation in our industry and HeidelbergCement is demonstrating leadership in this domain  In its operations worldwide HC is testing and developing (commercial) use of CO2 from our stacks applying various technologies
  • 21. CO2 will become a valuable asset….. Christoph Reißfelder Assistant Biodiversity & Public Affairs Global Environmental Sustainability jan.theulen@heidelbergcement.com +31 62 9097 354 Contacts: