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CEMCAP Framework for Comparative Techno-Economic Analysis of CO2 Capture from Cement Plants

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CEMCAP Framework for Comparative Techno-Economic Analysis of CO2 Capture from Cement Plants Grant Agreement Number: 641185 Action acronym: CEMCAP Action full title: CO2 capture from cement production Type of action: H2020-LCE-2014-2015/H2020-LCE-2014-1 Starting date of the action: 2015-05-01 Duration: 42 months D3.2 CEMCAP framework for comparative techno-economic analysis of CO2 capture from cement plants Revision 1 Due delivery date: 2017-01-31 Actual delivery date: 2017-05-11 Revised version delivery date: 2017-09-18 Organisation name of lead participant for this deliverable: SINTEF-ER Project co-funded by the European Commission within Horizon2020 Dissemination Level PU Public x CO Confidential , only for members of the consortium (including the Commission Services) Page iii Deliverable number: D3.2 Deliverable title: CEMCAP framework for comparative techno-economic analysis of CO2 capture from cement plants Work package: WP3: CEMCAP Framework Lead participant: SINTEF-ER Author(s) Name Organisation E-mail Rahul Anantharaman SINTEF ER [email protected] David Berstad SINTEF ER [email protected] Giovanni Cinti C.T.G SPA [email protected] Edoardo De Lena Politecnico di Milano [email protected] Manuele Gatti Politecnico di Milano [email protected] Matteo Gazzani ETH Zurich [email protected] Helmut Hoppe VDZ GmbH [email protected] Isabel Martínez Politecnico di Milano [email protected] Juliana Garcia Moretz- TNO [email protected] Sohn Monteiro Matteo Romano Politecnico di Milano [email protected] Simon Roussanaly SINTEF ER [email protected] Erin Schols TNO [email protected] Maurizio Spinelli Politecnico di Milano [email protected] Sigmund Størset SINTEF ER [email protected] Peter van Os TNO [email protected] Mari Voldsund SINTEF ER [email protected] Abstract This document provides a framework for comparative techno-economic analysis in the CEMCAP project, where four different CO2 capture technologies are to be evaluated for application in cement plants. It defines a reference cement kiln with description of the main unit, and characteristics of raw material and flue gas. The four capture technologies (oxyfuel, chilled ammonia, membrane assisted liquefaction, and calcium looping), and a reference technology (MEA absorption) are described. Specifications are set for process units (e.g. heat exchangers, compressors etc.) and for the generation of utilities (e.g. steam, electric power etc.). Conditions like the extent of CO2 capture and purity of the produced CO2 are set. Furthermore, relevant economic parameters are defined, and parameters relevant for sensitivity studies are suggested. Changes in revision 1 Clarifications are included on the definition of primary energy for renewable power production (Chapter 6.2.1) and cost of electricity in EU28 (Table 6.6). The new ISO 27913 standard on CO2 pipeline transportation systems is commented on in relation to the CO2 impurity specifications (Chapter 8.1.1). Temperature profiles in Fig. 3.6 are corrected. CEPCI for 2014 was updated with final 2014 value instead of a preliminary value. This project has received funding from the European Union's Horizon2020 Research and Innovation Programme under Grant Agreement No 641185. This work was supported by the Swiss State Secretariat for Education, Research and Innovation (SERI) under contract number 15.0160 Page v TABLE OF CONTENTS Page 1 INTRODUCTION ................................................................................................................... 3 2 GENERAL DEFINITION AND CONDITIONS .................................................................... 4 2.1 Units ............................................................................................................................. 4 2.2 Reference state for gas concentrations ......................................................................... 4 2.3 Ambient conditions ...................................................................................................... 4 3 REFERENCE CEMENT KILN .............................................................................................. 5 3.1 Size ............................................................................................................................... 5 3.2 Raw material ................................................................................................................. 6 3.2.1 Raw meal .......................................................................................................... 6 3.2.2 Fuel ................................................................................................................... 7 3.3 Preheater ....................................................................................................................... 7 3.4 Calciner ......................................................................................................................... 9 3.5 Kiln ............................................................................................................................. 10 3.6 Main burner ................................................................................................................ 12 3.7 Clinker cooler ............................................................................................................. 14 3.8 Flue gas ....................................................................................................................... 15 3.8.1 Interconnected and direct mode ...................................................................... 15 3.8.2 Air leak ........................................................................................................... 16 3.8.3 Flue gas conditions ......................................................................................... 17 3.8.4 Flue gas base case definition .......................................................................... 20 4 CAPTURE TECHNOLOGIES ............................................................................................. 21 4.1 Reference case: MEA absorption ............................................................................... 21 4.2 Oxyfuel ....................................................................................................................... 22 4.3 Chilled ammonia ........................................................................................................ 24 4.4 Membrane assisted liquefaction ................................................................................. 27 4.5 Calcium looping ......................................................................................................... 29 5 PROCESS UNIT SPECIFICATIONS .................................................................................. 32 5.1 Heat exchangers .......................................................................................................... 32 5.2 Separators ................................................................................................................... 32 5.3 Pumps, fans, compressors and expanders ................................................................... 32 5.4 Filters .......................................................................................................................... 33 6 CO2 CAPTURE UTILITIES ................................................................................................. 34 6.1 Steam .......................................................................................................................... 34 6.1.1 Steam produced from heat recovery in the cement power plant .................... 34 6.1.2 Steam import from external coal CHP plant ................................................... 34 6.1.3 Natural gas-fired boiler ................................................................................... 35 6.1.4 CO2 emissions and cost .................................................................................. 35 6.2 Electricity.................................................................................................................... 36 6.2.1 Reference efficiency and CO2 emission ......................................................... 36 6.2.2 Cost of electricity ............................................................................................ 38 This project has received funding from the European Union's Horizon2020 Research and Innovation Programme under Grant Agreement No 641185. This work was supported by the Swiss State Secretariat for Education, Research and Innovation (SERI) under contract number 15.0160. Page vi 6.3 Integrated power production ....................................................................................... 40 6.4 Air separation unit ...................................................................................................... 44 6.4.1 On-site production .......................................................................................... 44 6.4.2 Oxygen supplied by tank trucks ..................................................................... 45 6.4.3 Oxygen costs ................................................................................................... 45 6.5 Refrigeration system ................................................................................................... 45 6.6 Heat rejection system ................................................................................................. 49 7 EXTENT OF CO2 CAPTURE .............................................................................................
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