Displaying items by tag: flue gas

UK: C-Capture has initiated a carbon capture trial at Heidelberg Materials’ Ketton cement works in Rutland, as part of its national 'XLR8 CCS' project aimed at accelerating low-cost carbon capture solutions in industries like cement and glass. The trial utilises C-Capture’s technology, which employs a solvent to selectively capture CO₂ from emissions. According to the company, this process does not rely on the use of amines, therefore requiring 40% less energy than conventional methods and reduces costs. The carbon capture solvent compatibility unit designed by C-Capture and partner Wood will test the effectiveness of this technology in removing CO₂ from flue gas emissions produced during the cement manufacturing process.

XLR8 CCS is funded with €2m from the Department of Energy Security and Net Zero’s €1.2bn Net Zero Innovation Portfolio. The funding is part of the €23m Carbon Capture, Usage and Storage (CCUS) Innovation 2.0 programme aimed at accelerating the deployment of next-generation CCUS technology in the UK. Additional private sector contributions support a €3.1m total.

C-Capture CEO Tom White said "Decarbonising industry is one of the most pressing global issues. C-Capture’s XLR8 CCS project is a critical step in the race to net zero as we work with our innovative technology and leading industry partners to demonstrate that an affordable carbon capture solution is a reality – even for industries that are difficult to decarbonise. We are incredibly proud to be working with our project partners which have strong commitments to decarbonisation and are early adopters of novel carbon capture technology."

Simon Willis, CEO of Heidelberg Materials UK said “Carbon capture is a critical part of our strategy to decarbonise cement production and essential if we are to reach net zero and help our customers achieve their own decarbonisation goals. Our venture with C-Capture is another example of our commitment to developing new technologies and, if successful, has the potential to be rolled out at other sites across the Heidelberg Materials Group.”

UK: Hanson has announced a 'carbon capture breakthrough' in its use of recycled concrete paste (RCP) in the wet scrubber of its Ribblesdale cement plant in Lancashire. In under 30 minutes, 15t of RCP was able to capture 1.5t of CO₂ from the plant's flue emissions. Carbonated RCP is suitable to replace limestone in cement production.

Hanson's sustainability director Marian Garfield said “The trial was carried out with our parent company Heidelberg Materials’ research and development team, and marks another important milestone in our carbon capture journey."

UK: Denmark-based architecture fund Henrik Frode Obel Foundation has named Seratech as winner of its Obel Award 2022. The award recognises architectural contributions to global development. Seratech has developed an olivine-based composite cement produced using CO₂ from flue emissions, which can sequester double the CO₂ of ordinary Portland cement (OPC). When used as 40% of a blend with OPC, it is able to completely offset the emissions of concrete production.

Team member Barnaby Shanks said "The beauty of the idea is that you can just use it as normal concrete. There are other carbon-neutral materials, but they can be limiting because they can only be precast, cured in a lab in special conditions and shipped elsewhere. We want people to retain the freedom to use concrete the way that they are used to. We don’t want to limit people in any way because we’ll just lessen the amount of impact we can have."

China: Huaxin Cement and Hunan University have started a pilot production line that uses flue gas from a cement production line to manufacture concrete bricks. The process, being tested at the Huaxin Wuxue Industrial Park in Hubei Province, absorbs CO₂ from the flue gas and uses the heat of the gas to cure the bricks, according to the Xinhua News Agency. The average compressive strength of the bricks is above 15MPa. It is estimated that a production line with a brick output of 100m/yr could absorb 26,000t/yr of CO₂.

US: Elixsys has completed a 100hr continuous pilot test to extract ammonium sulphate and calcium carbonate from flue gas desulphurisation solids at a coal-fired power plant in Pennsylvania. Products made using the company’s proprietary process meet the specifications for fertiliser-quality ammonium sulphate and technical-grade calcium carbonate.

The company intends to start a commercial-scale project of its technology in 2019 once it finds a utility partner. Full-scale operations are planned by 2022. The company is also starting pilot testing on another process to extract metals from coal ash.

Poland: BWF Envirotec Group has purchased Orwat Filtertechnik. Based in Mysłowice, Silesia, the company has been producing and distributing filter bags and filter pockets for dedusting and flue gas cleaning technology as well as pockets, cartridges and compact filters for air conditioning and ventilation technology since 1995. The company also has a sales office in Warendorf, North Rhine-Westphalia in Germany giving it a European presence. No value for the acquisition has been disclosed.

"Orwat Filtertechnik, with its technologically outstanding equipment, is an excellent addition to our line-up with a high level of benefit for our customers, particularly for plant builders and operators of flue gas cleaning systems,” said Stefan Offermann and Philipp von Waldenfels, managing partners of BWF Group. They added that the acquisition also strengthens its Offingen-based headquarters.

Germany: HeidelbergCement and Aachen University of Applied Sciences (RWTH Aachen) have started a three-year research project ‘CO2MIN’ that started on 1 June 2017 examining the absorption of CO₂ from flue gas by olivine and basalt. The intention is that the carbonised minerals could be used as a value-added additive in the production of building materials. HeidelbergCement and RWTH are supported by the Potsdam Institute for Advanced Sustainability Studies (IASS) and the Dutch start-up Green Minerals. The Federal Ministry of Education and Research (BMBF) is funding the project with Euro3m.

"We are already reducing the CO₂ emissions of our plants very successfully by using alternative fuels and raw materials and by optimising the efficiency of our kilns," said Jan Theulen, Director of Alternative Resources at HeidelbergCement. He added that binding CO₂ in minerals was one approach the company was exploring to reduce its emissions further.

In the first year the research project will focus on the investigation of different minerals in small-scale experiments. The carbonation of the most suitable minerals will then be tested under process conditions in the second year. The experiments will be conducted by the institute of Process Metallurgy and Metal Recycling (IME), which is the coordinator of the RWTH group. Life-cycle assessments (RWTH) as well as analyses of economic aspects and social acceptance (IASS) complete this project phase. In the third year, marketability and acceptance will be further optimised through intensive cooperation with customers.

India: Redecam Group and Isgec Heavy Engineering have started a joint venture called Isgec Redecam Enviro Solutions in Noida, Delhi. The new company will provide for flue gas treatment systems for the cement, power and metals industries.

“Air pollution is one of the major environmental issues India and the rest of Asia face today and it is a serious problem with the major sources being industrial emission and biomass burning, vehicle emissions and traffic congestion. In the effort to reduce the country’s air pollution, Redecam and Isgec aim to build a strong business in Asia, drawing upon Redecam’s global expertise combined with the skills and knowledge of Isgec, a strong partner headquartered in India,” said Barry Downing, chief executive officer of Redecam Group.

Italy’s Redecam Group is an engineering company that serves the air pollution control industry around the world. India’s Isgec Heavy Engineering is a general engineering company with references in the cement, chemical, textile, power, oil, gas and sugar industries.

China: Tibet Tianlu has signed a contract worth US$154m to build an integrated cement plant in Lhasa, Tibet. The civil engineering company said in a statement to the Shanghai Stock Exchange that it will build the 4000t/day plant in partnership with the Tibetan Building Materials Company. The scope of contract includes building the production line, from limestone crushers to finished cement and auxiliary production facilities. The project will also include a waste heat recovery and flue gas denitrification systems. Construction is due to start in April 2016 with completion scheduled for September 2017.

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.