Cement oxyfuel technology

from a supplier perspective

07.11.2017 | Jost Lemke

thyssenkrupp Industrial Solutions

2 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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“Oxyfuel clinker burning – substitute nitrogen by carbon

dioxide, everything else stays the same...”

“We are ready to build a plant and everything will

be a bit different.”

3 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Oxyfuel clinker kiln

from silo

clinker

storage

water discharge

oxygen

supply

primary gas

and oxygen

raw mill

raw mill air

air

preheater

calciner main burner

cooler vent air

heat exchanger

baghouse

condensation flue gas recirculation

cooler CO2

purification

bypass

4 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Preheater and calciner

• Increased heat capacity alters the preheater

temperature profile

• Retrofitted plants require a flue gas recirculation for

temperature control and to ensure the material

lifting

• Calciner temperature is raised by 50...100 K due to

increased CO2 partial pressure

• Acceptable sulphur and chlorine levels will change

• Bypass rate needs to be adjusted

• Bypass gas should be returned to the process

from silo

calciner

bypass

preheater

5 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Rotary kiln and main burner

• Existing burner design can be used

for oxyfuel as well

• Recirculated flue gas is used for

fuel conveying

• Reduced recirculation rate could

require fuel shift from the main

burner to the calciner

primary gas

and oxygen

main burner

6 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Clinker cooler

• Cooler vent air is utilized for raw

grinding

• Grate area of cooler is separated

into CO2 and air compartment.

• Air must not enter the CO2 section

• Modified control loop for cooling

fans

clinker

storage

raw mill

cooler vent air

cooler

air

7 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Flue gas treatment and recirculation

• Excess heat from the raw gas is

transferred to the raw mill or WHRPG via

heat exchanger

• Recirculated flue gas is cleaned and dried

• Additional fans reduce air inleakage

• Recirculation gas cooling reduces the

plant efficiency

water discharge

oxygen

supply

air

heat exchanger

baghouse

condensation

flue gas recirculation

CO2

purification

8 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Process control and utilities

• Oxyfuel clinker line requires two grids for pressurized air and pressurized

CO2 (for air cannons, baghouse cleaning, fuel conveying etc.)

• For startup, fresh air is used until sufficient flue gas can be recirculated

• Reducing the recirculation rate will increase CO2 concentration and make

the process control easier

• Necessary auxiliary equipment is state-of-the-art and available on market

water discharge

oxygen

supply

baghouse

condensation

CO2

purification

9 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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CO2 utilization

• CO2 utilization often cause strict limits on certain gas components (SOx,

HCl, HF, heavy metals)

• Subsequent utilization may have an impact on the oxyfuel process design

due to

−Possible heat integration

−Hydrogen production also releases oxygen

which could be used in the oxyfuel kiln

• Overall optimization of the CCU chain could

cause increased energy use or fuel cost for

clinker burning due to

−Higher bypass rates

−Flue gas limits

thyssenkrupp Carbon2Chem project

10 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Integration potentials

clinker kiln

ASU

CO2 refining

CO2

conversion

waste heat

utilization

heat (during operation) heat

heat

CO2

CO2

cooling water

cooling water

cooling water

O2 O2

heat (for start up)

11 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Summary and outlook

• Retrofitting existing plants is technically viable

• All unit operations are well proven technology

• As the complete plant is affected by the oxyfuel operation, the experience

from a first demonstration plant will be

quite important

• Demo Plant experience will enable to test

optimization approaches and will be

beneficial for the layout of new oxyfuel

project.

12 | 07.11.2017 | Cement oxyfuel technology from a supplier perspective | Jost Lemke

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Let us make the next step towards CCU!

Thank you

for your Attention!