Carbon Capture in the Cement Industry: Technologies, Progress, and Retrofitting

Zero-Emission Cement Plants with Advanced Amine-Based CO2 Capture

Decarbonization of the cement sector is essentially required to achieve carbon neutrality to combat climate change. Amine-based CO2 capture is a leading and practical technology to deeply remove CO2 from the cement industry, owing to its high retrofittability to existing cement plants and extensive engineering experience in industrial flue gas decarbonization. While research efforts have been made to achieve low-carbon cement with 90% CO2 removal, a net-zero-emission cement plant that will be required for a carbon neutrality society has not yet been investigated. The present study proposed an advanced amine-based CO2 capture system integrated with a cement plant to achieve net-zero CO2 emission by pushing the CO2 capture efficiency to 99.7%. Monoethanomaine (MEA) and piperazine/2-amino-2-methyl-1-propanol (PZ-AMP) amine systems, which are considered to be the first- and second-generation capture agents, respectively, were detailed investigated to deeply decarbonize the cement plant. Compared to MEA, the advanced PZ-AMP system exhibited excellent energy performance with a regeneration duty of ∼2.6 GJ/tonne CO2 at 99.7% capture, 39% lower than the MEA process. This enabled a low CO2 avoided cost of $72.0/tonne CO2, which was 18% lower than that of the MEA-based zero-emission process and even 16.2% lower than the standard 90% MEA process. Sensitivity analysis revealed that the zero-emission capture cost of the PZ-AMP system would be further reduced to below $56/tonne CO2 at a $4/GJ steam production cost, indicating its economic competitiveness among various CO2 capture technologies to achieve a zero-emission cement plant.

Reducing China's building material embodied emissions: Opportunities and challenges to achieve carbon neutrality in building materials

Embodied emissions from the production of building materials account for 17% of China's carbon dioxide (CO2) emissions and are important to focus on as China aims to achieve its carbon neutrality goals. However, there is a lack of systematic assessments on embodied emissions reduction potential of building materials that consider both the heterogeneous industrial characteristics as well as the Chinese buildings sector context. Here, we developed an integrated model that combines future demand of building materials in China with the strategies to reduce CO2 emissions associated with their production, using, and recycling. We found that measures to improve material efficiency in the value-chain has the largest CO2 mitigation potential before 2030 in both Low Carbon and Carbon Neutrality Scenarios, and continues to be significant through 2060. Policies to accelerate material efficiency practices, such as incorporating embodied emissions in building codes and conducting robust research, development, and demonstration (RD&D) in carbon removal are critical.

Implications in the production of defossilized methanol: A study on carbon sources

The transition of the current fossil based chemical industry to a carbon-neutral industry can be done by the substitution of fossil carbon for defossilized carbon in the production of base chemicals. Methanol is one of the seven base chemicals, which could be used to produce other base chemicals (light olefins and aromatics). In this research, we evaluated the synthesis of methanol based on defossilized carbon sources (maize, waste biomass, direct air capture of CO2 (DAC), and CO2 from the cement industry) by considering carbon source availability, energy, water, and land demand. This evaluation was based on a carbon balance for each of the carbon sources. Our results show that maize, waste biomass, and CO2 cement could supply 0.7, 2, 15 times the carbon demand for methanol respectively. Regarding the energy demand maize, waste biomass, DAC, and CO2 from cement demand 25, 21, 48, and 45GJtonMeOH separately. The demand for water is 5300, 220, 8, and 8m3tonMeOH. And lastly, land demand was estimated to 1031, 36, 83, and 77m2tonMeOH per carbon source. The high-demanding-resource production of defossilized methanol is dependent on the availability of resources per location. Therefore, we analyzed the production of defossilized methanol in the Netherlands, Saudi Arabia, China, and the USA. China is the only country where CO2 from the cement industry could provide all the demand of carbon. But as we envision society becoming carbon neutral, CO2 from the cement industry would diminish in time, as a consequence, it would not be sufficient to supply the demand for carbon. DAC would be the only source able to provide the demand for defossilized carbon.

Tailoring Hydrophobicity and Pore Environment in Physisorbents for Improved Carbon Dioxide Capture under High Humidity

CALF-20, a Zn-triazolate-based metal-organic framework (MOF), is one of the most promising adsorbent materials for CO2 capture. However, competitive adsorption of water severely limits its performance when the relative humidity (RH) exceeds 40%, limiting the potential implementation of CALF-20 in practical settings where CO2 is saturated with moisture, such as postcombustion flue gas. In this work, three newly designed MOFs related to CALF-20, denoted as NU-220, CALF-20M-w, and CALF-20M-e that feature hydrophobic methyltriazolate linkers, are presented. Inclusion of methyl groups in the linker is proposed as a strategy to improve the uptake of CO2 in the presence of water. Notably, both CALF-20M-w and CALF-20M-e retain over 20% of their initial CO2 capture efficiency at 70% RH─a threshold at which CALF-20 shows negligible CO2 uptake. Grand canonical Monte Carlo simulations reveal that the methyl group hinders water network formation in the pores of CALF-20M-w and CALF-20M-e and enhances their CO2 selectivity over N2 in the presence of a high moisture content. Moreover, calculated radial distribution functions indicate that introducing the methyl group into the triazolate linker increases the distance between water molecules and Zn coordination bonds, offering insights into the origin of the enhanced moisture stability observed for CALF-20M-w and CALF-20M-e relative to CALF-20. Overall, this straightforward design strategy has afforded more robust sorbents that can potentially meet the challenge of effectively capturing CO2 in practical industrial applications.

Oxyfuel Combustion Makes Carbon Capture More Efficient

Fossil energy carriers cannot be totally replaced, especially if nuclear power stations are stopped and renewable energy is not available. To fulfill emission regulations, however, points such as emission sources should be addressed. Besides desulfurization, carbon capture and utilization have become increasingly important engineering activities. Oxyfuel technologies offer new options to reduce greenhouse gas emissions; however, the use of clean oxygen instead of air can be dangerous in the case of certain existing technologies. To replace the inert effect of nitrogen, carbon dioxide is mixed with oxygen gas in the case of such air combustion processes. In this work, the features of carbon capture in five different flue gases of air combustion and such oxyfuel combustion where additional carbon dioxide is mixed with clean oxygen are studied and compared. The five different flue gases originate from the gas-fired power plant, coal-fired power plant, coal-fired combined heat and power plant, the aluminum production industry, and the cement manufacturing industry. Monoethanolamine, which is an industrially preferred solvent for carbon dioxide capture from gas streams at low pressures, is selected as an absorbent, and the same amount of carbon dioxide is captured; that is, always that amount of carbon dioxide is captured, which is the result of the fossil combustion process. ASPEN Plus is used for mathematical modeling. The results show that the oxyfuel combustion cases need significantly less energy, especially at high carbon dioxide removal rates, e.g., higher than 90%, than that of the air combustion cases. The savings can even be as high as 84%. Moreover, 100% carbon capture was also be completed. This finding can be due to the fact that in the oxyfuel combustion cases, the carbon dioxide concentration is much higher than that of the air combustion cases because of the inert carbon dioxide and that higher carbon dioxide concentration results in a higher driving force for the mass transfer. The oxyfuel combustion processes also show another advantage over the air combustion processes since no nitrogen oxides are produced in the combustion process.

Electrified externally heated rotary calciner for calcination of cement raw meal

The cement industry can reduce its CO2 emissions by electrifying the calciner. It can avoid emissions from fuel combustion and produce pure CO2 from the calcination reaction (CaCO3 → CaO + CO2) for direct capture. A differential-algebraic equation (DAE) model of an electrified rotary calciner was developed and validated against experimental results. The heat transfer coefficient was around 30 W/(m2K), with the calciner inclined at 15°. This value increased to 80 W/(m2K) by reducing the inclination to 2°. The rotary calciner for producing 1 Mton/yr clinker with an internal diameter of 5 m needs a length of 485 m to reach a calcination degree of 94 %. The large system size suggests that this calciner may not be suitable for full-scale production. However, it can still be used for small-scale green production of calcined limestone.

Near-term pathways for decarbonizing global concrete production

Growing urban populations and deteriorating infrastructure are driving unprecedented demands for concrete, a material for which there is no alternative that can meet its functional capacity. The production of concrete, more particularly the hydraulic cement that glues the material together, is one of the world's largest sources of greenhouse gas (GHG) emissions. While this is a well-studied source of emissions, the consequences of efficient structural design decisions on mitigating these emissions are not yet well known. Here, we show that a combination of manufacturing and engineering decisions have the potential to reduce over 76% of the GHG emissions from cement and concrete production, equivalent to 3.6 Gt CO₂-eq lower emissions in 2100. The studied methods similarly result in more efficient utilization of resources by lowering cement demand by up to 65%, leading to an expected reduction in all other environmental burdens. These findings show that the flexibility within current concrete design approaches can contribute to climate mitigation without requiring heavy capital investment in alternative manufacturing methods or alternative materials.

Recent Advances on CO2 Mitigation Technologies: On the Role of Hydrogenation Route via Green H2

The increasing trend in global energy demand has led to an extensive use of fossil fuels and subsequently in a marked increase in atmospheric CO2 content, which is the main culprit for the greenhouse effect. In order to successfully reverse this trend, many schemes for CO2 mitigation have been proposed, taking into consideration that large-scale decarbonization is still infeasible. At the same time, the projected increase in the share of variable renewables in the future energy mix will necessitate large-scale curtailment of excess energy. Collectively, the above crucial problems can be addressed by the general scheme of CO2 hydrogenation. This refers to the conversion of both captured CO2 and green H2 produced by RES-powered water electrolysis for the production of added-value chemicals and fuels, which are a great alternative to CO2 sequestration and the use of green H2 as a standalone fuel. Indeed, direct utilization of both CO2 and H2 via CO2 hydrogenation offers, on the one hand, the advantage of CO2 valorization instead of its permanent storage, and the direct transformation of otherwise curtailed excess electricity to stable and reliable carriers such as methane and methanol on the other, thereby bypassing the inherent complexities associated with the transformation towards a H2-based economy. In light of the above, herein an overview of the two main CO2 abatement schemes, Carbon Capture and Storage (CCS) and Carbon Capture and Utilization (CCU), is firstly presented, focusing on the route of CO2 hydrogenation by green electrolytic hydrogen. Next, the integration of large-scale RES-based H2 production with CO2 capture units on-site industrial point sources for the production of added-value chemicals and energy carriers is contextualized and highlighted. In this regard, a specific reference is made to the so-called Power-to-X schemes, exemplified by the production of synthetic natural gas via the Power-to-Gas route. Lastly, several outlooks towards the future of CO2 hydrogenation are presented.

LCA and negative emission potential of retrofitted cement plants under oxyfuel conditions at high biogenic fuel shares

The implementation of oxyfuel carbon capture and storage technologies in combination with use of alternative fuels comprising high biogenic shares is promoted as an attractive climate change mitigation option for the cement sector to achieve low or even negative carbon emissions. Here, we perform a prospective life cycle assessment of two state-of-the art cement plants, one in Sweden and one in Germany, under conventional and retrofitted oxyfuel conditions considering alternative fuel mixes with increasing bio-based fractions of forest residues or dedicated bioenergy crops. The analysis also considers effects of the projected changes in the electricity systems up to 2050. Retrofitting the cement plants to oxyfuel reduces climate change impacts between 74 and 91%, while with additional use of biomass as alternative fuel the cement plants reach negative emission between - 24 and - 169 gCO_2eq. kg_clinker^-1, depending on operational condition, location, and biomass type. Additional emission reduction of - 10 (Sweden) and - 128 gCO_2eq. kg_clinker^-1 (Germany) are expected from the decarbonization of the future electricity systems. Retrofitting the cement plants to oxyfuel conditions shows trade-offs with other environmental impacts (e.g., human toxicity, water and energy depletion), which are partially offset with projected changes in electricity systems. Our results illustrate the large climate change mitigation potential in the cement sector that can be achieved by the implementation of oxyfuel carbon capture and storage and biomass use as alternative fuel.

CO2 Mineralization Methods in Cement and Concrete Industry

Production of Portland clinker is inherently associated with CO2 emissions originating from limestone decomposition, the irreplaceable large-scale source of calcium oxide needed. Besides carbon capture and storage, CO2 mineralization is the only lever left to reduce these process emissions. CO2 mineralization is a reversal reaction to clinker production—CO2 is bound into stable carbonates in an exothermic process. It can be applied in several environmentally and economically favorable ways at different stages of clinker, cement and concrete life cycle. These possibilities are assessed and discussed in this contribution. The results demonstrate that when combined with concrete recycling, the complete circularity of all its constituents, including the process CO2 emissions from the clinker, can be achieved and the overall related CO2 intensity significantly reduced.

Influence of Fineness of Wheat Straw Ash on Autogenous Shrinkage and Mechanical Properties of Green Concrete

This study investigates the effectiveness of an agricultural by-product wheat straw ash (WSA) as an internal curing agent in reducing the autogenous shrinkage of high-performance concrete (HPC). After incineration under different controlled time–temperature conditions, grinding and sieving were performed to obtain two different grades of fine WSA (F-WSA) and superfine WSA (SF-WSA). Subsequently, material characterization tests were carried out, followed by tests for mechanical properties and autogenous shrinkage potential of concrete incorporating 10% and 20% F-WSA and SF-WSA as a partial replacement of cement. The results demonstrated slightly higher compressive and tensile strength of concrete containing SF-WSA compared to control, whereas concrete with F-WSA demonstrated comparable strength results to that of the control concrete. Moreover, a significant reduction in 7 days’ autogenous shrinkage was observed in concrete containing 10% and 20% F-WSA by 42% and 25% compared to that of control concrete, respectively. This reduction in autogenous shrinkage increased further to 57% and 40% for concrete with 10% and 20% SF-WSA, respectively. The results of microstructural investigations on paste samples such as FTIR, TGA, and N2 adsorption analyses revealed a more refined and compact microstructure of paste samples with increasing fineness of WSA due to the formation of a more densified C-S-H phase. The improvement of the microstructure is attributable to the improved pozzolanic properties of SF-WSA compared with F-WSA.

Towards Sustainable Oxalic Acid from CO2 and Biomass

To quickly and drastically reduce CO2 emissions and meet our ambitions of a circular future, we need to develop carbon capture and storage (CCS) and carbon capture and utilization (CCU) to deal with the CO2 that we produce. While we have many alternatives to replace fossil feedstocks for energy generation, for materials such as plastics we need carbon. The ultimate circular carbon feedstock would be CO2 . A promising route is the electrochemical reduction of CO2 to formic acid derivatives that can subsequently be converted into oxalic acid. Oxalic acid is a potential new platform chemical for material production as useful monomers such as glycolic acid can be derived from it. This work is part of the European Horizon 2020 project "Ocean" in which all these steps are developed. This Review aims to highlight new developments in oxalic acid production processes with a focus on CO2 -based routes. All available processes are critically assessed and compared on criteria including overall process efficiency and triple bottom line sustainability.

Blending Wastes of Marble Powder and Dolomite Sorbents for Calcium-Looping CO2 Capture under Realistic Industrial Calcination Conditions

The use of wastes of marble powder (WMP) and dolomite as sorbents for CO₂ capture is extremely promising to make the Ca-looping (CaL) process a more sustainable and eco-friendly technology. For the downstream utilization of CO₂, it is more realistic to produce a concentrated CO₂ stream in the calcination step of the CaL process, so more severe conditions are required in the calciner, such as an atmosphere with high concentration of CO₂ (>70%), which implies higher calcination temperatures (>900 °C). In this work, experimental CaL tests were carried out in a fixed bed reactor using natural CaO-based sorbent precursors, such as WMP, dolomite and their blend, under mild (800 °C, N₂) and realistic (930 °C, 80% CO₂) calcination conditions, and the sorbents CO₂ carrying capacity along the cycles was compared. A blend of WMP with dolomite was tested as an approach to improve the CO₂ carrying capacity of WMP. As regards the realistic calcination under high CO₂ concentration at high temperature, there is a strong synergetic effect of inert MgO grains of calcined dolomite in the blended WMP + dolomite sorbent that leads to an improved stability along the cycles when compared with WMP used separately. Hence, it is a promising approach to tailor cheap waste-based blended sorbents with improved carrying capacity and stability along the cycles under realistic calcination conditions.

Carbon Storage in Portland Cement Mortar: Influences of Hydration Stage, Carbonation Time and Aggregate Characteristics

This study elucidates the effects of the particle size, carbonation time, curing time and pressure on the efficiency of carbon storage in Portland cement mortar. Using pressure chamber experiments, our findings show how carbonation efficiency increases with a decrease in the particle size. Approximately 6.4% and 8.2% (w/w) carbonations were achieved in the coarse-sand and fine-sand based mortar samples, respectively. For the hydration/curing time of 7 h, up to 12% carbonation was achieved. This reduced to 8.2% at 40 h curing period. On the pressure effect, for comparable curing conditions, 2 bar at 7 h carbonation time gives 1.4% yield, and 8.2% at 5 bar. Furthermore, analysing the effect of the carbonation time, under comparable conditions, shows that 4 h of carbonation time gives up to 8.2% yield while 64 h of carbonation gives up to 18.5%. It can be reliably inferred that, under similar conditions, carbonation efficiency increases with lower-sized particles or higher-surface areas, increases with carbonation time and higher pressure but decreases with hydration/curing time. Microstructural analyses with X-ray diffraction (XRD) and scanning electron microscopy (SEM) further show the visual disappearance of calcium-silicate-hydrate (C-S-H) together with the inhibition of ettringite formation by the presence of CO2 and CaCO3 formation during carbonation.

From Unavoidable CO2 Source to CO2 Sink? A Cement Industry Based on CO2 Mineralization

The cement industry emits 7% of the global anthropogenic greenhouse gas (GHG) emissions. Reducing the GHG emissions of the cement industry is challenging since cement production stoichiometrically generates CO₂ during calcination of limestone. In this work, we propose a pathway towards a carbon-neutral cement industry using CO₂ mineralization. CO₂ mineralization converts CO₂ into a thermodynamically stable solid and byproducts that can potentially substitute cement. Hence, CO₂ mineralization could reduce the carbon footprint of the cement industry via two mechanisms: (1) capturing and storing CO₂ from the flue gas of the cement plant, and (2) reducing clinker usage by substituting cement. However, CO₂ mineralization also generates GHG emissions due to the energy required for overcoming the slow reaction kinetics. We, therefore, analyze the carbon footprint of the combined CO₂ mineralization and cement production based on life cycle assessment. Our results show that combined CO₂ mineralization and cement production using today's energy mix could reduce the carbon footprint of the cement industry by 44% or even up to 85% considering the theoretical potential. Low-carbon energy or higher blending of mineralization products in cement could enable production of carbon-neutral blended cement. With direct air capture, the blended cement could even become carbon-negative. Thus, our results suggest that developing processes and products for combined CO₂ mineralization and cement production could transform the cement industry from an unavoidable CO₂ source to a CO₂ sink.

Industrial decarbonization under Japan's national mitigation scenarios: a multi-model analysis

Energy-intensive industries are difficult to decarbonize. They present a major challenge to the emerging countries that are currently in the midst of rapid industrialization and urbanization. This is also applicable to Japan, a developed economy, which retains a large presence in heavy industries compared to other developed economies. In this paper, the results obtained from four energy-economic and integrated assessment models were utilized to explore climate mitigation scenarios of Japan's industries by 2050. The results reveal that: (i) Japan's share of emissions from industries may increase by 2050, highlighting the difficulties in achieving industrial decarbonization under the prevailing industrial policies; (ii) the emission reduction in steelmaking will play a key role, which can be achieved by the implementation of carbon capture and expansion of hydrogen technologies after 2040; (iii) even under mitigation scenarios, electrification and the use of biomass use in Japan's industries will continue to be limited in 2050, suggesting a low possibility of large-scale fuel switching or end-use decarbonization. After stocktaking of the current industry-sector modeling in integrated assessment models, we found that such limited uptake of cleaner fuels in the results may be related to the limited interests of both participating models and industry stakeholders in Japan, specifically the interests on the technologies that are still at the early stage of development but with high reduction potential. It is crucial to upgrade research and development activities to enable future industry-sector mitigation as well as to improve modeling capabilities of energy end-use technologies in integrated assessment models.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s11625-021-00905-2.

High-Durability Concrete Using Eco-Friendly Slag-Pozzolanic Cements and Recycled Aggregate

Clinker production is very energy-intensive and responsible for releasing climate-relevant carbon dioxide (CO2) into the atmosphere, and the exploitation of aggregate for concrete results in a reduction in natural resources. This contrasts with infrastructure development, surging urbanization, and the demand for construction materials with increasing requirements in terms of durability and strength. A possible answer to this is eco-efficient, high-performance concrete. This article illustrates basic material investigations to both, using eco-friendly cement and recycled aggregate from tunneling to produce structural concrete and inner shell concrete, showing high impermeability and durability. By replacing energy- and CO2-intensive cement types by slag-pozzolanic cement (CEM V) and using recycled aggregate, a significant contribution to environmental sustainability can be provided while still meeting the material requirements to achieve a service lifetime for the tunnel structure of up to 200 years. Results of this research show that alternative cements (CEM V), as well as processed tunnel spoil, indicate good applicability in terms of their properties. Despite the substitution of conventional clinker and conventional aggregate, the concrete shows good workability and promising durability in conjunction with adequate concrete strengths.

CO2 Capture, Use, and Storage in the Cement Industry: State of the Art and Expectations

The implementation of carbon capture, use, and storage in the cement industry is a necessity, not an option, if the climate targets are to be met. Although no capture technology has reached commercial scale demonstration in the cement sector yet, much progress has been made in the last decade. This work intends to provide a general overview of the CO2 capture technologies that have been evaluated so far in the cement industry at the pilot scale, and also about the current plans for future commercial demonstration.

Carbon Capture and Storage: introductory lecture

Carbon Capture and Storage (CCS) is the only available technology that allows us to significantly reduce our CO₂ emissions while keeping up with the ever-increasing global energy demand. Research in CCS focuses on reducing the costs of carbon capture and increasing our knowledge of geological storage to ensure the safe and permanent storage of CO₂. This brief review will discuss progress in different capture and storage technologies.

Phase evolution, characterisation, and performance of cement prepared in an oxy-fuel atmosphere

Cement manufacture is one of the major contributors (7–10%) to global anthropogenic CO₂ emissions. Carbon capture and storage (CCS) has been identified as a vital technology for decarbonising the sector. Oxy-fuel combustion, involving burning fuel in a mixture of recycled CO₂ and pure O₂ instead of air, makes CO₂ capture much easier. Since it combines a theoretically lower energy penalty with an increase in production, it is attractive as a CCS technology in cement plants. However, it is necessary to demonstrate that changes in the clinkering atmosphere do not reduce the quality of the clinker produced. Clinkers were successfully produced in an oxy-fuel atmosphere using only pure oxides as raw materials as well as a mixture of oxides and clay. Then, CEM I cements were prepared by the addition of 5 wt% gypsum to the clinkers. Quantitative XRD and XRF were used to obtain the phase and elemental compositions of the clinkers. The particle size distribution and compressive strength of the cements at 3, 7, 14, and 28 days' ages were tested, and the effect of the particle size distribution on the compressive strength was investigated. Additionally, the compressive strength of the cements produced in oxy-fuel atmospheres was compared with those of the cement produced in air and commercially available CEMEX CEM I. The results show that good-quality cement can be successfully produced in an oxy-fuel atmosphere and it has similar phase and chemical compositions to CEM I. Additionally, it has a comparable compressive strength to the cement produced in air and to commercially available CEMEX CEM I.