Calcination CO2 Capture with Membrane Purification
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Solution Overview
Problem
Current technologies lack comprehensive integration of carbon capture from calcination processes in cement plants with power generation and do not effectively purify captured CO2, nor do they address NOx/SOx removal from calcination flue gases, leading to significant CO2 emissions and inefficiencies.
Innovation Solution
A system and method for capturing CO2 during calcination processes, integrating carbon capture with cement, steel, and power production, utilizing a reactor, separator, heat exchanger, and CO2 separation units, including membrane separation and purification, to produce 'carbon dioxide-free' industrial products and integrate with power plants for efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional solvent-based separation processes are used for CO2 capture, then CO2 can be captured from calcination processes, but the captured CO2 stream is not purified and the process lacks integration with power generation
Solution Approach 1:
The CO2 capture process is divided into distinct stages: initial capture from calcination flue gas, intermediate cooling and condensation to remove water and other condensables, and final purification through membrane separation. This segmentation allows each stage to optimize for its specific function, achieving both high capture quantity and high purity output.
Solution Approach 2:
The patent combines multiple functions into an integrated system: CO2 capture from calcination, power generation through a heat-driven turbine, and CO2 purification through membrane separation. The heat from calcination is utilized to drive power generation, and the system produces both electricity and purified CO2, resolving the contradiction between capture quantity and purity.
2Quantity of substance
If external carbonators are used for calcium looping, then carbon capture can be enabled, but the process complexity increases and NOx/SOx removal is not addressed
Solution Approach 1:
The calcination system is designed to perform multiple functions simultaneously: it produces quicklime for industrial use, generates power through heat-driven turbines, captures CO2 for purification, and removes NOx and SOx through selective catalytic reduction and absorption. This multi-functionality eliminates the need for separate external carbonators and pollution control devices, reducing overall process complexity while maintaining comprehensive carbon capture capability.
3Loss of energy
If complete process integration is implemented between carbon capture and power generation, then energy efficiency improves, but the system complexity and manufacturing difficulty increase
Solution Approach 1:
The system is designed to be self-sufficient by utilizing the heat generated from calcination to drive power generation turbines, thereby producing electricity to meet its own operational needs. The integrated design allows the system to generate its own power and process its own waste streams, reducing external dependencies and simplifying manufacturing requirements despite the complex integration.
4Device complexity
If CO2 is captured without purification, then the capture process is simpler, but the captured CO2 cannot be used for industrial applications requiring high purity
Solution Approach 1:
The patent replaces complex mechanical purification systems with membrane-based separation technology. The membrane system selectively allows CO2 to pass through while retaining other gases, achieving high purity CO2 production through a relatively simple and compact process that maintains capture simplicity while ensuring industrial-grade purity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the production of carbon dioxide-free industrial products while capturing a substantial portion of CO2 emissions, improving energy efficiency and reducing environmental impact by integrating carbon capture with power generation and NOx/SOx removal.
Implementation Method 1
a reactor configured to heat a carbonate-containing raw material to a high temperature to a decomposition stream comprising at least solids and carbon dioxide gas
Implementation Method 2
a heat exchange unit configured to receive one or both the gas stream including the carbon dioxide gas and the solid stream and withdraw heat therefrom to provide a cooled gas stream including the carbon dioxide
Implementation Method 3
a CO2 separation unit configured to separate the cooled gas stream into a CO2 lean stream and a CO2 rich stream
Data Source
AI summary
The present disclosure provides systems for carbon capture in combination with production of one or more industrially useful materials. The disclosure also provides methods for carrying out carbon capture in combination with an industrial process. In particular, carbon capture can include carrying out calcination in a reactor, separation of carbon dioxide rich flue gases from industrially useful products, and capture of at least a portion of the carbon dioxide for sequestration of other use, such as enhanced oil recovery.