Dual-Calciner Calcium Looping Assembly for Clinker Plants
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Solution Overview
Problem
Current CO2 capture systems in cement plants face challenges with reduced operability and energy performance due to recirculation of solids between the carbonator and calciner, leading to sorbent deactivation and process control difficulties.
Innovation Solution
A Dual-calciner calcium looping (Du-CaL) configuration with two calciners and a carbonator, where one calciner is integral to the conventional clinker production system, eliminating recirculation between the carbonator and calciners, allowing for independent operation of the calciners during maintenance and optimizing calcination and carbonation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If recirculation of solids between carbonator and calciner is implemented in CO2 capture systems, then CO2 removal capacity is improved, but sorbent deactivation occurs and process controllability deteriorates
Solution Approach 1:
The system is divided into two separate calciners: a first calciner dedicated to producing CaO for the carbonator, and a second calciner for regenerating sorbent from the carbonator outlet. This segmentation prevents the recirculation problems that occur when a single calciner serves both functions, maintaining sorbent activity while ensuring adequate CO2 removal capacity.
Solution Approach 2:
The first calciner acts as an intermediary that produces fresh CaO material which is then fed to the carbonator. This intermediary production of high-quality CaO prevents the degradation that would occur through repeated recirculation cycles, while still enabling effective CO2 capture in the carbonator.
2Productivity
If recirculation of solids between carbonator and calciner is implemented, then CO2 capture function is enhanced, but operability and maintenance flexibility are reduced
Solution Approach 1:
By segmenting the calcination function into two separate calciners, the system allows independent operation and maintenance of each unit. The first calciner can be maintained while the second continues to provide sorbent regeneration, and vice versa, significantly improving plant operability and maintenance flexibility compared to a single recirculating calciner system.
3Device complexity
If single calciner configuration with recirculation is used, then device complexity is reduced, but process control difficulty increases
Solution Approach 1:
The dual calciner configuration segments the complex recirculation control into two simpler, independent calcination processes. Each calciner operates with its own feed and output streams, eliminating the need to control solid recirculation rates and the associated process control difficulties, while the overall system complexity remains manageable.
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
This configuration maintains sorbent activity, improves CO2 removal efficiency, enhances process controllability, and facilitates easier plant operation by avoiding repeated calcination-carbonation cycles, resulting in significant CO2 emission reductions and improved energy performance.
Implementation Method 1
A first calcination reaction is conducted in a first calciner on a preheated raw material to give a first stream of CO2-enriched gas and a first stream of calcined material rich in CaO
Implementation Method 2
A carbonation reaction is performed between the CO2-rich stream from the rotary kiln and the CaO-rich stream from the first calciner in a carbonator to remove the CO2
Implementation Method 3
A second calcination reaction of the CaCO3-enriched stream from the carbonator is conducted in a second calciner, producing a second stream of CO2-enriched gas and a second stream of calcined material rich in CaO
Implementation Method 4
The CO2-rich stream exiting from the carbonator is then cooled, purified and compressed... The heat required for calcination is provided by combustion of a fuel
Data Source
AI summary
The invention concerns:A) An assembly to reduce the emission of CO2 in a plant for the production of clinkers comprising two calciners and a carbonator arranged between the two calciners, wherein one of the calciners is an integral part of a conventional clinker production system. Thanks to this assembly, the plant can continue to operate in the clinker production process even if the CO2 capture system which uses the carbonator and the other calciner of the assembly is disconnected due to malfunctions or maintenance characterized in that said carbonator is free of recirculation to both said two calciners.B) The relative plants comprising both the assembly and the actual clinker production plant in which the clinker production plant is of the conventional type existed before and already operational, or said plant is installed simultaneously with the assembly units.C) The clinker production process with reduction of CO2 emission conducted in the plants B.