Counter-Current Fluidized Bed Decarbonation Process
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Solution Overview
Problem
Current methods for reducing carbon dioxide emissions in cement production, such as carbon capture and oxy-combustion, are either energy-intensive, costly, or require significant modifications to existing cement plant processes, and do not efficiently produce a high concentration of carbon dioxide for subsequent transport and storage.
Innovation Solution
A decarbonation process using a counter-current fluidized bed heat exchanger where raw meal particles are decarbonated in a rising carrier gas containing carbon dioxide, producing an effluent gas with a high concentration of carbon dioxide, which can be recycled and stored, and is integrated into existing cement production without major modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If carbon capture is performed using solvents like amine after combustion, then carbon dioxide can be captured without modifying the production process, but the equipment becomes cumbersome, expensive and very energy-consuming
Solution Approach 1:
The invention performs decarbonation as a preliminary action before combustion in the clinkering kiln. By removing carbon dioxide from the raw meal before it enters the kiln, the process prevents carbon dioxide formation rather than capturing it afterward, thereby avoiding the energy-intensive post-combustion capture methods while still achieving carbon dioxide separation
Solution Approach 2:
The invention extracts carbon dioxide from the raw meal through decarbonation in a separate unit operation before the main combustion process. This extraction approach isolates the carbon dioxide removal function from the combustion process, allowing for efficient carbon dioxide separation without requiring complex post-combustion capture equipment
2Quantity of substance
If oxy-combustion is used to produce carbon dioxide concentrated effluent gas, then carbon dioxide separation becomes easy, but additional equipment must be integrated and oxygen-rich gas mix must be produced which is technically complicated and expensive
Solution Approach 1:
The invention converts the harmful effect of carbon dioxide presence in raw meal into a beneficial outcome. By intentionally causing decarbonation of raw meal in a controlled environment, the process generates concentrated carbon dioxide effluent gas as a useful product for storage or utilization, while the solid residue can be used in cement production
3Quantity of substance
If direct or indirect heating calcination is used to obtain pure carbon dioxide flow, then almost pure carbon dioxide can be obtained, but the heat transfer efficiency is low and the installation becomes cumbersome
Solution Approach 1:
The invention uses a fluidized bed system where gas flows through the particulate raw meal, creating efficient heat and mass transfer conditions. The pneumatic fluidization ensures intimate contact between the heating medium and raw meal particles, dramatically improving heat transfer efficiency compared to conventional direct or indirect heating methods while maintaining compact equipment design
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 process efficiently produces a flow of carbon dioxide concentrated at 90-95% by volume, reduces equipment encumbrance, and can be easily incorporated into existing cement plants, offering flexibility and continuous operation while minimizing energy consumption.
Implementation Method 1
a fluidised bed heat exchanger having a solid heat carrier circulating counter-current relative to the carrier gas
Implementation Method 2
said fluidised bed heat exchanger having a solid heat carrier circulating counter-current relative to the carrier gas
Implementation Method 3
decarbonation of particles of raw meal, in a fluidised bed heat exchanger, said particles being suspended in a rising carrier gas
Implementation Method 4
decarbonation of particles of raw meal... to provide an effluent gas comprising carbon dioxide and decarbonated raw meal
Implementation Method 5
production of a flow of substantially pure carbon dioxide coming mainly from decarbonation of the calcium carbonate
Data Source
AI summary
A process for decarbonation of particles of raw meal, to be burnt in a clinkering kiln at a cement plant, the process includes: a) decarbonation of particles of raw meal, in a fluidized bed heat exchanger, the particles being suspended in a rising carrier gas including carbon dioxide, the fluidized bed heat exchanger having a solid heat carrier circulating counter-current relative to the carrier gas, to provide an effluent gas including carbon dioxide and decarbonated raw meal; b) separating the effluent gas and the decarbonated raw meal c) separating the effluent gas into a first and second part; cooling the first part of the effluent gas and recycling to provide carrier gas, d) isolating the second part of effluent gas e) recovering and re-heating the heat carrier and recirculating to step (a).