CO2Valorize
Lead Research Organisation:
Siemens Process Systems Engineering Ltd
Department Name: Research and development
Abstract
Cement production is responsible for 8 % of global CO2 emissions, which mainly come from the processing of limestone. CO2Valorize
proposes a new approach to drastically reduce these emissions by partly replacing some of the limestone content with
supplementary cementitious materials (SCM). Such materials are additionally carbonated using captured CO2, so this partreplacement
process utilises captured CO2. Promising, calcium silicates rich SCM can come from waste materials such as mine tailings
and recycled concrete, all of which are available in large quantities. The carbonation process of such materials is complex and barely
understood to date. Our networks aim to lay the scientific foundations to create fundamental knowledge on the mechanisms,
reaction kinetics, the physico-chemical subprocess, and the performance of the modified cement in order to provide a proof-ofconcept
and show that a CO2 reduction by 50 % per tonne of cement produced is feasible. The project is driven by leading companies
that represent important parts of the value chain and ensure a fast uptake of the results with the potential to commercialise new
equipment, processes and software during and after the project. The structured approach combines complementary research for
each individual project in the academic and industry sector. This is accompanied by a balanced mix of high-level scientific courses
and transferable skills delivered by each partner locally and in dedicated training schools and workshops at network level. This way,
each doctoral candidate builds up deep scientific expertise and interdisciplinary knowledge to deliver game-changing cleantech
innovations during and after the project. CO2Valorize is impact-driven and strives for portfolios of high-class joint publications in
leading journals and patents. The transfer of the results into first-of-its-kind engineering solutions contribute to the next generation
of cement processes that can mitigate climate change.
proposes a new approach to drastically reduce these emissions by partly replacing some of the limestone content with
supplementary cementitious materials (SCM). Such materials are additionally carbonated using captured CO2, so this partreplacement
process utilises captured CO2. Promising, calcium silicates rich SCM can come from waste materials such as mine tailings
and recycled concrete, all of which are available in large quantities. The carbonation process of such materials is complex and barely
understood to date. Our networks aim to lay the scientific foundations to create fundamental knowledge on the mechanisms,
reaction kinetics, the physico-chemical subprocess, and the performance of the modified cement in order to provide a proof-ofconcept
and show that a CO2 reduction by 50 % per tonne of cement produced is feasible. The project is driven by leading companies
that represent important parts of the value chain and ensure a fast uptake of the results with the potential to commercialise new
equipment, processes and software during and after the project. The structured approach combines complementary research for
each individual project in the academic and industry sector. This is accompanied by a balanced mix of high-level scientific courses
and transferable skills delivered by each partner locally and in dedicated training schools and workshops at network level. This way,
each doctoral candidate builds up deep scientific expertise and interdisciplinary knowledge to deliver game-changing cleantech
innovations during and after the project. CO2Valorize is impact-driven and strives for portfolios of high-class joint publications in
leading journals and patents. The transfer of the results into first-of-its-kind engineering solutions contribute to the next generation
of cement processes that can mitigate climate change.
| Title | PROCESS MODELLING TOOLS FOR THE DIGITALIZATION AND DECARBONIZATION OF THE CEMENT SECTOR |
| Description | First principles mathematical models for the simulation of two of the most important unit operations inside a cement production facility have been developed and implemented in Siemens' gPROMS® Advanced Process Modelling software. The first model simulates the process behaviour of the suspension pre-heating cyclones, incorporating mass and energy conservation balances, heat-transfer phenomena between the gas-wall-solid phases and predicts important key performance indicators (KPI's) of the process such as heat losses, pressure drops (KPI's linked to energy consumption and carbon intensity of the process) and outlet mass flowrates and temperatures for the solid and gas streams. The second model simulates the behaviour of a cement pre-calciner, the most carbon-intensive unit operation inside a cement plant, responsible for 70-80 % of total carbon dioxide emissions. The model incorporates mass and energy conservation balances, and takes into account detailed limestone decomposition kinetics (heat and mass transfer limitations, diffusion limitations, CO2 partial pressure effects and pore efficiency). The resulting system of Partial Differential Algebraic Equations (PDAE) was implemented and solved in gPROMS for various reactor geometries and operating conditions. The simulation results are validated against published data, demonstrating the ability to predict accurately operating temperatures, degree of calcination, gas and solids mass fractions, pressure drop and fuel consumption. Most of the output variables calculated from the models are directly linked to economic and environmental KPI's and will be used for performing technoeconomic and environmental assessment of these processes, looking for potential process improvements that could result in mitigation of the process CO2 emissions. For example, the utilization of different fuels (from natural gas up to fully carbon neutral fuels like hydrogen) and the design of novel new reactor configurations (indirect calcination and oxyfuel combustion) will be tested as different decarbonization strategies. The second model simulates the behavior of a cement pre-calciner, the most carbon-intensive unit operation inside a cement plant, responsible for 70-80 % of total carbon dioxide emissions. The model incorporates mass and energy conservation balances, and takes into account detailed limestone decomposition kinetics (heat and mass transfer limitations, diffusion limitations, CO2 partial pressure effects and pore efficiency). The resulting Partial Differential Algebraic Equation (PDAE) system has been incorporated and solved in gPROMS® Advanced Process Modelling software for various reactor geometries adn operating conditions. The simulation results are validated against published data, demonstrating the ability to predict accurately operating temperatures, degree of calcination, gas and solids mass fractions, pressure drop and fuel consumption. Most of the output variables calculated from the models are directly linked to economic and environmental KPI's and will be used for performing technoeconomic and environmental assessment of these processes, looking for potential process improvements that could result in mitigation of the process CO2 emissions. For example, the utilization of different fuels (from natural gas up to fully carbon neutral fuels like hydrogen) and the design of novel new reactor configurations (indirect calcination and oxyfuel combustion) will be tested as different decarbonization strategies. |
| Type Of Material | Computer model/algorithm |
| Year Produced | 2024 |
| Provided To Others? | No |
| Impact | The development of the models above, is the first step in the research group's attempt to build a digital simulation tool for describing the operation of cement processing plants. The construction of a complete flowsheet of a conventional cement plant, will form the basis to conduct and apply various decarbonization strategies and technologies. The final objective is to perform technoeconomic and environmental evaluations and comparisons between different decarbonization technologies (based on the reference case - conventional plant) and identify the most promising ones for implementation and integration. One decarbonization concept that will be studied rigorously is the concept of mineral carbonation for the production of SCMs, as partners in the research groups consortium study and can provide data on the performance of this emerging and promising carbon negative technology. |
| Description | CO2Valorize Panel |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | The CO2Valorize Doctoral Network has established a formal working group which comprises of 8 young researchers (one of them coming from the UK side) and their respective supervisors (two of them coming from the UK side). The working group is actively discussing progress, exchanges ideas and establishes collaborations and synergies between research projects. The UK research group funded by UKRI, has established synergies with University of Padova, with which an additional working group has been formed. This working group works towards the modelling, design and technoeconomic assessment of cement decarbonization technologies (Project Work Package 3). |
| Year(s) Of Engagement Activity | 2023,2024 |
| Description | CO2Valorize Training School 2 |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | The research group hosted two doctoral training schools, providing a wide range of training courses to the Doctoral Network. The trainings focused on modelling and coding principles related to Siemens' gPROMS® Advanced Process Modelling Software and covered both introductory (first online training school) and advanced (second in-person training school) topics. The researchers gained new skills and knowledge that could benefit their research. Furthermore, during the second training school hosted by the research group, the project's midterm review took place, in which project management related matters were discussed and technical presentations of the Doctoral Candidates' work took place, while there was an overall assessment of the project's status from the EU's Project Officer. |
| Year(s) Of Engagement Activity | 2023 |