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Asignatura: Procesos Químicos Industriales, Profesor: fernando caballo, Carrera: Ingeniero Químico, Universidad: UGR
Tipo: Apuntes
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A Competitive
And effiCient
Lime industry
In 2011, the European Commission published a roadmap for moving to a competitive low carbon economy by 2050. It outlines an ambitious CO 2 reduction goal whilst keeping European industry competitive. We operate in a globalised economy, with global competition. Given the difference in energy costs and the rather flat growth curves of the European economies, this a bold goal.
The European lime industry, as energy and carbon intensive sector, looked at a wide range of options to contribute to the 2050 objective and move towards a competitive low carbon economy. Over the past 20 years, the European lime industry has lowered its emissions substantially, mainly by modernising plants and adjusting the fuel mix.
We started an in-depth analysis of how and what is possible now and in the future. We looked at all possible available options: substituting fuels, efficiency measures and even carbon capture.
We identified many areas where we can make a difference. However, lime production is different from many other industries. Although, about a third of emissions are caused by burning fuels to heat the kilns and some electricity is used for grinding and other mechanical operations, the bulk of our emissions come from the raw material used: limestone. When heated, a chemical reaction takes place where limestone is transformed into lime and CO 2 is released.
These process emissions are inevitable and fairly constant per tonne of lime. Unless the carbon is captured, and used or stored, but its economic feasibility has to be looked at.
Lime is enabling key material for many sectors. Its unique properties enable other industries to reduce their carbon footprint. For example hydrated lime in asphalt makes transport more energy efficient transport. However, in this roadmap, we focused our research on what we can do ourselves.
Our industry is closely interconnected with other industries. We, therefore, looked at external factors and how they could impact us. Lime is used in a variety of industrial processes and its sustainability is intrinsically linked to that of others. We also examined the potential impact of the cost of carbon on the European lime industry and the risk of carbon leakage.
The priority of the sector is to deliver quality products manufactured in a sustainable way and respectful of the environment. The lime industry would like to call upon the EU to put in place the necessary instruments that will allow th economy to become a low carbon one, whilst maintaining the competitiveness of the European industry by supporting its role in a complete value chain. We outlined a series of possible policy measures to support the development of innovative technologies and keep Europe’s industrial landscape economically vibrant.
04
Introduction
Introduction
Lime is an essential but often unseen ingredient. Not only does it help the construction and manufacturing industries optimise their products, but it also supports the drinking water, food and farming sectors with its versatile and unique characteristics.
It is the only mineral product that can be used to produce steel and sugar in the same day! Lime is a highly important and diverse substance, due to its alkalinity and ability to purify and neutralise.
Lime is an important, and often irreplaceable component of many industrial sectors; from steel manufacturing to the construction materials, chemical industries and paper pulp.
Even though it was discovered in ancient times, today it is manufactured using the latest industrial processes and techniques. Lime products are used in a wide variety of applications in Europe, and worldwide. The average EU citizen indirectly uses around 150 g/day of lime products.
“It is the only mineral
product that can be used
to produce steel and
sugar in the same day!
05
What is Lime?
What is Lime?
”
OVERVIEW OF CUSTOMER MARKETS AND FUNCTIONALITY OF LIME PRODUCTS
**- Removing impurities
**- Removing impurities from sugar
- Feedstock for calcium
- Versatile filler in paint,
- PH Correction
**- Nutrient in fertilizer
- Improving stability and load bearing
- Improve durability asphalt
- Drinking water treatment:
- Wastewater treatment:
- Flue gas purification
38%
11% 7%
16%
3%
7%
14%
4%
“Used in many products
for everyday life, lime is
probably the most versatile
natural mineral product.
”
07
What is Lime used for?
How is Lime made?
to storAGe
08
How is Lime made?
Energy Use
HEAT CONSUMPTION
Producing lime requires heating limestone between 900°C and 1200°C. Maintaining these kinds of temperatures requires a substantial amount of energy. In 2010, the average fuel consumption is 4.25 GJ/tonne of quicklime.
Calcination is the most energy intensive step in the lime production process, thus the energy efficiency of the kiln has a large impact on emissions. Thanks to the optimisation of the production process, the lime industry has made a lot of progress in terms of energy efficiency, nevertheless, we looked at a multitude of ways to reduce energy consumption even further.
However, we are limited by the laws of physics and chemistry. The theoretical minimum energy required for the chemical reaction that transforms limestone to take place, is 3.18 GJ/ tonne of quicklime. This number assumes complete conversion of limestone into lime. In reality, not all limestone is converted to lime. For example, limestone typically contains 1% of water which evaporates in the kiln and leads to increased energy use.
Other aspects, such as the specification of the desired lime, grain size, humidity of the limestone, fuel quality and residual CO 2 content in the lime product all play a role as well.
Nevertheless, the type of kiln has a major impact on the energy consumption per tonne of lime.
The vast majority of plants in Europe are equipped with modern, energy efficient kilns and the less efficient ones are continually improved or will be replaced over time. However, as plants modernise
and technology evolves, we will achieve improved thermal efficiency but options are very limited, not least by the theoretical minimum energy input.
Kiln orientation: Kiln type:
Heat use / consumption for quicklime production (GJ/tonne):
Vertical
Parallel flow regenerative kilns (PFRK) 3.2-4.
Annular shaft Kilns (ASK) 3.3-4.
Mixed Feed Shaft Kilns (MFSK) 3.4-4.
Horizontal
Long Rotary Kilns (LRK) 6.0-9.
Rotary Kilns with preheater (PRK) 5.1-7.
Other Kilns 3.5-7.
OVERVIEW OF THE MINIMUM AND MAxIMUM HEAT CONSUMPTION PER KILN TYPE FOR qUICKLIME PRODUCTION (JRC, 2013 (BREF))
10
Energy Use
FUELS
Currently, the European Lime industry uses
a wide variety of fuels, including fossil fuels
(natural gas, fossil solid fuels and oil), waste
or biomass.
Fuel use can influence the product quality.
Certain fuels can not be used for specifics application.
ELECTRICITY CONSUMPTION
The electricity consumption in lime manufacturing is relatively low. Electricity is mainly used for operating some of the kiln equipment and mechanically crushing the limestone. Electricity consumption varies, but it is estimated at ±60 kWh/t.
34%
51%
5%
8%
2%
FUEL MIX 2010, (EULA, 2012).
11
Energy Use
13
Reducing our emissions
FUEL SAVINGS
Over the past decades, the European lime industry has invested heavily in energy savings technology and continuously improved plants to reduce their energy consumption.
While the heat of reaction, the energy required for the chemical reaction to take place – for a typical quicklime quality – is 3.03 GJ/tonne. Theoretically, the potential for energy efficiency improvement is, therefore, limited to 29%; the rest of the fuel is needed to provide the energy
for the chemical reaction. Limestone always contains impurities and a driving force is always required to get the reaction going.
We estimate that implementing existing technology and future innovation could lead to a reduction of 16% in fuel intensity by 2050. This would be achieved mainly by building new
The main methods of this increased fuel
efficiency would be
Switching from horizontal to vertical kilns
Lime can be produced in different kinds of kilns.
Over the past decades, new kiln types have been
developed and existing kilns have been improved.
Newer vertical kilns are considerably more energy
efficient than horizontal kilns. In Europe, 80% of
lime is produced in vertical kilns. Some existing
horizontal kilns have been refurbished, but they
cannot achieve the same energy efficiency as a new vertical kiln. In the coming years, old kilns are likely to be replaced by new, more efficient ones.
Installing heat exchangers in horizontal kilns
In horizontal kilns heat exchangers can be used to recover some of the heat from the flue gases produced in the kiln and use this heat to preheat the feed limestone. This could generate – on average – a fuel saving of around 25%. However, this potential reduction is only applicable to horizontal kilns.
- Can partially be avoided
- Cannot be avoided
29%
71%
14
Reducing our emissions
Switching from vertical kilns to vertical kilns Parallel flow regenerative kilns
There are several types of vertical kilns. The Parallel Flow Regenerative (PFRK) type is the most efficient one. However, they cannot always produce all types of products to fully satisfy market needs and sometimes cannot process the smallest particles; therefore, they are not always the best solution from a resource efficiency point of view.
Further innovation could increase the applicability of PFRKs enabling them to handle smaller particles and, thus, making them more resource efficient.
Improved use of Waste Heat
Waste heat from the kiln can be used to dry limestone or in the milling process. In addition, the waste heat can be used in other industrial processes, in other sectors with a heat demand or they can be used to heat buildings and generate electricity. However, many lime plants are located in remote rural areas, which makes distributing the excess heat to other industries or as a residential heating source difficult at times.
Energy recovery in hydration
The production of hydrated lime and dolime is an exothermal reaction, i.e. it generates heat. The heat resulting from the production of hydrated lime amounts to about 1.2 GJ/tonne of CaO. This heat could be used in industrial processes or heating buildings if there is such a demand in the remote areas where the plants operate. This option will require further R&D to work out how to extract the heat without affecting the production process and quality of the product.
Other Measures
A range of other measures could also lead to increased fuel efficiency. These include efficient kiln insulation lining, optimised combustion processes improved process and input control, optimal change-over and further improved maintenance procedures.
Electricity Savings
Significant steps have been taken over the years to reduce our electricity consumption. Increasingly efficient engines and other technological progress have made a real difference but more stringent environmental legislation and increased controls in modern plants have offset some of these gains. Nerveless, we remain committed to finding ways to reduce our power consumption. The efficiency of motor systems is – conservatively - assumed to have a saving potential of 10%. Optimizing cooling and grinding for instance could lead to further energy efficiency gains.
“Optimizing cooling and
grinding for instance could
lead to further energy
efficiency gains.
”
16
Reducing our emissions
Use of gas instead of solid fossil fuels
The European lime industry currently uses
natural gas for about one third of its energy
needs. Switching from solid fossil fuels to
natural gas would reduce the CO 2 intensity of
lime production although the gas network may
be a concern, given the location of our plants.
Within the framework of this exercise, we
assumed that all solid fuels used today would
be replaced by natural gas. This can potentially
reduce the average emission factor of the fuel
mix by 30%.
This switch is dependent on a steady, secure
and affordable supply of natural gas and will be
affected by on a series of external factors such
as potential price hikes caused by a switch to
natural gas by the power sector or, inversely,
lower gas prices, as European unconventional
gas becomes available.
Use of waste as a fuel
Certain types of lime kilns are suited for the use
of waste as a fuel source. The European lime
industry is committed to remaining an important
factor in the circular economy. The use of waste
as a fuel source will continue but is conditional
upon the availability of the right kind of waste
and a regulatory environment that permits the
use of waste as a fuel.
Use of biomass as fuel
Different forms of biomass can be used as a fuel
in kilns. There are some technical restrictions,
especially in the fuel efficient vertical kilns, as to
the type of biomass that can be used, but ongoing innovation could ensure biomass will remain a fuel source of the European lime industry.
One of the ways to overcome the difficulties using biomass would be to convert it to syngas first. Using similar technology kilns could even be fuelled by biogas, sewage gas or landfill gas.
Use of electricity to heat kilns
Electricity could theoretically be used in the future to heat kilns. The European Commission’s Energy Roadmap plans a total decarbonisation of power, so this would result in a substantial reduction of our emissions. However, with current and foreseen power prices, this option is not economically viable. Moreover, this option is not yet technically feasible for the moment and will require further R&D.
However, the situation would be different in times of oversupply of electricity, resulting in cheap or even free electricity. Using electricity to heat the kilns might then be feasible and could help to bring supply and demand in equilibrium.
Solar heat
Solar heat could potentially be used, in some countries, to heat the kilns but they have to be heated to at least 900°C. In the future, high- temperature Central Receiver Systems (CRS) with pressurised air could reach temperatures up to 1000°C. However, this technology is still in an experimental phase, would require further research, and is only suitable for Southern Europe.
17
“The European lime industry is committed to
remaining an important part of the value chain
contributing to the circular economy.
”
Reducing our emissions
19
Reducing our emissions
A lime producer partnered in the Agical+ research project (financed under the European Commission LIFE+) that aimed at making use of the lime and glass sectors CO2 emissions. This project looked into an innovative solution, based on algae culture and biomass production, which would allow for the CO2 capture of lime or glass furnace fumes and the production of biofuel that could be used within the furnaces during the production process.
If applied at full-scale, such technology might significantly reduce CO2 emissions and consumption of fossil fuels related to lime and glass production industries. However, the economic analysis done in the project revealed that the cost of the biofuel produced would be around €650/GJ, or around 100-times more expensive than commercially traditional energy resources (natural gas, heavy fuel).
BIOFUEL PRODUCTION FROM CO2 EMISSIONS FROM LIME PRODUCTION
Storage or Utilization?
Assuming that the barriers of technical and
economic feasibility as well as social acceptance
have been overcome, the other big question is
what to do with captured CO 2. Two options are
available: storage or utilisation:
Storage
Storage involves transporting the CO 2 to a
geographically suitable location and storing it
underground. Currently, lime plants are typically
located right next to the limestone quarry, not
clustered in large industrial agglomerations. Transport
costs – to overcome the distance between the lime
plant where it is captured and the location where it is
stored – as well as any additional piping infrastructure
can add significantly to the capture costs.
Storage locations would need to be developed and
maintained and public and regulatory acceptance of
CO 2 storage still needs to be overcome.
Utilization The business case for capturing carbon, could be improved in case the captured CO 2 could be used, rather than stored. Storage costs could be saved, and it might get a financial value. The lime industry itself will not be able to use the it, but the business case to capture the CO 2 could benefit from others using it. A lot of research is currently devoted to developing new uses of CO 2 , including:
Many of these applications are, however, only at research stage for the moment.
“If capturing carbon is the key to substantially
lower emissions, it does represent a real challenge
in terms of cost.
”
CARBONATION
Although not a traditional abatement measure, and not within the scope of our analysis, it is important to note that during the lifetime of products in which lime is applied, CO 2 from the atmosphere is captured (basically reversing the reaction in which lime is produced from limestone).
If atmospheric CO 2 has good access to the material, as is the case for example in some building materials, the lime, or the new material can reabsorb CO 2. This so-called “carbonation” partly closes the loop starting with CO 2 process emissions during lime production.
Carbonation is highly dependent on the application; in some applications the main carbonation takes place within five years, in other applications it takes longer. For example, for lime mortars, it is estimated that within 100 years, 80-92% carbonation will take place.
Pathway to 2050
Taking into account the unique emission profile of the lime industry, the type of plants in operation today and the possible savings, we have mapped a possible carbon reduction roadmap from 2010 to 2030 and 2050.
DECARBONISATION TOWARDS 2050: RELATIVE DIRECT CARBON INTENSITY (99% OF TOTAL EMISSIONS)
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
?
? Carbonation??
Arrows indicate a hypothetical deployment of Fuel emissions abatement options, intended as a thought experiment
Process emissions Energy efficiency improvement
2010 2030 2050
20
Reducing our emissions