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D2.5: Safety and risk analysis for demonstration plant operations

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Confidential CLEANKER deliverables

D2.1 Engineering and detailed design of the demonstration plant
This document describes the layout and basic engineering of the Calcium Looping (CaL) demonstration plant to be built in Vernasca performed on base of the heat and mass balances calculated with a process model as given in the deliverable D2.3. The
D2.2 Project execution plan including detailed equipment list and specifications
This document describes the design and detailed engineering of the demonstrator system. The output is the detailed equipment list of items to be purchased together with the technical specifications and drawings for items to be fabricated, including
D2.3: Heat and mass balances of the demonstration plant under relevant operating conditions to support the design of the demonstration plant
In this deliverable, pilot plant configuration and heat and mass balances of the CaL pilot plant to be built in the Vernasca plant are presented. Nine different cases have been calculated to support the design of the demonstration plant.
D2.4: Definition of measuring points and instrumentation
In this deliverable, the most suitable gas measurement and solid sampling points and port configurations will be defined. Technical drawings and instrumentation specifications will be given with short explanation/notes of the reasons of the main c
D2.5: Safety and risk analysis for demonstration plant operations
The document will define the risks related to the demonstration plant operations. A brief description of the risks will be given and their management will be explained.
D3.1 Experimental test matrix for first short trials
Experimental text matrix for short trials defined based on process simulations, first unvalidated reactor models and lab pre-tests.
D3.2: Experimental test matrix for long term test
D3.3: Report on the first three short trials from the CaL demonstration plant
Description and preliminary results of the short trials carried out at the demonstration plant with considerations and “guidelines” for the next trials
D3.4: Report on the fourth and fifth short trials from the CaL demonstration plant
Description and results of the long trials carried out at the demonstration plant with considerations and “guidelines” for the long run tests.
D3.5: Report on the first two long run tests from the CaL demonstration plant
Description of the first two long run tests carried out at the demonstration plant, and analysis of the stable operating conditions and process performances achieved
D3.6: Report on the last two long run tests from the CaL demonstration plant
Description of the last two long run tests carried out at the demonstration plant, and analysis of the stable operating conditions and process performances achieved
D3.7: Detailed report on operational data from short and long term tests
Results from all the tests carried out at Vernasca plant will be presented in terms of operational data (gas composition, temperatures, mass flows etc.) and deeply detailed.
D3.8: Report on best practice for using efficiently the CaL technology in Vernasca plant
Best practices and guidelines for the implementation of CaL technology with detail about fuel needs, O2 consumption, maintenance effort.
D3.9: Detailed report on properties of calcined and re-carbonated material collected from the CaL demonstrator during short- and long-term tests
In this deliverable the solid samples taken from the CaL demonstration plant in Vernasca are displayed and the results of the subsequent analyses are shown.
D4.1: Experimental test matrix for Vernasca raw meal characterization
D4.2 Experimental test matrix for characterization of other raw meals
In this report, an updated experimental text matrix for tests in the 120 kW USTUTT mini-pilot based on outcomes of the first experimental campaign and experimental test matrix for tests in the drop tube reactors at CSIC and TSIU is defined.
D4.3 Characterization of BUZZI demo-plant raw meal under realistic entrained flow conditions
In this deliverable first results of the characterization of the raw meal used in the demonstration trials at BUZZI cement plant in Vernasca under relevant entrained flow conditions are presented: The focus of this report is on the achieved calcinati
D4.4: Comparative characterization of cement raw meal qualities for Calcium Looping
This report will summarize the findings of the comparative characterization test with various raw meal qualities obtained in the 120 kW test rig at USTUTT. This will also include a comparison to the demonstration tests in WP3.
D4.6 Experimental determination of intrinsic calcination/carbonation kinetics for various raw meals
This Deliverable includes the experimental results obtained in a drop tube furnace (L=6.5 m, ID=0.08 m) and in a thermogravimetric set-up available at INCAR-CSIC to determine the intrinsic calcination and carbonation kinetics for various raw meals
D5.2 Screening of kinetic parameters and performance of several raw meals at particle level
The work of 5.1.1 will be extended to several other promising raw meals to be used for the tests at the demonstration plant Mechanistic description of bellite formation, depending on aggregation levels of Ca and Si in the raw meals,will be included
D5.3 First stage demo system simulations using the early phase simulations tool with nonvalidated physical submodels
In this deliverable, new models for the global pilot plant and for the coupled calciner and carbonator reactors are presented and validated against previous simulations. CFD simulations of the splash boxes for calciner and carbonator indicate that
D5.4 Report on 1D and 3D model frames
The report describes the final 1D and 3D model frames for interconnected calciner and carbonator reactors. This includes decription of submodels and underlying model theories as well as sensitivity analyses of the reactor system operation.
D5.5 Report on second stage demo system simulations
The 1D and 3D simulation tools, which are developed in Task 5.2 are applied to simulate the demo scale units. The report describes the modelled flows and reactions.
D5.6: Tuning and validation of demo scale reactor models
The parameters of the earlier performed modelling studies are tuned based on experimental data from WP3. The deliverable reports the tuned parameters and submodels and the validated model results.
D5.7: Modelling of full scale units
The fully developed and validated model frame is applied to simulate the full scale units. The deliverable reports the model results in selected process configurations and process conditions.
D5.8 Performance of CaL processes in full scale cement plants, with full sensitivity analysis and comparison with benchmark
The purpose of this deliverable is to evaluate the energy – environmental performances of a full-scale cement plant integrated with the CaL Entrained Flow Reactors (EFR) system. The integrated CaL configuration is analyzed in details through a sens
D5.11 Final report on the optimal layout, performance and costs of the CPU for two different CO2 target purities, including also off-design evaluation
Description and results of the CPU process optimized from a technical and economic point of view, and off-design performance assessment via sensitivity analysis.
D6.1: Scale-up Study of full-scale cement plant with CaL process
The purpose of this deliverable is to provide a technical review of the equipment and machinery installed at the Demonstrator Plant and to provide a first study for a scale-up to a full-size Cement Plant.
D6.2: Preliminary economic analysis of cement plants equipped with CaL process and comparison with benchmark oxyfuel cement plant
Capital Cost estimate and cash-flow analysis of the preliminary full-scale commercial plant
D6.3: Full economic analysis of cement plants equipped with CaL, both newly designed and retrofitted, and a final comparison with benchmark oxyfuel cement plant
Final economic assessment of cement plants equipped with CaL.
D7.4 Lab-scale experiments on waste oil shale ash and CDW carbonation and recommendations for the design of the mineralization reactor in Vernasca
Lab tests were performed in order to: (a) specify the recommendations for a pilot design and (b) identify the most promising materials for CO2 capture. The respective mathematical models were implemented, developed and used for clarification and gene
D7.6: Final report with results of the mineralization tests at Vernasca
The Task aimed at demonstrating the feasibility of CO2 capture in Estonian burnt oil shale through the mineralization system developed in the framework of WP7 based on recommendation supplied in the Deliverable 7.5.
D7.7: Results from casting concrete containing CaLooped CO2 trapped in the Vernasca demo system
In this task the burnt oil shale (BOS) ashes carbonated via the pilot mineralization system installed in Vernasca and operated using the CO2 enriched gas stream coming from the oxyfuel calciner have been used in concrete, demonstrating the possible u
D8.1: Applicability of the CaL process in the ECRA oxyfuel demonstration project
Techno-economic assessment of the possible integration of the EF CaL process in the Colleferro cement plant. This plant was also selected by ECRA for the demonstration of the Oxyfuel process.
D8.2: Business plans and economic analysis for commercial exploitation of CLEANKER technology in selected ITC-HCG and BUZZI plants
Business plans and economic analysis for commercial exploitation of CLEANKER technology in selected ITC-HCG and BUZZI plants
D9.2 First year technical report for ECRA
This deliverable is the first annual report to ECRA. The first part is dedicated to the project description in terms of goals, scope of works, consortium etc. The second part is dedicated to the work carried out during the first year.
D9.3 Second year technical report for ECRA
This deliverable is the second annual report to ECRA. It focuses on the activities carried out during the second year of CLEANKER project and in particular on the design and engineering of the demonstrator.
D9.4 Third year technical report for ECRA
This deliverable is the third annual report to ECRA. It focuses on the activities carried out during the second year of CLEANKER project and in particular on the design and engineering of the demonstrator.
D9.5: Final technical report for ECRA
Report delivering all technical information required by ECRA relevant to monitoring the project execution.

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This project has received funding from the European Union’s Horizon2020 research and innovation programme under Grant Agreement N° 764816

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