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Overview of CCC process, economics &
market opportunity
Michael Priestnall2011(non-confidential)
Profitable CCS via electrochemical mineral carbonation
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Cambridge Carbon CapturePresentation overview
Mineral carbonation overview
Cambridge Carbon Captures unique technology
Economics & applications
Commercialisation & carbon impact
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Cambridge Carbon CaptureMineral carbonation overview
Primary process by which carbon dioxide is removed from the atmosphere
>99% worlds carbon reservoir is locked in limestone & dolomite
Thermodynamically favourable, but kinetically slow
CCC has electrochemical & aqueous-phase process chemistry to do this process quickly & cheaply
Mineral carbonation refers to the conversion of silicates to solid carbonates,
mimicking the natural process by which CO2 is removed from the atmosphere
~1012 tonnes CO2 inatmosphere
~109 t/yr
CO2cycle
CO2(g) + CaSiO3weathering CO32-(aq) + Ca2+(aq) + SiO2mineralisation CaCO3(s)
~1018 tonnes CO2 incarbonate rocks
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Cambridge Carbon CaptureGeological CCS vs Mineral Carbonation
Mineral carbonation avoids the compression, transport and long term
storage of gaseous/liquefied CO2
30% cost and energy penalty
More expensive than nuclear or on-shorewind
Estimated40-90/tonne* CO2 versusrecent ETS price of ~15/tonne
Public acceptance issues
Relatively well developed technology
Geological CCS Mineral carbonation
Stable, safe solid products
Output materials are usable in a variety ofapplications
Wastes can be used as inputs
Primary challenges are the energy intensivecarbon capture & mineral processing steps(CCCs chemistry addresses this)
* Source: McKinsey
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Mg, Ca, Fesilicates oroxides
MINERAL MINE
INDUSTRIAL WASTE
FOSSIL FUEL
Carbon-containing fuel(or flue gas CO2)
CARBON-FREEELECTRICITY
METALS & SILICA
Carbonatedcapture fluid
(K2CO3)
CARBONATES
DIGESTION
& CARBONATION
POWER GENERATION& CARBON CAPTURE
Power generation & capture steps integrated; carbon free power generation
is combined with the conversion of low value inputs to useful materials
e.g. serpentines,olivines
e.g. steel slags,mining waste,
red mud
Regeneratedcapture fluid (alkalimetal hydroxide)
Cambridge Carbon CaptureProcess overview
(+ water + CO2 free air)
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Illustrative process for a 500MW plant, coal and olivine
Cambridge Carbon CaptureProcess overview
MINERAL MINE
FOSSIL FUEL
Coal*
CARBON-FREEELECTRICITY
METALS & SILICA
K2CO3CARBONATES
DIGESTION& CARBONATION
POWER GENERATION& CARBON CAPTURE
SerpentineMg3Si2O5(OH)4
KOH
C + O2 + 2KOH K2CO3 + H2O
* Coal is variable in composition and is not pure carbon.However, for the sake of illustration the equations arewritten in terms of pure carbon.
Mg(OH)2 + K2CO3
MgCO3 + 2KOH
0.5Mg2SiO4 + H2OMg(OH)2 + 0.5SiO2
Overall: C(s) + O2(g) + 0.5Mg2SiO4(s) = MgCO3(s) + 0.5SiO2(s)
[+energy]0.9 milliontonnes/yr
~ 4 milliontonnes/yr
500 MWe power plant
>6.3 million tonnes/yrcarbonates
~500MW electricity
~12,000 tonnes/yr Ni
~4.5 million tonnes/yr SiO2
5-20% of energy output
(+ water + CO2 free air)
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Illustrative process for a flue gas CO2 and olivine
Cambridge Carbon CaptureProcess overview (flue gas CO2)
MINERAL INPUT
POWER PLANT
Flue gasCO2
PURIFIED FLUE GAS
SILICA
K2CO3CARBONATES
DIGESTION& CARBONATION(4)
CARBONCAPTURE
OlivineMg2SiO4
(1)
KOH
CO2 + 2KOH K2CO3 + H2O[and/or: CO2 + KOH KHCO3
(2)]
(1) Olivine is a common mineral and is used toillustrate the process. A large variety of Mg,Ca, & Fe oxides, hydroxides and silicatescould be used also. These could be minedminerals or wastes such as fly ashes or slagsfrom metal production.
Carbonation:
Mg(OH)2 + K2CO3MgCO3 + 2KOH
Digestion:
0.5Mg2SiO4 + H2OMg(OH)2 + 0.5SiO2
(3)
Overall: CO2(g) + 0.5Mg2SiO4(s) = MgCO3(s) + 0.5SiO2(s)
(2) Carbonate (CO32-)and bicarbonate (HCO3
-) arein equilibrium in solution depending on pH. Theequations can be written in terms of either.
(3) Somewhat simplified for clarity. Actuallyproceeds via a two steps.
(4) Shown as a single vessel for simplicity. May infact be performed in two separate vessels.
Poweroverhead
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Energy and capital requirements for mineralisation are reduced; carbon
free power generation is combined with the production of useful materials
CCC Process
Combines a number of features whichreduce energy & capital requirements andimprove process economics:
Advanced digestion routes are usedto convert silicates to reactiveoxides/salts in a low energy process
Carbon-containing fuels areefficiently, cleanly & cheaplyconverted to electricity via directelectro-chemical oxidation
Power generation and capture steps
are integrated more efficient, fewerlosses
Options to use CCC chemistry fordirect flue-gas CO2 sequestration
Process (by-)products are high-puritychemicals, metals and/or aggregates
Features
100% carbon capture feasible
Allows additional 15% power capture (CO2 to carbonate reaction) offsets energy required to digest/activate mineral feedstock
Economic CCS option higher process efficiency and revenuesfrom mineral products cover costs of CCS
Scalable from high value niches to large scale CCS
Feedstock flexibility - in principle, any calcium or magnesiumcontaining feedstock can be used
Wastes appropriate for use in smaller scale applications
Available volumes of relevant minerals (ultramafics andserpentines) match those needed for CCS
Volumes of carbonate produced match aggregates market
No requirement for pipeline, storage infrastructure, & sites
No safety concerns
Challenges:
Transport logistics & supply chain development
Optimising digestion & precipitation chemistry and process
Cambridge Carbon CaptureFeatures & benefits
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Cambridge Carbon CaptureInput and output materials
Alkaline waste products such as ashes, bauxite red muds, and steelmaking slags can be used as inputs to the CCC process
Remediation mechanism for hazardous wastes
Landfilling of air pollution collection dusts and slags can cost >100/tonne
Carbonate outputs can be consolidated to building materials &aggregates
Route to turning CO2 into high-value solid building materials at a global scale
Average price of carbonate powders is ~10/tonne, and is a >300 billionmarket
Other high value phases can be extracted providing additional valuedrivers
High value metals can be extracted, e.g. serpentine is typically 0.3% Ni
Cementations phases can be isolated and replace high value cements
Amorphous silica is extracted as a by-product, used as a rubber filler
Conversion of low value minerals or negative value wastes to valuable
materials outputs provides a significant & immediate commercial driver
Provides direct economic incentive to apply CCS today
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Cambridge Carbon CaptureApplications
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The CCC process is scalable and is applicable to a diverse range of markets
from waste treatment to utility scale CCS
Iron, steel and aluminiumindustry
Remediation of hazardouswastes; on-site cleanelectricity; CO2 permits
Minerals & mining industry
Remediation of mining wastes;on-site clean electricity
Industrial waste processingindustry
Profitable stabilisationprocess, avoidance of landfilltaxes
The aluminium industry produces ~100MT of red mud each year and the steelindustry about ~150MT of alkaline slag
Waste remediation andtreatment
Utilities and major powergenerators
Lower cost CCS option,technology differentiator,green energy that meets localrenewable obligations
Oil, gas & coal companies
Environmental & politicalcredit, CCS solution forcustomers, differentiation &value-add
Extraction andproduction of materials
Mining companies
Utilisation of marginalfeedstocks/wastes; on-site
clean electricity
Cement and buildingmaterials companies -
Lower cost, lower CO2manufacturing process,revenues from by-productclean-electricity generation
Large scale CCS
Global carbonate materials marketworth >300 billion/year & volumes
match CCS, of which high valuecements are ~3bn tonnes
IEA estimates CCS market ~$5 trillion2010-2050
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Cambridge Carbon CaptureFinancial modelling
The CCC process combines the following potential revenuestreams:
1) Clean, low cost electrical power2) Production of bulk materials (e.g. aggregates, cements,
concretes)3) Extraction of high value materials (e.g. metals)
4) Remediation of input wastes5) Carbon credits (where available)
Multiple revenues streams off-set the energy penalty fordigestion and carbonation and additional capital cost
Financial modelling* has shown that the CCC process can beprofitable at a range of scales for carbon prices ~20/tonne
In the most promising scenarios the process is profitablewithout subsidy even at zero carbon price
Key factors affecting the profitability include the efficiency ofthe power plant, the capex and opex for the digestion process,and the delta between input & output material value
Financial modelling has shown that the CCC process can be profitable
without subsidy under a range of scenarios
HydrocarbonsSilicate minerals
POWERGENERATION &
CAPTURE
DIGESTION &CARBONATION
CO2free electricity Silica and metal
by-products
Alkalinewastes
Remediationcredit
Carbon credits
Carbonate constructionmaterials
* Modelling performed by CCC in collaboration with the Judge Business School
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Cambridge Carbon CaptureApplication scenario
Example: Small power plant
100 MW scale plant, operating at 80%capacity
Produces 700,000 MWh/year of carbon freepower
~1m tonnes/year of mineral input required atcost of ~5/tonne
Produces ~800,000 tonnes of carbonatedaggregate material with a value of ~7/tonne
Annual profit of ~20m
The CCC process can be profitable without subsidy today
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Example: How CCCs process can be profitable at 7bn tonne/yr CO2 global-scale
REVENUES (lowest): COSTS (highest):
330 billion/yr (global market for aggregate materials) 350 billion/yr (7bn t/a @ 50/tonne CO2)90 billion/yr (abatement value at ~13/tonne CO2)420bn revenues(materials products + CO2 abatement) > 350bn costs(for CO2 mineralisation)
MARKET:
~8,000TWh/yr coal-fired electricity emits ~7bn t/yr CO2 3300 bn (period 2010-2050) global spend on CCS technology (IEA estimate)
global annual power growth ~2.5% + ~2% replacement
Cambridge Carbon CaptureApplication scenario
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*very approximate data (source: Calera) Million tonnes/yr(USA)
$/tonne
(USA)
US annual Market
$billion
Global estimate
$billion
Mineral fillers 100 100 10 100
Soil stabilisation 100 30 3 30
Light wt aggregate 200 40 8 80
Sand & aggregate
3000 7 21 210cementitious materials 24 60 1.4 14
bricks 20 20 0.4 4
drywall 20 25 0.5 5
Concrete blocks
50 30 1.5 15cement 120 80 10 100
Masonry cement 4 1000 4 40
Cambridge Carbon CaptureCarbonate materials markets*
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Cambridge Carbon CaptureDevelopment status
All steps of the process have been demonstrated, core IP secured:
Operation of a direct oxidation alkaline fuel cell to generate electrical power withsimultaneous, integral capture of product CO2
Regeneration of electrolyte & operation using regenerated electrolyte
Identification of practicable low-energy, low-cost digestion and mineralcarbonation processes
CCCs team consists ofincludes experienced technology developmentprofessionals and eminent academics
Development partners include Universities of Cambridge, Nottingham andSheffield and other expert research & technology organisations
Near term focus:
Engaging with industrial partners in initial target markets JDAs to develop pilot
scale processes and initial field trials Developing relations with key supply chain partners such as resource
companies & process engineering companies
Deepening relationships with expert RTOs to further develop digestion &
carbonation technology
Demonstration of the complete process at pilot-scale (10 tonnes/yr) in 2011/12followed by a small-scale (100-1000 tonne/yr) field trial in 2012/13
The CCC process has been proven at laboratory scale and development
partners are being engaged for scale up and commercialisation
Position[2Theta](Copper (Cu))
10 20 30 40 50 60
Counts
0
5000
10000
15000
NottA3 mix12-10-10
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Cambridge Carbon CaptureCarbon reduction potential
100% carbon capture has been demonstrated; massive potential for carbon
emission reductions CCC has demonstrated compete carbon capture using a methanol
DOAFC and hydroxide electrolyte (output CO2 level lower than air!)
The favourable economics of the CCC process potentially enablesCCS to be applied to the entire global fossil power generationindustry
Carbon saving potential is clearly vast potentially could address entire ~7billion tonne CO2/year industrial power sector
For illustration, applied to UK power generation sector:
Installation in 20% of UK power generation capacity and assuming a 20%penalty (much larger than anticipated) carbon savings of 48Mt/year1
Even small scale early stage industrial applications have huge
potential carbon impact:
Processing of 20% of bauxite red mud produced each year would save~20Mt CO2/year
2
Processing of 20% of steel making slags produced per year would save~10 MT CO2/year
3
Displacement of 1% of carbonate production would result in savings of150MT/year4
K2CO
3+ CaO @
100mACO
2level [relative units]
atmosphere 6.1 (~390ppm CO2)
fuel cell air outlet 4.1 (~260ppm CO2)
1 UK installed capacity of coal and gas fired generation is~28 GW and ~32 GW, emitting ~300 MT of CO2 per year.Assuming a 20% penalty for transport and losses in thesystem then the annual saving for a 20% uptake wouldbe: 300 * (1-0.2) * 0.2 = 48 MT CO2/year in the UK.
2 ~100 MT of alkaline oxide "Red Mud" is produced eachyear which can absorb about 1 tonne of CO2/tonne.Therefore if 20% of this Red Mud were processed eachyear the saving would be 100x1x0.2 = 20Mt
3 About 150 MT/year of steel slags are produced per year.These slags contain 30-50 wt% CaO/MgO and can absorb~0.33 tonne of CO2/tonne. If 20% were processed, thesaving would therefore 150*1/3*0.2 = 10MT
4 ~0.5tonnes of CO2 are absorbed per tonne of outputcarbonate product. Global aggregate & cement market is~30bn tonnes/yr. Assuming displacement of 1% ofproduction would result in savings of 150MT/year
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Cambridge Carbon CaptureSummary
A profitable approach to carbon capture to service the $1trindustrial & $5tr power generation CCS market, now to 2050
Uses CO2 to convert problem wastes or low-value silicateminerals to valuable solid carbonates while efficientlygenerating low cost zero-carbon electricity
Unique IP, proven & demonstrated at laboratory scale
Avoids cost, infrastructure & acceptability issues ofcompression, transport and storage of gaseous/liquefied CO2
Scalable and applicable to a diverse range of markets fromwaste treatment to high-value metals & minerals productionto industrial & utility scale CCS
A real-world solution that CCCs customers are funding nowfor their immediate strategic business applications
Breakthrough enabling technology to address the currentimpasse in commercial CCS deployment
Cambridge Carbon Capture is developing unique chemical processes that
safely, profitably and permanently store CO2 in useful solid materials
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Funding partners:Technology Strategy Board
East of England Development Agency
Renewables East
Cambridge Enterprise
Commercial customers
Technology development collaborators:
University of Cambridge Dept. Materials Science
Centre of Innovation in CCS (U. Nottingham)
University of Sheffield Dept. Materials Science
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Cambridge Carbon CapturePartners & Customers
www.cacaca.co.uk
Cambridge Carbon Capture, Hauser Forum, Charles Babbage Road,Cambridge, CB3 0GT, UK
mailto:[email protected]:[email protected]