Integrated carbon capture and energy generation plants for hard-to-abate industries
SFW’s Calcium Looping (SFW CaL+) technology offers a scalable and cost-efficient solution for decarbonizing industries like steel, cement, and power generation. Using a natural sorbent, calcium, it captures CO2 with over 90% efficiency, powered by bio-residues and waste streams via oxy-combustion.
By integrating with green hydrogen plants, which supply affordable oxygen as a by-product, CaL+ reduces capture costs and enables additional revenue streams like decarbonized power and lime. Validated through industrial pilots and EU-funded projects, CaL+ is a proven solution for hard-to-abate sectors.
Tabs
The carbonator or the Calcium Looping system is based on Sumitomo SHI FW’s Circulating Fluidized Boiler technology. Here’s how the process works:
Stage 1: Flue Gas Enters the Carbonator Reactor
Flue gas, which contains CO2, is directed from industrial processes into the Calcium Looping system. The flue gas passes through the first reactor, known as the carbonator, where calcium oxide (CaO) reacts with the CO2 to form calcium carbonate (CaCO3).
Stage 2: Calcium Carbonate Moves to the Calciner
The calcium carbonate is transferred to a second reactor, known as the calciner. Inside the calciner, the calcium carbonate is heated in an oxygen-rich environment through an oxyfuel process, where fuel is directly injected into the capture system. This process breaks the calcium carbonate down into calcium oxide (CaO) and releases CO2 for capture.
Stage 3: CO2 is Captured for Storage or Utilization
The pure CO2 can be captured and either stored underground through sequestration or repurposed for various industrial applications. These could include permanent removal in geological storages or the production of carbon-based materials, contributing to a circular economy and reducing the overall carbon footprint.
Stage 4: Calcium Oxide is Recycled
CaO is recycled within the system, with a portion extracted as valuable feedstock for industries like cement and steel production.
Stage 5: Energy Generation
Calcium Looping enhances overall energy efficiency by recovering heat and power from the exothermic reactions in both the carbonator and calciner. This approach allows the carbon capture plant to operate independently of the existing site, which, in some industrial cases, lacks the excess energy required to run the carbon capture process. Additionally, it generates decarbonized power as an extra revenue stream.
Natural calcium-based sorbents
The Calcium Looping (CaL) process uses readily available, non-toxic calcium oxide as the primary sorbent. This makes the system both environmentally sustainable and cost-efficient.
Dual fluidized bed technology
The CaL system operates through a dual fluidized bed reactor. Calcium oxide captures CO2, and then calcium carbonate is decomposed to release CO2. This setup ensures continuous and efficient carbon capture.
Integrated energy generation
CaL recovers heat and can generate power during the exothermic reactions of its process, making it energy-efficient and providing the potential for decarbonized power generation.
Lower levelized cost of capture
Calcium Looping is cost-effective due to its use of natural calcium-based materials, which are abundant and affordable making it an attractive solution for large-scale industrial applications.
High CO2 Capture Efficiency
CaL achieves over 90% CO2 capture efficiency, significantly reducing emissions in carbon-intensive industries such as steel, cement, and power production.
Enhanced Energy Efficiency
The system leverages the exothermic reactions from its processes to recover heat and power, reducing the overall energy consumption. This increases the energy efficiency of the plant and offsets some carbon capture costs.
Value-adding By-products
In addition to capturing CO2, CaL technology produces valuable by-products such as decarbonized lime, which can be used in other industries, such as cement, creating additional revenue streams.
Flexibility and Scalability
This technology is highly adaptable and can be retrofitted into existing plants or integrated into new industrial processes. It handles various flue gas conditions and is suitable for sectors such as energy, steel, and cement.
Proven Reliability
With successful pilot projects, such as La Pereda in Spain, CaL technology is well-established and has been tested under industrial conditions for over 5,000 hours.