Carbon Capture Concept Select for European Cement Facilities

Objective

A leading global cement manufacturer engaged io consulting to conduct a concept select study for Carbon Capture and Storage (CCS) at one of its fully integrated cement production sites in Europe. The objective was to determine the most cost-effective and technically viable carbon capture solution that supports the company’s net-zero ambitions while ensuring high-purity CO₂ for transport and sequestration.

This study is part of io’s broader experience supporting multiple European cement facilities in evaluating optimal carbon capture technologies. In addition to this fully integrated CCS concept study, io has provided process design assessments for CO₂ Purification Units (CPU) across other sites operated by this entity. Through these engagements, io has also developed CallithyiaCO2, an open-art cryogenic processing unit, designed as a flexible, cost-effective solution for CO₂ purification and liquefaction in cement and other industrial applications.

Project Scope

The study focused on defining a complete CCS system, covering capture, purification, liquefaction and transport. Key elements included:

1. Carbon Capture Technology Selection – Evaluating cryogenic separation, amine scrubbing, and oxyfuel combustion.
2. Flue Gas Cleaning & CO₂ Purification – Ensuring high-purity CO₂ by managing NOₓ, SO₂ and other contaminants.
3. CO₂ Liquefaction & Storage – Designing the optimal infrastructure for on-site storage and export.
4. Transport & Export Strategy – Assessing rail and pipeline options for CO₂ transport to sequestration sites.
5. Process Modelling & Cost Optimisation – Using io’s eMerge system modelling tool to refine system efficiency and reduce costs.

Findings & Recommendations

Findings

• Carbon Capture Technology Selection: Cryogenic CO₂ purification was the most effective approach, offering >96% capture efficiency and CO₂ purity >99.5%, making it suitable for transport.
• Flue Gas Cleaning & Contaminant Removal: High levels of NOₓ and SO₂ required Selective Catalytic Reduction (SCR) and wet Flue Gas Desulphurisation (FGD) to meet CO₂ purity requirements.
• CO₂ Liquefaction & Storage Strategy: A cryogenic liquefaction system with a cold box provided the best efficiency, minimising power demand while maximising CO₂ recovery.
• Transport & Export Strategy: Given the site’s inland location and the absence of dedicated CO₂ pipelines, rail transport was identified as the best solution for offloading CO₂ to sequestration hubs.
• Process Modelling & System Optimisation: Advanced modelling using io’s eMerge platform demonstrated additional efficiency gains through system integration and waste heat recovery.

Recommendations

1. Carbon Capture Technology Selection: Adopt io’s CallithyiaCO₂ open-art cryogenic CPU, a modular and scalable solution that reduces energy consumption and CAPEX compared to conventional liquefaction systems.
2. Flue Gas Cleaning & Contaminant Removal: Optimise the flue gas cleaning process to improve integration with the CPU and reduce reagent costs.
3. CO₂ Liquefaction & Storage Strategy: Use CallithyiaCO₂ CPU to streamline purification and liquefaction, optimising both CAPEX and OPEX.
4. Transport & Export Strategy: Implement a dual-tank storage and rail loading system to manage variable offloading schedules.
5. Process Modelling & System Optimisation: Use eMerge dynamic simulations to refine process control and energy management strategies.