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    基于石灰石加绿氢制备CaO的低碳水泥生产系统模拟

    Simulation of low-carbon cement production system based on limestone hydrogenation for CaO production

    • 摘要: 水泥生产是全球CO2排放的主要来源之一,目前广泛研究的碳捕集利用与封存技术面临高能耗的问题。在传统水泥生产过程中,大量CO2的排放主要来自石灰石的分解。通过将绿氢引入分解炉,不仅可以还原石灰石制备CaO,还能显著降低分解炉温度,并把CO2转化为高附加值化工原料CO,从而实现低碳和低能耗的水泥生产。为了探究用石灰石中温加氢分解替代石灰石高温煅烧分解对水泥生产系统能耗、CO2排放量、㶲效率及成本的影响,采用Aspen Plus软件对基于石灰石加氢制备CaO的低碳水泥生产系统进行模拟,并与采用单乙醇胺捕集CO2的传统水泥生产系统进行对比分析。结果表明,与采用单乙醇胺碳捕集技术的传统水泥生产系统相比,基于石灰石加氢制备CaO的水泥生产系统通过将生料源CO2转化为CO,显著减少了后续单乙醇胺碳捕集单元处理的CO2量,从而在能耗、CO2排放量和CO2生成量(包括封存的CO2)方面分别降低了19.42%、52.91%、37.55%。㶲分析表明,由于发生热力学不可逆的化学反应,系统㶲损主要集中在预热分解单元和回转窑;换热器的㶲损则主要源于冷热两侧的大温差。此外,基于石灰石加氢制备CaO的水泥生产系统不仅能够生产水泥熟料还可以产出合成气,从而提升了系统的有效输出㶲,使㶲效率从传统系统的31.11%增加到75.63%。成本分析表明,与采用单乙醇胺碳捕集技术的传统水泥生产系统相比,绿氢使基于石灰石加氢制备CaO的低碳水泥生产系统成本增加了122.66%。然而合成气的高利润抵消了这部分成本,并实现了430.15元/t熟料的净利润。基于石灰石加氢制备CaO的水泥生产系统在能耗、CO2排放量、㶲效率和成本等方面具有显著优势,展现出良好的工业应用前景。

       

      Abstract: Cement production is a significant contributor to global CO2 emissions, and widely researched carbon capture, utilization and storage (CCUS) technologies face challenges related to high energy consumption. In traditional cement production, substantial CO2 emissions result from limestone decomposition. The introduction of green hydrogen into the calciner not only facilitates the reduction of limestone to CaO but also significantly lowers the calciner temperature and converts CO2 into high-value chemical feedstocks such as CO, enabling low-carbon and low-energy cement production. To evaluate the effects of replacing limestone decomposition with limestone hydrogenation in the calciner on the energy consumption, CO2 emissions, exergy efficiency and cost of the cement production system, an Aspen Plus simulation of a low-carbon cement production system based on limestone hydrogenation for CaO production was conducted and compared with a traditional system employing monoethanolamine (MEA) for CO2 capture. The results demonstrate that the limestone hydrogenation-based system significantly reduces the CO2 load on the subsequent MEA capture unit by converting raw material CO₂ into CO. Consequently, this system achieves reductions in energy consumption, CO2 emissions, and CO2 generation (including captured CO₂) by 19.42%, 52.91%, and 37.55%, respectively, compared to the traditional system employing MEA for CO2 capture. Exergy analysis indicates that the primary exergy losses occur in the preheating and decomposition unit and the rotary kiln due to thermodynamically irreversible chemical reactions, with heat exergy losses arising from the large temperature differences between the hot and cold streams. Furthermore, the limestone hydrogenation-based system not only produces clinker but also generates syngas, thereby increasing the effective exergy output of the system. This results in an increase in exergy efficiency from 31.11% in the traditional system to 75.63%. Cost analysis indicates that green hydrogen raises the cost of the limestone hydrogenation-based system by 122.66% compared to the traditional system employing MEA for CO2 capture. However, the high profitability of the syngas offsets this cost, resulting in a net profit of 430.15 yuan/t clinker. The cement production system based on limestone hydrogenation for CaO production demonstrates significant advantages in energy consumption, CO2 emissions, exergy efficiency and cost, with promising prospects for industrial application.

       

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