Calcination Process

Abstract

Described is the use of a mineral comprising a metal carbonate fraction and a fuel fraction, such as oil shale or coal shale, in a calcination process. The disclosed process can advantageously result in carbon dioxide being removed from the atmosphere. Further, in the process, heat energy generated during calcination can be used to separate oxygen from air, so that the oxygen can be fed back into the system. Alternatively or in addition, heat energy may also be used to compress the gaseous carbon dioxide generated from the calcination process.

Claims

1. A process comprising the steps of: a) providing a mineral comprising a metal carbonate fraction and a fuel fraction, wherein the fuel fraction has a calorific value which is at least 50% of the energy needed to calcine the metal carbonate fraction, and combusting the mineral in the presence of oxygen, water vapour and carbon dioxide, to generate a metal oxide, water vapour, carbon dioxide and heat; b) using heat generated in step a) to: i) drive a gas separation process which generates high purity oxygen from air, wherein oxygen generated in step b) is used in step a); and/or ii) compress the carbon dioxide generated in step a).

2. A process according to claim 1, wherein the fuel fraction of the mineral has a calorific value which is sufficiently high to enable to calcination of the entire carbonate fraction.

3. A process according to claim 1, wherein the mineral is oil shale or coal shale, preferably wherein the mineral is oil shale from the Green River Formation.

4. A process according to claim 1, wherein the metal carbonate fraction of the mineral in step a) comprises a group II metal, or a combination of group II metals, preferably wherein the metal carbonate in step a) comprises calcium carbonate or magnesium carbonate.

5. A process according to claim 1, wherein the mineral is combusted in step a) in a mixture of gases comprising 5 to 20% by volume water vapour, 15 to 25% by volume oxygen and 60 to 75% by volume carbon dioxide.

6. A process according to claim 5, wherein the mixture of gases in which the mineral is combusted comprises nitrogen at a level of 0 to 1% by volume of the gases.

7. A process according to claim 5, wherein the mixture of gases in which the mineral is combusted comprises flue gases recycled from step a) and oxygen.

8. A process according to wherein claim 1, wherein the combustion/calcination reaction of step a) takes place in the range of 800 to 1350° C., preferably 900 to 1250° C., more preferably 1000 to 1150° C.

9. A process according to claim 1, wherein the gas separation process of step bi) occurs in an Air Separation Unit (ASU), a Pressure Swing Adsorption (PSA) System, and a Vacuum Swing Absorption (VSA) process.

10. A process according to claim 9, wherein the oxygen generation reaction of step bi) occurs in a Pressure Swing Adsorption (PSA) system.

11. A process according to claim 1, further comprising an additional step of sequestering the carbon dioxide generated in step a).

12. A process according to claim 11, wherein the heat generated in step a) is used to both i) drive a gas separation process which generates high purity oxygen from air and ii) compress the carbon dioxide generated in step a), in the process of sequestering the carbon dioxide.

13. A process according to any preceding claim, further comprising additional step d) of hydration of the metal oxide generated in step a) to produce a metal hydroxide and heat.

14. A process according to claim 13, wherein the heat generated during hydration of the metal oxide is used to drive the generation of oxygen and/or the compression of carbon dioxide in step b).

15. A process according to claim 1, wherein the oxygen and/or carbon dioxide used in the combustion reaction of step a) is at least 90% pure, preferably at least 95% pure.

16. Use of a process according to claim 1 carbon dioxide sequestration.

17. Use of a process according to claim 1 in oxygen generation.

18. A process comprising: providing a mineral comprising a metal carbonate fraction and a fuel fraction, wherein the fuel fraction has a calorific value which is at least 50% of the energy needed to calcine the metal carbonate fraction, and combusting the mineral in the presence of oxygen, water vapour and carbon dioxide, to generate a metal oxide, water vapour, carbon dioxide and heat.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] In order that the present invention may be more readily understood, it will be described further with reference to the figures.

[0073] FIG. 1 is a schematic representation of a process according to the invention.

EXAMPLE

[0074] FIG. 1 shows an example of the process of the invention, comprising step a), in which shale oil is used as the mineral. The shale oil is milled and introduced into a preheater with a mixture of 80% recycled flue gasses and 20% high purity oxygen (93% pure).

[0075] When the mineral has been heated, it moves to the calciner, and is set alight and burnt.

[0076] During this process, the fuel fraction of the shale oil, i.e. the kerogen, combusts releasing carbon dioxide, water vapour and heat. The heat energy released is sufficient to drive the calcination reaction, meaning that the carbonate fraction, which is predominantly calcium carbonate, decomposes into a material that is predominantly calcium oxide along with any residual mineral which include silica, alumina and iron oxide.

[0077] The fuel gases are collected, and a portion is recycled back into the preheater with oxygen added. The remainder of the flue gases are processed, with the carbon dioxide generated being separated from water vapour, by cooling the water vapour, and then directly sequestered, resulting in a carbon neutral system.

[0078] The metal oxide generated is cooled to ambient temperature and the heat energy released is used to drive an oxygen separation process by a PSA system. The oxygen generated is be fed back into step a).

[0079] In addition, in step d), the metal carbonate generated in step a) is subsequently hydrated, forming metal hydroxide (for example slaked lime), which is an exothermic reaction. The energy released in the hydration can also be fed into the oxygen separation process.

[0080] In step b) air enters an air separation processing unit, such as a PSA, which is being operated predominantly using energy produced in step a), thereby minimising the electrical input required. In this unit, the air is separated to produce a predominantly nitrogen stream, and a predominantly oxygen stream, of high purity oxygen (at least 90% by volume). The high purity oxygen is used in step a). The water vapour and carbon dioxide used in step a) are recycled from step a) flue gasses.

[0081] Alternately, or usually in addition, heat from step a) is used to drive a compressor, which compresses the carbon dioxide produced in the flue gasses from step a) in the sequestration process.