Systems and methods for carbon capture

Abstract

The present disclosure provides systems for carbon capture in combination with production of one or more industrially useful materials. The disclosure also provides methods for carrying out carbon capture in combination with an industrial process. In particular, carbon capture can include carrying out calcination in a reactor, separation of carbon dioxide rich flue gases from industrially useful products, and capture of at least a portion of the carbon dioxide for sequestration of other use, such as enhanced oil recovery.

1 . A system for calcination with carbon capture, the system comprising:
 a reactor configured to heat a carbonate-containing raw material in the presence of an oxidant to form a decomposition stream containing at least solids and carbon dioxide gas;   a separator configured to separate the decomposition stream into a gas stream including the carbon dioxide gas and a solids stream;   a heat exchange unit configured to receive one or both the gas stream including the carbon dioxide gas and the solid stream and withdraw heat therefrom to provide a cooled gas stream including the carbon dioxide and a cooled solids stream; and   a CO 2  separation unit configured to separate the cooled gas stream including the carbon dioxide into a CO 2  lean stream and a CO 2  rich stream.   
     
     
         2 . The system of  claim 1 , wherein the reactor and the separator are combined as a single unit. 
     
     
         3 . The system of  claim 1 , further comprising an oxygen-forming unit configured to provide oxygen to the reactor. 
     
     
         4 . The system of  claim 1 , further comprising a water separator downstream from the heat exchanger. 
     
     
         5 . The system of  claim 1 , wherein the CO 2  separation unit comprises at least one membrane separation stage configured to separate the cooled gas stream including the carbon dioxide into the CO 2  lean stream and the CO 2  rich stream. 
     
     
         6 . The system of  claim 5 , further comprising a low temperature CO 2  purification unit configured to receive at least the CO 2  rich stream from the at least one membrane separation stage. 
     
     
         7 . The system of  claim 6 , further comprising a compression unit configured to compress the cooled gas stream including the carbon dioxide, the compression unit being positioned upstream from the at least one membrane separation stage. 
     
     
         8 . The system of  claim 7 , further comprising an expander positioned downstream from the at least one membrane separation stage. 
     
     
         9 . The system of  claim 1 , further comprising a power generation cycle integrated with the heat exchanger. 
     
     
         10 . The system of  claim 9 , wherein the power generation cycle comprises a compression unit configured to provide a compressed working fluid to an inlet of the heat exchanger, a turbine configured to receive the compressed working fluid from an outlet of the heat exchanger, and a cooler positioned between, and in fluid connection, with an outlet of the turbine and an inlet of the compression unit. 
     
     
         11 . The system of  claim 1 , further comprising a carbonator configured to receive a portion of the solids stream from the separator. 
     
     
         12 . The system of  claim 11 , wherein the carbonator includes a solid product outlet in communication with an inlet of the reactor and configured for delivery of regenerated raw material to the reactor. 
     
     
         13 . The system of  claim 1 , further comprising a clinker unit configured to receive a portion of the solids stream from the separator. 
     
     
         14 . The system of  claim 13 , wherein the clinker unit includes one or more inlets configured for entry of one or more raw materials. 
     
     
         15 . The system of  claim 13 , further comprising a clinker cooler unit configured to receive a stream of cement clinker from the clinker unit and cool the stream of cement clinker with a portion of the cooled gas stream. 
     
     
         16 . The system of  claim 1 , wherein the system is integrated with a steel-making plant. 
     
     
         17 . The system of  claim 1 , wherein the system is integrated with a power production plant. 
     
     
         18 . The system of  claim 17 , wherein the system further comprises an ash burning unit. 
     
     
         19 . A method for calcination with carbon capture, the method comprising:
 processing a carbonate-containing raw material in a heated reactor to provide a decomposition stream comprising at least solids and carbon dioxide gas;   separating the decomposition stream in a separation unit into a gas stream including the carbon dioxide and a solids stream;   cooling one or both of the gas stream including the carbon dioxide and the solids stream in a heat exchanger;   one or both of providing at least a portion of the solids stream as a product for export and delivering at least a portion of the solids stream to a further reactor for forming a secondary product;   purifying the gas stream including the carbon dioxide to provide a substantially pure stream of carbon dioxide for export; and   carrying out a power production cycle that is integrated with the heat exchanger.   
     
     
         20 - 50 . (canceled) 
     
     
         51 . A method for calcination with carbon capture, the method comprising:
 processing a carbonate-containing raw material in a heated reactor to provide a decomposition stream comprising at least solids and carbon dioxide gas;   separating the decomposition stream in a separation unit into a gas stream including the carbon dioxide and a solids stream;   cooling one or both of the gas stream including the carbon dioxide and the solids stream in a heat exchanger;   one or both of providing at least a portion of the solids stream as a product for export and delivering at least a portion of the solids stream to a further reactor for forming a secondary product;   purifying the gas stream including the carbon dioxide to provide a substantially pure stream of carbon dioxide for export; and   processing a portion of the solids stream exiting the separator in a clinker unit.