Electrification of Clay Calcination: A First Look into Dynamic Modeling and Energy Management for Integration with Sustainable Power Grids
Bruno Laurini, Nicola Cantisani, Wilson R. Leal da Silva, Yi Zong, John Bagterp Jørgensen
TL;DR
The paper addresses decarbonizing cement production by electrifying the clay calcination step and integrating it with sustainable power grids, noting that conventional coal-based calcination emits about $0.80$ t CO$_2$/t cement and requires heat near $750$–$850^\circ$C. It develops a dynamic calcination model described by DAEs and an Energy Management System (EMS) based on Optimal Power Flow (OPF) to coordinate on-site renewables, storage, and grid imports. A multi-scale, integration framework couples process physics, represented by $\dot x(t)=f(x,y,u,d,p)$ and $0=g(x,y,u,d,p)$, with grid dispatch through $P^{EHGG}$-controlled heat generation, enabling demand-side flexibility and potential market participation. The framework aims to reduce both electricity costs and indirect grid emissions, providing a pathway toward grid-stable, low-emission cement production, with future work on market bidding and model-predictive control to enhance performance.
Abstract
This article explores the electrification in clay calcination, proposing a dynamic model and energy management strategy for the integration of electrified calcination plants into sustainable power grids. A theoretical dynamic modeling of the electrified calcination process is introduced, aiming at outlining temperature profiles and energy usage - thus exploring the feasibility of electrification. The model serves as a tool for optimizing parameters, estimating system behavior, and enabling model-based process control. An innovative energy management model is also presented, ensuring efficient assimilation of electrified calcination plants into the power grid. It encapsulates demand-supply balancing and optimizes renewable energy usage. In essence, we provide an insightful pathway to a more sustainable cement production, underlining the value of renewable energy sources and effective energy management in the context of clay calcination.