Fabrication of CO2 negative AGGREGAtes based on disruptive accelerated carbonation processes fuelled by carbon capture in refineries

Introduction

The AGGREGACO2 project targets the aggregates industry for a revolution through the successful commercial deployment of a sustainable aggregate as a solid alternative to conventional aggregates that are not fully environmentally friendly. The AGGREGACO2 proposes a FOAK innovation through the introduction of CO2 captured from refinery processes in an Accelerated Carbonation Technology (ACT), which revalorizes Air Pollution Control residues (APCr). These residues are currently hazardous waste stored after treatment, and the project aims to use them for the fabrication of carbon-negative aggregates.

Objectives

The AGGREGACO2 project will demonstrate the industrial feasibility and cost-effectiveness of the first carbon-negative aggregate that can compete directly in the market. It aims to drastically reduce the GHG emissions emitted by refineries, as well as the carbon footprint of fuels and APCr in landfills.

Collaboration

ALBA and OCO INT, together with the Repsol Group, will become the first companies in the world to introduce industrial ACT processes perfectly connected with refinery plants. This collaboration paves the way for the transformation of traditional oil and gas plants into facilities that fabricate derivative sustainable products with high added value.

Research Outcomes

This joint research has produced attractive and promising results at high TRL levels, making the AGGREGACO2 industrial concept profitable at a mass fabrication level. A perfect symbiosis scenario is achievable because the ACT process can be 100% fueled using the CO2 captured in a refinery as a resource.

Production Goals

The main objective of the project is to design, implement, and validate the first commercial production plant of carbon-negative aggregates in the EU with the following specifications:

1. Capacity of 56,000 Tn/year
2. Adequate stability (>7,000 h)
3. Capability to revalorize 22,000 Tn APCr/year
4. Use of 2,200 Tn CO2 captured

Environmental Impact

This project will avoid 2,836.44 TonCO2eq/year (i.e., 28,364 TonCO2eq considering 10 years of project operation). Additionally, REPSOL will produce around 400 Ton/year of low carbon hydrogen.