Project Proposal

Title:

Production Cement at Cement Factories by Using Energy with Zero Cost

Introduction:

The total quantities of cement which manufactured annually in the world are
4180 million ton as mentioned at web address:

https://en.wikipedia.org/wiki/List_of_countries_by_cement_production

Cement has been manufactured by fusing mixture of lime stone and clay in
furnace. The chemical structure of lime stone is CaCO 3 which has been changed
to CaO according to the equation (1):

CaCO3 Heating CaO + CO2 Gas (Emission)…………(1)

CaO percentage in the cement is 67% then we need 1196 Kg of lime stone to
produce one ton of cement due to emission 44% as CO 2 gas during heating lime
stone. So we need 5000 million ton of lime stone to produce 4180 million ton of
cement annually. 5000 Million ton of lime stone generate 2200 million ton of CO 2
gas according to equation (1). Currently this 2200 million ton of CO 2 gas go to
air annually as exhaust.

Changing CO2 Gas to Useful Energetic Products :

The following steps have been applied for changing exhaust gas (CO 2) in cement
factories to useful energetic products:

(1) Carbon dioxide gas capture system has been installed over cement production
furnace in cement factory (design of carbon dioxide gas capture system will be
attached)

(2) Find paper (it will be attached) includes main bases for changing above CO 2
gas to useful energetic products

(3) Changing water to vapor by using boiler instead of solar energy system High
Temperature Co-electrolysis (HTCE) which present in attached paper

(4) Electrolysis process has been applied on mixture of water vapor and carbon
dioxide gas (CO2) in the same electrolysis cell of the above attached paper but by
using normal DC unit instead of Solar Concentrator Photovoltaics (SCPV)
which mentioned in the attached paper. The products of electrolysis process is
mixture of carbon monoxide (CO) and hydrogen gases. Electrolysis process will
be according to equation (2):
CO2 + H2O vapor (in boiler) + electrolysis (by normal DC unit)  CO + H2 –(2)

Notice:
(a) The quantities of CO and H2 in equation (2) depend on initial quantities of
CO2 and water vapor in electrolysis process (CO quantity increases by
increasing quantity of CO2 but quantity of H2 increases by increasing of water
vapor)
(b) Oxygen gas O2 is other product for electrolysis process. It is generated from
electrolysis separately then is taken to storage tank

(5) The products in equation (2) have been taken for methanation process in
methanation unit (the same unit which present in the attached paper). Synthetic
natural gas CH4 mixed with some hydrogen gas H2 are the products of
methanation process

(6) Gas mixture of synthetic natural gas CH 4 and H2 gas has been directed
toward selective membrane for separating H2 gas from synthetic natural gas CH4

(7) Separated gases of item (6) have been directed to two tanks for storage, one
tank for H2 gas and second one for synthetic natural gas CH4

(8) Separated gas H2 of item (7) and separated gas O 2 of item (4) have been
applied by fuel cell for generating electric power

(9) The total produced energy and fuel by this project are as the following:

(i) Total produced synthetic natural gas CH 4. About 200 Kg of liquid synthetic
natural gas will be produced for every ton of manufactured cement

(ii) Part of produced synthetic natural gas CH4 will be used as a fuel of cement
furnace.

(iii) Produced electric power in item (8) can be used as part of total electric
power for cement production processes. The remaining synthetic natural gas
CH4 will be sold and its income can cover the main cost of used electric power in
cement production processes

(iv) Then we find in items (ii) and (iii) that the cost of energy for cement
production processes have been covered 100%

Experimental Application for the Project:

Partnership will be occurred between one of universities in United States (name

of the university will be informed to interested collaborator) and one of cleantech
companies which accepted to be sponsor of this project. The details of this
partnership will be as the following:

(1) A contract should be issued between above university and cleantech company
which accepted to be sponsor of this project
(2) Getting contracting between above cleantech company and one of cement
factories in United States for experimental application of the project on one of
cement furnaces inside this factory

(3) Supplying the above needed equipments to the factory for experimental
application of the project. The cost of these equipments will be paid by the above
cleantech company

(4) The supplying, installation and start working of equipments for experimental
application of the project will be under consultancy team from above university

(5) Above university's team has right to change or develop any part of the
project toward the best conditions during experimental application stage

(6) Above university gets fees of the consultancy for the experimental stage from
above cleantech company

(7) Above university is the unique which has the right of consultancy in future
for applying the project at all cement factories in United States (application of
the project at all cement factories in United States will be in view of results of
experimental application). Fees of the university in this case will be from people
who accepted to apply the project in their cement factories

(8) The experimental project will be reference for customers of cement factories
in United States who like to apply the project in their cement factories

(9) Cleantech company which financed the experimental application stage of the
project, will be the unique suppliers of project's equipments to all cement
companies in United States after finishing the experimental stage

(10) Interested cleantech companies contact elnekhily@ir-consulting.org