WO2026013603A1

WO2026013603A1 - System and method for mitigating negative impacts caused by volatile elements present within materials processed or consumed during a calcination process

Info

Publication number: WO2026013603A1
Application number: PCT/IB2025/056976
Authority: WO
Inventors: Michael Prokesch; Hisham OMAR; John Salmento; Pierre-Olivier CAMBIER; Charles ROBIN
Original assignee: FLSmidth AS
Current assignee: FLSmidth AS
Priority date: 2024-07-10
Filing date: 2025-07-10
Publication date: 2026-01-15
Anticipated expiration: 2027-01-10

Abstract

A process or method for reducing concentrations of a volatile element (or a circulating load containing a volatile element), and/or for reducing or mitigating buildup formations of volatile elements in a calcining operation is disclosed. A calciner system, plant, flowsheet, or apparatus configured to perform the method is also disclosed. A quenching chamber, a filter, and/or de-dusting circuit may be employed. Hot process gasses containing volatiles in a vapor form or phase are mixed with a cooler gas in a quenching chamber to precipitate out volatiles. The cooler gas comprise preheater circuit off-gas. An advantage offered by embodiments, is less buildup of volatiles on wall surfaces within components of the calciner system.

Description

SYSTEM AND METHOD FOR MITIGATING NEGATIVE IMPACTS CAUSED BY VOLATILE ELEMENTS PRESENT WITHIN MATERIALS PROCESSED OR

CONSUMED DURING A CALCINATION PROCESS

CROSS-REFERENCE TO RELATED APPLICATIONS

Reference is made to co-pending application PCT/IB2023/051958 which was filed on 2 March 2023 and which published as WO2023166464A1 on 7 September 2023, and which is hereby incorporated by reference in their entirety for any and all purposes as if fully set forth herein.

BACKGROUND

During the calcination of materials, for example, within a calciner system such as an oxyfuel flash calciner system, volatiles (i.e., “volatile components”, “volatile materials”, or “volatile elements”) can be volatilized in the high temperature flash calciner. Volatile elements may include, for example and without limitation, materials such as potassium (or compound(s) thereof), sodium (or compound(s) thereof), heavy metals, chloride(s) (or compound(s) thereof), alkalis (or compounds thereof), sulfur (or compounds thereof), or the like, without limitation.

A single type of volatile element, or, a combination of more than one type of the aforementioned volatile elements may be present within the calciner system during calcination of feed materials. These volatile components can end up entering the calciner system by virtue of being present within kiln feed materials being sent to the calciner and/or being present within fuel(s) being used to heat/operate the calciner. If the amounts of volatiles within the fuel(s) or feed(s) are trace amounts, most calcining systems may be able to handle them without incident. However, larger concentrations of volatiles in fuel(s) or feed(s) can cause problems. Such volatiles will tend to exit the calciner and enter the cyclone preheater circuit where, upon entering a zone of an appropriate lower temperature, they will condense on surrounding material particles suspended within gas flowing through the cyclone preheater circuit. These volatile-laden material particles may subsequently proceed to flow back to the flash calciner where the condensed volatile elements are re-volatilized due to a significant increase in heat.

This recirculation of volatiles within the calciner system ultimately results in a cycle of increasing concentrations of these volatile elements (or a building up of a “circulating load” within the calciner system). Higher circulating loads of volatiles within the calciner system can eventually lead to buildup formations in the preheater circuit and/or the calciner. For example, sticky residues can end up on wall surfaces of equipment within the calciner system, and this can restrict flow of gas and materials. Additionally, higher circulating loads of volatiles within the calciner system can degrade or negatively impact the quality or purity of processed final products. Calciner systems having high volatile circulating loads may produce final products that contain higher amounts or concentrations of volatiles within its composition. Moreover, a destabilization of calciner system operation can occur, due to the cohesive behavior of the material particles laden with high levels of volatile elements.

Thus, heretofore, there has been a long-felt need to address the shortcomings of prior and state-of-the art methods and systems which are used for calcining materials that may include large or trace amounts of volatile elements.

OBJECTS OF THE INVENTION

An aim of some embodiments may be to improve and benefit a calcination process by allowing a calciner system to process kiln feeds containing one or more volatile elements, or which contain elevated concentrations of one or more volatile elements in the feed, without limitation.

An aim of some embodiments may be to improve and benefit a calcination process by allowing a calciner system to utilize fuel(s) containing one or more volatile elements, or which contain elevated concentrations of one or more volatile elements in the fuel(s), thus providing greater fuel flexibility for the calciner system, without limitation.

An aim of some embodiments may be to provide an efficient low-cost manner in which to mitigate the negative effects that can be experienced in a calcination process as a result of volatiles being present within and/or building up within gas streams or on particulates suspended within the gas streams, without limitation.

An aim of some embodiments may be to provide an efficient or low-cost manner in which to mitigate negative effects that can be experienced during a calcination process as a result of an increasing circulation load of one or more volatiles being present within a calciner system, without limitation.

An aim of some embodiments may be to improve the quality of a final calcined product, or at least provide a manner in which to control or modify the composition of a final product of a calcination process, by extracting at least some of the volatile element(s) present within a calciner system, from the calciner system, thus regulating or reducing the overall content or concentration of the volatile element(s) present in the final product produced, without limitation.

An aim of some embodiments may be to provide a manner in which to reduce buildup of volatiles within a calciner system, whilst preventing loss of CO2, dilution of CO2, and/or changes to CO2 concentration within process gases leaving the calciner system, without limitation. BRIEF SUMMARY OF PREFERRED EMBODIMENTS

A process or method for managing a circulating load of volatiles within a calciner system is disclosed. A system, plant, flowsheet, or apparatus for practicing the process or method is also disclosed. The process or method and the system, plant, flowsheet, or apparatus are substantially shown in the accompanying figures.

A process or method for reducing concentrations of a volatile element (or a circulating load containing a volatile element), for reducing or mitigating buildup formations of a volatile element (or a circulating load containing a volatile element) in a preheater or calciner, for preventing destabilization of calciner system operation caused by cohesive behavior of material particles laden with high levels of one or more volatile elements, and/or for reducing the content or concentration of one or more volatile elements in a final (calcined) product is disclosed. The process or method may comprise the step of calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system.

The process or method may be characterized in that it comprises one or more of the following steps in any combination: maintaining one or more targeted volatile elements within the calciner cyclone preheater circuit in a vapor form or phase; extracting a portion or a fraction of process gas from the calciner cyclone preheater circuit at a temperature (or temperatures) at which the targeted volatile elements are maintained or remain in said vapor form or phase; preventing dilution and/or loss of CO2 within process gas within the calciner system; adjusting the quantity and/or changing the location of extracted process gas to control a circulating load or a total level of volatile elements circulating between the calciner and the calciner cyclone preheater circuit; reducing the potential for a circulating load (or a total level) of volatile elements circulating between the calciner and the calciner cyclone preheater circuit to grow to the extent at which material particles coated in condensed volatile elements become sufficiently cohesive to provide buildup formation and/or contribute to poor material particle flow(s); extracting a first portion or a fraction of CC -rich process gas containing particulates and volatile components in gaseous form from the calciner cyclone preheater circuit, at one or more locations of the calciner cyclone preheater circuit; extracting a second portion or a fraction of cooler CC -rich gas or off gas from the calciner cyclone preheater circuit; cooling an extracted first portion or fraction of CC -rich gas containing particulates and volatile components in gaseous form from the calciner cyclone preheater circuit by mixing it with, or directly or indirectly transferring heat to the extracted second portion or fraction using a quenching step, for example, using a quenching chamber provided to or within the calciner system; condensing and/or freezing the one or more volatile elements in a quenching chamber to facilitate subsequent removal of the one or more volatile elements from the calciner system via a filtration step, for example, using a filter provided to or within the calciner system; mixing an extracted portion or fraction of one or more process gases with preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen- depleted cooling gas to form a gas mixture; reducing a temperature of the gas mixture to below a boiling point or below a condensation temperature of one or more volatile elements within the gas mixture, by virtue of the step of mixing said extracted portion or fraction of one or more process gases with preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen-depleted cooling gas to form a gas mixture; promoting or encouraging one or more volatile elements within a gas mixture to take on a particulate form or adhere, adsorb, or absorb to material particles present in the gas mixture; mixing one or more extracted process gases with one or more cooling gases in a quenching chamber to provide a gas mixture, the gas mixture comprising one or more volatile elements therein; condensing at least some of the one or more volatile elements present within the gas mixture to produce a volatile element; preventing the volatile element condensation from contacting one or more wall surfaces of the quenching chamber, preheater circuit, and/or calciner; preventing buildup on the one or more wall surfaces of the quenching chamber by virtue of preventing the volatile element condensation from contacting one or more wall surfaces of a quenching chamber, the preheater circuit, and/or the calciner; separating one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements, from a cooled gas stream, by virtue of filtering the cooled gas stream within the calciner system using a filter provided to or within the calciner system; purging a separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system; controlling the level of circulating volatile elements within in the calciner system by virtue of the step of purging the separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system; mixing said extracted portion or fraction of the process gas with calciner string off-gas to form a cooled gas mixture which is at a temperature below the boiling point or condensation temperature of one or more volatile elements present in the cooled gas mixture; promoting or encouraging a transformation of the one or more volatile elements to a solid or particulate form, and/or promoting or encouraging the one or more volatile elements to enter a liquid form or phase which can adhere, adsorb, or absorb to material particles in a cooled gas mixture; maintaining a CO2 concentration in a cooled gas mixture, preventing loss of CO2, and/or preserving the concentration of CO2 in the cooled gas mixture; performing a CO2 extraction on a cooled gas mixture (e.g., using a CO2 purification unit (CPU)); producing a COs-rich exhaust gas using the calciner in the calciner system, ..the CO2- rich exhaust gas comprising more than about 70 wt% CO2 and less than about 98% wt% CO₂. producing a CO₂-rich exhaust gas using the calciner in the calciner system, Jhe CO2- rich exhaust gas comprising between about 75 wt% CO2 and 95% wt% CO2, without limitation.

In some non-limiting embodiments, the calciner system may use oxyfuel, without limitation. In some non-limiting embodiments, the calciner in the calciner system may comprise a flash calciner, without limitation. In some non-limiting embodiments, the calciner cyclone preheater circuit may comprise an oxyfuel calciner cyclone preheater circuit, without limitation. In some non-limiting embodiments, the calciner system may be configured as an oxyfuel flash calciner system, without limitation.

In some non-limiting embodiments, the calciner system may comprise a stationary or nonrotating calciner, without limitation. In some non-limiting embodiments, the calciner system comprises a Fluidized Bed (FB) or Circulating Fluid Bed (CFB) calciner, without limitation. In some non-limiting embodiments, the calciner system comprises an electric calciner, an electric heating unit, and/or a calciner comprising plasma torches, without limitation.

In some non-limiting embodiments, the one or more volatile elements contain or comprise: potassium (or compound(s) thereof), sodium (or compound(s) thereof), heavy metals, chloride(s) (or compound(s) thereof), alkalis (or compound(s) thereof), and/or sulfur (or compounds thereof), without limitation.

In some non-limiting embodiments, the one or more volatile elements within the calciner system are in a gaseous or vapor form or phase, a liquid or condensed form or phase, a frozen or solid form or phase, or in a transitory physical form or phase which is between frozen or solid forms or phases, without limitation.

A calciner system, plant, flowsheet, or apparatus may be provided in accordance with embodiments of the invention. The calciner system, plant, flowsheet, or apparatus may be configured to perform or enact the aforementioned process or method (or any one or combination of one or more of the aforementioned steps), without limitation.

In some embodiments, a calciner in the calciner system may be selected from at least one of the following: an oxyfuel calciner, a flash calciner, an oxyfuel flash calciner, a Fluidized Bed (FB) calciner, a Circulating Fluid Bed (CFB) calciner, an electric calciner, a calciner comprising plasma torches, a calciner comprising plasma torches and an electric heater, a biofuel-fired calciner, a hydrogen-fired calciner, a fossil fuel-fired calciner, an indirect heating or jacketed calciner, a stationary or non-rotating calciner, without limitation.

In some embodiments, the calciner system, plant, flowsheet, or apparatus may comprise a quenching chamber, for example which is located downstream of a preheater circuit and/or downstream of a de-dusting circuit (e.g., from a gas flow standpoint), without limitation.

In some embodiments, the calciner system, plant, flowsheet, or apparatus may comprise a filter; for example, a filter located downstream of the preheater circuit and downstream of a quenching chamber (e.g., from a gas flow standpoint), without limitation.

In some embodiments, the calciner system, plant, flowsheet, or apparatus may comprise a de-dusting circuit; for example, a de-dusting circuit located downstream of a preheater circuit and upstream of a quenching chamber (e.g., from a gas flow standpoint), without limitation.

In some embodiments, the calciner system comprises a de-dusting circuit between a cyclone preheater circuit and a quenching chamber, the de-dusting circuit being configured to recover and/or preserve particles which contain relatively low concentrations of volatile elements (as compared to concentrations of volatile elements contained by particles in the quenching chamber) from preheater off gas leaving the cyclone preheater circuit, without limitation.

In some embodiments, the process or method may be configured for reducing concentrations of a volatile element (or a circulating load containing a volatile element).

In some embodiments, the process or method may be configured for reducing or mitigating buildup formations of a volatile element (or a circulating load containing a volatile element) in a preheater or calciner. In some embodiments, the process or method may be configured for preventing destabilization of calciner system operation caused by cohesive behavior of material particles laden with high levels of one or more volatile elements. In some embodiments, the process or method may be configured for reducing the content or concentration of one or more volatile elements in a final (calcined) product. The process or method may be configured to perform one or more of the above aforementioned functions, without limitation.

The process or method may comprise the step of calcinating materials, for example, in a calciner system. The calciner system may have a calciner, and it may also have a calciner cyclone preheater circuit at one or more locations of the calciner system. In some embodiments, the process or method may be characterized in that it further comprises the steps of: maintaining one or more targeted volatile elements within the calciner cyclone preheater circuit in vapor form; extracting a portion or a fraction of the process gas from the calciner cyclone preheater circuit at a temperature (or temperatures) at which the targeted volatile elements are maintained in vapor form; and preventing dilution and/or loss of CO2 within process gas within the calciner system.

According to some embodiments, a process or method for reducing or mitigating concentrations of volatile element (or circulating load) or buildup formation of the same in a preheater or calciner, for reducing or mitigating destabilization of calciner system operation due to cohesive behavior of material particles laden with high levels of volatile elements, and/or for reducing the content or concentration of one or more volatile elements in a final (calcined) product, may comprise the step of calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system. The process or method may be characterized in that it further comprises the step of adjusting the quantity and/or changing the location of extracted process gas to control a circulating load or a total level of volatile elements circulating between the calciner and the calciner cyclone preheater circuit (or contained within the calciner system). The process or method may be characterized in that it further comprises the step of reducing the potential for this circulating load to grow to the extent at which material particles coated in condensed volatile elements become sufficiently cohesive to provide buildup formation and/or contribute to poor material particle flow.

According to some embodiments, a process or method for calcinating materials in a calciner system having a calciner and a cyclone preheater circuit at one or more locations of the calciner system may be characterized in that it comprises the step of extracting a portion or a fraction of gas containing particulates from the calciner cyclone preheater circuit at one or more locations, the particulates comprising one or more volatile elements in a condensed (e.g., liquid) or frozen (e.g., solid) state, such that the particulates can be filtered from the gases to remove them from the calciner system.

Another embodiment of a process or method for calcinating materials in a calciner system having a calciner and a cyclone preheater circuit at one or more locations of the calciner system is disclosed. The process or method in this embodiment may be characterized in that it comprises the step of extracting a portion or a fraction of gas containing particulates from the calciner cyclone preheater circuit at one or more locations, the portion or a fraction of gas comprising one or more volatile elements in a vapor (e.g., gaseous) state, such that the volatile elements can be subsequently cooled, wherein the volatile elements, when subsequently cooled, may be frozen (e.g., into solid particles) and/or condensed into a liquid form or phase which enables the particulates to adhere to, adsorb, or absorb the volatile elements. In this regard, the particulates/solid particles containing the volatile elements can be filtered from the extracted portion or a fraction of gas to remove them from the calciner system.

A process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system according to embodiments may be characterized in that process or method may comprise one or more of the following steps: extracting a first portion or a fraction of hot CC -rich gas containing particulates and volatile components in gaseous form from the calciner cyclone preheater circuit, at one or more locations of the calciner cyclone preheater circuit, extracting a second portion or a fraction of cooler CC -rich gas or off gas from the calciner cyclone preheater circuit, cooling the extracted first portion or fraction of hot CC -rich gas by mixing it with, or directly or indirectly transferring heat to, the extracted second portion or fraction of cooler 02-rich gas using a quenching chamber, condensing and/or freezing the one or more volatile elements in the quenching chamber, to facilitate subsequent removal of the one or more volatile elements from the calciner system via a filtration step.

It may be preferred that in some embodiments, the process or method step(s) are performed such that there is no substantial loss of CO2, change in concentration of CO2, or dilution of the extracted first (or second) portion or a fraction of CC -rich gas.

Additionally disclosed, is a process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system. The process or method may be characterized in that the process or method comprises one or more of the following steps: extracting a portion or a fraction of one or more process gases from within the calciner system; mixing said extracted portion or fraction of one or more process gases with preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen- depleted cooling gas to form a gas mixture; reducing a temperature of the gas mixture to below a boiling point or below a condensation temperature of one or more volatile elements within the gas mixture, by virtue of the step of mixing said extracted portion or fraction of one or more process gases with preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen-depleted cooling gas to form a gas mixture; encouraging the one or more volatile elements within the gas mixture to take on a particulate form or adhere, adsorb, or absorb to material particles present in the gas mixture.

According to some embodiments, a process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system may be characterized in that the process or method comprises one or more of the following steps: mixing one or more extracted process gases with one or more cooling gases in a quenching chamber to provide a gas mixture, the gas mixture comprising one or more volatile elements therein; condensing at least some of the one or more volatile elements present within the gas mixture to produce a volatile element condensation; preventing the volatile element condensation from contacting one or more wall surfaces of the quenching chamber, preheater circuit, and/or calciner; preventing buildup on the one or more wall surfaces of the quenching chamber by virtue of preventing the volatile element condensation from contacting one or more wall surfaces of the quenching chamber, preheater circuit, and/or calciner.

According to some embodiments, a process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system may be characterized in that the process or method comprises the step of reducing a circulating load of volatile components within the calciner system and/or reducing buildup of volatile components on wall surfaces of equipment within a calciner system (e.g., wall surfaces within cyclones of a calciner cyclone preheater circuit) by quenching hot CC -rich process gases from the calciner cyclone preheater circuit with cooler CC -rich process gases from the calciner cyclone preheater circuit in a quenching chamber. The process or method may further comprise the step of filtering the resulting cooled gas mixture in order to remove/purge particulates comprising frozen or condensed volatile components.

In some embodiments, a process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system may be characterized in that the process or method comprises one or more of the following steps: separating one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements, from the cooled gas stream, by virtue of filtering the cooled gas stream within the calciner system, purging the separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system; controlling the level of circulating volatile elements within in the calciner system by virtue of the step of purging the separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system.

In some embodiments, a process or method for calcinating materials in a calciner system having a calciner cyclone preheater circuit at one or more locations of the calciner system may be characterized in that the process or method comprises one or more of the following steps: extracting at least a portion or a fraction of process gas from the calciner system; mixing said extracted portion or fraction of the process gas with calciner string off-gas to form a cooled gas mixture which is at a temperature below the boiling point or condensation temperature of one or more volatile elements present in the cooled gas mixture; encouraging a transformation of the one or more volatile elements to a solid or p articulate form, and/or encouraging the one or more volatile elements to enter a liquid form which can adhere, adsorb, or absorb to material particles in the cooled gas mixture; maintaining a CO2 concentration in the cooled gas mixture, preventing loss of CO2, and/or preserving the concentration of CO2 in the cooled gas mixture; optionally, performing a CO2 extraction on the cooled gas mixture (e.g., using a

CO2 purification unit (CPU)).

In any of the proposed embodiments of the process or method disclosed above, the calciner system may be configured to use oxyfuel. In any of the proposed embodiments of the process or method disclosed above, the calciner in the calciner system may comprise a flash calciner. In any of the proposed embodiments of the process or method disclosed above, the calciner cyclone preheater circuit may comprise an oxyfuel calciner cyclone preheater circuit. In any of the proposed embodiments of the process or method disclosed above, the calciner system may be configured as an oxyfuel flash calciner system, without limitation.

In any of the proposed embodiments of the process or method disclosed above, the calciner system may comprise a stationary or non-rotating calciner, without limitation.

In any of the proposed embodiments of the process or method disclosed above, the calciner system may comprise a Gas Suspension calciner (GSC), without limitation.

In any of the proposed embodiments of the process or method disclosed above, the calciner system may comprise a Fluidized Bed (FB) or Circulating Fluid Bed (CFB) calciner, without limitation. In any of the proposed embodiments of the process or method disclosed above, the calciner system may comprise an electric calciner and/or a calciner comprising plasma torches, without limitation.

In any of the proposed embodiments of the process or method disclosed above, the calciner system may comprise an indirect heating calciner or a jacketed calciner which is configured for indirect heating, without limitation.

In any of the proposed embodiments of the process or method disclosed above, the process or method may further comprise the step of producing a CC -rich exhaust gas using a calciner in the calciner system. The CC -rich exhaust gas may comprise more than about 70 wt% CO2 and less than about 98% wt% CO2. For example, the CC -rich exhaust gas may comprise between about 75 wt% CO2 and 95% wt% CO2, without limitation.

In any of the proposed embodiments of the process or method disclosed above, the one or more volatile elements may contain or comprise: potassium (or compound(s) thereof), sodium (or compound(s) thereof), heavy metals, chloride(s) (or compound(s) thereof), sulfur (or compounds thereof), alkalis (or compound(s) thereof) , or a combination thereof, without limitation.

In any of the proposed embodiments of the process or method disclosed above, the one or more volatile elements within the calciner system may be in a gaseous or vapor phase, a liquid or condensed phase, a frozen or solid phase, and/or in a transitory physical form between phases, without limitation.

A calciner system, plant, flowsheet, or apparatus is also disclosed. Preferred embodiments of such a calciner system, plant, flowsheet, or apparatus may be configured to perform or enact any one of the processes or methods described above, or any one or more of the steps described above, without limitation.

In some embodiments of the calciner system, plant, flowsheet, or apparatus, a calciner in the calciner system calciner system, plant, flowsheet, or apparatus may be selected from at least one of the following: an oxyfuel calciner, a flash calciner, an oxyfuel flash calciner, a Fluidized Bed (FB) calciner, a Circulating Fluid Bed (CFB) calciner, an electric calciner, a calciner comprising plasma torches, a calciner having plasma torches and an electric heater, a biofuel-fired calciner, a hydrogen-fired calciner, a fossil fuel-fired calciner, an indirect heating or jacketed calciner, and a stationary or non- rotating calciner, without limitation.

Some embodiments of the calciner system, plant, flowsheet, or apparatus may comprise a quenching chamber. Some embodiments of the calciner system, plant, flowsheet, or apparatus may comprise a filter, for example, a filter located downstream of the preheater circuit (and/or downstream of a quenching chamber). Some embodiments of the calciner system, plant, flowsheet, or apparatus may comprise a de-dusting circuit; for example, a de-dusting circuit located downstream of a preheater circuit and upstream of a quenching chamber (from a gas flow standpoint).

Some embodiments of the calciner system, plant, flowsheet, or apparatus may optionally comprise a de-dusting circuit. The de-dusting circuit may be positioned or located between a cyclone preheater circuit and a quenching chamber, without limitation. The de-dusting circuit may be configured to recover and/or preserve particles which contain relatively low concentrations of volatile elements (as compared to particles in the quenching chamber) from preheater of gas leaving the preheater circuit.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures are intended representative in nature, and are being provided to enable the reader to more clearly understand the claimed invention. The accompanying figures are not to be construed as limiting. The figures may portray certain features or elements or conditions to facilitate understanding of the invention. These features or elements or conditions should not be construed as limiting the claimed invention.

Moreover, certain features or elements or conditions may not be expressly depicted in the accompanying figures. It should be understood that those skilled in the art may add or remove certain features or elements or conditions to the depicted embodiments without substantially departing from the scope and spirit of the claimed invention. FIG. 1 depicts an example PFD according to one particular non-limiting embodiment in accordance with the invention. In the particular embodiment depicted, a gas suspension calciner (GSC) is employed; however, other types of calciners may be alternatively used, without limitation. As suggested in the particular embodiment shown in FIG. 1 , while not required, a holding vessel downstream of the calciner may be optionally present within a calciner system according to some embodiments. As shown, this holding vessel, if present, can be vented to a quenching chamber (via return line G7) in accordance with certain non-limiting embodiments. Moreover, while not necessarily required, secondary string hot air for drying feed may be optionally present within a calciner system according to some embodiments, without limitation. Additionally, while the cooling circuit depicted suggests the use of cooling cyclones and a cooler, it should be understood that additional or alternative downstream calciner cooling circuit equipment (e.g., heat exchangers) may be employed, without limitation.

FIG. 2 depicts a more simplified PFD (i.e., “process island”) which has been derived from a portion of FIG. 1. As depicted, the process island comprises a novel quenching chamber. The process island may comprise means (e.g., piping, dampers, connectors) which are configured to convey one or more process gases or supplemental cooling gases that are nitrogen- and/or oxygen-depleted to the quenching chamber. It is preferred that the process island is sealed or isolated from ambient atmosphere so as to be configured to prevent loss of CO2 to the atmosphere, avoid dilution of process gas within the calciner system, or incur changes in the concentration of CO2 within process gases in calciner system. FIG. 2 further suggests that the use of the holding vessel downstream of the calciner may be optional for certain embodiments, and/or that the use of the secondary string hot air for feed drying in FIG. 1 may be optional for certain embodiments.

It should be understood that some embodiments of the depicted process island may omit certain depicted features, elements, or conditions, or include certain non- depicted features, elements, or conditions, without limitation. As shown, the process island may contain a quenching chamber configured for receiving an elevated temperature process gas (i.e., gas comprising volatiles in gaseous form) and it may be configured for receiving a lower temperature gas (i.e., process gas such as off gas from one or more locations of a cyclone preheater circuit). Embodiments of the process island depicted may or may not expressly comprise the calciner reactor (e.g., oxyfuel flash calciner), process gas, exhaust gas (e.g., oxyfuel exhaust gas) leaving the calciner reactor, bypass gas (G11 ) leaving the cyclone preheater circuit, optionally-vented gas (G7) leaving an optional holding vessel or calciner, or other optional cooling gas stream(s) entering the quenching chamber for cooling a process gas.

The process island (or portions thereof) may be provided as part of a retrofit solution to modify an existing brownfield calciner system installation. The process island (or portions thereof) may be supplied with a calciner system (or portion thereof) in conjunction with the installation of a greenfield calciner system installation. While not expressly shown or depicted, a fan or blower may be provided between G16 and G17, without limitation. While not expressly shown or depicted, a fan or blower may be provided along cooled mixed gas stream G18

- and such a fan may be used to control the gas bypass rate, without limitation. As suggested in the figure, an optional de-dusting circuit may be provided between the cyclone preheater circuit and the quenching chamber, and this may form a portion of the process island, without limitation.

FIG. 3 depicts an alternative PFD according to another non-limiting embodiment in accordance with the invention. As suggested by the particular embodiment shown, the quenching chamber may not receive vented process gas (G7, FIGS. 1 & 2) from the calciner and/or holding vessel. As suggested, a stream of rich CO2 gas which has been depleted of filtered/purged of volatiles is produced.

While certain features or elements may be included and shown in the figures for clearer understanding of the invention, it should be understood that not all embodiments of the invention will comprise all or each and every one of the features depicted in each figure. Rather certain depicted features or elements may be optionally omitted for some embodiments, without limitation. Moreover, additional features or elements may be optionally introduced to any one of the figures, without limitation. Accordingly, the embodiments depicted in the figures should not be used to improperly narrow the accompanying claims, but should only be used for understanding practical use applications of the inventive concepts discussed herein.

DETAILED DESCRIPTION OF EMBODIMENTS

According to some non-limiting embodiments of the invention, a process or method may entail the step of removing a portion of the gas leaving a flash calciner and/or a cyclone preheater circuit, where the volatile elements may be present in a vapor form.

Hot gas within the oxyfuel flash calciner system (e.g., a gas which may contain volatile elements present in a vapor form) may be cooled in a special chamber, such as a quenching chamber. Cooling of process gases within the quenching chamber may be performed, for example, via an injection of a lower temperature gas. This lower temperature gas is preferably nitrogen- and/or oxygen-depleted. In some embodiments, a low temperature calciner cyclone preheater off gas may be used as a cooling gas. In some embodiments, CO2 or steam may be used as a cooling gas. In some limited circumstances, air or a gas ‘enriched’ in CO2 or depleted in nitrogen and oxygen may be used as a cooling gas within the quenching chamber. In most embodiments, it is preferrable for gases within the quenching chamber to maintain high levels of CO2 concentration, and thus utilizing a cooler process gas leaving a portion of the calciner system (e.g., preheater circuit off gas) is preferably used as the cooling gas, without limitation.

In some non-limiting embodiments, it may be preferable to configure the quenching chamber such that it remains environmentally-isolated or sealed from the surrounding environment in order to prevent dilution of process gas with ambient air. However, it is possible to introduce air to the quenching chamber as a cooling gas in a less-preferred embodiment. In most preferred embodiments, a cooler process gas from within the calciner system is used to precipitate or condense out gaseous volatiles residing within a hotter process gas within the calciner system. The hotter process gas may be extracted from one or more portions of the calciner system and diverted to the quenching chamber. The cooler process gas may be extracted from one or more portions of the calciner system and diverted to the quenching chamber.

The cooler process gas may be extracted, for example, from an upper region of a calciner cyclone preheater circuit, without limitation. The cooler process gas may enter an intermediate de-dusting circuit before entering the quenching chamber, without limitation. The cooler process gas could optionally be used alone within the quenching chamber, or it may mix with a combination of one or more of the aforementioned lower temperature cooling gases, in order to cool down the hotter process gas, without limitation. Injection of lower temperature gases to the quenching chamber may involve some mixing of gases to form a cooler mixed gas. However, it is also contemplated that cooling gases may indirectly transfer heat from the hotter process gas at the quenching chamber (e.g., via thermal heat exchange), wherein the hotter and cooler process gases do not physically mix.

Within the quenching chamber, the lower temperature mixed gas may help to condense and/or freeze the volatile elements which may be present in the hot gas in vapor form. In their cooler state, the volatile elements may freeze to form solids or particulates that can precipitate and be filtered out of the cooled gas mixture. Or, the volatile elements may, in their cooled condensed state, adhere, adsorb, or absorb to other suspended particulate materials within process gases of the calciner system, thereby facilitating separation (e.g., via filtration).

After the volatile elements are cooled, condensed, adsorbed, absorbed, and/or frozen in the quenching chamber, they may be subsequently separated (e.g., filtered) from the resultant cooled gas mixture stream leaving the quenching chamber, and removed or purged from the calciner system (e.g., at reference “M13” in FIG. 1 ).

This purge process aims to regulate the circulating load of volatile elements recirculating within the calciner system. The purge process helps control and maintain a concentration of volatile elements within the calciner system to within a level (or levels) at which the material particles are not cohesive, and thus, the material particles do not contribute to buildup formations on wall surfaces, calciner destabilization, and/or end products having chemical compositions that are high in volatile components. The hot gas cooling/quenching step may be performed in a variety of ways, for example, by mixing with one or more cooler gases, or by running the hot gas through a heat exchanger, without limitation. Thus, the prescribed quenching chamber may take on many different forms and configurations, without limitation.

Regardless of the means or manner used to cool/quench hot gases, it should be understood by those skilled in the art that cooling/quenching using process gas (e.g., oxyfuel string off gas, calciner cyclone preheater circuit gas, or the like) may provide an advantageous technical effect. For example, using cooler oxyfuel string off gas may serve as means to cool/quench hot process gases to isolate volatile element(s), change a physical state of volatile element(s) from a vaper form to a liquid (i.e., condensed) or solid (i.e., frozen) form, as well keep the CO2 concentration in the hot process gases and offgas unchanged (as compared to quenching with gases such as air, CO2, nitrogen, oxygen, or a combination thereof). Using process gas(es) for cooling also avoids the need for other cooling apparatus.

In some embodiments, using a process gas, such as oxyfuel string off gas, to cool/quench a hot gas may provide the benefit of not losing (or “retaining”) the quantity of CO2 extracted by the bypass gas (G1 1 ). Using a process gas (e.g., G16) for cooling bypass gas (G11 ), without the use of supplemental air to cool/quench in the quenching chamber preserves a high level of CO2 concentration whilst preserving CO2 recovery rates.

In some embodiments, a process or method may involve extracted process gases being mixed with oxyfuel string off-gas. This may reduce the temperature of the resulting gas mixture to below the boiling point or condensation temperature of the volatile elements in the extracted process gases. As such, the volatile elements may become particulate in form or adhere to other material particles suspended within the extracted process gases. This is all accomplished whilst the CO2 concentration in the extracted gas stream(s) can be maintained or remain unchanged, which is advantageous for subsequent CO2 extraction/carbon capture. Said differently, quantities or concentrations of CO2 in the extracted bypass gas (G1 1 ) can be prevented from being lost, diluted, or altered by using process gas to cool it.

It should be understood that an oxyfuel flash calciner system described herein may comprise embodiments where feed is dry, and gases are extracted from a preheat string within the calciner system, without limitation. It should also be understood that some non- limiting embodiments may include a flash drier string provided within a calciner system described herein. Embodiments may have enhanced applicability to oxyfuel flash calciner systems, without limitation.

Turning now to FIG. 1 , a non-limiting example of a calcination process comprising a calciner is depicted. The calciner can be of any preferrable type, such as a gas suspension calciner (GSC) as shown, without limitation. Preferably, the calciner is a stationary or non-rotary calciner. The calciner may comprise an electric calciner (e.g., a calciner comprising plasma torches), or it may comprise a flash calciner such as an oxyfuel flash calciner, without limitation. Optionally, an indirectly-heated calciner or jacketed calciner can be used in embodiments of a calciner system disclosed herein.

As shown, an optional holding vessel may be employed in the calciner system, for example, downstream of the calciner as depicted, without limitation. An optional dryer may be employed in the calciner system, as depicted without limitation. A quenching chamber may be used to mix a portion or fraction of a hot process gas with a cooler temperature gas, such as process gas. As depicted, an off gas (G10, G16, G17) of a cyclone preheater circuit, may be used as a cooling gas to form a cooler gas mixture. As depicted, hot gas (G7, G1 1 ) provided to the quenching chamber may be derived from one or more portions of the calciner system, such as from a lower portion of a cyclone preheater circuit, a slipstream from the calciner, or a vented return from a holding vessel, without limitation.

Due to the reduction in temperature of the hot process gas sent to the quenching chamber, any entrained vaporized volatiles are either frozen and precipitate out as solid particulates, or they are condensed, such that they may adhere to, or become adsorbed or absorbed with other particles, particulates, or materials suspended within the gas mixture.

The cooled gas mixture (G18) leaving the quenching chamber can be sent to a cooling tower to supplementally cool the gas mixture (G18) leaving the quenching chamber. The resulting gas stream (G19, G20) can then be filtered to separate out and purge the volatiles. For example, a baghouse or dry filtration circuit may be utilized. While not depicted, an optional liquid removal step may optionally be employed to remove excess moisture from the cooled gas mixture (G18), should there be instances where the rate of condensation of volatiles exceeds the capacity to bind to dry particulates (saturation limit) - or, if steam is optionally used to supplementally cool gas in the quenching chamber.

The separation/filtration step may incorporate an electrostatic precipitator (ESP) unit, without limitation. It should be understood that while the by-pass stream (G1 1 ) is shown to come from one or more portions of a calciner cyclone preheater circuit, and optionally from a holding vessel (G7), a by-pass stream may also come directly from one or more portions of the calciner stage, without limitation. Such a configuration may be practiced in particular relation to embodiments which may not incorporate the optional holding vessel depicted.

Turning now to FIG.2, an abbreviated “process island” portion of the flowsheet depicted in FIG. 1 is presented. FIG. 2 suggests that some embodiments may comprise only a portion of a calciner system. The portion may be configured with steps and/or equipment to retrofit an existing calciner system installation that is experiencing problems due to buildup of volatiles or increased circulation loads of volatiles within the calciner system. The process island may be configured with a quenching chamber and means for receiving a portion or fraction of hot process gas (e.g., by virtue of provision of a slipstream or bypass (G1 1 ) or other means (e.g., optional holding vessel vent return G7) for transferring hot process gas directly or indirectly from a calciner) from one or more locations of the calciner system.

The process island may also be configured to include means (G10, G16, G17) for receiving a portion or fraction of off gas from one or more locations of a cyclone preheater circuit. This off gas may be used as a cooling gas, and may or may not optionally include other cooling gases such as CO2, steam, CO2 enriched air, or other nitrogen- or oxygen- depleted gas. Accordingly, the process island may comprise additional means (not shown) for receiving one or more supplemental cooling gases to the quenching chamber. The quenching chamber is preferably configured for cooling hot process gas containing vaporized volatiles with process gas derived from one or more other locations within the calciner system and produce a cooled gas mixture (e.g., a gas mixture between approximately 300 and 600 °C), without limitation. The calciner, itself, may or may not form a portion of the process island. The process island (or portions thereof) may be adapted to be retrofitted in whole, or in part, to an existing brownfield calciner system installation, without limitation.

Turning now to FIG. 3, an alternative PFD depicting a slightly alternative embodiment is shown. FIG. 3 suggests that oxygen (02) and a fuel such as natural gas (NG) may be used to operate the calciner. Thus, in some preferred embodiments, the calciner may comprise a gas suspension calciner (GSC) or an oxyfuel flash calciner, without limitation. As discussed above for FIGS. 1 and 2, the holding vessel and/or dryer depicted in FIG. 3 are purely optional portions of a process island according to some preferred embodiments. Moreover, the downstream cooling circuit may change or vary from what is depicted.

As shown, the bypass (G1 1 ) shown in FIG. 3 may originate from a hotter, lower portion of the cyclone preheater circuit. While not shown, the by-pass(es) may alternatively or additionally originate from one or more other locations (e.g., calciner or holding vessel) within the calciner system, without limitation. Similar to FIGS. 1 and 2, the embodiment shown in FIG. 3 depicts a cooling tower and subsequent filtration circuit for separation and removal of volatiles. The cooling tower and/or or filtration circuit may optionally form a portion of the process island shown in FIG. 2 in certain anticipated embodiments. As with FIGS. 1 and 2, the flowsheet shown in FIG. 3 produces a rich CO2 stream and a stream of purged material laden with volatile components. The purged material may comprise frozen volatile elements in solid or particulate form. The purged material may comprise condensed volatile elements in liquid form which has adhered, adsorbed, absorbed onto other particulate solid materials, without limitation.

A process island according to some preferred embodiments may comprise a cooling or “quenching” chamber for condensing, adsorbing, absorbing, or freezing volatiles out of vapor form. This may be accomplished, for example, by cooling a stream of hot process gas derived from a cyclone preheater circuit (or cyclone therein), a calciner, an optional holding vessel, and/or any other portion of a calciner system, without limitation. The hot process gas contains vaporized volatiles in gaseous form. The hot process gas may be cooled by another process gas, and/or steam or a CO2-enriched gas (e.g., CO2 or CO2- enriched air). One or more different types of cooling gases may be used in the quenching chamber. For example, ambient air may or may not be optionally used to supplementally cool hot process gases in the quenching chamber, without limitation. Off gas (G16, G17) from the cyclone preheater circuit may be used to feed the quenching chamber, and/or to provide cooling to the hot process gases, without limitation. Bypass gas (G11 ) may be fed to the quenching chamber, without limitation.

The cooling and filtering and purging processes downstream of the cooling/quenching steps depicted in the figures may vary from the embodiments depicted in the figures. In some embodiments, purged dust may be recycled to the calciner. In some embodiments, purging of volatiles may occur from the electrostatic precipitation (ESP) unit. In some embodiments, one or more fans may be employed downstream of the calciner cyclone preheater circuit, quenching chamber, cooling tower, or filtration circuit. In some embodiments a de-dusting circuit may be employed to process cooling process gas entering the quenching chamber. In some embodiments, a CO2 removal/take off unit may be provided to a calciner system and/or used or practiced with embodiments of the process and method disclosed herein.

EXAMPLE

In some embodiments, there may be a large economic benefit (e.g., lower operating cost in terms of lower fuel consumption) to installing a gas bypass (G1 1 ) system and/or a cooling (i.e., “quench”) chamber within an oxyfuel flash calciner system, in order to more efficiently process materials with elevated volatile matters and/or to reduce problems outlined in the background section of this application.

While more costly from a capital expenditure (CAPEX) point of view, it is possible that such a configuration could handle processing material containing elevated volatile elements despite the oxyfuel flash calciner system having an oxyfuel string with only one (single) cyclone.

In such embodiments, the calciner may be responsible for both preheating and calcining the feed material in a high fuel consumption mode of operation. The one (single) cyclone off-gas can be quenched (in a gas bypass system and/or a specially-purposed cooling (i.e., “quenching”) chamber before and/or after entering an optional dust collector or dedusting circuit. As depicted in FIGS. 1 and 2, this optional dust collector or de-dusting circuit may be provided between the cyclone preheater circuit and the quenching chamber, without limitation. The optional dust collector or de-dusting circuit may comprise suitable means for de-dusting, such as a bag filter, a baghouse, an electrostatic precipitator (ESP), a Multiclone Dust Collector (MDC), or a combination thereof, without limitation.

Quenching the off gas will encourage and/or cause the volatiles to condense onto dust particles, which will then be purged out of the system later (e.g., downstream). Quenching may be done after off gas is processed by a dust collector. Due to the high off-gas temperature(s) coming from the calciner, this type of configuration would preferably incorporate multiple steps or stages of cooling (e.g., through the use of one or more gas conditioning towers). Accordingly, this type of configuration would not utilize the sensible heat hot off-gas to preheat fresh feed entering the preheater string of the oxyfuel flash calciner system in its high fuel consumption mode of operation.

It should be noted that where used herein, the language “one or more of the following steps” and/or the language “at least one of the following steps” may include or comprise a single method step, or a plurality of method steps. Therefore, various different combinations of recited steps herein are anticipated, without limitation. This language may, in certain embodiments, mean “only one step”, “two or more” steps, “three or more” steps, “four or more” steps, etc. The inventors anticipate many different possible novel and inventive combinations of the method steps discussed and recited herein, without limitation to a specific combination or grouping of recited steps.

Claims

CLAIMS:

1 . A process or method for reducing concentrations of a volatile element (or a circulating load containing a volatile element), for reducing or mitigating buildup formations of a volatile element (or a circulating load containing a volatile element) in a preheater or calciner, for preventing destabilization of calciner system operation caused by cohesive behavior of material particles laden with high levels of one or more volatile elements, and/or for reducing the content or concentration of one or more volatile elements in a final (calcined) product, the process or method comprising the step of: calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system;

CHARACTERISED IN THAT the process or method further comprises the following steps: maintaining one or more targeted volatile elements within the calciner cyclone preheater circuit in a vapor form or phase; and extracting a portion or a fraction of process gas from the calciner cyclone preheater circuit at a temperature (or temperatures) at which the targeted volatile elements are maintained or remain in said vapor form or phase.

2 The process or method according to claim 1 , comprising the step of: preventing dilution and/or loss of CO2 within process gas within the calciner system.

3 The process or method according to any one of the preceding claims, comprising the step of: adjusting the quantity and/or changing the location of extracted process gas to control a circulating load or a total level of volatile elements circulating between the calciner and the calciner cyclone preheater circuit.

4 The process or method according to any one of the preceding claims, comprising the step of: reducing the potential for a circulating load ( or a total level) of volatile elements circulating between the calciner and the calciner cyclone preheater circuit to grow to the extent at which material particles coated in condensed volatile elements become sufficiently cohesive to provide buildup formation and/or contribute to poor material particle flow(s).

5. The process or method according to any one of the preceding claims, comprising the step of: extracting a first portion or a fraction of CC -rich process gas containing particulates and volatile components in gaseous form from the calciner cyclone preheater circuit, at one or more locations of the calciner cyclone preheater circuit.

6 The process or method according to any one of the preceding claims, comprising the step of: extracting a second portion or a fraction of cooler CC -rich gas or off gas from the calciner cyclone preheater circuit.

7 The process or method according to any one of the preceding claims, comprising the step of: cooling an extracted first portion or fraction of CC -rich gas containing particulates and volatile components in gaseous form from the calciner cyclone preheater circuit by mixing it with, or directly or indirectly transferring heat to the extracted second portion or fraction using a quenching step, for example, using a quenching chamber provided to or within the calciner system.

8 The process or method according to any one of the preceding claims, comprising the step of: condensing and/or freezing the one or more volatile elements in a quenching chamber to facilitate subsequent removal of the one or more volatile elements from the calciner system via a filtration step, for example, using a filter provided to or within the calciner system.

9 The process or method according to any one of the preceding claims, comprising the step of: mixing an extracted portion or fraction of one or more process gases with preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen-depleted cooling gas to form a gas mixture.

10 The process or method according to any one of the preceding claims, comprising the step of:

- reducing a temperature of the gas mixture to below a boiling point or below a condensation temperature of one or more volatile elements within the gas mixture, by virtue of the step of mixing said extracted portion or fraction of one or more process gases with preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen-depleted cooling gas to form a gas mixture.

11 . The process or method according to any one of the preceding claims, comprising the step of: promoting or encouraging one or more volatile elements within a gas mixture to take on a particulate form or adhere, adsorb, or absorb to material particles present in the gas mixture.

12. The process or method according to any one of the preceding claims, comprising the step of: mixing one or more extracted process gases with one or more cooling gases in a quenching chamber to provide a gas mixture, the gas mixture comprising one or more volatile elements therein.

13. The process or method according to any one of the preceding claims, comprising the step of: condensing at least some of the one or more volatile elements present within the gas mixture to produce a volatile element condensation.

14. The process or method according to any one of the preceding claims, comprising the step of: preventing the volatile element condensation from contacting one or more wall surfaces of the quenching chamber, preheater circuit, and/or calciner.

15. The process or method according to any one of the preceding claims, comprising the step of: preventing buildup on the one or more wall surfaces of the quenching chamber by virtue of preventing the volatile element condensation from contacting one or more wall surfaces of a quenching chamber, the preheater circuit, and/or the calciner.

16. The process or method according to any one of the preceding claims, comprising the step of: separating one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements, from a cooled gas stream, by virtue of filtering the cooled gas stream within the calciner system using a filter provided to or within the calciner system.

17. The process or method according to any one of the preceding claims, comprising the step of: purging a separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system.

18. The process or method according to any one of the preceding claims, comprising the step of: controlling the level of circulating volatile elements within in the calciner systemby virtue of the step of purging the separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system.

19. The process or method according to any one of the preceding claims, comprising the step of: mixing said extracted portion or fraction of the process gas with calciner string off-gas to form a cooled gas mixture which is at a temperature below the boiling point or condensation temperature of one or more volatile elements present in the cooled gas mixture.

20. The process or method according to any one of the preceding claims, comprising the step of: promoting or encouraging a transformation of the one or more volatile elements to a solid or particulate form, and/or promoting or encouraging the one or more volatile elements to enter a liquid form or phase which can adhere, adsorb, or absorb to material particles in a cooled gas mixture.

21 . The process or method according to any one of the preceding claims, comprising the step of: maintaining a CO2 concentration in a cooled gas mixture, preventing loss of CO2, and/or preserving the concentration of CO2 in the cooled gas mixture.

22. The process or method according to any one of the preceding claims, comprising the step of: performing a CO2 extraction on a cooled gas mixture (e.g., using a CO2 purification unit

(CPU)).

23. The process or method according to any one of the preceding claims, wherein the calciner system uses oxyfuel, the calciner in the calciner system comprises a flash calciner, the calciner cyclone preheater circuit is an oxyfuel calciner cyclone preheater circuit, and/or the calciner system is configured as an oxyfuel flash calciner system.

24. The process or method according to any one of the preceding claims, wherein the calciner system comprises a stationary or non-rotating calciner.

25. The process or method according to any one of the preceding claims, wherein the calciner system comprises a Fluidized Bed (FB) or Circulating Fluid Bed (CFB) calciner.

26. The process or method according to any one of the preceding claims, wherein the calciner system comprises an electric calciner, an electric heating unit, and/or a calciner comprising plasma torches.

27. The process or method according to any one of the preceding claims, further comprising the step of: producing a CC -rich exhaust gas using the calciner in the calciner system, the CC -rich exhaust gas comprising more than about 70 wt% CO2 and less than about 98% wt% CO2.

28. The process or method according to any one of the preceding claims, comprising the step of: producing a CC -rich exhaust gas using the calciner in the calciner system, the CC -rich exhaust gas comprising between about 75 wt% CO2 and 95% wt% CO2.

29. The process or method according to any one of the preceding claims, wherein the one or more volatile elements contain or comprise: potassium (or compound(s) thereof), sodium (or compound(s) thereof), heavy metals, chloride(s) (or compound(s) thereof), alkalis (or compound(s) thereof), and/or sulfur (or compounds thereof).

30. The process or method according to any one of the preceding claims, wherein the one or more volatile elements within the calciner system are in a gaseous or vapor form or phase, a liquid or condensed form or phase, a frozen or solid form or phase, or in a transitory physical form or phase which is between frozen or solid forms or phases.

31 . A calciner system, plant, flowsheet, or apparatus which is configured to perform or enact the process or method described in any one of the preceding claims.

32. The calciner system, plant, flowsheet, or apparatus according to claim 31 , wherein a calciner in the calciner system is selected from at least one of the following: an oxyfuel calciner, a flash calciner, an oxyfuel flash calciner, a Fluidized Bed (FB) calciner, a Circulating Fluid Bed (CFB) calciner, an electric calciner, a calciner comprising plasma torches, a calciner comprising plasma torches and an electric heater, a biofuel-fired calciner, a hydrogen-fired calciner, a fossil fuel-fired calciner, an indirect heating or jacketed calciner, and a stationary or non-rotating calciner.

33. The calciner system, plant, flowsheet, or apparatus according to claim 31 or 32, further comprising a quenching chamber.

34. The calciner system, plant, flowsheet, or apparatus according to any one of claims 31 -33, further comprising a filter; for example, a filter located downstream of the preheater circuit and downstream of a quenching chamber.

35. The calciner system, plant, flowsheet, or apparatus according to any one of claims 31 -34, further comprising a de-dusting circuit; for example, a de-dusting circuit located downstream of a preheater circuit and upstream of a quenching chamber (e.g., from a gas flow standpoint).

36. The calciner system, plant, flowsheet, or apparatus according to any one of claims 31 -35, wherein the calciner system comprises a de-dusting circuit between a cyclone preheater circuit and a quenching chamber, the de-dusting circuit being configured to recover and/or preserve particles which contain relatively low concentrations of volatile elements (as compared to concentrations of volatile elements contained by particles in the quenching chamber) from preheater off gas leaving the cyclone preheater circuit.

37. A process or method for reducing concentrations of a volatile element (or a circulating load containing a volatile element), for reducing or mitigating buildup formations of a volatile element (or a circulating load containing a volatile element) in a preheater or calciner, for preventing destabilization of calciner system operation caused by cohesive behavior of material particles laden with high levels of one or more volatile elements, and/or for reducing the content or concentration of one or more volatile elements in a final (calcined) product, the process or method comprising the step of: calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system;

CHARACTERISED IN THAT the process or method further comprises the following steps: maintaining one or more targeted volatile elements within the calciner cyclone preheater circuit in vapor form; extracting a portion or a fraction of the process gas from the calciner cyclone preheater circuit at a temperature (or temperatures) at which the targeted volatile elements are maintained in vapor form; and preventing dilution and/or loss of CO2 within process gas within the calciner system.

38. A process or method for reducing or mitigating concentrations of volatile element (or circulating load) or buildup formation of the same in a preheater or calciner, for reducing or mitigating destabilization of calciner system operation due to cohesive behavior of material particles laden with high levels of volatile elements, and/or for reducing the content or concentration of one or more volatile elements in a final (calcined) product, the process or method comprising the step of: calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system;

CHARACTERISED IN THAT the process or method further comprises one or both of the following steps: adjusting the quantity and/or changing the location of extracted process gas to control a circulating load or a total level of volatile elements circulating between the calciner and the calciner cyclone preheater circuit; reducing the potential for this circulating load to grow to the extent at which material particles coated in condensed volatile elements become sufficiently cohesive to provide buildup formation and/or contribute to poor material particle flow.

39. A process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system, CHARACTERISED IN THAT the process or method comprises one or more of the following steps: extracting a first portion or a fraction of CC -rich gas containing particulates and volatile components in gaseous form from the calciner cyclone preheater circuit, at one or more locations of the calciner cyclone preheater circuit, extracting a second portion or a fraction of cooler CC -rich gas or off gas from the calciner cyclone preheater circuit, cooling the extracted first portion or fraction by mixing it with, or directly or indirectly transferring heat to the extracted second portion or fraction using a quenching chamber, condensing and/or freezing the one or more volatile elements in the quenching chamber to facilitate subsequent removal of the one or more volatile elements from the calciner system via a filtration step.

40. A process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system, CHARACTERISED IN THAT the process or method comprises one of the following steps or a combination of one or more of the following steps: extracting a portion or a fraction of one or more process gases from within the calciner system which contain volatile elements; mixing said extracted portion or fraction of one or more process gases with preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen-depleted cooling gas to form a gas mixture; reducing a temperature of the gas mixture to below a boiling point or below a condensation temperature of one or more volatile elements within the gas mixture, by virtue of the step of mixing said extracted portion or fraction of one or more process gases with said preheater off gas from the calciner cyclone preheater circuit and/or with another nitrogen- or oxygen-depleted cooling gas to form a gas mixture; promoting or encouraging the one or more volatile elements within the gas mixture to take on a particulate form or adhere, adsorb, or absorb to material particles present in the gas mixture.

41 . A process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system, CHARACTERISED IN THAT the process or method comprises one or more of the following steps: mixing one or more extracted process gases with one or more cooling gases in a quenching chamber to provide a gas mixture, the gas mixture comprising one or more volatile elements therein; condensing at least some of the one or more volatile elements present within the gas mixture to produce a volatile element condensation; preventing the volatile element condensation from contacting one or more wall surfaces of a quenching chamber, preheater circuit, and/or calciner; preventing buildup on the one or more wall surfaces of the quenching chamber by virtue of preventing the volatile element condensation from contacting one or more wall surfaces of the quenching chamber, preheater circuit, and/or calciner.

42. A process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system, CHARACTERISED IN THAT the process or method comprises one or more of the following steps: separating one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements, from a cooled gas stream, by virtue of filtering the cooled gas stream within the calciner system, purging the separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system; controlling the level of circulating volatile elements within in the calciner systemby virtue of the step of purging the separated one or more condensed, adsorbed, absorbed, or frozen volatile elements and/or associated material particles which may contain or which may be attached to one or more volatile elements from the calciner system.

43. A process or method for calcinating materials in a calciner system having a calciner and a calciner cyclone preheater circuit at one or more locations of the calciner system, CHARACTERISED IN THAT the process or method comprises one or more of the following steps: extracting at least a portion or a fraction of the process gas which contains volatile elements; mixing said portion or fraction of the extracted process gas with calciner string off-gas to form a cooled gas mixture which is at a temperature below the boiling point or condensation temperature of one or more volatile elements present in the cooled gas mixture; promoting or encouraging a transformation of the one or more volatile elements to a solid or particulate form, and/or promoting or encouraging the one or more volatile elements to enter a liquid form or phase which can adhere, adsorb, or absorb to material particles in the cooled gas mixture; maintaining a CO2 concentration in the cooled gas mixture, preventing loss of CO2 in the cooled gas mixture, and/or preserving the concentration of CO2 in the cooled gas mixture; performing a CO2 extraction on the cooled gas mixture (e.g., using a CO2 purification unit

(CPU)).

44. The process or method according to any one of claims 37-43, wherein the calciner system uses oxyfuel, the calciner in the calciner system comprises a flash calciner, the calciner cyclone preheater circuit is an oxyfuel calciner cyclone preheater circuit, and/or the calciner system is configured as an oxyfuel flash calciner system.

45. The process or method according to any one of claims 37-44, wherein the calciner system comprises a stationary or non-rotating calciner.

46. The process or method according to any one of claims 37-45, wherein the calciner system comprises a Fluidized Bed (FB) or Circulating Fluid Bed (CFB) calciner.

47. The process or method according to any one of claims 37-46, wherein the calciner system comprises an electric calciner, an electric heating unit, and/or a calciner comprising plasma torches.

48. The process or method according to any one of claims 37-47, comprising the step of: producing a CC -rich exhaust gas using a calciner in the calciner system, the CC -rich exhaust gas comprising more than about 70 wt% CC and less than about 98% wt% CO2.

49. The process or method according to any one of claims 37-48, comprising the step of: producing a CC -rich exhaust gas using a calciner in the calciner system, the CC -rich exhaust gas comprising between about 75 wt% CO2 and 95% wt% CO2.

50. The process or method according to any one of claims 37-49, wherein the one or more volatile elements contain or comprise: potassium (or compound(s) thereof), sodium (or compound(s) thereof), heavy metals, chloride(s) (or compound(s) thereof), alkalis (or compound(s) thereof), and/or sulfur (or compounds thereof).

51 . The process or method according to any one of claims 37-50, wherein the one or more volatile elements within the calciner system are in a gaseous or vapor form or phase, a liquid or condensed form or phase, a frozen or solid form or phase, or in a transitory physical form or phase between frozen or solid forms or phases.

52. A calciner system, plant, flowsheet, or apparatus which is configured to perform or enact the process or method described in any one of preceding claims 37-51 .

53. The calciner system, plant, flowsheet, or apparatus according to claim 52, wherein a calciner in the calciner system is selected from at least one of the following: an oxyfuel calciner, a flash calciner, an oxyfuel flash calciner, a Fluidized Bed (FB) calciner, a Circulating Fluid Bed (CFB) calciner, an electric calciner, a calciner comprising plasma torches, a calciner having plasma torches and an electric heater, a biofuel-fired calciner, a hydrogen-fired calciner, a fossil fuel-fired calciner, an indirect heating or jacketed calciner, and a stationary or non-rotating calciner.

54. The calciner system, plant, flowsheet, or apparatus according to claim 52 or 53, further comprising a quenching chamber.

55. The calciner system, plant, flowsheet, or apparatus according to any one of claims 52-54, further comprising a filter; for example, a filter located downstream of the preheater circuit and downstream of a quenching chamber.

56. The calciner system, plant, flowsheet, or apparatus according to any one of claims 52-55, further comprising a de-dusting circuit; for example, a de-dusting circuit located downstream of a preheater circuit and upstream of a quenching chamber (from a gas flow standpoint).

57. The calciner system, plant, flowsheet, or apparatus according to any one of claims 52-56, wherein the calciner system comprises a de-dusting circuit between a cyclone preheater circuit and a quenching chamber, the de-dusting circuit being configured to recover and/or preserve particles which contain relatively low concentrations of volatile elements (as compared to particles in the quenching chamber) from preheater off gas leaving the cyclone preheater circuit.

58. A process or method as substantially shown and described in FIG. 1.

59. A system, plant, flowsheet, or apparatus as substantially shown and described in FIG. 1 .

60. A process or method as substantially shown and described in FIG. 2.

61. A system, plant, flowsheet, or apparatus as substantially shown and described in FIG. 2.

62. A process or method as substantially shown and described in FIG. 3.

63. A system, plant, flowsheet, or apparatus as substantially shown and described in FIG. 3.