Calcium Carbonate Decomposition Coupled with In Situ Conversion of CO₂ into Syngas: Industrial Scenario Analysis for Carbon Capture and Clinker Production

CaCO₃ calcination is closely associated with the production of essential materials. However, the manufacturing processes are characterized by high temperatures and intense CO₂ emissions. Herein, we proposed a novel technology called CaCO₃ bireforming of CH₄ (CaBRM), which converted CaCO₃ directly into CaO and syngas through the combined steam and dry reforming of CH₄ (BRM). First, thermodynamic analysis and temperature-programmed calcination experiments were conducted to validate the feasibility of CaBRM technology. Then, two industrial scenarios were established using Aspen Plus. In Scenario 1, implementing an integrated calcium looping (CaL) and BRM process for CO₂ capture and utilization (CCU) reduced energy consumption, carbon emissions, and costs by 43, 28, and 27%, respectively, compared to conventional CCU. In Scenario 2, CaBRM technology enabled low-carbon clinker production with reduced energy consumption (2.711 MJ/kgClinker), lower carbon footprint (0.157 kgCO₂e/kgClinker), decreased production costs (126.38 USD/tClinker), and syngas coproduction. Thus, the CaBRM technology achieved energy savings, emission reduction, and in situ CO₂ conversion, making it a promising option for carbon mitigation in the carbonate-related industry.