Sequestering CO2

in the built environment

May 14th 2009

Calera Corporation

Carbon cycle: Most of the carbon is sitting the form of carbonate rock
The built environment:
32B tons of cement and
aggregate used every year

CO 2
conversion

(Ca, Mg)

CO 3

Fossil Fuels:
All fossil fuels = 4,000 B tons CO2
11B tons of CO2 emitted by power and cement industry per year
Kyoto requires a reduction of 5B tons of CO2
Atmosphere:
1700s: 400 B tons CO2
Today: 700 B tons CO2
2

Calera Corporation

Sedimentary Rocks &

marine sediments:
70-100 million B tons CO2

23 years of cement expertise, 3 successful medical device ventures

founded and sold, worldwide penetration of high performance products

Calera Corporation

World class team with international expertise in Energy, Geology,

Water, and Building Materials
Calera was founded in June 2007, by Brent R. Constantz, Ph.D.
Calera has been funded by its unique investor Khosla Ventures

Collectiveexperience
5MBA
Power,geology,waterandbuildingmaterials
Khosla
Toptalentwithcredentials
Over100patents
Publiccompanyexecs
ScientificAdvisoryBoard
Upwardsof100
2JD,3patentagents,1paralegal
Successfulentrepreneurs
CarbonAdvisoryBoard
ManagementTeam
Collectivelybuiltlargescaleprojectsin15countriesaroundthe
70people
SpecialtyTechnicalAdvisoryBoard
InvestorsandAdvisors
14MS
18PhD

Calera Corporation

The Calera Process: Mineral Carbonation

Fresher Water
(stripped of Ca & Mg)

Saline
Water
Flue gas
Reactor

Power
plant

Calera Corporation

Cement&
Aggregate

Coal is the problem to solve, however the cost of CCS for fossil fueled
power generation remains prohibitive
3,000

Quantity
Quanity

$90

Cost

$80

2,500

$70

2,000

$60
$50
Cost to Capture & Store CO2 ($/(MT
$40 CO2))

1,500
CO2 Emissions (MT/Yr)
1,000

$30
$20

500

$10

$1

Mole Fraction of CO2 in Emission Stream

95%-100%
1) CO2 from Ethanol
Fermenters
2) CO2 from steam reforming
at Refineries, Ammonia
Plants, SNG Plants,
3) CO2 Separated from sour
natural gas

20% - 40%
1) CO2 from Cement Calcination
2) Other chemical plants

10 % 15%
1) Coal Fired power plants
2) Oil & diesel generators

4% - 10%
1) Natural gas fired power
plants
2) Furnaces, small boilers,
etc.

Source:NatcarbEIAIPCCSpecialReportonCarbonCaptureandSequestrationKurtHouseAnalysis(MIT)
6

Calera Corporation

Novel technologies and integrated design allow for beneficial reuse at

global industrial scale

Breakthroughs:
- Maximized
absorption
efficiency with low
energy use
- Mineral loading
- Multi-pollutant
capture

Breakthroughs:
- Novel chemistry
- Novel material
science producing
undefined
polymorphs with
cementitious
properties
- Industrial scale and
economics

Breakthroughs:
- Ability to control
particle size
and material
density
- Reuse of waste
heat

Benefits of integrated solution: Lower capex and opex

Partnering with top equipment suppliers and EPC firms to design for low
cost and large scale from beginning
Modular plant design allows for rapid deployment worldwide and added
Intellectual Property protection
7

Calera Corporation

Calera technology is mature and ready for a demo scale project

Laboratory, Small Batch and Large Batch Scale
Has established the ability to efficiently capture and convert to mineral
carbonate with seawater and waste base sources
Generating 5 tons of product capturing 2.5 tons of CO2 per single batch

Pilot
Establishes continuous process at 1 ton per day of product (0.5 tons of CO2
from coal fired boilers
Will test efficiency and integration of individual process technologies
Testing on pulverized coal flue gas and site specific conditions and
materials

Demo
Takes flue gas from 20MW to 80MW of coal fueled host plant
Scales up in segments / modules
Chemistry,
Laboratory and
Batch Processes
KPI
hurdle
8

Calera Corporation

KPI
hurdle

CA pilots validate process, product and environmental feasibility

Pilot plants running large scale batch and continuous processes

Flue gas simulator Ability to test any type of coal and flue gas composition
Producing material for product development and testing
Demonstration of waste mineral utilization
Monterey Bay Marine Sanctuary requires highest level of environmental
performance

Calera Pilot and

Global R&D
150,000 sqft covered
200 acres total
60m gpd discharge permit

5m tons of mineral waste

Calera Corporation

MossLanding
PowerStation

>1000MWbaseload
>1500MWpeaking
Fuel:NaturalGas
Operator:Dynegy

Moss Landing Pilot Plant - Process Flow

GastoLiquid
Absorber

CoalFired
BoilerSimulator

Coal

CO2Depleted
Flue Gas

Pulverized
Coal
Hopper

Induced
Draft
Fan

Baghouse

ScrewFeeder
Recirculation
Pump

Air

Absorber
Pump

Forced
Draft
Fan

WatertoTreatment
Cement
Aggregate

Seawater
Seawater
Pump

Moss
Mag/Dolime

MossMag

10

Calera Corporation

BaseFeed
Pump

Dewatering
FeedPump

Precipitator
With
PaxAgitator

SprayDryer
FeedPump

Epuramat1500

WetMill

SprayDryer

Moss Landing Pilot Plant - Process Flow

CoalFired
BoilerSimulator

Coal

Pulverized
Coal
Hopper

GastoLiquid
Absorber

CO2Depleted
Flue Gas
Induced
Draft
Fan

Baghouse

ScrewFeeder

Air

Absorber
Pump

Forced
Draft
Fan

Recirculation
Pump

WatertoTreatment
Cement
Aggregate

Seawater
Seawater
Pump

Moss
Mag/Dolime

MossMag

11

Calera Corporation

BaseFeed
Pump

Dewatering
FeedPump

Precipitator
With
PaxAgitator

SprayDryer
FeedPump

Dewatering

WetMill

SprayDryer

Moss Landing Pilot Plant Coal Boiler Simulator

CoalFiredBoilerSimulator(CFBS)
Simulates time-temperature
combustion history of fullscale utility boilers
Capable of burning
pulverized coal from
anywhere in the world
Capacity 1 MMBtu/hr
Generates flue gas
composition and
temperature identical to full
scale

12

Calera Corporation

Moss Landing Pilot Plant

SeawaterFeedandBaseAdditionSystems
Providescontinuoussuppliesofseawaterandsolidbasetotheprocess

13

Calera Corporation

Moss Landing Pilot Plant - Process Flow

GasLiquid
Absorber

CoalFired
BoilerSimulator

Coal

CO2Depleted
Flue Gas

Pulverized
Coal
Hopper

Induced
Draft
Fan

Baghouse

ScrewFeeder

Air

Absorber
Pump

Forced
Draft
Fan

Recirculation
Pump

WatertoTreatment
Cement
Aggregate

Seawater
Seawater
Pump

Moss
Mag/Dolime

MossMag

14

Calera Corporation

BaseFeed
Pump

Dewatering
FeedPump

Precipitator
With
PaxAgitator

SprayDryer
FeedPump

Dewatering

WetMill

SprayDryer

Moss Landing Pilot Plant Gas Liquid Absorber

NSGPureStreamTMAbsorber

HighefficiencycompactCO2capturetechnologyutilizesplanarliquidjet
technology.

CEMS

15

Calera Corporation

Moss Landing Pilot Plant - Process Flow

GastoLiquid
Absorber

CoalFired
BoilerSimulator

Coal

CO2Depleted
Flue Gas

Pulverized
Coal
Hopper

Induced
Draft
Fan

Baghouse

ScrewFeeder

Air

Absorber
Pump

Forced
Draft
Fan

Neumann
Recirculation
Pump

WatertoTreatment
Cement
Aggregate

Seawater
Seawater
Pump

Moss
Mag/Dolime

MossMag

16

Calera Corporation

BaseFeed
Pump

Dewatering
FeedPump

Precipitator
With
PaxAgitator

SprayDryer
FeedPump

Dewatering

WetMill

SprayDryer

Moss Landing Pilot Plant

Precipitator

PrecipitatesabsorbedCO2intosolids

17

Calera Corporation

Moss Landing Pilot Plant Systems

SolidLiquidsSeparator
PrecipitatesabsorbedCO2intosolidsandseparatessupernatant.

18

Calera Corporation

Moss Landing Pilot Plant - Process Flow

GastoLiquid
Absorber

CoalFired
BoilerSimulator

Coal

CO2Depleted
Flue Gas

Pulverized
Coal
Hopper

Induced
Draft
Fan

Baghouse

ScrewFeeder

Air

Absorber
Pump

Forced
Draft
Fan

Neumann
Recirculation
Pump

WatertoTreatment
Cement
Aggregate

Seawater
Seawater
Pump

Moss
Mag/Dolime

MossMag

19

Calera Corporation

BaseFeed
Pump

Dewatering
FeedPump

Precipitator
With
PaxAgitator

SprayDryer
FeedPump

Dewatering

WetMill

SprayDryer

Moss Landing Pilot Plant Systems

WetMillandSprayDryer

Modifiesparticlesizeandshapeofprecipitantandthendriesfinalproduct.

20

Calera Corporation

Multi-pollutant Robustness and Control Potential

Retrofit CapEx Costs *

SO2
NOx
Hg
TOTAL

~ $ 325/kW - $ 450/kW
~ $ 225/kW - $330/kW
~ $36/kW - $ 42/kW
~$ 586kW - $822/kW

Calera Process not

sensitive to presence
of other pollutants

In Calera Process SO2 is

absorbed in alkaline liquid
and converted to sulfate

Actual retrofit costs can vary significantly due to complexity of

engineering for existing systems configurations
(*)Sources: Sargent & Laundy (2007), DOE, Hoskins 2008 & PNM SJGS BART Analysis
21

Calera Corporation

Base Case Process Flow Diagram

Flue Gas In

Base
Recovery
Brine In

CO2
Capture

Product
Processing

Precipitation

Base Manufacture
Natural, Waste Base Processing
22

Calera Corporation

Mass and Energy Balance Base Case Site

188 MW power

Coal for 200 MW

402 kta CO2 emitted

12 MW
Sale

2,900 kta mineral

Calera
Plant

Power
Plant

800 kta fly ash

780 m3/h brine
(5.9 MGD)

938 kta CO2 captured (70%)

4,398 kta solids

2,336 kta
Carbonate-rich
Aggregate

23

Calera Corporation

123 kta
Cement

1,938 kta
Silica-rich
Mineral Residue
(potential for
aggregate, other)

Mass and Energy Balance Generation 2 Site

160 MW power

Coal for 200 MW

402 kta CO2 emitted

40 MW
Sale

2,213 kta mineral

Calera
Plant

Power
Plant

402 kta fly ash

41 kta salt
(95% recovery)

938 kta CO2 captured (70%)

<120 m3/h brine

(<1 MGD)

3,683 kta solids

2,183 kta
Carbonate-rich
Aggregate

24

Calera Corporation

115 kta
Cement

1,485 kta
Silica-rich
Mineral Residue
(potential for
aggregate, other)

Go to market strategy: the business model relies on revenue streams

Project development co-invested with site host (CO2 emitter)

Cooperating closely with cement, materials and architecture companies
Localizedsourcingtosuitrangeofsitesandsituations
Carbonnegativeproductpipelinetofitneedsformoresustainablebuildingmaterial
Positioning:costeffective,lowrisk
Calerabuilds,ownsandoperatescarboncapturefacilities
Productdistributionisverylocalizedwithhighinfrastructureneeds
Apartnershipdrivenapproach
Sharedownershipwithpower,cementandwaterpartners
Severalrevenuestreams:

Caleraispartneringwithcementcompanies,watersuppliersandothersinsupplychain
Marketentrywillbeginwithmostprogressivecompaniesandregions,especiallysituationswherecarbonmi
Offtakeagreementsforregulatedpollutants($/tonpollutant)
Products:Pipelinedevelopment
Flexibletechnologyallowsbroadrangeofsites
Sustainable,stableandbenignreuseofCO
CO
Low
Productsales($/tonproduct)

25

Calera Corporation

Cement&CO2

Cement is inherently a heavy CO2 emitting process (since 1824)

Approximately1tonCO2
foreachtonofcement
(Range0.71.1)

Source: EPA 2004, International Energy Agency July 2008

26

Calera Corporation

Calera Business Model: Sequester CO2 from emitters and avoid CO2
emitted in the traditional making of concrete
Calera business model generates several revenues streams:
Building materials manufactured and sold
Carbon monetization of CO2 sequestered and avoided
Softened water for RO

Calera generates revenue from providing carbon emissions solutions:

CARBON EMISSIONS REDUCTION:
Power generation (~25% of worldwide emissions) and cement production (~7%
of worldwide emissions) by converting CO2 into stable building materials

CARBON EMISSIONS AVOIDED:

Displacing conventional concrete mix components with carbon neutral (or better)
materials
Reducing by 50% the energy demand for desalination process

27

Calera Corporation

Calera is developing a line of carbon negative building materials being

tested against existing industry standards for large markets

First 3 products:
Synthetic Aggregate
(SA)

Reactive Carbonate
Pozzolan (RCP)

Footprint = - 0.5t CO2/t

Footprint = - 0.25t CO2/t

Mitigates fly ash

Carbonate Mineral SCM

(CM-SCM)
Footprint = - 0.5t CO2/t

Cement Displacement
Up to 20% of cement
blend

Testing against ASTM

C 1157 Standard
Performance Specification
for Hydraulic Cement

Worldwide
market size:
28

~$25B

Calera Corporation

Replaces all sand

and aggregate
Adjustable particle
size

High performance, high

value concrete
Up to 50% of cement
blend

Testing against ASTM

C 1157 Standard
Performance Specification
for Hydraulic Cement

Testing against
ASTMC33
Standard
Specification for
Concrete Aggregate

~$330B

~$25B

Calera Mineral Carbonate can address a variety of large markets

$/ton
100

Masonry
Cement
4Mt

U.S. Market

Mineral
Filler
100Mt

Global Market = ~10X

Cement
120Mt
SCM 24Mt

60
Light
Weight Agg.
Soil
200Mt
Stabilization
100Mt

30

10

Bricks
20Mt

Sand &Aggregate
3Bt
0

1 year

2 years

Drywall
20Mt

3 years

Product Development Time

29

Calera Corporation

Concrete
Blocks
50Mt

4 years

5 years

Transportation considerations are important

Similar to shipping coal
Cost + business model proven

Other factors to consider

Rail

Long term contracts

Offloading
Handling

Trucking
Coal and
Chemicals are
top rail
categories by
revenue

Barges
30

Calera Corporation

Concrete Carbon
Footprint Calculator
IntroducedatWorldofConcrete2009
by Calera Corporation

31

Calera Corporation

Carbon Footprint Basic Calculation

Embodied
Pounds of
x Ingredient
CO2 of
Ingredient
(per cubic yard)

sum all
ingredients

Concrete
Carbon
Footprint

First Carbonate Mineral concrete July 2008

32

Calera Corporation

Embodied CO2 of Concrete Materials

Production

Transportation

Embodied
CO2Per
Ingredient
tonCO2/tonmaterial

0.86

0.016

0.876

0.013

0.013

0.013

0.013

FlyAsh

0.045

0.045

Water

0.01

0.01

Cement
FineAggregate
(sand)
CoarseAggregate
(gravel)

33

Calera Corporation

Carbon Capturing Building Materials

Production

Transportation

Embodied
CO2 Per
Ingredient
ton CO2 / ton material

34

Calera SCM

- 0.50

0.05

- 0.45

Calera Fine
Aggregate

- 0.50

0.05

- 0.45

Calera Coarse
Aggregate

- 0.50

0.05

- 0.45

Calera Corporation

Ordinary Concrete emits ~537lb CO2 / yd concrete

NetCO2EmissionsPerCubicYard
100%OPC
Ingredient

lb CO2 / lb
ingredient

lb ingredient / yd
concrete

lb CO2 / yd
concrete

Portland
Cement

0.876

564

494.1

Water

0.01
0.013

282
1,300

2.8
16.9

0.013

1,800

23.4

3,946

537

Fine
Aggregate
Coarse
Aggregate

TOTALS
35

Calera Corporation

Net CO2 Emissions of Ordinary Concrete

Total
537lbCO2

600

NetCO2Emissions(lb)

500
400

PerCubicYard

300
200
100
0

36

Cement

Calera Corporation

Water

Fine
Agg.

Coarse
Agg.

Use of high volume fly ash mix (50%) can help reduce to some extent
the carbon footprint of concrete
Ingredient

lb CO2 / lb
ingredient

lb ingredient / yd
concrete

lb CO2 / yd
concrete

Portland
Cement
Water

0.876

282

247.0

0.01
0.013

271
1,225

2.7
15.9

0.013

1,800

23.4

0.045

282
3,860

12.7

Fine
Aggregate
Coarse
Aggregate
Fly Ash
TOTALS

37

Calera Corporation

302

but has some performance and workability problems

50% High Fly Ash Mix

Net CO2 Emissions (lb)

600

500

Total
302 lb CO2

400
300

Cement

200
100
0

38

Calera Corporation

Fly
Water Ash

Fine
Agg.

Coarse
Agg.

44% Reduction in carbon

footprint from traditional
concrete OPC
BUT Slower strength gain

Carbon Capturing Concrete

Carbon Capturing Mix
20% Calera SCM, 20% Fly Ash
used as cement replacement
600

Compared to 50% fly

ash:

Net CO2 Emissions (lb)

500

Total
400

293 lb CO2

Cement
300

No strength gaining
issues

200
100

Water

Fine
Agg.

Fly
Ash

0
-100

39

Similar carbon
footprint reduction

Calera Corporation

Calera
SCM

Coarse
Agg.

Improved working
properties

Carbon-Neutral Concrete

CarbonNeutralMixwith100%OPC,
usingmostlyCalerafineaggregate

Net CO2 Emissions (lb)

600

Cement

400
200

Total
Fine
Water Agg.

Coarse
Agg.

0lbCO2

0
-200
-400
-600

40

Calera Corporation

Calera
Fine Agg.

Opportunities for
cement companies to
partner with Calera to
manufacture green &
sustainable concrete
while maintaining their
cement sales

Carbon-Neutral Concrete
Carbon Neutral Mix
with High OPC Replacement
& Improved Working Properties
600

Net CO2 Emissions (lb)

400
200

20% SCMA
20% Fly Ash
Cement
Fly
Water Ash

Coarse
Agg.

-200
-400
-600

41

Fine
Agg.

Calera Corporation

Calera
SCM

Replace a
portion of fine
aggregate with
Calera Fine
Aggregate

Total
-0 lb CO2

Calera
Fine Agg.

Improved
working properties
No strength
gaining issues

Negative-carbon Concrete

Ingredient

lb CO2 / lb
ingredient

lb ingredient / yd
concrete

lb CO2 / yd
concrete

Portland
Cement

0.876

338

269.1

Water

0.01
0.045
(0.450)
(0.450)
(0.450)

271
113
113
1,250
1,800
3,885

2.7
5.1
(50.9)
(562.5)
(810.0)

Fly Ash
Calera SCM
Calera Fine
Agg.
Calera Coarse
Agg.
TOTALS

42

Calera Corporation

(1,146)

Calera allows for carbon negative concrete mixes which sequester

AND avoid CO2
537 lb CO2/yd3 of concrete

600

NetCO2Emissions(lb)

400

Reference
Ordinary
Concrete

Cement

200

Water Fly Ash

0
-200

NetCO2avoided=
1,683lbCO2

Calera
SCM

-400
-600
-800
-1000
-1200

Source:Caleraanalysis
43

Calera Corporation

Calera
Fine
Agg.
Calera
Coarse
Agg.

Total: 1,146lbCO2/yd3
ofconcrete

Mix design:
20% Calera SCM
100% Calera Fine Agg.
100% Calera Coarse
Agg.

Caleras value proposition

Economically viable CO2 control solution (avoided cost of allowances)
Carbon negative concrete (offsets revenue streams + products sales)
Valuestreams
600
537 lb CO /yd3 of concrete
2

NetCO2Emissions(lb)

400

Reference
Ordinary
Concrete

Cement

200

Water Fly Ash

-200

Calera
SCM

CO2controlsolution
(CO2conversion)

-400

-600

-800

-1000

-1200

44

Calera Corporation

Carbonnegativeconcrete
(CO2avoided)

Calera
Fine
Agg.

Calera
Coarse
Agg.

- 1,146lbCO2/yd3
ofconcrete

+
Salesofcarbonnegative
concrete

Calera Net CO2 Avoided (Capture Emissions + Displacement) can be

more than 100% of CO2 emitted by power plant

Conservative life cycle analysis shows total CO2 avoided is higher than the total
emissions of the power plant by ~7%
Alternative cases show scenarios of up to 40% above total
3rd party studies in progress with Harvard/MIT and others
7%>>upto40%

45

Calera Corporation

To maximize revenue from CO2 solutions, Calera has initiated an effort

to quantify, verify and certify the carbon footprint of its technology
Pilotrunning

Instrumentationand
analyticsinplace

Carbonlife
cycleanalysis

Nextsteps

Calerahasengagedleadingcarbonmarketsexperts
(CarbonAdvisoryBoardCarbonSymposium)
Source:Caleraanalysis
46

Calera Corporation

Calera is a mature, profitable and sustainable solution to climate change

Acontinuousprocessprovenatpilotfacility

Calera
Pilot and
Global
R&D

Thelargestnatural
storageofCO2

(Ca, Mg)CO 3
Thefirstcarbonnegative
concrete
Reference
Ordinary
Concrete

Net CO2
Emissions
(lb)
600

400
200

Cement
Fly
Water Ash

Afinanceableprojectwithrevenuestreams
Carbon negative
concrete
(CO2 Avoided)

+
CO2 control solution
(CO2 conversion)

+
Sales of carbon
negative concrete and
softened water

47

Calera Corporation

-200
-400
-600
-800
-1000
-1200

Calera
SCM
Calera
Fine Agg.
Calera
Coarse
Agg.
- 1,146 lb CO2/yd3
of concrete

Endorsements
You really ought to be able to replace most of the worlds need for cement, with the by-product of sequestering
most of the worlds power plant emissions of CO 2 - that would be game changing
- Carl Pope, President, Sierra Club

CalerasprocessforcreatingcementfromsequesteringtheCO2frompowerplantsisthemost
promisingapproachcurrentlyonthetable
MarciaMcNutt,PresidentandCEO,MontereyBayAquariumResearchInstitute
TheCaleraprocessshowsgreatpromiseforgreencementandsustainableconcrete

PauloMonteiro,Phd.,Professor,AuthorofConcrete
Calerasproducts,includingcementitiousmaterialsandaggregates,areofgreatinteresttothebuildingindustryaswellas
governmentalagencies.
Gottfried,Founder:U.S.andWorldGreenBuildingCouncils

Theabilityofyourprocesstocaptureofparticulates,nitrogenoxides,sulfurdioxide,mercury,andotherpollutantswillgive
utilitiesanopportunityforonestopshoppingastheyfacemultipleemission reductionchallenges.
ThomasB.Carter,SeniorVicePresident,GovernmentAffairs,NationalReadyMixedConcreteAssn.
TheCaleraproductnotonlyprovidesanappropriaterepositoryforCO 2,butcanbeusedfurtherforsomething
constructive.

JamesR.ONeil,Prof.Emeritus,UniversityofMichiganand2004GoldschmidtMedalist
Myviewistheirideasarecreativeanddemandcarefuldebateanddemonstrationprojectstoseewhattheycandoatlarge
scale.Couldbeasignificantnewwaytohelpusinventourwayoutofsometheclimatechangeproblemswe'refacing.
ProfessorStephenH.Schneider,StanfordUniversity
48

Calera Corporation