Carbon Capture Costs: FEED & pre-FEED Cost Reports

Dastur International Inc., with Cleveland-Cliffs Inc., is designing a carbon capture system for the 5 mtpa integrated steel plant in Burns Harbor, Indiana, to capture 50–70% of CO₂ emissions from blast furnace gas. The system will combine a gas flow distribution network, a specialized conditioning process, and ION Clean Energy’s solvent-based capture technology with 90–98% efficiency, with water-gas shift reactors enabling higher capture rates. Dastur will lead overall plant integration and engineering, while ION designs the capture island and Dastur Energy optimizes design and energy performance.

The Red Trail Energy (RTE) ethanol facility in Richardton, North Dakota, is implementing a CO₂ capture and liquefaction system designed by Trimeric. The system captures CO₂ from fermentation, compresses it to ~350 psig, dehydrates and liquefies it using an ammonia refrigeration loop, and purifies it via distillation to remove oxygen and other gases. The liquid CO₂ can be stored for sale or geologic sequestration. The facility is designed to process 587 tonnes/day (scalable to 675 tonnes/day), with nearly complete CO₂ recovery.

General Electric Gas Power, with Linde, Kiewit, and Southern Company Services, is conducting a FEED study for a “Generation 2” amine-based post-combustion CO₂ capture system at an existing NGCC power plant. Targeting at least 95% capture efficiency, the design will emphasize optimized integration, lower CCS costs, and flexible operation to complement renewable energy. The 18-month project will progress from multiple conceptual designs to a single configuration, culminating in a detailed design, technical viability assessment, techno-economic and life cycle analyses, and a business case evaluation.