Carbon Capture Costs: FEED & pre-FEED Cost Reports

Cleco Power (Cleco) performed a three-phase front-end engineering and design (FEED) study evaluating installation of a carbon dioxide (CO2) Capture System at Madison Unit 3 (MU3), Project Diamond Vault (DV) The work was performed under a Department of Energy (DOE) grant DE-FE0032165. The FEED study included three phases: (1) a feasibility phase which sought to define the scope of the project, (2) a pre-FEED phase which sought to develop a detailed cost estimate, and (3) a final FEED phase which sought to develop the project to be ready to move into execution. The FEED study was completed by Cleco, Mitsubishi Heavy Industries America (MHIA), and Sargent & Lundy, LLC (S&L) with oversight provided by the Louisiana Economic Development (LED). The feasibility phase was completed in February 2023, which was followed by the pre-FEED phase which concluded in January 2024. The project subsequently entered the final FEED phase, during this phase Cleco made the decision to stop work on the FEED study due to market conditions which resulted in a project that was not economically viable at the time.

Phillips 66, with Worley Group Inc., is developing the initial design for a commercial-scale CCS system at the Rodeo Refinery hydrogen plant, targeting over 90% capture efficiency and storage of about 190,000 tonnes of CO₂ annually. The project will evaluate three capture configurations—flue gas plus PSA tail gas, syngas plus flue gas, and flue gas only—selecting the most cost-effective option through a techno-economic analysis. The chosen design will be advanced to a level suitable for the next engineering phase, concluding with a final TEA for the selected CCS configuration.

Analysis sets the design and cost-estimating basis for evaluating pulp and board mills with and without CCS. Two base cases are considered: a market pulp mill and an integrated pulp and board mill. Six CCS cases are evaluated, capturing CO₂ from the recovery boiler, multi-fuel boiler, lime kiln, or their combinations. The mills are assumed to be energy independent, with black liquor and bark burned to produce steam and electricity, and excess electricity exported to the grid. The CO₂ capture system uses post-combustion MEA technology with a 90% capture rate, and if on-site electricity is insufficient, an auxiliary boiler firing forest residues will supply the additional energy. Capture of CO2 in the Multi-fuel Boiler only