Carbon Capture Costs: FEED & pre-FEED Cost Reports

CO₂ capture from the SMR flue gas stacks located in Plant 01 and Plant 09 of the facility. Combined flue gases from each of the two sources would be collected and transported by ducts to the carbon capture facility. The design of the capture facility is 2,100 – 2,200 tpd of CO₂, including the CO₂ captured from the SMRs and additional flue gas generated from the steam boiler supplying the CCS unit. The CCS unit is to be designed for a minimum 30% plant turndown, this is to ensure the operation of CCS unit when flue gas from Plant 01 is the only feed to the CCS unit. For the purposes of the study the carbon capture facility design, including flue gas pretreatment and downstream CO₂ compression and dehydration, is provided by licensor. Hatch designed the flue gas transportation from the stacks to the Carbon Capture and Sequestration (CCS) unit battery limit, flue gas pressure boosting and Balance of Plant (BOP) which includes all the utility and offsite systems

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.

The University of Texas at Austin, with AECOM Technical Services and Trimeric Corporation, is conducting a FEED study for the Piperazine Advanced Stripper (PZAS) CO₂ capture process at Golden Spread Electric Cooperative’s Mustang Station in Denver City, Texas. Designed for two GE gas turbines with HRSGs and a steam turbine totaling 464 MWe, the PZAS process uses 30 wt% piperazine for higher efficiency, solvent stability, smaller absorber size, and cost savings compared to conventional amine systems. The project will deliver a 30–60% complete design package and a capital cost estimate with ±15% accuracy.