Carbon Capture Costs: FEED & pre-FEED Cost Reports

Studied the replacement of the SMR units with auto-thermal reforming (ATR) technology. ATRs produce a high concentration CO₂ stream, instead of low concentration combustion flue gases, that is more efficient to capture for sequestration. H₂ production from the unit may also be oversized to provide H₂ as a fuel source for the ATR if target overall CO₂ recovery of the facility is not achieved with the replacement of the SMR alone. The facility capacity is based on the total H₂ production requirements of the existing Plant 01 and Plant 09 ammonia synthesis units. 3 | P a g e Public – Approved for external distribution The scope for the study involves the SMR unit replacement with an integrated ATR and downstream syngas purification including CO₂ capture. The project scope also includes an Air Separation Unit (ASU) to supply oxygen to the ATR unit.

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.

ION Clean Energy, with Nebraska Public Power District, is conducting a FEED study to retrofit a CO₂ capture system on Unit 2 of the 700 MWe Gerald Gentleman Station in Nebraska. Using ION’s low-aqueous ICE-21 solvent, proven in prior DOE-funded projects to reduce energy use, solvent degradation, and emissions, the design will feature two parallel 350 MWe capture units. The project aims to decarbonize most of Unit 2 while maintaining maximum operational flexibility for the plant.