Carbon Capture Costs: FEED & pre-FEED Cost Reports

Scope starts with the receipt of natural gas and fuel gas mixture from the existing Plant 01 and Plant 09 source and terminates with hydrogen (H₂) at the required specification and conditions to be used as fuel in the existing SMR unit. High concentration CO₂ from the ATR is captured and H₂ production from the proposed facility will replace the fuel gas feed to the primary reformer for heating. The facility capacity is based on the heating duty required to replace the current fuel source. The scope for the study involves the new ATR unit and associated downstream shift, CO₂ capture, and syngas purification unit. The project scope also includes an ASU to supply oxygen to the ATR unit.

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 Peterhead CCS Project in Aberdeenshire, Scotland, was designed to demonstrate the world’s first commercial-scale post-combustion CO₂ capture from a gas-fired power station. Using amine-based CANSOLV technology, it aimed to capture around one million tonnes of CO₂ annually from one turbine at SSE’s Peterhead Power Station, compress and condition it, and transport it via a new offshore pipeline for injection into the depleted Goldeneye gas reservoir over 2 km beneath the North Sea. The FEED study defined project scope, refined CAPEX and OPEX estimates, and assessed cost uncertainties, providing a basis for the Execute phase while also documenting budget performance and emergent costs during FEED.