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Subtask 5.2 – Transportation and Infrastructure Assessment

The CarbonSAFE Illinois – East Sub-Basin project is conducting a pre-feasibility assessment for commercial-scale CO2 geological storage complexes. The project aims to identify sites capable of storing more than 50 million tons of industrially-sourced CO2. To support the business development assessment of the economic viability of potential sites in the East Sub-Basin and explore conditions under which a carbon capture and storage (CCS) project therein might be revenue positive, this document provides a screening level estimate of capital and operating costs for CO2 compression and dehydration surface equipment for the planned Quasar Syngas facility in Terre Haute, IN. Although preliminary, this estimate is based upon a significant amount of Trimeric in-house project experience and data extracted from projects of a similar nature that are applicable to this CarbonSAFE project.

01 COAL, LIGNITE, AND PEAT↗

Subtask 1.4 - Techno-Economic Assessment of Regional Carbon Utilization Scenarios and Attendant Monitoring Technology

The U.S. Department of Energy (DOE) Carbon Storage Program seeks to develop technologies to significantly improve the effectiveness of carbon capture and storage (CCS), reduce the cost of implementation, and support the readiness of widespread commercial deployment by 2035. To accomplish this goal, technical and economic barriers must be addressed and the results used to inform regulators and industry on the safety, permanence, and viability of carbon storage. To help overcome these barriers, the Energy & Environmental Research Center (EERC) conducted three activities: 1) investigate the regional techno-economic life cycle of CO2 enhanced oil recovery (EOR) in North Dakota, 2) assist DOE in determining the prospective CO2 storage resource of residual oil zones (ROZs), and 3) develop a seismic technique for monitoring geologic storage of CO2. These three activities address two strategic goals enumerated in the DOE–EERC Cooperative Agreement, namely, 1) to advance foundational science and 2) to inform data-driven policies that enhance U.S. economic growth and job creation, energy security, and environmental quality. Activity 1 In North Dakota, there is synergistic incentive to develop and implement CO2 EOR technologies. Regional industry partners are actively seeking options that can cost-effectively improve the efficiency of power production, while also coproducing CO2 for use in EOR applications. A full-value-chain techno-economic assessment that links lignite resources, power generation, and EOR is needed to determine the implications for a state or region to continue to use these resources or look elsewhere for other energy sources and revenue streams. The integration of North Dakota’s lignite power industry with the state’s oil industry has the potential to revitalize legacy oil fields and produce up to 1 billion barrels of additional oil using CO2 EOR while providing a market for a CO2 commodity captured at coal-fired power plants. Revitalization of North Dakota’s legacy oil fields will bring new industry investment to the state, resulting in the growth of oil-related jobs and revenue through oil sales, severance tax, and associated oilfield development activities (drilling, pipelines, etc.). CO2 demand for EOR and incremental oil production were calculated for 201 conventional oil fields in North Dakota. Infrastructure development in the fields was estimated using 1) a traditional vertical well arrangement of CO2 injectors and oil producers and 2) an advanced case where horizontal wells were used exclusively. Pipeline, compression, and recycling infrastructure requirements were also estimated. When viewed from the CO2 capture and CO2 EOR sectors, the advanced case showed a positive investment scenario when including potential benefits of the 45Q tax credit policy. An economic evaluation of a full implementation of CO2 EOR showed an average $60 billion potential state economic impact estimated over the 37-year construction and production time frame could be realized with an assumed oil price of $65/bbl. Oil price ranges of $35–$90/bbl cause an estimated variation of ±$5 billion over the potential effort. The total net state government revenues were estimated over the 37-year construction and production time frame. With an assumed oil price of $65/bbl, total potential fiscal impact could average $7.4 billion. This result ranges about ±$2.5 billion for a potential EOR implementation effort for oil price ranges of $35–$90/bbl. This broad-brush assessment was focused on “magnitude-of-effect” perspectives of what CO2 capture and use for EOR could mean to the state. Whether CO2 EOR ever becomes widely adopted is not the issue at this stage of evaluation. The question being answered is, How valuable could CO2 capture and CO2 EOR be for the state and local jurisdictions in western North Dakota? The results of the current economic assessment remove any ambiguity to that question. Full implementation of CO2 EOR as modeled in this study provides substantial economic benefits to the state, even at low oil prices (i.e., $35/bbl). Job creation and government revenues could be substantial, depending on the scale of implementation. With a better understanding of what CO2 EOR might mean for the state’s economy, the focus can now shift to the policies and financial mechanisms needed to make private investment in CO2 capture and use as EOR competitive with other energy-related pursuits. Activity 2 ROZs contain remnants of oil not swept away by natural waterflooding. Although nearly all of the identified ROZs are found in West Texas, there is evidence that this category of oil reservoir can be found in other major oil-producing basins of the United States. Because the formation of these oil reservoirs is distinct from other conventional reservoirs, the method to estimate the prospective CO2 storage resource in ROZs may be equally distinct from the method used for conventional fields. As such, the EERC collaborated with DOE’s National Energy Technology Laboratory (NETL) to investigate the feasibility of CO2 storage in ROZs and determine what specific modification (if any) needs to be made to the current DOE volumetric method to estimate prospective CO2 storage resource in oil reservoirs. This activity built on a previous EERC investigation to identify ROZs in the Williston and Powder River Basins and upon collaborations between the EERC and NETL to develop storage resource estimation methods for different types of geologic CO2 storage. Review of the volumetric approach raised questions about the applicability of such an approach to hydrocarbon-bearing zones without the inclusion of potential hydrocarbon production. A production-based approach was presented by the EERC to inform the working group of additional methods of increasing the CO2 storage resource potential. Because the production-based method focuses more heavily on oil recovery than CO2 storage, it was not included in the working group manuscript. Activity 3 The EERC has used sparse and irregular seismic arrays to detect CO2 injected into a reservoir. The variability of seismic noise recorded by the sensors directly impacts the seismic interpretation. However, designing noise attenuation workflows effectively can be a more challenging task using sparse and irregular arrays for data acquisition. Based on the hypothesis that noncoherent noise is stationary during weekly data acquisition, a new machine-learning algorithm was developed to automatically estimate noise conditions using passive records, noise from active records, and ancillary information. The new noise attenuation processing workflow can improve the time-lapse detection of CO2 from sparse and irregular array acquisitions. Results show spatial and temporal noise patterns can be related to the location of the sensors and the weather conditions during the data acquisition and that our attenuation processing workflow can improve the time-lapse detection of CO2 from sparse and irregular array acquisitions. This effort was funded in part through the EERC–DOE Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Department of Commerce.

Peck, Wesly↗

A Summary of CO2-Enhanced Oil Recovery Options in the Illinois East Sub-Basin

Illinois Basin oil fields have an estimated CO2 storage resource of 140 to 440 million metric tons, 58 to 180 million metric tons of which are in reservoirs with conditions suitable for miscible CO2-EOR (Finley, 2005). Untapped reserves remain locked in established mature oil fields as well as prospective greenfields waiting for development. CO2-EOR recovery in the ILB has the potential to be economically significant by improving oil recovery and providing possible storage of anthropogenic CO2, and CO2-EOR reservoirs could potentially be co-located (stacked) with saline storage options. CO2-EOR interests in the wider region may assist the economics of a storage project long-term, via potential revenue from sale of CO2 for EOR and/or by taking advantage of Carbon Capture and Storage (CCS) tax credits under 26. U.S. Code § 45Q (and 2018 FUTURE Act amendments). Pilot scale injection tests have been performed at a few locations across the ILB with positive indications of oil response, but there have been no field-scale applications of CO2-EOR in the ILB. Enhanced ILB oil field miscibility classification maps show additional reservoir-level detail and help expand the screening area for CO2-EOR opportunities in the East Sub-Basin. Examination of the oil fields and their productive reservoirs revealed the presence of several carbonate and siliciclastic candidates for miscible/near miscible and immiscible CO2-EOR in the East Sub-Basin study area. In addition, related studies have identified and assessed residual oil zones (ROZs) in sandstone and carbonate formations throughout the region. These results and ongoing work highlight key reservoirs in primary fields of interest and provide the basis for targeted oilfield and site-specific work in assessing the feasibility of industrial-scale CO2 storage and CO2-EOR in the Illinois East Sub-Basin study area.

01 COAL, LIGNITE, AND PEAT↗

CCUS and 45Q

Presented by NETL at IEAGHG CCS Cost Network Workshop, 03/19

Grant, Timothy↗

Environmental, Health and Safety Assessment Application of a Heat Integrated, Post-combustion CO2 Capture System Using Monoethanolamine and Hitachi H3-1 Solvent at the E.W. Brown Coal-fired Power Plant

An Environmental Health and Safety (EH&S) Assessment was completed for operation of a pilot scale carbon dioxide (CO2) capture system (CCS) at the Louisville Gas & Electric (LG&E) and Kentucky Utilities (KU) Energy, LLC (LG&E-KU) E. W. Brown Generating Station in Harrodsburg, Mercer County, Kentucky. The pilot system was evaluated using two CO2 capture solvents, monoethanolamine (MEA) and Hitachi’s H3-1 solvent. The purpose of the EH&S Assessment was to determine if there were any unacceptable environmental, health or safety concerns that may prevent operation or environmental permitting of a larger scale pilot scale plant. The assessment included review of process flow diagrams, input and output flow rates for primary materials, literature describing similar processes and chemicals used or created during the process, actual air emission and wastewater test data and air emission calculations. The evaluation included identification of risks related to hazardous chemicals, air emissions, wastewater discharges, solid wastes generated and employee hazards. Most potential EH&S issues that were identified are commonly found and successfully managed at large industrial facilities. No risks were identified that could not be successfully managed or would likely prevent implementation or environmental permitting of the pilot or larger scale plant. Potential exposures and resulting health risks from exposure to low concentrations of nitrosamines generated from degradation of the Hitachi H3-1 and possibly MEA solvents may be a health concern for site workers, but additional investigation is needed to accurately assess this risk. Applying the information gained from operating the pilot plant, performing air emission testing and used solvent testing to a large-scale facility at a commercial coal-fired electric generating plant suggests additional air emission control measures may be necessary to reduce potential site worker health risks and possibly community risks. Depending upon the location and regional air quality, considerable effort may be required to obtain the necessary air permit for construction and operation of a similarly configured large-scale PCCCS facility.

gas separation↗

Environmental, Health and Safety Assessment Application of a Heat Integrated, Post-combustion CO 2 Capture System Using Monoethanolamine and Hitachi H3-1 Solvent at the E.W. Brown Coal-Fired Power Plant

An Environmental Health and Safety (EH&S) Assessment was completed for operation of a pilot scale carbon dioxide (CO 2 ) capture system (CCS) at the Louisville Gas & Electric (LG&E) and Kentucky Utilities (KU) Energy, LLC (LG&E-KU) E. W. Brown Generating Station in Harrodsburg, Mercer County, Kentucky. The pilot system was evaluated using two CO 2 capture solvents, monoethanolamine (MEA) and Hitachi’s H3-1 solvent. The purpose of the EH&S Assessment was to determine if there were any unacceptable environmental, health or safety concerns that may prevent operation or environmental permitting of a larger scale pilot scale plant. The assessment included review of process flow diagrams, input and output flow rates for primary materials, literature describing similar processes and chemicals used or created during the process, actual air emission and wastewater test data and air emission calculations. The evaluation included identification of risks related to hazardous chemicals, air emissions, wastewater discharges, solid wastes generated and employee hazards. Most potential EH&S issues that were identified are commonly found and successfully managed at large industrial facilities. No risks were identified that could not be successfully managed or would likely prevent implementation or environmental permitting of the pilot or larger scale plant. Potential exposures and resulting health risks from exposure to low concentrations of nitrosamines generated from degradation of the Hitachi H3-1 and possibly MEA solvents may be a health concern for site workers, but additional investigation is needed to accurately assess this risk. Applying the information gained from operating the pilot plant, performing air emission testing and used solvent testing to a large-scale facility at a commercial coal-fired electric generating plant suggests additional air emission control measures may be necessary to reduce potential site worker health risks and possibly community risks. Depending upon the location and regional air quality, considerable effort may be required to obtain the necessary air permit for construction and operation of a similarly configured large-scale PCCCS facility.

gas separation↗

Techno-Economic Analysis for GTI's Compact Hydrogen Generator

A technoeconomic analysis of the compact hydrogen generator compared to a traditional steam methane reformer (SMR) was performed for both processes with and without carbon capture. The project goal for the technoeconomic analysis was to demonstrate a minimum of 20% lower CAPEX and 15% lower levelized cost of hydrogen compared to SMR with and without carbon capture. GTI obtained baseline capital and costs for the SMR with and without and methodology to calculate the levelized cost of hydrogen from an IEAGHG Technical Report: 2017-02 Techno-Economic Evaluation of SMR Based Standalone (Merchant) Hydrogen Plant with CCS. This methodology was then applied to GTI’s compact hydrogen generator using direct material costs previously obtained from a reputable engineering procurement and construction company, CB&I Howe-Baker. The analysis was performed for plants producing 90MMSCFD (million standard cubic feed per day) of hydrogen. Direct material costs were converted to total installed costs and total capital requirements using the same multiplying factors for both processes. We have found that the direct materials cost of the compact hydrogen generator is less than half the direct materials cost required for SMR without capture, and about one quarter the direct materials cost of SMR with carbon capture. This low materials cost translates into a significant CAPEX savings and lower levelized cost of hydrogen that exceed the goals of the techno-economic assessment. We have found that the CHG has a 43% lower installed cost and capital requirement compared to SMR without capture, that results in a levelized cost of hydrogen that is 19% lower than SMR. When 90% CO2 capture is added to the plants, the advantages is even better. The CHG has a 51% lower installed and capital requirement compared to SMR with capture, resulting in a 28% lower levelized cost of hydrogen. A sensitivity analysis was performed and showed natural gas feedstock cost and discount rate to be the main contributors to hydrogen price sensitivity. Given these significant cost advantages, GTI is encouraged to continue to develop the technology and market the economic advantages as well as the efficiency gains and ability to inherently capture CO2.

08 HYDROGEN↗