MTR Full Scale Carbon Capture Front-End Engineering and Design (FEED) Study
Project Highlights
- Preliminary comparative cost estimates for different configurations to allow for the least risk and most cost-effective design.
- Dispersion analysis to evaluate if the existing stack could be used for the carbon capture system emissions without reheat of the plume.
- Equipment design optimizations to reduce overall capital and operating and maintenance costs of the system.
- The water supply and management was especially challenging, requiring unique solutions to maintain the overall plant water balance.
Project Description
Sargent & Lundy working with MTR, Basin Electric Power Cooperative (BEPC), Electric Power Research Institute (EPRI), and Trimeric Corporation, completed a full-scale FEED study to evaluate the retrofit of MTR’s membrane-based post-combustion carbon dioxide (CO2) capture technology to the BEPC Dry Fork Station (DFS) Unit 1. The carbon capture system is designed to treat the entire flue gas flow from DFS. It is estimated that the system will capture 6,560 tonnes per day of CO2, or approximately 70% of DFS’s current CO2 emissions. This capture rate reflects a 90% capacity factor of Dry Fork Station. The captured CO2 is compressed to 2,213 psia (152.58 bara) before flowing to the capture plant boundary tie-point. For this study, it was assumed the CO2 would be sent to the nearby Carbon Storage Assurance Facility Enterprise (CarbonSAFE) storage complex, currently in development, for geological sequestration.
Project Scope
Sargent & Lundy performed the overall project management and balance of plant (BOP) engineering for the FEED Study. The firm also provided valuable input and support to MTR, Trimeric, and EPRI who were responsible for the process engineering. BEPC/DFS personnel provided valuable input/decisions on design options throughout the study, that could impact the power plant operations; they also provided the cost estimate input for the switchyard modifications and power line installation to the new carbon capture utilization and storage substation. The following are some of the key deliverables/activities completed during the study:
- Developed the flue gas (composition) design basis & project design criteria.
- Detailed 3D Model, overall site plan and general arrangement drawings.
- Auxiliary power sourcing study.
- Water supply, cooling water design, & wastewater treatment evaluations.
- Piping & instrumentation diagrams and piping isometrics.
- Structural steel & ductwork drawings.
- Foundation and civil works drawings.
- Electrical one-line drawings.
- Electrical load list.
- Instrument and input/output lists.
- Controls architecture diagram.
- Major equipment datasheets used to solicit equipment budgetary quotes.
- Hazard identification facilitation.
- Permit matrix.
- Contracting strategy & project execution schedule.
- Constructability review.
- Capital cost estimate and operations and maintenance estimates.
- FEED report.
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