CCS front end engineering & design report: American Electric Power Mountaineer CCS II Project. Phase 1

Topic(s): Carbon capture use and storage (CCUS), Engineering and project delivery

This public design report provides select non-proprietary design information from the Phase I – Project Definition work products associated with the carbon capture and storage (CCS) system planned for installation at Appalachian Power Company’s Mountaineer Plant, located in New Haven, West Virginia, under US Department of Energy (DOE) Cooperative Agreement No. DE-FE002673.

The overall objective of the project is to design, build and operate a commercial-scale CCS system capable of treating a nominal 235 MWe slip stream of flue gas from the outlet duct of the Flue Gas Desulfurization system. The project was planned for execution in four phases: Phase I - Project Definition (February 2010 – September 2011), Phase II - Design and Permitting (October 2011 – December 2012), Phase III – Construction and Start-up (January 2013 – August 2015), and Phase IV – Operations (September 2015 – June 2019). AEP and its integrated project team successfully completed Phase I objectives, as outlined in the cooperative agreement, calling for:

• the resolution of outstanding conditions with the DOE cooperative agreement;
• project specific developmental activities (front end engineering and design (FEED));
• the initiation of the NEPA process; and
• the identification of exceptionally long lead time items.

The FEED package incorporated knowledge gained and lessons learnt (construction and operations related) from the Mountaineer Product Validation Facility and the design package also established the fit, form, and function of the project including design criteria, mass and energy balances, plot plans, general arrangement drawings, electrical one-lines, flow diagrams and P&IDs.

Based on the work completed in the FEED package, the project team also:

• developed a +/- 25 per cent cost estimate;
• developed a detailed Phase II project schedule;
• provided DOE with all information it needed to complete the NEPA process;
• developed a multi prime construction contracting strategy for Phase III;
• issued preliminary PFDs and overall mass and energy balances;
• drilled a deep well for characterisation of subsurface geology at one of the alternative CO₂ storage sites;
• completed preliminary project design; and
• submitted a decision point application regarding future project plans.

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