https://doi.org/10.1016/j.ccst.2022.100041
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Capital Costs
CO2 capture island equipment costs were estimated based on proprietary costs, budgetary pricing, and allowances. All costs are provided in 2017 dollars. Labor costs were estimated for each individual subcontracted process or component rather than a blanket percentage over the whole project, and include the associated labor indirect costs which apply to this type of work such as overtime, per diem, contractor’s G&A and profit.
Indirect project costs, such as engineering, construction management, startup, and commissioning support, construction materials and initial fills for testing were also included in the estimate to provide a total capital investment. The owner’s costs were not included.
The overall cost for the commercially available amine-based CO2 capture system is provided for each of the three facility sizes. To calculate the total cost per mass of CO2 captured, all costs must be evaluated on an annual basis. In previous U.S. Department of Energy (DOE) case studies, a capital annualization factor or Capital Charge Factor (CCF) of 0.1243 (1/yr) was used to evaluate costs on a constant dollar basis. This methodology was used to calculate the total cost of capture for this TEA.AnnualizedCapitalCost=CCFXPWhere,CCF=i(1+i)n(1+i)n−1
Table 5 provides a breakdown of the capital cost.
Table 5. Capital cost summary of CO2 capture slipstream systems (McPherson et al., 2018)
| Description | Case 1 (65% Capture) | Case 2 (90% Capture) | Case 3 (1,000 lb/MWhg) |
|---|---|---|---|
| Balance of Plant (BOP) Scope | |||
| Civil, Site Prep and Structural | 6,168,200 | 7,125,500 | 5,434,200 |
| Architectural | 4,812,000 | 5,850,000 | 4,016,100 |
| Mechanical | 15,945,200 | 18,867,300 | 13,704,900 |
| Electrical and I& C | 2,342,900 | 2,342,900 | 2,342,900 |
| CO2 capture System (EPC) | 470,000,000 | 610,000,000 | 380,000,000 |
| Total Direct Capital Cost ($) | 499,268,300 | 644,185,700 | 405,498,100 |
| Other Direct and Construction Indirect Costs (Excludes EPC) | 6,221,000 | 7,266,000 | 5,420,000 |
| Engineering (Excludes EPC) | 3,549,000 | 4,145,000 | 3,092,000 |
| Construction management (Excludes EPC) | 710,000 | 829,000 | 618,000 |
| Startup/Commissioning (Excludes EPC) | 366,000 | 427,000 | 318,000 |
| Contingency (Excludes EPC) | 8,022,000 | 9,370,000 | 6,989,000 |
| Total Other Cost ($) | 18,868,000 | 22,037,000 | 16,437,000 |
| Total Capital Investment ($) | 518,136,300 | 666,222,700 | 421,935,100 |
| CCF | 0.1243 | 0.1243 | 0.1243 |
| Annualized Capital Cost ($/yr.) | 64,404,400 | 82,811,500 | 52,446,600 |
Operating Costs
Operating costs were estimated based on a capacity factor of 77% and are provided in 2017 dollars. Fixed O&M costs for operators, maintenance material and labor, and administrative labor costs were also included based on typical assumptions.
The overall O&M cost for the commercially available amine-based CO2 capture system is provided for each of the three facility sizes Table 6. provides a breakdown of the annual O&M cost.
- 1
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Operating labor is based on the addition of 24 operators for the CO2 capture system.
- 2
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Water treatment costs include chemical and solids disposal costs.
- 3
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Solvent costs include the cost for new makeup solvent and disposal of the degradation products.
- 4
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TS&M is based on the DOE suggested rate of $10/tonne of CO2 captured.
Table 6. O&M cost summary of CO2 capture slipstream systems (McPherson et al., 2018)
| Description | Case 1 (65% Capture) | Case 2 (90% Capture) | Case 3 (1,000 lb/MWhg) |
|---|---|---|---|
| Total Fixed Operating Cost ($) | 7,195,000 | 7,195,000 | 7,195,000 |
| Annual Operating Labor¹ | 3,295,000 | 3,295,000 | 3,295,000 |
| Maintenance Material & Labor | 3,900,000 | 3,900,000 | 3,900,000 |
| Total Variable Operating Cost ($) | 39,492,000 | 51,507,000 | 31,030,000 |
| Makeup Water | 1,052,000 | 1,465,000 | 769,000 |
| Demin Makeup Water | 41,000 | 57,000 | 30,000 |
| Water Treatment² | 356,000 | 454,000 | 235,000 |
| Pre-scrubber Caustic Solution | 809,000 | 1,079,000 | 540,000 |
| Lost Generation/Auxiliary Power | 14,570,000 | 20,236,000 | 10,793,000 |
| Lost Generation/Process Steam | 14,570,000 | 16,998,000 | 12,681,000 |
| CO2 Capture Solvent³ | 8,094,000 | 11,218,000 | 5,982,000 |
| CO2 Transportation, Storage and Monitoring4 ($) | 19,581,000 | 27,138,000 | 14,472,000 |
| Total annual O&M Cost ($) | 66,268,000 | 85,840,000 | 52,697,000 |
Notes:
Cost of Capture
Table 7 provides an estimate of the total quantity of CO2 captured in a year as well as the evaluated cost for the CO2 capture system.
Table 7. Evaluated cost of CO2 capture systems (McPherson et al., 2018)
| Description | Case 1(65% Capture) | Case 2(90% Capture) | Case 3(1,000 lb/MWhg) |
|---|---|---|---|
| Annualized Capital Cost ($/yr.) | 64,404,400 | 82,811,500 | 52,446,600 |
| Annual O&M Cost ($/yr.) | 66,268,000 | 85,840,000 | 52,697,000 |
| Total Annual Cost ($/yr.) | 130,672,400 | 149,079,500 | 118,714,600 |
| Annual CO2 Captured (tons/yr.) | 2,158,460 | 2,991,500 | 1,595,240 |
| Cost of Capture ($/tons) | 61 | 50 | 74 |
The development of a new solvent can reduce the overall cost of CO2 capture by slashing the utility usage (water, steam, power), and the size of the unit. For example, the recently developed amine-based solvent shows promising qualities in capturing CO2 with a lower cost of $50.6/tonne CO2 (Zheng, Barpaga et al. 2020) and $47.10/ tonne of CO2(Jiang, Mathias et al. 2021).
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