Carbon Capture Economics: Lessons Learned from the Field

Historically, the cost of adopting carbon capture technology across oil and gas sites has challenged gas compression operators. An economically viable solution that offers efficiency and longevity is desirable, as such an approach incentivizes investments in this promising field.

Following years of research, Caterpillar Oil & Gas engineers have developed and successfully tested a temperature swing adsorption (TSA) system that effectively captures CO2 emissions from existing gas compression assets. Importantly, this innovative solution can deliver 95% carbon capture performance at a cost below $40/tonne , offering a scalable method to help operators lower greenhouse gas (GHG) emissions and optimize total cost of ownership (TCO) through the system’s lifecycle.

Gas compression equipment with pipes outdoors
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The Need for Accessible Carbon Capture Systems

Global climate-related objectives continue to reshape the operational landscape. Carbon capture technologies introduced in the 1970s have evolved to support GHG emissions reduction in oil and gas operations through recovery, storage and utilization methods. However, it remains challenging for gas compression operators to balance increasing energy demands with climate-related objectives.

With this in mind, the Caterpillar Carbon Capture Solutions team tested a unique environmentally benign molecular (mole) sieve technique on an active gas compression site in Northwest Texas running a Cat® G3606 1,875 horsepower engine. The 1,000-hour pilot program confirmed the evolved approach achieves economical CO2 capture at a higher efficiency than other methods. The project also demonstrated that effective utilization of the engine's waste exhaust heat can increase carbon capture performance without harmful byproducts or carcinogens.

It was additionally noted that the system’s inherent modularity provides the flexibility to meet unique capacity and layout requirements for a wide range of greenfield and brownfield sites.

Modular carbon capture system at an outdoor site
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The Advantages of a Temperature Swing Adsorption System

Achieving high CO2 product purity is challenging with traditional mole sieves. Scaling to high-capacity systems is also a challenge, as larger vessels typically experience a high-pressure drop which results in high energy consumption. Caterpillar's innovative capture vessel design reduces pressure drop and leverages engine backpressure to minimize parasitic loads. The three steps in the CO2-TSA system’s batch process are adsorption, regeneration and cooling. With adsorption, when the media is cold then the ability of the media to store more CO2 increases. As the temperature increases, the media no longer holds CO2. Dehydrated gas then proceeds to molecular sieve beds. CO2 is removed in adsorption and the depleted flue gas is cooled. After adsorption, the bed regenerates and exhaust heat heats the media to recover CO2. Lastly, the media is cooled with the depleted exhaust from the adsorption bed to allow the adsorption step to occur. Key lessons from the pilot project helped refine the CO2-TSA system design, resulting in innovative technologies for water removal, repurposing waste heat, and increasing capture efficiency in any climate. Ongoing testing to optimize and evolve the system ensures the availability of a low-maintenance, scalable solution for gas compression sites operating 5,000 to over 50,000 horsepower.

Affordable Carbon Capture

The results and lessons learned from the pilot program informed Caterpillar’s next-generation TSA system design, leading to commercial viability at a projected cost of $40/tonne to capture 100 tonnes per day (TPD) or more of CO2 This is crucial, as it allows gas compression operators to capture CO2 at a cost below the government tax credits and align with evolving regulations.

At this cost, carbon capture is a feasible option for a greater number of gas compression operators. Removing the long-standing cost barrier to carbon capture technology adoption in the oilfield allows operators greater flexibility as requirements shift.

The TSA approach is engineered to meet the unique needs of the oil and gas industry and maximize operators’ existing assets. Achieving business objectives while lowering GHG emissions is a powerful combination to remain competitive in today’s climate.

1 Projected carbon capture cost of $40 USD/tonne is based on the pilot site results when capturing a minimum of 100 TPD; total skidded cost does not account for any significant foundation, piling and electrical work. Achieved during a 20 TPD pilot on a customer Cat® G-3606 engine during 40 °F conditions.

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