Optimizing One of the World’s Largest CO2 Collection, Compression and Sequestration Networks

Abstract Optimizing the design of the root national CO2 network is vital for achieving a cost-effective project with efficient operation and an expandable future. This paper covers a vital example of challenging traditional approaches proposed by design offices with an untypical concept for carbon collection, compression and sequestration. This achieved optimization of one of the World’s largest CO2 collection (23 MMTPA), compression and sequestration networks that serves current and future users in their significant roles toward decarbonization targets in today’s challenging environment. The key objective of this national development is to establish a national decarbonization grid that provides carbon abatement services to nearby CO2 emitting plants (e.g. Saudi Aramco, SABIC, Air Products, Linde) for capturing, transporting, compressing and storage elements of the Carbon Capture and Sequestration (CCS) chain. Not only does this help achieve the Kingdom of Saudi Arabia’s net-zero targets but also paves the pathway for blue-hydrogen energy transition plans. Cutting-edge technologies, along with modularization and localization concepts were considered in the design enhancements to have a pivotal role in addressing the real-world challenges and requirements. The subject mega project consists of a CO2 collection system, compression/pumping, and a sequestration system. The collection system gathers CO2, with limited contaminants, from emitters after primary compression and dehydration. The system design allows for further CO2 emitters to be added to in future expansions. All the collected dry CO2 is then further compressed/pumped, in a centralized dry gas compression plant, to the required high pressures for sequestration. This creates a CCUS industry that can incrementally increase storage capacity and drive down costs 1 in a steady pace achieving the Saudi Arabia decarbonization targets. The current first-phase scope (approx. 9-14 MTPA) 23 sets the seed for all future phases as they would be expansions building on the first-phase structure. This is why it is essential to consider all possible options of non-traditional solutions that can be used, instead of proceeding with typical perceptions and traditional concepts. A common ‘traditional’ perception is that the transportation of CO2 is best done in supercritical phase. Another traditional concept is the use of integrally-geared compressors for the required CO2 compression duties. These and other ideas were considered and challenged meticulously to arrive at the presented final ‘out-of-the-box’ solution and design that defies the above-mentioned traditional concepts and provides minimal cost and optimal flexibility and expandability.