PARAMUS, N.J., Feb. 20, 2024–Koch Modular Process Systems is proud to announce its collaboration with PPL Corporation (PPL) as a key research partner for a groundbreaking carbon dioxide (CO₂) capture project, funded with a $72 million award from the U.S. Department of Energy (DOE) Office of Clean Energy Demonstrations (OCED).

The project, designated as a “Large-Scale Pilot” by the carbon capture, utilization, and storage (CCUS) industry, will see the development of a cutting-edge 20-megawatt research system at Cane Run and will capture 90,000 metric tons of CO₂ per year. Koch Modular’s involvement builds upon its previous success, having constructed a smaller 0.7 megawatt (MWe) pilot plant for the University of Kentucky in 2014. This new venture represents a significant scaling up of technology, demonstrating Koch Modular’s pivotal role in implementing carbon capture methodologies toward commercialization.

This ambitious endeavor aims to refine and prepare the technology for widespread commercial use. Koch Modular’s expertise in designing CO₂ removal processes and equipment will be instrumental in optimizing the efficiency and economic viability of the CO₂ capture system. The key to the technology is a process developed by the University of Kentucky, previously demonstrated in the 0.7 MWe pilot plant funded by the DOE.

The collaboration between PPL, the University of Kentucky, Koch Modular and others underscores a longstanding partnership to drive innovation in clean energy solutions. The Large-Scale Pilot will be installed at PPL’s subsidiary, Louisville Gas and Electric, utilizing technology pioneered by the University of Kentucky. Koch Modular’s selection as a partner for this project reflects its reputation for excellence and extensive experience in CO₂ capture technology development.

“We are excited to contribute our expertise to this transformative project, which aligns with our commitment to advancing sustainable energy solutions,” states Tom Schafer, Co-founder, and Vice President of Koch Modular Process Systems. “Through collaboration with PPL and the University of Kentucky, we aim to accelerate the adoption of low-carbon technologies and build a more resilient energy infrastructure for the future.”

This initiative is part of PPL’s broader commitment to advancing low-carbon energy technologies and enhancing grid resilience.  PPL is at the forefront of innovation in the energy sector with over 150 research and development projects involving more than 30 industry and academic partners.

Additional information about the project can be found HERE.

About Koch Modular

Koch Modular has successfully designed and constructed modular systems for the global chemical processing industry for over 25 years and has over 40 years of process engineering experience. Specializing in mass transfer, Koch Modular supports innovative technology companies on their pathway from concept to commercialization, providing pilot testing and process conceptualization services, process design package development, detailed engineering, and modular constructed systems. To learn more, visit kochmodular.com.

Contacts

Emily Steinhauer
CG Life
esteinhauer@cglife.com

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Carbon Capture Demonstration Scale System (Project Enterprise) installed at Calpine’s Los Medanos Energy Center in Pittsburg, CA. (Photo: Business Wire)

Groundbreaking New Technology Anticipated to Reduce Emissions by at Least 95%

[Paramus, NJ], [July 19th, 2023] — Koch Modular, a global leader in process engineering design and modular construction, is proud to announce and celebrate the forthcoming launch of a unique Carbon Capture Demonstration Scale System, aptly named Project Enterprise. Unveiled on Friday, July 14th, this project represents a significant milestone in the advancement of carbon capture technology, and it is poised to achieve a remarkable reduction in carbon emissions, projected to be at least 95%.

The Carbon Capture Demonstration System showcases Koch Modular’s pivotal role in developing, testing, and modular delivery of a highly efficient carbon dioxide capture process. The process harnesses a groundbreaking carbon capture solvent developed by ION Clean Energy, a Colorado-based trailblazer in sustainable solvent technologies. This breakthrough was made possible through a collaborative effort, with Koch Modular and ION’s engineers contributing their respective expertise to design the system.

Recently shipped as a series of modules and installed at Calpine’s Los Medanos Energy Center in  Pittsburg, CA, Project Enterprise makes strides in addressing carbon emissions from natural gas combustion. This power plant utilizes natural gas as its primary fuel source to generate electricity. Traditionally, the flue gases produced during natural gas combustion, which contain carbon dioxide, are released directly into the atmosphere. To assess the efficiency of CO2 capture with ION Clean Energy’s proprietary solvent, a portion of Calpine’s flue gas will be diverted to the new system, generating invaluable data to evaluate the advantages of ION’s solvent technology.

Tom Schafer, Vice President of Koch Modular, expresses his enthusiasm about the launch, “We are proud to be at the forefront of solving the critical issue of carbon emissions. Project Enterprise represents Koch Modular’s commitment to developing innovative solutions for a sustainable future. Through our engineering expertise and collaborative efforts with ION Clean Energy, Sargent & Lundy, Calpine, and the Department of Energy, we aim to demonstrate the effectiveness and viability of carbon capture technologies.”

Project Enterprise employs a three-step process to achieve its desired results. Initially, the hot flue gases are cooled, facilitating the subsequent absorption of carbon dioxide from the flue gas using ION’s transformative ICE-31 solvent. ION’s proprietary solvent boasts a faster and higher-capacity reaction with CO2 than other commercial solvents. Next, the solvent is regenerated in a state-of-the-art distillation column, allowing the captured carbon dioxide to be stripped from the solvent and collected as a valuable distilled product. This demonstration-scale system will not only validate the removal efficiency but also shed light on the unprecedented stability and low energy consumption required with ION’s carbon capture technology.

A significant achievement of Project Enterprise lies in its focus on addressing carbon dioxide emissions from natural gas combustion, presenting a unique challenge due to the lower carbon-to-hydrogen ratio of flue gases. Koch Modular and ION Clean Energy have demonstrated their expertise and ingenuity by successfully overcoming this challenge, showcasing their capabilities to address emissions from diverse fuel sources.

Jointly funded by the Department of Energy, ION Clean Energy, and Calpine, Project Enterprise is a pivotal step in showcasing the capabilities of carbon capture technology. By highlighting capture efficiency, remarkable stability, and efficient energy consumption, this project promises to provide insights that will contribute to the advancement of carbon capture technologies across different fuel sources.

“Project Enterprise is an invaluable opportunity to confirm the transformative performance of ICE-31,” said ION VP of Engineering Andrew Awtry, Ph.D. “Our partners at Koch Modular and Calpine are fantastic, and the data we derive from this pilot will prove that our technology is as well. We’re excited about ION’s contributions to helping our clients achieve their low-carbon energy goals.”

Koch Modular is honored to have been entrusted with such a transformative project. It remains committed to leveraging its engineering prowess and collaborative spirit to combat climate change through innovative solutions.

About Koch Modular:

Koch Modular is a global leader in process engineering design and the delivery of modular constructed systems. With a rich legacy spanning 40 years, we specialize in developing customized solutions for a wide range of industries, including energy, chemical, and pharmaceutical. Our unwavering commitment to innovation and sustainability drives us to deliver cutting-edge projects that address complex challenges. Through strategic partnerships and pioneering technologies, Koch Modular continues revolutionizing process engineering and contributing to a greener future.

Media Contact:

Emily Steinhauer
CG Life
esteinhauer@cglife.com
203.218.9906

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No one realized the implications of the CO₂ capture project that came through on Koch’s web inquiry page. This project, which would end up in the New York Times(1) and Scientific American(2), became the first operating carbon capture and storage facility. The requested scope was to design and build a section of a CO2 capture unit in a Wisconsin power plant.

Challenges And Solution

The customer had contracted another engineering company to develop an engineering package, but it soon became obvious that they were not geared to handle a pilot plant unit. A redesign was necessary and the customer contacted Koch Modular who immediately grasped the scope and potential technical problems ahead. They helped design a carbon capture unit based on the client’s Chilled Ammonia Process. The process first absorbed the CO2 using an ammonium carbonate solvent. The CO2 was then stripped out from the solvent in a regenerator, converting the ammonium bicarbonate back into ammonium carbonate. The latter was returned to the CO2 absorber, completing the solvent cycle.

The project was completed to the customer’s satisfaction, with significant lost project time recovered.

However, operating a CO2 capture unit in the Wisconsin winters presented special challenges.

The teams worked together, customer and Koch Modular, to resolve a few unique operating issues resulting in a successful test program.

Scale-Up

When the same customer needed a partner to build a larger carbon capture unit in a West Virginia power plant, Koch Modular was the logical choice.

With its own expertise and the experience gained from the Wisconsin project, Koch Modular designed heat-traced, free-draining piping with no stagnant areas. For high temperature corrosion areas, higher alloys instead of 316SS were used.

Because this project was also schedule-driven, modular construction was recommended to meet the schedule. This allowed the power plant to limit their on-site labor focus on off-module engineering, and other infrastructure while Koch Modular handled the design and construction off-site.

Results

The Koch Modular unit was the first to be completed within the larger Carbon Capture pilot project. The pilot unit was run by the power utility for two years to test the concept – up to 300 tons a day of CO2 was compressed, injected and sequestered between layers of rock deep underground. The project was deemed a complete success(1).

References: (1) Scientific American 2009/11/06, (2) NY Times 2011/07/14

Read more about Koch Modular’s Carbon Dioxide and Acid Gases experience and offerings here.

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