Koch Modular engineering team helped the client design a modular pilot plant system as a significant part of the first ever operating carbon capture and storage facility. The system was installed at a pulverized coal-fueled power plant where the captured CO2 was injected underground for permanent storage. The process boasts high CO2 removal rates, low solvent slip (release) and high CO2 purity.

1. Telephone: (201) 267-8670
www.modularprocess.com
Carbon Capture from
Power Plant Flue Gas
KMPS Whitepaper Series

2. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
2
Case Study: Carbon Capture Project
Koch Modular engineering team helped the
client design a modular pilot plant system as a
significant part of the first ever operating
carbon capture and storage facility. The
system was installed at a pulverized coal-
fueled power plant where the captured CO2
was injected underground for permanent
storage. The process boasts high CO2 removal
rates, low solvent slip (release) and high CO2
purity.
 CLIENT:
A Major Construction and
Technology Company.
 INDUSTRY:
Power Plant Construction

3. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
3
Key Engineering Features
 KMPS was selected as the supplier because of its successful experience
in carbon dioxide removal and the capability of designing modular units.
 As a test unit, the system was designed to accommodate a broad range
of operating conditions.
 Modular design allowed for the customer to concentrate on the balance
of the greenfield project’s engineering, infrastructure and on-site
construction activities, with minimal interruption.
 KMPS’s modular system was the earliest to be completed at the site and
required minimum site labor.

4. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
4
Core Challenges
 The solvent had a tendency to form solids at low temperatures and in
stagnant spots. Proper temperature control and piping design to avoid
pockets are essential.
 Materials of construction – certain high temperature areas required the
use of higher alloys than regular stainless steel.
 Installation – most of the column packing and internals were installed
in the KMPS shop but the random packing and internals had to be
installed on site. A KMPS engineer was on-site to ensure proper
installation.
 Schedule – the project was schedule-driven. The use of KMPS modules
substantially reduced the site labor requirement and shortened project
schedule.

5. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
5
The Solution
 Multi-module flue gas carbon capture system including solvent
regeneration and recovery.
 Based on the client’s “Chilled Ammonia Process”.
 The process first absorbs 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 is returned to the CO2 absorber,
thus completing the solvent cycle.

6. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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Flue Gas Return
-90% CO2
Flue Gas Feed
With CO2
Wash Water
CO2
CO2Removal&
SolventRegeneration
CO2Absorber
Solvent Cooling
Heat
Recovery
Lean Solvent
Rich Solvent
CO2 Removal Basic Process Flow Diagram

7. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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Installed Modular Process System

8. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
8
Impact
1. Because of KMPS’ previous experience with similar projects, Koch Modular was
able to capture the special design features to ensure smooth operation of the
unit.
2. 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.
3. Despite the complexity of the equipment, the Koch Modular unit was the most
trouble-free section of the plant.
4. 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.

9. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
9
Why Modular from KMPS?
For this project, KMPS leveraged its extensive CO2 removal experience, proprietary
distributor design technology and experience designing modular process systems which
resulted in a complete multi-module flue gas carbon capture system including solvent
regeneration and recovery that was supplied with a Process Performance Guarantee. Our
modular fabrication approach to process systems has many advantages, the main points of
which are highlighted below. To learn specifically how modular fabrication achieves these
benefits, please visit our website: www.modularprocess.com
 Shorter schedule / faster time to market
 Lower cost / lump sum bid / single source
 Minimal plant site interruption / improved safety

10. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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Koch Modular Products & Services
Customer Inquiry Data
Startup Assistance and
Training
Process Development
(In Collaboration with Client’s
Engineers and Scientists)
Material Balance, PFD’s, Unit Operation
Selection, Process Simulation
Process Design
Equipment Design, P&ID’s, Equipment
General Arrangement
Detailed Engineering
Equipment, Piping, Structural,
Electrical, Instrumentation & Controls
Construction
Modular System
Specialists in Process Design and Construction of Modular Mass Transfer Systems for the
Chemical Processing Industry.
Pilot Plant Testing
(If Required)
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Case Study: Carbon Capture from
Power Plant Flue Gas
Stan Lam, P.E. | Process Engineering Manager
www.linkedin.com/in/stan-lam
Stan Lam is an expert in the design and troubleshooting of distillation
columns. Stan has been designing, inspecting and installing distillation
column trays, packing and internals for over 35 years. Stan is a graduate
of The University of Birmingham and a certified Professional Engineer.