Pipeline transport

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Category: CO2 transportation

DESCRIPTION

Pipeline transport is an efficient and established method for moving large volumes of carbon dioxide (CO2) in dense (highly compressed gas phase) or supercritical phases from capture sites to storage or utilization locations. As of today, approximately 11,500 km of CO2 pipelines are operational worldwide, with about 8,500 km located in the United States and Canada. The first large-scale CO2 pipeline, the Canyon Reef Carriers (CRC) pipeline, was constructed in 1972, extending 225 km. It has a capacity of approximately 5.2 MtCO2/yr and remains in operation today.1 The pipeline system includes compressors for dense-phase transport or for initial gas compression (followed by pumps in supercritical transport), as well as booster compressors or pumps, pressure and flow control stations, monitoring equipment, and valves. Over at low-to-medium distances and large volumes, pipeline transport is most efficient and economical.2 Depending on the distance, pipeline transport may also require midway recompression or pumping, typically at every 70-140 km, so that the pressure is maintained above the minimum pipeline operating pressure.3 Challenges of pipeline transport include fracture control, corrosion, flow assurance, and operational issues, impurity control, leakage risk, etc.4 CO2 can be transported efficiently in the supercritical state, having temperature and pressure beyond the critical point (31.1 °C and 72.9 atm). When CO2 is in a supercritical state, its density is like a liquid, making it easier to store large amounts in small volumes, and its viscosity is like a gas, which makes it easier to pump over long distances. The recommended pressure for long-distance transport, such as in offshore pipelines for CO2 transportation, is above 74.5 bar and should be dehydrated to avoid pipeline corrosion.2 Commercial CO2 pipelines operate across a broad pressure range, typically between 83 and 152 bar, with peak pressures reaching 172 to 193 bar, which is equivalent to the storage pressures found at depths of 800 to 1500 meters.2 At these high pressures and appropriate temperatures, CO2 behaves as a supercritical fluid, enabling the use of pumps instead of compressors, resulting in low energy consumption and high flow capacities.  However, for dense-phase CO2 transport for onshore pipelines over short to medium distances, such as in CO2 backbone networks, the recommended pressures are lower (around 40 bar).

CO2 Pipeline

FUNCTION IN CCU VALUE CHAIN

  • Transporting large volumes of CO2.
  • Linking the capture phase with storage or utilization sites.
  • Provide a steady and continuous flow.

LIMITATIONS

Pipeline transport of CO2 faces several limitations and challenges:

Technical

  • Strict CO2 purity requirements, typically between 95-99%, are required to prevent corrosion and pipeline integrity.5
  • Sensitivity to impurities such as H2O, SOx, and NOx.5

Economics

  • High capital investment requirements for onshore and/or offshore pipeline infrastructure.
  • Operating costs for compression, maintenance, and monitoring.
  • Cost inefficiency for transporting small volumes of CO2 over long distances due to economies of scale.6
  • Pipeline costs are proportional to distance.7

Regulatory & Environmental

  • Complex permitting and approval processes for new pipeline projects.
  • Safety aspects related to potential leaks could pose risks to both human health and the environment.

ENERGY

Electricity is the primary energy source for CO2 transport via pipelines.8 Mainly used for compression, pumping, and booster stations, which are essential for maintaining the pressure of the CO2 during transportation.

Energy and Consumables
Parameter Value
Electricity (kWh/tCO2) Variable (depending on booster station inlet and outlet pressure)

COSTS

CO2 pipeline costs are divided into construction, operation and maintenance, and other expenses (e.g., design, insurance).9 Pipeline transport is CAPEX-intensive, and cost depends on distance, diameter, and terrain.7 Offshore pipelines are 40–70% more expensive due to higher pressure and lower temperature requirements.9 Larger diameters reduce per-unit transport cost. Terrain (e.g., wetlands, mountains) also impacts costs.2 Repurposing natural gas pipelines can cut costs to 1–10% of new builds4, but isn't ideal for high flow or long distances due to lower pressure ratings (class 600 vs 900 pipelines for CO2 pipelines).7

CAPEX: Capital investment costs of the pipeline as a function of its diameter can be estimated using the equation below.8

Y = 2.1575*X + 0.018

Where Y is the pipeline CAPEX in €/m and X is the pipe diameter in mm.

OPEX: Fixed OPEX is 2.6% of CAPEX.8

Variable OPEX are the costs associated with booster station electricity consumption. Booster station placement depends on the pipeline diameter and CO2 flow rate. A general rule is that a booster station is placed between 70 and 150 km with a pressure drop of 0.5 – 1.5 bar/km or an allowable pressure drop of 50 – 70 bar along the total pipeline length.8

Total CO2 transportation costs at 150 bar and 3.65 MtCO2/yr:8

CO2 Transportation Cost
Distance Pipeline diameter* Compression cost** Transport cost***
km mm €/tCO2 €/tCO2
25 300 33.6 0.5
100 350 2.5
200 400 5.7
300 350 8.4
400 350 11.8
500 400 15.1

*Reduction in optimal pipeline diameters after 200 km is attributed to the presence of booster stations influencing the overall cost.

**Initial compression costs to a pressure of 73.8 bar (see separate infosheet on CO2 compression).

***Transport cost excluding initial compression costs.

8 Pipeline capacity factor – 90%; interest rate – 8%; pipeline lifetime – 50 yrs; electricity price – 31 €/MWh; 2024 euros; CO2 transport capacity - 10,000 tCO2/d; compressor outlet pressure – 73.8 bar; compressor stages – 5; CO2 transport pressure – 150 bar; CO2 transport temperature – 30°C; allowable minimum pressure before booster pump – 100 bar.

10 Another source provides the costs for transporting pure CO2 using onshore and offshore pipelines for CO2 capacities in the range 1 – 20 MtCO2/yr. Lower capacities have higher transport costs.

CO2 Transportation Costs (Onshore and Offshore)
Distance Transport cost (onshore) Transport cost (offshore)
km €/tCO2 €/tCO2
100 20 – 10 28 – 11
500 57 – 18 80 – 20
1000 >80 – 28 >80 – 38
1500 >>80 – 35 >>80 – 50
2000 >>>80 – 42 >>>80 – 68

10 Pipeline capacity factor – 85%; interest rate – 8%; pipeline lifetime – 25 yrs; electricity price – 80 €/MWh; 2017 euros; CO2 transport capacity - 1 – 20 MtCO2/yr; CO2 transport pressure – 150 bar for onshore and 200 bar for offshore pipelines.

TECHNOLOGY PROVIDERS

ALTERNATIVE TECHNOLOGIES

  • Truck: Flexible for short distances, but higher operational costs.
  • Rail: Offers a flexible and lower-capital option for smaller volumes, but higher OPEX.

          Truck/Rail CO2 conditions: Liquid at -18 °C and 14-20 bar, water <30 ppmv, and oxygen <10 ppmv.11

  • Ship: Suitable for offshore transport, flexibility in routes and distance (see infosheet).

          Medium-pressure shipping: Liquid at -30 °C and 15 bar, water <30 ppmv, and oxygen <10 ppmv.11

          Low-pressure shipping: Liquid at -50 °C and 6.5 bar, water <5 ppmv, and oxygen <10 ppmv.11

CONTACT INFO

Mohammed Khan (mohammednazeer.khan@vito.be)

Miet Van Dael (miet.vandael@vito.be)

ACKNOWLEDGEMENT

This infosheet was prepared as part of the MAP-IT CCU project funded by VLAIO (grant no. HBC.2023.0544).

REFERENCES

1.  Doctor R, Palmer A, Coleman D, et al. Transport of CO2. In: Pichs-Madruga R, Timashev S, eds. Carbon Dioxide Capture and Storage. Cambridge University Press; 2005:431.

2.  IEA. CO2 Transport and Storage - Energy System. 2024. Accessed February 18, 2024. https://www.iea.org/energy-system/carbon-capture-utilisation-and-storage/co2-transport-and-storage

3.  Knudsen J. Technology Data for Carbon Capture, Transport and Storage.; 2021. Accessed May 5, 2022. http://www.ens.dk/teknologikatalog

4.  DNV. CO2 pipelines. 2024. Accessed February 18, 2024. https://www.dnv.com/focus-areas/ccs/carbon-pipelines.html

5.  Serpa J, Morbee J, Tzimas E. Technical and Economic Characteristics of a CO2 Transmission Pipeline Infrastructure.; 2011.

6.  Jakobsen J, Roussanaly S, Anantharaman R. A techno-economic case study of CO2 capture, transport and storage chain from a cement plant in Norway. J Clean Prod. 2017;144(2017):523-539.

7.  ZEP. The Costs of CO2 Transport: Post-Demonstration CCS in the EU.; 2011.

8.  Solomon MD, Scheffler M, Heineken W, Ashkavand M, Birth-Reichert T. Pipeline Infrastructure for CO2 Transport: Cost Analysis and Design Optimization. Energies . 2024;17(12).

9.  Club CO2. CO2 transport. 2024. Accessed February 18, 2024. https://www.club-co2.fr/en/content/co2-transport

10. Roussanaly S, Deng H, Skaugen G, Gundersen T. At what Pressure Shall CO2 Be Transported by Ship? An in-Depth Cost Comparison of 7 and 15 Barg Shipping. Energies. 2021;14(5635):1-27.

11. NOV. CO2 Dehydration Product Offerings.; 2024. https://www.nov.com/-/media/nov/files/capabilities/carbon-capture-utilization-and-storage-solutions/co2-dehydration-product-offerings-brochure.pdf

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