Matthew T Usher, CCS Engineering Manager: Final Technical Report Page 1 of 66

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project
Final Technical Report
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Report Title: Final Technical Report

Type of Report: Final Scientific/ Technical Report
Reporting Period: 02/01/2010 11/30/2011
Author(s): Deanna M Gilliland, Assistant Project Manager
Matthew T Usher, CCS Engineering Manager
Issue Date: December 8, 2011
DOE Award No.: DE-FE0002673
Recipient: American Electric Power Service Corporation
1 Riverside Plaza, Columbus, OH 43215

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Disclaimer: "This report was prepared as an account of work sponsored by an agency of

the United States Government. Neither the United States Government nor any agency
thereof, nor any of their employees, makes any warranty, express or implied, or assumes
any legal liability or responsibility for the accuracy, completeness, or usefulness of any
information, apparatus, product, or process disclosed, or represents that its use would not
infringe privately owned rights. Reference herein to any specific commercial product,
process, or service by trade name, trademark, manufacturer, or otherwise does not
necessarily constitute or imply its endorsement, recommendation, or favoring by the United
States Government or any agency thereof. The views and opinions of authors expressed
herein do not necessarily state or reflect those of the United States Government or any
agency thereof."

Abstract
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The Final Technical documents all work performed during the award period on the
Mountaineer Commercial Scale Carbon Capture & Storage project. This report presents the
findings and conclusions produced as a consequence of this work.

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Table of Contents
Table of Contents
List of Tables
List of Figures
Executive Summary
Project Approach
II
FEED Approach
1.1
Process Overview
1.2
Technical Approach to Integration
11
1.3
Operational Philosophy
12
1.4
Integration Philosophy
13
III
Results and Discussion
15
1.1
Studies & Investigations
15
Chilled Ammonia Process bleed stream study
15
1.1.1
Heat Sourcing and Integration (Steam Supply / Condensate Return) Study 17
1.1.2
Compression Study
20
1.1.3
Geologic Characterization Study
22
1.1.4
Pipeline Routing / Siting Study
34
1.1.5
CAP Design Basis
37
1.1.6
CAP Reagent / Material Handling Study
37
1.1.7
Miscellaneous Studies
39
1.1.8
Process Makeup Water and Wastewater Study
39
1.1.9
Flue Gas Study
42
1.1.10
Refrigerant Study
44
1.1.11
Power Assessment Study
46
1.1.12
Building / Architectural Study
49
1.1.13
Refrigeration Heat Rejection Vapor Study
49
1.1.14
Accessibility Review
51
1.1.15
Spares Study
52
1.1.16
Constructability Study
53
1.1.17
1.2
Civil/ Structural
Preliminary Plot Plan
1.2.1
General Arrangement Drawings
1.2.2
54
54
54
1.3
Chilled Ammonia Process
Preliminary Safety Analysis
1.3.1
Process Flow Diagram (PFD) and Mass and Energy Balance
1.3.2
Piping & Instrumentation Diagram (P&ID)
1.3.3
Process Description
1.3.4
54
54
55
55
56
1.4
Mechanical
Equipment List
1.4.1
56
56

1.5
Electrical/ I&C
Preliminary Electrical One Lines
1.5.1
Distributed Control System (DCS) Control Philosophy
1.5.2
56
56
57
1.6
Permits, Insurance, & Infrastructure
Relocations
1.6.1
Identify Permits
1.6.2
57
57
58
1.7
Professional Services
WBS
1.7.1
Cost Estimate
1.7.2
Project Schedule
1.7.3
Procurement Template
1.7.4
Contract Template
1.7.5
Phase I Alstom Contract
1.7.6
Phase I Storage Contract
1.7.7
Phase II Alstom Contract
1.7.8
Phase II Storage Contract
1.7.9
Phase II Construction Contract
1.7.10
Phase II Project Work Plan
1.7.11
Contracting Strategy
1.7.12
58
58
58
59
60
60
60
60
60
61
61
61
61
1.8
Wells and Monitoring Verification and Accounting (MVA) System
Preliminary Safety Analysis
1.8.1
Develop the Preliminary Monitoring Plan
1.8.2
61
61
63
1.9
63
AEP Project Management and Support
1.10
IV
V
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National Environmental Policy Act (NEPA)
Conclusions
Products Produced/ Technology Transfer Activities
Appendix A Permit Summary Report
64
64
66

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List of Tables
Description
Table 1: CAPEX & 1st Year OPEX Summary for Byproduct Handling Options
Table 2: Mountaineer CAP Makeup Water Usage
Table 3: Typical Ohio River Water Quality
Table 4: ODP & GWP of various refrigerants considered
Table 5: Refrigerant specific power consumption
Table 6: Summary of RAM calculated results
Page
15
39
40
44
44
52
List of Figures
Description
Figure 1: Simplified Chilled Ammonia Process Schematic
Figure 2: Chilled Ammonia Process Schematic
Figure 3: Steam Extraction Location and Energy Penalty
Figure 4: Simplified Schematic of Mountaineer Turbine Arrangement with CAP
Integration
Figure 5: Throttling of Crossover Valves with and without BFPT valve
upgrade
Figure 6: Schematic of the location of the injection and monitoring wells for PVF
Figure 7a: Reference map for Rose Run and Copper Ridge cross sections
Figure 7b: Cross section showing Rose Run (A-A) from north to south (datum top
of the Rose Run sandstone).
Figure 7c: Cross section of Copper Ridge (B-B) Formation showing structure from
west to east
Figure 8a: Meigs County Linament broken into four areas
Figure 8b: Aerial relationship between Devonian shale core fracture orientations
and the BA-02 characterization well
Figure 9: Example of image log within the Beekmantown formation showing some
of the fractures (red) and the bedding planes (green)
Figure 10: CT scan of a core sample from BA-02 showing the presence of vugs
Figure 11: Example of integration of core mapping on triple combo log; yellow
segments indicate depth from which side wall cores were obtained
Figure 12: Site location for pipeline and injection wells for the MT CCS II project
Figure 13: Location of Vapor Plume Sources (From 3-D Model)
Figure 14: 3-D Model Snapshot showing Some Aspects of Accessibility
Page
9
10
17
18
19
22
23
25
26
28
28
30
31
32
35
49
50

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Executive Summary
As identified in the Cooperative Agreement DE-FE0002673, AEPs objective of the
Mountaineer Commercial Scale Carbon Capture and Storage (MT CCS II) project is to
design, build and operate a commercial scale carbon capture and storage (CCS) system
capable of treating a nominal 235 MWe slip stream of flue gas from the outlet duct of the
Flue Gas Desulfurization (FGD) system at AEPs Mountaineer Power Plant (Mountaineer
Plant), a 1300 MWe coal-fired generating station in New Haven, WV. The CCS system is
designed to capture 90% of the CO 2 from the incoming flue gas using the Alstom Chilled
Ammonia Process (CAP) and compress, transport, inject and store 1.5 million tonnes per
year of the captured CO 2 in deep saline reservoirs.
Specific Project Objectives include:
1. Achieve a minimum of 90% carbon capture efficiency during steady-state operations.
2. Demonstrate progress toward capture and storage at less than a 35% increase in
cost of electricity (COE).
3. Store CO 2 at a rate of 1.5 million tonnes per year in deep saline reservoirs.
4. Demonstrate commercial technology readiness of the integrated CO 2 capture and
storage system.
The MT CCS II project was planned to be executed in four phases: Phase I - Project
Definition (February 2010 September 2011), Phase II - Design & Permitting (October
2011 December 2012), Phase III Construction & Start-up (January 2013 August
2015), and Phase IV Operations (September 2015 June 2019). Phase I - Project
Definition, included resolution of outstanding conditions with the Department of Energy
(DOE) cooperative agreement, front-end engineering and design, initiation of the NEPA
process, and identification of exceptionally long lead time items. The front-end engineering
and design package incorporated knowledge gained and lessons learned from the
Mountaineer Product Validation Facility (PVF). The front-end engineering and design
package is also expected to establish the fit, form, and function of the project including
design criteria, mass & energy balances, plot plans, general arrangement drawings,
electrical one-lines, flow diagrams, P&IDs, etc. Phase II - Design & Permitting, would
include detailed engineering and design, permitting activities, refinement of cost estimate,
design review board meeting(s) and scope freeze, procurement activities, site preparation
activities, and injection well construction. Phase III Construction & Start-up, will include
construction, start-up and commissioning, and initial performance testing of the CO 2
capture and storage systems. Phase IV Operations, will correlate to DOEs Operations,
Data Collection, and Reporting Phase and will include DOE required data collection and
reporting associated with the initial four years of project operation and subsequent two
years of post injection monitoring of the storage system.
During Phase I, AEP developed the integrated project team responsible for completing the
project objectives. The project team consisted of individuals from Alstom Power, Inc., the
CAP technology owner who would be responsible for the development of the CAP conceptual
design, WorleyParsons Group, Inc., who provided architectural and engineering services for
the balance of plant (BOP) scope, and Battelle Memorial Institute, who held responsibility
for the development of the CO 2 storage scope. Additionally, AEP executed multiple
agreements to formulate a Geologic Experts Team. The Geologic Experts Team (Team)
served as an advisory body which considered the strategies, plans, designs, operations,
problems, concerns, results and recommendations of AEP and its project team as they

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relate to the injection and sequestration of carbon dioxide as part of the MT CCS II Project,
and to provide guidance to AEP to promote the success of the project.
The project identified many significant findings through the course of the Phase I studies,
investigations, and conceptual design. A prime example being the Lower Copper Ridge
formation, identified through PVF efforts, was confirmed to be a suitable storage reservoir in
the Mountaineer area through analysis of regional data as well as data obtained from the
Borrow Area characterization well (BA-02). The project team was successful in completing
the conceptual design of a commercial scale CCS facility, capable of capturing 90% of the
CO 2 from the flue gas stream and sequestering 1.5 million tonnes of CO 2 , per year in deep
saline reservoirs. Additionally, during Phase I, the project developed a refined cost estimate
for the engineering, design, construction, commissioning, and the initial four years of
operation of this facility. The complete scope of this project, being a first of its kind, was
estimated to cost $1.065 billion including risk based contingency.
As the project was drawing near the end of Phase I, AEP expressed its intention to suspend
the project and terminate the Cooperative Agreement following the completion of Phase I
objectives. This decision was result of the changes in the CCS arena since the beginning of
the project, and in the ability to fund AEPs cost share of the commercial scale project.
Although the project will not continue into Phase II immediately following the conclusion of
Phase I, the project did complete the Phase I objectives and key milestones identified in the
cooperative agreement. The work completed in Phase I continues to support the
commercial readiness of Alstoms CAP technology at the intended scale and provides AEP
and DOE with a good understanding of the projects risks, capital cost, and expected
operations and maintenance costs during planned Phase IV operations. The completed
front-end engineering and design package provides a sound basis for completion of the
project when conditions warrant the continuation of this or a similar project elsewhere in the
U.S.
I
Project Approach
More specifically to the Phase I Project Definition effort, AEP was required to complete
resolution of outstanding conditions with the DOE cooperative agreement, project specific
developmental activities (i.e. front-end engineering and design), development of an
Environmental Impact Statement (EIS) to satisfy National Environmental Policy Act (NEPA),
and identification of exceptionally long lead-time items. The front-end engineering and
design (FEED) package incorporates knowledge gained and lessons learned (engineering,
design, construction and operations related) from the Mountaineer Product Validation
Facility (PVF). The FEED package also establishes the fit, form, and function of the project
including design criteria, mass & energy balances, plot plans, general arrangement
drawings, electrical one-lines, flow diagrams, P&IDs, etc.
During Phase I (Project Definition), the DOE identified the following key milestones:
+/- 25% Cost Estimate Complete

Project Design Basis Complete
Detailed Phase II Project Schedule Developed
Provide DOE with all information it needs to complete the NEPA process.
Select Prime Construction Contractor(s)
Issue Preliminary PFD and Overall Mass and Energy Balance
Complete FEED
Submit Phase I Decision Point Application

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The activities outlined in Section III, Results and Discussion, provide the summary of work
completed during the Phase I, Project Definition of the MT CCS II project in order to achieve
the key milestones identified for Phase I while working toward achieving the overall project
objectives.
II
FEED Approach
1.1 Process Overview
The proposed CO 2 capture facility at AEPs existing Mountaineer Plant utilizes Alstoms
CAP technology to capture approximately 1.5 million metric tons of CO 2 annually based
on a design target of 90 percent CO 2 reduction from a 235-MW flue gas slipstream of
the 1,300-MW Mountaineer Power Plant. The captured CO 2 is transported by pipeline to
injection wells located up to approximately 12 miles (approx. 19 kilometers) from the
plant.
The existing Mountaineer Plant began commercial operation in 1980. The plant consists
of a 1,300-MW pulverized coal-fired electric generating unit, a hyperbolic cooling tower,
material handling and unloading facilities, and various ancillary facilities required to
support plant operation. The plant uses (on average) approximately 10,000 tons of coal
per day. Coal is delivered to the plant by barge (on the Ohio River), rail, and conveyors
from a nearby coal mine located west of the site. The plant is equipped with air
emissions control equipment, which includes: (1) an electrostatic precipitator for
particulate control; (2) selective catalytic reduction for nitrogen oxides (NO x ) control;
(3) a wet flue gas desulfurization (FGD) unit for sulfur dioxide (SO 2 ) control; and (4) a
Trona injection system for sulfur trioxide (SO 3 ) control.
The existing Mountaineer Plant Product Validation Facility (PVF) utilizes Alstoms CAP
system, shown simplified in Figure 1 below, to treat approximately 20 MW of flue gas,
or 1.5 percent of the total plant flue gas flow. The PVF started capturing CO 2 in
September 2009 and initiated injection in October 2009. The PVF is designed to capture
and store approximately 100,000 metric tons of CO 2 annually. Captured CO 2 from the
PVF is injected via two onsite wells into two geologic formations (Rose Run and Copper
Ridge, shown in Figure 6 below) located approximately 1.5 miles below the plant site.
The PVF also includes three deep monitoring wells used for monitoring geologic
conditions and assessing the suitability of the geologic formations for future storage.
The PVF supplied data to support the design and engineering of the MT CCS II project.
The CO 2 capture system designed for the Mountaineer CCS II Project is similar to the
Alstom CAP system currently operating at the Mountaineer Plant PVF, but approximately
12 times the scale. As with the PVF, the process uses an ammonia-based reagent to
capture CO 2 and isolate it in a form suitable for geologic storage. The captured CO 2
stream is cooled and compressed to a supercritical state for pipeline transport to the
injection well sites. In general terms, supercritical CO 2 exhibits properties of both a gas
and a liquid. The process is designed to remove approximately 90 percent of the CO 2
from the 235-MW slipstream of flue gas.

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Figure 1: Simplified Chilled Ammonia Process Schematic
The CAP uses an ammonia-based reagent to remove CO 2 from the flue gas. As shown in
Figure 2 below, the first step in the process is to cool the flue gas, following treatment
by the plants FGD system, with chilled water to temperatures necessary for CO 2
capture. The capture process involves CO 2 reacting with ammonia (NH 3 ) ions to form a
solution containing ammonia-CO 2 salts. These reactions occur at relatively low
temperatures and pressures within the absorption vessels. The solution of ammoniaCO 2 salts is then pumped to a regeneration vessel. In the regeneration vessel, the
solution is heated under pressure with steam from the power plant, and the reactions
are reversed, resulting in a high-purity stream of CO 2 . The regenerated reagent is then
recycled back to the absorption vessel to repeat the process. The CO 2 stream is
scrubbed to remove excess ammonia, then compressed, and transported via pipeline to
injection wells for geologic storage.

Gas
Water
Rich Solution
Lean Solution
CO2
Treated
REF
Refrigerant
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Cooling
Chiller
System
REF
Steam
REF
Fluegas
Liquid
CO2 to Storage
Stripper
G6
Cooling
G7
Water Wash
NH3
WATERWASH
G5
CO2
Compression
ByProduct
DCH 1
Cooling Tower
G3
Direct Contact
Cooling
REF
G4
Steam
Booster Fan
G1
Fluegas from
FGD
CO2 Regenerator
DCC 1
FLUE GAS COOLING &

TREATING
CO2 Absorber
CO2 ABSORPTION
CO2 REGENERATION,
Dehydr.& COMPRESSION
Figure 2: Chilled Ammonia Process Schematic
1.2 Technical Approach to Integration

Prior to presenting how the systems would ultimately be retrofitted and integrated into
the existing Mountaineer Plant, it is important to understand AEPs approach to
integration and the philosophy on which technical and design basis decisions were
made.
The CAP for CO 2 capture, like other post-combustion CO 2 capture technologies, is a
complex chemical process with a certain energy demand. As such, the power plant,
operating with CO 2 capture capabilities, resembles a chemical plant with process
equipment like regenerating columns, packed absorber columns, and stripping
equipment. Much of this equipment, while not dramatically different in scale or
appearance from equipment found in a modern conventional coal-fired power plant, is
still unique and often must be approached differently with respect to design,
engineering, operation, and maintenance.
AEP began the MT CCS II commercial scale application of the chilled ammonia
technology with the philosophy that is typical for retrofit of major equipment across the
AEP fleet. That philosophy is built upon over a century of power plant design and
operating experience that has been incorporated and documented in engineering
specifications, design criteria, and operating procedures which form a standardized
technical basis for the engineering, design, installation and operation of any new
equipment or system. However, AEP had less knowledge and experience with respect
to the chemical process equipment that comprises the CAP. Much of the knowledge

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that went into the design basis for the MT CCS II project was obtained through
operation of the PVF, interface with Alstom process engineers and operators, supplier
interaction, and a core team of AEP process and operations engineers dedicated to
understanding how this first-of-a-kind technology can be integrated into a power plant,
and fostering its advancement.
The outcome of AEPs experience with the PVF and efforts to better understand the
CAPs application in a power plant setting resulted in two key findings:
Power plants and chemical plants have different operating philosophies.

Integration philosophy drives process efficiency, and process complexity.
1.3 Operational Philosophy

Chemical plants are generally designed to produce a product to meet certain
specifications, and the raw materials or feedstock required to produce the products in a
chemical plant are generally supplied to the process in a uniform fashion with minimal
variability. Process upsets can and do occur, but generally the processes and products
within a chemical plant are held within specified tolerances, and consistent production
schedules. Variables are minimized to reduce the impact to processes and products.
Mountaineer Plant first and foremost is a power generating station. It is designed and
operated to generate reliable electricity to meet consumer demand. The demand for
electricity is not constant, but often cyclical based on seasonal weather, time of day, or
other factors. To meet this changing demand, generating units like Mountaineer must
adjust their operating load. Load adjustments can be infrequent with the unit base
loaded at a constant load for days or weeks; or frequent with the unit increasing
and/or shedding hundreds of megawatts of its load in as little as an hour.
While Mountaineers primary product (electricity) is consistent with respect to quality,
its feedstock (the coal fuel), and the feed rate of that feedstock can vary dramatically.
Coal characteristics vary with respect to region of origin, chemical composition, heating
value, moisture content, etc. Furthermore, variable fuel characteristics, coupled with
variable operating loads, produce varying flue gas characteristics (temperature,
moisture content, CO 2 content, chemical composition, etc.). The flue gas leaving the
plant ultimately becomes the feedstock for post combustion CO 2 capture systems.
The challenge then becomes operating a complex system of chemical processing
equipment, typically designed with a chemical plant operations philosophy of high
consistency and low variability, with a continuously variable feedstock of flue gas, to
produce a highly consistent, high purity (> 99.5%) CO 2 product. Meeting this challenge
requires technical innovation spurred by operating experience. Flue Gas Desulfurization
(FGD) systems did not achieve 95+% SO 2 removal efficiency overnight, and similar
success should not be expected of post-combustion CO 2 capture technology. Evolution
in FGD technology and improvements in operating techniques since its inception have
allowed the industry to achieve positive and consistent results over time. CCS
technology innovation, while challenging at present, will likely evolve in similar fashion.
Lessons learned through the operation of the PVF pointed to this difference in operating
philosophy. Operation of the PVF proved that often minor process variability could lead
to upset conditions in the CAP. Based on years of Power Plant operational experience,
AEP has successfully incorporated levers into the design and operation of integrated

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systems such that if variability in one system arises, a lever is available that allows
operations to adjust the process, and alleviate the problem before it becomes a
significant issue and threatens unit operability or availability. A goal of the MT CCS II
design was to understand where in the CAP process it was appropriate to have design
margin and process flexibility that would allow rapid recovery of process upsets and
operational issues.
An advantage of the MT CCS II project scale was that the CAP could operate at its
maximum capacity (nominally 235 MW) for all normal operating loads of the main unit.
Mountaineer normally operates between 55% and 100% of its rated capacity (1300 MW
net). Within this operating range, the CAP would not be required to follow load on the
main unit, as there would always be a 235 MW equivalent flue gas slipstream available
for the process. Therefore, the processs ability to adjust and follow unit load was not
investigated in detail for the Phase I conceptual design. Alstom provided margin the
CAP design to achieve a 50% turndown to accommodate process upsets, startup and
shutdown, etc., but the ability to follow load on the main unit was not a design priority.
Operation of the facility in Phase 4 would provide operational data and experience
needed to address this issue on future scale-up of the technology.
Alstom and AEP, equipped with lessons-learned from the PVF, approached the design
and integration of the commercial scale project with the intent of ensuring that
sufficient margin or levers existed in the systems design to handle many of the
variables that might be encountered. To achieve the necessary margin in the design,
AEP worked closely with Alstom to develop a design that would accept as much process
variability as practical. This was accomplished by effective communication to develop:
Detailed flue gas specifications with expected ranges for significant characteristics
like temperature, moisture content, CO 2 content, SO 2 content, etc. which can vary
based on fuel or unit operating parameters.
Expected quality and temperature range of makeup water (which can vary
significantly season to season) to properly identify equipment sizing, treatment
needs, and heat exchanger capacities.
Expected quality and quantity of available steam (which can change significantly
in the heat cycle based on unit load changes and ambient conditions) to accurately
identify the steam source, maximize efficiency, and minimize complexity of
operations.
A suite of material and energy balances depicting not only the main generating
units variability with respect to changes in load and ambient conditions, but also
the CAPs modeled process variability with respect to these conditions, which
impacts equipment sizing and the sizing of auxiliary support systems.
The effort outlined above was the result of approximately four (4) months of
collaborative effort between AEP and Alstom process engineers in Weisbaden, Germany
and Knoxville, Tennessee. During this time, the team worked together to understand
what was learned from the PVF, apply it to the ongoing engineering and design efforts
of Alstoms dedicated process engineering team, and produce a CAP design that both
AEP and Alstom agreed could be successfully implemented and operated at a power
plant on a commercial scale.
1.4
Integration Philosophy

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AEP approached integration of the CAP at Mountaineer from a conservative perspective.

As mentioned previously, AEP has a long history of power plant design, engineering,
operation and innovation. Over the years AEP has consistently pushed the industry
limits to achieve higher efficiency, lower emissions, and enhanced performance and
reliability across its fleet of generating units. These efforts have earned AEP a sense of
what can practically be accomplished within the boundaries of the power plant with
respect to safety, efficiency, performance, complexity, operations flexibility and return
on investment.
The CAP is a complex array of systems and components working together to capture
and generate a high-purity stream of CO 2 . It demands energy (in the form of heat and
electricity) to accomplish this task. As a result there are several areas in the system
and around the power plant that deserve to be explored to potentially recover that
energy and reduce the CAPs overall demand. Areas considered for integration of heat
and/or energy during Phase I of the MT CCSII project were:
Flue gas heat recovery to reduce the CAP energy demand.

Heat of compression recovery from the CO 2 compression process prior to
injection.
Steam extraction from the Mountaineer steam turbine and condensate
return from the CAP to Mountaineers feed water heating system for heat
recovery.
Rich/Lean heat exchanger network design by Alstom to maximize the CAP
efficiency (not discussed in detail due to Alstom intellectual property
concerns).
From this list, AEP focused on heat of compression integration and steam/condensate
heat integration. However, both scenarios produced what AEP determined to be low
value sensible heat, offering little if any significant energy benefit to the Mountaineer
plant or CAP. AEP engineers considered the heat recovery options, and screened each
option qualitatively and then quantitatively if the option appeared promising from a
qualitative perspective. For example, the option for flue gas heat recovery to reduce
CAP energy demand was immediately dismissed because of space constraints and the
operational risks imposed to the main unit. Additional screening criteria employed by
the team were:
Qualitative complexity related to location of the equipment, required

piping runs, control parameters, and additional equipment/components
required to achieve proposed energy recovery.
Qualitative assessment of impact of heat recovery to other

systems/equipment.
Quantitative assessment of maximum energy recovery potential (Btu or

kJ), availability of energy with respect to time (e.g. is the benefit only
seasonal, etc.) and average $/Btu based on Mountaineer-specific
economic evaluation factors.
Quantitative assessment of additional capital cost to achieve proposed

energy recovery versus operating cost benefit of recovering the energy,
and the payback period.
It must also be understood that in addition to the screening criteria above, AEPs
integration assessments involved the recurring element of risk associated with the

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incorporation of a first-of-a-kind technology in a slip-stream application. The team was

reluctant to integrate systems to improve efficiency without a firm grasp of how the
system was going to ultimately function. As with any technology, the level of
integration will significantly improve as functionality and operations are better
understood. This is evident in the power generation industry, as unit efficiencies have
improved significantly over the years, while the premise of the technology remains
essentially unchanged. CCS technology will experience similar improvements in its
innovation over time. For the MT CCS II project, AEP chose not to prematurely add to
the complexity of scaling, demonstrating and assessing the technology by attempting to
over-integrate.
Section 1.1 Studies and Investigations discusses how various aspects of the overall
project were evaluated and integrated into the existing power plant for the MT CCS II
project.
III Results and Discussion
To establish the design basis of the CCS system, the engineering and design team,
comprised of individuals from Alstom, AEP, Battelle, and WorleyParsons collaborated to
integrate lessons-learned with respect to capture and storage from the PVF, with additional
studies and investigations specific to the design and characterization of the commercialscale system. The studies and investigations performed in Phase I served as a basis for key
design decisions, and outlined the decision-making process which generally included options
considered, economics, and risk evaluation.
The studies, investigations and plans described herein are in general treated as protected
data as they contain such data. They are available to the DOE but are not a part of this
public document. The summaries and discussions in this section have been worded as to
not compromise the integrity of any intellectual property.
1.1
Studies & Investigations

1.1.1 Chilled Ammonia Process bleed stream study
Alstoms CAP produces a byproduct stream rich in dissolved ammonium sulfate.
Possible solutions for this waste stream include:
Ammonium sulfate recovery for commercial end-use
Reaction of ammonium sulfate to a secondary byproduct that can be
either sold commercially or disposed of in a landfill
Reuse of the ammonium sulfate solution within the Mountaineer flue
gas path.
At the request of AEP, the re-injection options were eliminated from
consideration for this study. As a team, Alstom, AEP, and WorleyParsons
selected the following options for evaluation in this study: (a) Recovery of
Crystallized Ammonium Sulfate for Resale (Base Case Option); (b) Recovery of
40 Weight Percent Ammonium Sulfate for Resale (Alternate Option 1); (c)
Alternate process referred to as Lime Boil to react ammonium sulfate with lime
to recover ammonia and produce gypsum that could be combined with
Mountaineers gypsum waste product from the FGD (Alternate Option 2).
The CAP byproduct stream is proposed to be a 25 weight percent (typical)
aqueous solution of dissolved ammonium sulfate. However, the CAP byproduct

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stream could be as dilute as 10 percent total dissolved solids (TDS) ((NH 4 ) 2 SO 4 )

under non-steady-state operating conditions. In order to accommodate a large
range of composition for the CAP bleed, the CAP byproduct treatment options
are designed for 15 weight percent TDS, with additional tanks to handle dilute
CAP by-product. As such, treatment operation with the CAP byproduct stream
greater than 15 weight percent TDS would proceed as designed, and for periods
when TDS is below 15 weight percent, the treatment option would accommodate
design flow while the residual would be routed to the storage tanks. When
operation of the CAP returned to normal steady-state operation and the CAP
byproduct stream was greater than 15 weight percent TDS, the low and lower
purity storage tanks would be drawn down, mixed with higher purity byproduct
and processed through the treatment option to the extent possible.
OEMs were contacted to aid in the development of heat and material balances,
PFDs and P&IDs, equipment lists, and utility consumption values. These items
were used, in turn, to develop capital expense (CAPEX) and operating expense
(OPEX) values for each option so that they could be assessed from an economic
perspective. AEP contacted potential end-users of the fertilizer products to
insure that the product would meet agricultural specifications and could in fact
be considered for beneficial use. Potential end-users in the region indicated that
either a crystallized product or a 40 wt% liquid product would be desirable.
Estimated constituents of the byproduct were within acceptable agricultural
specifications, so AEP proceeded with a design basis that relied upon beneficial
use of the byproduct stream in lieu of disposal. AEP must take steps in future
project phases, however to ensure a long term purchase contract can be
established and that byproduct specification estimates do not change
significantly.
The estimated capital costs and first year operating costs for the three treatment
options considered are summarized in Table 1 below.
Case
Base Case (Crystallized Ammonium Sulfate)
Option 1 (Ammonium Sulfate Solution)
Option 2 (Lime Boil Process)
CAPEX
Estimate
Base
-32%
-19%
1st Year OPEX

Estimate
Base
+2.7%
+148%
Table 1: CAPEX & 1st Year OPEX Summary for Byproduct Handling Options
The project team decided that generation of a concentrated solution of

ammonium sulfate (Option 1) be implemented as the CAP byproduct stream
design basis. Generation of crystallized ammonium sulfate is also a viable
alternative. Both employ some of the same equipment, so choosing the 40 wt%
option as the design basis and allowing space in the equipment layout offers the
opportunity at some point in the future of producing both a solid product and an
aqueous solution. This provides maximum flexibility to increase marketability of
the end product. As such, the conceptual design of the plant included space to
add crystallized byproduct processing equipment with bagging and 15-day solid
product storage capability. It should be noted that there might be occasions
where the ammonium sulfate can not be sold.
The lime boil process was not selected for the conceptual design due to its
expected high OPEX, and increase in solid waste material to the plants landfill.

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1.1.2 Heat Sourcing and Integration (Steam Supply / Condensate Return) Study
The purpose of this study was to evaluate alternative scenarios for steam
extraction and condensate return from/to the power plant and to recommend
the optimum extraction/return methods for use in terms of energy penalty and
reliability at the Mountaineer Carbon Capture II Project at the AEP Mountaineer
Power Plant Facility.
The AEP Mountaineer Power Plant consists of a B&W boiler and an Alstom
turbine set. The turbines are arranged in a cross compound arrangement due
to the large size. The arrangement consists of two turbine shafts, one consisting
of the High Pressure (HP) turbine and two Low Pressure (LP) turbines connected
to one Generator, the other shaft consisting of the Intermediate Pressure (IP)
turbine and the remaining two LP turbines connected to a second generator.
In order to efficiently supply the CAP with the required steam to be utilized as
heating media, the water-steam cycle of the AEP Mountaineer facility was
investigated and modeled.
The extraction of steam can be done in several locations; however the extraction
philosophy and selection will have significant impact on the final energy penalty
of the capture plant addition. To illustrate this difference, a comparison was
made for extraction from various locations in the steam cycle. The analysis
included extraction from the cold reheat (CRH), compared to extraction from the
intermediate pressure (IP) turbine, as well as from the cross-over between IP
turbine and the low pressure (LP) turbine. The results clearly indicate the
advantage of choosing an extraction point with a pressure that is as close as
possible to the required operating pressure. Figure 3 shows the effect based
upon an approximate thermal load chosen to determine the impact on the steam
cycle.

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Figure 3: Steam Extraction Location and Energy Penalty
Because this application is treating a slipstream of the flue gas, the capture
plant is expected to operate at, or close to 100% of its capacity over the entire
range of power plant loads from 55-100%. Due to the variance in available
pressure at each extraction point during normal unit operation in this range, a
single extraction point could likely not provide the required steam conditions to
the CAP. The first approach investigated transferring to another steam
extraction point at a certain unit load when the pressure in the IP/LP cross-over
falls below the required value.
The advantage of this multiple extraction method is that it can be designed
without any additional throttling devices in the steam line, and hence exhibits
excellent performance at the design point. Disadvantages are the capital
expense of multiple extraction ties, potential for turbine modifications to better
match steam conditions, and the controls required to provide smooth transitions
during load swings or other unstable events. As an alternative, the team
considered the installation of throttling valves in the IP/LP cross-over line to
eliminate the need to change extraction points with load changes. Correctly
sized, these valves can provide minimal pressure drop at the design point when
they are fully open and gradually close at part load in order to keep the
extraction pressure constant.
Based on the desire to minimize extraction ties, eliminate significant turbine
modifications, and keep the operation of the steam supply as simple as practical,
it was decided to continue evaluation using throttling valves in the cross-over
line between the IP and the LP turbines. Another factor that contributed to this
decision is the fact that the AEP cross compound fleet of turbines are managed
on a fleet basis, and any significant change to the Mountaineer turbines would

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make Mountaineer no longer interchangeable with the other turbines on the

fleet.
In the end it was decided, based on steam cycle evaluation and process
optimization, to extract steam at two different pressure levels (see Figure 4):
higher pressure steam for regeneration from the IP/LP crossover utilizing
throttling valves, and also a lower pressure to supply steam for process
stripping. Both extraction points are able to supply the required steam for the
expected range of main unit operating loads 55% - 100% without moving to an
alternate extraction location (with minimal impact on energy consumption).
Condensate leaving the CAP boundary is returned to the Mountaineer feed water
heating system to reclaim the condensate as well as offset a portion of the
overall energy demand. To minimize contamination concerns, a condensate
storage buffer tank is included in the design, which is continuously monitored
for contamination.
LP Turbine
New Throttling Valve
LP Turbine
HP Turbine
To
Generator
LP Turbine
LP Turbine
IP Turbine
To
Generator
Boiler
To CAP
To CAP
To Feedwater Heaters
Figure 4: Simplified Schematic of Mountaineer Turbine Arrangement with CAP Integration
Challenges/Opportunities to Overcome Inefficiency

Any retrofit installation requires a balance to be struck between practicality,
performance, and cost effectiveness. For the MT CCS II project, the team spent
considerable effort evaluating various methods of steam supply and condensate
return and, as mentioned above in the explanation of process extraction
alternatives, sometimes opted for operations simplicity/practicality over
maximizing efficiency. Furthermore, the team investigated and identified areas
where capital improvements could be made to existing equipment to reduce
overall energy demand of the CAP. The most prominent example of this
involved the existing boiler feed pump turbine control valves at Mountaineer.
The boiler feed pump turbine (BFPT) at Mountaineer plant is equipped with inlet
control valves that have an unusually high pressure drop. This is problematic
during summer conditions when the plant is operated at maximum load; the
valves are wide open allowing for little to no control of the feed water flow. This
limits the operation of the unit, as it limits the flow of feed water to the boiler,
hence also limiting steam flow. In order to increase unit load under these

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conditions, steam to the BFPT can be taken from the cold reheat line instead of
from the IP/LP cross-over pipe, which negatively impacts unit efficiency.
The situation will worsen when combined with the steam extraction needs of the
Mountaineer CO 2 capture plant. Heat balance analyses at peak summer
conditions (cooling water inlet temperature 103F) were performed, and
demonstrated that without an upgrade of the BFPT valves, the throttle valves in
the cross-over pipe will have to be further throttled to compensate for the
pressure drop over the BFPT control valves. As Figure 5 shows, an upgrade of
the BFPT valves could result in a considerable improvement of performance and
efficiency during summer operation. AEP has been unable to justify an upgrade
to these valves in the past, as the savings during peak summer conditions
(when the upgrade is most effective) could not offset the capital expenditure.
AEP would likely carry out additional economic evaluations in Phase II to
determine if the reduced energy demand of the CAP as a result of new control
valves would justify the upgrade.
Figure 5, Throttling of Crossover Valves with and without BFPT valve upgrade
1.1.3 Compression Study

The purpose of this study is to explain the results of a technology study that
evaluated options for compressing the full CO 2 product stream from the
proposed nominal 235 MWe commercial scale application of Alstoms chilled
ammonia process (CAP) at American Electric Powers Mountaineer generating
station, in New Haven, West Virginia.
The study focused on commercially available, integrally-geared, inter-cooled,
gas compression systems. The scope of the study included all of the equipment
required to compress and condition the captured CO 2 for sequestration.
Geologic characterization information and actual operating data from the
Mountaineer Chilled Ammonia Product Validation Facility (PVF), which operated
from 2009 to 2011, provided injection parameters on which to base the design

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for the commercial scale compression system. Equipment arrangements,

auxiliary power demands, balance of plant integration, and capital and operating
costs were considered in the evaluation of each compression system.
Five basic configuration options to pressurize CO 2 from a nominal 300 psia (20.7
bar) to 3,000 psig (207 bar) were identified. Two of the five options evaluated
were an emerging compression technology and are not discussed in this report
due to intellectual property concerns with the technology supplier. The
remaining three alternatives are:
Option 1 Integrally-geared, inter-cooled, centrifugal compressor with

after-cooler to 1,320 psig (91 bar) followed by pump and after-cooler to
3,000 psig (207 bar).
Option 3 Integrally-geared, inter-cooled, centrifugal compressor with
after-cooler to 860 psig (59 bar) followed by cooling with cooling water
and liquefaction via heat exchange with a refrigerant. Liquid CO 2 then
pumped to 3,000 psig (207 bar).
Option 4 - Integrally-geared, inter-cooled, centrifugal compressor with
after-cooler to 3,000 psig (207 bar).
Process Flow Diagrams (PFDs) were developed for each option. Based on the
PFDs developed, equipment suppliers and OEMs were contacted in order to
procure budgetary proposals, performance data and cost estimates for the
equipment defined by the configuration descriptions given above.
Heat recovery via heat exchange with the CAP and/or Mountaineer steam cycle
was considered as part of the overall study as a means to reduce the overall
energy demand. Based on results from the Mountaineer PVF, injection pressures
in the 1200 psi 1500 psi (83 103 bar) range are expected early in the life of
the target injection wells. As CO 2 is injected over time, the required injection
pressure is expected to increase, and the estimated maximum injection pressure
into the geological formations targeted for the project is expected to be
approximately 3000 psi (207 bar).
Heat of compression available at the lower injection pressures 1200 psi 1500
psi (83 103 bar) was not considered practical for use at Mountaineer as it was
of little value to integrate back into the CAP or back into the Mountaineer main
unit. It was determined that at the 3000 psi (207 bar) injection pressure, heat
of compression integration with the CAP and the Mountaineer feed water heating
system was possible to offset a portion of the compressor power. However, the
heat integration provided no net overall energy reduction, thus the capital cost
to implement the equipment and controls necessary to recover the heat could
not be justified. Furthermore, at the lower expected injection pressures, the
project team determined that variable speed injection pumps could be utilized
downstream of the compressor to provide better process flexibility and operating
efficiency over the life of the system.
The compression study generated the following primary conclusions:
All options evaluated are technically feasible

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Compression to an intermediate pressure (Options 1 and 3), followed by

variable speed pumping to the final injection pressure offers greater
flexibility and efficiency over the life of the system as compared to full
compression to the maximum expected injection pressure (Option 4).
Performance and total evaluated cost for Option 1, compression with an

integrally-geared compressor to an intermediate supercritical condition
followed by cooling and pumping to final pipeline pressure, and Option
3, subcritical compression, cooling and CO 2 liquefaction followed by
pumping to final pipeline pressure, are similar. Detailed engineering and
design in Phase II of the project, focusing on these options, is
recommended to determine the best option for Mountaineer plant.
Based on the study, the team recommended that integrally-geared centrifugal

compression to either a super-critical (Option 1) or sub-critical (Option 3)
condition followed by cooling and pumping to the final CO 2 pipeline pressure be
employed for the MT CCS II installation. The technology is proven, cost
effective, and offers, with the use of a variable-speed drive on the CO 2 pump, a
wide range of outlet pressure flexibility over the other options considered. Based
on experience with injection at Mountaineer, pressures below 3000 psig are
likely to be sufficient to inject CO 2 into the targeted underground reservoirs,
which would result in additional power savings and reduced total evaluated costs
for options having the flexibility to produce lower injection pressures. Estimated
performance and total evaluated cost values for options 1 and 3 are similar. It is
recommended that further work in Phase II be undertaken in order to determine
the optimal solution. For Phase I, it is recommended that the cost estimate
reflect the cost for Option 3 as that would be the more conservative approach in
that Option 1 is less complicated, with less moving parts, lower CAPEX, and
lower total installed cost.
1.1.4 Geologic Characterization Study
The purpose of this study is to develop a sub-regional and local geologic
characterization using seismic survey data, drilling of a test well, reservoir
testing, conceptual system design for injection and monitoring, and development
of overall project schedule and cost estimates. This final report discusses the
sub-regional and site characterization activities that included drilling and logging
a deep test well, analyzing new 2D surface seismic data, and performing other
related characterization activities. The comprehensive characterization effort was
completed to support CO 2 storage applications near the site.
The subsurface geological investigations of the Mountaineer site and surrounding
sub-region conducted under this project during 2010 and 2011 build on a large
amount of work done at the site during the last eight years, under two separate
projects. First, DOE and others funded Battelle to conduct an initial site
characterization effort under the Ohio Valley CO 2 Storage Project, from 2002 to
2007, which included a 2D seismic survey and drilling of a deep characterization
well (AEP-1) in 2003 followed by logging, reservoir testing, geochemical
analysis, modeling, and conceptual CCS design. Second, AEP hired Battelle in
2007 to construct the sequestration infrastructure for the 20 MW CCS pilot
system called the Product Validation Facility (PVF). This included transformation
of AEP-1 into an injection well and drilling of an additional deep injection well

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(AEP-2) and three new deep monitoring wells (MW-1, MW-2, MW-3) within the
Mountaineer Plant property. A schematic of the PVF wells is shown below in
Figure 6. This system was commissioned in 2009 and CO 2 injection lasted until
May 2011.
Figure 6, Schematic of the location of the injection and monitoring wells for PVF.

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The investigations in Phase-1 of the characterization effort have focused on the

evaluation of cap rock (Silurian/Ordovician shales) and Cambrian age reservoirs
in the Knox Dolomite Group, including Rose Run and underlying Copper Ridge
Formations. Extensive evaluation of wireline log, core, and pressure test data
from the Product Validation Facility wells (AEP-1, MW-1, MW-2, and MW-3) and
the newly completed Borrow Area (BA-02) characterization well indicate that the
lower part of the Copper Ridge Formation may have significant reservoir storage
potential. While additional injection potential is present in the Rose Run
Sandstone and Beekmantown dolomite, the injectivity might be lower compared
to the Lower Copper Ridge zone.
In the past eight years a significant amount of detailed subsurface geological
information has been collected at the PVF and more recently the BA-02
characterization well. This effort has lead to the detailed evaluation and
understanding of a relatively small subsurface area surrounding the Mountaineer
facility. In order to understand how this information can be extrapolated away
from this site and to understand the lateral continuity of the potential reservoirs,
a sub-regional geologic study was undertaken. An extensive database has been
created with data from more than 7,000 wells in and around Mason County,
West Virginia. It includes all wells from Meigs, Gallia, and Lawrence Counties in
Ohio as well as Mason, Jackson, Putnam, and Cabell Counties in West Virginia.
There are a limited number of oil and gas wells that penetrate the CambrianOrdovician rocks near the Mountaineer site (Figure 7a).
Figure 7a: Reference map for Rose Run and Copper Ridge cross sections.
Information had to be collected, analyzed, and related to the site from as far
away as 100 miles. In Figure 7a above, the MT Plant is located near the point
where lines A-A and B-B cross. The database incorporates all publically

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available data sets to include such information as well location, lease name, total
well depth, available formation tops, and available geophysical logs and cores.
Two software packages, PETRA developed by IHS and Petral developed by
Schlumberger, were used to conduct a detailed local and sub-regional evaluation
and delineate locations with the best potential for deep reservoir CO 2 injection,
focusing primarily on the Rose Run, Copper Ridge, and Beekmantown
formations. Geological cross sections, shown in Figure 7b & 7c, isopach maps,
and structure maps have been generated to clarify the relationship between the
stratigraphy and structure at the Mountaineer area in relation to that of the subregion. This analysis points strongly towards the discovery of a significant new
storage reservoir in the upper portion of the lower Copper Ridge dolomite.

Page 26 of 66
Figure 7b: Cross section showing Rose Run (A-A) from north to south (datum top of the Rose Run sandstone).

Page 27 of 66
Figure 7c: Cross section of Copper Ridge (B-B) Formation showing structure from west to east.

Page 28 of 66
Analysis indicates that the good secondary vugular porosity present in the Lower
Copper Ridge dolomite has potential for storage of large volumes of carbon
dioxide. Analysis of wells in the sub-region that penetrate the Copper Ridge
Formation, up to 25 miles from the Mountaineer Plant indicate that this vugular
porosity is wide spread and appears to be laterally continuous to the north/south
and east/west. A detailed sequence stratigraphy analysis of the Mountaineer
wells has revealed the relationship between reservoir quality and depositional
and diagenetic overprints. The integration of stratigraphic, digenetic, and
tectonic data for predicting lateral and vertical heterogeneity in the Copper
Ridge reservoir may indicate a compartmentalized reservoir.
In conjunction with the petrophysical work, seismic evaluations using data from
purchased 2D seismic lines (near Jordan tract) and previously collected seismic
data in 2003 were performed. The Jordan tract 2D lines cover approximately
22.5 miles. Preliminary structural analysis indicates the absence of any major
geologic features, especially near the Mountaineer Plant, with formations gently
dipping to the southeast. However, the potential for some faulting closer to the
Rome Trough area in the southeast cannot be ruled out until more detailed
seismic surveys are completed in the area.
Tangential to these efforts, a lineament analysis was completed based on
remote sensing data and oriented core data from Devonian shale (obtained from
wells close to the Mountaineer plant). The lineament analysis suggested that the
reservoirs can have a preferential flow direction along N3375E This trend is
the principal stress direction in this part of the Appalachian Basin. This trend is
also evident in the image log rose diagram from 6,703 to 8, 840 feet.
Orthogonal to the principal stress direction are natural fractures found in the
WV-5 shale well (N53W) near the PVF and lineaments in Area 4 (Figure 8a &
8b) that trend N50W. This direction is also found on this image log, although it
is not as prominent as the northeast trend. The northeast to southwest trend will
potentially influence the flow path direction for the injection of carbon dioxide in
the Rose Run and Copper Ridge reservoirs.

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Figure 8a: Meigs County Linament broken into four areas
Figure 8b: Aerial relationship between Devonian shale core fracture orientations and the BA-02
characterization well.

Page 30 of 66
An 8,875-foot deep characterization well (BA-02) was completed two miles

south of the Mountaineer Power Plant site to characterize the sub-surface
geology. The borehole penetrated all of the Copper Ridge formation and was
drilled into the Maryville dolomite. Well construction methods were designed to
facilitate the reservoir testing of the Beekmantown dolomite, Rose Run
sandstone, and Copper Ridge dolomite Formations. Separate reports were
generated to document the well construction and reservoir testing. A full suite of
wireline logs was completed to obtain a continuous log of the rock formations in
the test well. Wireline logs were used for identifying formation tops, casing
points, reservoir potential, and selection of coring depths. Over 40 rock
formations were identified through evaluation of wireline logs, drill cuttings logs,
and rock cores. Most of the rock consisted of dense shale, mudstone, limestone,
dolomite, and sandstone. The Copper Ridge reservoir that was identified in PVF
well AEP-1 was also identified in the BA-02 characterization well.
A continuous oriented core in the Black River unit was taken for 30 feet and
measured 4 inches in diameter; continuous core in the Copper Ridge Formation
was taken for ~270 feet and measured 3.5 inches in diameter. In all, 67 sidewall
cores were collected from key depth intervals. The rock core samples were
subject to many hydraulic, geochemical, and geomechanical tests to determine
the suitability of key formations for CO 2 injection and storage.
Vertical containment at the Borrow Area site is provided by an unbroken
succession of Ordovician shales and dolomites. These formations include the
Wells Creek shale, Gull River, Black River, and Trenton limestones, which have
an aggregated thickness of over 1,300 feet. With the single exception of the
Wells Creek, each of these units is massively bedded, thick, and largely
homogenous. Wireline logs indicate that none of these units has enough primary
or secondary porosity development to be considered a zone of potential
migration. This is reinforced from the fracture analyses that were performed on
Core #1 that was taken in the Black River Formation. Detailed analysis indicates
that only stylolites and wavy sedimentary bedding are present with no
observable fractures or slickensides.
From earlier investigations and experience at the Product Validation Facility, oil
and gas in commercial volumes is unlikely in this area in the zones of interest for
CO 2 storage. The historical record of exploration in this area indicated a poor
capacity for formations that were tested for oil and gas in Mason County and
adjacent counties. These horizons include the Berea sandstone, the Lower Huron
shale, and to a lesser extent the Clinton sandstone. The well was drilled through
these units with only minor shows, if any, of gas. Similarly, there minor shows
of gas in deeper horizons with porosity, such as the Beekmantown dolomite,
Rose Run sandstone, and Lower Copper Ridge dolomite.
Data acquired from the previous PVF well tests indicated that the primary
injection reservoir is essentially contained in a single zone in the upper portion
of the lower Copper Ridge Formation. In contrast, data acquired from the BA-02
well indicates reservoir potential in the Beekmantown and Rose Run Formations,
as well as in the Copper Ridge Formation. As an overall trend, the average
porosity for all potential reservoir zones tracked the closest to the porosities
derived from log cross plots. Neutron porosity tended to track high across all

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zones, while density porosity tended to track lower. The best zones of calculated
porosity, within the lower Rose Run sandstone and the upper portion of the
Lower Copper Ridge dolomite, correlated well with the best indications of
porosity from the log cross plots.
Image log analysis of the reservoir sections did not indicate large numbers of
natural fractures. However, the number of observed drilling induced fractures,
particularly in the Queenston and Utica shale sections, was significant. In any
10-foot section, it is rare to find more than five fractures, including drilling
fractures. In this log image, the maximum count is 12 fractures in a 10-foot
interval within the Queenston shale section. The Beekmantown Formation was
not found to have any significant fractures. Overall, the dominant type of
fracture is drilling-induced. Zone 3 (Beekmantown B zone) was found to have
the highest concentration of natural fractures (Figure 9). This may indicate that
the porosity in this interval is fracture-controlled. The Rose Run Formation has a
low density of fractures compared to most of the rest of the well. It does not
appear that the porosity in the Rose Run is due to secondary porosity. Although
it appeared that the vugs developed along fractures in the Copper Ridge
Formation, this phenomenon is not well represented in the image logs. It is
likely the fractures seen in the cores were not easily interpreted within the log.
There are no drilling induced fractures in the interval where vugs are present;
however, there are some natural fractures, which are likely a subset of the ones
represented in the core.
Figure 9: Example of image log within the Beekmantown formation showing some of the fractures
(red) and the bedding planes (green).
The CT scan was utilized to determine with greater precision the presence and
depths of vugs within the Copper Ridge dolomite. The correlation between
internal structure and observation on the whole and slabbed core was confirmed.
The connectivity of the vugs throughout the core was also established by being
able to see into the core with the CT scan technology. The CT scan also revealed

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the tendency of the vugs to track along fracture features. Finally, the highly
variable nature of the vugs with respect to vertical depth was confirmed (Figure
10).
Figure 10: CT scan of a core sample from BA-02 showing the presence of vugs.
A good potential correlation was noted between core identified vugs, the triple
combo neutron peaks, and vugs visible on the image log. A neutron cut off
between 78% correlates well all of the vuggy intervals that were identified in
the core (Figure 11). Within the Lower Copper Ridge, an upper and lower bound
to the vuggy interval was identified. This interval was approximately 130140
feet in total thickness, and correlates well with the current depositional model.
The vugs are not present everywhere throughout this larger interval. This work
allows the identification of the vuggy intervals by the triple combo only. Since it
is positively correlated in the core in BA-02, future wells may have less need to
take full core in the same intervals. Further, by tying the vuggy intervals to the
triple combo, future work may be able to tie it to the 3D seismic as the gross
interval of 130140 feet should be resolvable on 3D seismic images. This can be
potentially used as a prospecting tool for vugs detection via seismic without
having to drill more wells right away.

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Figure 11: Example of integration of core mapping on triple combo log; yellow segments indicate depth
from which side wall cores were obtained.
The wireline log derived fracture pressure for the Trenton-Black River Formation
appears to average consistently around 0.9 psi/ft, with only slight variation plus
or minus evident in the curve throughout the log. This is consistent with the
monolithic behavior in these formations. As is seen within the PVF wells, the
Rose Run Formation exhibits a lower fracture pressure in the sandy members. In
BA-02 well, fracture pressure averages around 0.7 psi/ft. The more dolomitic
sections are at the overall well average of 0.9 psi/ft. Within the Copper Ridge
Formation, the vugular region shows a slight drop in fracture pressure from 0.9
psi/ft to closer to 0.8 psi/ft.
Overall, the regional analysis and data from the BA-02 well have yielded
important results. The potential injection interval in the Lower Copper Ridge has
been confirmed in the data from the BA-02 well and anecdotal evidence from the
wells analyzed nearby indicates that the vugs may be wide spread (shown in

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Figure 7 above). Through the core analysis, the beginning of a relationship

between the core, the wireline logs, and the seismic reflection data has been
developed that may allow for identifying optimal drilling locations for future
sequestration sites.
Three main recommendations for future work have come out of this effort. A 3D
seismic survey in the Mason County area will help to delineate any significant
geologic features, such as faulting associated with the Rome Trough, as well as
form the basis for attempting to map the location of high-quality reservoir rock
with high probability. Future work should focus on fully analyzing the data and
formally integrating it with the wireline data. Finally, an additional
characterization well, at the Jordan Tract site, would assist in continuing to
refine the geologic understanding of the area.
1.1.5 Pipeline Routing / Siting Study
The purpose of the pipeline routing and siting study was to identify a proposed
pipeline route, characterize the soil conditions of the area in which the pipeline
would be installed, identify any pipeline crossings, and develop technical
specifications for the pipe, linings, coatings, and cathodic protection of the CO 2
pipeline for the MT CCS II CAP.
The captured CO 2 is compressed and then pumped to a supercritical fluid with
sufficient pressure to inject into the well. AEP has selected two injection well
sites, Borrow Area 2 approximately 2.5 miles from the plant and Jordan Tract,
approximately 10.5 miles from the plant where the CO 2 is planned to be injected
into deep saline reservoirs. The pipeline was routed through AEP properties and
transmission line corridors where possible. The maximum operating conditions
are 3000 psig and 110oF at the CO 2 Compressor Building. The pipeline design
conditions are 3300 psig and 140oF.
The supercritical CO 2 is pumped from the compressor building overhead on
utility racks to an area beneath the Mountaineer Plant precipitators where it is
routed in an open swale with the ash pipes across the plant to the south side.
From this area it is routed above ground, supported from an existing gypsum
conveyor (Gypsum Overland Conveyor No. 1), across Route 62 at the west end
of the plant.
This routing study applies to the pipeline located west of Route 62 as shown on
the routing drawings. This pipeline is designed in accordance with ASME B31.4,
Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids.
The pipeline is 12-inch diameter API 5L-X65 with a wall thickness of 0.469 (Ref.
Doc No. AEPMT-1-LI-1.01.02.01.05-0009). The pipeline is provided with an
internal high density polyethylene (HDPE) lining and an external fusion bonded
epoxy (FBE) coating in accordance with the specifications included in this report.
A pig launcher is provided at the beginning of the pipeline west of Route 62 and
a pig receiver is provided near the end of the pipeline at the Jordan Tract well
site. Pigging is not provided for the pipeline branch to the Borrow Area well site
since this branch line is short.
WorleyParsons used USGS mapping to design potential pipeline routes and then
walked each route to prepare the preliminary routing drawings Initially four sites

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were chosen from properties owned by AEP near the Mountaineer Power Plant;
the four initial sites included Western Sporn, Borrow Area, Eastern Sporn and
the Jordan Tract. The choice of these four sites was driven by availability of AEP
owned property in the vicinity of the Mountaineer power plant. Parts of the
Western Sporn land parcel was identified as wetlands and was not considered as
a prospective injection site. The accessibility of Eastern Sporn site was an issue
and hence this site was also dropped as a prospective injection location. Finally
Borrow Area and Jordan Tract were selected as the preferred sites for CO 2
injection. Figure 12 shows the location of the Mountaineer plant, the preliminary
pipeline layout plan and the initially selected injection sites.

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Figure 12: Site location for pipeline and injection wells for the MT CCS II project.

Page 37 of 66
The piping downstream of the CO 2 pump discharge is carbon steel, ASTM A106
Grade C, Schedule 160 in accordance with ASME B31.1, Power Piping. This
section is above ground and is unlined, however, the standard schedule 160
used for this onsite portion includes corrosion allowance of 0.161 over the code
required minimum wall thickness. The B31.1 piping code was applied since the
piping was being routed through the plant site area with greater exposure to
plant traffic and operations. At the point where the piping is supported from the
gypsum conveyor the piping code transitions to ASME B31.4 since exposure to
plant traffic is reduced and the pipe weight can be reduced for support from the
existing conveyor. The pipe material is API 5L-X52 pipe with a wall thickness of
0.809 inch. This pipe section is provided with HDPE lining similar to that of the
main pipeline.
1.1.6 CAP Design Basis
As part of the Phase I, Conceptual Design of the MT CCS II project, Alstom
developed a process design basis for the CAP facility. The design basis
supported the overall Phase I conceptual design effort, and was used as a basis
for developing the material and energy balances, equipment sizing, and
ultimately the refined cost estimate.
The design basis characterizes the conditions and characteristics of the flue gas
inlet and outlet, CCS equipment turndown capabilities, system reagents and
refrigerant specifications, makeup and cooling water requirements and
conditions, process cooling tower and evaporative condenser specifications, CO 2
product stream characteristics, byproduct bleed stream characteristics, the
refrigeration system design basis, steam, electrical, and auxiliary plant
requirements, and overall site conditions for the Mountaineer Power Generating
Station.
1.1.7 CAP Reagent / Material Handling Study
The purpose of the CAP Reagent/ Material Handling Study was to evaluate and
select the reagent to be used in the CAP, and to determine scope of supply,
design criteria, controls and equipment associated with the storage and handling
of the process reagent.
The CAP utilizes an ammonia based reagent for the removal of carbon dioxide
gas from combustion flue gases. The technology allows the use of various
ammonia based reagents to replenish ammonia losses in the CO 2 product
stream, byproduct bleed stream, and from ammonia slip into the exiting flue
gas. The reagents considered in this study from commercially available ammonia
products were:
Anhydrous ammonia
Urea / ammonia on demand (AOD)
Aqueous ammonia - 19 wt% and 29 wt% solution
Ammonium carbonate
Ammonium bicarbonate

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These reagents were first evaluated based on technical factors. After initial
screening, anhydrous ammonia and 29% aqueous ammonia were recommended
for more detailed evaluation. The other reagents were eliminated for various
reasons, which most notably include difficulty with maintaining required
ammonia molarity due to non-ammonia constituents (H20, CO 2 , etc.) included in
the reagent, lack of operating experience with the reagent, and inadequate
supply.
For anhydrous ammonia and 29% aqueous ammonia, a detailed economic
evaluation was performed consisting of total installed capital costs and annual
operating costs. Sourcing constraints, material safety, and handling
characteristics were also considered. The reagent costs used for evaluation
purposes were obtained from suppliers and AEP.
Based on the technical information developed for this report, anhydrous
ammonia is the recommended reagent for use on the Mountaineer CCS II
Project.
Anhydrous ammonia is recommended over other ammonia based reagents for
the following reasons:
Anhydrous ammonia has the lowest capital and operating cost of the
reagents compared. Anhydrous ammonia offers significant capital
and operating costs savings over 29% aqueous ammonia.
Anhydrous ammonia is the optimum reagent to maintain/control
ammonia molarity in the CAP and to recover from molarity upsets
during process upsets, load fluctuations and maintenance activities.
Anhydrous ammonia has the least risk of impurity addition, which
can cause process upsets, and effluent for streams requiring
additional treatment.
Anhydrous ammonia, like other chemical reagents, has safety hazards
associated with its use and requires a safety program and preventative
maintenance auditing to maintain and operate the equipment and site storage
facilities in a responsible manner. These safety programs are well established
and are implemented for SCRs in power plants and other facilities across the
country.
It should be noted that all reagents considered in this study require precautions,
special handling, and training for use within the CAP and the power plant.
The CAP anhydrous ammonia storage and material handling system consists of
two (2) storage tanks, reagent unloading equipment including a vaporizer
system, piping, controls, and electrical equipment. All system equipment will
comply with AEP design specifications.

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1.1.8 Miscellaneous Studies

The subtask for Miscellaneous Studies was created for any new studies identified
during Phase I. One such study was evaluation of the Mountaineer Power Plant
barge unloading system and design of the facility to be used during the
construction of the CCS plant. The results of this study are discussed and
incorporated into the MT CCS II Constructability Study (see subtask 1.1.18).
Additionally, AEP conducted periodic risk review and analysis of the projects
perceived risks. Risk reviews brought together key individuals from AEP,
Alstom, WorleyParsons, and Battelle. The sessions typically consisted of a
review of previously identified risks containing discussion on progression of
mitigation efforts and any changes in probability of occurrence or severity of
impact. The sessions also allowed for discussion of any new risks identified
since the previous risk review. Following completion of each session, AEP would
update the project risk register and issue updates to the integrated project
team. Some of the key risks identified on the project include: uncertainty
associated with the Class VI Underground Injection Control (UIC) Permit
requirements, cost and schedule risks associated with well drilling activities, cost
and schedule risks encountered due to late design changes and/ or
requirements, and the volatility of the escalation factors applied to the project
cost estimate due to various influences such as hyperinflation, market
saturation, material availability, etc.
1.1.9 Process Makeup Water and Wastewater Study
The purpose of this study was to verify and document the interfaces between
the CAP and existing plant water and wastewater systems. The report also
describes any new facilities and systems necessary to accommodate those
interfaces.
The Makeup Water System for Mountaineer CCS II Project is designed to receive
raw water from the Ohio River using the plants existing river water makeup
system and to treat the water for use by various consumers, including
evaporative condensers, pump seal water, wash down hose stations, process
water makeup, and Direct Contact Cooler (DCC) makeup. The primary demand
for makeup water is makeup to the CAP refrigeration system evaporative
condensers.
Three (3) existing pumps, each rated at 20,000 gpm, furnish river water
makeup from the Ohio River to supply the existing demand of the Mountaineer
Plant. The existing river water makeup pump capacity is considered more than
adequate to supply the additional makeup required for the CAP process.
The entire makeup water stream for the capture plant is treated by chlorination
for biological control and by chemical precipitation and clarification, primarily for
removal of total suspended solids (TSS) that might interfere with operation of
the evaporative condensers and other equipment requiring makeup water.
Treatment will reduce the concentration of iron and other heavy metals that
might be present in the water.
The makeup water treatment plant required for the capture plant at Mountaineer
will consist of the following principal components:

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Rapid mix tank
Reactor tank
Clarifier/thickener
Sludge recirculation pumps
Sludge blowdown pumps
Chemical storage tanks
Chemical feed pumps
The portion of the makeup water used for DCC makeup requires additional
treatment to produce relatively high purity water. The existing plant condensate
system could not support the maximum demand of the CAP. Therefore, makeup
to the DCC will receive treatment by additional multimedia filtration and a new
two-pass reverse osmosis (RO) system.
The multimedia filtration and reverse osmosis system will consist of the following
principal components:
Multimedia filters, including filter feed pumps, filter vessels and media,
filter backwash pumps, and filter air scour blowers
Reverse osmosis system, including two-pass reverse osmosis system,
cartridge filters, and RO booster pumps
Chemical feed systems, including antiscalant, sodium bisulfite, and
caustic soda
RO cleaning system, including solution tank, cleaning pump, and
cartridge filter
RO permeate tank and forwarding pumps
The nominal makeup water requirement is summarized in Table 2, and typical

Ohio River water quality is provided in Table 3.
Evaporative condenser evaporation

Evaporative condenser blowdown
Pump seal cooling water
Wash down hose stations
Process water makeup (clarified water)
DCC makeup (RO product)
Filter backwash and RO concentrate
Makeup water clarifier sludge blowdown
Total makeup requirement
Flow Rate
(% of CAP Total Makeup)
51%
26%
4%
4%
3%
7%
3%
2%
100%
Table 2: Mountaineer CAP Makeup Water Usage

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Parameter
Nominal
Range
Iron, Fe (mg/l)
3.29
Copper, Cu (g/l)
5.39
Sulfate, SO 4 (mg/l)
131
56 - 169
Total Hardness, as CaCO 3 (mg/l)
197
95 - 210
60
14 - 60
Total Dissolved Solids (mg/l)
300 - 500
Conductivity @ 25 C (mho)
600
300 - >1000
Total Suspended Solids
30
<100
pH @ 25 C
7.7
6.4 9.1
Alkalinity, Total (mg/l as CaCO 3 )
80 max.
Calcium, Ca (mg/l)
7 - 50
10
7 - 17
Sodium, Na (mg/l)
11 - 35
Potassium, K (mg/l)
2-4
Manganese, Mn (mg/l)
<0.5
Total Organic Carbon (mg/l)
2 - 17
Total Kjehldahl Nitrogen (mg/l)
0.3 1.41
Total Phosphorus, P (mg/l)
0.03 0.24
Silica (mg/l)
0.7 6.3
60
33 - 90
20 - 50
Chloride, Cl (mg/l)
Magnesium, Mg (mg/l)
Temperature, F
Pressure, psig
Table 3: Typical Ohio River Water Quality
The Ohio River water used for makeup is relatively high in concentrations of
total dissolved solids (TDS), conductivity, sulfate, and total hardness.
The CAP is designed to minimize wastewater production, as liquid streams
generated by the process are either usable (as in the case of the ammonium
sulfate by-product), or returned, to the extent practical, back to the process.
The most significant non-usable liquid streams generated from the cooling of the
flue gas and capture of CO 2 are 1) condensed moisture from the flue gas
entering the CAP and 2) evaporative condenser blowdown from the CAP
refrigeration system.
Moisture condensing out of the flue gas as it enters the CAP via the supply duct
will be collected and sent back to the main stack drain system which flows to the

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plants wastewater ponds and eventually to outfall. The supply duct will have a
dedicated drain system, which will be separate from the drain tanks of the
return ductwork. The flue gas condensate collected in the flue gas return duct
will be sent to a local drain tank. As the liquid in the drain tanks reaches the
high level, the condensate will be pumped back to the CAP Island to be re-used
in the process.
The separate drain systems were a site-specific requirement and were provided
as a precaution in the event that a CAP upset increased the ammonia
concentration in the return flue gas condensate, which could potentially impact
the plants ammonia discharge limits. It is expected that as CAP technology is
demonstrated, a common drain system could be employed. The design and
optimization of gutters and liquid collectors in the ductwork and stack flue are
dependent on the duct/stack geometry, gas velocity, and flow patterns.
Therefore, a flow model will eventually be needed to determine the optimum
location and configuration of the gutters and liquid collectors within the ductwork
and stack.
Evaporative condenser blowdown will be discharged to existing plant wastewater
ponds through a new 10-inch line connecting to the existing 18-inch main unit
cooling tower blowdown line. A blowdown sump and two (2) 100% capacity
blowdown sump pumps will be added to pump the evaporative condenser
blowdown to the interface point with the existing line. Clarifier sludge
blowdown, multimedia filter backwash and RO concentrate will be discharged to
the water treatment building sump, from which the wastewater will be pumped
to the wastewater pond via the new 10-inch evaporative condenser blowdown
sump discharge line mentioned above. Solid waste from the sump will be
collected and taken to the landfill.
Sanitary wastewater will be collected from all CAP facilities that use potable
water (with the exception of some emergency showers) and will be connected to
the existing plant sanitary wastewater collection system, which discharges to the
New Haven, West Virginia municipal system through a duplex pneumatic lift
station.
1.1.10 Flue Gas Study
This study was performed to evaluate options for exhausting treated flue gas
from the CAP. The three options considered were:
Option 1 CAP exhaust to existing Mountaineer stack

Option 2 CAP exhaust to newly constructed stack close-coupled to
the process island
Option 3 CAP exhaust to existing Mountaineer hyperbolic cooling
tower
AEP recommended early in the project that Option 3, be eliminated from

consideration based upon technical and environmental risk factors associated
with discharging flue gas in a cooling tower. Therefore, this option was not
evaluated in detail.
The major differences between options are as follows:

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Option 1 requires approximately twice the duct length as compared to

Option 2. For Option 1, the CAP exhaust ductwork returns the flue-gas
to the existing stack, whereas in Option 2, the exhaust is sent to a
new dedicated stack in close proximity to the CAP facility. The
estimated installed cost of the two options was nearly equal; Option 2
having a slight cost advantage of approximately 0.6%, which is
negligible with respect to the accuracy of the estimate.
Option 2 also offers an operating cost benefit over Option 1 due to

lower auxiliary power consumption of the existing ID Fans and the new
CAP Booster Fan as a result of eliminating the return duct to the
existing stack. Option 2 would operate at a lower static pressure to
exhaust the flue gas out of a new, closely-coupled stack.
Concerns were addressed in the study with respect to the Option 1

configuration. There was a concern with introducing cooler CAP gas back into
the saturated wet FGD exhaust gas stream. This was analyzed and determined
that the change in mass flow through the stack for this option is negligible. The
flue gas temperature decrease in the existing stack due to the cooler CAP flue
gas re-entry also has minimal, if any, effect on the flue gas buoyancy in the
existing stack. The volumetric flow through the existing stack for Option 1 is
based on the mixture of 84% higher temperature untreated flue gas and 16%
lower temperature treated flue gas. The decrease in stack velocity is considered
to be negligible. The existing stack drainage system is adequately sized to
handle the additional moisture that will condense in the stack due to flue gas
cooling. Estimated stack condensation was calculated using ASPEN process
modeling software to determine the effect of mixing the two saturated gas
streams at different temperatures, and is based on a flue gas moisture content
of approximately 10% to 15% by volume.
The proposed supply and return ducts are round fiberglass reinforced plastic
(FRP) based on its cost effectiveness and resistivity to corrosion. No insulation is
included for the supply duct since heat loss is not a concern. For the purposes
of the FEED, the return duct in Option 1 was assumed to be insulated, Further
evaluation during the detailed engineering and design would determine the
extent of insulation required to maintain the desired outlet flue gas
temperatures. The exhaust duct for Option 2 would not be insulated, as the run
of ductwork to the new stack would be no more than 100 feet. It should be
noted that, based on feedback from FRP vendors, shop fabrication may be a
consideration for the 15 diameter duct. Further evaluation is required to
determine if shop fabrication might yield an overall cost savings to the project
For Option 2, the new stack height considered in the Phase I evaluation was
593.5 based on Good Engineering Practice" (GEP) stack height. The basic stack
components include a concrete shell and a 15 diameter FRP flue liner. During
the detailed engineering and design of this project, a dispersion model should be
performed to determine the necessary stack height, which may be lower than
the estimated GEP height, potentially reducing the cost of Option 2. A lower
stack height requirement may allow the stacks to be placed on top one of the
CAP vessels, which would further reduce the cost of Option 2.

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In addition, a more-detailed computational fluid dynamics (CFD) analysis is

recommended to determine any modifications required to existing duct work
and/or flow distribution devices in the existing stack. A flow model analysis is
also recommended to optimize the drain collection system within the ductwork
and stack for any potential impacts related to the design. A transient analysis is
also recommended during Phase II to minimize the duct design pressures and
potentially reduce costs for either option.
Based on the technical and economic results of this evaluation, the project team
initially recommended Option 2, where the CAP exhaust is sent to a new,
dedicated stack. However, uncertainties associated with modeling and
permitting a new stack in the timeframe of the project restricted AEP from
considering this option for the Phase I conceptual design. It was determined
that selecting Option 1 was the more conservative approach. As more
information becomes available with respect to CAP exhaust gas constituents and
characteristics, Option 2 could be revisited during detailed engineering and
design and ultimately implemented.
1.1.11 Refrigerant Study
The purpose of this study was to provide an overview of the potential
refrigerants available for use in the CAP refrigeration system, and to ultimately
select the design basis refrigerant for the CAP. The study was based on a
relative comparison of different refrigerants with respect to various technical and
economic parameters.
The chilled ammonia process uses ammonia solution as chemical solvent to
remove CO 2 from the flue gas. The chemical reactions are exothermic resulting
in the release of heat to the process. The reactions are also reversible allowing
for the regeneration of the ammonia reagent and re-use in CO 2 absorption. After
the solvent has absorbed the CO 2 , it is routed to a regenerator where the CO 2 is
desorbed by heating the solvent with steam. The operating temperature in part
of the process is slightly below ambient temperature most times of the year,
which requires the application of a refrigeration system.
The refrigeration system is a significant portion of the CAPs energy demand, so
selection of the optimum refrigerant is an important factor in minimizing the
CAPs power consumption. This study indicated which refrigerants are commonly
available and provides information regarding physical properties, environmental
impact, safety considerations and specific power consumptions as a basis for the
selection of the right refrigerant for this CAP application.
In the past decade, synthetic refrigerants like Chlorofluorocarbons (CFC) and
Hydrochlorofluorocarbons (HCFC) were widely used because of advantageous
qualities, such as low toxicity and non-flammability, compared to most of the
existing refrigerants. After observation of the hazardous impact of these
substances on the earths atmosphere, the international community decided with
the 1987 Montreal protocol to eliminate the application and production of these
substances. Therefore CFCs and HCFCs cannot be used anymore for new
facilities, and were not considered in this study.

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Chemical companies are trying to develop safe, cost effective, and efficient
refrigerants for industry that encompass a wide range of applications.
Hydrofluorocarbons (HFC) are a promising solution as these refrigerants do not
deplete the ozone layer and have many of the desirable properties of CFCs and
HCFCs. However, they contribute to global warming if released to the
atmosphere. Countries, trade associations and companies are increasingly
adopting regulations and voluntary programs to minimize these releases and,
hence, minimize potential environmental effects while continuing to allow use of
these refrigerants.
During the realization of the Montreal protocol (phase-out procedure) and the
limitation of the application of partly halogenated hydrocarbons, the utilization of
synthetic refrigerants has been reduced and there is growing interest in
hydrocarbons and natural refrigerants. Table 4 below shows a compilation of
various refrigerants considered for this project and their Ozone Depletion
Potential (ODP) and their Global Warming Potential (GWP).
Substance
Ammonia
Carbon Dioxide
Hydrocarbons
HFCs (R134a, R-410A, etc.)
HCFCs
CFCs
ODP
0
0
0
0
0.05
1
GWP
0
1
3
>1,000
>1,000
>1,000
Table 4: ODP & GWP of various refrigerants considered
Besides environmental considerations, a good refrigerant should have low

specific power consumption, which is not the case when carbon dioxide is used
as a refrigerant. The power consumption is approx. 40% higher compared with
the refrigerant with the lowest specific power consumption. Therefore the use of
carbon dioxide as a refrigerant is usually limited to applications where power
savings is not a consideration, and non-toxicity, low ozone depletion, and global
warming potential are of most importance.
A comparison of the refrigerant specific power consumption is indicated below
(Table 5) using ammonia as the baseline as it has the lowest specific power
consumption.
Substance
Ammonia (Base Case)
Hydrocarbons
Carbon Dioxide
Specific Power
Consumption (%)*
100
103-110
104-142
142
*Specific power consumption (%) is defined as the compressor

power of the refrigeration system divided by the chilling duty.
Table 5: Refrigerant specific power consumption
Due to their flammability, hydrocarbons are rarely used in refrigeration systems

having chillers inside of closed buildings, which is typical for air conditioning or
in the food industries. However, hydrocarbons are often applied in industrial
refrigeration systems. The design of such plants needs special consideration

Page 46 of 66
regarding fire protection, but these systems are well established in the industry
and have a long record of experience.
Ammonia is the single natural refrigerant being used extensively in industrial
applications for its good thermodynamic and thermophysical characteristics.
Ammonia is an excellent refrigerant but also a hazardous substance. Although
hazardous, there are well established practices, common in industry, for the safe
handling of anhydrous ammonia.
The focus for safe handling and operation of ammonia is concentrated on:
Using a small quantity of circulating flow rate
Limitation of accident impacts
The potential environmental and safety risk of chemicals depends, among other
factors, on the inventory of the system. In this regard, ammonia has an
advantage compared to other substances, due to its high volumetric cooling
capacity. The indicated figures below provide a list of the system inventory of
different refrigerants compared to ammonia.
Substance
Ammonia (Base Case)
Hydrocarbons
Carbon Dioxide
Inventory (%)*
100
350
740
420-1,000
*The system inventory (%) is defined as the total amount of refrigerant inside of
the refrigeration system (equipment and piping) on a mass basis.
The evaluation and comparisons carried out in the study showed that an
ammonia refrigeration system is optimal for the Mountaineer CCS II project.
This system has the lowest energy consumption (highest efficiency) and the
lowest installed capital cost, with minimal environmental impact with respect to
ozone depletion, greenhouse effect, or global warming.
1.1.12 Power Assessment Study
The purpose of this study was to identify the electrical system configuration and
specific equipment ratings for the AEP Mountaineer CCS II Project. This
auxiliary power system assessment establishes the system configuration, the
sizing and the ratings for the auxiliary transformers, secondary auxiliary
transformers, station service transformers, medium voltage switchgear, medium
voltage starters, low voltage switchgear, and low voltage motor control centers
to provide an electrical distribution system that has sufficient capacity to startup and run all the loads for AEP Mountaineer CCS II Project.
The electrical system configuration was developed using AEP electrical design
criteria and the overall electrical load list for the CCS II system. The following
four alternatives were considered after the base configuration was determined:
1. Three (3) winding auxiliary transformers
2. Variable frequency drive (VFD) for the HT Refrigerant Compressor motor

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3. Soft start for the HT Refrigerant Compressor motor

4. Using the Plant Reserve 138/13.8kV Spare Auxiliary Transformer as the
spare transformer for CCS II System
Each configuration was evaluated to determine the steady state load flows, large
motor starting, resultant bus voltage and short circuit duty to size and
determine the equipment ratings.
Based on the results of the power assessment, a VFD is recommended for the
HT Refrigerant Compressor: Equipment ratings for the medium voltage
switchgear should be specified to accommodate use of the Plant Reserve
138/13.8kV Spare Auxiliary Transformer as the spare Auxiliary Transformer for
the CCS II System.
The following are the recommended electrical system configuration and
equipment ratings:
1. The auxiliary transformers steps down the 138kV lines from the
Mountaineer Sub Station to 13.8kV and provides 13.8kV power to the
medium voltage switchgear.
Auxiliary Transformers:
Quantity: 2
2 winding
MVA: 54/72
Impedance: 8%
2. The medium voltage switchgear feeds the secondary auxiliary transformers,
the station service transformers and large motor loads over 5000hp.
13.8kV Switchgear:
Quantity: 1
Configuration: Double ended (Main Tie Main)
Bus 1 Rating: 3000A (Feeds Large Motors)
Interrupting rating: 50kAIR
13.8kV Switchgear:
Quantity: 1
Bus 2 Rating: 2000A ( Feeds Auxiliary Transformers and Station
Service Transformers)
3. The secondary auxiliary transformers steps down the 13.8kV to 4.16kV and
provides 4.16kV to the medium voltage switchgear / medium voltage motor
control center.
Secondary Auxiliary Transformers:
Quantity: 2
MVA: 15/20
Impedance: 6.5%
4. The 4.16kV medium voltage switchgear / medium voltage motor control
center feeds the medium voltage motors less than 5000hp.

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4.16kV Switchgear/ Medium Voltage Motor Control Center:

Quantity: 1
Bus Rating: 3000A
5. The station service transformers steps down the 13.8kV to 480V and
provides 480V to the low voltage switchgear
Station Service Transformers:
Quantity: 8
kVA: 2000/2666
Impedance: 5.75
6. The 480V low voltage switchgear feeds the low voltage motor control
centers and building feeds.
480 Switchgear:
Quantity: 4
Configuration: Main Tie Main
Bus Rating: 3200A
7. The 480V low voltage switchgear feeds the low voltage motors and
miscellaneous 480V loads.
480 Motor Control Centers:
Quantity: 16
Bus Rating: 800A 1200A
Mountaineer lacked the additional capacity in its existing electrical system to
adequately accommodate the equipment and infrastructure needed to operate
the CAP system. To meet the demands of the process and BOP equipment it
was determined that two (2) dedicated 138 kV circuits were needed.
Mountaineers existing substation did not have available 138 kV breakers
sufficient for this service. In order to provide the needed power, AEP
Transmission and Distribution engineers determined necessary modifications and
additions to the existing 138kV auxiliary substation at Mountaineer to
accommodate the CAP. A summarized breakdown of the scope of integration
required to supply the necessary electrical power to the Mountaineer CCS
system is as follows:
Installation of multiple additional circuit breakers, switches, control cables

and breaker foundations
Installation of three phase metering class capacitance coupled voltage

transformers (CCVTs) on 138kV bus #1 and bus #2 and single phase
metering class CCVTs on each feeder. The existing CCVT structure and
foundation for bus #1 CCVT will be used, with new CCVT foundations and
structures required on bus#2 and all feeders.

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Expansion of the existing 138 kV substation control house by 10ft in order

to fit the new panels. This involves land improvement work to restore a
ditch right next to the control house.
Expansion of the existing fence and addition of new ground grid.
1.1.13 Building / Architectural Study

As part of the building architectural study, WorleyParsons developed the
conceptual design for an administrative building, control room/ laboratory,
electrical building, and a warehouse to service the CCS plant. Basic floor plans
for these buildings were developed as a basis for the cost estimate.
Prior to developing the building designs, the project investigated the measures
needed in order to meet a Leadership in Energy and Environmental Design
(LEED) classification. The study evaluated multiple areas including sustainable
sites, water efficiency, energy and atmosphere, materials and resources, indoor
environmental quality, innovation and design, and regional priority. Under each
category of evaluation, there are multiple qualifiers with respective ratings or
points. For each qualifier which is met by the building, the points are earned.
Once the building has been evaluated in all categories, the earned points are
summarized. To be a LEED certified facility, 40-49 points must be earned, LEED
Silver requires 50-59 points, LEED Gold requires 60-79 points, and LEED
Platinum requires 80-110 points.
The project team evaluated the items identified within each category and
determined whether the buildings for the project would be designed in order to
meet the qualifier. After this evaluation, a LEED Silver rating was determined to
be the standard that would be used on the project in the design of the
administrative building, control room/ laboratory, electrical building, and
warehouse for the CCS plant.
1.1.14 Refrigeration Heat Rejection Vapor Study
This study was performed to evaluate the impact of the plume emitted by the
evaporative cooling equipment included in the CAP for the AEP Mountaineer CCS
II Project. The equipment concerned consists of the refrigeration system
Evaporative Condenser and the Direct Contact (DC) Cooling Tower, shown in 13
below.

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Figure 13: Location of Vapor Plume Sources (From 3-D Model)
The evaluation was performed based on the design site ambient conditions
provided in the Project Specific Design Criteria, AEPMT-1-DB-1.01.01.01.060001. The prevailing wind direction for the site is 220 degrees (SW) with an
overall average wind speed of 7 mph. Monthly site wind direction and speed
frequency data in the form of wind roses were used based on the USDA wind
data for Huntington, WV airport. Data for the Evaporative Condenser and DC
Cooling Tower were provided by Alstom. The locations considered in the study
are those shown on the plant layout drawings. The location was examined with
respect to negative wind effects to the equipments performance as well as
negative impacts of the vapor plume drift.
Based on this evaluation, the location and orientation of the evaporative
condenser is acceptable and should not cause frequent problems with the vapor
plume becoming a nuisance or hazard for surrounding roads and structures. The
condenser is in a favorable orientation with the centerline nearly parallel to the
prevailing wind direction. In addition, it is sufficiently distant from surrounding
tall structures that the plume will not likely drift into those structures.
The location of the smaller DC Cooling Tower is not ideal. Its location was
chosen to minimize distance between it and the process equipment it serves,
and, to maintain space for future equipment. For prevailing winds, plume
problems associated with its location are not expected. When the wind blows
opposite the direction of the prevailing winds, the DC Cooling Tower plume will,
during unfavorable weather, be carried into the open absorber steel structure in
the higher elevations. Given the small size of the tower and its distance from the
structure, this effect is not expected to be significant. The effect can be further
minimized by adjusting operation of the tower. To accomplish this, provisions
should be included in the tower for future addition of individual cell bypass and
variable speed fans, to allow the plume carryover effect to be minimized.

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1.1.15 Accessibility Review

Throughout the course of Phase I, the project team held monthly 3-D model
reviews to assess the accessibility of the facilitys design. A tremendous amount
of effort and detail went into the 3-D model to demonstrate a realistic view of
the conceptual design. The 3-D model, a snapshot of which is shown in Figure
14, contains detailed information such as:
Building sizes
All major process and BOP piping (2.5)
All major process and BOP equipment
Equipment arrangements
Containment barriers
Access/egress design and critical maintenance considerations (pull
spaces, tool cart access)
Structural steel
Electrical panels, cable tray, and pipe racks
The complete 3-D model allowed Alstom and WorleyParsons to obtain precise
quantity take-offs for the detailed bottom-up cost estimate for the project.
Alstom also used the 3-D model to develop detailed facility renderings that
display what the CAP facility and auxiliary support systems will look like as a
finished product. The renderings and model snapshots were used in the teams
Phase I presentations to AEP Management, DOE, and others to better facilitate
understanding of the finished commercial-scale facility and to show the amount
of detail that went into the projects cost estimate and plan for future phases.
In future project phases, the 3-D model will be updated as the facility design
matures to ensure adequate accessibility and maintainability.
Multiple access
platforms/walkways at
DCC, absorber, and water
wash vessels
Multiple
inspection/maintenance
access platforms on
supply/return ducts
Figure 14: 3-D Model Snapshot showing Some Aspects of Accessibility
Absorber tower
elevator

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1.1.16 Spares Study

Alstom in coordination with AEP performed a Reliability, Accessibility,
Maintainability (RAM) study during the Phase I FEED. Based on the design
requirements set, the CCS Plant shall have a minimum capability of 85%
Availability Factor. During this 85% Availability of the plant, the CCS plant shall
be able to demonstrate a capture capability of 90 wt.% of CO 2 from the flue gas.
Both these factors are considered as success criteria and were considered as
target values for the RAM study.
The RAM study was performed by Alstom using data from existing pilot and
demonstration projects and technical information available during the Phase I
FEED. It is expected that in the detailed design and engineering phase, this
study would be refined based on more detailed process design and vendor
information. The results of this study are summarized as follows:
Considering the redundancy provided on the PFDs and P&IDs, and under
the assumption that there would be no spares in stock available on
CCS II site, the calculated Equivalent Availability Factor is calculated as:
o 91.0% for the CCS II Plant (without BOP and Sequestration
Network)
o 87.7% for the CCS II Plant (incl. BOP and Sequestration
Network)
Note: the assumption of no spares on site is conservative and indeed

unrealistic in this context. The Equivalent Availability is more likely to be closer
to the value calculated with full spares on site (shown next):
Considering the redundancy provided as shown on the PFDs and P&IDs,

and under the assumption that all required spares would be available on
CCS II site, the calculated Equivalent Availability Factor is calculated as:
o
o
94.4% for the CCS II Plant (without BOP and Sequestration

Network)
92.1% for the CCS II Plant (incl. BOP and Sequestration
Network)
The most critical components in terms of having adverse effects on the CCS II
plant availability (in case of failure) can be considered as:
o
o
o
o
CO 2 Compressor (CP-6070),
HT Refrigerant Compressor (CP-6002)
LT Refrigerant Compressor (CP-6002)
Air Compressor (1-IA-CP-6090)
Below is a summary table of the calculated Equivalent Availabilities; CAP

availabilities not including BOP and the Sequestration Network are reported in
bold and including BOP and the Sequestration Network are in parenthesis.

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Current Redundancy, no spares on site

Current Redundancy, full spares on site
Equivalent Availability
91.0% (87.7%)
94.4% (92.1%)
Table 6: Summary of RAM calculated results
It should be noted that the Phase I RAM study was a preliminary assessment of
equivalent availability based upon the complete equipment scope as determined
in Phase I. Detailed engineering, design, and analysis of failure modes, repair
durations, startup/shutdown durations, curtailment effects, and lessons learned
from other CAP systems in operation will significantly improve the accuracy of
the MT CCS II equivalent availability expectations. The team did not have
adequate time or information in Phase I to appropriately evaluate all of the
factors that affect availability of the system. For the purposes of the Phase I +/25% cost estimate, the Current redundancy, no spares on site was the
identified basis of estimate.
1.1.17 Constructability Study
This study presented Phase I information on constructability issues related to
the Mountaineer CCS II project. Key constructability issues include
modularization, equipment delivery methods, crane/lift requirements, lay-down
and staging, site improvements, impact on equipment design,
sequencing/schedule planning, and risk mitigation.
The primary value of this study is enhancement of early project planning with
the goal of steering the project toward a successful and cost-effective
construction plan. Two meetings involving the primary stakeholders were
conducted in Columbus during the Phase I conceptual design process. Following
is a summary of the constructability plans based on Phase I information:
Equipment and structures will be modularized to the extent practical

to enhance quality, improve productivity, decrease overall project
cost, and improve schedule.
Barge transport will be the primary delivery method for large
modularized items.
The CAP absorber area vessels will be fabricated and delivered in ring
sections and erected with a standard crane.
The more slender, but heavier, regenerator vessels will be delivered
in one horizontal piece and up-righted with a crane.
The absorber packing vendor strongly recommends an absorber
erection sequence that avoids field-welding of ring sections with preinstalled packing, therefore packing will be installed after vessel
welding is complete.
Unloading and transport of large equipment items will require site
improvements at the barge unloading facility.
CAP vessel and equipment design must consider anticipated delivery
and construction methods to ensure integrity from fabrication through
erection.
Construction-specific risks include river water level, absorber vessel
packing material flammability, and weather exposure of the absorber
packing material.

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Key recommendations to ensure that constructability issues remain prevalent as

the project moves forward include:
1. Schedule follow-up meeting(s) to track progress.
2. Include early activities for site investigation in Phase II schedule
development.
3. Continue Phase III schedule development with input from all key
stakeholders.
4. Designate dedicated lay-down areas on arrangement drawings.
5. Maintain heavy lift contractors involvement in delivery/erection
discussions as design progresses.
6. Confirm/update equipment weights as design progresses.
7. Consult other AEP projects for any relevant lessons-learned.
8. Incorporate risk mitigation measures into Phase II schedule as
appropriate.
9. Consider adding included risks to the project register.
1.2
Civil/ Structural
1.2.1 Preliminary Plot Plan
As part of the Phase I effort, WorleyParsons developed the preliminary plot plan
of the CCS Capture facility and of the Geologic Sequestration System (GSS) site
plan. Each of the two plans provide an overview of the entire plant site,
showing site boundaries and major facilities such as buildings, switch yards,
major equipment, water intakes, roadways, and interfaces with any existing
facilities. The process of developing the preliminary plot plan was iterative
throughout the Phase I FEED to optimize the arrangements for access while
conserving the available area. The final preliminary plot plans identify the
arrangements which were the basis of the refined project cost estimate and
identified in the NEPA Environmental Impact Statement.
1.2.2 General Arrangement Drawings
The general arrangements of the CAP and GSS are more detailed depictions than
shown in the overall plot plans. The general arrangement of the CAP facility
identifies the arrangement of CAP specific equipment and further details
dimensions and other components of the various process systems. The GSS
general arrangement also distinguishes a greater detail of information specific to
the two primary sites of interest, Borrow Area and Jordan Tract. The layout
depicts the proposed layout of injection and monitoring wells along with the
anticipated area of review based upon model simulations performed by Battelle.
1.3
Chilled Ammonia Process

1.3.1 Preliminary Safety Analysis
This study presented preliminary information on potential hazards related to the
Mountaineer CCS II project. It is a fundamental risk study based on preliminary
design information and represents participation of the key stakeholders involved
in the design process. The primary value of this study is enhancement of early
project planning through identification and assessment of potential events that
present risk to health, safety, and environment; the Phase I effort also focuses
on risk identification for potential impact on the capital cost estimate and Phase
II planning. This analysis is limited to the Capture portion of the project scope;

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the safety analysis for the Storage portion of the project is the responsibility of
the storage contractor, Battelle, and is discussed in section 1.8.1.
Two meetings involving AEP, Alstom, WorleyParsons, and the Department of
Energy were conducted for risk identification and assessment; the results of
these sessions were recorded on a spreadsheet that employs WorleyParsons
Risk Management Software for processing and prioritizing of the input. This
exercise was completed in Phase I with the understanding that the process will
continue through Phase II with confirmation and completion of risk evaluation
and treatment.
The two risk planning sessions, along with the resulting risk register and
preliminary action plan, satisfy the objectives of the Phase I planning effort with
respect to health, safety, and environmental risk analysis. The impact of risk
items affecting project design and budget have been incorporated into the Phase
I planning effort.
1.3.2 Process Flow Diagram (PFD) and Mass and Energy Balance
One of the earliest efforts in Phase I was the development of the process flow
diagrams and material and energy balances which would serve as the basis for
the Phase I conceptual design. Alstom issued the initial material and energy
balances in August 2010. Upon review of the PFD and mass and energy
balances, AEP and Alstom agreed that there were several areas of the design
and its integration into the Mountaineer plant that needed to be addressed
before finalizing the conceptual design.
Alstom and AEP engineering met in Alstom's Wiesbaden, Germany office during
a two week period in September 2010 to discuss the design. Several process
design alternatives were proposed that would potentially correct problems
experienced on the PVF, simplify the process, and/or make it more operatorfriendly. Further design workshops were held throughout October and
November to work through the final details of design concerns, address Balance
of Plant (BOP) integration, and to review process simulations. Alstom issued
final PFDs and full load material and energy balances in December 2010, and
later provided additional mass and energy balance simulations at defined
operating parameters that better defined the operating envelope of the CAP.
Additionally, WorleyParsons developed PFDs encompassing the BOP scope.
1.3.3 Piping & Instrumentation Diagram (P&ID)
As identified the Cooperative Agreement, Alstom and WorleyParsons developed
P&IDs for the CAP facility, advancing the detail shown in the process PFDs.
P&IDs fully depict all processes, controls and instrumentation; P&IDs include all
major pipe, equipment, equipment tag numbers, nominal pipe sizes, pipe
material, control and safety valves, specialties, and instrumentation designation.
The development of the P&IDs underwent multiple design reviews during Phase
I. The final P&IDs were used in the development of the process functional
design and mechanical functional design, and furthermore incorporated into
requests for quotations submitted to vendors.

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1.3.4 Process Description

The CAP Process Description describes the major process components of the CAP
Island. The CAP system includes:
Flue Gas Cooling/Cleaning

Absorber
Regenerator
CO 2 Compressor
Reagent Handling
Refrigeration
The Process Description provides the basis for normal operation, start-up, and
commissioning procedures for the process and is based on information
developed and obtained during the Phase I FEED process.
The BOP Process Description outlines the operation of the BOP equipment
intended to support the Mountaineer CCS II Project. These systems support the
CAP whose function is removal of CO 2 from the flue gas stream.
The BOP systems include:
Byproduct Storage and Processing

Flue Gas Duct Drains
Instrument and Service Air
Potable Water
Process Steam Condensate
Process Steam
Makeup Water / Service Water
Waste Water
The BOP Systems for AEPs Mountaineer CCS II Project are designed to meet the
applicable requirements of the AEP Project Specific Design Criteria and other AEP
criteria documents specified therein. For each BOP system, the process
description discusses a description of the equipment, functional requirements,
and a general description of the control and operation.
1.4
Mechanical
1.4.1 Equipment List
An equipment list was developed as an all inclusive document providing the
piece of equipment, equipment tag number, equipment rating, manufacturers
model number, electric motor rating and speed.
1.5
Electrical/ I&C
1.5.1 Preliminary Electrical One Lines
Preliminary electrical one-lines developed for the MT CCS II project depict the
schematic representation of the electrical system, including generators,
transformers, switch gear, motor control centers, breakers, etc., showing
redundancy, control methods, sparks, phase relationship, power cable rating,
and electrical characteristics of equipment.

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1.5.2 Distributed Control System (DCS) Control Philosophy

The CAP Process Control Description is intended to provide the Process Control
Description for the systems comprising the Carbon Capture System at AEPs
Mountaineer Station. This document describes the purpose, equipment make-up,
and process description for each of the following systems:
Flue Gas Cooling

Circulation Water Distribution
Absorption
NH 3 Wash and Stripping
Regeneration
CO 2 Compression
Refrigeration
Auxiliaries and Sumps
Sulfuric Acid
Ammonia Storage and Handling
Process Monitoring
Gas Analyzers
During the Phase I effort, Alstom developed the CAP Process Control Description
and provided to AEP. AEP reviewed the document and submitted comments in
return. AEP agreed to push resolution of the comments to this document until a
future phase, as Alstoms document adequately described the functionality to a
level of detail appropriate for Phase I design and estimating.
In addition to the Process Control Description for the CAP scope developed by
Alstom, WorleyParsons was given the task to develop the CCS DCS Control
Description. This document describes the operating, control and monitoring
philosophy associated with the MT CCS II project. As part of the general control
philosophy, WorleyParsons identified plant functions, critical protection and trips,
non-critical protection and trips, critical control, non-critical control, monitoring,
permissive and interlocks, overrides, and e-stops requirements. The DCS
Control philosophy also discusses general operator interface, the operator
interface terminal, controls, equipment arrangement, system control and I/O,
redundancy and separation, DCS data communication, DCS monitoring, process
historian, and flue gas monitoring.
Battelle was also responsible for developing the control logic for the well
monitoring and maintenance system (WMMS) as part of the Phase I efforts.
Within the WMMS control logic, Battelle provides an overview of hardware which
makes up the WMMS control system, the programmable logic controller (PLC)
software, the WMMS operation, preliminary alarm conditions, and interlocks and
fail safe operation.
1.6
Permits, Insurance, & Infrastructure

1.6.1 Relocations
As part of the Phase I effort, WorleyParsons completed a relocation study. Once
equipment arrangements were finalized, WorleyParsons investigated the area for
interferences with utilities and structures in the area of the CCS facility and
determined what if any relocations were necessary. Following completion of the

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study, WorleyParsons developed a drawing showing the items identified by the

study and proposed location for the utility to be moved.
1.6.2 Identify Permits
Identification of permits needed to complete the MT CCS II project was an
important process in the planning of future phases of the project. Much of this
effort was handled by AEPs internal resources who are accustomed to
permitting requirements specific to the Mountaineer Plant. WorleyParsons aided
AEP in the identification of required permits as did Battelle in relation to the CO 2
pipeline and GSS wells, respectively. Some planning, such as that associated
with the UIC Class VI permit, required greater coordination with the West
Virginia Department of Environmental Protection (WV DEP) or corresponding
government agency. Permit requirements were documented in the Permit
Summary Report (Attachment A), and were incorporated into other project
documents such as the project schedule and cost estimate.
1.7
Professional Services
1.7.1 WBS
A Work Breakdown Structure (WBS) was developed in the initial phase of the
project and incorporated into the Cooperative Agreement. The WBS sectioned
Phase I into the Capture portion, the Storage portion, AEP activities and NEPA
activity. The project Phase I schedule and costs, along with their metrics, were
reported based on the WBS.
The WBS was later expanded to delineate all phases of the project and
maintained the same sections within each phase of Capture, Storage and AEP
Services. Phase II was tailored to the Engineering and Design phase of the
project and included a further breakdown by component systems within each
section. Phase III focused on the construction activities by system and category.
Phase IV reflected the operations phase.
The WBS was utilized by the project team as the outline of the project and was
used to relate various elements including cost, schedule, communications, scope
management, and division of work. AEP, Alstom, Worley Parsons and Battelle
collaborated on the items contained in the WBS and contributed to the published
definitions of limits and inclusions within each WBS.
1.7.2 Cost Estimate
One of the main deliverables for Phase I of the project was a +/-25% cost
estimate of all phases of the total project. A detailed Work Breakdown Structure
(WBS) was established that continued the delineation of the project between
Capture and Storage initiated in Phase I. The sections were further broken down
to component systems and basic construction categories. The WBS evolved with
the addition and changes in scope and each WBS was defined to determine what
was to be included in each.
Early in Phase I, a kick-off meeting was held with all entities contributing to the
final estimate. The purpose of the meeting was to inform participants of the
various common aspects of the estimate and the expectations. This initial
meeting was followed up with bi-weekly meetings to discuss progress in

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completing deliverables, identify obstacles in meeting timing and make decisions

to resolve issues.
The following factors were initiated in advance of the estimate development and
contributed to the successful compilation of the estimate:
A matrix with all WBS codes was published to all entities showing who
supplied the quantities, material costs, labor cost and input to the
consolidated estimate.
An estimate format and template was established that was compatible with
the estimating systems of all the entities and easily consolidated in the
master estimate.
Coding was developed for estimate source code, contracting strategy,
escalation and risk factors applicable to individual items that was common
to all entities.
Labor unit rates, crews, productivity factors and indirect costs were
determined in conjunction with all entities and applied uniformly to all
component estimates.
Escalation was a composite forecast based on various sources both
internally and externally for several high level categories such as type of
work, commodities, equipment and services. A table was developed and
applied consistently.
Major material costs were obtained by RFQ wherever possible.
Several meetings and discussions along with input from an erection
contractor were utilized to focus on constructability of the system
components including delivery, on site handling, erection and sequencing.
These factors were incorporated into the fabrication and estimated costs of
the components.
Several meetings were held to review the estimate. One was with all parties to
review the estimate by individual WBS to determine if there were any omissions,
changes, or deletions based on the current scope and also to validate the
reasonableness of various items. Separate meetings were held to determine
which items had risk and/or opportunity potential and to what extent. A risk
analysis was performed using the double triangle method suggested by the DOE.
The risk was incorporated into the final estimated amount where appropriate.
The overall thoroughness in executing the estimate resulted in a product that
achieved the anticipated +/- 25% accuracy. Details of the estimate are
described in the Preliminary Public Design Report which is available on the NETL
website (netl.doe.gov). The total estimated constructed cost including
escalation and risk based contingency is approximately $1 billion.
1.7.3 Project Schedule
As part of the Phase I effort, Alstom, Worley Parsons, Battelle & AEP developed
the necessary activities for Phase II and III. Each group developed a Level 1 for
their scope in each phase. Once the Level 1 was reviewed, integrated and
approved by the project team, the schedule was then detailed to a Level 2. The
Level 2 was reviewed, integrated and approved by the project team and the
process of developing the Phase II Level 3 schedule proceeded.

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To develop the Level 3 schedule, each group developed the detailed activities
they identified for Phase II. Once the activities were entered into the software,
meetings were held to discuss the logic and integration and actions were taken
to detail new activities. Critical Path Method reviews were done and an
integrated Phase I, II & III schedule was completed in June 2011.
1.7.4 Procurement Template
A procurement template was developed for the MT CCS II project following the
general AEP procurement guidelines. The procurement template consists of an
Engineering Requisition, a detailed Scope of Work document, Proposal
Requirements, AEP Project and Field Services Invoicing Requirements, Project
Engineering and Design Criteria, Specifications, Guidelines, and Standards, and
a Bid/ Contract Summary.
1.7.5 Contract Template
AEP developed a standard contract template for use on the MT CCS II project.
This template consists of a Request for Proposal, a detailed Scope of Work
document, Proposal Requirements, AEP General Terms and Conditions,
Supplemental Safety Terms and Conditions, Government Flowdown
Requirements, AEP Scheduling Requirements, AEP Project and Field Services
Invoicing Requirements, Project Engineering and Design Criteria, Specifications,
Guidelines, and Standards, and the vendors proposal.
Due to AEPs position at the Phase I Decision Point, AEP did not proceed with
Phase II contract negotiations.
1.7.6 Phase I Alstom Contract
As the identified owner of the CAP technology, AEP negotiated a contract with
Alstom to participate in the conceptual design of the MT CCS II facility. AEP
began negotiations with Alstom on February 1, 2010, once the Cooperative
Agreement with the U.S. DOE was finalized, and reached agreement on June 4,
2010.
1.7.7 Phase I Storage Contract
A contract was also negotiated with Battelle Memorial Institute to perform the
Phase I work of developing the conceptual design for the GSS. AEP began
contract negotiations with Battelle in March 2010, and executed a contract on
July 16, 2010.
1.7.8 Phase II Alstom Contract
AEP engineering, in conjunction with Alstom and WorleyParsons engineering,
developed a detailed division of responsibility. The division of responsibility
depicts in a tabular format, the organization which is responsible for the
functional design, detailed design, detailed design review, deliverable submittal,
equipment/ material supply, fabrication drawing approval, site erection
supervision, site erection execution, and site commissioning for each WBS
element.
In anticipation of the Phase II contract development, Alstom developed a
description of the scope which would be performed by Alstom during Phase II of

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the project. Further contract negotiation never came to fruition due to AEPs
decision to suspend the project after completion of Phase I deliverables.
1.7.9 Phase II Storage Contract
AEP engineering, in conjunction with WorleyParsons and Battelle, developed a
detailed division of responsibility. The division of responsibility depicts in a
tabular format, the organization which is responsible for the functional design,
detailed design, detailed design review, deliverable submittal, equipment/
material supply, fabrication drawing approval, site erection supervision, site
erection execution, and site commissioning for each WBS element.
In anticipation of the Phase II contract development, Battelle Memorial Institute
developed a description of the planned scope which would be performed by
Battelle during Phase II of the project. Further contract negotiation never came
to fruition due to AEP Managements decision to suspend the project after
completion of Phase I deliverables.
1.7.10 Phase II Construction Contract
A construction contract was not required for the Phase II effort planned during
Phase I; however AEP, Alstom, WorleyParsons, and Battelle developed a
proposed contracting strategy for the construction work to occur in Phase III.
The contracting strategy is discussed below in section 1.9.14.
1.7.11 Phase II Project Work Plan
The development of the Phase II Project Work Plan was originally planned to be
developed during the final three months of Phase I following AEPs delivery of
the Phase I Decision Point Application. Due to AEPs position at the Decision
Point, AEP did not proceed with development of the Phase II Project Work Plan.
1.7.12 Contracting Strategy
AEP, with input from Alstom, WorleyParsons, and Battelle, developed a proposed
contracting strategy for the MT CCS II project. The contracting strategy for the
project is to firm price as many contracts as possible, where the scope and
schedule are well known, followed by unit price, cost reimbursable, or T&M
contracts where the scope of work is not well defined or there are other
constraints. The contracting strategy document lists all anticipated contracts
required for Phases 2-3 along with the corresponding strategy. This strategy
was incorporated into the Division of Responsibility and refined cost estimate.
1.8
Wells and Monitoring Verification and Accounting (MVA) System

1.8.1 Preliminary Safety Analysis
Similar to the preliminary safety analysis conducted for the capture and
compression scope of the project, Battelle performed a safety analysis of the
geologic storage system. For the purpose of the Safety Analysis the project was
divided into distinct elements called Nodes as listed below:
Node
Node
Node
Node
Node
1:
2:
3:
4:
5:
Drilling / Monitoring Injection Well

Well Completion
CO 2 Pipeline Transport
Injection
Site/Well Closure

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Node 6: Post Injection Storage & Monitoring

Node 7: Maintenance and Workover Programs
The method used to conduct this safety analysis was the what-if analysis. The
what-if analysis technique was developed specifically for the process industry to
identify both safety hazards and operability problems that could compromise the
ability to achieve design productivity.
The what-if study method entails analyzing hazardous events (incidents) to see
how they may occur and what undesired consequences are possible. Each
sequence of failures and conditions leading to an accident event is a unique
scenario. Every accident scenario includes an initiating event or cause (e.g.,
mechanical or human failure), an accidental event or consequence, and an
impact (injuries and/or damage). Safeguards may be employed to keep the
incident from occurring. Mitigation may reduce the severity of the impact.
The concept of the system review is to assume that the system works well when
operating under design conditions. Problems arise when deviations from the
design conditions occur. The what-if methodology requires a team of subject
matter experts to review the system of interest, in this case the transport,
injection, and storage of CO 2 . The system is divided into its major elements
(nodes) and what-if questions are generated for each element within the
system. Following are the type of what-if questions that are asked during the
review:
What
What
What
What
if
if
if
if
{a
{a
{a
{a
specific
specific
specific
specific
accident} occurs?
system} fails?
human error} occurs?
external event} occurs?
The team then responds to the what-if questions with potential consequences,
assuming no safeguards are in place. Once the potential consequences are
determined, the team then identifies possible engineering and/or administrative
safeguards to protect against a particular mishap. The team assesses the
protection measures included in the system design that may reduce the
likelihood of the scenario and/or to prevent or minimize the consequences or
impacts. Based on the estimated frequency and severity of the consequences,
the team may make recommendations to reduce the overall risk of the scenario.
Although the overall objective of the safety review is to identify potential
accident scenarios and identify opportunities for risk reduction, it is important to
table discussions on risk reduction solutions outside of the safety review to
ensure that all of the potential scenarios can be addressed in a timely manner.
For each scenario, the risk associated with that scenario was estimated. The risk
estimate was formed by assigning a score to the probability of the scenario
occurring and the impact of the consequence, considering each with and without
safeguards. The team looked at the health and safety, environmental and
business loss consequences to determine an overall consequence of the
scenario.

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1.8.2 Develop the Preliminary Monitoring Plan

The Preliminary Monitoring Plan developed by Battelle provides an overview of
the testing and monitoring that can be deployed near the Mountaineer Power
Plant.
The specific testing and monitoring requirements for the commercial-scale
project are not known at this time because an Underground Injection Control
(UIC) permit has not yet been issued for the project. Therefore, it was assumed
that testing and monitoring requirements for the commercial-scale project will
be similar to those for the ongoing pilot-scale CO 2 capture and storage project
at the Mountaineer Power Plant. It was also assumed that the testing and
monitoring requirements in U.S. EPAs new Geologic Sequestration (GS) Rule will
apply. The 20 MW PVF pilot scale project is authorized by West Virginia
Department of Environmental Protection (WVDEP) Underground Injection
Control (UIC) Permit No. 1189-08-53, a Class V (experimental) permit. The
Class V permit stipulates testing and monitoring requirements to verify that the
experimental geologic sequestration project is operating as permitted and is not
endangering underground sources of drinking water (USDW). The U.S. EPA, in
December 2010, issued the GS Rule, which establishes a new class of injection
well, Class VI, for wells that will be used to inject CO 2 into deep geologic
formations for long-term storage (sequestration). The GS rule sets minimum
federal technical criteria for Class VI wells for the purpose of protecting USDWs
and mandates comprehensive monitoring of all aspects of well integrity, CO 2
injection and storage, and groundwater quality during the injection operation
and the post-injection site care period. A Class VI UIC permit will be sought for
the commercial-scale project; therefore, testing and monitoring requirements in
the new GS Rule were considered in developing this testing and monitoring plan.
Another driver for monitoring requirements is the Mandatory Reporting of
Greenhouse Gases Rule (MRR) (74 FR 56260), which requires that all facilities
that inject CO 2 for the purpose of long-term geologic sequestration to report
basic information on CO 2 injected underground and imposes additional
monitoring to quantify CO 2 emissions to the atmosphere.
The preliminary monitoring plan discusses design assumptions, a summary of
the monitoring and testing program, and the purpose, description, baseline
monitoring, and operational phase monitoring for the following components:
quarterly analysis of the CO 2 injection stream, injection and annulus
pressure/temperature monitoring, corrosion monitoring, external mechanical
integrity testing, pressure fall-off testing, groundwater monitoring, surface
microseismic monitoring, wireline logging for plume tracking, monitoring fluid
chemistry in the injection reservoirs, monitoring pressure in injection reservoirs,
modeling, and mandatory reporting requirements for the injection and geologic
sequestration of carbon dioxide.
1.9 AEP Project Management and Support
As outlined in the Cooperative Agreement DE-FE0002673, AEPs Project Management
Team (PMT) employed earned value management techniques meeting industry
standards for tracking completion of work, keeping activities on schedule, and
controlling costs to remain within the budget throughout the Phase I. The PMT

Page 64 of 66
implemented and managed the Project and reported on activities in accordance with the
approved Project Management Plan (PMP).
The PMP is the critical document that integrates how: (a) work is executed to
accomplish the Project objectives; (b) Project risks are considered; (c) the Project
technical scope, cost and schedule are managed; (d) Project performance is monitored
and controlled; and, (e) Project information is communicated within the Integrated
Project Team (IPT) (which includes the DOE) and to external stakeholders.
1.10 National Environmental Policy Act (NEPA)
Pursuant to the National Environmental Policy Act (NEPA), the U.S. Department of
Energy (DOE) was required to evaluate potential environmental impacts as part of its
decision-making process to determine whether to provide financial assistance beyond
Phase I of the commercial-scale Mountaineer CCS project.
The NEPA evaluation considered all aspects of the proposed project (i.e. CO 2 capture,
transport, and storage) with a focus on 18 key resource areas: air quality; greenhouse
gases; geology; physiography & soils; groundwater; surface water; wetlands &
floodplains; biological resources; cultural resources; land use & aesthetics; traffic;
noise; materials & waste management; human health & safety; utilities; community
services; socioeconomics; and environmental justice.
This comprehensive evaluation is collectively referred to an Environmental Impact
Statement (EIS). Preparation of the draft EIS required a significant amount of field
studies to evaluate biological, cultural, and water resources that may be impacted by
the project. DOE issued a draft EIS for public review on March 11, 2011. A copy of the
draft EIS can be found at:
www.netl.doe.gov/technologies/coalpower/cctc/EIS/eis_mountaineer_draft.html
IV Conclusions
On July 7, 2011, AEP provided a letter to the DOE proposing a partial termination of the
scope of work for Phases II, III or IV as defined in the Statement of Project Objectives
(SOPO) contained in Attachment No. 2 to Cooperative Agreement DE-FE0002673. This
decision resulted from the changes which have occurred in the CCS arena since the
beginning of the project. When the original grant application was submitted by AEP in
response to DE-FOA-0000042, AEP believed it was important to advance the science of CCS
due to pending action regarding climate change legislation and/or regulations concerning
CO 2 emissions at our coal-fired power plants. Various bills in Congress were introduced to
limit emissions but also provide funding for early CCS projects. AEP also believed that
regulatory support for the remaining cost recovery beyond the DOE or legislative support
was probable given the potential for emission reduction requirements on an aggressive
timetable. While AEP still believes the advancement of CCS is critical for the sustainability of
coal-fired generation, the regulatory and legislative support for cost recovery simply does
not exist at the present time to fund AEPs cost share of the commercial scale CCS facility.
Notwithstanding AEPs decision to dissolve the existing cooperative agreement and postpone
project activities, AEP and its extended project team successfully completed the Phase I
effort for the Mountaineer Commercial Scale Carbon Capture and Storage Project, as
outlined in the cooperative agreement. Within Phase I the cooperative agreement called for:

Page 65 of 66
The resolution of outstanding conditions with the U.S. Department of Energy (DOE)
cooperative agreement;
Project specific developmental activities (i.e., front-end engineering and design);
The initiation of the NEPA process; and
The identification of exceptionally long lead time items.
The front-end engineering and design package developed within Phase I incorporated
knowledge gained and lessons learned (construction and operations related) from the
Mountaineer Product Validation Facility (PVF) and the design package also established the
fit, form, and function of the project including design criteria, mass and energy balances,
plot plans, general arrangement drawings, electrical one-lines, flow diagrams, P&IDs, etc.
Based on the work completed in the front-end engineering and design package, AEP and its
extended project team also:
Developed a +/- 25% cost estimate,

Developed a detailed Phase II project schedule,
Provided DOE with all information it needed to complete the NEPA process,
Developed a multi prime construction contracting strategy for Phase III,
Issued preliminary PFD and overall mass and energy balances, and
Completed preliminary project design.
In summary, the work completed in Phase I continues to support the commercial readiness
of Alstoms CAP technology at the intended scale and provides AEP and DOE with a good
understanding of the projects risks, capital cost, and expected operations and maintenance
costs during planned Phase IV operations. The completed front-end engineering and design
package provides a sound basis for completion of the project when conditions warrant the
continuation of this or a similar project elsewhere in the U.S.

V
Page 66 of 66
Products Produced/ Technology Transfer Activities

DOE sponsored Japanese Utilities tour of the Mountaineer Product Validation Facility,
7/15/10.
McElwee, Charles; Spitznogle, Gary. Can America Capture and Store Carbon? Charleston
Gazette 9/5/10
DOE CCS Program Conference, Pittsburgh, PA, 9/16/10.
AEP gave project presentations at the Racine Town Council meeting on 10/18/10, the WV
building trades meeting on 10/20/10, the Mason Town Council meeting on 10/21/10, and
the New Haven Town Council meeting on 10/26/10 as part of the semiannual community
leaders updates.
AEP presented the MT CCS project semi-annual update to the Mason County Commission
on 11/5/10.
AEP conducted a Conference of Right hearing with the IRS on 11/23 to respond to the IRS
tentative adverse opinion on AEPs request for a Private Letter Ruling designating the
Cooperative Agreement funding as non-taxable. AEP Legal responded to the IRS position
on two issues and submitted a supplemental letter to the IRS on 12/10/10 providing
written confirmation of the information presented at the Conference of Right hearing. In
response to AEP's requests, the IRS determined that published guidance is the appropriate
way to address the CCPI funding tax status. The IRS will therefore not issue AEPs private
ruling and will refund the $14,000 user fee.
AEP hosted the DOE sponsored North America Knowledge Sharing Agreement task force
on 11/30- 12/1/10. The activities included a tour of the 20 MWe Mountaineer CCS Product
Validation Facility on 11/30/10 and CCS presentations and discussions on 12/1/10 at
AEPs corporate office. The MT CCS II project team gave a presentation at the 12/1/10
conference including lessons learned from the MT PVF and MT CCS II projects.
On 2/16/11, AEP issued a press release announcing the funding agreement with the
Global CCS Institute.
AEP developed an issued an Activity Management Plan to the Global CCS Institute on
4/15/11.
AEP participated in the CCS Conference held in Pittsburgh, PA on 5/2-5/5/11.
AEPs Matt Usher provided a presentation of the project at the Southeast Electric
Exchange conference held in Atlanta, GA 5/18-5/20.
AEPs Guy Cerimele provided a presentation of the project at the Southeast Electric
Exchange conference held in Orlando, FL 6/29-7/1/11.
AEPs Gary Spitznogle contributed to the article in The Columbus Dispatch Ohio goal:
Extract oil by getting rid of CO 2
AEP developed an issued a CCS Integration White Paper to the Global CCS Institute on
10/25/11.
AEP presented at the Global CCS Institutes CCS Integration Conference in London,
England on 11/3/11.
AEP will present at the Global CCS Institutes CCS Roadshow events in Austin, Texas on
11/8/11, and in Calgary, Alberta, Canada.
AEP has also developed additional reports for the Global CCS Institute including a report
on CO 2 Storage, a Compression report, a FEED report, a Lessons Learned report, and a
Financial Modeling/ Business Case report. AEP is in the process of addressing comments
to these reports at this time, and expects to issue in final version by the end of 2011.
Appendix A
MT CCS II - Project Permit Summary Report
MT CCS II - Project Permit Summary

PERMIT NAME
GOVERNING
AGENCY
PERMIT REQUIRED FOR
PERMIT DEVELOPMENT REQUIREMENTS
RESPONSIBL
PERMIT
E GROUP/
DEVELOPMENT
ENGINEER
DURATION
PERMIT REVIEW
DURATION
COMMENTS
ENVIRONMENTAL
PERMITS
AIR PERMITS
WV Reg 13
WATER PERMITS
Cultural Resource
Investigation - Agency
Concurrence
Threatened/ Endangered
Species Investigation - Agency
Concurrence
Threatened/ Endangered
Species Investigation - Agency
Concurrence
Section 10/404
Permit application for Stacks, Absorbers

and other emission sources within
Capture, Pipeline & Storage areas.
Mass balances, cooling tower location & emissions,

CEMS, Design freeze
WV SHPO
Capture, Pipeline & Storage areas
WV DNR
WV DEP
AQS
30 days
1 year
Plot Plan, Cultural Resources Study
WERS
10 days
30 days
Endangered species studies, plot plan
WERS
10 days
30 days
US FWS
Endangered species studies, plot plan
WERS
10 days
30 days
US COE
Stream or river crossing and/or changes.

Construction activities, dredging, dock
improvements and borings within Capture, Field surveys, corridor and well site plans, mussel survey
Pipeline and Storage areas. Permit
required prior to site prep/ construction.
WERS
2 months
9 months
401 water Quality Certification
WV DEP
Mussel Survey
US FWS
Nationwide Permit
US COE
Stream or river crossing and/or changes.

Construction activities, dredging, dock
improvements and borings within Capture, Field surveys, corridor and well site plans, mussel survey
Pipeline and Storage areas. Permit
required prior to site prep/ construction.
WERS
4-6 weeks
Underground Injection Control

(UIC Permit)
WV DEP
Required prior to any site preparation

work/ construction of injection well site(s)
Seismic study, well design
WERS
1 months
12 months +
Well work permit
WV DEP
Well design, site layout, UIC permit for injection wells,
WERS
4 months
30 (calendar) days
Monitoring plan
WERS
40 days
1 year
Plot Plan, stormwater calculations
WERS
6 weeks
4 months
Plot Plan, P&IDs, General Arrangements
WERS
3 months
6 months
Plot Plan, P&IDs, General Arrangements, pipeline

contractor developed hydro plan
WERS
6 weeks
1 year
GHG (MRV) Monitoring Plan

NPDES/ Stormwater
Construction Permit
WV DEP
NPDES/ Plant Permit

Modification
WV DEP
NPDES - Hydrotest Pipeline
WV DEP
Last Update: 7/27/11
Required prior to any site preparation

work/ construction of well site(s)
required 180 days after UIC permit
issuance
Disturbance of a soil area 1.0 acre or
greater within Capture, Pipeline and
Storage areas
Operation/ Discharge of wastewater to
surface water within Capture, Pipeline and
Storage areas.
Hydrotesting the pipeline
Field surveys, corridor and well site plans, mussel survey
WERS
2 months
9 months
WERS
10 days
5 months
Indiana Bat, Zebra Mussel, etc.

Can only be performed in warm weather.
Wait until after EIS ROD received
Indiana Bat, Zebra Mussel, etc.
Can only be performed in warm weather.
Wait until after EIS ROD received
Requires Threatened/ Endangered Species concurrences
from WV DNR & US FWS, and Cultural Resource
concurrence from WV SHPO
Triggered by application for USA COE 10/404
Requires Threatened/ Endangered Species concurrences
Agency review/ approve plan - 30 (calendar) days
Conduct Survey/ Prepare Final Report - 34 days
Agency Concurrence - 30 (calendar) days
Follow-up Field work - 30 days
Issued in lieu of Section 10/404

30 day completeness review Requires Threatened/ Endangered Species concurrences
+ 45 day permit review
Required prior to any site preparation work; 1 permit
required for each injection site
UIC permit required prior to well work permit application for
injection wells; 1 permit required for each well site
Page 1 of 2
MT CCS II - Project Permit Summary

PERMIT NAME
GOVERNING
AGENCY
PERMIT REQUIRED FOR
PERMIT DEVELOPMENT REQUIREMENTS
RESPONSIBL
PERMIT
E GROUP/
DEVELOPMENT
ENGINEER
DURATION
PERMIT REVIEW
DURATION
COMMENTS
NON-ENVIRONMENTAL
PERMITS
Certificate of Public
Convenience and Necessity
Floodplain Development
FAA Aeronautical Study Obstruction Lighting
Architectural Review
Fire Alarm System Review
WV PUC
Prior to start of construction
Entire Carbon Capture & Storage Project

Mason County Office
area; required prior to start of any
of Emergency
construction within designated floodplain
Services
boundaries
Required for each structure =/< 200';
breaks a plane. Required approval prior to
FAA
start of foundation excavation for stacks,
etc.
Control Room/ Lab Bldg, Warehouse/
Maintenace Bldg, Admin Building, Byproduct Storage Bldg, Electrical Bldg, ByState Fire Marshall product Processing Bldg, Power
Distribution Center, Refrigeration
Compressor Bldg.; required prior to start of
structure erection
WV State Fire
Marshall
Sprinkler System
agency approval required prior to start of

system installation
Tank Review
WV State Fire
Marshall
Review of all tanks containing flammable/

combustable liquids and gases to be
installed as part of the project; required
prior to tank erection
Fire Code Variance Request
WV State Fire
Marshall
Railroad Crossing
Highway Crossing
Easements/ Right-of-Way
Risk Management Plan
Required prior to start of system

installation
needed prior to start of any construction
CSX Transportation
work associated with the side track
Crossing over or Under Railroad Right-ofWay; required prior to accessing and/or
CSX Transportation
starting any construction activity within
railroad right-of-way
WV DOT
One set of drawings and/or documents specifying the

locations and dimensions of the construction or alteration.
Specifications, site plan, architectural plan, plubing plan,

mechanical plan, electrical plan, bldg elevations and
sections
Control Room/ Lab Bldg, Warehouse/

Architectural drawings which identify room usage, all
Maintenace Bldg, Admin Building; required alarm devices, wiring diagrams, spec sheets for fire
prior to start of system installation
alarms, devices and panels, and battery calculations.
WV State Fire
Marshall
Railroad Spur Modification
Class II legal advertisement (public notice) in the

publication area in each county.
The exact size of the structure to be constructed, or
repaired, The location of the construction on the property,
The location of other existing structures, or ongoing
construction projects on the property.
Crossing over or under highway; required

approval prior to start of any work within,
or occupancy of, highway right-of-way
Sprinkler system layout and devices, fire dept connection

location, hydralic calculations, water flow test information,
valves, tamper flow switches and gauges, underground
piping size and location, water supply pump and tank size
and location.
Site plan that locates the tank with respect to property
lines, buildings and public ways; locates and provides the
size of protection bollards; locates emergency shutoff
valves and tank manufacturers drawings and/or spec
sheets (stamped and signed).
Required to submit prior to containing

anhydrous ammonia on site (will only be
within Capture Area)
Environmental & Safety Plans
40 days
90 days
see Bob Long's Non-environmental permit procedures
P&FS
10 days
30 days
One permit per county
130 days
Also requires notice of start of construction 2 days prior (5

days to develop), and notice of construction complete no
later than 5 days after reaching final height (5 days to
develop)
20 days
Durations are for each structure. Agency site inspection

after completion of building construction; occupancy permit
issued in conjunction with approval of Fire Alarm System
and Sprinkler System; one per structure; permit fees
calculated on % of building construction costs
20 days
Durations are for each structure. Agency site inspection

after completion of system installation; occupancy permit
issued in conjunction with approval of Sprinkler System and
P&FS
P&FS
P&FS
10 days
10 days
10 days
P&FS
10 days
20 days
Durations are for each system. Agency site inspection after

completion of system installation; occupancy permit issued
in conjunction with approval of Fire Alarm System and
P&FS
10 days
20 days
Durations are for each tank. Agency site inspection after

completion of tank installation
P&FS
10 days
20 days
Drawings stamped and signed by the supervising

engineer
Durations are for each system. Agency site inspection after

completion of system installation;
P&FS
5 days
5 days
Drawings stamped and signed by the supervising

engineer
P&FS
10 days
175 days
Requires to prepare/ submit notice of construction complete

(5 days)
Drawings that sufficiently show the nature of work to be

performed
P&FS
10 days
30 days
Requires to prepare/ submit notice of construction complete

(5 days)
AEP Physical
Security
1 year
None
PEC
3 months
None
Land
Management
WV DOT & Railroad Approval of pipeline route

US EPA
P&FS
Plot Plan, P&IDs, General Arrangements

Existing Environmental & Safety Plans
Seismic Permit
see comments
see comments
Elevator Inspection
see comments
see comments
Last Update: 7/27/11
Battelle is responsible for obtaining prior to performing any

seismic studies
Elevator contractor is responsible for certifying all installed
elevators; must be ASME 17.1 certified
Page 2 of 2

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Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Final Technical Report

Report Title: Final Technical Report

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Disclaimer: "This report was prepared as an account of work sponsored by an agency of

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Technical Approach to Integration

Results and Discussion

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

AEP Project Management and Support

National Environmental Policy Act (NEPA)

Appendix A Permit Summary Report

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

+/- 25% Cost Estimate Complete

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Figure 1: Simplified Chilled Ammonia Process Schematic

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

FLUE GAS COOLING &

Figure 2: Chilled Ammonia Process Schematic

1.2 Technical Approach to Integration

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Power plants and chemical plants have different operating philosophies.

1.3 Operational Philosophy

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

AEP approached integration of the CAP at Mountaineer from a conservative perspective.

Flue gas heat recovery to reduce the CAP energy demand.

Qualitative complexity related to location of the equipment, required

Qualitative assessment of impact of heat recovery to other

Quantitative assessment of maximum energy recovery potential (Btu or

Quantitative assessment of additional capital cost to achieve proposed

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

incorporation of a first-of-a-kind technology in a slip-stream application. The team was

Studies & Investigations

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

stream could be as dilute as 10 percent total dissolved solids (TDS) ((NH 4 ) 2 SO 4 )

1st Year OPEX

The project team decided that generation of a concentrated solution of

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

Figure 3: Steam Extraction Location and Energy Penalty

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

make Mountaineer no longer interchangeable with the other turbines on the

New Throttling Valve

New Throttling Valve

New Throttling Valve

New Throttling Valve

Figure 4: Simplified Schematic of Mountaineer Turbine Arrangement with CAP Integration

Challenges/Opportunities to Overcome Inefficiency

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

1.1.3 Compression Study

Mountaineer Commercial Scale Carbon Capture and Storage (CCS) Project

for the commercial scale compression system. Equipment arrangements,

Option 1 Integrally-geared, inter-cooled, centrifugal compressor with