Engineering topics

Fout, Timothy [Department of Energy (DOE)]

Publications and source records attributed to Fout, Timothy [Department of Energy (DOE)].

6 records

DOE OSTI2026

Insights from Initial Engineering Designs of Point Source Capture at Industrial Facilities

Initial engineering design studies examining the application of state-of-the-art carbon capture technology at industrial plants contain generally overlooked real-world design considerations for near-term deployment of point source capture (PSC). The implementation of PSC across a wide range of industrial applications presents unique challenges associated with fluctuating CO<sub>2</sub> concentrations, flue gas composition, and utility and land availability. In this article, seven recent industrial retrofit PSC projects are reviewed to investigate the impact of site-specific factors on project design and cost. Across the seven projects, three capture technology classes and four industrial applications are considered, allowing insight into industry-specific opportunities for PSC technology synergy. Common challenges across projects and proposed design solutions are highlighted to propagate ideas and solutions to close the technology gaps and accelerate learning rates.

FEED Studies↗

DOE OSTI2025

Project-specific considerations for retrofitting carbon capture technology to power generating and industrial facilities

The National Energy Technology Laboratory (NETL) has previously reported on learnings from 7 FEED studies examining retrofitting power plants with capture. This presentation builds on this effort by highlighting learnings from 3 additional FEED studies examining retrofitting power plants with capture and 7 FEED and pre-FEED studies examining retrofitting industrial plants with capture. This includes a discussion of the design, performance, and cost implications associated with (1) site-specific considerations such as water availability, land availability, and site accessibility, and (2) host-plant-specific factors such as flue gas specifications, operational mode, and allowable degree of integration between the capture system and host plant.

FEED Studies↗

DOE OSTI2025

Front-end engineering design (FEED) studies: a quantitative analysis

NETL has devised a methodology for normalizing FEED study metrics of interest and allowing cautious quantitative comparison across FEED studies. This presentation introduces the novel quantitative comparison methodology and presents results from utilizing this methodology to examine data presented in recent FEED study reports. The quantitative methodology developed for the examination of FEED study performance and cost also allows comparison of real-world performance and costs against NETL TEA model predicted performance and cost. Learnings from examining NETL model predicted performance and cost versus real world reported values are highlighted. These learnings provide insight into NETL TEA model uncertainty and highlight opportunities for further model development.

FEED Studies↗

DOE OSTI2025

Screening analysis of enhanced weathering of igneous rocks and industrial waste materials

Enhanced weathering (EW) is a promising emerging carbon dioxide removal approach that involves harnessing and accelerating the natural weathering process by which atmospheric CO2 passively reacts with exposed alkaline minerals and is removed from the atmosphere. This manuscript reports on a screening level techno-economic analysis of EW. Two primary cases utilizing different sources of alkaline material are considered: (1) utilizing naturally occurring mined igneous rocks, and (2) utilizing industrial waste materials. The modeled EW process encompasses material purchase, comminution, transport, distribution of material on farmland, and measurement, reporting and verification of CO2 removal. Detailed sensitivities are performed to highlight promising scenarios for application. The analysis highlights that utilizing materials with high weathering potential in suitable locations may result in relatively low levelized cost of captured (less than $100 per total tonnes of CO2 captured from the atmosphere). NETL is publishing a detailed and transparent report titled “Enhanced Weathering: Techno-Economic and Life Cycle Screening Analysis” that includes more detail on the screening level techno-economic analysis and includes a life cycle analysis.

Leptinsky, Sarah [NETL Site Support Contractor, Na↗

DOE OSTI2025

Decarbonization of the Iron and Steel Sector: Challenges and Opportunities

The iron and steel industry is one of the largest contributors to industrial emissions in the United States (U.S.). As this industry represents an impactful opportunity for industrial decarbonization, this paper presents the techno-economics of retrofitting iron/steel plants in the U.S. with post-combustion carbon dioxide (CO2) capture technology. For a representative base plant, this analysis considers an integrated steel mill, including a blast furnace (BF) and basic oxygen furnace (BOF), and evaluates CO2 capture as applied to the three largest and highest concentration emission sources of these facilities. A levelized cost of CO2 captured (LCOC) of $80.3/tonne CO2 and $80.7/tonne CO2 was estimated for a retrofit site with 99 and 90 percent capture, respectively.

Henry, Samuel [NETL Site Support Contractor, Natio↗

DOE OSTI2025

Techno-Economic Analysis of Sorbent-Based Direct Air Capture Informed by EPC Input and Recent Technological Advancements

Direct air capture (DAC) technology has been developing at an accelerated rate. Independent, comprehensive, and transparent techno-economic analyses (TEAs) of DAC technologies are required to inform future development. NETL is publishing an update to the 2022 sorbent-based DAC case study report. This manuscript highlights select TEA results that will be presented in the upcoming NETL report. The analysis considers three sorbent-based DAC system configurations (direct steam temperature swing, indirect steam temperature swing, and direct steam temperature/vacuum swing) and two scenarios for providing the required electricity and steam (stand-alone system with a combined heat and power plant generating the required steam and electricity, and a purchased power case utilizing an electric boiler). Detailed sensitivity analyses are included and highlight the impact of external market factors, sorbent performance, and economies of scale. The potential for cost reductions by opting for temperature vacuum swing adsorption is highlighted. More detailed background and TEA results will be presented in the upcoming NETL report titled “Direct Air Capture Case Studies: Sorbent System (Revision 1)”.

carbon dioxide removal↗