Chemical Pilot Plant with Batch Reactor System

EPIC engineered and fabricated a pilot plant system to test carbon dioxide removal from flue gas at coal-based power plants. Using a modular design and off-site fabrication, EPIC ensured faster, safer skid construction and installation—ultimately delivering a scalable process system for CO₂ capture testing. 

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Hygienic Process System Design

Project

Overview

  • Industry: Environmental
  • Customer: Gas Technology Institute 
  • Location: USA
  • Customer Use Case: Carbon Capture, Absorption Systems

Customer’s

Challenge

To support national decarbonization efforts, EPIC partnered with the Gas Technology Institute (GTI), a non-profit energy research organization, to design and build a pilot plant system that tested the process of carbon dioxide (CO₂) removal from flue gas at coal-fired power plants. The system would be used to validate a new gas-to-liquid membrane absorption process and a CO₂ sequestration unit — both untested technologies at pilot scale. 

Engineering the system came with several unique challenges: 

  • Humidity Management: The pilot plant had to compress flue gas saturated at 100% humidity — a condition that posed a significant risk to conventional equipment. 
  • CO₂ Recovery Method: The original client-proposed method for CO₂ recovery and regeneration proved unviable at the pilot scale, requiring EPIC to find an alternative. 
  • First-of-a-Kind Design: The system’s novel components, including the membrane absorption unit, had never been implemented at this scale. 
  • Site Constraints: Installation at the test site had to be executed efficiently and safely, avoiding disruptions and on-site delays. 

Epic

Solution

chemical pilot plant carbon capture

EPIC developed a fully modular, skid-mounted pilot plant system — enabling rapid, flexible fabrication and safer installation. The project leveraged proven engineering methodologies, combined with the adaptability required for emerging clean energy technologies. 

Key solutions included: 

  • Gas-to-Liquid Membrane Absorption Unit: Borrowing from similar flue gas desulfurization PFDs, EPIC replaced the sulfur absorption unit with a CO₂-specific membrane system. The membrane contained a liquid absorbent with high CO₂ affinity, effectively trapping emissions as they passed across the surface. 
  • Thermodynamic CO₂ Regeneration Process: Through EPIC’s detailed Front-End Engineering process, it was determined that the original regeneration approach would not work. EPIC redesigned the system to use a more reliable thermodynamic process, incorporating heat exchangers and flash tanks to isolate and recover CO₂. 
  • Humidity-Tolerant Compression: To safely compress fully saturated flue gas, EPIC’s process team replaced traditional blowers with a liquid ring compressor — eliminating the risk of moisture-related malfunctions. 
  • Flexible Fabrication and On-Site Coordination: EPIC’s in-house engineering and fabrication teams collaborated in real time to address configuration changes during assembly. For example, modifications to the blower unit were implemented quickly, avoiding the typical delays of subcontracted systems. 

Project

Impact

  • Faster, Safer Project Execution: Modular design and off-site fabrication enabled safer, quicker installation and testing. 
  • Scalable Clean Energy Process: Created a reliable pilot platform for CO₂ removal with potential application across U.S. coal plants. 
  • Reduced Risk Through Engineering Expertise: FEL/FEE processes and EPIC’s flexibility avoided costly redesigns and delays. 
  • Operational Reliability in Humid Conditions: Liquid ring compressor prevented failure due to saturated gas stream. 
  • Successful CO₂ Capture, Recovery, and Reuse: System proved capable of removing and regenerating CO₂ for potential reuse, not release. 

 

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