US Operator Establishes the Nation’s First CCS Project Using FlexSteel Pipeline Products

Date Installed:
July 2021

Location & Region:
U.S. North, Bakken

Product Used:
4-inch, 3000 PSI

Application:
CO₂ Injection Line

Project Overview 

In Richardton, North Dakota, a corn-based ethanol operator used 

FlexSteel line pipe to create a reliable and cost-effective pipeline network for the nation’s first carbon capture and storage (CCS) project permitted by state primacy laws. As a result of the project, the company was able to geologically store 200,000 tons of carbon dioxide each year, resulting in a 40% reduction in net carbon dioxide emissions. 

Key Points: 

  • Nation’s first CCS project allowed under state primacy laws 

  • The North Dakota Industrial Commission and the U.S. Environmental Protection Agency approved project 

  • CCS program reduced net CO2 emissions by ~40% 

  • The project qualified for carbon offset credits 

The Challenge

A corn-based ethanol operator near Richardton, North Dakota, sought to establish the nation’s first carbon capture and storage (CCS) project allowed under state primacy laws. The project began upon approval from the North Dakota Industrial Commission (NDIC) and the U.S. Environmental Protection Agency (EPA). The development of the CCS facility would allow the company to geologically store up to ~200,000 tons of carbon dioxide (CO2) each year. The facility would enable the company to qualify for carbon offset credits, which are traded on the carbon compliance market, by meeting the requirements of other state programs to promote low-carbon fuels. 

As part of the design of its facility, the operator wanted a reliable pipeline solution that could be used to transport and inject captured CO2, compressed into supercritical form, into underground reservoirs. The selected pipeline material would need to resist attack from carbonic acid formed in the presence of CO2 and water, along with any impurities in the fluid stream. Lastly, the company needed a solution that would enable it to operate in areas where state environmental policies had restricted gas transportation infrastructure. 

The Solution

The operator evaluated several pipeline solutions before choosing FlexSteel 4-inch, 3,000 psi line pipe. The pipe’s high-density polyethylene (HDPE) liner protects against potential carbonic acid attacks. In addition, the pipeline system is resistant to blistering, splitting, and other surface defects, which would pose a challenge for other pipeline alternatives. FlexSteel pipe’s patented annulus space along the length of the pipeline protects the surrounding environment by capturing any emissions that escape the HDPE liner. Furthermore, FlexSteel’s history of performance and compliance with API 15S, the standard used to validate spoolable reinforced pipelines, and API 17J, the technical requirements for interchangeable flexible pipe, influenced the operator’s decision. 

As part of the collaboration with the operator, FlexSteel’s support team provided technical and operational guidance to the NDIC and its representatives. Because of the NDIC’s confidence in the program and FlexSteel pipeline systems, the project was preapproved for use before an official permit was issued. The NDIC also approved the operator’s Class VI injection well permit in less than five months. 

Following the installation of the pipeline, the operator used FlexSteel’s ShieldSure® Annulus test, which ensures the integrity of the pipe’s shield post-installation, to verify the pipeline was safely installed. The operator then began injecting its captured carbon dioxide into an underground reservoir buried several miles below the surface of South Dakota’s Broom Creek Formation. As an added benefit, the use of FlexSteel line pipe provided an option for the operator to monitor the pipeline in real-time. 

The Result

For the operator and FlexSteel, the CCS project was a major success. The project showed that the company’s CCS program could reduce its net CO2 emissions by ~40%. By installing FlexSteel line pipe, the company was able to minimize pipeline risks and lower its carbon footprint. The project also revealed that with the use of FlexSteel’s durable pipeline solution, the company could expand its production into areas where the infrastructure for gas transportation was limited due to environmental constraints. 

Using FlexSteel pipeline products, the operator built a pipeline network that is reliable, cost-effective, resistant to corrosion caused by carbonic acid attacks, and durable enough to protect against longitudinal crack propagation. Moreover, the FlexSteel pipeline system exhibited its ability to exist in environmentally sensitive areas with minimal environmental impact and disturbance.