Decarbonisation Technology February 2026 Issue

contributes to energy savings and operational efficiency, while the reduced column height may enable more compact equipment design and decrease construction costs. These combined advantages position Flexipac CP packing as a solution for applications where spatial limitations and operating costs are pivotal factors. Through extensive pilot-scale operation, the test facility has demonstrated the scalability and robustness of Flexipac CP structured packing under a range of simulated industrial conditions. These insights provide a foundation for optimising full-scale column designs, inform the selection of appropriate packing and solvent combinations, and guide process adjustments to maximise performance in real- world installations. The pilot plant’s advanced instrumentation and flexible configuration helps move innovative packing technologies from pilot testing to commercial use. This aims to help new solutions meet operational requirements for energy efficiency, emissions reduction, and cost- effectiveness in large-scale PCCC projects. Case study 1: Economic savings in an NGCC power plant CO 2 absorber Replacing conventional structured packing with Flexipac CP packing in a 1,200 MW natural gas combined cycle (NGCC) power plant represents a significant upgrade in carbon capture efficiency with lower capital expense. Traditionally, NGCC absorber columns are equipped with standard packing to handle approximately 7 million lb/hr of flue gas, equivalent to about 3.5 million tons/year of CO 2 emissions. However, conventional packing often requires larger column cross-sections and greater packing heights to achieve the necessary CO 2 removal rates, resulting in higher capital and operational costs. By switching to Flexipac CP packing, NGCC plants benefit from a 15% reduction in packing height and a 6% reduction in column cross- sectional area compared to conventional designs. This translates to a capital savings of $4.5 million for the absorber and operational cost savings of $350,000 due to lower pressure drop. Flexipac CP packing delivers the same level of CO2 removal with significantly less packing volume. This not only reduces costs for the vessel and associated components but also reduces installation time. Additionally, the reduced pressure drop

across the flue gas blower before the absorber decreases electricity consumption, further lowering operational expenses. In summary, replacing conventional packing with Flexipac CP structured packing yields measurable economic benefits, enhances process reliability, and is designed to support flexible compliance with environmental regulations. This upgrade enables NGCC plants to achieve sustainable, large-scale carbon capture while optimising both performance and cost. Case study 2: Design of a direct contact cooler The direct contact cooler (DCC) plays a pivotal role in optimising thermal energy recovery and efficiently handling large gas flows and significant temperature drops, ensuring robust process reliability and effective heat transfer between upstream heaters and downstream operations. An important consideration when applying Flexipac CP structured packing to the DCC is the benefit provided by its advanced liquid spreading geometry, especially in systems where solvents or process fluids exhibit high surface tension. This innovative geometry enhances liquid distribution across the packing surface, overcoming wetting challenges that are common with high surface tension fluids. As a result, the system achieves more uniform mass and heat transfer, maintaining high efficiency even under demanding process conditions. This feature is particularly valuable in direct contact cooling applications, where consistent thermal performance and reliable operation are critical to overall plant efficiency. Specifically, for an 8 million lb/hr flue gas stream from an industrial process at 130°F, Flexipac CP structured packing is expected to deliver a 22% reduction in tower diameter and a 10% increase in capacity compared to the standard, conventional structured packing offering. These reductions in tower diameter are primarily driven by the lower pressure drop associated with Flexipac CP packing, which enables the system to handle higher gas flow rates without requiring larger column sizes. The decreased pressure drop not only allows for a more compact design, but also leads to operational cost savings of $100,000 per year by reducing the energy required for gas movement through the column. Similarly, the smaller vessel requirements results in capital savings of approximately $500,000 by lowering