From Source to Sink: Embracing the CCUS Learning Curve

Peter Hunszinger is the director of CCUS project delivery at Worley.

While carbon capture, utilization and storage (CCUS) is essential to meeting global net-zero targets, progressing projects from concept through final investment decision (FID) can be challenging due to the steep learning curve. First-of-a-kind projects often navigate technical, economic and operational uncertainties with limited precedent to follow.

But industry players are learning fast. First-of-a-kind projects may be challenging, but the engineering work carried out to deliver them has highlighted key barriers to deployment and how to overcome them. The more these lessons are applied, the faster the industry can standardize approaches, drive down costs and deliver operational projects.

Alignment across the entire value chain from CO₂ source to final storage creates significant opportunities to reduce costs, streamline schedules and reduce uncertainty. Proactively addressing potential supply chain bottlenecks, design misalignments and operational gaps early in the process helps projects progress more efficiently and with greater confidence.

FEED to FID

That’s why the front-end engineering design (FEED) phase plays such a crucial role. A well-executed FEED makes it easier to secure FID by reducing uncertainties that could slow progress. Technical integration, cost viability, regulatory approvals and supply chain readiness all need careful consideration before major financial commitments are made. The focus isn’t just on designing a capture system but on ensuring the entire source-to-sink value chain has been assessed and is set up for operational success.

The best projects use FEED to bring every key player into alignment from the start. CCUS depends on multiple parties working together, and if expectations aren’t aligned early, integration challenges will eventually surface when they’re more expensive to overcome.

On a typical project, there are distinct groups: the design team, the technology licensor, supply chain, and facility operations and construction. These contributors and stakeholders have their own commercial structures, technical considerations and regulatory frameworks and if these are not aligned early, integration challenges will inevitably surface.

No one wants to complete FEED and then realize that stakeholders had different expectations. That is why getting everyone on the same page early is essential and ensures that when the time comes to make an investment decision, the project is ready to proceed with no major gaps or uncertainties.

Getting stakeholder alignment

One of the most effective ways to prevent misalignment is to involve facility operations from the start. A capture facility does not operate in isolation, so integrating it smoothly with the power plant, industrial facility or refinery producing the CO₂ is essential. Engaging operations teams early helps address key questions such as how the capture unit will interface with flue gas streams, how energy will be supplied, and how the system will be maintained, all of which sets the stage for a more efficient and reliable operation.

Operations and construction teams bring valuable insight into process efficiency and layout. A well-designed capture unit should not just work effectively but also be easy to construct, operate and maintain over the long term. If operability and maintenance planning are left too late projects may need costly rework to fix issues.

Technology licensors and supply chain partners also need to be involved early to ensure that key equipment decisions align with procurement timelines. Some early CCUS projects designed highly specific compression and dehydration systems only to find that equipment lead times were too long to meet their needs, which is exactly the type of issue that must be avoided.

This is where experienced project integrators play a critical role, ensuring that technology licensors, supply chain and execution teams work toward a single, coordinated plan while bridging gaps between design, procurement and delivery.

Supply chain readiness, equipment commissioning

Logistics, supply chain and lead times are now some of the defining challenges for CCUS. Certain categories of equipment are already facing supply constraints, which will only intensify as more projects secure FID.

Of course, when considering supply chain risks, availability is just one piece of the puzzle. Transport and logistics also play a key role. For large and complex components with long fabrication and delivery timelines, designing with supply constraints in mind helps keep the project on track. When demand for a component is high, having a plan in place ensures it does not become a bottleneck.

CO2 compressors, for example, have some of the longest lead times. Planning for this early helps avoid delays, and standardizing specifications rather than relying on bespoke solutions significantly reduces bottlenecks. Incorporating modularity and transport constraints into design decisions makes execution smoother and more efficient.

Another key factor is ensuring that equipment specifications are fit for purpose without being over-engineered. Specifications developed for petrochemical and refining applications may increase costs without improving performance. Using standards developed specifically for CO₂ compression, transport and injection optimizes cost and efficiency.

Lessons from first-of-a-kind projects

Much has been made of CCUS as a new technology, but there is a gap to close from first-of-a-kind to business-as-usual where the industry moves beyond demonstration and pilot projects to execution at scale. That means standardization, cost reduction and applying lessons from what has already worked. If every project is treated as a bespoke engineering challenge, it will be difficult to deploy at the necessary speed. Applying first-of-a-kind project learnings is critical.

A major lesson is the importance of water management in CO₂ systems. Water formation, corrosion and material selection should be well understood before construction begins. If these factors are not accounted for in FEED, projects may run into long-term operational issues that are expensive to overcome.

Energy integration is another opportunity to reduce costs. Some early projects missed opportunities to optimize power use and heat recovery, leading to higher operating costs. There is significant value in designing CCUS facilities that integrate efficiently with host facilities. Waste heat recovery and optimizing compression power requirements can have a significant impact on long-term economics.

Material selection has also been a key learning. Some projects initially applied existing process plant standards for compression and materials, assuming they would work for CO₂. That was not always the case. CO₂ behaves differently from hydrocarbons, and materials must be selected accordingly to prevent unexpected issues during various operating modes.

CCUS projects are global, and sharing the knowledge gained improves deployment. Worley, has supported more than 390 CCUS projects across various industries to date, including Gorgon LNG, VPI Immingham and Kasawari CCS. These experiences have reinforced how early planning, supply chain alignment and standardization drives efficiency and reduces risk while working to accelerate the deployment of CCUS.

From first-of-a-kind to nth-of-a-kind

The industry now needs to focus on execution at scale, requiring disciplined project delivery, greater standardization and robust supply chain planning. A well-executed FEED phase is the foundation for success and projects that integrate technology, supply chain and operations planning early will progress faster, with less risk and with fewer surprises.

By applying these proven approaches, projects are in the best position to secure funding, accelerate timelines, and achieve successful execution. The lessons learned from first-of-a-kind projects are now paving the way for CCUS to become a scalable solution to achieve net-zero ambitions. Those who implement these insights now will not only reduce risk but also gain a competitive edge as CCUS moves forward with increasing momentum.