Woodside Carbon to Products Pilot Plant

Woodside was exploring and assessing utilisation pathways for sources of carbon that could generate value-add products in an economic and energy-efficient way, through high-level assessments carried out to date on available technologies for CO₂ utilisation. The production and use of synthesis gas (syngas) was selected as the method for generating valuable carbon-containing products, noting that syngas is well-established across numerous conventional and novel industrial processes for producing an array of significant products.

From early-stage feasibility studies with two Technology Providers (comprising syngas production/generation (Technology Provider 1) and syngas utilisation (Technology Provider 2)), production of ethanol from CO₂ and methane-derived syngas was identified as the desired pathway for realising value from conventional carbon sources.

GPA was engaged to carry out a pre-FEED study followed by a FEED study to integrate recommendations and evaluate overall performance. The studies address integrating the two technology offerings, together with the integration and design of facility balance of plant and supporting utilities and infrastructure.

GPA developed a basis of design package for the integration scope of 1 TpD of Ethanol at the pilot facility, including:

  • implementation of relevant design and construction standards
  • safety system design philosophy
  • control system design philosophy
  • end-to-end process design coordination and checks to ensure compatibility of technologies and utilities
  • coordination with technology providers for key interface data

GPA works included an integrated site layout and preliminary cost estimate, supporting Woodside with licenses, permits, regulatory approvals, and noise modelling.

GPA gained significant expertise during the execution of this green energy project, with a specific focus on the integration of novel technologies to develop an innovative energy solution.

Throughout the project’s life cycle, GPA faced numerous challenges, primarily due to our involvement in supporting the development of technology on a scale not previously tested as well as the integration of novel technologies with multiple process interfaces and varying levels of existing data available. Beyond the technical challenges, GPA navigated financial, regulatory, and social complexities, making this project a multifaceted and complex exercise.

GPA successfully provided all project deliverables within budget and time constraints.

GPA was engaged by Woodside to provide early-stage feasibility studies through to front end engineering design of a carbon capture facility converting CO2 and methane into syngas and subsequently ethanol.