Masdar is developing several carbon capture projects from power plants, smelters, steel works, industrial facilities and oil and gas processing plants in Abu Dhabi in a phased series of projects. Captured CO2 will be transported in a new national CO2 pipeline network with a nominal capacity of 20×106 T/y to oil reservoirs where it will be injected for reservoir management and sequestration. Design of the pipeline network considered three primary factors in the selection of wall thickness and toughness, (a) steady and transient operating conditions, (b) prevention of longitudinal ductile fractures and (c) optimization of total project owning and operating costs. The paper explains how the three factors affect wall thickness and toughness. It sets out code requirements that must be satisfied when choosing wall thickness and gives details of how to calculate toughness to prevent propagation of long ductile fracture in CO2 pipelines. It then uses cost optimization to resolve contention between the different requirements and arrive at a safe and economical pipeline design. The design work selected a design pressure of 24.5 MPa, well above the critical point for CO2 and much higher than is normally seen in conventional oil and gas pipelines. Despite its high operating pressure, the proposed network will be one of the safest pipeline systems in the world today.

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