Direct Air Capture Case Studies
Presentation given by the National Energy Technology Laboratory's Tim Fout at the Carbon Intel Forum, September 2022 on the recent NETL Direct Air Capture Case Study reports.
Fout, Timothy↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Characterization of Solid Sorbent for Direct Air Capture of CO2 using a CFD-based Methodology
Computational Fluid Dynamics (CFD) was used to investigate the CO2 capture by a novel PIM sorbent developed in National Energy Technology Laboratory (NETL) for direct air capture (DAC) applications. The CO2 adsorption kinetics used in the CFD was developed using isotherm data and CO2 breakthrough data obtained from experiments. Effect on humidity on the CO2 adsorption was also investigated and compared with the CO2 adsorption in dry conditions.
Aziz, Hossain↗
Synergistic direct air capture of CO 2 with aqueous guanidine/amino acid solvents
We report that Methylglyoxal-bis(iminoguanidine) (MGBIG) has been recently identified as a promising sorbent for direct air capture (DAC) of carbon dioxide via crystallization of guanidinium carbonate salts. In this study, the effects of aqueous amino acids and oligopeptides, such as glycine, sarcosine, serine, arginine, taurine, lysine, and glycylglycine, on the efficacy of DAC by crystallization of MGBIG carbonate have been investigated. While most of the amino acids studied were found to precipitate with MGBIG, thereby rendering the sorbent unavailable for DAC, sarcosine, the only amino acid in the series with a secondary amine group, remained soluble in the presence of MGBIG, leading to enhanced DAC compared to MGBIG alone. Specifically, for the same amount of MGBIG (5 mmol), the addition of a small amount of sarcosine to the aqueous solvent–as little as 0.5 mmol–led to extraction of six times as much CO 2 from the air (4.15 mmol vs. 0.7 mmol). Thus, aqueous MGBIG and sarcosine work in synergy, offering the prospect for an effective DAC process.
36 MATERIALS SCIENCE↗
Aging studies of Dual functional materials for CO 2 direct air capture with in situ methanation under simulated ambient conditions: Ru thrifting for cost reduction
Dual function materials (DFMs) comprised of 0.25 %Ru, 6.1 %Na 2 O/γ-Al 2 O 3 //monolith were evaluated for about 250 hours time-on-stream (TOS) at various simulated ambient climate capture conditions followed by temperature swing methanation to 280 °C. Herein this paper focuses on the impact of thrifting Ru to low levels and the impact on performance. Results showed both stable CO 2 capture capacity and CH 4 production with 0.25 % Ru DFM deposited on a ceramic monolith. The CO 2 conversion to CH 4 production was decreased slightly by the Ru decrease from 1 % to 0.25 %. The capture capacity decreased since a lower Ru content reduces the complete decomposition of the Na 2 CO 3 precursor producing fewer active adsorption sites (“Na 2 O”). The deployment of a low Ru DFM monolith would significantly decrease the overall capital cost and give more potential for a large-scale direct air capture and methanation (DACM) application.
03 NATURAL GAS↗
Micropatterning of alumina tubular membranes via laser carving for enhanced direct air capture
An approach for preparing and applying micropatterned alumina tubular membranes was developed for improved gas-liquid contact at low air pressure drop in direct air capture application. The paper demonstrated that the laser carving of micropatterns on the outer surface of the alumina tubular membranes could greatly increase their outer surface area and enhance gas-liquid turbulence for a reduced diffusion mass transfer resistance. Six kinds of micropattern configurations were fabricated and studied, including random and regular micropatterns. By introducing a 500-μm solid grid micropattern, the outer surface area doubles and enhances carbon dioxide capture efficiency from 61% to 97% after the membrane was hydrophobically modified with fluoroalkylsilane. Here, the air pressure drop through the tube lumen remained low even when the packing density increased from 382 to 906 m 2 /m 3 . The liquid entry pressure of this micropatterned membrane was the same after testing for 220 h running with the help of periodic drying.
20 FOSSIL-FUELED POWER PLANTS↗
Modular Integrated System for Carbon-Neutral Methanol Synthesis Using Direct Air Capture and Carbon-Free Hydrogen Production
This study investigates the development and economic analysis of a modular integrated system for carbon-neutral methanol synthesis, leveraging direct air capture (DAC) and solid oxide electrolysis cells (SOEC) for carbon dioxide and hydrogen production, respectively. The proposed system integrates a novel building-based DAC process, functionalized solid sorbents, and low-energy SOEC technology, aiming to minimize operational and capital costs. A comparison between the base case system (1,000 t methanol/year) and a scaled-up model (14,758 t methanol/year) reveals significant improvements in efficiency and economic feasibility. The scaled-up system achieves a levelized cost of methanol (LCOM) of $740/t, a 7.5% reduction compared to that of conventional DAC-based systems, while utilizing existing building HVAC infrastructure for air handling. Detailed sensitivity analyses were conducted, evaluating the effects of plant capacity and air flow rate on the LCOM, demonstrating the scalability of the building-based DAC system. The cradle-to-gate life cycle analysis shows that the proposed process using renewable-sourced electricity achieves a 38% reduction in greenhouse gas (GHG) emission compared to reported values of green methanol production technologies that use a conventional DAC and a conventional methanol synthesis catalyst. When fossil-sourced electricity is used in the proposed process, it leads to about a 37.5% reduction in GHG emission in comparison to reported values for conventional methanol production technologies using steam methane reforming technology and fossil-sourced electricity.
alcohols↗
Advancing a Low-Temperature, Low-Cost Direct Air Capture System Based on Organic Chemistry
Holocene Climate Corporation (Holocene) partnered with Oak Ridge National Laboratory (ORNL) to conduct bench-scale testing of a new optimized Direct Air Capture (DAC) process to assist the U.S. Department of Energy (DOE) in achieving the Carbon Negative Shot target of under $\$$100/net tonne CO₂ removed by 2031. Holocene’s DAC process for carbon dioxide (CO₂) removal uses amino acids and guanidine compounds, an ORNL-invented chemical process and licensed by Holocene. Holocene will use this novel chemistry to develop a new process and deploy the technology commercially.
36 MATERIALS SCIENCE↗
Reactive direct air capture of CO 2 to C–C coupled products using multifunctional materials
A single sorbent-catalytic (non-noble metal) material has been developed for the integrated direct air capture and catalytic conversion of captured CO 2 into C-C coupled products.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Technoeconomic Analysis of a Direct Air Capture System Utilizing a Looped CaCO3/Ca(OH)2 Process
This presentation reports preliminary results from a screening level techno-economic analysis of a looped CaCO3/Ca(OH)2 direct air capture process. Preliminary results reveal that the looped CaCO3/Ca(OH)2 process may be cost competitive with solvent- and sorbent-based DAC technologies. Results from a detailed sensitivity analysis revealing multiple avenues for system optimization and cost reduction are presented.
Homsy, Sally↗
Overcoming the Entropy Penalty of Direct Air Capture for Efficient Gigatonne Removal of Carbon Dioxide
Atmospheric carbon poses an existential threat to civilization via global climate change. Hundreds of gigatonnes of carbon dioxide must be removed from earth’s atmosphere in the next three decades, necessitating a low-cost, energy-efficient process to extract low concentrations of carbon dioxide for conversion to a stable material permanently stored for thousands of years. In this work, the challenge of removing gigatonnes of CO 2 is described via the scale of effort and the thermodynamics of collecting and reducing this diffuse chemical, the accumulation of which imparts a substantial entropy penalty on any atmospheric carbon capture process. The methods of CO 2 reduction combined with upstream direct air capture (DAC) including absorption, membrane separation, and adsorption are compared with biomass torrefaction and permanent burial (BTB). A Monte Carlo model assesses the mass, energy, and economics of the full process of biomass torrefaction from biomass collection and transport to stable carbon burial to determine that 95% of scenarios could remove carbon for less than $200 per CO 2 -tonne-equivalent. Torrefied carbon is further discussed for its long-term stability and availability at the scale required to substantially mitigate the threat of climate change.
biomass↗
Direct Air Capture of CO 2 and Delivery to Photobioreactors for Algal Biofuel Production (Final Report)
A mobile DAC system was designed and constructed to pair with photobioreactors growing algae for biofuel production. The DAC system was designed as a versatile research system, rather than a compact production unit. The system was constructed and mounted on a mobile skid to facilitate transportation to the algae production site. Within the DAC system, CO 2 was captured using amine-loaded monoliths that allow for high CO 2 uptake with low pressure drop. The CO 2 is collected using a Global Thermostat patented temperature/vacuum swing adsorption (TVSA) process. Amine sorbents and process conditions were optimized to produce 10 to >20 g CO 2 .h-1. The stability of the amine sorbents was also studied, with sorbent modifications made to improve stability to degradation by oxidation. An Algenol-developed Spirulina strain (Arthrospira platensis AB2293) was selected as the production cyanobacterial strain. AB2293 cultured was inoculum for outdoor production following PBR installation by Algenol. The PBR system was composed of three independent PBRs, with each PBR composed of four hanging bags internally recirculated by a liquid turnover pump. The PBRs were operated outdoors in Atlanta, GA, and integrated with the DAC system. Algae were grown with similar productivity using DAC-CO 2 as algae grown using pure CO 2 obtained commercially (Airgas). Throughout the experimental duration, no discoloration was observed, and cellular morphology was consistent between the two experimental treatments. An LCA including lifecycle greenhouse gas emissions, full life cycle inventory of the Algenol system and the DAC system and integrated DAC+PBR system was developed. Lifecycle greenhouse gas emissions were calculated for capture of carbon dioxide using input from Global Thermostat and the National Renewable Energy Laboratory. Three scenarios for energy provision were evaluated: a natural gas combined heat and power system sized to meet the electricity requirement, a natural gas combined heat and power system sized to meet the process heat requirements, and a system without on-site power that procures the electricity from the grid. In all three cases, as expected, the major contributor to the emissions is the energy consumption associated with the desorption step of the DAC process. The LCA quantified the reduced potential energy and greenhouse gas emissions of heat and mass integration of DAC and Algenol compared to unintegrated DAC and Algenol systems. A life cycle assessment of the role of sorbent productivity and lifetime was also developed. The development of more robust, oxidation resistant DAC sorbents may enable small reductions in energy requirements and in lifecycle greenhouse gas emissions and other environmental impacts. NREL performed techno-economic analysis (TEA) to identify the integration scenario most likely to achieve a 15% cost reduction target versus the baseline. Heat and mass integration of DAC and the PBR is critical to minimizing the MFSP. The baseline case utilizes no heat and mass integration, and the DAC system provides 100% of the CO 2 required by the photobioreactors (20 tonnes/hr), operating for 12 hours/day capturing 40 tonnes CO 2 /operating hour. The minimum fuel selling price (MFSP) of ethanol calculated from the baseline case was $10.68/gal ethanol. This corresponds with a targeted MFSP of $9.07/gal ethanol (or 15% reduction). This target was achieved by integration Option 2a with the greatest cost reduction of 17.8% (or $8.78/gal) and integration Option 2b with a cost reduction of 16.4% (or $8.93/gal). Reductions in MFSP are attributed to two primary process considerations: (a) CO 2 storage at night reduces the capital expenses associated with DAC (i.e., increasing on-stream time); and (b) distributed DAC scenarios (DAC-PBR integration Options 2a and 2b) make use of boiler and DAC CHP flue gas CO 2 (free). Direct air capture on-stream time was one of the largest contributors to MFSP reduction.
09 BIOMASS FUELS↗
Direct Air Capture (DAC) With Nuclear Power Sources
The presentation summarizes a recently published report, along with ANL and INL, on utilizing waste heat and power from nuclear power plants (NPP) for direct air capture (DAC) applications. Two DAC technologies are considered – solid sorbent (S-DAC) and liquid solvent (L-DAC). S-DAC uses both heat and power from NPPs, while L-DAC uses only power. The results show that using NPPs for DAC applications results in an economic benefit compared to using fossil fired power plants
Mantripragada, Hari↗
Electrochemically Regenerated Solvent for Direct Air Capture with Co-generation of Hydrogen at Bench-scale
The goal of this final project report is to summarize the work conducted on project DE-FE0032125. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Institute for Decarbonization and Energy Advancement (UK IDEA) (Recipient) developed an intensified process to capture CO 2 from ambient conditions (415 ppm CO 2 ). The process combines low-temperature solvent-aided membrane capture with electrochemically-mediated solvent regeneration to simultaneously capture ambient CO 2 while regenerating the solvent. The technology employs only two primary units, a regenerator and an absorber/contactor, while generating high purity hydrogen as a co-product that can be sold, used for energy storage, or cost-saving depolarization of the direct air capture (DAC) system during the grid peak demand, allowing for flexible operation. Since the technology is powered directly by DC electricity, it can seamlessly tie in with power sources like solar cells without the need for AC/DC converters, therefore allowing for a remote operation to further mitigate greenhouse gas generation toward deploying a negative carbon emissions technology that is completely decoupled from the carbon emissions from the power source for the DAC unit. The completion of the project results in significant progress toward the Department of Energy’s (DOE’s) goal of advancing lab and bench-scale DAC systems to a sufficient maturity level that can justify their continued scale-up through the verification testing of the electrochemically regenerated solvent system for DAC with co-generation of hydrogen at bench-scale. The technology addressed the complexities of incumbent DAC systems by demonstrating at ambient conditions (1) low gas-side pressure-drop facile CO 2 capture via an intensified membrane absorber with in-situ regenerated hydroxide as capture solvent, (2) multi-functional electrochemical regenerator for hydroxide regeneration, CO 2 concentration and hydrogen production at less than 3 V, and (3) stable DAC performance including >90% capture with air influent at the CFM scale. The data from this project enables the completion of Techno-Economic Analysis (TEA) and Life Cycle Assessment (LCA). TEA and LCA demonstrate the potential of the proposed electrochemical solvent-based process to be a viable DAC option. The analysis did not identify any obvious concern for the bench-scale operation and no apparent barriers to implementing UK IDEA carbon capture and solvent regeneration system at a larger scale.
08 HYDROGEN↗
Provincial-scale assessment of direct air capture to meet China’s climate neutrality goal under limited bioenergy supply
China has large, estimated potential for direct air carbon capture and storage (DACCS) but its deployment locations and impacts at the subnational scale remain unclear. This is largely because higher spatial resolution studies on carbon dioxide removal (CDR) in China have focused mainly on bioenergy with carbon capture and storage. This study uses a spatially detailed integrated energy-economy-climate model to evaluate DACCS for 31 provinces in China as the country pursues its goal of climate neutrality by 2060. We find that DACCS could expand China’s negative emissions capacity, particularly under sustainability-minded limits on bioenergy supply that are informed by bottom-up studies. But providing low-carbon electricity for multiple GtCO 2 yr -1 DACCS may require over 600 GW of additional wind and solar capacity nationwide and comprise up to 30% of electricity demand in China’s northern provinces. Investment requirements for DACCS range from 330 to 530 billion dollars by 2060 but could be repaid manyfold in the form of avoided mitigation costs, which DACCS deployment could reduce by up to $6 trillion over the same period. Enhanced efforts to lower residual CO 2 emissions that must be offset with CDR under a net-zero paradigm reduce but do not eliminate the use of DACCS for mitigation. For decision-makers and the energy-economy models guiding them, our results highlight the value of expanding beyond the current reliance on biomass for negative emissions in China.
54 ENVIRONMENTAL SCIENCES↗
Model-Based Energy and Cost Analysis of Direct Air Capture Using ePTFE-Based Laminate-Structured Gas–Solid Contactors
Carbon dioxide removal (CDR) technologies will play a significant role in limiting global warming if implemented on a large scale. Direct air capture (DAC) is a scalable approach for removing atmospheric carbon, yet the true scope of its scalability remains unclear due to the early stage of technology development and high first plant costs. This study provides groundwork for understanding the technoeconomic trade-offs in developing DAC systems using laminate-structured gas–solid contactors, encompassing the analysis of both contactor and process design spaces. The robust mass transfer and process models outlined in this study provide tools for evaluating DAC processes and designing DAC plants based on cost and energy analysis. First, the key contactor geometrical parameters are identified to understand the CO 2 productivity–energy demand trade-offs, where geometries yielding higher mass transfer rates can achieve higher CO 2 productivities at the expense of energy consumption by fans and steam use. Next, a detailed process parametric study is conducted for DAC systems coupled with steam-assisted temperature-vacuum swing adsorption (S-TVSA) to visualize the trade-offs in the multidimensional design space. The main cost driver dramatically changes over different process conditions, but the operating cost prevailed on the Pareto front, with potential to operate as low as 150 $/tonne-CO 2 (within the cost range of 148–504 $/tonne-CO 2 in this study where the DAC system is coupled with industrial facilities for steam production).
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Energy-Efficient and Water-Saving Sorbent Regeneration at Near Room Temperature for Direct Air Capture
Here this study reports energy-efficient and water-saving microwave-accelerated regeneration of sorbent (MARS) for dilute carbon capture from the ambient air. The experimental studies indicated that the CO 2 desorption rate from the chemisorbents increased with microwave output under near-isothermal conditions at near room temperature. The reduced activation energy of MARS, i.e., 20–28 kJ/mol, indicated enhanced CO 2 desorption kinetics by microwave-induced rotational–vibrational (rovibrational) coupling transitions, primarily due to the highly polarized feature of the carbamate (CO 2 -PEI). The instant and selective delivery of microwave energy to the targeted polarized C–N bonds at room temperature is particularly advantageous for energy-efficient direct air capture. The experimental results also demonstrated a good working capacity of 0.6–1.4 mmol of CO 2 /g and a promising rapid MARS-DAC process with microwave swing. As it does not require steam regeneration and heat exchanger, a simple MARS process is attractive for CO 2 capture in water-stressed regions.
36 MATERIALS SCIENCE↗
Integrated Process for Direct Air Capture of CO 2 and Electrochemical Conversion to Ethanol
This Cooperative Research and Development Agreement (CRADA) between UT-Battelle, LLC and Reactwell, L.L.C. aimed to facilitate the development of an energy-efficient and cost-effective technology that captures carbon dioxide (CO 2 ) from ambient air and converts it electrochemically to ethanol. Direct air capture (DAC) of CO 2 offers the prospect of permanently lowering the atmospheric CO 2 concentration, providing economic and energy-efficient technologies can be developed and deployed at a large scale. DAC has the potential for high-capacity atmospheric CO 2 capture, the flexibility of placement anywhere on earth, and the generation of high-purity CO 2 streams. The most significant technical challenge with DAC is the very low atmospheric concentration of CO 2 , thereby requiring sorbents that bind CO 2 quickly, strongly, and selectively against other components in the air. Integrating DAC with CO 2 conversion into useful chemicals, fuels, or materials can provide an economically feasible solution for mitigating climate change. As long as the carbon contained in these products is taken from the atmosphere and no additional carbon emissions result from their production, processing, and transportation, they can be considered carbon-neutral products. This CRADA facilitated the development of a new net-zero emission technology that closes the carbon cycle by combining DAC with the catalytic electrochemical conversion of CO 2 into ethanol.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Modeling and Analysis of Climate Variation Effects on Fixed-Bed Direct Air Capture Systems
This poster was presented at the 2024 FECM/ NETL Carbon Management Research Project Review Meeting held August 5th-9th in Pittsburgh, PA. The poster discusses the modeling, optimization, and analysis of a solid sorbent based direct air capture process. Analysis of the performance of the system when exposed to varying ambient conditions is also presented.
Hughes, Ryan↗