A Process for Capturing CO2 from the Atmosphere

We describe a process for capturing CO2 from the atmosphere in an industrial plant. The design captures ∼1 Mt-CO2/year in a continuous process using an aqueous KOH sorbent coupled to a calcium caustic recovery loop. We describe the design rationale, summarize performance of the major unit operations, and provide a capital cost breakdown developed with an independent consulting engineering firm. We report results from a pilot plant that provides data on performance of the major unit operations. We summarize the energy and material balance computed using an Aspen process simulation. When CO2 is delivered at 15 MPa, the design requires either 8.81 GJ of natural gas, or 5.25 GJ of gas and 366 kWhr of electricity, per ton of CO2 captured. Depending on financial assumptions, energy costs, and the specific choice of inputs and outputs, the levelized cost per ton CO2 captured from the atmosphere ranges from 94 to 232 $/t-CO2. [Display omitted] •Detailed engineering and cost analysis for a 1 Mt-CO2/year direct air capture plant•Levelized costs of $94 to $232 per ton CO2 from the atmosphere•First DAC paper with commercial engineering cost breakdown•Full mass and energy balance with pilot plant data for each unit operation An industrial process for large-scale capture of atmospheric CO2 (DAC) serves two roles. First, as a source of CO2 for making carbon-neutral hydrocarbon fuels, enabling carbon-free energy to be converted into high-energy-density fuels. Solar fuels, for example, may be produced at high-insolation low-cost locations from DAC-CO2 and electrolytic hydrogen using gas-to-liquids technology enabling decarbonization of difficult-to-electrify sectors such as aviation. And second, DAC with CO2 sequestration allows carbon removal. The feasibility of DAC has been disputed, in part, because publications have not provided sufficient engineering detail to allow independent evaluation of costs. We provide an engineering cost basis for a commercial DAC system for which all major components are either drawn from well-established commercial heritage or described in sufficient detail to allow assessment by third parties. This design reflects roughly 100 person-years of development by Carbon Engineering. First direct air capture paper for which all major components are either drawn from well-established commercial heritage or described in sufficient detail to allow assessment by third parties. Includes energy and materials balances, commercial engineering cost breakdow