Direct air capture of CO2 with chemicals: optimization of a two-loop hydroxide carbonate system using a countercurrent air-liquid contactor

Direct Air Capture (DAC) of CO2 with chemicals, recently assessed in a dedicated study by the American Physical Society (APS), is further investigated with the aim of optimizing the design of the front-end section of its benchmark two-loop hydroxide-carbonate system. Two new correlations are developed that relate mass transfer and pressure drop to the air and liquid flow velocities in the countercurrent packed absorption column. These relationships enable an optimization to be performed over the parameters of the air contactor, specifically the velocities of air and liquid sorbent and the fraction of CO2 captured. Three structured Sulzer packings are considered: Mellapak-250Y, Mellapak-500Y, and Mellapak-CC. These differ in cost and pressure drop per unit length; Mellapak-CC is new and specifically designed for CO2 capture. Scaling laws are developed to estimate the costs of the alternative DAC systems relative to the APS benchmark, for plants capturing 1 Mt of CO2 per year from ambient air at 500 ppm CO2 concentration. The optimized avoided cost hardly differs across the three packing materials, ranging from $518/tCO(2) for M-CC to $568/tCO(2) for M-250Y. The $610/tCO(2) avoided cost for the APS-DAC design used M-250 Y but was not optimized; thus, optimization with the same packing lowered the avoided cost of the APS system by 7 % and improved packing lowered the avoided cost by a further 9 % The overall optimization exercise confirms that capture from air with the APS benchmark system or systems with comparable avoided costs is not a competitive mitigation strategy as long as the energy system contains high-carbon power, since implementation of Carbon Capture and Storage, substitution with low-carbon power and end-use efficiency will offer lower avoided-cost strategies.