Techno-Economic Analysis of An Integrated Direct Air Capture and Mineralization System

Abstract

Carbon sequestration involves the conversion of carbon dioxide gas into carbonates through reactions with magnesium or calcium bearing minerals, presenting a potential method to mitigate CO2 emissions and reduce their release into the atmosphere. This process can be classified into two categories: in-situ (subsurface) and ex-situ (surface). CO2 mineralization has demonstrated the ability to permanently store substantial quantities of CO2 without the need for extensive post-monitoring efforts, while also offering potential business model benefits for the generated end products. However, the field of mineralization still faces substantial technical and economic challenges, including high cost projections and slow carbonation kinetics, impeding further technological advancements in the field. Additionally, logistical challenges related to plant design and associated emissions contribute to the complexity of finding solutions to these problems.

In this particular study, the investigation focused on ex-situ carbon dioxide sequestration primarily through direct aqueous mineral carbonation, incorporating a direct air capture element. This approach was chosen due to the flexibility provided by direct air capture in terms of CO2 supply and the desirable characteristics of direct aqueous carbonation. Various models were developed using Aspen Plus software and compared, leading to the selection of the direct aqueous carbonation system as the optimal choice for CO2 carbonation. Further enhancements were implemented in the system, including recycled streams and heat integration, to reduce overall energy consumption. Optimization steps were also undertaken to determine the appropriate sizing of key equipment that make up the majority of the system's overall costs and to improve system efficiency.

An economic analysis was then performed, revealing that plant scales of 50 ktons/year yielded a positive Net Present Value (NPV), indicating profitability. Conversely, smaller-scale plants of 0.5 ktons/year and 5 ktons/year did not generate positive revenue, even with a high carbon credit price. This was followed by a sensitivity analysis that showcased the relevant parameters that holds significant effects on the economic performance of the system.

Moreover, business model cases were also explored, and it was concluded that utilizing the end products in building materials and road construction could potentially generate additional revenue for the mineralization system beyond storage options.

Overall, this investigation highlights the potential of ex-situ carbon sequestration through direct aqueous mineral carbonation, considering direct air capture, and emphasizes the importance of economic viability and revenue diversification in the successful implementation of mineralization systems to mitigate the effects of global warming.