Gad
Licht
*a,
Ethan
Peltier
b,
Simon
Gee
b and
Stuart
Licht
*abc
aDirect Air Capture LLC, A4 188 Triple Diamond Blvd, North Venice, FL 34275, USA. E-mail: slicht@gwu.edu
bCarbon Corp, 1035 26 St NE, Calgary, AB T2A 6K8, Canada
cDept. of Chemistry, George Washington University, Washington DC 20052, USA
First published on 7th February 2025
This study introduces the concept and first demonstration of an effective molten carbonate chemistry for Direct Air Capture (DAC). Molten carbonate electrolysis is a high-temperature decarbonization process within Carbon Capture, Utilization and Storage (CCUS) that transforms chemistry transforming flue gas CO2 into carbon nanotubes and carbon nano-onions. The key challenge for molten carbonate DAC is to split air's 0.04% CO2 without heating the remaining 99.6%. This is accomplished by integrating a diffusive, insulating membrane over an electrolyte with a high affinity for CO2.
Sustainability spotlightThe concept and first demonstration of an effective direct air capture molten carbonate chemistry is presented for removal of the greenhouse gas carbon dioxide to mitigate global warming which is an existential threat to the planet. Molten carbonate electrolysis is an CCUS high-temperature decarbonization chemistry transforming flue gas CO2 to graphenes. Its direct air capture challenge is to split air's 0.04% CO2 without heating the remaining 99.6% of the air, which is accomplished here by integration of a membrane over a high CO2 affinity electrolyte. |
CNTs possess the highest tensile strength ever recorded (93900 MPa) and feature exceptional thermal conductivity, high charge storage, flexibility, and catalytic properties.5,6 As described in the ESI,† they enhance structural materials such as cement and steel, and are used in a variety of applications including in medical and electrochemical fields, electronics, batteries, supercapacitors, sensing, plastics, textiles, hydrogen storage, and water treatment.
High-temperature molten carbonate electrolytic CO2-splitting into C and O2 as a mitigation strategy was first introduced by our group in 2009–2010.7 By 2015, it was demonstrated that this process could convert CO2 into valuable, specialized graphene carbons, GNCs, through transition metal nucleated growth.8–10 The type of useful GNCs, such as CNTs and CNOs produced depends on the electrochemical conditions (ESI†), which offers a promising climate change mitigation approach. The process follows a 4-electron redox reaction of carbonate:
CO32−(molten) → C(GNC) + O2(gas) + O2−(dissolved) | (1) |
The oxide reacts with CO2 to regenerate carbonate:
CO2(gas) + O2−(dissolved) → CO32−(molten) | (2) |
These reactions combine to split CO2 into carbon products and O2:
CO2(gas) → C(GNC) + O2(gas) | (3) |
The CCUS molten carbonate electrolysis process for CNT and CNO production has evolved into a sophisticated technology. By adjusting the CO2 electrolysis conditions, specific GNCs can be produced, including doped, thin, thick, long, magnetic, nano-bamboo, and helical CNTs, as well as nano-scaffold, graphene, nano-pearl, and nano-onion morphologies as described in the ESI.†9,10
We have explored alternative alkali carbonate mixtures and lower electrolysis temperatures, which can produce 3D-symmetry graphene scaffolds (ESI†). Electrolysis current densities ranging from 0.03–0.6 A cm−2 affect GNC growth; higher densities favour the formation of helical CNTs (ESI†). Electrolysis requires a voltage range from 0.8–2 V. Using renewable energy sources can further reduce the CO2 footprint (ESI†). High purity GNCs form directly on the cathode and are separated from the molten electrolyte through high-temperature filtration, as described in the ESI.†
C2CNT process modules are called the Genesis Device®, and large-scale CCUS Genesis modules transforming the 5% CO2 flue gas from the Shepard Natural Gas Power Plant are operating in Calgary, Canada. Today, large-scale Genesis electrolysis uses cathodes over 10000 cm2. The oxidation resistance of the CNTs produced is high, with a 97.1% TGA purity. SEM and TEM images of the CNT product are detailed in the ESI.† The units tested in this study are bench-top scale, using similar Muntz brass cathodes, 304SS anodes, and 99.5% purity Li2CO3 electrolyte. These units are housed in a 12 × 12 × 15 cm carbon pot electrolyzer, which contains the molten electrolyte and serves as the electrolysis chamber, housed within a converted Caldera Paragon kiln. The CO2- concentration is measured with a CO2meter (http://co2meter.com/) sensor situated externally from the hot chamber connected via a 304SS tube which allows sufficient cooling to facilitate the room-temperature sensor performance.
C2CNT decarbonization is a unique process, unlike other CCS processes in that it directly (without pre-concentration) transforms CO2 to high-purity, high-yield GNCs at ∼750 °C. This decarbonization process, which eliminates the need for CO2 concentration, as the electrolyte is a carbon sink that draws in CO2 with a high affinity, applies to both C2CNT industrial CCUS (Carbon Capture, Utilization and Storage) and C2CNT DAC. However, the feed gas for industrial gas typically ranges from 5% CO2 (natural gas power plant stack emissions) to over 30% CO2 (cement plant emissions), and furthermore is generally hot coming off the industrial process. In contrast, DAC utilizes ambient temperature air containing a very low CO2 concentration. Unlike C2CNT CCUS, DAC may require more energy to heat the entire air feed to >700 °C electrolysis temperatures. Air contains 0.042% CO2, with the remaining >99.95% consisting of N2, O2, H2O and Ar. While the latter are highly insoluble in molten carbonates, CO2 dissolves reactively as shown in eqn (2). For effective DAC decarbonization, the C2CNT process energy should not be used to heat the 99.95% non-CO2 components of air.
The first DAC technology is presented that simultaneously (1) directly (without preconcentration) removes CO2 from the air, (2) transforms the CO2 into a valuable product (such as CNTs) provides a strong incentive to remove this greenhouse gas, and (3) unlike previous regular C2CNT processes, insulates the feed air from the hot electrolysis chamber while still allowing CO2 to diffuse into the electrolysis chamber.
DCO2(TK) = 2.7 × 10−5TK1.59/e(102.1/TK) | (4) |
We recently characterized the rate of CO2 diffusion at room temperature through a variety of high temperature porous insulations acting as membranes.11 These diffusion results are now used to develop a new high temperature direct air capture, in which these membranes are placed between the feed air and a high-temperature molten electrolyte that removes CO2via electrolysis in the carbon pot. Insulation materials tend to be porous and low-density. The majority of high-temperature alumina or CaO/MgO silicate insulations we recently studied have densities ranging from 0.06–0.14 g cm−3, with a measured porosity, of ε ranging from 0.89–0.96. Higher density-insulation (0.59 to 0.70 g cm−3) had a measured porosity of ε = 0.45–0.67.11 As expected, the manufacturer's thermal insulation values tend to vary linearly with thickness and, to a lesser extent, with density. For example, 1/4′′ insulation with densities of 0.10 and 0.13 g cm−3 have respective R-values of 0.3 and 0.4, while 4× thicker insulation has R-values of 1.1 to 1.5. Alumina and CaO/MgO silicate insulations had similar R-values.
In that room temperature study, we determined that CO2 readily diffuses through porous ceramic thermal insulators. The measured CO2 diffusion coefficient for the silicate membranes was found to correlate with the measured open-channel porosity as follows:11
DM-porous-CO2 = DCO2·ε(M)3/2 | (5) |
These diffusion rates were further increased by approximately 50% with turbulent flow (either parallel or perpendicular flow) over the upper membrane surface.11 These findings, combined with eqn (4) and (5), are now used to configure a DAC C2CNT process that enables the chemical permeation of CO2 while insulating air's other components from the hot molten carbonate electrolysis.
The Genesis DAC configuration was tested according to the lower left-illustration of Fig. 1 using the 12 × 12 × 15 cm tall 304SS pot. Air is fed into the upper chamber at a low flow rate, proportional to the applied constant electrolysis eqn (8). Higher flow rate conditions (×1.5 and ×2 flow rate) conditions were also investigated.
Two aluminosilicate insulations were used as membranes in this configuration, a 1′′ (CeraBlanket 8254870040000) and a 1/4′′ (CeraBlanket 825680600200P2), with measured porosities of ε = 0.93 and ε = 0.91, respectively.11 Each was configured in the 3D open-bottom structure shown in the lower left of Fig. 1 with four 20 × 20 cm walls and a top, providing a total membrane surface area of 2000 cm2.
The Genesis DAC configuration in the bottom of Fig. 1 utilizes the recently characterized CO2 diffusion properties of open-channel porous thermal insulation, and reduces heat loss while sustaining CO2 transfer between an ambient air feed gas and the interior of the C2CNT electrolysis chamber, which acts as a carbon sink. CO2-transport in the upper air feed chamber and in both the lower electrolysis chamber are dominated by convection. As illustrated at the bottom portion of Fig. 1, Genesis DAC positions a high-surface area porous insulation as a membrane creating a quiescent zone between the air feed and the electrolysis chamber. In this quiescent zone CO2 mass transport by diffusion, rather than by convection, dominates. By maintaining a high 3D surface area of this interfacial diffusion zone, sufficient CO2 enters the electrolysis chamber to replenish the CO2 consumed.
JMCO2(TK, mA cm−2 membrane) = 1000·4F·CoDM-CO2(TK)·1 cm2/(lM × Videal(TK)) |
V(TK) = 22![]() | (6) |
These experiments are constant-current electrolyses at Ielectrolysis (A) conducted for a time telectrolysis (s). This charge passed is then converted to the max moles of CO2 at 20 °C, which can be split by the n = 4-electron electrolysis, molmax-CO2:
molmax-CO2 = (Ielectrolysis (amps)/4F)·telectrolrysis (s) | (7) |
This ideal conversion of CO2 will produce an equal number of maximum moles of carbon and oxygen, i.e., molmax-CO2 = molmax-C = molmax-O2. From the respective molar masses, the maximum masses are calculated as mmax-CO2 = 44.01 × molmax-CO2; mmax-C = 12.01 × molmax-CO2; mmax-O2 = 32.00 × molmax-CO2. Oxygen (O2) from the electrolysis evolves as a gas, and exits the electrolysis chamber.
The required 20 °C airflow (LPM) per amp of electrolysis charge, fA, is given by:
fA(LPM/A) = Co−1·1 mol CO2·Videal (298.15 K) (60 s min−1)/4F | (8) |
From eqn (8)fA is 9 LPM air per A of CO2 splitting electrolysis.
DAC eff (%) = 100%(Δmelec + mmax-CO2)/(mmax-C + mmax-CO2) | (9) |
The membrane temperature is estimated as the average temperature of its upper and lower surfaces, which is 300 °C for both the 1-inch and 1/4-inch thick membranes The electrochemical current density from eqn (6), JMCO2 (300 °C = 573 K), is 0.67 and 2.5 mA cm−2 for the respective 1-inch and 1/4-inch membranes. The Amembrane = 2000 cm2, which multiplied by the area current densities, should support respective electrolysis currents of 1.3 and 5.0 A, respectively.
Fig. 2 presents Genesis DAC Efficiencies from eqn (9) based on the measured mass change, Δmelec at the start and finish of 16 hours 750 °C electrolyses with brass cathodes, and with the carbon pot walls acting as anodes. In the Genesis DAC configuration using a 1-inch insulation as a membrane in the pure Li2CO3 electrolyte, a maximum DAC efficiency of 87% was achieved with an electrolysis current of 1 A. However, as shown in the black curve, the efficiency decreases rapidly at higher currents due to insufficient CO2 reaching the electrolysis chamber.
![]() | ||
Fig. 2 DAC efficiency as a function of the electrolysis current in DAC Genesis as configured in the lower left of Fig. 1. Black data is measured with eqn (9) required airflow, and red and blue data with 2× higher flow. |
We have previously noted that in accordance with eqn (2), the addition of 1 m Li2O increases the rate of CO2 uptake.8 At an electrolysis current of 1 A, this addition increases DAC efficiency to 91%. In medium or high airflow (1.5× or 2× the eqn (8) flow), the efficiency rises further to 95% and 99% DAC (red curve). Even with high airflow, however, the DAC efficiency, as shown in the Fig. 2 red curve, decreases again at cell currents >1 A. The systematic increase in cell current (1, 2, 3, 5 and 9 amps) through the 2000 cm2 surface area membrane demonstrates that DAC efficiency in Fig. 2 decreases with increasing membrane diffusion limited current density. Lower current densities support higher levels of DAC efficiency.
A 1/4-inch membrane supports greater CO2 diffusion to the electrolysis chamber improving DAC efficiency. This is measured with turbulent (2×) air flow using a pure electrolysis Li2CO3 configuration. This configuration supports the highest electrolysis current of 2 A at 98% DAC efficiency, as shown in the Fig. 2 blue curve. Both this, and the 1-inch membrane, measured maximum DAC efficiencies, but these currents occur lower than the calculated eqn (6) supporting currents. The cathode bus bar (seen in Fig. 1) interferes with downward CO2 flow in the lower chamber and appears to create a bottleneck for CO2 mass transport to the electrolyte. Future experiments will explore configurations to mitigate this bottleneck, as well as surface-enhanced membranes, such as zig-zag, dimpled and multiple membrane layer designs, which increase the effective membrane area.
The experimental data verifying the accuracy of the theoretical framework is shown in Fig. 3; specifically, the percentage of the applied cell current used for DAC conversion is compared to the theoretical membrane diffusion-limited current:
DAC modelled achieved experimentally (%) = (DAC efficiency × cell current)/(Amembrane × JMCO2) | (10) |
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Fig. 3 A comparison of the DAC modelled CO2 diffusion limited currents and the experimentally measured DAC currents. Black data is measured with eqn (9) required airflow, and red and blue data with 2× higher flow. |
As shown in Fig. 3, the product of the modelled membrane-limited rate of CO2 membrane diffusion limited current, (based on eqns (5) and (6)), generally underestimates the observed DAC capabilities by up to a factor of two, depending on the applied cell current. The observed DAC rate is higher for thinner membranes and tends to increase at higher currents. This two-fold underestimate in the model is a satisfactory preliminary approximation for CO2 membrane diffusion constants measured at room temperature and extrapolated for use with the 750 °C electrolysis of the Genesis DAC configuration. Future studies will explore whether the membrane porosity exponent in eqn (5) (ε(M)3/2) is itself a function of temperature, and the assumption of a linear temperature profile through the membrane's cross section. For example, the results suggest that the lower outer wall temperature of the membrane has a larger effect on the rate of CO2 diffusion.
Under CO2-limiting conditions, where insufficient air CO2 is fed into the DAC system, an oxide buildup occurs as described by eqn (1) oxide. In this case, we observe that the product tends to be high-purity carbon nano-onions (CNOs) as shown in Fig. 5, panels A through I. When excess CO2 is reintroduced to the DAC Genesis, CNT production resumes.
As with CNTs,12 and as seen in the upper left corner of Fig. 5 (panel A), the CNO growth begins with a thin layer of graphene (observed as removed from the cathode) from which a matrix of CNO growth occurs. Under conditions of insufficient CO2, higher oxide concentration buildup in the electrolyte, this (i) reduces the solubility and prevalence of transition metal cations in the electrolyte, inhibiting CNT growth by transition metal nucleation, and (ii) induces sp3 defects in the sp2 graphene lattice. These sp3 sites favor the formation of spherical, rather than planar cylindrical, graphene growth.8,13 Thus, an oxide-rich electrolytic environment promotes CNO over CNT growth.13
In a recent advancement of the CCUS C2CNT decarbonization chemistry, the majority of the lithium carbonate electrolyte was replaced by strontium carbonate-based electrolytes. The thermodynamic and kinetic chemistry of the electrolytes has been shown to be equivalent for the electrolytic splitting of CO2 to GNCs. This is economically significant, as strontium salts are an order of magnitude less expensive and considerably more abundant than lithium salts. This shift also alleviates competition for limited lithium carbonate resources which are increasingly used for EVs and grid electric storage. An analysis of C2CNT decarbonization costs based on energy consumption, and the new strontium electrolytes, estimates $198 per tonne of CO2 ($791 per tonne GNC produced).25 In that study the equivalent affinities of SrCO3 and Li2CO3 for absorbing and releasing CO2 are demonstrated to be comparable, and are unlike all the other alkali and alkali earth carbonates. The temperature domain in which the CO2 transformation to GNCs can be effective is <800 °C. Although the solidus temperature of SrCO3 is 1494 °C, it is remarkably soluble in Li2CO3 at temperatures less than 800 °C, and the electrolysis energy is low. High purity CNTs are synthesized from CO2 respectively in SrCO3 based electrolytes containing 30% or less Li2CO3. These strontium-based electrolytes are also applicable to the DAC Genesis Device® for direct air capture. The components of DAC and CCUS C2CNT technologies are similar and the additional cost of the porous ceramic diffusion membranes is minor. As a first approximation, the cost per tonne of decarbonization will be similar, and will be analyzed in depth in a subsequent study as the technology is scaled. It is important to note that the C2CNT deployment involves not only the costs mentioned, but also revenue, as GNCs have high value. This provides an additional incentive for DAC C2CNT Genesis deployment.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4su00679h |
This journal is © The Royal Society of Chemistry 2025 |