Industry eyes modular carbon capture solutions for EOR and emissions reductions

New carbon capture technology promises to capture carbon dioxide directly from the atmosphere and could reduce costs by up to 50%, compared to existing methods, as well as increasing efficiency. This breakthrough may enable enhanced oil recovery, while significantly minimizing environmental impact.

SAMIR ADAMS, Managing Director, Carbon Capture & Commercialization

The oil and gas industry faces a critical challenge: meeting a 17-billion-metric-ton annual shortfall in CO₂¹ supply for enhanced oil recovery (EOR), while simultaneously navigating increasing pressure to reduce emissions.² Traditional carbon capture approaches and early Direct Air Carbon Capture (DACC) implementations have struggled to bridge this gap cost-effectively. However, emerging technologies at the pre-commercialization stage are showing promise in laboratory testing, potentially offering new pathways to address these challenges.

EVOLUTION AND INNOVATION IN CARBON CAPTURE

Fig. 1. Modular and deployable carbon capture system.

The carbon capture landscape has developed through distinct technological approaches, each shaped by its own limitations and capabilities. Traditional Carbon Capture and Storage (CCS) has focused primarily on geological storage, requiring specific underground formations for operation. This approach, while proven, remains limited by location constraints and infrastructure requirements, resulting in high operational costs that challenge widespread adoption. Carbon Capture, Utilization and Storage (CCUS) emerged as an evolution of CCS, emphasizing industrial utilization of captured carbon. While this approach opens new possibilities for CO₂ use, it remains constrained by its reliance on point-source capture and the need for extensive pipeline infrastructure.

First-generation Direct Air Carbon Capture (DACC) represented a significant shift, moving away from point-source capture to atmospheric collection. However, these systems—typically requiring large-scale facilities and substantial land area—face significant efficiency challenges in rural settings, where CO₂ concentrations average 423 ppm.³ Operating costs, ranging from $350–$900 per metric ton,⁴ have limited widespread adoption, Fig. 1.

Recent laboratory testing at TRL7 demonstrates the potential of new approaches to carbon capture. Unlike traditional absorption-based systems requiring chemical solvents and high energy inputs, novel adsorption-based technologies under development aim to operate at ambient temperatures and pressures, in environments where CO₂ concentrations range from 420 to 1,200 ppm or more. This represents a significant departure from conventional approaches, potentially offering simpler operation and reduced energy requirements while targeting costs under $100 per metric ton.

DEVELOPMENT STATUS AND INDUSTRY APPLICATIONS

Current laboratory testing has validated several key aspects of emerging DACC technology. Achieving 30% capture rates in controlled conditions demonstrates potential viability, while successful operation at ambient temperature and pressure suggests possibilities for simplified implementation. The modular design approach, utilizing container-sized units, could enable flexible deployment directly at oil field sites, without extensive pipeline infrastructure or site preparation. This scalable approach aims to allow operators to match capture capacity with operational demands, though these benefits require validation in field conditions.

Pre-commercialization modeling suggests several potential economic advantages, compared to traditional approaches. The modular design could reduce initial capital investment requirements, while simplified operations may lower ongoing costs. The elimination of extensive transportation infrastructure could further improve project economics, particularly for EOR operations, where proximity to injection sites is crucial. These projections, based on current laboratory results, require validation through continued development and eventual field testing.

RESEARCH AND DEVELOPMENT FOCUS

Recent research and development efforts are concentrated on several critical aspects of system optimization and deployment. A.I. integration, while still in development, represents a key area of investigation. The research explores potential applications for real-time monitoring of environmental conditions, predictive maintenance and energy optimization, through intelligent, interconnected nodes within a distributed network.

Development work addresses practical implementation challenges, from environmental monitoring systems and performance optimization to deployment planning frameworks for site selection and capacity planning. Laboratory testing has particularly focused on optimizing the adsorption process for various environmental conditions, including humidity levels, temperature fluctuations and varying CO₂ concentrations typical in urban settings. This work includes extensive materials testing, to validate durability and performance consistency over multiple capture-release cycles.

The research team is also investigating potential system enhancements that could further improve capture efficiency. This includes advanced flow dynamics modeling to optimize air handling, exploration of novel material combinations for improved adsorption performance and development of sophisticated control algorithms for the planned A.I. integration. Additional focus areas include energy consumption optimization, particularly in the CO₂ release cycle, and investigation of potential hybrid approaches that could combine the benefits of both temperature and electrical stimulus for optimal CO₂ release.

These efforts aim to create comprehensive solutions that can meet both technical requirements and operational needs in field conditions. Additionally, research includes evaluation of potential benefits regarding emissions reduction, carbon credit opportunities, and ESG performance improvements while ensuring alignment with regulatory requirements.

THE PATH FORWARD

As development progresses toward commercialization, several key factors will determine the technology's ultimate impact on industry operations. The modular approach under development offers particular advantages for oil and gas operators. Rather than investing in massive, fixed infrastructure projects, companies could potentially deploy scalable units, based on actual CO₂ demand. This flexibility could help operators better manage capital expenditure while maintaining operational efficiency. Fig. 2.

Fig. 2. A full-sized carbon capture unit at a wellhead.

Cost remains a critical factor. While traditional carbon capture systems operate at $350–$900 per metric ton, achieving target costs under $100 per metric ton would represent a significant breakthrough for the industry. However, these projections require validation through continued development and eventual field testing.

Moving beyond the theoretical potential, the practical implementation of these technologies could transform how the industry approaches carbon management. Early laboratory results suggesting 30% capture rates at TRL7—combined with the potential for urban deployment, where CO₂ concentrations exceed 1200 ppm—indicate possibilities for more efficient carbon capture solutions.

As these technologies complete development and move toward commercial deployment, they may offer new possibilities for sustainable oil and gas operations. However, successful implementation will depend on continued technical validation, successful capitalization and careful attention to operational requirements in field conditions. Ongoing collaboration between technology developers and industry operators will be crucial for ensuring that solutions meet real-world operational requirements while delivering the necessary economic and environmental benefits.

Technical note: This article discusses pre-commercialization technology currently at TRL7. Performance metrics, including 30% capture rates, are based on laboratory testing. Cost projections and advanced capabilities, including A.I. integration, represent development targets. Commercial deployment timelines are dependent on successful capitalization. All forward-looking statements are based on current research data, and actual field performance may vary from laboratory results.

Safe Harbor Statement: This article discusses technological developments currently at Technology Readiness Level 7 (TRL7). Performance metrics, including projected capture rates and cost targets under $100 per metric ton, are based on laboratory testing and modeling. The technology described includes systems and artificial intelligence capabilities in various stages of research and development, with commercial deployment anticipated within six to nine months of capitalization. Actual results and timelines may vary.

REFERENCES

SAMIR ADAMS is the managing director at Carbon Capture & Commercialization, and his role is focused on driving innovation in carbon capture technology. He has extensive experience in leading teams to develop sustainable energy solutions and advancing emissions reduction technologies. Mr. Adams holds an Executive MBA from the University of Tampa and a bachelor’s degree from the University of South Florida.

More information on Carbon Capture & Commercialization can be found on the company’s site: https://ccandc.ai/

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