Highly efficient CO2 sorbents: development of synthetic, calcium-rich dolomites

CO2 Capture at Medium to High Temperature Using Solid Oxide-Based Sorbents: Fundamental Aspects, Mechanistic Insights, and Recent Advances

Carbon dioxide capture and mitigation form a key part of the technological response to combat climate change and reduce CO₂ emissions. Solid materials capable of reversibly absorbing CO₂ have been the focus of intense research for the past two decades, with promising stability and low energy costs to implement and operate compared to the more widely used liquid amines. In this review, we explore the fundamental aspects underpinning solid CO₂ sorbents based on alkali and alkaline earth metal oxides operating at medium to high temperature: how their structure, chemical composition, and morphology impact their performance and long-term use. Various optimization strategies are outlined to improve upon the most promising materials, and we combine recent advances across disparate scientific disciplines, including materials discovery, synthesis, and in situ characterization, to present a coherent understanding of the mechanisms of CO₂ absorption both at surfaces and within solid materials.

Effect of Sodium Bromide on CaO-Based Sorbents Derived from Three Kinds of Sources for CO2 Capture

The calcium looping (CaL), which applies carbonation/calcination cyclic reactions of a CaO sorbent, has received extensive attention for postcombustion CO₂ capture. However, as the number of cyclic reactions increased, the capture efficiency of regenerated CaO decreased rapidly. Sodium doping was proposed for modification of a CaO sorbent, but there was little research on whether sodium doping had a good effect on different kinds of sorbents. In this paper, three different kinds of calcium-based sorbents, i.e., CaCO₃, dolomite, and SG-CaO, were modified by NaBr to explore the effect of sodium on CO₂ capture performance. The results showed that the modification effects of sodium on three kinds of precursors were different. For CaCO₃, the modification effect of sodium doping was the best. After 50 cycles, the sorption capacity of CaO/NaBr was over 3.5 times that of an unmodified sorbent; for dolomite, sodium had a moderate effect during initial cycles and then showed obvious improvement in the stability of the sorbent, the sorption capacity of the modified dolomite increased by over 30% after 50 cycles; for the SG-CaO, sodium had a negative effect, the sorption capacity of the modified sorbent decreased by about 30% after 50 cycles. When the atmosphere contained SO₂, the doping of an alkali metal also showed a certain effect.

Techno-economic performance of HCl and SO2 removal in waste-to-energy plants by furnace direct sorbent injection

With the impending release of Best Available Techniques (BAT) conclusions on waste incineration, existing European waste-to-energy (WtE) plants will be required to achieve a higher efficiency in the removal of several target pollutants, such as acid gases (above all, HCl and SO₂). The direct injection of a sorbent in the furnace as a primary deacidification stage may be a cost-effective option to achieve the required performances. The present study investigated the furnace injection of a specific dolomitic sorbent, with the aim of identifying the techno-economic optimum for the sorbent feed rate considering different scenarios of flue gas composition. A full-scale test run campaign was carried out on two WtE plants and a phenomenological model linking HCl and SO₂ conversion to reactant feed rate was developed. The model allowed assessing the cost-effectiveness of dolomitic sorbent furnace injection for WtE plants equipped with either a single or a two-stage acid gas treatment system. The addition of dolomitic sorbent resulted particularly suitable for WtE plants equipped with a single stage treatment coping with a high SO₂ concentration in the flue gas, where the injection of dolomitic sorbent can increase the redundancy of flue gas treatment with a reduction of the total operating costs.

System and Processes of Pre-combustion Carbon Dioxide Capture and Separation

In this chapter, the development of H2/CO2 separation technology, including a new CO2 chemical adsorbent, a pressure swing adsorption (PSA) reactor model, and the continuous operation of a pilot-scale test system for pre-combustion CO2 capture, are presented. Potassium-promoted Mg–Al layered double oxides (LDOs) are shown to be appropriate candidate adsorbents for elevated temperature (250–450 °C) PSA for pre-combustion H2/CO2 separation. The adsorption heat of CO2 on the surface of LDOs is only 2.5–60.4 kJ mol−1, which is beneficial for achieving isothermal desorption by a pressure swing. Further, methods for enhancing the CO2 capacity and the mechanical strength of adsorbent pellets are introduced. The single- and double-column fixed-bed experiments provided useful results for the development and validation of scalable modeling. The PSA model was built by coupling a non-equilibrium kinetic adsorption model and a column model. The effects of operating parameters on the H2 recovery ratio and CO2 capture ratio were studied. A 4-column pilot-scale elevated temperature PSA (ET-PSA) system was developed with a processing capacity of 4.0–6.6 Nm3 h−1 to determine the feasibility of such a system for industrial application. It achieved 1089 h of accumulated operation and 75 h of continuous operation, maintaining a CO2 removal ratio higher than 91.7%.

Multishelled CaO Microspheres Stabilized by Atomic Layer Deposition of Al2 O3 for Enhanced CO2 Capture Performance

CO₂ capture and storage is a promising concept to reduce anthropogenic CO₂ emissions. The most established technology for capturing CO₂ relies on amine scrubbing that is, however, associated with high costs. Technoeconomic studies show that using CaO as a high-temperature CO₂ sorbent can significantly reduce the costs of CO₂ capture. A serious disadvantage of CaO derived from earth-abundant precursors, e.g., limestone, is the rapid, sintering-induced decay of its cyclic CO₂ uptake. Here, a template-assisted hydrothermal approach to develop CaO-based sorbents exhibiting a very high and cyclically stable CO₂ uptake is exploited. The morphological characteristics of these sorbents, i.e., a porous shell comprised of CaO nanoparticles coated by a thin layer of Al₂ O₃ (<3 nm) containing a central void, ensure (i) minimal diffusion limitations, (ii) space to accompany the substantial volumetric changes during CO₂ capture and release, and (iii) a minimal quantity of Al₂ O₃ for structural stabilization, thus maximizing the fraction of CO₂ -capture-active CaO.

A Model to Stabilize CO2 Uptake Capacity during Carbonation-Calcination Cycles and its Case of CaO-MgO

Nowadays, capturing anthropogenic CO₂ in a highly efficient and cost-effective way is one of the most challenging issues. Herein, the key parameters to stabilize CO₂ uptake capacity have been studied based on four kinds of pure calcium oxides (CaO) prepared by a simple calcination method with four different calcium precursors. A simple ideal particle model was proposed to illustrate the uniform distribution of pure CaO, in which the CO₂ uptake capacity is positively related with surface area of CaO particles and the stability is opposite to the distance between two CaO particles after carbonation. The adsorption capacity of the best sample with a distance of 398 nm between two CaO particles after carbonation only lost 0.344% per cycle, which is originated from the low possibility of the agglomeration between neighboring particles. On the basis of the proposed model, the composite with magnesium oxide (MgO) distributed uniformly in CaO was fabricated by a simple ball milling method, which possessed an excellent stability with a decay rate of only 3.9% over 100 carbonation-calcination cycles. In this case, MgO played as inert to increase the distance between CaO particles for agglomeration prevention.

Mechanisms of absorption and desorption of CO2 by molten NaNO3-promoted MgO

We present details of the mechanism of absorption and desorption of carbon dioxide by molten NaNO₃-promoted MgO and their implications for the applications of alkali nitrate-promoted MgO absorbents with many repeated absorption and desorption cycles.

Improved CO2 adsorption capacity and cyclic stability of CaO sorbents incorporated with MgO

The CO₂ adsorption capacity of CaO sorbents with different MgO wt% (calcination temperature 800 °C, carbonation at 650 °C with 100% CO₂, and de-carbonation at 800 °C in 100% N₂).

The development of effective CaO-based CO2 sorbents via a sacrificial templating technique

A carbon-based sacrificial templating approach was employed to realize single-pot synthesis of cyclically stable CaO-based CO₂ sorbents. The sacrificial carbonaceous template was formed through resorcinol–formaldehyde polymerization reaction. The resultant sorbents following the thermal decomposition of the carbonaceous template featured an inverse opal-like macrostructure composed of a highly porous nanostructured backbone. In addition to pure CaO, sorbents supported with Al₂O₃, MgO, Y₂O₃, and ZrO₂ were synthesized. SEM and XRD were utilized to characterize the morphology and the chemical composition of the synthetic CO₂ sorbents, respectively. The cyclic CO₂ uptake performance of the synthetic sorbents was assessed by TGA and compared to limestone. All of the synthetic sorbents exhibited an improved CO₂ uptake performance when compared to limestone. The performance enhancement became more pronounced in the case of supported sorbents. The sorbent with the best CO₂ uptake performance was supported by a mixture of Al₂O₃ and Y₂O₃, and exhibited a CO₂ uptake of 0.61 g CO₂/g CaO after 10 cycles of calcination and carbonation under practically relevant operating temperatures, which exceeded the CO₂ uptake of limestone by more than 350%.

Tailor-Made Core-Shell CaO/TiO2-Al2O3 Architecture as a High-Capacity and Long-Life CO2 Sorbent

CaO-based sorbents are widely used for CO2 capture, steam methane reforming, and gasification enhancement, but the sorbents suffer from rapid deactivation during successive carbonation/calcination cycles. This research proposes a novel self-assembly template synthesis (SATS) method to prepare a hierarchical structure CaO-based sorbent, Ca-rich, Al2O3-supported, and TiO2-stabilized in a core-shell microarchitecture (CaO/TiO2-Al2O3). The cyclic CO2 capture performance of CaO/TiO2-Al2O3 is compared with those of pure CaO and CaO/Al2O3. CaO/TiO2-Al2O3 sorbent achieved superior and durable CO2 capture capacity of 0.52 g CO2/g sorbent after 20 cycles under the mild calcination condition and retained a high-capacity and long-life performance of 0.44 g CO2/g sorbent after 104 cycles under the severe calcination condition, much higher than those of CaO and CaO/Al2O3. The microstructure characterization of CaO/TiO2-Al2O3 confirmed that the core-shell structure of composite support effectively inhibited the reaction between active component (CaO particles) and main support (Al2O3 particles) by TiO2 addition, which contributed to its properties of high reactivity, thermal stability, mechanical strength, and resistance to agglomeration and sintering.

Synthesis of highly efficient CaO-based, self-stabilizing CO2 sorbents via structure-reforming of steel slag

Capturing anthropogenic CO2 in a cost-effective and highly efficient manner is one of the most challenging issues faced by scientists today. Herein, we report a novel structure-reforming approach to convert steel slag, a cheap, abundant, and nontoxic calcium-rich industrial waste, as the only feedstock into superior CaO-based, self-stabilizing CO2 sorbents. The CO2 capture capacity of all the steel slag-derived sorbents was improved more than 10-fold compared to the raw slag, with the maximum uptake of CO2 achieving at 0.50 gCO2 gsorbent(-1). Additionally, the initial steel slag-derived sorbent could retain 0.25 gCO2 gsorbent(-1), that is, a decay rate of only 12% over 30 carbonation-calcination cycles, the excellent self-stabilizing property allowed it to significantly outperform conventional CaO, and match with most of the existing synthetic CaO-based sorbents. A synergistic effect that facilitated CO2 capture by CaO-based sorbents was clearly recognized when Mg and Al, the most common elements in steel slag, coexisted with CaO in the forms of MgO and Al2O3, respectively. During the calcium looping process, MgO served as a well spacer to increase the porosity of sorbents together with Al2O3 serving as a durable stabilizer to coresist the sintering of CaCO3 grains at high temperatures.

Effect of cerium oxide doping on the performance of CaO-based sorbents during calcium looping cycles

A series of CaO-based sorbents were synthesized through a sol-gel method and doped with different amounts of CeO2. The sorbent with a Ca/Ce molar ratio of 15:1 showed an excellent absorption capacity (0.59 gCO2/g sorbent) and a remarkable cycle durability (up to 18 cycles). The admirable capture performance of CaCe-15 was ascribed to its special morphology formed by the doping of CeO2 and the well-distributed CeO2 particles. The sorbents doped with CeO2 possessed a loose shell-connected cross-linking structure, which was beneficial for the contact between CaO and CO2. CaO and CeO2 were dispersed homogeneously, and the existence of CeO2 also decreased the grain size of CaO. The well-dispersed CeO2, which could act as a barrier, effectively prevented the CaO crystallite from growing and sintering, thus the sorbent exhibited outstanding stability. The doping of CeO2 also improved the carbonation rate of the sorbent, resulting in a high capacity in a short period of time.

Effect of pelletization and addition of steam on the cyclic performance of carbon-templated, CaO-based CO2 sorbents

In this work, we report the development of a synthetic CO2 sorbent that possesses a high cyclic CO2 uptake capacity and, in addition, sufficient mechanical strength to allow it to be used in fluidized-bed reactors. To overcome the problem of elutriation of the original powdered material, the synthetic CO2 sorbent was pelletized. An important aspect of this work was to assess the effect of steam on the cyclic CO2 capture capacity of the original, powdered CO2 sorbent and the pelletized material. After 30 cycles of repeated calcination and carbonation reactions conducted in a fluidized bed, the CO2 uptake of the pellets was 0.29 g of CO2/g of sorbent, a value that is 45% higher than that measured for the reference limestone. For the case that carbonation/calcination cycles were conducted in a thermogravimetric analyzer under steam-free carbonation conditions, the CO2 uptake of the best sorbent was 0.33 g of CO2/g of sorbent (after 10 cycles). Importantly, it should be noted that, after 10 cycles using wet carbonation conditions, the CO2 uptake of this material increased by 55% when compared to dry conditions. This observation was attributed to enhanced solid-state diffusion in the CaCO3 product layer under wet conditions. However, independent of the reaction conditions, the pelletized material showed a lower cyclic CO2 uptake when compared to the original powder. A detailed morphological characterization of the pellets indicated that the destruction of the primary, hollow micrometer-sized spheres during pelletization was responsible for the lower cyclic CO2 uptake of the pellets.

Influence of the operation conditions on CO2 capture by CaO-derived sorbents prepared from synthetic CaCO3

In this work, a statistical experimental design is performed in order to prepare CaCO3 materials for use as CaO-based CO2 sorbent precursors. The influence of different operational parameters such as synthesis temperature (ST), stirring rate (SR) and surfactant percent (SP) on CO2 capture is studied by applying Response Surface Methodology (RSM). The samples were characterized using different analytical techniques including X-ray diffraction, N2 adsorption isotherm analysis and Scanning Electron Microscopy-X-ray Energy Dispersive Spectroscopy (SEM-EDX). CO2 capture capacity was determined by means of a thermogravimetric analyzer which recorded the mass uptake of the samples when these were exposed to a gas stream containing diluted (15%) CO2. The statistical approach used in this work provides a rapid way of predicting and optimizing the main preparation variables of CaO-derived sorbents for CO2 sorption. The results obtained clearly indicate that four parameters statistically influence CO2 uptake: SR, the square of SR, its interaction with SP and the square of SP.

CaO-based CO2 sorbents: from fundamentals to the development of new, highly effective materials

The enormous anthropogenic emission of the greenhouse gas CO2 is most likely the main reason for climate change. Considering the continuing and indeed growing utilisation of fossil fuels for electricity generation and transportation purposes, development and implementation of processes that avoid the associated emissions of CO2 are urgently needed. CO2 capture and storage, commonly termed CCS, would be a possible mid-term solution to reduce the emissions of CO2 into the atmosphere. However, the costs associated with the currently available CO2 capture technology, that is, amine scrubbing, are prohibitively high, thus making the development of new CO2 sorbents a highly important research challenge. Indeed, CaO, readily obtained through the calcination of naturally occurring limestone, has been proposed as an alternative CO2 sorbent that could substantially reduce the costs of CO2 capture. However, one of the major drawbacks of using CaO derived from natural sources is its rapidly decreasing CO2 uptake capacity with repeated carbonation-calcination reactions. Here, we review the current understanding of fundamental aspects of the cyclic carbonation-calcination reactions of CaO such as its reversibility and kinetics. Subsequently, recent attempts to develop synthetic, CaO-based sorbents that possess high and cyclically stable CO2 uptakes are presented.

High-purity hydrogen via the sorption-enhanced steam methane reforming reaction over a synthetic CaO-based sorbent and a Ni catalyst

Sorbent-enhanced steam methane reforming (SE-SMR) is an emerging technology for the production of high-purity hydrogen from hydrocarbons with in situ CO2 capture. Here, SE-SMR was studied using a mixture containing a Ni-hydrotalcite-derived catalyst and a synthetic, Ca-based, calcium aluminate supported CO2 sorbent. The fresh and cycled materials were characterized using N2 physisorption, X-ray diffraction, and scanning and transmission electron microscopy. The combination of a Ni-hydrotalcite catalyst and the synthetic CO2 sorbent produced a stream of high-purity hydrogen, that is, 99 vol % (H2O- and N2-free basis). The CaO conversion of the synthetic CO2 sorbent was 0.58 mol CO2/mol CaO after 10 cycles, which was more than double the value achieved by limestone. The favorable CO2 capture characteristics of the synthetic CO2 sorbent were attributed to the uniform dispersion of CaO on a stable nanosized mayenite framework, thus retarding thermal sintering of the material. On the other hand, the cycled limestone lost its nanostructured morphology completely over 10 SE-SMR cycles due to its intrinsic lack of a support component.

CO₂ sorbents with scaffold-like Ca-Al layered double hydroxides as precursors for CO₂ capture at high temperatures

A highly stable high-temperature CO₂ sorbent consisting of scaffold-like Ca-rich oxides (Ca-Al-O) with rapid absorption kinetics and a high capacity is described. The Ca-rich oxides were prepared by annealing Ca-Al-NO₃ layered double hydroxide (LDH) precursors through a sol-gel process with Al(O(i)P)₃ and Ca(NO₃)₂ with Ca(2+)/Al(3+) ratios of 1:1, 2:1, 4:1, and 7:1. XRD indicated that only LDH powders were formed for Ca(2+)/Al(3+) ratios of 2:1. However, both LDH and Ca(OH)₂ phases were produced at higher ratios. Both TEM and SEM observations indicated that the Ca-Al-NO₃ LDHs displayed a scaffold-like porous structure morphology rather than platelet-like particles. Upon annealing at 600 °C, a highly stable porous network structure of the CaO-based Ca-Al-O mixed oxide (CAMO), composed of CaO and Ca₁₂Al₁₄O₃₃, was still present. The CAMO exhibited high specific surface areas (up to 191 m(2)g(-1)) and a pore size distribution of 3-6 nm, which allowed rapid diffusion of CO₂ into the interior of the material, inducing fast carbonation/calcination and enhancing the sintering-resistant nature over multiple carbonation/calcination cycles for CO₂ absorption at 700 °C. Thermogravimetric analysis results indicated that a CO₂ capture capacity of approximately 49 wt% could be obtained with rapid absorption from the porous 7:1 CAMO sorbents by carbonation at 700 °C for 5 min. Also, 94-98% of the initial CO₂ capture capability was retained after 50 cycles of multiple carbonation/calcination tests. Therefore, the CAMO framework is a good isolator for preventing the aggregation of CaO particles, and it is suitable for long-term cyclic operation in high-temperature environments.

Influence of the calcination and carbonation conditions on the CO₂ uptake of synthetic Ca-based CO₂ sorbents

In this work we report the development of a Ca-based, Al(2)O(3)-stabilized sorbent using a sol-gel technique. The CO(2) uptake of the synthetic materials as a function of carbonation and calcination temperature and CO(2) partial pressure was critically assessed. In addition, performing the carbonation and calcination reactions in a gas-fluidized bed allowed the attrition characteristics of the new material to be investigated. After 30 cycles of calcination and carbonation conducted in a fluidized bed, the CO(2) uptake of the best sorbent was 0.31 g CO(2)/g sorbent, which is 60% higher than that measured for Rheinkalk limestone. A detailed characterization of the morphology of the sol-gel derived material confirmed that the nanostructure of the synthetic material is responsible for its high, cyclic CO(2) uptake. The sol-gel method ensured that Ca(2+) and Al(3+) were homogenously mixed (mostly in the form of the mixed oxide mayenite). The formation of a finely and homogeneously dispersed, high Tammann temperature support stabilized the nanostructured morphology over multiple reaction cycles, whereas limestone lost its initial nanostructured morphology rapidly due to its intrinsic lack of a support component.

Application of the sol-gel technique to develop synthetic calcium-based sorbents with excellent carbon dioxide capture characteristics

An option for reducing the release of greenhouse gases into the atmosphere is the implementation of CO(2) capture and storage (CCS) technologies. However, the costs associated with capturing CO(2) by using the currently available technology of amine scrubbing are very high. An emerging second-generation CO(2) capture technology is the use of calcium-based sorbents, which exploit the carbonation and calcination reactions of CaO, namely, CaO+CO(2) ↔CaCO(3). Naturally occurring Ca-based sorbents are inexpensive, but show a very rapid decay of CO(2) uptake capacity with cycle number. Here, we report the development of synthetic Ca-based CO(2) sorbents using a sol-gel technique. Using this technique, we are able to synthesize a nanostructured material that possesses a high surface area and pore volume and shows excellent CO(2) capture characteristics over many cycles. Furthermore, we are able to establish a clear relationship between the structure of the sorbent and its performance. After 30 cycles of calcination and carbonation, the best material possessed a CO(2) uptake capacity of 0.51 g of CO(2) per gram of sorbent; a value that is about 250 % higher than that for naturally occurring Havelock limestone.