Demonstration of an Electrochemical Mobile CO₂ Capture and Utilization System: Design and Implementation at Industrial Sites

A containerized, mobile CO₂ capture and utilization demonstration plant was designed, constructed, and implemented. The demonstration plant, built as part of the ConsenCUS project, has a maximum capacity to treat a flue gas of 500 Nm3/h removing up to 100 kg/h CO₂. The plant comprises three modules: CO₂ capture, solvent regeneration, and CO₂ utilization. The CO₂ absorbing solvent is mainly composed of potassium hydroxide and the unit can handle high temperature flue gas impurities of SOx and NOx types. The demonstration plant incorporates the electrochemical regeneration of K2CO3 using two electrolyzer stacks, each capable of operating at current densities of up to 1000 A/m². This regeneration module offers a combination of operational flexibility and potential advantages in terms of electrification and energy integration. Four operational modes for the regeneration process - parallel, sequential, serial, and island - are presented and discussed. The utilization module could produce 15 l/h of potassium formate solution (20 wt%) turning the captured CO₂ into an economically and environmentally beneficial product. The implementation of this pilot plant offers insights into scaling up mobile CO₂ capture and utilization systems. Its flexibility and efficiency, coupled with the conversion of CO₂ into a valuable product, demonstrate its potential for broader industrial use. This work advances sustainable carbon capture, utilization, and storage (CCUS) technologies for real-world applications.