A Carbon Capture and Utilization Process for the Production of Solid Carbon Materials from Atmospheric CO₂ – Part 2: Carbon Characterization

This article is the second part of a study reporting the results of a novel carbon capture and utilization (CCU) process, which converts atmospheric CO₂ into solid carbon materials. The CCU process combines direct air capture (DAC) with catalytic methanation, which is then followed by methane pyrolysis in a reactor filled with liquid tin. While Part 1 discussed the performance of the overall process and individual process steps regarding conversions and yields, Part 2 characterizes the solid carbon products obtained under various synthesis conditions. The effects of the pyrolysis temperature and the composition of the gas mixture from the methanation step on the solid carbon product are analyzed. Carbon powder is synthesized from methane with either N₂, H₂ or CO₂ as most important impurity. Carbon samples are characterized using SEM, TEM, Raman spectroscopy, XPS and XRD analysis. Very thin, disordered carbon flakes, soot aggregates and large carbon onions are identified as the main solid products of the process. Their formation mechanisms in the liquid metal-filled pyrolysis reactor are discussed.