Modular Air Capture System Incorporating Process Intensification Techniques and Energetically Efficient Electronics for Monitoring and Control

Reducing CO2 emissions alone is no longer sufficient to mitigate climate change. Achieving net-negative emissions through carbon removal is essential to reverse the damage caused by fossil fuel combustion and deforestation. Direct Air Capture (DAC) has gained attention for its flexible deployment, but its viability is often constrained by sorbent performance and costs. This study presents an innovative and multidisciplinary approach to DAC technology development by enhancing CO2 removal efficiency through process intensification. Specifically, custom-designed, 3D-printed static mixers were integrated into the system to improve the performance of physical solid adsorbents. While static mixers have been used to improve mass transfer applications, their effect has not yet been studied for adsorption with solid adsorbent systems for CO2 capture. Additionally, the proposed modular DAC unit incorporates IoT technologies, utilizing microcontrollers and sensors for real-time monitoring and control. Experimental results demonstrate that static mixers increase CO2 removal efficiency by 32.1% and extend the adsorbent’s breakthrough time by 24 minutes, while IoT integration reduces power consumption by 32.7%. A cost analysis confirms that the unit’s low manufacturing cost (180 USD) supports the widespread adoption of energy-efficient, cost-effective DAC technology.