Simulation of carbon dioxide direct air capture plant using potassium hydroxide aqueous Solution: Energy optimization and CO2 purity enhancement

While various methods of direct air capture (DAC) technology have been implemented, its widespread effectiveness hinges on achieving optimal design and process improvements, largely owing to the high energy costs involved. Literatures reports a substantial heat demand for high-temperature aqueous solutions DAC (HT DAC), ranging from 1420 to 2250 kWh per ton of CO2, accompanied by electricity consumption rates varying from 366 to 2790 kWh per ton of CO2. The present study adopts the HT DAC method with an aqueous KOH absorbent as its focus, aiming to mitigate energy consumption. Given that a substantial portion of energy consumption in comparable processes can be attributed to the calciner and slaker units, our research centers its attention on the Air Separation Unit (ASU) and the steam cycle unit, investigating their impact on the system's production capacity, the enhancement of CO2 purity, and the augmentation of equipment thermal recovery. Process optimization, results a remarkable increase in heat recovery (21.1 %) and significant reductions in utilities consumption. The outcomes indicate that this facility has the capacity to annually capture around 1.1 million tons of CO2 with a purity of 99 mol% for utilization across various industries. The process design necessitates 5.24 gigajoules (GJ) of heat and 343 kW-hours (kWh) of electricity per ton of captured CO2. Notably, in addition to fulfilling the internal electricity requirements, the facility can export 8 MWh of electricity per ton of captured CO2 to the grid.