Carbon Capture & Utilization (CCU) Technology

Carbon capture and utilization (CCU) is the process of capturing carbon dioxide (CO₂) emissions from industrial sources and converting them into fuels, chemicals and materials. CCU technology development often begins with pilot-scale systems, which test and validate processes before scaling up to larger integrated systems connected to industrial gas streams at demonstration facilities.

Female researcher using carbon capture technology at SwRI

CCU valorization: converting CO₂ to construction material.

Southwest Research Institute (SwRI) helps industry develop and optimize CCU technology across the full process lifecycle, spanning laboratory evaluation through pilot-scale deployment.

Our integrated approach combines experimentation, modeling and system-level design to de-risk scale-up, overcome challenging feedstocks (different sources of CO₂), and enable commercially viable pathways toward net-zero goals.

Carbon Capture Engineering & CCU Process Development

SwRI’s carbon capture engineering team integrates modeling, experimentation and system design early and iteratively to accelerate scale-up while reducing technical and commercial risk. This approach enables rapid concept validation, informed engineering decisions and efficient transition toward deployable CCU technologies.

Carbon Capture Approaches Developing and scaling PSCC, DAC, CDR and other CC processes and technologies	CO₂ Valorization & Conversion Converting captured CO₂ into value added products while reducing lifecycle emissions
Point-source carbon capture Direct air conversion (DAC) Carbon dioxide removal (CDR) Solid sorbent technologies Liquid sorbents (amines and advanced solvents) Membrane separations (low- and high-temperature) Direct mineralization pathways	Fuels via Fischer-Tropsch and catalytic conversion routes Specialty and platform chemicals Polymers and advanced materials Minerals and materials Carbon products and graphene Electrochemical CO₂ Reduction Biochar and reactive carbon CCU for Enhanced Oil Recovery (EOR)

Core Engineering Capabilities Across the Technology Lifecycle

Our capabilities span early scientific validation through pilot and demonstration-scale systems that bridge the gap between laboratory concepts and commercial deployment.

Fundamental Development (TRL 1-3) Science-driven validation and feasibility	Applied Development (TRL 4-7) Execution-driven scale-up and deployment
Vapor–Liquid Equilibrium and phase behavior characterization Adsorption, desorption, absorption, and reaction kinetics Thermodynamic property measurement Catalyst and sorbent screening studies First-principles and data-driven process modeling Early-stage feasibility and concept evaluation Electrochemical	Benchtop experimental testing and proof-of-concept validation Reactor development (CSTR, fixed bed, plug flow, fluidized bed, bubble columns) Pilot and demonstration-scale unit design and operation Process modeling and system optimization Equipment sizing and utility integration Balance-of-plant engineering Long-duration testing and performance evaluation

We integrate the following chemical and mechanical engineering expertise into our projects to deliver CCU R&D at various technological readiness levels:

Producing Graphene from CO₂

Lab-to-pilot project demonstrates CO2 utilization and commercialization with small-scale pilot plant.

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Carbon Capture Pilot Plant & First-of-a-Kind CCU Systems

SwRI’s Chemical Engineering Department is uniquely positioned to translate CCU concepts into operating processes through in-house fabrication capabilities, carbon capture pilot plant infrastructure, and integrated engineering support.

Capabilities Include:

Carbon capture pilot plant at SwRI.

Bench-scale and fume-hood systems
Indoor pilot units and outdoor demonstration facilities
Custom reactor and separation system fabrication
Heat and mass transfer analysis
Equipment specification and procurement
Energy optimization and process control integration

Scales range from laboratory testing through large outdoor pilot systems designed to replicate commercial operating conditions.

Graphene production by bubbling CO₂ through a bed of liquefied alkali Earth metals.

Integrated Testing, Modeling and Scale-Up – Our iterative development workflow unites experimental validation with predictive modeling and progressive scale-up to derisk first-of-a-kind technologies.

Pilot-scale operation and long-duration performance testing
System degradation and lifecycle evaluation
Process simulation and TEA/LCA integration
Scale-up risk reduction strategies
Commercial operating envelope definition

Front-End Engineering & Techno-Economics – Techno-economic and lifecycle modeling are embedded throughout development to quantify performance, cost and environmental impact.

FEL-1: Feasibility packages and techno-economic analysis
FEL-2: Detailed process design (BFDs, PFDs, P&IDs, equipment specifications)
FEL-3: FEED packages and cost refinement
Lifecycle analysis and energy penalty assessment
Commercialization risk evaluation