Carbon Capture, Utilization, & Storage

Ayers maintains a leading research program focused on technologies that capture carbon dioxide from industrial emissions before they enter the atmosphere. Engineers develop advanced amine-based absorption systems with improved solvents that reduce regeneration energy requirements and minimize degradation, solid sorbent systems using temperature swing or pressure swing regeneration, and membrane separation technologies for specific industrial applications. The program encompasses process intensification strategies including novel contactor designs, heat integration schemes, and modular system architectures that enable deployment across diverse industrial facilities. Testing protocols evaluate carbon dioxide capture rates, energy consumption per ton captured, solvent or sorbent stability over thousands of cycles, and system response to variable inlet conditions. The research addresses cost reduction through materials optimization, equipment standardization, and operational efficiency improvements. This specialty supports the development of capture systems suitable for deployment at power plants, cement facilities, steel mills, and chemical manufacturing sites.

The facility operates a dedicated division for developing systems that remove carbon dioxide directly from ambient air, enabling capture from distributed sources and historical emissions. Researchers investigate solid sorbent systems using amine-functionalized materials, metal-organic frameworks, and alkaline earth metal oxides that selectively adsorb carbon dioxide at atmospheric concentrations. The program encompasses contactor design for maximizing air throughput and sorbent exposure, thermal management systems for efficient regeneration, and integration strategies for coupling with renewable energy sources. Testing facilities evaluate carbon dioxide uptake capacity under varying humidity and temperature conditions, regeneration energy requirements, and sorbent lifetime through accelerated aging protocols. The research addresses cost reduction targets necessary for large-scale deployment, including modular system designs, automated operation, and optimized energy integration. This specialty supports the development of negative emissions technologies essential for achieving climate goals.

Ayers conducts intensive research into the safe and permanent storage of carbon dioxide in deep geological formations including saline aquifers, depleted oil and gas reservoirs, and unmineable coal seams. Engineers develop injection strategies that optimize storage capacity and minimize risk, modeling techniques that predict carbon dioxide plume migration and pressure buildup, and monitoring systems that track stored carbon over time. The program encompasses geochemical analysis of formation fluids and rocks, geomechanical evaluation of cap rock integrity, and seismic monitoring techniques for detecting carbon dioxide movement. Testing utilizes high-pressure core flooding apparatus to evaluate injectivity and storage capacity, along with numerical simulation tools for site characterization and risk assessment. The research addresses regulatory requirements for storage site permitting, long-term liability frameworks, and verification protocols for carbon accounting. This specialty supports the development of secure geological storage essential for carbon capture and storage deployment at scale.

The facility maintains an active program developing technologies that convert captured carbon dioxide into construction materials through mineralization reactions. Researchers investigate processes that carbonate industrial waste materials including steel slag, coal ash, and concrete demolition debris to produce supplementary cementitious materials and aggregates. The program encompasses direct carbonation of fresh concrete during mixing and curing, accelerated mineralization of alkaline waste streams, and production of precipitated calcium carbonate for various applications. Testing facilities include high-pressure carbonation reactors, concrete mixing and curing chambers with controlled carbon dioxide atmospheres, and mechanical testing equipment for evaluating product performance. The research addresses product quality standards, durability characteristics, and lifecycle assessment of carbon-negative building materials. This specialty supports the development of utilization pathways that provide economic value while permanently sequestering carbon in long-lived products.

Ayers engineers catalytic and electrochemical systems that convert captured carbon dioxide into valuable chemicals, fuels, and industrial feedstocks. The research focuses on thermochemical processes producing methanol, formic acid, and synthetic hydrocarbons through hydrogenation reactions, electrochemical reduction generating carbon monoxide and multi-carbon products, and biological conversion pathways using engineered microorganisms. The program encompasses catalyst development for selective carbon-carbon bond formation, reactor design for optimizing conversion and selectivity, and process integration strategies combining carbon capture with utilization. Testing facilities include high-pressure catalytic reactors, electrochemical cells with various electrode configurations, and product separation and purification equipment. The research addresses energy integration with renewable hydrogen production, economic viability compared to fossil-derived products, and lifecycle environmental impacts. This specialty supports the development of circular carbon economy pathways that transform waste carbon dioxide into valuable products while reducing dependence on fossil fuel feedstocks.