Background/Objectives

To meet CO₂ reduction goals, in addition to reduction in CO₂ emissions, Direct air capture (DAC) will be needed to reduce the amount of carbon already in the atmosphere. Once captured, there must be a plan for storing or utilizing the CO₂ in a beneficial way. This project captures CO₂ from the atmosphere and sequesters it in a concrete batching process in a way that reduces needed cement and thereby partially solves another problem – that of heavy carbon emissions from the cement manufacturing process.

The greater Chicago and Gary areas have significant environmental justice issues as well.

Approach/Activities

The University of Illinois Urbana-Champaign (UIUC) is spearheading a front-end engineering design (FEED) study of a direct air capture and utilization (DACU) system that can remove 5,000 tonnes/yr net CO₂ from ambient air and utilize it in the production of concrete. The designed system, if built, would be larger than any currently existing DACU system, covering northern Indiana, the Chicago area and southern Wisconsin. Such carbon negative technologies are critical to meeting the goals of the DOE’s program to accelerate climate-critical technology.

CarbonCapture has developed an innovative DAC system using novel adsorbents to cost-effectively capture CO₂. At the turn of the year, it designed the models necessary to contain its prototype reactors that will be at the core of carbon collection.

U. S. Steel, Gary Works will be the Host Site, providing waste heat and utilities. The site is fairly centrally located to the approximately 250 Ozinga concrete batch plants that will utilize the captured CO₂, minimizing transportation costs.

CarbonCure has developed two processes that will be incorporated into the DACU system. The first, in which CO₂ is mixed into the concrete batch to react with the calcium in the cement, is already in use at these plants and reduces the required cement by 3%. The second, in which the mix water from the previous day’s truck washings is carbonated, is also a proven technology, but would have to be added to these sites. It also reduces the required cement by 3%.

The captured, liquified CO₂ will be trucked to Ozinga ready-mix concrete plants across Illinois, Indiana, and Wisconsin. The Ozingas also own a fuel company that harvests methane from cows to make CNG, which is used in most of their fleet. By utilizing this technology, the transportation carbon footprint will be better than that of electric trucks.

Different aspects of the impact of this project on the Chicago/Gary community has been studied and will be discussed in this presentation.

Results/Lessons Learned

This FEED study demonstrates a full CO₂ value chain for a DACU system, supported by an industrial facility. If this project were constructed, it would have a very positive and lasting impact on both the environment and the community.