From Molecules to Megatons: Materials, Process Intensification, and Infrastructure Integration for Scalable CO₂ Capture

Abstract

Carbon capture is moving from single-unit demonstrations toward integrated, multi-sector deployment—yet scale-up remains constrained by the coupled limits of materials performance, regeneration energy, and infrastructure readiness. This review synthesizes advances across post-combustion, pre-combustion, oxy-fuel, and direct air capture routes, with a comparative focus on adsorption, absorption, membrane separation, and cryogenic methods under realistic operating conditions. Emphasis is placed on how humidity, trace impurities, and low CO₂ partial pressure reshape sorbent/solvent selection and dictate practical process windows. We consolidate reported benchmarks for capacity, kinetics, cyclic stability, heat duties, and cost ranges, and connect these metrics to process intensification strategies such as structured contactors, hybrid solvent–sorbent concepts, and low-grade heat utilization. In parallel, we assess integration pathways—industrial clusters, renewable coupling, and CO₂ transport/storage networks—highlighting how shared infrastructure and heat/power integration can reduce energy penalties and improve technoeconomic feasibility. Finally, we outline research and deployment priorities for the next decade, including standardized testing protocols, durability-focused material design, and system-level optimization that links capture performance to downstream utilization or permanent storage.