Building and scaling Direct Air Capture plants

The urgency to address climate change is undeniable, and Direct Air Capture (DAC) technology has emerged as a potential game-changer. As industries explore innovative solutions for carbon removal, understanding the process of building and scaling DAC plants becomes crucial.

Climeworks has removed more CO? through Direct Air Capture than all other companies in the DAC field combined. As the only player currently building and operating DAC facilities, Climeworks has successfully transitioned from research and development to large-scale operational success. This is what we’ve learned:

Key considerations when building a DAC plant

Building a DAC plant requires complex engineering, substantial investment, and careful planning. While the technology is promising, several key challenges need to be addressed, including energy consumption, cost efficiency, and scalability. However, the opportunities are immense—not only in mitigating climate change and paving the way for a sustainable future but also driving significant economic value: DAC plants have the potential to create high-quality jobs, unlock new market opportunities, and drive growth in local economies.

Climeworks currently operates two Direct Air Capture plants in Iceland: Orca and Mammoth. In 2024, Orca received the first-ever AAA rating from BeZero Carbon, recognizing its commitment to high-quality, durable, and measurable carbon removal.

Typically, the realization of a plant follows these stages:

1. The preparation phase typically spans four to five years, laying the foundation for a successful project. It begins with research and development (R&D) focused on innovating materials and processes to enhance CO? adsorption and improve cost efficiency. Concurrently, site selection is conducted to evaluate access to low-carbon energy, proximity to CO? storage facilities, and the availability of local infrastructure. The Front-End Engineering and Design (FEED) study follows, developing detailed plans, cost models, and timelines, leading to the Final Investment Decision (FID). For example, Mammoth’s FEED study began in April 2021, with the FID made within a year.
2. The design and construction phase lasts two to three years and brings the plant to life. Infrastructure is built, and key components are installed. Mammoth broke ground in June 2022, with initial CO? removal operations beginning by May 2024. Climeworks’ modular design allows for scalability and flexibility, enabling the plant to adapt to demand while reducing construction time and costs.
3. Commissioning takes six to twelve months, testing and integrating all systems to ensure the plant operates as intended. At Mammoth, the first twelve collector containers were commissioned in late 2023, providing valuable data while construction continued. Phased commissioning accelerates the learning curve and refines the plant’s performance.
4. The ramp-up phase lasts one to two years, gradually increasing CO? capture operations. The plant starts at lower volumes to test system integration and identify any inefficiencies, ensuring it is fully optimized for steady-state operations.
5. Once ramp-up is complete, the plant enters steady-state operations, lasting over 20 years. It captures CO? at stable capacity, with ongoing monitoring and maintenance to ensure optimal performance. Modular upgrades, including filter replacements, integrate R&D advancements to improve efficiency and reduce costs. For Mammoth, steady-state operations are expected by 2026.
6. At the end of its operational lifespan, the plant undergoes decommissioning, safely dismantling systems and responsibly recycling or disposing of materials. Climeworks prioritizes sustainability, aiming to maximize the recyclability of plant components.

This structured approach ensures that each DAC plant not only meets its operational goals but also aligns with Climeworks’ commitment to innovation and environmental stewardship.

Conclusion

The potential of DAC technology is clear: By following a well-defined process—focusing on R&D, site selection, and continuous optimization—DAC companies can play a pivotal role in tackling climate change. As the industry evolves, carbon removal will become an integral part of global environmental strategies.

At Climeworks, we believe that technological innovation and strategic collaboration will make DAC a critical tool in the fight against climate change. While the road ahead is challenging, the opportunity for lasting, positive environmental impact is within reach.