Optimizing Air Contactor Design for Efficient Carbon Capture in Direct Air Capture Systems: A Multi-Disciplinary Approach
Authors: Eke Victor , Soares Couto Danillo , O'Brien Paul , Freire-Gormaly Marina 
Published: August 2024

As carbon dioxide (CO2) emissions continue to rise, direct air capture (DAC) has emerged as an important technology for removing CO2 from ambient air to combat climate change. The air contactor design is a critical factor impacting DAC system performance and costs. This research describes a strategy for improving the design of a single air contactor unit to increase CO2 capture flux while minimizing costs using optimization techniques grounded in experimental data .
The research focuses on a 100 m2 slab air contactor modeled utilizing cooling tower and scrubber principles. The system includes the chemical, mechanical, and structural engineering disciplines. The mass transfer coefficient, air velocity, packing depth, and capital cost per frontal area are four major design characteristics that were maximized.
The model integrated requirements for low air velocity, pressure drop, and energy consumption, as well as adequate gas-liquid interaction via structured packing selection and depth.
The design space was explored using a multi-objective optimization strategy based on gradient-based and heuristic methods. Initial sampling via a design of experiments methodology demonstrated response surface trends in the objective function across the design space. The response surfaces mapped the optimization objective as a function of the design variables. Using gradient information, sequential quadratic programming efficiently located an optimal design vector that met all constraints on the design variables and feasibility requirements. The constraints included bounds on mass transfer coefficient, air velocity, packing depth, and capital cost per frontal area. The optimized air contactor design achieved a CO2 capture flux of 10,440 kg/m2-yr at a cost of $ 0.068 per kg CO2 captured. The developed optimization framework maximizes contactor performance while decreasing operational costs. A multi-objective genetic algorithm approach was used to identify the trade-offs between the two competing objectives of maximized CO2 capture and minimized cost by expanding the formulation. The Pareto-optimal front of the optimization results offered numerous optimized solutions with specific DAC system setups.
This methodology, as well as the optimum configurations identified, serve as the foundation for constructing larger-scale DAC systems, in future. Ongoing research aims to improve solution approaches by including advanced optimization software packages such as DAKOTA, which offers global optimization algorithms, as well as to boost model accuracy via integrating additional choice variables. Future optimization and modeling studies will include contactor interactions and the modeling of a full DAC facility to boost confidence that a globally optimal design has been established.
Overall, this study illustrated an efficient optimization strategy for air contactor design and contributes to the improvement of sustainable carbon capture technology, which is crucial to controlling rising global CO2 levels. Contactor configuration optimization enables superior DAC system designs at lower costs, hence promoting the urgent deployment of negative emissions solutions.