Design and Development of Integrated Direct Air Capture and Methanation Processes

The synergies from integrating direct air capture and CO₂ methanation are assessed and quantified. Three direct air capture and methanation processes with different integration strategies are proposed: only heat integration, direct air capture sorbent regeneration with high-pressure H₂, and complete integration in a single unit. The heat integration study via pinch analysis evaluated the potential energy demand reduction. Overall autothermal operation is achievable, as the heat generated in methanation often exceeds that required for direct air capture sorbent regeneration. A novel process combining CO₂ adsorption and methanation in one reactor provided the best productivity and energy demand results. However, this design requires complex cycles and strict demands on the sorbent and catalyst, requiring further development and experimental demonstration.