Carbon Capture Utilization & Storage (CCUS) Explained

CCS, or Carbon Capture and Storage, encompasses various methods to prevent CO₂, produced during energy generation or as a byproduct of industrial activities, from entering the atmosphere. If required it can also be captured directly from the air through Direct Air Capture (DAC). This is the capture component of CCS / CCUS.

After capturing carbon dioxide, it can be managed in several ways. Carbon storage involves injecting CO₂ into the ground, effectively removing it from the atmosphere permanently. Carbon utilization includes processes that use captured CO₂ instead of other compounds. Enhanced Oil Recovery (EOR) is one such process, where CO₂ is injected into oil and gas wells to boost oil recovery, partially sequestering the CO₂. Other utilization examples may involve treatment / cleaning of the captured CO₂ for us in Food & Beverages or as a feedstock for other industrial processes. [source]

It's essential for operators to differentiate between CO₂ utilization and storage opportunities very early in the assessment phase of any proposal to implement CCS / CCUS.

Post 2024 the Inflation Reduction Act (IRA) and the Infrastructure Investment and Jobs Act (IIJA) continue to provide momentum in support of reducing U.S. carbon emission(s) by the installation of carbon capture and storage technologies. This ironically coupled with a shortage of CO₂ (for use) in the USA, primarily due to a mismatch between supply and demand, worsened by maintenance shutdowns at key production plants and (other) disruptions in the supply chain, also provides positive momentum for the installation of new/improved utilization facilities.

CCS involves three main steps: (1) capturing CO₂ from emission sources, (2) transporting it, and (3) storing it safely underground an optional (interim) stage of treating the capture CO₂ and retaining it for utilization in other ways. Each of these steps has different methods and technologies. Understanding these can help project owners and operators in industrial gas, CO₂, and LNG markets to make informed decisions early in any project lifecycle.

How Carbon Capture Works

The first step in CCS is capturing CO₂ from the gas streams produced by power plants, factories, other industrial processes or directly from the air. There are four main capture methods:

Post-Combustion Capture

• Description: CO₂ is removed from the flue gas after fossil fuels are burned.

• Applications: Commonly used in coal-fired power plants and natural gas facilities.

• Advantages: Can be retrofitted to existing plants.

Pre-Combustion Capture

• Description: CO₂ is captured before combustion occurs. The fossil fuel is partially oxidized to produce a gas mixture from which CO₂ can be separated.

• Applications: Widely applied in natural gas processing.

• Advantages: Results in a relatively pure CO₂ stream.

Direct Air Capture (DAC)

• Description: This technology captures CO₂ directly from the ambient air using chemical processes.

• Advantages: Can potentially reduce atmospheric CO₂ levels significantly.

Oxy-Fuel Combustion

• Description: Combustion occurs in a mixture of oxygen and recycled flue gas, resulting in a more concentrated CO₂ stream.

• Advantages: Simplifies the capture process due to higher CO₂ concentration.

Each method has pros and cons. Post-combustion is easier to retrofit but less efficient. Pre-combustion and oxy-fuel offer higher capture rates but typically require new plant designs.

Transporting Captured Carbon Dioxide

Once CO₂ is captured, it needs to be moved to storage sites. Transport options include pipelines, ships, or trucks. Pipelines are the most common and cost-effective for large volumes over land. The safe transportation of CO₂ requires careful consideration because it is often compressed into a dense, liquid-like state called supercritical CO₂. This reduces volume and makes transport safer and cheaper.

Storing Carbon Dioxide Safely

The final step (for CCS) is storing CO₂ so it never enters the atmosphere. Storage options include:

• Geological storage: Injecting CO₂ deep underground into rock formations such as depleted oil and gas fields, deep saline aquifers, or unmineable coal seams. These formations trap CO₂ for thousands of years.

• Mineral storage: Reacting CO₂ with certain minerals to form stable carbonates. This method is slower but permanent.

• Utilization (Re-use): Using captured CO₂ in products like concrete, chemicals, enhanced oil recovery or treating it for use in food and beverage products. This reduces new emissions by replacing fossil-based sources for CO₂.

Challenges and Future of CCS

The implementation of CCUS solutions is proven to provide significant capital, operational, reputational and political benefits, with a very positive future. However its safe, compliant and successful deployment can come with challenges and expert consultation is strongly recommended. Some potential challenges;

• Potential high capital costs for capture and transport infrastructure.

• Need for reliable storage sites with proper monitoring.

• Public acceptance that land based underground storage is safe.

• Regulatory and political uncertainty

• Political uncertainty

  
  

Salof have over 300 years of in-house experience in working with customers and successfully deploying a wide variety of type and size of CCS / CCUS equipment.

Real-World Examples

As of Q2 2026, Salof have delivered more than 160 CO₂ processing plants to our worldwide customer base. An increasing focus within this sector being the provision of CCS / CCUS equipment for installation on new or existing industrial plants. A recent example of this sector; Salof Limited Inc. delivered two similar CCS equipment sets for installation by its U.S. customer as additions to two of its existing bio-ethanol plants - designed to Capture, Treat and provide supercritical CO₂ for permanent underground storage. The underground storage being handled by the clients operators. Salof also have significant real world experience delivering a number of CCUS plants typically focused on the provision of clean , consumable CO₂ for the food and beverage industry.

Summary

According to the Global CCS Institute, in 2020 some 40 million tons of CO₂ per year capacity of CCS was in operation with an additional 50 million tons per year in development. The world emits about 38 billion tonnes of CO₂ every year, so CCS captured (in 2020) about one thousandth of the total released to the atmosphere.

As part of the Inflation Reduction Act legislation the U.S. Department of Energy (DOE) awarded (circa) $72 million in Federal funding to support the development and advancement of carbon capture technologies. Under this program, DOE awarded $51 million to nine new projects for coal and natural gas powere and industrial sources. An additional $21 million was also awarded to 18 projects for technologies that remove CO₂ from the atmosphere. The focus at that time being the development of methods / materials for use in DAC

As of 2023; Fifteen CCS facilities are were operating in the United States. Together, they have an ability to capture up to 0.4 percent of the nation’s (then) total annual CO₂ emissions. An additional 121 CCS / CCUS facilities were under construction or in development with an expectation of many more to follow up to 2030.

Present day; On-going advances in capture technology are expected to further improve efficiency and provide additional reductions in capital / operating costs linked to the successful deployment of CCS / CCUS. Combining carbon capture / utilization with other innovations, like renewable energy use, can further enhance sustainability. Investing in CCS / CCUS today prepares industrial plants for a cleaner energy future.

"If you want to explore CCS / CCUS solutions for your facility, consider reaching out to our experts who specialize in CO₂ and industrial gas systems. Taking action now can help secure your plant’s long term future in a low-carbon economy". Bob Luhrs, President.