Integrated Platform for Carbon Capture and Utilization 

Integrated Platform for Carbon Capture and Utilization is a comprehensive, hands-on educational system designed to bring real-world Carbon Capture, Utilization, and Storage (CCUS) processes into the classroom and research environment. Tailored for engineering and science institutions, this lab-scale setup simulates the complete CCUS cycle—from carbon emission simulation and adsorption to desorption and final mineralization into stable compounds like CaCO₃. With integrated sensors, a PID-based control system, and an IoT-enabled data acquisition unit, this platform is suitable for both foundational learning and advanced experimentation. 

Key Features

  • Complete End-to-End Simulation: Covers all core CCUS stages—emission simulation, selective CO₂ capture, regeneration, and mineralization.
  • Advanced Gas Handling: High-precision Mass Flow Controllers allow simulation of various CO₂ source streams (400 ppm to 60%+).
  • Selective Adsorption & Desorption: Packed bed columns with MS 5816 BG sieves; PID-controlled TSA process for accurate regeneration
  • PID-Controlled Desorption: Enables accurate, energy-efficient regeneration of the adsorbent via Temperature Swing Adsorption (TSA).
  • Precision Gas Blending: Uses mass flow controllers to simulate a wide range of CO₂ concentrations—from ambient (400 ppm) to industrial flue gases (up to 60%)..
  • Mineralization Module: Bubble reactor demonstrates CO₂ conversion to CaCO₃ with real-time sparging.
  • Real-Time Monitoring: Includes CO₂ sensors and six-point thermocouple array for comprehensive data acquisition and thermal analysis.
  • IoT-Enabled Interface: Enables live monitoring, user-controlled experiments, CSV data logging, and export for post-lab analysis.
  • Research-Grade Accuracy: Enables isotherm modeling, breakthrough curve analysis, and techno-economic feasibility assessments.
  • Scalable & Modular: Designed for easy integration into academic curriculums or industry-aligned research programs.
Ecosense

Learning Module 

Ecosense

Adsorption and Desorption Science

  • Adsorbent Characterization: Measure CO₂ adsorption capacity at different inlet concentrations; compare adsorbents.
  • Thermal Swing Adsorption (TSA): Understand heating-based regeneration cycles and monitor efficiency and kinetics.
  • MTZ Analysis: Use thermocouple data to observe the movement of the mass transfer zone and thermal gradients.

Gas Composition and Capture Efficiency

  • Breakthrough & Isotherm Modeling: Construct breakthrough curves, generate adsorption isotherms, and apply Langmuir/Freundlich models.
  • Process Parameter Studies: Analyze the effect of partial pressure, gas composition, and flow rate on adsorption efficiency.
  • Desorption Methods Comparison: Evaluate energy use and purity levels in TSA vs inert gas purging.

Mineralization and Techno-Economics

  • Visual CO₂ Mineralization: Observe CaCO₃ formation via bubble reactor; correlate with CO₂ input volume.
  • Process Optimization: Modify flow rates and temperatures to improve conversion efficiency.
  • Feasibility Studies: Estimate energy consumption and cost per kg of CO₂ captured; apply concepts to Direct Air Capture (DAC) and flue gas streams.

Technical Description

  • The Integrated Platform for Carbon Capture and Utilization is a lab-scale CCUS system to demonstrate the complete capture-to-utilization workflow in a controlled environment.
  • A dynamic gas blending unit with precision mass flow controllers simulates real emission sources ranging from ambient air (≈400 ppm CO₂) to industrial flue gas concentrations.
  • The blended gas stream passes through a packed-bed adsorption column containing advanced molecular sieves for selective CO₂ capture under ambient conditions.
  • Multiple thermocouples distributed along the column enable detailed thermal and mass-transfer zone analysis during adsorption.
  • A PID-controlled Temperature Swing Adsorption (TSA) system regenerates the adsorbent, releasing concentrated CO₂.
  • High-speed NDIR CO₂ sensors continuously monitor inlet and outlet concentrations for efficiency calculations.
  • Regenerated CO₂ is routed to a transparent bubble reactor, where mineralization converts CO₂ into stable CaCO₃, providing clear visual and analytical learning outcomes.
  • An IoT-based data acquisition system logs temperature, flow, and gas concentration data for real-time visualization and post-processing. 
Ecosense

Technical Specifications 

Ecosense

Gas Blending & Sensing


ParametersSpecifications
CO₂ concentration range400 ppm to >15%
Mass Flow Controllers0.1–10 L/min, ±3% FS accuracy
CO₂ sensing methodNDIR (0–100% range)
Sensor resolution10 ppm

* specifications can be customized as per user's requirements.

Adsorption & Desorption Unit


ParametersSpecifications
Adsorbent materialMolecular sieve MS 5816 BG
Reactor materialSS316 packed-bed column
Temperature measurement6 × K-type thermocouples
Regeneration methodTemperature Swing Adsorption (PID-controlled)

* specifications can be customized as per user's requirements.

Utilization & Data System


ParametersSpecifications
Utilization reactorGlass bubble reactor with sintered spargers
Mineralization mediumAlkaline Ca(OH)₂ solution
Data acquisitionMulti-channel IoT-based DAQ
Data outputReal-time plots & CSV export

* specifications can be customized as per user's requirements.

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Frequently Asked Questions

In Carbon Capture Utilisation & Storage, captured CO₂ can be permanently stored in stable forms. Storage options include mineralization into solid carbonates, geological storage in deep saline aquifers or depleted oil and gas reservoirs, and utilization pathways where CO₂ is converted into useful products. In laboratory systems, storage is often demonstrated through mineralization, where CO₂ reacts with alkaline solutions to form stable solids, ensuring long-term carbon containment.

CCUS helps prevent global warming by capturing CO₂ emissions at the source before they are released into the atmosphere. By reducing the concentration of greenhouse gases, CCUS directly lowers the overall carbon footprint of industrial processes and energy systems. When combined with renewable energy and efficiency measures, CCUS enables significant emission reductions while allowing existing infrastructure to transition toward low-carbon operation.

CCUS plays a critical role in clean energy transitions by addressing emissions from hard-to-abate sectors such as power generation, cement, steel, and chemical industries. It complements renewable energy by enabling low-carbon operation of existing assets, supporting hydrogen production, and enabling negative-emission pathways when paired with bioenergy. CCUS also provides a bridge technology while renewable and storage systems scale globally.

The key advantages of CCUS include significant reduction of CO₂ emissions, compatibility with existing industrial infrastructure, and flexibility across multiple sectors. It enables carbon recycling through utilization pathways, supports climate targets without immediate system overhauls, and provides valuable research and training opportunities. CCUS also accelerates innovation in sustainable fuels, materials, and long-term carbon management strategies.

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