Researchers at the New York State Center of Excellence in Advanced and Sustainable Manufacturing (COE-ASM) at Golisano Institute for Sustainability (GIS) are helping advance a lab-born breakthrough into viable climate technology.
Project lead and GIS mechanical engineer Catherine Swail is leading efforts to scale a method that captures carbon dioxide and locks it into rock-like materials using industrial waste.
The sequestration process was developed and patented at Cornell University in Ithaca, N.Y., and licensed to Carbon To Stone for scale-up deployments. Their researchers developed a method to accelerate a naturally occurring mineralization process using a reusable, low-energy solvent system.
The process starts with gaseous industrial waste streams that are introduced to a chemical solution, which is mixed with byproducts of heavy industry, such as steel slag or cement kiln dust. These elements react in a slurry to form a solid carbonate that is filtered, separating the solvent for reuse from the solid “mineralized material.” This sustainable material can be used in cement or concrete production, thereby permanently locking away the captured carbon dioxide.
The potential is two-fold for industry partners, as they can utilize their waste resources to help meet emission regulations and generate carbon capture credits as well as revenue through the sale of the mineralized products.
Successful laboratory demonstration of this crystallization technology prompted the founders of Carbon To Stone to form the startup in 2022, with the goal of scaling the process for real-world industrial impact. That’s where COE-ASM comes in.
Swail and a multidisciplinary team of engineers and technicians have spent the last nine months designing and building a mobile prototype system. The goal is to capture tons of carbon dioxide per year from an industrial waste stream, a step toward commercial use.
“It’s not as simple as just doubling everything,” Swail said about bringing the system to scale. “The goal is to stagger the timing of the reactions between the two reactors by adding semi-automated controls and measurement to enable more continuous carbon capture.”
Among the many upgrades Swail and her team implemented are a custom flue gas conditioning system (including a chiller and heat exchanger), a second reactor, an upgraded filtration press to handle more material throughout, and LabVIEW based software to communicate with a programmable logic controller. The custom software developed by the GIS team gives an operator control over valves, pumps, sensor readings and shutdowns as well as records data for analysis from a computer interface. The system is mounted within a trailer, which will allow the startup to be more mobile, piloting the technology at various partner sites.
“Material handling has been a challenge, especially with the slurry,” Swail said. “You need specific types of pumps and compatible materials, and even small details like pressure and height differentials in the lines make a substantial difference. We’ve been testing and redesigning as we go, adding things like a compressed air line to clear blockages. It’s all part of the iterative design process.”
The partnership began through Scale for ClimateTech, when RIT Technical Program Manager Mark Walluk conducted a manufacturing readiness level assessment of Carbon To Stone’s technology and recommended the RIT team’s support given the company’s preparedness to scale.
“Working with COE-ASM significantly accelerated our product development timeline,” said Sravanth Gadikota, CEO of Carbon To Stone Inc. “They bring a team with broad expertise in various disciplines, including mechanical, electrical, machining and project management. Further, the funding support from New York state agencies made it possible for us to access such incredible skills, right here in Upstate New York. Working with this team is a no-brainer.”
Funding for the project was provided by the New York State Department of Economic Development.
“New York state funding allows the Center of Excellence to offset the cost of helping companies advance their green technologies,” added Walluk. “It’s very rewarding to help startups like Carbon To Stone on their journey to bring new and impactful technology to the market.”
Note: Any opinions, findings, conclusions or recommendations expressed are those of the author(s) and do not necessarily reflect the views of the DED.
