Global warming stands face-to-face with honeycomb technology

At an increasing number of facilities around the world, carbon capture technology is taking greenhouse gas by force. Literally.

Carbon capture – the practice of pulling climate-change-causing carbon dioxide (CO2) out of the air or catching it from industrial exhaust – has been gaining traction. It’s now endorsed by the United Nations as a key method for staving off the most catastrophic effects of global warming.

So how exactly do we remove CO2 from the air? And can we do it at the scale needed to combat climate change?

According to scientists at Corning, the honeycomb structure that the company pioneered for emissions-combatting ceramic substrates provides a powerful solution.

One Corning honeycomb ceramic substrate can help to remove up to one ton of CO2 per year through direct-air capture.

What is a honeycomb?

Take a look at the tiny grid-like structure of a Corning ceramic honeycomb and you’ll see a meticulous structure formed during the “extrusion” process. Extrusion is the process in which a paste is pushed through a die, a mold-like tool that imparts a shape or pattern on a raw material. The die creates thousands of tiny, parallel channels – the perfect size for air molecules to bounce through… and then get trapped.

Invented as the United States’ Clean Air Act was going into effect in the early 1970s, the technology has helped automakers around the world meet evolving emissions regulations. It has helped prevent billions of tons of pollutants from entering the atmosphere, saving 230,000 lives in the United States alone, according to the U.S. Environmental Protection Agency.

In carbon capture, much like with tailpipe exhaust, air is cycled through hundreds of the honeycomb’s long, tiny channels, with carbon attaching itself to the sorbent lining inside.

The concentration of CO2 in ambient air is low (0.04%), requiring a substantial amount of air to be handled and captured by direct-air capture (DAC) facilities. The inside of Corning’s substrates features a high geometric surface area, which can process large volumes of flow-through and support active sorbent materials critical to carbon capture.

When a honeycomb becomes saturated with carbon dioxide, it’s heated to detach the carbon dioxide from the honeycomb. That carbon dioxide then gets sequestered into the ground or used to make useful compounds.

“With honeycomb ceramics, we have the potential of being the heart of a system that directly removes these harmful gases from the atmosphere. At scale, we could start reversing human impact on the Earth,” says Dr. Jayant Rane, Carbon Capture Program Manager at Corning. “Corning’s value to this process is immense.”

Carbon capture in action

At a DAC facility, fans force air through Corning’s honeycomb ceramic-based substrates, which are stacked, like building blocks, into a single module, operated by a carbon-capture company. Layer these modules and you have a whole facility dedicated to processing air through ceramic substrates.

Now imagine facilities all over the world, pulling out carbon dioxide and making a dent in greenhouse gas levels.

“We are ready for the growing demand,” Rane says of Corning’s ability to manufacture the honeycombs and supply a growing industry. “With billions of tons of CO2 to be captured globally on an annual basis, there is plenty of opportunity with partners around the world.”

“Government regulation on emissions will likely be needed for carbon capture to become a large industry”, Rane says. But the United States is already taking action.

In 2021, recognizing the urgency for technology’s role in mitigating climate change, the federal government provided a boost for carbon removal technologies within the Inflation Reduction Act, which more than tripled tax credits for these projects. The legislation directs more than $12 billion dollars for carbon management research, development, and demonstration through 2026.

The momentum for the technology also continues to build in Europe. In early 2024, the European Commission has outlined ambitious plans to reduce greenhouse gas emissions by 90% by 2040. Part of the proposed industrial carbon management strategy is the large-scale deployment of carbon capture technologies, which will play a crucial role in the continent’s move to climate neutrality by 2050.

The U.S. forecasts a growing need for millions of tons of carbon dioxide to be pulled from the atmosphere. Assuming one substrate can capture one ton of CO2, the number of honeycomb ceramics rises directly with the demand.

It provides an exciting opportunity for Corning, a company built on constant materials innovation. While ceramic technology is a long-standing area of expertise for Corning, the company's experts are evaluating other materials for use with the honeycomb structure.

“We’re working with most of the direct air capture start-ups and private companies to understand and reduce system specific costs with materials innovations and supply chain development and integration,” Rane said.

The future of environmental technologies

In the race for sustainable solutions, being able to apply tested – and retested – expertise is vital. Cassandra Taliaferro, Vice President & General Manager, Corning Environmental Technologies, says it’s all about stepping up and thinking big.

“We know the world needs to decarbonize quickly and continue to improve air quality for healthier communities,” Taliaferro says. “Carbon capture is our leading program to effectively use our existing skills and assets. Corning is well-positioned to rise to the challenge and help solve these tough problems.”

As carbon capture gains traction, the need for environmental technologies is stronger than ever.

“Our mastery of honeycomb ceramic has enabled us to push the world into the future,” Taliaferro said. “Carbon capture is just one of the many ways Corning’s expertise is vital to progress. We will keep delivering.”