Sorbent materials for direct air capture (DAC) programs often demonstrate strong performance early in lab settings. The more complex challenge is moving from early material verification to commercial deployment, turning that sorbent into a coated component that performs predictably at scale, across real operating conditions, and across regeneration cycles.
In many direct air capture designs, that coated component is a monolith substrate, also called an air contactor. We apply the sorbent material via an OEM grade coating technology to monolithic substrates used within direct air capture systems, supporting the transition from laboratory development to full commercial manufacturing and mass production.
Why Honeycomb Monoliths are a Cost-Effective Structure
Honeycomb monoliths used in direct air capture systems are a practical structure because they are manufacturable and adaptable to different sizes and shapes. That flexibility helps engineering teams optimize sorbent coated monolith designs for surface area, backpressure, and energy efficiency while maintaining cost control as projects scale.
When moving sorbent material from lab scale to commercial deployment, cost effectiveness goes beyond raw material pricing. It depends on repeatable production, predictable flow behavior, and consistent sorbent performance from unit to unit across direct air capture operations.
What Matters When Scaling Sorbent onto Coated Monolith Production
1. Coating uniformity
Coating uniformity is the foundation for repeatable sorbent performance. Variability in coating thickness or distribution can drive higher back pressure and inconsistent sorption kinetics across the coated monolith.
Our direct air capture development approach includes access to the latest industry produced sorbent materials, relationships with suppliers of raw monoliths optimized for direct air capture systems, and in-house expertise and equipment to efficiently scale up and optimize coating production.
What engineers typically want to lock down early:
- Consistent coating loading across channels
- Controlled coating uniformity so channels stay open
- Repeatable results across multiple builds
2. Pressure drop
Pressure drop should be treated as a primary design input, not something to check at the end. It influences blower power, system sizing, and operating cost. Honeycomb monolith geometry can support good flow distribution, but the coating process must protect channel openness and consistency to avoid unnecessary restriction.
CDTi specializes in coating of monolithic substrates, whether metallic or ceramic honeycomb, and can provide solid sorbents in a wide range of sizes and shapes. That same monolith and coating experience translates directly to coated substrate work where flow behavior matters.
3. Cyclic Performance Across Adsorption and Regeneration
Commercial deployment of sorbent coated monoliths for direct air capture depends on stable performance across repeated operation. Adsorption and regeneration need to stay consistent over repeated cycles to keep performance from drifting.
Our direct air capture work focuses on developing and producing high-performance sorbent coated substrates tailored to the needs of system developers. Using in-house coating expertise and equipment we can scale and optimize coating efficiently, supporting the process from research and development through mass production.
Over time, direct air capture teams need to see:
- Stable CO₂ uptake
- Stable CO₂ release during regeneration
- Stable cycle behavior across the full monolith
4. Durability Over Repeated Cycles
Repeated adsorption and regeneration put stress on the coated sorbent material. The sorbent coating must stay consistent, so performance stays predictable over time. Adhesion and coating integrity help keep results repeatable as DAC technology moves toward broader deployment. This is where our expertise in materials and coating capabilities come into play for direct air capture coated substrates.
5. Production at Volume for Sorbent Coated Monoliths
Commercial deployment of sorbent coated monoliths for direct air capture requires producing coated substrates consistently at higher volumes. Repeatable coating processes help keep sorbent performance steady from one production run to the next as systems transition from lab scale and pilot builds to commercial manufacturing. Variation that seems minor early can show up later as measurable performance spread during validation and scale-up.
CDTi’s direct air capture sorbent coatings are supported by in-house coating expertise and equipment designed to efficiently scale up and optimize coating production. Support extends from research and development through mass production, helping ensure coated monolith consistency at commercial volumes.
Product and Engineering Support for Coated Monoliths
As direct air capture programs move from lab scale verification to commercial deployment, strong product and process engineering support becomes critical. Our team works closely with system developers to advance sorbent coated monolith substrates and coating solutions that meet performance, durability, and manufacturing requirements at scale.
Contact our team to discuss your application and learn more about sorbent coated monolith substrates and coating solutions.