Evolution Happens: How Carbon Capture & Sequestration has become truly profitable and sustainable

Carbon offsets or avoided costs are gradually becoming a “thing” that pays dividends — a sector-focused update after 30 years of progress.

As co-founder of CDS, we have been mainly engaged with the marketplace as financiers (impact investors since 1996, before the word “cleantech” let alone “impact investing” has been coined), and thus have seen a progression with biogenic wastes, all types of biomass, from climate change-related diseased trees needing to go somewhere to abate wildfire risk (especially those that encroach on populated areas, but also because the most carbon is already stored in older trees) to agriculture field “residue” to food processing wastes to nutrient-containing municipal solid sludges and livestock-related solid wastes. All of these deserve to be “upcycled” and put back to productive use.

To not do so is a “triple bottom line” opportunity lost. We can support and encourage mainstreaming of these practices while making a good living.

A brief retrospective of biochar, now a flourishing, award-winning marketplace

At first, making biochar was overhyped. Unsubstantiated claims were made that were, owing to the unbridled passion and enthusiasm of activists worldwide, destined to fail and disappoint. The promise of biochar and early types of pyrolysis (inefficient at best, but often also ineffective in terms of product quality and performance, batch-to-batch consistency, and operating costs). Some states, such as our home state of California, banned pyrolytic systems altogether, as some reactors generated air emissions, so the Air Board (CARB) concluded that it was no better than burning.

Properly designed pyrolysis is a closed reactor — entirely anaerobic — with no emissions whatsoever. The earlier ban has been lifted in CA, now aligned with other states , so that overlooked feedstocks are once again a “carbon negative” business opportunity. Instead of disposal, closed loop designs repurpose the liability of such wastes, many of them generating methane or ammonia, into products of value, a way to “valorize” such liabilities, meaning to create or assign value and merit where there was the opposite before.

The earlier “55 known uses of biochar” was really just a proxy for not knowing what to do with it! The quality and economic fundamentals were hit or miss, mainly due to lack of commercial-scale experience, as well as challenges with controlling inputs, as biomass is diverse in nature, and massive volumes are needed over time for consistent product offerings. We have successfully processed obscure types of stockpiled biomass — some that required ingenious pre-processing just to make pyrolysis possible — with biochar characteristics via lab testing — now functioning as steady-state solutions to disposal problems not previously available.

Now biomass conversion has become “mature” and diverse feedstocks are easily aligned with offtakers where the technology in between is somewhat commoditized, less art, more science, with diverse applications across many sectors commanding attractive pricing. Biochar specialists have sprung up globally, many not even mentioning the “char” component to make a clean start away from the hype.

What about “technical” nutrients from petroleum? Is there hope for closing that loop?

Similar progress is in evidence with non-biogenic waste such as rubber and plastic feedstocks. Here the business case is based on proper post-consumer handling of such wastes, already well organized when you purchase new vehicle tires (you pay a “disposal” fee in the US), but most end-of-life tires just go into a special-purpose landfill called a monofil. There are many other valuable resources that end up buried, lost and forgotten, but that’s quickly changing.

Plastics are still a big mess. Recycling plastics or separating and using them as the source of value, with adequate upside (in some cases due to incentive for proper handling) are all over the map. Some communities are now simply phasing out single-use plastic bags, a modern disaster in the US for anyone that eats, as we can’t seem to master bringing our own food-contact containers (embarrassingly far from mainstream practice), and packaged goods manufacturers and everyone else are entirely addicted to the convenience of plastics. Systemic changes at the source are needed.

Let’s divide the problem into 2 aspects, the first showing signs of hope in some markets, but the second one arguably a problem as wicked and gnlarly as climate change:

Replacing plastic bags with bioplastic (compostable) ones is the right idea, though probably “too little, too late,” but at least we can focus on the happier ending of billions of bags going through composting to reuse those nutrients in living soils.

For other plastics, pyrolysis and gasification systems are a fine waste-to-energy (WTE) solution when there is adequate sourcing (securing feedstock supply over decades), which itself depends on sorting and separation, to ensure adequate caloric content to profitably generate “renewable” fuels or other baseload power.

After extracting these calories (include residual thermal energy), either as methanol-to-jet fuel, or renewable diesel, gasoline, or as electricity in certain markets with no better options for electricity, what’s left over is just ash, which can be safely landfilled. Some companies are finding novel molecules and chemistries in this process, though nothing at scale so far.

WTE is probably best-case scenario for industrial and post-consumer plastics, at least for now, so haulers need to invest in proper separation and recovery of usable materials for either this thermochemical decomposition pathway and/or mechanical recycling, widely used with most paper, glass, aluminum and identifiable types of plastic wastes. We have yet to find an effective way of handling films and wraps in the US (even if we replace all the plastic bags, switching to biobased or biodegradable films is not yet happening due to performance concerns).

Meanwhile, tipping fees will continue to climb at US landfills, despite increased “clean” incineration, so closing various loops becomes an attractive business opportunity. China and India no longer accept US waste, which was arguably the worst band-aid of a solution to begin with. Coping is not solving.

Our oceans are a total disaster, filled with microplastics. Conventional plastics photodegrade into a toxic mass that is unhealthy for living organisms. We desperately need a breakthrough in this area — perhaps some microorganism that can “digest” plastics in waterways and render them benign?

Overuse of plastics may go down in history as the “one thing” we, as a society, botched completely, with unintended consequences we have yet to fully realize, even though “enhanced” Materials Recovery Facilities (MRFs) are springing up, some with AI-enabled sorting, so many systemic challenges remain, this is code for business opportunity.

Ditto for water reuse. We need the best minds to rethink and reshape the status quo.

Status Updates by Sector

In the case of end-of-life tires, clients of ours have “cracked the code” on profitably generating massive amounts of recovered Carbon Black (rCB) that meets the necessary ASTM standards for making new tires. Virgin CB was always a dirty process, and now rightly an expensive one (the true costs add up in multiple ways, not just economic), so rCB is gradually replacing the need to make any new “furnace” CB, with all the major tire manufacturers living up to their rhetoric about being greener and more sustainable. There is no loss of price/performance. There’s a promising road ahead for those who pay attention to the industry’s peculiarities and preferences.

Agriculture and food systems are turning the corner, still a long way to go, but with “carbon farming” catching on worldwide — a set of agricultural practices designed to increase carbon sequestration in soil and biomass, aiming to create a net reduction of atmospheric CO₂ by enhancing soil organic matter and plant carbon storage. Arguably this is needed the most in the US, where inputs are still 99% fossil-derived synthetics with vast issues and inefficiencies as a result. Regenerating “living soil” with microorganisms has become profitable so farmers are volunteering to do the right thing, an area that can use properly formulated products to take advantage of biochar’s benefits.

The transportation sector can decarbonize by going electric, continuing to replace fossil sources with renewables, and avoiding combustion as the source of energy.

Green building gets a boost from innovative solutions from valorizing biomass wastes (forest slash and managed forest wood waste, for fire suppression or other goals, ag residue, food processing waste, …) as interior walls, floors, furniture, and construction materials can be made without toxic additives, designed to save “stick built” labor — in shortest supply when needed most, such as for rebuilding homes in neighborhoods affected by fires or other climate change-related disasters. The built environment is often overlooked as an opportunity to uplevel living standards as toxins in the air — volatile organic compounds and persistent organic compounds — that “new car/home” smell, gradually decrease over time, but actually last forever. That’s a long time. Reconstruction and regeneration of living spaces can be about health, wealth and better indoor living.

Capital markets embrace natural carbon storage

Still often seen by investors as “first-of-a-kind” (FOAK) solutions to accelerated risks from climate change (so-called “runaway” or cascading greenhouse effect), there are now large-scale, commercial implementations of nature-based carbon capture that are far more lucrative than more commoditized renewable energy projects, so the sector has become attractive to capitalists, including CDS funding partners In3 Capital and Impact Guarantee Fund, when the mix of market timing, management, and adequate readiness are evident.

How It Works

How the CDS Solution Works

CDS systems are semi-mobile and containerized consisting of a pyrolysis module integrated with the necessary components to ensure continuous, turnkey operation. What is pyrolysis, you may be wondering, and how does it work?

Pyrolysis is a type of thermochemical process that involves feeding feedstocks to temperatures between 250-800 degrees C in an oxygen free environment.  See illustrations below.

In the words of one expert:

How It Works

“The biomass is essentially ‘cooked’ [but not burned] until various lignin and cellulose products breakdown to produce a hydrogen-rich fuel stream that can either be combusted or condensed for energy generation.  The high-carbon product that remains is biochar which has essentially been mined of hydrogen.”

– Dr. John Gaunt, Cornell University

An impressive variety of feedstocks can be continuously fed into the inlet and broken down into a stream of products and coproducts, each with substantial market value. See the illustrated production process for a description of the various stages of operation these systems use in practice.

System Flow image
Simplified view of pyrolysis system in practice

This technology is fully mature and ready for immediate application

Here is an illustration of the process flow from raw feedstocks to the various coproducts:

CDS Production Model

Once operational, a full-sized unit produces its own power plus an additional thermal energy or electricity (for local consumption or via grid interconnection), where syngas can also be on-converted or condensed into various intermediary forms, such as methane, renewable diesel, etc., or some feedstocks also produce bio-oil (also called “pyrolysis oil”) that can be further processed into transportation fuels. 

See Customers or Contact Us to register interest or inquire about system pricing, availability and delivery. Got questions? We can help.

The Liquid Carbon Pathway

Technical Brief:  the symbiotic relationship between soil microbes and plants

The Liquid Carbon Pathway (LCP) is a symbiotic relationship between mycorrhizal fungi and 90% of all plants that has developed over the past 420 million years. Plants will purposely produce extra carbohydrates (simple plant sugars) then exude that surplus into the soil to feed the fungi.  Mycorrhizal fungi cannot live without a host plant and, in exchange for this sugar, the fungi will mine and transport nutrients and water back to its host.  For every cubic meter of soil, these fungi will send out as much as 20,000 km (12,000 miles) of hyphae — part of what comprise the fungal mycelium — so that they infiltrate every area of soil.  Fungi can access nutrients and water unavailable to the larger plant roots.

 Mycchorizal fungiMycorrhizal Fungi — root system of plantBiochar inoculated with mycorrhizal fungi further sequesters carbon in normal agricultural soils long after its application. At CDS, we call this Micro-charged Biochar™

Nurturing this symbiotic relationship with biochar is essential for long-term climate change mitigation and reversal. One of the most notable results of the shift in weather patterns has been a deluge of rain followed by drought. Not only does the biochar itself absorb more water but it also can establish and nurture the growth of mycorrhizal fungi (see image at left). Mycorrhizal fungi produce glomalin, a sticky substance that cements soil particles together, creating good tilth and passageways for air and water infiltration, allowing soils to absorb and retain more water. Then when drought follows and water become more tightly held by soil particles, it is the fungi that can send its hyphae into the smallest crevices of soil and extract and accumulate molecules of water and transport it back to the thirsty plant.

In a similar way the fungi transport nutrients back to the plant.  Fungi can use its acids to release nutrients from soils and even rocks — transforming rock minerals into formats now usable by the plant.  

Likewise there are certain nutrients that only bacteria can extract from soils and the fungi will exchange sugar for the nutrient requested by the plant in a complex symbiotic exchange. The study of this relationship has shown that soils under perennial crops that are allowed to fully develop contain more available nutrients than neighboring soils on which agricultural chemicals have been used. A study done at the University of Illinois showed that agricultural chemicals kill or reduce soil microbes resulting in the net loss of soil carbon.

The Liquid Carbon Pathway is the primary means for sequestering long-term soil carbon.  It has long been thought that most of the soil carbon was contained in the top 8 inches of the soil strata in the form of the organic matter in humus.  It is known that this carbon is liable and easily returned to the atmosphere via bacterial action. Since the discovery of glomalin in 1996 by USDA researcher, Dr. Sara Wright, large amounts of carbon have been found all the way down to 4 feet deep.  It is expected, as research goes deeper into soils, that carbon deposits from the LCP will also be scientifically verified.  

As the mycorrhizal fungi go deeper into the soil to mine nutrients and water for the plant, they deposit more and more carbon in the form of glomlin — a substance that is believed to be quite stable once it is deposited.  The more mature this relationship is between plant and microbe the more volume of soil is accessed on behalf of the plant and the bigger and more reliable is corresponding crop production.

According to research done by Dr. Christine Jones of Australia (view slideshow), pasture soils with healthy LCP associations have been increasing the amount of carbon that they sequester beneath the grasses each year. Currently, some pastures have been sequestering as much as 32 tons of CO2 per hectare/year. This makes biochar even more key to the reversal of climate change because biochar enables this vitally important process.  And in areas where all of the mycorrhizal fungi have been killed off, biochar can be inoculated to return them to full productivity.

So in terms of carbon drawdown biochar plays several important functions:

  1. Sequesters carbon draw down by the plant taking it out of the carbon cycle for centuries
  2. Increases crop production and thereby the amount of carbon drawn from the air by the increased biomass
  3. Supports the LCP for centuries so that this plant/microbe symbiosis can remove large amounts of carbon from the air year after year and deposit it in our carbon-starved soils.

More about biochar | About biochar’s many applications | How to make biochar

Tire ThermoChemical Conversion (Depolymerization) via Pyrolysis becomes mainstream practice

Over the past 2-3 years, the market has shifting from “nice idea” to proof-of-commercial viability when faced when stockpiled rubber that otherwise had no profitable and sustainable pathway. 

In Europe, 2021 saw the first-ever European Carbon Black Summit, with the joint statement of tire manufacturers, Bridgestone and Michelin committing to creating more sustainable tires. For the second annual summit in June of 2022, tire pyrolysis equipment designer and manufacturer, Klean CEO will be presenting about Recovered Carbon Black. 

This summit provides a forum for chemical companies, carbon black manufacturers, carbon black users, plastic & rubber manufacturers, masterbatch processors, and tire manufacturers to hear from the pyrolysis industry veterans, experts, and innovators who will share their perspective of the rapidly growing Recovered Carbon Black market. In addition to information sharing, the Summit reinforces the significance of the industry as a whole and the strides it is making.

“It’s a known fact that the tire industry is the single largest consumer of virgin Carbon Black and that the potential demand for Recovered Carbon Black is currently enormous.“ (Source)

Smart Tire Recycling is proud to be at the forefront of emerging technologies that produce rCB and is excited to see what new information will be shared at the summit. 

This method of turning rubber back into the elements of Carbon Black, steel and energy greatly decreases the demand for “virgin” Carbon Black by the producers. 

Various US states have begun publicizing and implementing plans to better dispose of and recycle tires. Examples:

  1. Pima County in Tucson, Arizona has started a program that allows residents to drop off up to five times per year in their recycling facilities. (Source
  2. In North Carolina, Liberty Tire Recycling is opening up a new plant to accommodate an increase in tire recycling needs. The facility will produce rubber mulch and create 30 new jobs. (Source)
  3. In Shreveport, Louisiana, a program called Waste Tire Cleanup Pilot Program has been launched to stop illegal tire dumping. The plan is to educate the local community through various programs about tire dumping and why and how it’s happening. (Source)
  4. The Tennessee Department of Environment and Conservation has launched the Tire Environmental Act Program (TEAP). The department will be awarding grants to fund projects that create or expand uses for waste tires. “Such projects include tire recycling and processing, using materials such as aggregate that are derived from tires, initiating research and development in tire management, using tires for alternative fuels or promoting innovation in infrastructure.” (Source)