How heat exchangers make carbon capture work — Efficiently and sustainably

The energy efficiency dilemma in carbon capture

Though CCUS can help decarbonize major industrial emitters, it’s often perceived as energy intensive.

Key inefficiencies arise across the entire carbon capture value chain:

• Solvent regeneration demands high steam input
• CO₂ compression consumes significant electricity
• Cooling and liquefaction steps require additional energy and water

For example, increasing capture efficiency from 85% to 90% may seem like a small step — but it can lead to a much bigger increase in the amount of steam needed. That’s why making carbon capture energy efficient is so important.

Smarter carbon capture starts with smarter heat exchangers

Heat exchangers are fundamental to improving CCUS efficiency.

1. Lean/rich solvent heat recovery

In post-combustion systems, using plate-type heat exchangers (like gasketed or Packinox units) for solvent heat recovery can reduce reboiler steam consumption by up to 2.9%. This directly lowers OPEX while optimizing space and performance.

CO₂ compression cooling

In a typical 6-stage CO₂ compression system, using compact exchangers like Compabloc in interstage cooling cuts moisture by 30% and compressor power demand by 2.9% — a crucial gain for clean energy operations.

Waste heat recovery (WHR)

Capturing low-grade heat from flue gases using spiral or plate & shell exchangers can generate up to 40% of the steam required for solvent regeneration, boiler fuel use and operational costs are reduced by €3.8M per year.

Water optimization

Pre-cooling solvent and flue gas streams with high-efficiency exchangers reduces cooling water needs by 50% and make-up process water by 98% — boosting sustainability while lowering water-related costs.

The carbon capture heat exchanger portfolio

A diverse range of carbon capture heat exchangers is used in CCUS systems, including:

• Welded & Spiral Heat Exchangers – Maximum solvent cooling and heat recovery in the lean/rich interchanger
• Air & Water Surface Coolers – Maximise recovery in pre/post-capture stages
• Gasketed & Semi-Welded Plate Heat Exchangers – Exceptional Heat Transfer Resulting in low Capex and OPEX in CCUS Application.
• Plate & Shell (Ziepack) – High-pressure, high-efficiency performance
• Gas-to-Liquid & Printed Circuit Heat Exchangers – Compact, modular, and efficient

Each type plays a unique role across the CCUS journey — from capture to compression and storage.

Real results: Efficiency that pays off (PTQ report)

Refinery case studies have shown that integrating energy-efficient heat exchangers into CCUS systems delivers:

• €7.48 million/year in operational savings
• €5.12 million in capital cost reductions
• €21.5 per tonne of CO₂ decrease in capture costs

These savings accelerate the business case for CCUS and support sustainable energy solutions across multiple sectors — including green methanol, beverages, and specialty chemicals.

A cleaner future, one system at a time

To scale carbon capture across industries, we must move beyond one-size-fits-all systems. The future lies in:

• Exchangers designed for tight temperature approaches
• Modular waste heat recovery units
• Integration of multidisciplinary engineering for total system efficiency

Carbon capture heat exchangers may not make headlines, but they quietly enable clean energy systems that are efficient, scalable, and financially sustainable.

The path to decarbonization isn’t just about capturing CO₂ — it’s about doing it smarter and more sustainably. As industries across the Middle East, Africa, and beyond gear up for CCUS, optimizing thermal efficiency with the right heat transfer solutions will be key.

For companies ready to act, the question isn’t if carbon capture will play a role — it’s how efficiently they can make it work.