This article was written by Jeffrey Jones and was published in the Globe & Mail on February 6, 2025.
Canadian-developed air-capture facility prepares for Texas launch
Kathleen Cruz Gaw is searching for the perfect recipe. She and eight technicians she oversees spend their days in the lab at Carbon Engineering’s research and development centre in Squamish, B.C., analyzing and tweaking formulas for chemical compounds used in the company’s process for extracting carbon dioxide from the sky.
It’s painstaking work that’s taken on new urgency with a US$1.3-billion direct air-capture plant using CE’s technology nearing completion in West Texas, and with a rightward political shift creating uncertainty for the future of capturing and removing CO2 from the atmosphere as a weapon in the fight against climate change.
Since construction in Texas got under way in 2023, CE’s partner, Houston-based Occidental Petroleum Corp., bought the Canadian cleantech developer in a US$1.1-billion deal. Oxy has provided CE with corporate backing and its own global network of experts to improve the technology, as well as a pledge to maintain CE’s Innovation Centre in Squamish.
“We’ve doubled the way we routinely analyze samples,” Ms. Cruz Gaw, CE’s laboratory supervisor, said.
“We do a lot of different characterizations on the internal structure of our calcium carbonate. So a lot more studies are being done to make sure that we have the right key parameters in the production,” she added, before sprinkling a little of the powdery substance into her hand during a recent tour.
Ms. Cruz Gaw also has a hand in designing a look-alike lab in Ector County, Tex., where Oxy is building the world’s largest direct air capture, or DAC, project to date, known as Stratos. The facilities will share their scientific data – much of which is kept closely guarded – in real time when the commercial plant starts up in a few months.
Stratos is due to start extracting 250,000 tonnes of CO2 per year by the end of June, using the technology CE began developing 15 years ago under the stewardship of its former chairman, David Keith. Dr. Keith is an Ottawaborn scientist who was educated at the Massachusetts Institute of Technology. His work at CE drew early backing from Bill Gates and Canadian oil and gas financier Murray Edwards.
In the next 12 months, Stratos will ramp up to full capacity of 500,000 tonnes a year, powered by renewable energy.
The project is coming to fruition in a different era than the one in which it began. With U.S. President Donald Trump back in the White House, subsidies for ventures aimed at lowering emissions, championed by former president Joe Biden, are in question.
Mr. Trump has famously called the science behind climate change a scam, and as one of his first executive orders, he pulled the United States out of the Paris climate accord for the second time. Stratos, meanwhile, is a recipient of green incentives made available under Mr. Biden’s Inflation Reduction Act.
Under the legislation, DAC projects are eligible for a tax credit of US$180 per tonne of CO2 injected into geological formations – up from a previous credit of US$50 – and Oxy has said that has been beneficial in moving Stratos forward. Mr. Trump has ordered a freeze on funds disbursed under the program, pending a review.
CE declined to comment on possible outcomes of the review and potential impact on the project. “We continue to follow recent developments in the U.S. but remain focused on advancing commercial scale DAC pathways through the ongoing technology development work in Squamish,” said Kel Coulson, CE’s director of policy.
It is part of a political backlash that environmental activists worry could sap the momentum of decarbonization – from the adoption of clean energy to electrifying transportation – in an attempt to fuel a hydrocarbon renaissance.
Critics have decried DAC, arguing it could actually be used for cover for increasing oil and gas production, and that the sheer scale of facilities needed to make a dent in atmospheric CO2 levels render it impractical.
However, Occidental chief executive officer Vicki Hollub, who presided over the acquisition of CE a year-and-a-half ago, has remained bullish on the concept and its technological improvements. When Oxy bought the company, it pledged to maintain the Innovation Centre in Squamish. The centre now has 185 employees and two-thirds work at the site, which features a miniature version of the DAC system being built in Texas to test drive the process.
Now, the operation is expanding. CE has purchased two hectares nearby in the coastal B.C. town to build more facilities. That is evidence of Oxy’s commitment to the site, said Rick Ritter, CE’s general manger.
During Oxy’s third-quarter earnings call in November, Ms. Hollub touted improvements under way as construction proceeds to plan. “Collaboration within our technical teams across Oxy, paired with insight from the CE Innovation Centre, have given rise to incredible technological breakthroughs and engineering design innovation, which we will integrate into the continued build-out of Stratos,” she told analysts.
One of those is a move to fewer front-end air-contact units, a modification she said will lower costs. Those are fans installed in long banks of towers called air contactors that pull air through plastic honeycombs moistened with a potassium hydroxide solution, which bonds to the CO2, creating a carbonate salt.
From there, the fluid flows into a reactor to separate the salt from the solution into calcium carbonate pellets. The pellets are fed into a cylinder called a calciner, where they are heated to 900 C to release the CO2 as a pure gas that can be injected underground or stored for other uses such as synthetic aviation fuel. The calcium is then rehydrated in a slaker, so it can be reused in the process.
Until recently, one of the big benefits of CE’s technology was its ability to make use of off-theshelf equipment from a number of different industries, including water treatment, pulp and paper, and oil and gas.
Oxy’s global scale and the advancement of the construction in Texas have shifted that model, said Toby Stedham, CE’s vicepresident of operations. Now, the company is moving to specially designed parts and air contactor fill – the stuff between the gas and the capture solution – for the process, improving efficiency by about 20 per cent, he said.
“That’s driving lower capital expenditures because you’re building fewer units. It’s driving lower operating expenditures because you’re operating fewer pumps, you’re operating fewer fans. So you’ve got less of an electrical demand to drive the process,” he said at the Squamish site.
To be sure, for the technology to make a dent in the carbon already released into the atmosphere, numerous plants of much grander scale would be required worldwide. Though CE’s project is currently in the lead, other players are looking to compete.
Swiss-based Climeworks AG has a two-step process to remove CO2 and inject it underground as a liquid. In 2021, the company began operating a project in Iceland called Orca that removes 4,000 tonnes of CO2 a year, and last year it started up a second project there called Mammoth, which is about 10 times larger.
Climeworks also has its sights on a DAC project in Louisiana that could eventually capture up to one million tonnes of carbon a year.
In Canada, Montreal-based startup Deep Sky Corp. is assembling a demonstration centre in central Alberta, where it is installing eight different DAC technologies to run in side-by-side tests to judge performance measures such as energy efficiency, the absence of waste byproducts and the ability to expand to commercial scale.
Occidental, under its subsidiary 1PointFive, is looking to advance a new project in south Texas that would dwarf its first one. It recently won up to US$500million from the U.S. Department of Energy’s Office of Clean Energy Demonstrations for the initial DAC facility at the site, which could increase by another US$150-million to expand a regional carbon network in the region.
Ms. Hollub said the company can keep pushing DAC forward with more technological improvement and applying lessons from Stratos into future projects. However, she also said continued government support and thirdparty capital are needed to grow the technology to “climate-relevant scale.” BlackRock Inc., the world’s largest asset manager, for instance, is investing US$550-million in Stratos.
Another key is the market for carbon credits. Last summer, Microsoft Corp. agreed to buy credits for 500,000 tonnes of carbon removal from Stratos, making it the biggest buyer. Microsoft is aiming to be carbon-negative by 2030. It joins such other players as Shopify Inc., Thermo Fisher Scientific and the NFL’s Houston Texans.
Ultimately, a move from voluntary markets, which have been slow to build credibility, to government-sanctioned ones, known as compliance markets, would boost the attractiveness of investing in the credits, Ms. Coulson said. “That is a great demand signal,” she said.
Despite North American uncertainty, other governments such as those in the United Kingdom and Japan are now taking inspiration from policies such as the IRA, and measures in Canada, including carbon-capture tax credits and a DAC incentive protocol, that are supporting development. CE hopes all that will lead to more adoption around the world, she said.