Carbon Capture And Utilization Research Articles

Molten-salt-mediated Chemical Looping Oxidative Dehydrogenation of Ethane with In-situ Carbon Capture and Utilization.

The molten-salt-mediated oxidative dehydrogenation (MM-ODH) of ethane (C2H6) via a chemical looping scheme represents an effective carbon capture and utilization (CCU) method for the valorization of ethane-rich shale gas and concurrent mitigation of carbon dioxide (CO2) emissions. Here, stepwise experimentation with Li2CO3-Na2CO3-K2CO3 (LNK) ternary salts (i) assessed how each component of the LNK mixture impacted ethane MM-ODH performance and (ii) explored physicochemical and thermodynamic mechanisms behind melt-induced changes to ethylene (C2H4) and carbon monoxide (CO) yields. Of fifteen screened LNK compositions, nine exhibited ethylene yields greater than 50% at 800°C while maintaining C2H4 selectivities of 85% or higher. LNK salts rich in Li2CO3 content yielded more ethylene and CO on average than their counterparts, and net CO2 capture per cycle reached a maximum of ~75%. Extended MM-ODH cycling also demonstrated long-term stability of a high-performing LNK medium. Density functional theory (DFT) calculations and ab initio molecular dynamics (AIMD) simulations suggested that the molten salt does not directly activate C2H6. Meanwhile, an empirical model informed by experimental data and reaction thermodynamics adequately predicted overall MM-ODH performance from LNK composition and provided insights into the system's primary drivers.

Investigating proton shuttling and electrochemical mechanisms of amines in integrated CO2 capture and utilization

Carbon capture and utilization (CCU) technologies present a promising solution for converting CO2 emissions into valuable products. Here we show how amines, such as monoethanolamine (MEA) and 2-amino-2-methyl-1-propanol (AMP), influence the electrochemical CO2 reduction process in an integrated CCU system. Using in situ spectroscopic techniques, we identify the key roles of carbamate bond strength, proton shuttling, and amine structure in dictating reaction pathways on copper (Cu) and lead (Pb) electrodes. Our findings demonstrate that on Cu electrodes, surface blockage by ammonium species impedes CO₂ reduction, whereas on Pb electrodes, proton shuttling enhances the production of hydrocarbon products. This study provides additional insights into optimizing CCU systems by tailoring the choice of amines and electrode materials, advancing the selective conversion of CO₂ into valuable chemicals.

Computational design for enantioselective CO2 capture: asymmetric frustrated Lewis pairs in epoxide transformations.

Carbon capture and utilisation (CCU) technologies offer a compelling strategy to mitigate rising atmospheric carbon dioxide levels. Despite extensive research on the CO2 insertion into epoxides to form cyclic carbonates, the stereochemical implications of this reaction have been largely overlooked, despite the prevalence of racemic epoxide solutions. This study introduces an in silico approach to design asymmetric frustrated Lewis pairs (FLPs) aimed at controlling reaction stereochemistry. Four FLP scaffolds, incorporating diverse Lewis acids (LA), Lewis bases (LB), and substituents, were assessed via volcano plot analysis to identify the most promising catalysts. By strategically modifying LB substituents to induce asymmetry, a stereoselective catalytic scaffold was developed, favouring one enantiomer from both epoxide enantiomers. This work advances the in silico design of FLPs, highlighting their potential as asymmetric CCU catalysts with implications for optimising catalyst efficiency and selectivity in sustainable chemistry applications.

A Carbon Capture and Utilization Process for the Production of Solid Carbon Materials from Atmospheric CO2 - Part 2: Carbon Characterization.

This article is the second part of a study reporting the results of a novel carbon capture and utilization (CCU) process, which converts atmospheric CO2 into solid carbon materials. The CCU process combines direct air capture (DAC) with catalytic methanation, which is then followed by methane pyrolysis in a reactor filled with liquid tin. While Part 1 discussed the performance of the overall process and individual process steps regarding conversions and yields, Part 2 characterizes the solid carbon products obtained under various synthesis conditions. The effects of the pyrolysis temperature and the composition of the gas mixture from the methanation step on the solid carbon product are analyzed. Carbon powder is synthesized from methane with either H2 or CO2 as most important impurity. Carbon samples are characterized using SEM, TEM, Raman spectroscopy, XPS and XRD analysis. Very thin, disordered carbon flakes, soot aggregates and large carbon onions are identified as the main solid products of the process. Their formation mechanisms in the liquid metal-filled pyrolysis reactor are discussed.

Highly dispersed Ni-Ce catalyst over clay montmorillonite K10 in low-temperature CO2 methanation

The Carbon Capture and Utilization (CCU) option can be an efficient solution for CO2 emission mitigation. To this end, we have investigated the carbon dioxide methanation at low temperatures. Highly active, selective, stable, low-cost catalysts are required for energy and carbon balance benefits. Supported nickel-based catalysts result as the most studied and promising candidates showing a good compromise between performance and low preparation costs. The catalyst design role is key to obtaining the best performance, requiring many experiments and optimisation procedures. Herein, the enhanced Montmorillonite MK10-supported Ni(0)Ce(III) catalyst, prepared by consecutive hydrothermal and electrostatic adsorption methods followed by reduction under hydrogen flow, was used in batch CO2 methanation, exhibiting 76 % of CO2 conversion with 100 % CH4 selectivity after 3 h. The catalytic system reveals very high robustness preserving the same activity and selectivity for at least 5 reaction cycles if compared with γ-Al2O3-supported Ni(0)Ce(III) catalyst, the latter showing the same activity but only in the first cycle. EDX, XPS, SEM, TPD, TPR, and BET characterisation techniques were used to elucidate and evaluate the potential synergistic effect of the active metal centre-promoter-support interfaces, highlighting their role in the activity and robustness of the catalyst, comparing the same effect using different alumina and silicate solid supports. The effects of the reaction conditions on the methane yield and selectivity were also evaluated.

Can't see the carbon for the CO2? Regulating CCU value chains under and beyond climate law

AbstractTo realise the objectives of the European Green Deal (EGD), fossil carbon will have to be not only reduced but also replaced with recycled carbon. The European Commission considers industrial carbon management and carbon capture and utilisation (CCU) technologies to be part of the solution. A value chain ensues when carbon dioxide (CO2) is captured and utilised as raw material. Examination of the climate, energy and environmental legal landscape of one specific CCU value chain—comprising of waste, waste incineration and plastic raw material—reveals the varied approaches regulation has towards CO2 and carbon. In this article, both carbon cycle legislation and legislation on the carbon source and the material storing carbon are analysed. The legislation being developed directly for CCU for products (other than synthetic fuels) focusses on the carbon cycle and CO2 under the EU emissions trading system (ETS) and a proposed Carbon Removal Certification Framework. Regulatory uncertainty remains for the studied CCU value chain as the capture of CO2 from waste incineration has yet to be incentivised under the EU ETS. Further, the criteria for the permanence of carbon storage in products to qualify under the EU ETS and of the long‐term storage under the Carbon Removal Certification Framework (CRCF) have yet to be developed. For a more complete understanding, we have also analysed waste and product regulations. The conceptual structure of the EU Waste Framework Directive does not seem to support circulating carbon. This context also raises the fundamental question of whether the purpose of waste incineration could be carbon recycling instead of mere energy production. Regarding material storing carbon, plastics, the regulator has been silent as CCU‐originated plastic raw material is not recognised in EU plastics law. These issues must be identified and resolved one by one before the EGD can be secured; revisiting only climate law instruments does not suffice.

Advancements in Green Chemical Engineering: Developing Sustainable Catalysts for Carbon Capture and Utilization

The development of sustainable catalysts for carbon capture and utilization (CCU) represents a pivotal advancement in green chemical engineering, addressing both climate change and resource scarcity. This study utilizes a qualitative approach, specifically employing literature review and library research methods, to analyze recent advancements in catalyst development for CCU technologies. The analysis highlights the growing emphasis on designing catalysts that are not only efficient but also eco-friendly, with a focus on minimizing environmental impact. By examining various catalytic processes, including chemical absorption, photocatalysis, and electrochemical reduction, this research identifies key strategies for enhancing the effectiveness and sustainability of CCU systems. The findings reveal that while significant progress has been made in improving catalyst performance, challenges remain in scaling up these technologies for industrial applications. Moreover, this study underscores the role of green chemical engineering in fostering a circular economy by converting captured carbon dioxide into valuable products such as fuels and chemicals. Future research should focus on overcoming existing limitations, including catalyst stability and cost-effectiveness, to ensure broader adoption of sustainable CCU technologies. This review contributes to the growing body of knowledge on sustainable chemical processes and offers a roadmap for advancing green engineering practices.

Advancing syngas production: A comparative techno-economic analysis of ICCU and CCU technologies for CO2 emission reduction

The Paris Agreement stresses the need to cut CO2 emissions, a global priority. Innovative methods like carbon capture and utilization (CCU) aim to limit the temperature increase to 1.5 °C by 2100. Traditional CCU involves separate CO2 collection and purification steps, while integrated carbon capture and utilization (ICCU) streamlines the process by capturing CO2 using CaO adsorbents and using it with CH4 on-site to produce syngas. ICCU reduces CO2 conversion costs by eliminating intermediaries, potentially resulting in lower operational costs than traditional CCU. This study employs the Aspen Plus model to evaluate ICCU and CCU processes, analyzing parameters such as CaCO3 consumption, purge production, annual CO and H2 production, energy balance, total annual costs, and CO production costs. Results show that ICCU generates 1.39 million tons of CO annually, with lower CH4 and CaCO3 consumption along with improved energy efficiency at 46.75% compared to CCU for 42.49%. ICCU incurs an annual capital outlay of $554.92 million with $396.94/ton of CO, while CCU costs M$853.10/year with $325.11/ton of CO. Notably, ICCU reduces costs of CO2 avoidance to $380.44/ton compared to $513.59/ton for CCU. These findings highlight ICCU as a more efficient and cost-effective approach to reducing CO2 emissions, aligning with the Paris Agreement goals and providing insights for future deployment and regulatory considerations. The use of Aspen Plus simulation software has been instrumental in facilitating the analysis, modeling, and validation of these conclusions.

Transforming waste to wealth: Harnessing carbon dioxide for sustainable solutions

The escalating levels of carbon dioxide (CO₂) emissions present a critical challenge to global sustainability, considering that CO2 is the primary cause of climate change. This dilemma presents a unique opportunity: converting waste CO₂ into useful resources. This review provides an in-depth analysis of CO₂ sources and waste streams, examining their potential as feedstocks for various industrial processes. By reviewing cutting-edge conversion technologies—such as catalysis, electrochemical, and photochemical methods—this work emphasizes how revolutionary ideas in Carbon Capture and Utilization (CCU) can play a pivotal role in reducing greenhouse gas emissions while generating both environmental and economic advantages. Through a systematic review of case studies and success stories in Carbon Capture and Utilization (CCU), the review illustrates the practical viability of these technologies. Additionally, the challenges facing CCU implementation, including economic, technical, and policy-related barriers, are explored. The review fills a critical gap by providing a comprehensive overview of both the current state and future potential of CO₂ utilization. Finally, it outlines future directions, emphasizing the need for interdisciplinary approaches, policy frameworks, and technological advancements to fully realize the potential of harnessing CO₂ for sustainable solutions.

A novel framework for the economic and sustainability assessment of carbon capture and utilization technologies

This study presents a novel framework for assessing early-stage carbon capture and utilization (CCU) reactions. The introduced greenhouse gas abatement, sustainability, and economics framework (GASEF) assesses commercial viability by simultaneously analyzing a CCU technology's CO2 fixation potential with its economic potential. The developed framework combines a previously published CO2Fix parameter and the metric for inspecting reactants and sales (MISR) to estimate CO2 fixation and economic potentials. Both metrics can be estimated using limited information such as temperature, pressure, conversion, molecular weights, the heat of reaction, and the prices of the reactants and products of the CCU reaction. Results from this novel framework are demonstrated via case studies of notable CCU technologies, such as Dry Reforming of Methane and CO2 hydrogenation to methanol processes. Furthermore, the possible implications of providing CO2 subsidies for CCU processes for the gross CO2 input into these processes versus providing CO2 subsidies for the net CO2 fixation of the process is evaluated. In particular, the GASEF assessment on the DRM process showcased a potential for commercial viability even when the technology implementation requires additional investment of 0.1 $/kgCO2 (pertaining to low-concentration CO2 streams) due to carbon capture and sequestration efforts to achieve net-zero emissions. In the case of CO2 hydrogenation to methanol process, the GASEF assessment showcased the potential for commercial viability only at low CO2 credit (0.05 $/kgCO2); however, at values higher than this, the process becomes tenuous. These case studies provide a comprehensive demonstration of the use of the GASEF as a versatile tool to support rapid economics and sustainability evaluation of the new CCU technologies.

The microbiome of bioreactors containing mass-cultivated marine diatoms for industrial carbon capture and utilization

Marine microalgae are a promising innovation platform for carbon capture and utilization (CCU) biotechnologies to mitigate industrial greenhouse gas emissions. However, industrial-scale cultivation of algal mono-cultures is challenging and often unscalable. Non-axenic microalgae in large semi-open photobioreactors lead to the co-cultivation of diverse microbial communities. There is limited knowledge about the “bioreactor ecology” involving microalgae interacting with the microbiome and its subsequent impact on process stability and productivity. In this study, we describe the semi-continuous industrial mass cultivation of the cold-adapted marine diatom, Porosira glacialis UiT201, by investigating the prokaryotic and microeukaryotic (phytoplankton and heterotrophic protist) communities. Data were collected in two consecutive time series experiments, representing the initiation and operation of an industrial-scale CCU photobioreactor (300,000 L). The first experiment experienced a culture “crash” of the focal strain after 39 days, while the second culture remained stable and “healthy” for 60 days. The results highlight that this mass cultivation system represents a unique industrial marine microbial ecosystem. The succession of the prokaryotic community was primarily driven by species replacement, indicating turnover due to selective bioreactor conditions and/or biological interactions. Nonetheless, the bioreactor consistently harbors a recurring and abundant core microbiome, suggesting that the closely associated bacterial community is influenced by microalgae-specific properties and can endure a dynamic and variable environment. The observed culture collapse of P. glacialis coincided with changes in the core microbiome structure and different environmental growth conditions compared to the stable and “healthy” experiment. These findings imply that cohabiting microbial taxa within industrial microalgae cultivation likely play a critical role in stabilizing the conversion of industrial CO2 into marine biomass, and changes in community structure serve as an indicator of process stability.

Mechanism investigation of direct electrochemical reduction of CO2-loaded 2-(ethylamino)ethanol solution into CO

Carbon capture and utilization (CCU) has attracted considerable interest recently as CO2 emission and global warming have greatly affected various aspects of the environment, economy, and society. However, energy consumption during CCU must be substantially reduced. In this study, we propose an alternative approach using electrochemical reduction to directly convert CO2-loaded amine solutions into CO. The effects of the electrodes, temperature, potential, and CO2 loading on the Faradaic efficiency (FE) of CO were comprehensively investigated. The Ag NPs/CP electrode showed good catalytic performance on the electrochemical reduction of CO2-loaded amine solution to CO. By comparing the chemical composition in the solution before and after the electrochemical reaction, we determined that the main source of CO might be free CO2, which is mainly converted from bicarbonate rather than carbamate. In addition, electrochemical impedance spectroscopy was used to investigate the resistance during the reaction. The electric double-layer was found over the electrode surface when different amine solutions were used as the electrolyte. The spatial structure of ammonium cations and carbamate plays a key role in the FE of CO in this process.

Delicate control of a gold-copper oxide tandem structure enables the efficient production of high-value chemicals by electrochemical carbon dioxide reduction

The electrochemical carbon dioxide reduction reaction (CO2RR) has substantial potential for carbon capture and utilization (CCU), aiming to produce carbon-neutral fuels and valuable chemical feedstocks. Copper (Cu) is recognized as the primary metal catalyst capable of facilitating C-C coupling and producing multi-carbon compounds. The tandem catalyst approach, particularly the oxide-derived Cu (OD-Cu)-based tandem catalyst, has been reported to improve the selectivity for multicarbon compounds such as ethylene and ethanol. However, the impact of the loading structure of the CO-producing catalyst in the tandem catalyst on CO2RR performance has not been thoroughly investigated. In this study, we developed Au nanoparticles with different sizes and loading densities on Cu2O and investigated their CO2RR properties. Tandem catalysts featuring smaller Au nanoparticles exhibited increased activity in the electrochemical CO2RR, resulting in an anodic shift in the potential. Improved Faradaic efficiencies (FEs) and partial current densities (PCDs) of C2+ were also observed for tandem catalysts with smaller Au nanoparticles. Remarkably, the FE and PCD of n-propanol increased as the coverage of Au nanoparticles increased, in contrast to those of C2 products such as ethylene and ethanol. The effectiveness of the tandem effect depends on the increase in local CO concentration facilitated by the CO-generating catalyst on the confined OD-Cu surface. Our research presents a strategy for constructing a productive tandem structure for the CO2RR.

Hydrogen liquefaction process using carbon dioxide as a pre-coolant for carbon capture and utilization

With the increasing demand for hydrogen (H2), producing liquefied H2 with a high energy density (10.1 MJ/L) has become essential. Research on the H2 liquefaction process, specifically, the effects of various refrigerants and cooling cycles has been conducted. Yet, large-scale use of carbon dioxide (CO2) in H2 liquefaction hasn't been achieved. In this study, a cooling cycle that uses captured CO2 as a refrigerant in large quantities was selected for a 100 tpd H2 liquefaction process. Optimization minimized the specific energy consumption (SEC), leading to SEC of 7.3 kWh/kgLH2, a coefficient of performance of 0.17, a figure of merit of 0.33, a specific exergy efficiency (SEE) of 33 %, and an overall exergy efficiency of 82.2 %. Performance indicators were compared with other processes, showing that the SEC and SEE were improved by 43 % and 50 % compared to commercial processes and by 4 % and 6 % compared to previous studies using CO2. This study used 5.7 times more CO2 at the same capacity, utilizing 47.8 Mt of CO2, representing 14 % of the CO2 utilization amount of the total carbon capture and utilization (CCU) project. Thus, the results should facilitate the development of hydrogen liquefaction processes for use in CCU applications in the future.

Rotating cylinder electrode in reactive CO2 capture: Identifying active C species via transport, VLE models and kinetics

AbstractThis article explores technical challenges and potential methodologies for understanding electrochemical Reactive CO Capture (RCC) mechanisms. RCC offers potential energy cost advantages by directly converting captured CO into fuels and chemicals, unlike traditional carbon capture and utilization (CCU) processes that require sequential capture, concentration, and compression. However, direct conversion of captured CO introduces complexity due to additional equilibrium buffer reactions, making it challenging to identify active species for reduction in electrochemical studies. This article discusses methods to integrate transport, thermodynamics, and kinetics concepts to identify active carbon sources in RCC. Vapor‐Liquid Equilibrium (VLE) and transport models are validated against experimental results obtained in a gastight rotating cylinder electrode reactor and are shown as useful tools for studying RCC in heterogeneous electrocatalysts across different capture agents, solvents, and temperatures. This article establishes an experimental framework for advancing research in electrochemical RCC.

Hierarchically porous carbon foams coated with carbon nitride: Insights into adsorbents for pre-combustion and post-combustion CO2 separation

Adsorption is fundamental to many industrial processes, including separation of carbon dioxide from other gases in pre- or post-combustion gas mixtures. Adsorbents should have high capacity and selectivity, which are both intimately linked with surface area, pore size distribution, and surface energy. Porous carbons are cheap and scalable adsorbents, but greater understanding of how their textural properties and surface chemistry affects their performance is needed. Here, we investigate the effect of nitrogen doping on CO2 adsorption. Microporous carbon foams with large surface area (>2500 m2 g−1) and pore volume (1.6 cm3 g−1) are synthesized, then coated with varying amounts of carbon nitride (up to 17 at% nitrogen) to achieve high CO2 uptake (25.5 mmol g−1) and selectivity (CO2:N2 = 21), whilst also giving insights into the relationship between structure and function. At low pressure (relevant to post-combustion capture), moderate carbon nitride loading leads to enhanced uptake and selectivity by combining large ultramicropore volume with the introduction of Lewis base sites, leading to high isosteric heat of adsorption. Higher carbon nitride loading further increases selectivity but lowers uptake by blocking micropores. Conversely, at high pressure (relevant to pre-combustion capture) the uncoated carbon foam displays superior uptake, because mesoporosity is the dominant factor in this regime, rather than the presence of ultramicropores. Finally, the samples displayed excellent regeneration under repeated adsorption–desorption cycles, and breakthrough curves were measured. These results underscore the delicate balance required for optimal material design when applying porous carbon adsorbents to CO2 separation processes. Moving forward, improved adsorbents will contribute to the proliferation of carbon capture and storage (CCS) and carbon capture and utilisation (CCU) technologies, ultimately contributing reduced anthropogenic CO2 emissions.

The politics of carbon management in Austria: Emerging fault lines on carbon capture, storage, utilization and removal

With the proliferation of net zero targets in climate policy and corporate climate governance, the question of how to deal with greenhouse gas emissions considered hard-to-abate is attracting growing attention. In this context, the notion of carbon management has emerged on the political agenda – an umbrella term typically encompassing carbon capture and storage (CCS), carbon capture and utilization (CCU) and carbon dioxide removal (CDR). Here, we investigate the emerging politics around the design of a national carbon management strategy in Austria, a country which can be considered a yet understudied latecomer regarding CCS and novel CDR methods including BECCS and DACCS. Based on expert interviews with policy actors as well as qualitative document analysis, we identify four actor coalitions as well as key fault lines. These fault lines specifically relate to a) whether the CCS ban in Austria should be lifted, and b) which economic sectors get access to carbon storage and transport infrastructure as well as subsidy schemes (selective vs. unrestricted integration). We also find that framing CCS, CCU and CDR under the umbrella term carbon management produces specific coalitional effects while simultaneously concealing contested climate policy choices – a finding with wider implications beyond the Austrian case.

Effect of in situ CO2 mixing of cement paste on the leachability of hexavalent chromium (Cr(VI))

In situ CO2 mixing technology is a potential technology for permanently sequestering CO2 during concrete manufacturing processes. Although it has been approved as a promising carbon capture and utilisation (CCU) method, its effect on the leachability of heavy metals from cementitious compounds has not yet been studied. This study focuses on the effect of in situ CO2 mixing of cement paste on the leaching of hexavalent chromium (Cr(VI)). The tank leaching test of the CO2 mixing cement specimen resulted in a Cr(VI) cumulative leaching of 0.614 mg/m2 in 28 d, which is ten times lower than that of the control mixing specimens. The results in thermogravimetric analysis indicated that a relatively significant amount of CrO42− is immobilised as CaCrO4 during the CO2-mixing, and a higher Cr–O extension is observed in the Fourier transform infrared spectra. Furthermore, a portion of the monocarboaluminate is inferred from microstructural analyses to incorporate CrO42− ions. These results demonstrate that in situ CO2 mixing is beneficial not only in reducing CO2 emissions, but also in controlling the leaching of toxic substances.

Carbon Capture and Utilization Projects Run by Oil and Gas Companies: A Case Study from Russia

As oil and gas companies are one of the major greenhouse gas emitters, they face increasing responsibility to address climate challenges. This highlights the necessity of integrating decarbonization options into their operations to meet global climate objectives. While progress in technologies for capturing, utilizing, and storing CO2 (CCUS technologies) is often attributed to oil and gas companies, CCUS projects in the sector predominantly focus on carbon storage, namely CO2 injection for enhanced oil recovery, which presents limited possibilities. Meanwhile, carbon capture and utilization (CCU) technologies offer a promising avenue for producing valuable products from CO2, a potential that has been underexplored in theory and practice within the oil and gas sector. This study analyzes the development of the full CCU cycle by oil and gas companies, assessing the economic viability of such projects. It includes a content analysis of research materials on CCU deployment and a case study modeling the economic viability of producing methanol from CO2 in Russia. The findings indicate that the estimated minimum price for CO2-based methanol to achieve project payback is USD 1128 per ton, compared to approximately USD 400 per ton for traditional methanol. This price gap underscores the need to foster the development of low-carbon technologies, markets, and measures to support these projects. In the domain of CCU projects, cost-reduction measures could be more applicable, while regulatory measures, such as carbon taxes, currently have a limited impact on the economic viability of these projects.

Carbon capture and utilisation (CCU) solutions: Assessing environmental, economic, and social impacts using a new integrated methodology

Carbon Capture and Utilisation (CCU) technologies play a significant role in climate change mitigation, as these platforms aim to capture and convert CO2 that would be otherwise emitted into the atmosphere. Effective and economically sustainable technologies are crucial to support the transition to renewable and low-carbon energy sources by 2030 and beyond.Currently, studies exploring the financial viability of CCU technologies besides the joint analyses of life-cycle costs and environmental and social impacts are still limited.In this context, the study developed and validated an innovative and integrated methodology, called Life Cycle Cost and Sustainability Assessment (LCC-SA) which allows the joint assessment of (i) project life-cycle costs, (ii) socio-cultural and environmental externalities. This tool was validated with an application to an algal photobioreactors (PBRs) and allowed to assess the economic and environmental sustainability besides identifying the main critical issues to be addressed during the transition from pilot-scale plant to industrial application.The methodology's implementation estimated benefits in two main areas: (i) environmental, including CO2 removal and avoidance through biodiesel production instead of fossil-derived diesel; (ii) socio-cultural, encompassing new patents, knowledge spillovers, human capital formation, and knowledge outputs. The analysis returned as main result that the present value of the social externalities amounts to around EUR 550,000 and the present value of the costs to approximately EUR 60,000. The Economic Net Present Value (ENPV) is EUR 487,394, which shows the significance of the extra-financial effects generated by the research project. At full-scale application, environmental benefits include capturing 187 to 1867 tons of CO2 per year and avoiding 1.7 to 16.7 tons of CO2 annually through biodiesel production instead of fossil-derived diesel.