Rotating Packed Bed (RPB) technology is increasingly recognized in the field of carbon capture for its potential to broaden application scopes and significantly reduce capital expenditures by minimizing packing volume. However, the commercialization of RPB-based CO2 capture presents several challenges at the process level, including enhancing energy efficiency, refining equipment design, and achieving scalability. Given the mechanical constraints, designing excessively large RPB units may be impractical. Thus, the economic scalability of RPB-based CO2 capture under practical constraints remains an unresolved issue. This study explores the cost-optimal CO2 capture scale through rigorous process simulation using 30-70 wt% monoethanolamine (MEA) solvents. It optimizes the process design and operating parameters to minimize the specific CO2 avoidance costs, within the bounds of practical RPB design limitations. The findings suggest that a capture scale of 100–200 Tons Per Day (TPD) is cost-optimal when using 50 wt% MEA for flue gases with CO2 concentrations above 14.5 mol%. However, cost-effective RPB design becomes challenging at CO2 concentrations as low as 4 mol%. The analysis suggests that the optimal scale might increase with future advancements in RPB design technologies. Current design constraints necessitate a modular approach as the most economically viable strategy for scaling up RPB-based CO2 capture. This modularization strategy supports the wider adoption of CO2 capture technologies at small- to medium-scales, facilitating industry-wide implementation and sustainable progress by reducing initial investment and allowing for phased scaling.