Researchers at the Karlsruhe Institute of Technology (KIT) developed the NECOC (No Emissions through converting Carbon diOxide to Carbon) process. The technology converts carbon dioxide (CO₂) emissions into high-purity solid carbon. This carbon can be stored safely or reused as an industrial raw material.

After successful pilot testing, the team is preparing the first industrial application. A cast iron foundry in Baden-Württemberg, Germany, will host the initial installation. The regional government is supporting the project with €1.4 million. KIT researchers are also working with industrial partners to adapt the technology for everyday manufacturing.

The development could benefit industries with unavoidable CO₂ emissions. Instead of treating carbon dioxide as waste, manufacturers can turn it into a valuable material.

Closing Carbon Loops in Foundry Production

KIT launched the NECOC project in 2020. The original goal was to capture atmospheric and industrial CO₂ and convert it into a stable solid material. Researchers have already demonstrated the process in a test facility. The installation produces high-purity carbon powder for industrial use.

The next phase focuses on integrating the technology into existing factories. One of the first sites is a cast iron plant in Singen. The facility manufactures axle and brake components for the automotive industry.

Conventional cast iron production relies on coke as both a fuel and an essential part of the metallurgical process. As a result, the process generates unavoidable CO₂ emissions. The NECOC system captures exhaust gases from the furnace and concentrates the CO₂. It then combines the gas with hydrogen to produce methane. Next, the methane passes through molten tin. During pyrolysis, the methane splits into hydrogen and solid carbon. The process reuses the recovered hydrogen. The resulting solid carbon can replace part of the coal-based coke used in the furnace.

Flexible Energy Sources and Material Applications

Like other carbon capture and utilisation (CCU) technologies, NECOC requires energy. However, the system can work with several energy sources. KIT’s methane pyrolysis technology allows the process to use heat, electricity, hydrogen, biogas or natural gas. The Singen installation will operate with biogas or natural gas while avoiding additional emissions.

The carbon produced through NECOC could also serve other industries. Early research suggests it could work as an electrode material for batteries. Researchers are also studying its use in durable construction materials, where it may improve material performance. These applications could reduce the need for virgin carbon-based raw materials while creating additional value from captured CO₂.

Towards Circular Industrial Production

The researchers are now exploring the technology for waste incineration plants, another sector with unavoidable CO₂ emissions. By converting captured carbon dioxide into reusable carbon, NECOC supports more circular industrial processes and reduces dependence on fossil-derived raw materials.

The KIT team believes the process could help industries combine carbon capture, hydrogen technologies, gas processing and material production in one system. If the technology scales successfully, manufacturers could reduce emissions while producing valuable raw materials for new products.

Source & photo: Karlsruhe Institute of Technology