Why mechanical seals are critical for supporting carbon capture, utilisation and storage (CCUS)

Carbon capture can quickly decarbonise industrial operations using proven technology, with the added benefit of providing captured carbon dioxide for applications such as food and beverage.

Beyond being an effective strategy for curbing emissions across hard-to-abate sectors, CCUS can also enable low-carbon hydrogen production and remove existing carbon dioxide from the air.

The International Energy Agency (IEA) estimates that carbon capture solutions could contribute approximately 9% of the world’s total carbon dioxide reduction under its Sustainable Development Scenario. To achieve this target, progress must be accelerated. However, expanding the CCUS value chain is a complex task that requires operators to not only handle supercritical fluids safely and reliably but also to capture carbon — including fugitive emissions — while maintaining peak operational efficiency and ensuring the longevity of their equipment. Mechanical seals are vital components that can help operators overcome each of these challenges.

Mapping the CCUS landscape

After decades of slow progress, carbon capture has gained momentum across the energy and process sectors. Today, many commercial CCUS facilities operate worldwide, with numerous projects at various development stages. Developers have committed to launching more CCUS initiatives by the end of the decade, which are expected to capture a total of 125Mt of carbon dioxide annually, according to IEA estimates. However, less than half of these projects have reached a final investment decision. Even if all succeed, the IEA estimates our progress in carbon capture will still fall short of what's necessary to meet its Net Zero Emissions by 2050 Scenario.

To speed up progress, many countries are prioritising CCUS as a policy focus. This includes the US, where the 2021 Infrastructure Investment and Jobs Act and the 2022 Inflation Reduction Act provide funding and tax credits for carbon capture projects. The U.K. has also increased funding for CCUS initiatives, and the European Union’s Net Zero Industry Act has simplified carbon capture permitting processes across the union. Although these financial incentives are encouraging, the IEA highlights the need for more coordinated efforts, such as setting regional or national CCUS targets, implementing carbon pricing systems, and increasing R&D funding to lower carbon capture costs for more complex applications. This supportive policy environment must be complemented by innovative technologies that ensure the CCUS value chain can safely and reliably achieve net zero goals.

Latest technological innovations in CCUS

Recent and emerging carbon capture innovations include:

• Modular systems: These fit-for-purpose systems have the potential to accelerate CCUS progress and expand adoption.
• Systems with high capture rates: As University of Delaware researchers have illustrated, novel technologies have the potential to deliver capture rates as high as 99% — a significant improvement over current solutions offering a maximum 90% capture rate.

While these advancements are critical to CCUS progress, the importance of reliable, safe transport and storage infrastructure cannot be understated. According to the IEA, an imbalance between storage demand and supply could become a “bottleneck” to CCUS deployment.

John Crane has been at the forefront of CCUS innovation since installing the first dry gas seal in a carbon capture facility in 1996. And we are investing in new carbon dioxide sealing technologies — including next-generation sealing for supercritical carbon dioxide — to support safe, reliable transportation and storage. As we develop the sealing solutions of the future, we are also delivering measurable progress today through mechanical sealing innovations that address critical CCUS challenges.

How mechanical seals solve key CCUS challenges

Mechanical seals serve as robust barriers between moving parts in machinery, ensuring a sealed environment that prevents leakage while enhancing reliability and safety. They have proven their effectiveness across numerous mission-critical sectors for which CCUS is a viable path to decarbonisation, including:

• Natural gas coupling: Facilitating natural gas's safe and efficient transport and coupling
• Power generation: Ensuring the smooth functioning of turbines and other machinery critical to energy production
• Ammonia and urea production: Safeguarding the production process against leaks and ensuring product purity
• Hydrogen production and distribution: Aiding in safe hydrogen transport, production and distribution of hydrogen
• Power generation: Enhancing the longevity of machinery and reducing maintenance downtime

John Crane has been at the forefront of CCUS innovation since obtaining the patent for dry gas seal spiral groove technology in 1968. Our robust portfolio of dry gas seals, high-performance couplings and gas systems plays a crucial role in advancing carbon dioxide capture, transport and storage at an impressive scale. By addressing the unique challenges of CCUS, our technologies play a pivotal role in shaping a future in which CCUS initiatives unlock peak sustainability and reliability.

The value of a trusted partner for CCUS mechanical seals

In the rapidly developing CCUS landscape, partnering with the right sealing solutions provider is essential. With the largest global installed base of dry gas seals for carbon dioxide sequestration and EOR, and carbon dioxide pipeline pumping, John Crane is a market leader. Our technologies are used in the majority of sites where carbon dioxide is injected underground, across every stage of the CCUS value chain - in liquid, gaseous and supercritical phases. We combine our technologies with services that help operators achieve peak sustainability and reliability.

As the CCUS landscape continues to mature, these technologies will become increasingly sophisticated — and critical to our industry’s future. John Crane is committed to pioneering progress through mechanical seal technologies that safely handle supercritical carbon dioxide, extend the lifespan of rotating equipment and unlock peak operational efficiency in even the most hard-to-abate sectors. Contact our experts today to explore how our CCUS innovations can help you achieve your sustainability goals.