Solvent-Free Manufacturing of Electrified Structured Sorbents for Scalable Direct Air Capture

Direct air capture (DAC) of CO2 is an irreplaceable carbon removal technology, but its gigatonscale deployment requires the continuous manufacturing of highly efficient structured sorbent. Conventional solvent-based manufacturing fundamentally limits active material loading and imposes massive energy and environmental penalties, undermining the net-negative emissions goal of DAC. Here, we report a universal, solvent-free dry fabrication platform to continuously manufacture electrified structured sorbents with an unprecedented 97wt% active material loading. By exploiting the shear-induced fibrillation of polymer binders, we process diverse sorbent powders, including zeolites, mesoporous silicas, and metal-organic frameworks, into self-supporting flexible films. Lamination of these films onto conductive graphite creates an architecture capable of rapid, spatially homogeneous Joule heating. Assembled into a lowpressure-drop spiral-would module, an electrically driven temperature vacuum swing adsorption (e-TVSA) system delivers an exceptional volumetric productivity of 73.5 kgCO2/m 3 /day and maintains robust cyclic stability under realistic humid conditions. Supported by techno-economic analysis projecting a competitive levelized cost of $380 per tonne of CO2, this scalable, chemistry-agnostic manufacturing paradigm bridges the critical gap between bench-scale material discovery and industrially viable, gigaton-scale carbon removal.