Small Coating, Big Leap: Texas Scientists Rethink Carbon Capture

A new Texas-developed coating blocks salt buildup in carbon capture systems, cutting costs and downtime

4 Apr 2025

Researchers in Texas have developed a coating designed to prevent salt build-up in carbon capture equipment, a persistent technical problem that has raised costs and reduced reliability across the industry.

The technology, created by scientists at Rice University and the University of Houston, uses a water-repelling surface treatment to stop salts and minerals from adhering to internal components as carbon dioxide is removed from industrial exhaust gases.

Salt accumulation occurs when moisture and trace minerals condense during the capture process. Over time, these deposits can clog equipment, reduce efficiency and force operators to halt systems for cleaning or replacement. The problem has been a major contributor to maintenance costs and downtime, particularly in large-scale installations.

The researchers say the new coating forms a protective barrier that prevents moisture and salt from settling. It can be applied to existing equipment and does not require changes to system design, making it suitable for retrofitting.

“With this coating, we’re addressing a problem that has quietly hindered scalability for years,” said one of the lead scientists. “It’s about unlocking reliability and making carbon capture cheaper, faster, and more durable.”

The development comes as governments and heavy industries increase investment in carbon capture to meet climate targets. While the technology is seen as essential for reducing emissions from sectors such as cement, steel and chemicals, deployment has been slower than anticipated due to technical complexity and high operating costs.

Reducing salt-related damage could improve system uptime and make capture projects more economically viable, particularly as operators move from pilot plants to continuous commercial use.

Several climate technology companies are monitoring the work. Groups such as Carbon Clean and Twelve, which focus on capturing carbon dioxide for reuse in fuels, chemicals and construction materials, rely on stable and efficient capture systems to support their business models.

The coating is still undergoing laboratory and field testing to assess its durability under prolonged industrial conditions. Researchers say further trials will determine whether it can withstand the temperatures, pressures and chemical exposure typical of large-scale operations.

If successful, the approach could remove one of the less visible but costly barriers to wider adoption of carbon capture, at a time when industry is under growing pressure to cut emissions quickly.