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Post-Combustion Carbon Capture for Industrial Facilities

Realize the benefits of an integrated control architecture for carbon capture facilities.

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As the global imperative for decarbonization intensifies, post-combustion carbon capture emerges as a critical technology for decarbonizing not only power generation but also difficult-to-abate industrial sectors such as cement and steel production. However, implementing carbon capture at scale introduces significant technical, operational, and economic challenges.

These challenges include managing highly energy-intensive absorption and regeneration cycles, maintaining stable process performance under variable flue gas conditions, coordinating large electrical loads with the facility’s broader power system, and ensuring safe operation in environments that involve thermal swings, corrosive materials, and high-pressure equipment. Organizations also face escalating operating costs, complex solvent management, and the need for reliable data to support emissions reporting and regulatory compliance. An Integrated Architecture where process control, power management, safety, and analytics are unified offers a compelling solution to these challenges, enabling safer, more efficient, and cost-effective carbon capture operations.

Why Integrated Architecture Can Be Your One Plant-Wide Control System
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Why Integrated Architecture Can Be Your One Plant-Wide Control System
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Providing a holistic approach to control, design, cybersecurity and more.
Date:
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Duration: 60 Minutes
Language: English

Optimize Budget-Spend and Deliver Projects Swiftly

Reduce Capital and Design Costs: A unified environment for Controls, HMI, and alarms, combined with object-oriented programming and pre-built templates, reduces engineering effort and design inconsistencies. Simulation and emulation validate designs before deployment, minimizing project risks and costly rework.

For electrical distribution and motor management, a seamless architecture that unifies process and power systems streamlines project execution and commissioning, resulting in substantial time and resource savings.

Seamless Integration with Existing Infrastructure: Post-combustion carbon capture plants must interface with legacy power or industrial plant systems. Integrated Architecture® enables smooth connectivity between new carbon capture units and existing assets, minimizing disruption and leveraging current investments. Unified platforms support modular plant and skid integration, allowing new process skids to be incorporated into the plant’s production system with consistent HMI and alarm structures.

Reducing Risk and Facilitating Compliance while Boosting Reliability

People and Process Safety: Safety at every level. Key functions - including compressor surge prevention, system redundancy, emergency shutdown capabilities, and interface with fire and gas systems - are inherent to the overall design. Safety instrumented systems (SIS) certified to SIL 2 and SIL 3 standards deliver comprehensive protection, while centralized alarm management confirms that critical events are quickly detected and addressed.

Regulatory Compliance and Reporting: Environmental regulations require accurate tracking of CO₂ capture rates, emissions reductions, and other performance metrics. Integrated process control systems automate data collection, reporting, and compliance management, reducing manual effort and the risk of errors. Embedded analytics and KPI dashboards provide real-time insights for both on-premises and cloud deployments.

Cybersecurity by Design: Modern designs align with industrial cybersecurity standards (e.g., IEC 62443-3-3), featuring user authentication, network segmentation, secure remote access, data encryption, intrusion detection, audit trails, and patch management. This robust security posture helps protect critical infrastructure from evolving threats.

Industrial OT Cybersecurity – Rockwell Automation SecureOT
 Industrial OT Cybersecurity – Rockwell Automation SecureOT
Industrial OT Cybersecurity – Rockwell Automation SecureOT
SecureOT combines OT‑nativedesigned software, expert services, and global scale to reduce risk, improve uptime, and simplify compliance for industrial operations.

Achieve Operational Excellence - Operations and Maintenance efficiency

Enhanced Visibility and Decision-Making: Operators benefit from rich diagnostic data and situational awareness-based HMI, providing a clear, comprehensive view of system status. This enables faster, more informed decision-making and proactive maintenance. Unified integration with intelligent electronic devices (IEDs) and motor control delivers seamless data exchange, improving reliability and safety for critical power systems.

Process Optimization and Flexibility: Fluctuating flue gas composition, high energy requirements, and solvent management remain persistent challenges in post-combustion carbon capture systems. Integrated solutions now incorporate advanced process optimization tools, including dynamic optimization of the absorber, stripper, and solvent regeneration stages. These tools are designed to handle the non-linear dynamics and complex variable interactions inherent in carbon capture processes, enabling stable and efficient operation even under changing process conditions

PlantPAx Distributed Control System
PlantPAx Distributed Control System
PlantPAx Distributed Control System
Solve industry challenges throughout the plant lifecycle with a modern DCS.

Maintenance Efficacy: Unified access to diagnostic data and system health information, enabling predictive maintenance, faster troubleshooting, and reduced downtime. This streamlined approach helps maintenance teams address issues proactively and maintain optimal system performance with less effort.

Improved Energy Management and Efficiency: Integrated energy management applications provide granular data on energy consumption at the plant, process area, and equipment levels. This enables precise monitoring and optimization strategies, supporting both cost savings and sustainability goals.

Create future-ready operations and long-term performance and expandability

Systems designed for long-term performance. Open, modular platforms enable future expansion and upgrades without major overhauls.

Real-time production, process and power insights
Real-time production, process and power insights
Real-time production, process and power insights
Our industrial control system integrates process and power control. Reduce design time, capital and operational costs. Get real-time production data in one HMI.

Integrated Architecture® is a foundational enabler for successful post-combustion carbon capture projects. By unifying process control, power management, safety, analytics, and cybersecurity, it addresses the complex challenges of integration, optimization, compliance, and cost control. The result is a safer, more efficient, and future-ready facility-capable of delivering dependable carbon capture performance and supporting the transition to a low-carbon future.

 

Further Reading:

https://literature.rockwellautomation.com/idc/groups/literature/documents/br/oag-br011_-en-p.pdf

https://literature.rockwellautomation.com/idc/groups/literature/documents/br/oag-br009_-en-p.pdf

 
FactoryTalk Energy Manager Application
FactoryTalk Energy Manager Application
FactoryTalk Energy Manager Application
A scalable approach to energy monitoring to help increase efficiency, identify opportunities for energy reduction, and accelerate digital transformation.

Published March 10, 2026

Topics: Build Resilience Optimize Production Drive Sustainability Distributed Control Systems (PlantPax) Packaged Solutions Industrial Automation & Control Process Solutions Sustainable Solutions Sustainability Cement Chemical Metals Oil & Gas Power Generation FactoryTalk Energy Manager PlantPAx PlantPAx DCS

Fabio Mielli
Fabio Mielli
Strategy Marketing Manager, Energy & Mining, Rockwell Automation
Fabio Mielli brings extensive knowledge of industrial systems to the energy and mining sectors, with a focus on process, power and digital transformation. His 20+ years of experience include strategic planning and marketing leadership. His publications address topics such as predictive analytics for equipment reliability, energy optimization, and the application of digital platforms for improved operational efficiency in resource industries.
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