
The remarkable cost declines in solar photovoltaic (PV) and lithium-ion batteries over the past several decades have fueled optimism in the climate policy and investment community, with many hoping direct air capture (DAC) technologies might follow a similar trajectory. Policymakers, investors, and industry proponents frequently draw analogies between DAC and these wildly successful clean-energy technologies, invoking Wright’s Law—a rule of thumb where costs fall predictably with cumulative doubling of production—to justify unjustifiably bullish projections for DAC’s future costs. Given the unrealistic scenarios requiring carbon removal to achieve net-zero emissions, the attractiveness of DAC scaling cheaply and quickly is understandable, yet such optimism demands critical scrutiny grounded in the realities of technology, markets, and physics.
I’m drawn back to this space, one I’ve been exploring for 15 years, doing technoeconomic assessments of Global Thermostat’s applicability in heavy rail, Carbon Engineering’s natural market of enhanced oil recovery and speaking to many of the leading researchers and entrepreneurs in the space. Why am I drawn back? Because I wrote about Climework’s ongoing trainwreck—105 tons total captured from a 40,000-ton annual homeopathy device and now 22% layoffs—recently, and many commenters made it clear that they thought DAC would follow solar and batteries into the nirvana of cheapness.
Solar PV and batteries achieved their cost revolutions through clear, consistent factors. Foremost was Wright’s Law itself: with each doubling of global cumulative production, solar PV saw about a 20% reduction in cost, while lithium-ion batteries experienced roughly a 19% drop per doubling. Historically, Wright’s Law saw 20% to 27% decreases, depending on the simplicity of the product. These impressive and predictable learning rates emerged for solar and batteries because both technologies quickly found mass-market applications with billions of end-users—solar panels across rooftops worldwide and lithium-ion cells powering consumer electronics and, later, electric vehicles. Such enormous, diverse markets spurred massive economies of scale, standardization of manufacturing processes, and continuous incremental innovation, driving down prices dramatically over relatively short periods.
In solar manufacturing, scale-up to gigawatt-scale factories allowed for unprecedented efficiency gains. Automation, production-line standardization, reduced material usage, and steady incremental improvements in cell efficiency combined to achieve a 99% reduction in costs since the 1970s. Batteries followed a similar pattern. Initially expensive lithium-ion cells rapidly benefited from global consumer electronics markets, then exploded in scale with the electric vehicle boom of the 2010s. Innovations in chemistry, manufacturing methods, and supply chain management drove battery costs down by over 90% since 2010 alone. Crucially, both technologies became genuinely commoditized, their costs falling sufficiently low to be attractive purely on market economics, independent of ongoing subsidies.
In stark contrast, DAC technology faces fundamental structural, thermodynamic, and market constraints that severely limit its potential to emulate these learning-curve successes. While DAC systems like those developed by Climeworks and Carbon Engineering also involve engineered modular units, their scale and replicability differ drastically from solar and batteries. Solar PV and battery units are small, identical, easily mass-produced components numbering in the billions, allowing rapid parallel production and iterative optimization. DAC, conversely, involves large, complex industrial-scale modules that process massive volumes of air. Even highly modularized DAC units like those envisioned by Climeworks represent significant, capital-intensive systems, each processing hundreds of thousands to millions of cubic meters of air per ton of CO₂ captured. Achieving large-scale global deployment would involve thousands of units—not billions—limiting opportunities for rapid learning through repetition and optimization.
Further compounding this problem, DAC relies heavily on mature, off-the-shelf technologies. Key components such as large industrial fans, chemical sorbents, heat exchangers, compressors, and pumps are already widely used across industries. Unlike emerging semiconductor processes or battery chemistries that initially featured substantial inefficiencies ripe for innovation, DAC’s hardware components are closer to their optimized cost floors, having already benefited from decades of engineering and scale in other applications. Incremental improvements in sorbent chemistry or component efficiency may yield modest savings, but the potential for radical cost reductions through fundamentally new approaches or extensive technological simplifications is inherently limited.
Perhaps the most stubborn barrier DAC faces in following a PV-like cost curve is rooted in basic physics: the energy-intensive nature of extracting CO₂ from the atmosphere. Unlike solar cells, whose primary cost drivers are fabrication efficiency and material utilization, DAC confronts unavoidable thermodynamic constraints. The fundamental minimum energy required to capture CO₂ at the dilute concentrations found in ambient air sets a hard, non-negotiable energy floor. Current DAC operations use energy at several times the theoretical minimum, but even highly optimistic scenarios still require substantial energy input, typically hundreds to thousands of kilowatt-hours per ton of CO₂. Thus, DAC will always incur significant operational energy costs that place a lower bound on achievable pricing, unlike solar panels and batteries, whose unit costs dropped rapidly with better manufacturing processes and materials science advances.
Adding complexity, DAC is physically and materially intensive. Capturing millions of tons of CO₂ per year demands enormous amounts of infrastructure—steel, concrete, sorbent materials, and sophisticated capital equipment. Unlike digital technology or small-scale consumer goods, DAC units cannot shrink significantly or dramatically reduce material inputs without sacrificing performance. Indeed, the large physical dimensions of air contactors, substantial volumes of sorbent material needed, and considerable infrastructure for regeneration and compression suggest that DAC systems will remain heavy, complex installations. As DAC scales, rather than benefit from continuously cheaper materials, increased demand for specialty chemicals and industrial materials may drive prices upward, potentially offsetting some manufacturing efficiency gains. This scenario contrasts sharply with the declining per-unit material intensity that helped accelerate solar and battery cost reductions.
Critically, DAC lacks the autonomous, self-sustaining market demand that propelled solar PV and batteries. Solar power and battery storage offered direct economic benefits to millions of end-users, enabling them to become cost-competitive with conventional energy sources over time. DAC, however, provides an environmental service—carbon removal—whose value remains purely policy-dependent. Without robust carbon pricing, governmental incentives, or regulatory mandates, DAC has no inherent private market demand, severely limiting its potential cumulative production growth. Whereas solar panels and batteries rapidly scaled through consumer and business demand, DAC expansion hinges exclusively on sustained public policy support. Such policy-driven markets are vulnerable to political shifts, budget constraints, and public sentiment, making exponential growth in DAC production far less predictable or assured.
Historical analogues from other large-scale industrial and environmental technologies underscore DAC’s challenging trajectory. Technologies such as nuclear power, large-scale carbon capture on fossil plants, and industrial chemical plants have all faced similar complexities and constraints, often resulting in slow, incremental cost reductions—or even cost escalation—as they scaled. These technologies offer more instructive benchmarks for DAC than solar or batteries, highlighting the cautious reality that DAC may experience only modest learning curves of around 10% per cumulative doubling, far slower than the 20% or more seen in clean-energy consumer markets.
All of this leads to 10% or less cost take out for a lot fewer doublings for DAC fan units, the only component which will have any volumes. The chart ends at just below 10,000 units. For context, a million ton per year Carbon Engineering system might have 250 contactor units, the basic module in a wall two kilometers long and 20 meters high. They’d have to build 64 km of their system to get to 8,000 fans, and that’s exceedingly unlikely. To get another 10%, they’d have to build 128 km of walls of their system with 16,000 units. To get another 10, 256 km with 32,000 units.
Meanwhile, a single one GW solar farm has around 1.8 million solar panels. The volumes are radically different, and the rate of cost decreases per doubling are radically different.
Looking forward, expert analyses from independent institutions like the International Energy Agency, Harvard’s Belfer Center, and the National Academies broadly agree: DAC costs will likely remain in the triple-digit dollar range per ton even after decades of scaling. Starry eyed scenarios predict DAC might achieve costs around $150 to $250 per ton by mid-century under aggressive deployment assumptions. More realistic projections settle higher, acknowledging inherent thermodynamic limits, persistent energy costs, and material constraints. Industry-driven forecasts that envision DAC below $100 per ton are simply delusional, hinging on technological breakthroughs that would require changing the laws of physics and ludicrously low energy cost assumptions as a result.
Given these realities, policymakers and investors must fundamentally rethink their near-term engagement with DAC. Aggressively reducing emissions through proven, lower-cost technologies such as electrification, renewable energy, and energy efficiency should remain the clear and unambiguous priority until energy systems are fully decarbonized and surplus renewable electricity is abundant—likely not until after 2040 and probably beyond 2050. DAC, due to its inherently high energy intensity and substantial infrastructure requirements, should not divert limited resources from direct emission-reduction strategies until we reach a point where clean energy is inexpensive and plentiful.
Policymakers and investors should limit current DAC involvement strictly to research and development, aiming to improve technology performance, reduce energy requirements, and better understand realistic long-term potential. Public spending on commercial-scale DAC deployment or infrastructure is premature and risks locking in inefficient, high-cost solutions before cleaner, lower-cost alternatives are fully exploited.
Carbon removal strategies in the immediate decades should instead emphasize nature-based methods and improved soil carbon sequestration—technologies with significantly lower energy demands and clearer short-term scalability. The belief that we can vacuum enough CO2 out of the atmosphere to reach 2050 goals should be abandoned, and more aggressive decarbonization scenarios driven through.
Sign up for CleanTechnica's Weekly Substack for Zach and Scott's in-depth analyses and high level summaries, sign up for our daily newsletter, and/or follow us on Google News!
Whether you have solar power or not, please complete our latest solar power survey.
Have a tip for CleanTechnica? Want to advertise? Want to suggest a guest for our CleanTech Talk podcast? Contact us here.
Sign up for our daily newsletter for 15 new cleantech stories a day. Or sign up for our weekly one on top stories of the week if daily is too frequent.
CleanTechnica uses affiliate links. See our policy here.
CleanTechnica's Comment Policy