Catalyst with Shayle Kann
Catalyst with Shayle Kann

DAC’s bumpy road to commercial scale

The world’s first large-scale, commercial direct-air capture (DAC) plants are coming online – or are about to. How soon will we see a boom in high-quality, durable DAC supply? In this episode, Shayle talks to Andreas Aepli, chief financial officer of Climeworks, the world’s largest provider of DAC.

Featured Speakers

Andreas Apley Guest

Topics Discussed

Episode Summary

Executive Summary: The episode examines how Climeworks is scaling direct air capture from first-of-a-kind pilots to larger commercial plants, and why transparency about technical and financial challenges matters. CFO Andreas Apley explains the company’s capital strategy, operational learning curve, evolving buyer market, pricing and contract structures, and the likely near-term shakeout in DAC as the industry moves from hype to execution.

Main Topics: Climeworks’ growth from startup to commercial DAC leader (Priority: 5/5): Apley traces Climeworks from its 2009 university spinout origins through early angel/family-office funding, the first collector in 2014, the first commercial pilot in 2017, Orca’s commercial launch, and the later large Series F round. Capital formation and financing strategy for DAC (Priority: 5/5): The discussion focuses on why scaling DAC requires a diversified capital stack, why Climeworks raised large corporate equity before project finance was fully available, and how future projects may combine grants, project equity, project debt, and other structures. Operational realities and learning curve at Orca (Priority: 5/5): Apley details lessons from operating the first commercial DAC plant: supply chain quality variability, harsh Icelandic weather, sequestration purity requirements, lifecycle emissions accounting, and the gap between design capacity and real-world output. Market growth, buyer composition, and voluntary carbon demand (Priority: 4/5): The conversation covers who buys durable carbon removals today, how Microsoft remains the dominant buyer while more firms from tech, finance, insurance, and hard-to-abate sectors enter the market, and how education and quality concerns shape demand. Pricing, contract terms, and bankability (Priority: 5/5): They explore why DAC pricing is not yet a commodity market, how Climeworks structures long-duration take-or-pay contracts with indexation, and why such terms are necessary to make projects financeable over time. Ecosystem development and the role of intermediaries (Priority: 3/5): Apley evaluates brokers, carbon markets intermediaries, and MRV/verification providers as important market enablers, while explaining why direct customer relationships can still be preferable for long-term, creditworthy offtake. Future market outlook and industry shakeout (Priority: 4/5): The episode closes with a forecast that DAC will both grow and consolidate: more players will deploy, some will fail, and larger compliance and corporate demand may emerge by 2030 and beyond as supply remains constrained.

Key Arguments: DAC must be scaled in digestible steps rather than jumping from lab to giant commercial plants, because the technological and operational risk is too high. A diversified capital stack is essential for first-of-a-kind DAC projects; corporate equity alone can bridge early scale-up, but project finance becomes more important as plants mature. Transparency about underperformance and challenges is strategically important because overpromising could damage trust in the entire carbon removal industry. Orca’s real-world ramp showed that commercial DAC operation involves many hidden challenges that pilots do not reveal, including component quality drift and weather exposure. Long-term offtake contracts with take-or-pay terms and indexation are critical to make future DAC plants bankable and to align pricing with energy-cost risk. The market for high-quality carbon removals is growing, but it remains education-heavy, with buyers needing help structuring portfolios and understanding quality differences. The industry will likely experience a shakeout as more companies attempt to move from promise to deployment, and not all will survive the transition.

Data Points: Climeworks founded: 2009 - Company founded by Jan and Kristoff as a university spinout. First collector deployed: 2014 - Initial DAC machine/collector was built and deployed. First commercial pilot plant: 2017 - Commercial in the sense of delivering CO2 to customers such as Coca-Cola and a greenhouse. Orca nominal capacity: 4,000 tons/year - First commercial DAC plant designed capacity. Orca achieved run rate: 2,500 to 3,000 tons/year - Actual performance after ramp-up. Orca ramp time: About 2.5 years - Time taken to reach the reported run rate. Series F equity raise: $650 million - Large corporate equity round completed in April 2022. Series F close date: April 2022 - Raised after the 2021 market peak as conditions were turning. Mammoth scale-up: About 10x Orca - Next plant deployed in May, substantially larger than Orca. Next planned plant size: About 250,000 tons/year - First U.S. plant and another 7-8x scale-up from Mammoth/Orca pathway. Globally sold volumes at end of 2021: About 100,000 tons - Used to illustrate early carbon removal market size. Current market volume: 4.6 million tons last year; 5.7 million tons year to date - Shows rapid growth in the carbon removal market. Typical buyer contract duration: 5 to 15 years - Climeworks prefers long-duration offtake to enable project finance. Longest contract signed: 15 years - Longest offtake agreement mentioned. Energy Hub VPP capacity ad: 3.4 gigawatts - Promotional sponsor detail included in the transcript. Energy Hub devices ad: 2.5 million customer devices - Promotional sponsor detail included in the transcript.

Pivotal Quotes: "What we're worried about is what's going to happen if people are not transparent about the challenges, is that people will lose faith at some point when they say, well, this is just an industry that makes a lot of promises but doesn't really keep them." — Shail Kahn: Framing the importance of honesty in climate tech and carbon removal. "We're building a tractor, not a sports car" — Climeworks CTO (referenced by Andreas Apley): Describing the rugged, industrial nature of DAC operations in harsh Icelandic conditions. "The direct air capture industry still lives of a lot of promise." — Andreas Apley: Summing up the current state of DAC as it enters a more mature, reality-tested phase.

Implications: DAC is moving from narrative to execution: buyers, financiers, and developers will reward credible delivery, durable contracts, and transparent operations. Expect more scale, more scrutiny, and likely consolidation as the sector proves which models can actually finance and operate at industrial scale.

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