Design and Development of a Low-Cost Portable Carbon Capture Unit for Reducing Gas Flare Emissions in Niger Delta Region, Nigeria

Abstract

This study aimed to design, develop, and evaluate a low-cost portable carbon capture unit (PCCU-01) for mitigating greenhouse gas emissions at gas flare sites in the Niger Delta region of Nigeria. Five flare sites across Rivers, Bayelsa, Delta, Akwa Ibom, and Edo states were assessed for baseline emissions, including CO₂, CH₄, NOx, SO₂, and black carbon. The prototype was fabricated using locally available materials and tested under controlled laboratory and real-field conditions. Laboratory testing demonstrated a mean CO₂ capture efficiency of 75.2%, while field deployment across five flare sites achieved an average efficiency of 66.3%, with slight reductions attributable to environmental fluctuations and flare instability. Statistical analyses, including one-way ANOVA, paired t-test, and regression modeling, confirmed significant differences among sites (p < 0.001) and identified flare volume and co-pollutant reductions as key predictors of CO₂ capture efficiency (R² = 0.83). The unit demonstrated substantial environmental benefits, reducing annual CO₂ emissions by ~66% and black carbon by 55% per site, while ensuring economic feasibility with a payback period of less than six months. These findings indicate that PCCU-01 is a viable, scalable, and cost-effective solution for emission mitigation in remote flare-prone regions.