Calera has continually scaled up the various process units from lab scale to continuous pilot to demonstration scale. In the Los Gatos laboratories, the Calera team conducts bench scale studies designed to elucidate optimal process conditions for different potential feedstock. In 2009, Calera scaled up these conditions to a continuous pilot plant for capture of CO2 from different flue gas compositions and conversion to carbonate products. At this pilot facility, capture rates above 85% of CO2 and SO2 have been achieved for coal combustion and conversion with MAP, to materials that have been proven to be usable as building materials.
In 2010 Calera scaled up the ABLE technology to pilot plant scale which allowed testing of large electrochemical cell components. Calera's active scale-up risk mitigation strategy includes the design, construction, and operation of a continuous pilot plant at Moss Landing, CA; the design and scale-up analysis for a natural gas plant that is 10 MWe coal equivalent carbon capture demonstration facility; and the selection of currently operating technologies that have proven reliable at the scales required by our process. Calera is now using the materials generated from CO2 captured from the Moss Landing power plant in external construction and architectural demonstration projects.