Abstract: Potassium-based solid adsorbents show important application potential in the field of post-combustion carbon dioxide capture and direct air capture due to their advantages of low cost, environmental friendliness and good matching with low-temperature flue gas. However, the low mechanical strength, large bed pressure drop, and poor mass transfer performance of powdered adsorbents in practical engineering applications have seriously restricted their large-scale applications. For this reason, this paper systematically reviews the research progress on materials and processes of potassium-based adsorbents from powder to structured molding, focusing on the types and properties of carrier materials, the principles, advantages and limitations of molding technologies, and the key challenges faced in the scale-up application of potassium-based adsorbents. In terms of carriers, traditional porous materials, structured honeycomb carriers and new materials all show different performance characteristics, and the adsorption capacity and cycling stability can be effectively enhanced by regulating the pore structure and surface properties. In the molding process, extrusion, extrusion rounding, graphite casting, coating, hydrophobic surface-assisted synthesis, spray pelletizing and the emerging 3D printing and other technologies have their own advantages, which can significantly improve the mechanical properties of adsorbents, mass transfer efficiency and engineering applicability. However, in the face of the poisoning of adsorbents caused by complex components in real industrial flue gas, microstructural degradation due to deliquescence, and high energy consumption for regeneration, potassium-based adsorbents still need to make further breakthroughs in material design and process integration. Future research should focus on the development of multifunctional composite adsorption systems with antitoxicity, hydrophobicity, catalysis, etc., and promote the scale-up and commercial application of potassium-based adsorbents by combining intelligent structural design and system energy-efficiency optimization, with a view to providing theoretical support and technical references for the development of potassium-based adsorbents from laboratory research to industrial application.