Compacted to capture carbon dioxide (CO2)

Description

1 / 73 COMPACTED TO CAPTURE CARBON DIOXIDE (CO2) Divided from BR112023022061-0, filed on May 11, 2022. FIELD OF TECHNIQUE

[0001] The present invention relates to systems and methods for capturing CO2. BACKGROUND

[0002] Global warming resulting from increased atmospheric CO2 concentrations is considered an imminent threat to society. According to the National Oceanic and Atmospheric Administration (NOAA) (Monday, 2020), global atmospheric carbon dioxide was 409.8 ± 0.1 ppm in 2019, a new record high. This is an increase of 2.5 ± 0.1 ppm since 2018, the same as the increase between 2017 and 2018. In the 1960s, the global growth rate of atmospheric carbon dioxide was approximately 0.6 ± 0.1 ppm per year. Between 2009-2018, however, the growth rate has been 2.3 ppm per year. Techniques for removing carbon dioxide emissions from the atmosphere have become a critical area of ​​research.

[0003] Furthermore, low-carbon, carbon-neutral, or carbon-negative consumer goods and services have become important in the global market. It is also important to minimize the energy and environmental impacts of the production, use, and disposal of manufactured goods, which range from fundamental products such as metals and chemicals to sophisticated end-use products such as electric cars, solar panels, wind turbines, etc. Renewable energy from its many sources is an incredible way to provide energy, heat, and fuel for our habitat. Each type of renewable energy, from hydro to solar and biomass, contributes in a different way. The use of renewable energy in combination with the reduction of carbon emissions in the manufacture of consumer goods and services can produce highly economical reductions in greenhouse gas (GHG) emissions.These improvements can be further enhanced by the development of new materials and process technologies. Carbon removal, including point source and direct air capture (DAC) processes, are among many technologies to reduce GHG emissions.

[0004] Many technologies designed for capturing CO2 from point sources, such Petition 870260084693, dated 08 / 20 / 2026, page 111 / 196 2 / 73 as combustion gas for industrial plants, are generally ineffective at capturing CO2 from the atmosphere due to significantly lower CO2 concentrations and the large volumes of air required for processing. In recent years, progress has been made in finding better-suited technologies to capture CO2 directly from the atmosphere, and a variety of DAC technologies have been described in the technical and patent literature. Some of these DAC systems utilize a solid sorbent where an active agent is bound to a substrate. These DAC systems typically use a cyclic adsorption-desorption process where, after the solid sorbent is saturated with CO2, it releases the CO2 using moisture or thermal oscillation and is regenerated. Although solid sorbent DAC systems can have a high cyclic yield, large-scale deployment is a challenge due to the maintenance requirements inherent in a batch process.

[0005] Other DAC systems utilize a liquid sorbent (sometimes referred to as a solvent) to capture CO2 from the atmosphere. An example of such a gas-liquid contact system would be one based on cooling tower designs where a fan is used to draw air through a large surface area compact that is moistened with a solution comprising the liquid sorbent. The CO2 in the air reacts with the liquid sorbent. The rich solution is further processed downstream to regenerate a lean solution and release a stream of concentrated CO2. DAC systems designed based on cooling towers are advantageous as they use some commercially available equipment, and these can operate more effectively in certain environments than others. It is desirable that DAC systems be easy to maintain and operationally flexible. SUMMARY

[0006] In an exemplary implementation, a compact for capturing carbon dioxide (CO2) from a dilute includes at least one panel comprising a mesh material configured to be wetted by a CO2 capture solution and defining a gas channel having a first dimension defined along a first direction and a second dimension defined along a second direction different from the first direction, the gas channel configured to receive a stream of CO2-laden gas from the dilute gas source in the second direction and contacting the stream of CO2-laden gas with the CO2 capture solution in the mesh material. Petition 870260084693, dated 08 / 20 / 2026, page 112 / 196 3 / 73

[0007] In an aspect combinable with the exemplary implementation, at least one panel includes a plurality of panels, and adjacent panels of the plurality of panels are spaced from each other in the first direction and define respective gas channels between each of the adjacent panels, each of the respective gas channels defined by the respective first dimension.

[0008] In another aspect combinable with any of the preceding aspects, each panel of the adjacent panels defines a planar surface, the planar surfaces of adjacent panels being parallel to each other.

[0009] In another aspect combinable with any of the preceding aspects, at least one panel of the adjacent panels includes a plurality of planar portions and a plurality of protruding portions, the plurality of planar portions defining parallel planes, the plurality of protruding portions extending outward from the parallel planes in the first direction and into the respective gas channels.

[0010] In another aspect combinable with any of the preceding aspects, each panel of the adjacent panels has the same shape.

[0011] In another aspect combinable with any of the preceding aspects, the gas channel is collinear with the second direction of the CO2-laden gas flow.

[0012] In another aspect combinable with any of the preceding aspects, at least one panel is a single panel, and the mesh material includes a continuous sheet of mesh material.

[0013] In another aspect combinable with any of the preceding aspects, the continuous sheet of mesh material includes a plurality of panel segments spaced apart from each other in the first direction and defining the gas channel.

[0014] In another aspect combinable with any of the preceding aspects, at least one panel includes a plurality of panels spaced apart from each other in the first direction, the plurality of panels defining a plurality of gas channels between adjacent panels of the plurality of panels; at least one gas channel of the plurality of gas channels is defined by the first dimension comprising a first width; and at least another gas channel of the plurality of gas channels is defined by the first dimension comprising a second width different from the first width. Petition 870260084693, dated 08 / 20 / 2026, p. 113 / 196 4 / 73

[0015] In another aspect combinable with any of the preceding aspects, the gas channel defines a gas channel cross-sectional shape in a plane normal to the second dimension, the gas channel cross-sectional shape being at least one of rectangular, triangular or rhomboidal.

[0016] In another aspect combinable with any of the preceding aspects, the first dimension is 152.4 mm (6 inches) or less.

[0017] In another aspect combinable with any of the preceding aspects, the CO2 capture solution is at least one of a hydroxide solution, a bicarbonate / carbonate solution, or an amine solution.

[0018] In another aspect combinable with any of the preceding aspects, the mesh material includes a plurality of fibers that define a plurality of mesh pores, the mesh material configured to be wetted by the CO2 capture solution so that the CO2 capture solution passes through at least one portion of the mesh pores of the wetted mesh material and defines a gas-liquid interface.

[0019] In another aspect combinable with any of the preceding aspects, the gas-liquid interface includes a first side disposed on a first side of the mesh material; and a second side disposed on a second side of the mesh material opposite the first side of the mesh material.

[0020] In another aspect combinable with any of the preceding aspects, the first side of the gas-liquid interface and the second side of the gas-liquid interface collectively define a total reactive gas-liquid interfacial area that is greater than a corresponding fiber surface area of ​​the mesh material.

[0021] In another aspect combinable with any of the preceding aspects, a wetting fraction of the mesh material is greater than 100%.

[0022] In another aspect combinable with any of the preceding aspects, at least one panel has a vertical orientation, and the second dimension is less than three orders of magnitude larger than the first dimension.

[0023] In another aspect combinable with any of the preceding aspects, the mesh material includes a hydrophilic material.

[0024] In another aspect combinable with any of the preceding aspects, the hydrophilic material is a hydrophilic coating disposed over at least a portion of the mesh material. Petition 870260084693, dated 08 / 20 / 2026, p. 114 / 196 5 / 73

[0025] In another aspect combinable with any of the preceding aspects, the hydrophilic material includes at least one of a nonwoven material or an organic material.

[0026] In another aspect combinable with any of the preceding aspects, the organic material includes at least one of jute, hemp or cellulose.

[0027] In another aspect combinable with any of the preceding aspects, the mesh material includes a hydrophobic material.

[0028] In another aspect combinable with any of the preceding aspects, the hydrophobic material is a hydrophobic coating disposed over at least a portion of the mesh material.

[0029] In another aspect combinable with any of the preceding aspects, the mesh material includes a plurality of fibers that have a surface texture.

[0030] In another aspect combinable with any of the preceding aspects, the mesh material includes a plurality of fibers each having a diameter ranging from 0.0001 mm to 10 mm.

[0031] In another aspect combinable with any of the preceding aspects, the mesh material includes a plurality of mesh pores, the plurality of mesh pores having one or more shapes that include at least one of hexagonal, rectangular, or round.

[0032] In another aspect combinable with any of the preceding aspects, the mesh material is formed to form a plurality of printed textures comprising at least one of rounded protrusions, ridges, corrugations, or herringbone.

[0033] In another exemplary implementation, a gas-liquid contactor for capturing carbon dioxide (CO2) from a dilute gas source includes: a housing that at least partially surrounds a plenum that includes an inlet and an outlet; at least one compact supported in the housing downstream of the inlet, the at least one compact including at least one panel that includes a mesh material and that defines a gas channel having a first dimension defined along a first direction and a second dimension defined along a second direction different from the first direction; a liquid distribution system configured to wet the mesh material with a capture solution. Petition 870260084693, dated 08 / 20 / 2026, pp. 115 / 196 6 / 73 of CO2, the liquid distribution system including one or more tanks configured to contain the CO2 capture solution received from the mesh material; and a gas handling device configured to flow a CO2-laden gas from the diluted gas source through the gas channel in the second direction to contact the CO2-laden gas with the CO2 capture solution on the moistened mesh material.

[0034] One aspect that can be combined with exemplary implementation also includes a float eliminator coupled to the housing and positioned downstream of at least one compaction.

[0035] In another aspect combinable with any of the preceding aspects, the gas moving device is a fan disposed downstream of at least one compacted at the outlet, and the fan is rotatable around a geometric fan axis to draw CO2-laden gas into the inlet and through the gas channel in the second direction.

[0036] In another aspect combinable with any of the preceding aspects, the liquid distribution system is configured to wet the mesh material, the wetted mesh material forming a liquid film of the CO2 capture solution on the mesh material.

[0037] In another aspect combinable with any of the preceding aspects, the liquid distribution system is configured to flow the CO2 capture solution at a solution flow rate ranging from 1 L / min to 4 L / min.

[0038] Another aspect combinable with any of the preceding aspects also includes a structural support supported by the housing and configured to support at least one compacted object, the structural support including one or more support rods mounted on one or more support beams.

[0039] In another aspect combinable with any of the preceding aspects, the mesh material is securely mounted on one or more support rods by at least one insertion, tension, or fastening device.

[0040] In another aspect combinable with any of the preceding aspects, the liquid distribution system includes one or more distribution facilitating devices configured to provide the CO2 capture solution over at least a portion of the mesh material.

[0041] In another aspect combinable with any of the preceding aspects, the one or more distribution facilitation devices include at least one Petition 870260084693, dated 08 / 20 / 2026, pp. 116 / 196 7 / 73 liquid distribution rods or liquid distribution spacers.

[0042] In another aspect combinable with any of the preceding aspects, one or more of the liquid distribution spacers include at least one tube having a tapered end.

[0043] In another aspect combinable with any of the preceding aspects, the liquid distribution rods include a plurality of grooves that are operable to flow the capture solution.

[0044] In another aspect combinable with any of the preceding aspects, one or more liquid distribution spacers are pressed against one or more liquid distribution rods to form at least a portion of an upper tank.

[0045] In another aspect combinable with any of the preceding aspects, the one or more liquid distribution rods and the one or more liquid distribution spacers are integrally formed with the mesh material.

[0046] In another aspect combinable with any of the preceding aspects, the one or more liquid distribution rods, the one or more liquid distribution spacers, and the at least one panel include a fiberglass core at least partially covered with a PVC coating.

[0047] In another aspect combinable with any of the preceding aspects, a first support rod of one or more support rods is configured to interlock with a second support rod of one or more support rods.

[0048] In another aspect combinable with any of the preceding aspects, the one or more support rods have a cross-section that is C-shaped or arc-shaped.

[0049] In another aspect combinable with any of the preceding aspects, the one or more support rods each have a thickness that tapers from a first end of the respective support rod to a second end of the respective support rod.

[0050] In another aspect combinable with any of the preceding aspects, the one or more tanks include at least one upper tank positioned above at least one panel; at least one lower tank positioned below at least one panel; and the liquid distribution system is configured to flow at least a portion of the CO2 capture solution from at least one tank. Petition 870260084693, dated 08 / 20 / 2026, page 117 / 196 8 / 73 lower for at least one upper tank.

[0051] In another aspect combinable with any of the preceding aspects, the gas-liquid contactor is configured to operate as part of a cooling tower system, a direct air capture contactor system, or a combination thereof.

[0052] Another combinable aspect with any of the preceding aspects still includes a structural support supported by the housing and configured to support at least one compacted object, the structural support including one or more support rods, a first subset of rods of the one or more support rods being offset from a second subset of rods of the one or more support rods, the second subset of rods being spaced from the first subset of rods in a direction perpendicular to the first dimension and the second dimension, the mesh material including a continuous sheet of mesh material tensioned around the first subset of rods and around the second subset of rods to form a plurality of panel segments, the plurality of panel segments extending between spaced rods of the first subset of rods and the second subset of rods.

[0053] In another aspect combinable with any of the preceding aspects, adjacent panel segments of the plurality of panel segments are spaced from each other in the first direction and define the gas channel, the first dimension decreasing in a direction parallel to a distance between the first subset of rods and the second subset of rods.

[0054] In another aspect combinable with any of the preceding aspects, adjacent panel segments of the plurality of panel segments have a non-parallel orientation with respect to each other.

[0055] Another aspect combinable with any of the preceding aspects also includes a structural support supported by the housing and configured to support at least one compacted material, the structural support including one or more support rods, wherein the mesh material is suspended from the one or more support rods.

[0056] Another combinable aspect with any of the preceding aspects still includes one or more spacers, each spacer of the one or more spacers being interposed between adjacent support rods of the one or more support rods. Petition 870260084693, dated 08 / 20 / 2026, pp. 118 / 196 9 / 73

[0057] In another aspect combinable with any of the preceding aspects, the one or more spacers include one or more distribution spacers.

[0058] Another aspect that can be combined with any of the preceding aspects also includes one or more distribution facilitation devices.

[0059] In another aspect combinable with any of the preceding aspects, the one or more distribution facilitating devices include at least one of the distribution support rods or distribution spacers.

[0060] In another aspect combinable with any of the preceding aspects, the one or more spacers include at least one tube that has a tapered end.

[0061] In another aspect combinable with any of the preceding aspects, the liquid distribution system further includes one or more flow devices configured to flow the CO2 capture solution over at least one compact, the one or more flow devices including at least one of nozzles, atomizing sprayers, or liquid distribution rods.

[0062] In another aspect combinable with any of the preceding aspects, the at least one compact includes two compacts that are spaced laterally apart from each other within the housing; and the gas movement device includes a fan disposed laterally between the two compacts and downstream of it at the outlet, the fan being rotatable around a vertical fan geometric axis to draw CO2-laden gas from the diluted gas source through the two compacts and emit CO2-poor gas through the outlet.

[0063] In another aspect combinable with any of the preceding aspects, at least one panel defines a planar surface that has a vector normal to the planar surface, the vector having a horizontal orientation.

[0064] In another aspect combinable with any of the preceding aspects, at least one panel has a vertical orientation and includes a defined leading edge relative to a flow of CO2-laden gas, the leading edge being inclined in a direction of the flow of CO2-laden gas and defining an angle relative to a vertical geometric axis.

[0065] In another exemplary implementation, a method for capturing CO2 from a CO2-laden gas includes: wetting at least a portion of spaced mesh panels with a CO2 capture solution to cause the CO2 capture solution to flow along the spaced mesh panels; flowing the CO2-laden gas Petition 870260084693, dated 08 / 20 / 2026, pp. 119 / 196 10 / 73 of CO2 along a defined gas channel between spaced mesh panels; react the CO2-laden gas with the CO2 capture solution on the moistened spaced mesh panels; and absorb at least a portion of the CO2 in the CO2-laden gas with the CO2 capture solution.

[0066] In one aspect combinable with the exemplary implementation, flowing the CO2-laden gas along the gas channel includes flowing the CO2-laden gas linearly through the gas channel along a first dimension of the gas channel.

[0067] In another aspect combinable with either of the preceding aspects, wetting at least a portion of the spaced mesh panels with the CO2 capture solution includes flowing the CO2 capture solution over the spaced mesh panels in a first direction; and flowing the CO2-laden gas along the gas channel includes flowing the CO2-laden gas along the gas channel in a second direction transverse to the first direction.

[0068] In another aspect combinable with any of the preceding aspects, the second direction is countercurrent to the first direction.

[0069] In another aspect combinable with any of the preceding aspects, wetting at least a portion of the spaced mesh panels with the CO2 capture solution includes flowing the CO2 capture solution at a flow rate ranging from 1 L / min to 4 L / min.

[0070] In another aspect combinable with any of the preceding aspects, wetting at least a portion of the spaced mesh panels with the CO2 capture solution includes saturating at least a portion of the spaced mesh panels with the CO2 capture solution; and flowing the CO2 capture solution along at least a saturated portion of the spaced mesh panels to form one or more meandering streams.

[0071] In another aspect combinable with any of the preceding aspects, wetting at least a portion of the spaced mesh panels with the CO2 capture solution includes forming a liquid film of the CO2 capture solution along at least a portion of the spaced mesh panels.

[0072] In another aspect combinable with any of the preceding aspects, flowing the CO2-laden gas along the gas channel includes rotating one or more fans to draw the CO2-laden gas along the gas channel.

[0073] Another aspect that can be combined with any of the preceding aspects also includes collecting at least a portion of the CO2 capture solution in one or Petition 870260084693, dated 08 / 20 / 2026, pp. 120 / 196 11 / 73 plus lower tanks; and flow at least a portion of the CO2 capture solution from one or more lower tanks to one or more upper tanks.

[0074] Another aspect combinable with any of the preceding aspects also includes reacting the CO2-laden gas with the CO2 capture solution to form a CO2-poor gas and a CO2-rich capture solution; and discharging the CO2-poor gas.

[0075] Another aspect combinable with any of the preceding aspects still includes flowing the CO2-poor gas through one or more float eliminators.

[0076] Another aspect combinable with any of the preceding aspects still includes flowing the CO2-poor gas through an open plenum after flowing the CO2-laden gas along the gas channel defined between the spaced mesh panels.

[0077] In another aspect combinable with any of the preceding aspects, wetting at least a portion of the spaced mesh panels with the CO2 capture solution includes passing the CO2 capture solution through the mesh pores of the spaced mesh panels to define a gas-liquid interface.

[0078] In another aspect combinable with any of the preceding aspects, traversing the CO2 capture solution through the mesh pores includes forming the gas-liquid interface on both opposite sides of each spaced mesh.

[0079] In another aspect combinable with any of the preceding aspects, passing the CO2 capture solution through the mesh pores includes wetting the hydrophilic mesh fibers of the spaced mesh panels with the CO2 capture solution, the hydrophilic mesh fibers defining the mesh pores.

[0080] In another aspect combinable with any of the preceding aspects, wetting at least a portion of the spaced mesh panels with the CO2 capture solution includes wetting an outer surface of the hydrophilic mesh fibers of the spaced mesh panels with the CO2 capture solution.

[0081] In another aspect combinable with any of the preceding aspects, wetting the outer surface of hydrophilic mesh fibers includes flowing the CO2 capture solution along the outer surface of the hydrophilic mesh fibers.

[0082] In another aspect combinable with any of the preceding aspects, wetting the outer surface of hydrophilic mesh fibers includes wetting the hydrophilic mesh fibers with the CO2 capture solution beyond a level of Petition 870260084693, dated 08 / 20 / 2026, pp. 121 / 196 12 / 73 Saturation of the hydrophilic mesh fibers to form a liquid film of the CO2 capture solution that extends through the mesh pores defined by the hydrophilic mesh fibers.

[0083] In another aspect combinable with any of the preceding aspects, wetting at least a portion of spaced mesh panels with the CO2 capture solution includes conditioning at least a portion of the spaced mesh panels by forming precipitates of solids on the mesh fibers of the spaced mesh panels.

[0084] In another exemplary implementation, a method for capturing CO2 from dilute sources includes providing a capture solution to one or more compacted sections of one or more upper tanks using a liquid distribution system, the one or more compacted sections each including one or more mesh sheets; distributing the capture solution over at least a portion of the compacted section; aspirating a CO2-laden gas through the mesh compacted section by operating a fan; collinearly flowing the CO2-laden gas through one or more gas channels defined by the one or more mesh sheets by operating the fan; reacting the CO2-laden gas with the capture solution to form a CO2-poor gas and a CO2-rich capture solution; collecting the CO2-rich capture solution in one or more lower tanks; and discharging the CO2-poor gas.

[0085] One aspect that can be combined with exemplary implementation also includes flowing the CO2-poor gas through one or more flotation eliminators.

[0086] Another aspect that can be combined with any of the preceding aspects also includes flowing CO2-poor gas through an open plenum section.

[0087] In another aspect combinable with any of the preceding aspects, providing the capture solution for one or more compacted sections includes providing the capture solution through one or more liquid distribution facilitating devices.

[0088] In another aspect combinable with any of the preceding aspects, providing the capture solution using one or more liquid distribution facilitating devices includes providing the capture solution using at least one liquid distribution rod or liquid distribution spacers.

[0089] In another exemplary implementation, a method of configuring a cooling tower to capture CO2 from a dilute source of CO2 gas includes supporting Petition 870260084693, dated 08 / 20 / 2026, page 122 / 196 13 / 73 at least one mesh pack inside the cooling tower between an inlet and an outlet of the cooling tower; and orient the at least one mesh pack inside the cooling tower to form unobstructed flow paths between gas channels of the at least one mesh pack and the inlet and outlet.

[0090] One aspect that can be combined with exemplary implementation also includes removing the existing compaction from inside the cooling tower before supporting at least one mesh compaction inside the cooling tower.

[0091] Details of one or more implementations of the subject described in this description are presented in the accompanying drawings and in the description below. Other features, aspects and advantages of the subject will become apparent from the description, the drawings and the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0092] Figure 1 shows a schematic illustration of an elevation view of an exemplary gas-liquid contactor.

[0093] Figure 2 shows a schematic illustration of an exemplary counterflow gas-liquid contactor.

[0094] Figure 3 shows a schematic illustration of an exemplary cross-flow gas-liquid contactor.

[0095] Figure 4 shows a schematic illustration of an elevation view of an exemplary mesh and support compaction system.

[0096] Figure 5 is an orthogonal view of an exemplary mesh and support compaction system.

[0097] Figure 6 is a perspective view of an exemplary mesh compact that includes mesh panels positioned substantially horizontally.

[0098] Figure 7 shows exemplary rod designs for a structural support system.

[0099] Figure 8A shows a schematic illustration of a side elevation view of an example of a mesh and support compaction system.

[0100] Figures 8B-8J show different gas channel arrangements for the mesh and support compaction system of Figure 8A.

[0101] Figure 9 shows a schematic illustration of a front elevation view of an exemplary mesh and support compaction system. Petition 870260084693, dated 08 / 20 / 2026, pp. 123 / 196 14 / 73

[0102] Figure 10 shows a schematic illustration of an end view of an exemplary mesh and support compaction system.

[0103] Figure 11 shows a schematic illustration of a front elevation view of an exemplary mesh compact support and liquid distribution system.

[0104] Figure 12 shows a schematic illustration of a plan view of an exemplary mesh compact support and liquid distribution system.

[0105] Figure 13 shows an exemplary integrated structural support system.

[0106] Figure 14A shows an illustration of an exemplary hydrophobic mesh sheet.

[0107] Figures 14B and 14C show liquid distribution techniques for the exemplary hydrophobic mesh sheet of Figure 14A.

[0108] Figures 15A and 15B show illustrations of an exemplary hydrophilic mesh sheet.

[0109] Figure 15C presents an exemplary liquid distribution technique for the exemplary hydrophilic mesh sheet of Figures 15A and 15B.

[0110] Figure 16A-C shows illustrations of front, side and plan views of a prototype mesh and exemplary support system test.

[0111] Figure 17 shows a graph of mass transfer versus air velocity by sorbent loading rates.

[0112] Figure 18A and Figure 18B show examples of molded mesh that includes a mesh sheet with printed textures.

[0113] Figure 19 shows exemplary flow patterns of capture solution at varying solution flow rates on a mesh sheet.

[0114] Figure 20 is a schematic illustration of an elevation view of an exemplary mesh and support compaction system.

[0115] Figure 21 shows a schematic illustration of an exemplary gas-liquid contactor used in a direct air capture (DAC) installation.

[0116] Figure 22 shows a schematic illustration of an elevation view of an exemplary gas-liquid contactor.

[0117] Figure 23 shows a schematic illustration of a top view of an exemplary gas-liquid contactor. DETAILED DESCRIPTION

[0118] The present description refers to systems and methods for air capture. Petition 870260084693, dated 08 / 20 / 2026, p. 124 / 196 15 / 73 Direct CO2 capture (DAC) from atmospheric air or other dilute gaseous sources containing CO2, using a gas-liquid contactor that includes a mesh pack. CO2 concentrations in dilute sources (approximately 400-420 ppm or 0.040.042% v / v), such as atmospheric air, are much lower than CO2 concentrations in point sources (approximately 5-15% v / v), such as flue gas. The mass transfer kinetics are favorable for capturing CO2 from point sources. Thus, the design considerations for a CO2 capture subsystem and capture solution regeneration subsystem are different for dilute sources compared to point sources.Although the present description refers to capturing CO2 from atmospheric air or other dilute gaseous sources containing CO2, it will be appreciated that the systems, methods and description herein can also be used to capture CO2 from more concentrated CO2 sources that have or carry a dilute gaseous source, for example, from a combustion gas that is mixed with atmospheric air.

[0119] Commercially available compacted material, for example compacted material used in cooling towers or flue gas scrubbers, has been used in DAC applications. However, these commercially available compacted materials were not specifically designed for the diluted CO2 mass transfer requirements of DAC applications and are therefore not optimized for DAC applications. For example, commercially available compacted material in the cooling tower industry is designed for use with water and to maximize heat transfer with less consideration for mass transfer, which is important for a DAC system.In contrast to commercially available compacts from the cooling tower industry, the mesh compact described here can be used to facilitate the mass transfer of CO2 from a gaseous source (e.g., atmospheric air) containing CO2 to a capture solvent that wets the mesh compact.

[0120] Commercially available cooling tower compact is also specifically designed to achieve sufficient wetting under high liquid loading conditions, while air is drawn through the compact block. As such, cooling tower compact has demonstrated lower wetting efficiency for low liquid loading rates, often of interest for DAC applications. At low liquid loading rates, the capture solution may tend towards a stream flow regime and form channels to Petition 870260084693, dated 08 / 20 / 2026, pp. 125 / 196 16 / 73 measure that descends through the cooling tower compaction. The low wetting efficiency caused by the stream flow of the capture solution can lead to unnecessarily low mass transfer due to the reduced interfacial area per unit area of ​​compaction (resulting in low CO2 absorption), higher pumping rates required to increase the flow of the liquid sorbent, and may ultimately end up requiring a large air contactor footprint.

[0121] The compacted gas produced for conventional compacted towers, compacted columns, and / or flue gas scrubbers in chemical processing plants is designed for much higher CO2 concentrations of approximately 10-15% v / v and lower volumetric gas flow rates per scrubber column compared to DAC applications such as those described herein. Thus, a significantly smaller gas volume is required for processing in these conventional compacted towers in order to capture the equivalent amount of CO2 from the air using DAC. Furthermore, conventional compacted towers are typically used in a counterflow orientation (rather than crossflow) because this is the flow orientation with the highest mass transfer efficiency; but counterflow scrubber column designs are not suitable for DAC primarily because air flow rates are restricted by the flooding point.The capture kinetics in a flue gas scrubber, or high-concentration chemical absorption tower, are generally more favorable compared to those associated with the absorption of dilute CO2 concentrations, such as in a DAC system like the one described herein.

[0122] Although both point source capture and DAC technologies capture CO2 from a gas stream, the process designs for both technologies differ due to their different feedstocks and process conditions. However, there are ways in which the present description can be used to modernize, modify, or redesign existing cooling towers to facilitate at least a portion of the CO2 capture capabilities seen in existing DAC systems. Furthermore, when incorporated into DAC systems, the present description can further improve at least one aspect of capture efficiency, pressure drops, capital expenditure, operating expenses, and / or simplify and reduce maintenance and installation.

[0123] The gas-liquid contactor systems and methods described herein may Petition 870260084693, dated 08 / 20 / 2026, pp. 126 / 196 17 / 73 include mesh compaction coupled to structural support(s), a liquid distribution system, and one or more liquid collection systems. In some cases, the mesh compaction may include one or more mesh screens positioned adjacent to each other. The mesh compaction material, design, and configuration can allow for high effective mass transfer of CO2 to the solution, lower pressure drop and higher air velocities through the air displacement depth (ATD), and lower total liquid flow rates. These characteristics, individually and additively, provide several advantages for the performance, maintenance, and overall economics of CO2 capture from dilute gaseous sources.

[0124] The mesh compact design and operation properties described herein, taken individually or when combined, for example, with liquid distribution modalities according to the present description, can lead to overall economic benefits for the gas-liquid contactor DAC system. For example, for a given CO2 capture rate, the mesh compact design and additional features described herein can help reduce the air displacement depth (ATD), reduce the overall DAC system footprint, including key construction materials such as structural requirements and concrete, all of which lead to reduced capital costs for the gas-liquid contactor system. Furthermore, the sorbent pumping system and energy demands using the mesh compact design and additional features described herein are decreased due to lower flow rates.This is achieved in part because the mesh compact and the mode of operation can facilitate large areas of wetted interfacial contact which are continuously replenished through a uniform solution distribution throughout the mesh compact. The design and materials used in the manufacture of the mesh compact can improve wettability compared to conventional compact.

[0125] In addition to the aforementioned reduction in material requirements and overall footprint of the gas-liquid contactor, another advantage of mesh compaction over commercially available compaction includes the ability to reduce compaction volume and decrease compaction material requirements, which in turn helps to reduce pressure drop across the ATD and the resulting fan power required to operate the system.

[0126] As the gas-liquid contactor is the largest system in DAC applications Petition 870260084693, dated 08 / 20 / 2026, p. 127 / 196 18 / 73 on a large scale, any improvement in performance, energy efficiency, or reduction in material and footprint has a significant and attractive impact on the overall DAC installation economics.

[0127] Advantages for maintenance can also be achieved with the present description. The inserted mesh material is easily replaceable with new mesh material should any part of the mesh material be damaged. The mesh material can be detached from the rods when uncoupled from the support beam. In some respects, the use of mesh material with commercially standardized thickness and dimensions (without the need for customized alterations) can make it a low-cost material that is readily available, convenient to replace and maintain, resulting in reduced maintenance / operating costs and associated air contactor downtime.

[0128] In addition, the methods and systems described herein can be used in systems that are built or have been modified for CO2 capture and operated with a variety of liquid solutions containing CO2 capture sorbents. They can also be used through the modernization of existing cooling tower systems. The mesh compact is compatible for use in existing DAC or cooling tower systems and between their associated components, including float eliminators, fans or blowers, housing, structures, one or more CO2 capture solution tanks and / or distribution systems, gas inlet and outlet areas, etc.

[0129] Mesh compaction can be installed in existing contactor housings without the need for significant redesign. It can also be installed in contactor housings designed to operate without existing cooling tower structural elements. Mesh compaction can be mounted inside and outside the cooling tower. Mesh compaction can be installed in the cooling tower using a method similar to any installation method for commercial compaction, for example, from the top or side of the cooling tower. Mesh compaction includes lightweight and low-cost woven and / or inserted mesh material with durable structural integrity.

[0130] In some implementations, the gas-liquid contactor may be an air contactor, which has one or more cells, based on modified cooling tower equipment and including similar components such as one or more fans, pumps, tanks, float eliminators, compacted housing, Petition 870260084693, dated 08 / 20 / 2026, p. 128 / 196 19 / 73 structural components, control systems, and the like. In some respects, the gas-liquid contactor may be a double-cell cross-flow contactor. In some respects, the gas-liquid contactor may be an existing cooling tower system, which has one or more cross-flow or counter-flow arrangements, that has been modernized with the described mesh compaction.

[0131] In some implementations the gas-liquid contactor includes one or more upper tanks, a structural support frame, one or more plenums, one or more lower liquid collection tanks, a housing, one or more liquid distribution systems (coupled to one or more pumps, valves and nozzles), one or more fans and fairing, compaction components and a float eliminator.

[0132] In some implementations, the mesh compact is coupled to one or more liquid distribution facilitation devices. In some cases, these devices may include existing support components or new components that facilitate or assist in the uniform distribution of liquid solution over the mesh material. In some implementations, liquid distribution facilitation devices include, for example, one or more existing upper support rods that are modified (e.g., made hollow, with holes, or other similar internal or external features that allow liquid distribution) to transport liquid along the length of the support rod and over the mesh material, in addition to serving the structural function of supporting and / or tensioning the mesh material.Another example of a liquid distribution facilitator device is a distribution spacer, which includes one or more upper spacers that are modified (for example, with holes or made of rigid mesh material or material with similar characteristics that allow liquid distribution) to transport liquid along the length of the spacer and over the mesh material, in addition to serving its structural function of maintaining the space between the support rods.

[0133] In some implementations, the gas-liquid contactor includes the mesh pack (or multiple mesh pack sections). In some aspects, the mesh pack is comprised of a single continuous sheet of mesh material inserted through the structural components to create the pack, or the pack may be comprised of one or more discrete panels or sheets of mesh material coupled to the structural components to create the pack. Petition 870260084693, dated 08 / 20 / 2026, pp. 129 / 196 20 / 73 The mesh compaction is configured and positioned to promote mass transfer between the gas and liquid flows moving through the gas-liquid contactor.

[0134] In some implementations, the gas-liquid contactor uses liquid distribution systems similar to currently known cooling tower or DAC systems - for example, top tank and nozzle distribution systems, or a pressurized piping and spray nozzle distribution system.

[0135] The methods and systems described in this description may enable the concept of net zero emissions through the deployment of large-scale DAC facilities in association with a variety of downstream processes, including, for example, enhanced oil recovery (EOR) and / or sequestration applications, and the production of synthetic products, including hydrocarbons, fuels, plastics, chemicals and the like.

[0136] To optimize the technoeconomics of specific DAC applications, the low CO2 concentration in ambient air drives the compact design toward a high airflow rate and low pressure drop across the compact, while providing a high gas-liquid interfacial area at low solution flow rates (compared to conventional cooling towers which have high solution flow rates and thus higher pumping and solution distribution costs). In some implementations, the decrease in solution flow rate can change the total flow pattern from film flow to stream flow, which can reduce the gas-liquid interface area available for mass exchange of CO2-laden air to a CO2 capture solution.

[0137] The flow rate at which transitions in flow patterns occur is dependent on many factors, including the free energy of the solid surface, the geometry of the compact, and the density, viscosity, and surface tension of the CO2 capture solution. Such properties in the CO2 capture solution differ from those of water, which is the typical liquid in cooling tower applications, due to the presence of concentrated sorbents (e.g., KOH or NaOH, carbonate / bicarbonate chemistries, liquid amines, capture or mass transfer promoting additives, etc.) in the CO2 capture solution.

[0138] In some cases, the mesh material is configured to reduce the overall weight of the system as well as reduce the pressure drop across the sheet. In Petition 870260084693, dated 08 / 20 / 2026, page 130 / 196 21 / 73 In some cases, this allows for greater volumetric airflow and higher air velocities, which in turn improves overall efficiency, financial savings, and energy savings.

[0139] In some implementations, the mesh pack may consist of one or more sheets of mesh material, arranged to create multiple gas channels for large volumes of gas (e.g., atmospheric or other gas containing dilute concentrations of CO2) to move through at high speed and low pressure drop, in a direction collinear to the mesh sheet surface. In some cases, the mesh pack may include one or more screens arranged adjacent to each other.

[0140] In some implementations, the mesh compact is a structured (i.e., not loose) compact, wherein one or more sheets of mesh material comprising the structured mesh compact are themselves structured, are structures provided through the use of structural components such as support rods, beams and the like, or a combination thereof.

[0141] In some implementations, the mesh material consists of multiple fibers woven or bonded together to form a mesh with multiple openings or pores. The geometry of this structure can be adjusted to allow the minimum amount of material required to facilitate the formation of a continuous or uniform liquid film surface with a given CO2 capture solution. In some implementations, the technique for forming the interfacial area is capillary traversal; here, the mesh fiber diameter, the surface energy of the fiber material, as well as the fiber spacing (pore size) can be optimized to allow a minimum mass of mesh material while still providing sufficient conditions for a given CO2 capture solution to traverse the mesh pores / openings, generating and maintaining a continuous liquid film across the mesh pores and producing a large interfacial area for gas-liquid contact.

[0142] In some implementations, specific sorbent solution properties, such as surface tension, viscosity, density, etc., may dictate the maximum mesh pore size, above which the solution will no longer be able to pass through the pore openings and a stream flow pattern will dominate, resulting in reduced sorbent retention. Therefore, in some implementations, material selection and mesh design (including pore size) must take into account, at least in part, the type of capture solution being considered.

[0143] In some implementations, the design and / or operation of the compacted Petition 870260084693, dated 08 / 20 / 2026, pp. 131 / 196 22 / 73 mesh, and gas-liquid contactor can incorporate features to better allow the capture solution, given its specific properties, to disperse and create an optimal interfacial surface area for CO2 capture. For example, this can be done by taking into account specific liquid solution properties, including but not limited to temperature, pH, viscosity and / or density, and adjusting the mesh compact material properties, fiber diameter, pore aperture size, and / or liquid sorbent flow rates, to optimize system performance.

[0144] Furthermore, total wettability is partly determined by the physical wettability of the mesh material, which is directly related to surface energy, and partly determined by the completeness of coverage as the liquid moves from one end of the mesh material to the other end. The path of liquid displacement through the mesh material is determined in part by the geometry, surface structure, and surface energy of the mesh material.

[0145] In some implementations, the fiber thickness of the mesh material can vary between 0.01 mm and 10.0 mm and can be optimized to ensure that the surface tension of the sorbent facilitates complete encapsulation of the sorbent around each individual fiber. In some cases, the fiber thickness is minimized in order to minimize the amount of mesh material while maintaining structural integrity and durability.

[0146] In some implementations, the fiber spacing of the mesh material creates pores (openings) with sizes / widths ranging from 0.1 mm to 30.0 mm. In some cases, the fiber spacing is optimized to work with the surface tension of the sorbent to pull the sorbent through the space / pore, facilitating the use of the sorbent for the formation of the reaction interface / surface rather than the mesh material. In one embodiment, a relationship between pore size and liquid film formation is provided. For example, the pore size (opening) can be maximized while still facilitating complete liquid film formation and passage through openings. Optimizing the pore size minimizes the volume and mass of mesh material while maintaining a specific interfacial reaction area.

[0147] In some implementations, the mesh material may be made of fibers. Petition 870260084693, dated 08 / 20 / 2026, page 132 / 196 23 / 73 which can be straight or wavy with smooth or rough surfaces. Sheets of knitted material can be produced by weaving warp and weft yarns with the same or different diameters and thicknesses. Continuous yarns not previously crimped or shaped can be used. The types of weave patterns used to form the knitted material can include woven, twill, basket weave, herringbone, square or rectangular sheets, with mesh pores (or openings) having a hexagonal (honeycomb), square, rectangular, or round shape, or a combination thereof. The selection of mesh shape can impact the open surface area, material strength, and how much material needs to be used to form the mesh.

[0148] Mesh compaction can be made using a variety of materials, and can be based on either a hydrophobic or a hydrophilic technique (described here in detail) for surface wetting, depending on the intended application and design. In some respects, the mesh material is selected to be compatible with the CO2 capture solution, for example high pH and / or hydroxide solution such as KOH, NaOH and the like.

[0149] In some implementations, mesh material sheets may comprise portions that are made of or coated with one or more materials. In some implementations, mesh material sheets may comprise more than one group of fibers, each group of fibers being made of a different material, and these groups of fibers may be woven, or connected together to form a blended mesh material for use in one or more sheets within the compact. In some cases, the fibers are made of a blended fiber material.

[0150] In some hydrophobic implementations, the mesh material sheet(s) can be made of different types of materials, for example plastic, metal, polymer composites or a combination thereof. In some cases, the plastic mesh material sheets can be extruded, oriented, expanded, woven or tubular. Plastic materials that can be used are, for example, polypropylene, polyethylene, PVC-coated fiberglass, PVC or PTFE.

[0151] In some hydrophilic implementations, the mesh material may be made of metal, fiberglass material, polyamide (e.g., nylon) or organic fabrics such as jute, hemp or cellulose or a combination of similar materials. The composition of hydrophilic mesh material may be further modified by the use of microstructures, coatings or additives to optimize the contact angle for use in specific DAC applications. Petition 870260084693, dated 08 / 20 / 2026, pp. 133 / 196 24 / 73

[0152] In some implementations, the surface characteristics of the fibers that make up the mesh material can be adjusted or improved to optimize the gas-liquid interface, regardless of how hydrophilic or hydrophobic the fiber material is initially. For example, in some cases, the deposition of precipitates or solids (such as low-solubility salts such as CaCO3) from one or more fluid streams in the gas-liquid contact application, accumulated over time (and often described as compact conditioning), can alter the total surface energy or fiber topology, thereby changing the fiber interaction with the sorbent solution (notably the solution that passes through the mesh pores). In some cases, this is based on the resulting effective contact angle or geometric influence.

[0153] In addition, fibers can have a surface texture introduced to influence the fiber / sorbent solution interaction characteristics. Fiber surfaces can be smoothed or roughened, depending on the surface energy properties of the material, to adjust or optimize the fiber-liquid solution interface characteristics.

[0154] In some cases, fibers, whether hydrophobic or hydrophilic in nature originally, can be optimized through the use of a coating or additive, to achieve a targeted gas-liquid interface in a given gas-liquid application.

[0155] In some implementations, combinations of fibers exhibiting different surface or texture characteristics may be woven together as a means of adjusting or optimizing the properties of the mesh material sheet (sometimes referred to herein as mesh sheet) for retention and / or elimination of liquid sorbent solution.

[0156] In both hydrophobic and hydrophilic mesh material wetting techniques, mesh material reduction can be performed by leveraging the surface tension properties of the liquid to achieve a high ratio of gas-liquid interface area to compacted material mass. Based on the given surface tension of the liquid solution, sorbent solution films can traverse the mesh pore openings resulting in a total reactive gas-liquid interfacial area greater than the surface area of ​​the mesh compact alone. In these cases, the wetting fraction, ε, is greater than 100%, so that when the mesh sheet is wetted and the solution traverses the spaces / pores Petition 870260084693, dated 08 / 20 / 2026, page 134 / 196 25 / 73 open, the gas-liquid interfacial area is larger than the total surface area of ​​the mesh fibers. Furthermore, the open nature of the pores coupled with solution traversal provides an interfacial area on both sides of the mesh sheet(s). This contrasts with some conventional heat exchange compacts or structured compact surfaces, which may have a gas-liquid interface on one surface as opposed to a uniform gas-liquid film interface formed on both sides of the mesh compact surface described here. In some cases, the mesh sheets can be considered as internal supports for a nearly uniform solution film.

[0157] As previously mentioned, commercially available cooling tower compact has challenges with maintaining a highly wettable surface area under DAC applications. One of the causes of poor wettability is the low surface energy of conventional compact. For example, commercially available compact, such as cooling tower compact, tends to be hydrophobic in nature, which tends to have low surface energy. Surface energy describes the strength of intermolecular bonds on the surface of a material and is the energy required to increase the degree of surface exposure. If a material has high surface energy, its bulk interactions will be stronger and its surface exposure will be greater. If a material has low surface energy, its bulk interactions will be weaker and its surface exposure will be less.Poor wettability and hydrophobicity (tendency to repel or not mix with water) are usually associated with a high contact angle. The contact angle is defined as the angle between the liquid-solid interface and the liquid-vapor interface, measured through the liquid. Poor wettability and a high contact angle are both potential causes of the compacted material having low surface energy. If not properly designed, these hydrophobic material attributes can lead to poor performance in DAC applications.

[0158] The mesh compact of the present description includes embodiments that utilize hydrophobic or hydrophilic properties in modes that support improved performance in DAC applications, in contrast to the low wettability of some commercially available cooling tower compacts.

[0159] Two general wetting techniques, a through-passage technique and a capillary technique, are possible when using liquid capture sorbents. Petition 870260084693, dated 08 / 20 / 2026, pp. 135 / 196 26 / 73 aqueous base. The specific wetting technique may be dictated by the material characteristics of the mesh sheet fibers that constitute a mesh sheet. For example, the cross-wetting technique, described in more detail in reference to Figures 14A-14C, occurs when the compacted material is more hydrophobic in nature, and results in the solution establishing a liquid film or cross-wetting through mesh pores and between fibers. The capillary technique, described in more detail in reference to Figures 15A-15C, occurs when the compacted fibers are more hydrophilic in nature. With this technique, capillary action draws the solution along the fiber surface and there is less or possibly no cross-wetting through the mesh pores.

[0160] In some implementations with hydrophobic mesh compact, the hydrophobicity of the mesh fibers promotes the preferential movement of the capture liquid into the open area of ​​a mesh pore without substantial wetting of the fiber itself. Any excess liquid can detach in a droplet and run down the mesh fiber.

[0161] The cross-through technique is frequently seen with hydrophobic mesh material, and results in solution cross-through between the fibers due to the minimization of the surface energy of the liquid capture sorbent at the interface of the liquid with the compact fibers combined with the surface tension of the liquid capture sorbent. In some cases, the dimensions of the cross-through solution will be defined by the fiber diameter, spacing (e.g., mesh pore width), hydrophobicity of the fiber material, and surface tension of the solution. A maximized air / sorbent interface for hydrophobic mesh compact applications can be targeted by optimizing the above parameters for a given capture solution composition and air contactor operating parameters, since larger air / sorbent interfaces provide a more available surface area for increased CO2 mass transfer in the liquid capture sorbent.

[0162] Using this traversal technique, the surface of the compacted fiber itself will remain largely unwetted and therefore will not contribute significantly to the air / absorbent interfacial area by virtue of its hydrophobic nature. Therefore, an optimized hydrophobic mesh compact will maximize the interfacial area by adjusting the fiber diameters and the spacing between the fibers that make up the mesh pores. In some cases, a width / Petition 870260084693, dated 08 / 20 / 2026, pp. 136 / 196 27 / 73 Very large fiber spacing will result in sorbent traversal failure for a given solution surface tension, where liquid traversal will no longer span the mesh pore width.

[0163] In some cases, hydrophilic designs can enhance the wetting of the mesh compact with the capture solution. With hydrophilic mesh compact designs, the capillary technique can be the dominant form of mesh material wetting. In some cases, this technique can occur through capillary action, rather than solution penetration. For example, the capillary technique draws the solution along the fiber surface, and there is less or possibly no penetration through the mesh pores. The gas-liquid interfacial area will subsequently be defined by the area of ​​wetted fibers and the thickness of the liquid sorbent layer, which will be defined by the hydrophilicity of the fiber material and the liquid sorbent flow rate along the mesh sheet. Using this capillary technique, the mesh pores may or may not be fully wetted depending on the liquid sorbent layer thickness and fiber spacing of the compact.Therefore, optimizing a hydrophilic mesh compact for the capillary wetting technique will differ from optimizing a mesh compact for the penetration technique.

[0164] Improved wetting of mesh compacts that have hydrophilic properties (e.g., by increasing the wetted surface area of ​​the mesh sheet) can be achieved by at least two proposals. The first proposal is to increase the hydrophilicity of the mesh material surface by increasing the surface free energy, which is a property of the material. The second proposal is to increase the surface roughness of the mesh material and the apparent contact angle. These proposals for improved wetting can be used independently or in combination with each other.

[0165] Since the wetted surface area determines the amount of CO2 capture solution exposed to air, and a hydrophilic material surface maximizes the wetted area for a given volume of solution, hydrophilic materials for mesh compaction may be suitable for gas-liquid contactor applications. In some cases, hydrophilicity can be incorporated into the mesh material when it is produced, or it can be introduced as a post-production coating. Hydrophilic coatings increase the surface energy and decrease the contact angle of the capture solution on the mesh sheets. In Petition 870260084693, dated 08 / 20 / 2026, page 137 / 196 28 / 73 In some cases, some surface treatments that expose a material to a change in bonds on its surface can achieve similar hydrophilic results.

[0166] In an exemplary implementation, the hydrophilic mesh sheet may include a coating applied to the mesh compact to increase hydrophilicity. In some cases, this coating fully wets with a minimal solution flux. This can result in higher capture rates with significantly reduced solution fluxes compared to an uncoated mesh sheet.

[0167] In some implementations, the hydrophilic mesh sheet is moistened with the capture solution, soaking the hydrophilic material until the mass or volume of liquid exceeds a saturation threshold within the mesh sheet and forms droplets that flow along the mesh fibers into the pores (openings) to produce a liquid film within the pores, in addition to the moistened surface of the hydrophilic mesh material itself. This is different from the hydrophobic wetting technique, which relies on the mesh material repelling the liquid to force the droplets away from the mesh fibers and into the pores.

[0168] In some implementations, the mesh compact may include material additives to further optimize hydrophilicity and decrease the contact angle between the liquid-solid interface in at least a portion of the mesh sheet.

[0169] In addition to or as an alternative to the previous exemplary means of increasing the hydrophilicity of the mesh material, the surface roughness of the mesh fiber can be modified to increase hydrophilicity.

[0170] As can be seen in Figure 14A, in some implementations, the mesh compact contains at least a portion of the 901 mesh sheet which has hydrophilic properties. In some cases, this can increase the effectiveness of the 901 mesh sheet in capturing CO2 (sometimes referred to as the CO2 capture flux), for example, by at least 10%. This increased effectiveness can be achieved by increasing the wetting fraction of the mesh compact. If the mesh material is already inherently somewhat hydrophilic (tending to be wetted by water), then the addition of small microstructures can increase the wetted surface area.

[0171] The mesh compact is designed to be positioned in the path Petition 870260084693, dated 08 / 20 / 2026, p. 138 / 196 29 / 73 of airflow from a gas-liquid contactor, such as an air contactor in DAC applications, or a cooling tower housing (if modernized or adapted for CO2 capture applications). The mesh compact consists of one or more mesh panels, inserted and / or aligned to form relatively straight gas channels, wherein the larger (flat) surface area of ​​the mesh sheet is collinear with the direction of gas stream flow. The upper edge of the mesh panel(s) is coupled to a liquid distribution system, where the liquid capture solution is applied (e.g., continuously or intermittently, using pulse flow, discharge flow, or a combination thereof) to the upper edge or portion of the mesh sheet and allowed to move below the height of the mesh sheet, forming a uniform liquid film within most of the mesh pores and / or along the fibers that delineate the mesh pores.This liquid film provides a gas-liquid interfacial area through which CO2 from the airstream is absorbed or captured as the airstream moves through the gas channels between the mesh sheets. The mesh sheet compact described here has mesh sheets that are arranged relative to the airflow. For example, in one embodiment, the mesh sheets are positioned in a collinear orientation with the airflow direction, so that the airstream moves along a direction that is parallel to a flat surface of the mesh sheets. In another embodiment, the airflow moves along a direction that is parallel to the air displacement depth (ATD) defined by the mesh sheets.The airflow movement in this direction allows the airflow to contact the interfacial area of ​​the capture solution (liquid film) while moving along a largely unobstructed path or channel for air displacement, minimizing pressure drop. In other words, the less restricted air path created by the orientation of the mesh sheets decreases the differential pressure along the ATD. The mesh sheets, when positioned parallel to the gas flow direction, maximize the gas-sorbent contact efficiency for capturing CO2 from dilute sources, such as air.

[0172] High gas velocity, solution properties, and varying operating temperatures can affect the mesh sheet's ability to maintain a uniform liquid film across the mesh pores (openings), a phenomenon referred to as liquid film stability. In some cases, significant liquid film instability can reduce the overall performance of the mesh compact, leading to reduced CO2 capture. This problem can arise if the size of Petition 870260084693, dated 08 / 20 / 2026, pp. 139 / 196 30 / 73 mesh pores become too large to support the liquid film under given operating conditions, such as solution properties (surface tension, viscosity, etc.) and gas velocities. The potential increase in wetted area of ​​mesh sheets with larger pore diameters, which increases the wetted interfacial surface area and thus improves CO2 mass transfer to the liquid, must be balanced against the risk of liquid film destabilization, which can lead to a reduced wetted interfacial area for the given operating conditions. To best achieve this balance, the mesh material configuration, either hydrophilic or hydrophobic, for CO2 capture from dilute sources is optimized to maintain maximized mass transfer with respect to mesh pore size and DAC operating conditions.In some cases, mesh sheets with a range of pore sizes, if selected to handle the operating conditions, can have a significantly larger wetted interfacial area and lower pressure drop than a similar volume of compacted material commonly used in DAC applications, for example, the compacted material or fill commonly used in the cooling tower industry.

[0173] The mesh compact, when combined with a liquid distribution system as described herein, can reduce sorbent flow rate requirements while still providing uniform liquid distribution throughout the height and length of the sheet. In some cases, the liquid distribution system may include one or more nozzles that are operable to apply a spray or mist of capture solution onto the mesh sheet. The liquid can be applied to the top of the mesh sheet or at any point along the mesh sheet (e.g., to wet dry spots).Given that the mesh sheet surface defines the gas channel and is porous, it does not form a significant impediment to airflow (especially compared to compacted arrangements where airflow moves through the compacted block rather than collinearly along a flat surface). The mesh compaction and operating method described here significantly reduce the pressure drop for a given air velocity and ATD, which in turn also reduces the energy required to operate the system. Thus, in some implementations, the primary direction of airflow through the gas channel is along a surface of the mesh sheet, it being understood that some residue and a comparatively smaller volume of air move through the mesh sheet due to the porous nature of the mesh sheet. Petition 870260084693, dated 08 / 20 / 2026, pp. 140 / 196 31 / 73

[0174] In some implementations, the mesh compact is operated with a liquid distribution system configured for continuous and / or intermittent flow of capture solution over the mesh compact, wherein the intermittent flow may be provided in a series or cycle of variable flow rates, such as discharge flows (higher), no flows, and pulse flows (lower), each for a discrete period of time. In some cases, this intermittent mode of liquid distribution over the compact is used to reduce or mitigate the formation of stream flow. As discussed above, at low liquid loading rates, the capture solution may tend towards a stream flow regime as it moves down the compact. Poor or incomplete wetting of the mesh sheets caused by stream flow of capture solution may lead to lower mass transfer due to the reduced interfacial area per unit compact area.In some cases, the use of intermittent flow and discharge, and / or pulse can mitigate this problem.

[0175] Mesh compaction can also provide a significantly larger reactive surface area for a given volume, which can result in a high degree of CO2 capture from the airflow. The mesh sheet surface is exposed to a direct sorbent feed (e.g., on an upper edge of the mesh sheet or another area of ​​the mesh sheet), which can result in uniform liquid sorbent distribution across the width of the mesh sheet. In this way, the mesh material can be thoroughly wetted, avoiding any significant dry or unwetted sections.

[0176] DAC compact designs can aim to maximize and maintain the reactive gas-liquid interfacial area and increase solution capture performance to maximize the absolute capture flux of the reactant gas (equation 1), for example, capturing ambient CO2 without incurring prohibitive energy or economic penalties. Although solution kinetics dominate, as is consistent with the two-film mass transfer theory, the availability of CO2 in solution for reaction is governed by the equilibrium solubility of CO2 in the sorbent medium under the respective conditions according to Henry's constant (equation 2). Therefore, under an optimal process condition, there would be no depletion of the gas-phase CO2 concentration through the depth of the mesh compact (e.g., an infinite air velocity condition), and the sorbent would have a uniform capture rate throughout the gas-liquid contactor. However, in practice Petition 870260084693, dated 08 / 20 / 2026, pp. 141 / 196 32 / 73 this is not the case, and the capture flow is driven both by mass transfer kinetics and by exhaustion through the gas-liquid contactor system. Capture Flow (g / s^m2) = pC02vair[1 - exp ( - ε KLSSA ATDvair )] equation 1 Mass Transfer Coefficient (mm / s) = KL = Hcc7DCO2 · koH · {OH} equation 2 Where: Contactor air velocity [m / s] ATD Air Displacement Depth [m] SSA Specific Surface Area [m2· m-3] ε Wetting Fraction Pco2 g / m3 KL Mass Transfer Coefficient [mm / s] HccHenry solubility constant DCO2 CO2 diffusivity [mm2 / s] k(jH-Infinite dilution rate constant [m3mol-1s-1] {OH} Hydroxide concentration [kmol / m3]

[0177] A model incorporating equations 1 and 2 above can be used with the mesh compact designs of this description to lead to an optimized capture flow. For example, the method of operating a gas-liquid contactor to flow the diluted CO2 gas stream collinearly through the plane of a mesh compact surface, the mesh compact moistened with a capture solution having known solution properties, as described in a variety of embodiments in this description, can be shown to support a reduction in pressure drop across the ATD of the compact, allowing an increase in gas velocity which in turn reduces the impact of the CO2 capture gradient on overall performance.

[0178] The mesh compact with characteristics according to the present description is designed in an embodiment for commercial DAC applications and as such has the ability to maximize the CO2 gas-liquid interfacial area by Petition 870260084693, dated 08 / 20 / 2026, pp. 142 / 196 33 / 73 unit compaction area for efficient capture of CO2 from the air while minimizing the mass of the mesh sheets and energy consumption. The mesh compaction is designed to contain small openings for the solution to pass through and form a thin liquid traverse to generate interfacial area for reaction with CO2 to occur. This can improve capture performance and also decrease the volume of material required for a given surface area of ​​mesh compaction.

[0179] Figure 1 shows a schematic illustration of an exemplary gas-liquid contactor 100. The gas-liquid contactor 100 includes a frame 105, a housing 104, one or more upper distribution tanks 107, a plenum 114, a gas moving device (sometimes referred to herein as a fan or blower 102), a fan shroud 103, a lower liquid collection tank 106, at least one section of mesh compact 101, and a control system 999. Referring to Figure 1, the gas-liquid contactor 100 is a double-cell cross-flow air contactor because there are two sections of mesh compact 101 separated by the plenum 114, and the air moves through the mesh compact 101 in a direction that is substantially perpendicular to the liquid flow from the upper distribution tanks 107 to the lower liquid collection tank 106.As described below in greater detail, other configurations of the gas-liquid contactor 100 are possible. The mesh compact 101 can be formed to conform to the shape of the gas-liquid contactor and can be sized to fit within the frame 105 and housing 104. In some cases, the gas-liquid contactor may include a cylindrical or conical housing. The term tank is used throughout the present description, but any fluid containment receptacle may be used. Some non-limiting examples include tanks, galleries and channels.

[0180] Referring to Figure 1, structure 105 (e.g., a combination of interconnected structural members) provides structural support and stability for the gas-liquid contactor 100, and housing 104 provides a partial enclosure for the illustrated components. Referring to Figure 1, housing 104 defines a portion of the plenum 114, which is a hollow interior of the gas-liquid contactor 100.

[0181] With reference to Figure 1, the upper distribution tank(s) 107 are formed or positioned within the structure 105. Each upper tank 107 may, at least partially, include or store a CO2 capture solution 124 (e.g., a liquid sorbent). The CO2 capture solution 124 may flow Petition 870260084693, dated 08 / 20 / 2026, pp. 143 / 196 34 / 73 downwards from the upper tanks 107 by, for example, gravity flow, uniform or laminar flow, to at least one section of the mesh compact 101, flow along the flat surface of the mesh compact 101, and eventually flow into one or more lower collection tanks 106. The gas-liquid contactor 100 may include a liquid distribution system 109. The liquid distribution system 109 may include a set of nozzles, the distribution tank 107 (also referred to as the upper tank), a pressurized header, or a combination thereof, configured to distribute the CO2 capture solution 124 over the compact 101. For example, the upper tank 107 may contain the CO2 capture solution 124 and nozzles positioned at the bottom of the upper tank 107 may flow the CO2 capture solution 124 over at least one section of mesh compact. 101.The CO2 capture solution 124 can flow through at least one section of mesh compaction 101 by gravity and then be collected in the collection tank 106 (also referred to as the bottom tank). Other exemplary embodiments of liquid distribution systems 109 are described below.

[0182] As the CO2 capture solution 124 circulates through and over at least one section of mesh compact 101 in a dominant liquid flow direction, CO2-laden air 120 is flowing (e.g., by the action of the fan or blower 102) through at least one section of mesh compact 101 in a dominant gas flow direction that is substantially orthogonal to the dominant liquid flow direction in order to thereby contact the CO2 capture solution 124. By contacting these two fluids in a cross-flow, as shown in Figure 1, a portion of the CO2 within the CO2-laden air stream 120 is transferred to the CO2 capture solution 124, and the fan 102 positioned in the fan housing 103 moves the CO2-poor air stream 130 out of the gas-liquid contactor 100 to an environment.A CO2-rich solution flows into at least one collection tank 106, and one or more pumps recirculate at least a portion of the CO2-rich solution 124 back into at least one upper distribution tank 107. The term air in the expression CO2-laden air does not limit the mesh pack 101 to be used only for atmospheric air processing. Other gases may flow through the mesh pack 101 as well. In some implementations, as shown in Figure 1, the fan 102 is an induced draft fan that pulls air through the... Petition 870260084693, dated 08 / 20 / 2026, pp. 144 / 196 35 / 73 at least one section of mesh compact 101. In some cases, the fan 102 is a forced draft fan which pumps or pushes air through at least one section of mesh compact 101. In some implementations, the gas-liquid contactor 100 may include an induced draft blower or a forced draft blower. In some cases, the CO2 capture solution 124 is provided for at least one section of mesh compact 101 at a liquid loading rate ranging from 1 L / min to 4 L / min.

[0183] The lower tanks 106 of the gas-liquid contactor 100 act as collection tanks for the CO2-rich capture solution 124. In some implementations, at least a portion of the solution may be sent, using either a swirling recirculation pump system or a separate pump and piping system, downstream to other units or facilities for further processing. In one embodiment, some or all of the CO2-rich capture solution flows from the gas-liquid contactor 100 to downstream units for further processing. For example, a CO2 capture solution 124 may be regenerated and some or all of the absorbed CO2 may be recovered from the CO2-rich solution. The regenerated CO2 capture solution 124 may be sent back to the gas-liquid contactor 100.

[0184] In some implementations, instead of the double-cell cross-flow configuration shown in Figure 1, the gas-liquid contactor system 100 may consist of one or more gas-liquid contact cells, each having one or more fans, similar to larger industrial cooling tower systems. Some non-limiting examples of other possible configurations for the gas-liquid contactor system 100 are described with reference to Figures 1A and 1B.

[0185] Referring to Figure 2, the gas-liquid contactor system 200 is a vertical body. The gas-liquid contactor system 200 has an air inlet 110 along a lower portion through which CO2-laden air 120 is admitted into the gas-liquid contactor system 200. The fan 102 rotates around a geometric fan axis to draw the CO2-laden air 120 through the air inlet 110 in an upward direction to contact the mesh compact section 101. In the configuration of Figure 2, the gas-liquid contactor system 200 has only one mesh compact section 101, and can therefore be referred to as a single-cell gas-liquid contactor system 200. The solution of Petition 870260084693, dated 08 / 20 / 2026, pp. 145 / 196 36 / 73 CO2 capture solution 124 circulates downwards, for example by gravity flow, uniform or laminar flow, etc., within the mesh compact 101 and eventually flows to one or more lower collection tanks 106. As a CO2 capture solution 124 circulates through and over the mesh compact 101, CO2-laden air 120 is flowing (for example by the action of the fan 102) upwards through the mesh compact 101 to thereby contact the CO2 capture solution 124. Thus, the flow of CO2 capture solution 124 through the mesh compact 101 in Figure 2 is countercurrent or contrary to the flow of CO2-laden air 120 through the mesh compact 101. A portion of the CO2 within the CO2-laden air stream 120 is transferred to (for example, absorbed by) a CO2 capture solution. 124, and the fan 102 moves the CO2-poor air stream 130 out of the gas-liquid contactor 200 into an environment.The CO2-rich solution flows into at least one collection tank 106.

[0186] With reference to Figure 3, the gas-liquid contactor system 300 is a vertical body. The gas-liquid contactor system 300 has an air inlet 110 along a vertical lateral portion through which CO2-laden air 120 is admitted into the gas-liquid contactor system 300. The fan 102 rotates around a geometric fan axis to draw the CO2-laden air 120 through the air inlet 110 in a substantially horizontal direction to contact the mesh compact section 101. In the configuration of Figure 3, the gas-liquid contactor system 300 has only one mesh compact section 101 and can therefore be referred to as a single-cell gas-liquid contactor system 300. The CO2 capture solution 124 circulates downward, e.g., gravity flow, uniform or laminar flow, etc., within the mesh compact 101 and eventually flows to one or more lower collection tanks 106.As the CO2 capture solution 124 circulates through the mesh pack 101, the CO2-laden air 120 is flowing (e.g., by the action of the fan 102) substantially horizontally through the mesh pack 101 in order to thereby contact the CO2 capture solution 124. Thus, the flow of CO2 capture solution 124 through the mesh pack 101 in Figure 2 is substantially perpendicular to the flow of CO2-laden air 120 through the mesh pack 101. Such a flow configuration can be referred to as a cross-flow configuration. A portion of the CO2 within the CO2-laden air stream. Petition 870260084693, dated 08 / 20 / 2026, pp. 146 / 196 37 / 73 120 is transferred to a CO2 capture solution 124, and the fan 102 moves the CO2-poor air stream 130 out of the gas-liquid contactor 300 to an environment. The CO2-rich solution flows to at least one collection tank 106. While in embodiments one or more sections of the mesh compact 101 are shown having substantially vertical orientations (i.e., defining a plane that has a vertical orientation), one or more sections of mesh compact 101 may have substantially horizontal orientations (i.e., defining a plane that has a horizontal orientation). Similarly, one or more sections of mesh compact 101 may have orientations that form non-zero angles with a vertical plane and / or a horizontal plane.

[0187] Referring to Figure 1, the exemplary gas-liquid contactor system 100, as well as other exemplary implementations according to the present description, include process streams (also referred to as streams) within a gas-liquid contactor system used to capture CO2. The process streams, as well as the downstream process streams to which the gas-liquid contactor systems are fluidly coupled, may be flowed using one or more flow control systems (e.g., control system 999) implemented throughout the system. A control system 999 may include one or more flow pumps, fans, blowers, or solids conveyors to move the process streams, one or more flow pipes or conduits through which the process streams are flowed, and one or more valves to regulate the flow of streams through the pipes.Each of the configurations described here may include at least one variable frequency drive (VFD) coupled to a corresponding pump that is capable of controlling at least one inlet liquid flow rate or at least one outlet liquid flow rate. In some implementations, the liquid flow rates are controlled by at least one flow control valve.

[0188] In some embodiments, a 999 flow control system can be operated manually. For example, an operator can set a flow rate for each pump or transfer device and set the open or closed valve positions to regulate the flow of process streams through the pipes in the 999 flow control system. Once the operator has set the flow rates and open or closed valve positions for all flow control systems Petition 870260084693, dated 08 / 20 / 2026, pp. 147 / 196 38 / 73 Distributed throughout the system, the flow control system can manage the streams under constant flow conditions, for example, constant volumetric rate or other flow conditions. To change the flow conditions, the operator can manually operate the 999 flow control system, for example, by changing the pump flow rate or the open or closed valve position.

[0189] In some embodiments, the 999 flow control system can be operated automatically. For example, the 999 flow control system can be communicatively coupled to a computer or a computer-readable medium that stores instructions (such as flow control instructions and other instructions) executable by one or more processors to perform operations (such as flow control operations). An operator can set the flow rates and open or closed valve positions for all 999 flow control systems distributed throughout the installation using the 999 control system. In such embodiments, the operator can manually change the flow conditions by providing inputs through the 999 control system.Also, in such embodiments, the 999 control system can automatically (i.e., without manual intervention) control one or more of the flow control systems, for example, using feedback systems connected to the 999 control system. For example, a sensor (such as a pressure sensor, level sensor, flow rate sensor, temperature sensor, or other sensor) may be connected to a pipe through which a process stream flows. The sensor can monitor and provide a flow condition (such as pressure, temperature, or other flow condition) of the process stream to the 999 control system. In response to the flow condition exceeding a limit (such as a limit pressure value, a limit temperature value, or other limit value), the 999 control system can automatically perform one or more operations.For example, if the pressure or temperature in the pipe exceeds the limit pressure value or the limit temperature value, respectively, the 999 control system can provide a signal to the pump to decrease the flow rate, a signal to open a valve to relieve pressure, a signal to shut off a process stream flow, or other signals. For example, if a flow rate sensor monitoring the gas velocity at the inlet or mesh pack reads that the gas velocity is above a limit gas velocity value, the flow rate sensor can send a signal to a controller in the 999 control system that instructs a fan to reduce its fan speed. Petition 870260084693, dated 08 / 20 / 2026, pp. 148 / 196 39 / 73

[0190] In another example, the 999 control system may be communicatively coupled to a variable frequency drive (VFD) pump and a liquid distribution system that responds to a controller in the 999 control system. If a flow rate sensor reads that the liquid loading rate (flow rate of capture solution to the mesh compact) is above a limiting flow rate value, the flow rate sensor may send a signal to a controller in the 999 control system to reduce the rotational speed of the motor in the VFD pump and thereby reduce the liquid loading to the mesh compact. In another example, the 999 control system may be communicatively coupled to a control valve and nozzles distributing liquid to the mesh compact.If a flow rate sensor reads that the liquid loading rate is above the flow rate setpoint limit value, a signal will be sent to the control valve to partially close and reduce the flow rate.

[0191] Referring to Figure 4, the gas-liquid contactor 400 includes a structural support system 401 for at least one mesh compact section 101. The structural support system 401 includes one or more support rods, support beam 204, upper spacer(s), lower spacer(s), at least one air inlet area for the CO2-laden air stream 220 and at least one outlet area for the CO2-poor air stream 230. The one or more support rods include a first rod subset(s) (also referred to as an upper rod 206) and a second rod subset(s) (also referred to as a lower rod 208). The use of the term "upper" in the upper rod and the term "lower" in the lower rod does not limit the rod to a specific position relative to another element of the gas-liquid contactor 400. There may be another element positioned above the upper rod 206 and / or below the lower rod 208.Mesh compact 101 includes multiple mesh panels 202a, 202b (two are shown in Figure 4, but more are possible). Each mesh panel 202a, 202b is a segment of mesh compact 101 that includes, or is composed of, a mesh material 203. The mesh material 203 can take any suitable form. For example, in one implementation, the mesh material 203 is a porous sheet (e.g., a screen), sometimes referred to herein as a mesh sheet. In another possible example, the mesh material 203 is a rigid body with pores extending through it. The mesh material 203 is a porous body that has a length and a... Petition 870260084693, dated 08 / 20 / 2026, pp. 149 / 196 40 / 73 width which are many orders of magnitude greater than their thickness or depth. The mesh material 203 of each mesh panel 202a, 202b is fastened by one or more of the upper rods 206 and lower rods 208 so that there is sufficient tension acting on the mesh material 203. For example, the mesh material 203 may have sufficient tension to form a flat surface. The tension of the mesh material 203 can be adjusted to adjust the flow properties of the CO2 capture solution 124 or sorbent stream. Referring to Figure 4, the upper rods 206 are mounted on one or more support beam(s) 204 and are positioned to allow the CO2 capture solution 124 or sorbent stream to flow from a distribution tank (such as distribution tank 107) to the top of the mesh panels 202a, 202b.The support beam(s) 204 may have an orientation that is transverse or perpendicular to the orientation of the upper rods 206. In the configuration of Figure 4, the CO2 capture solution 124 is introduced on top of the mesh panels 202a, 202b. In an alternative configuration, the CO2 capture solution 124 is introduced at a different location from the mesh panels 202a, 202b. In some cases, the CO2 capture solution 124 flows into the mesh panels 202a, 202b at a solution loading rate ranging from 1 L / min to 4 L / min.

[0192] Referring to Figure 4, mesh panels 202a, 202b and upper rods 206 are not self-supporting. Additional structural support is therefore provided, such as support beam(s) 204 and one or more support column(s) 214. These components can be coupled to one or more of the mesh panels 202a, 202b and to the housing 104 (see Figure 1). The support beam 204 can be supported at intermediate locations within the gas-liquid contactor structure 105, either by means of a rigid connection as shown in Figure 4, or by the use of cables, ropes or wires. In some respects, the support beams 204 can be coupled with upper spacer(s) to maintain a constant distance between the upper rods 206 and the mesh material 203.In some respects, the position of mesh material 203 with respect to the lower rod(s) 208 is adjustable so that mesh material 203 can be coupled to, in contact with, or spaced from the lower rod(s) 208, for example, to maintain a constant distance between the lower rod(s) 208 and the upper rods 206. In some respects, the spacing between mesh material 203 of adjacent mesh panels 202a, 202b creates gas channels. Petition 870260084693, dated 08 / 20 / 2026, pp. 150 / 196 41 / 73

[0193] With reference to Figure 4, the CO2-laden gas stream 220 enters and flows through mesh panels 202a, 202b in a collinear direction. By collinear, it is understood that the CO2-laden gas stream 220 flows along a direction that is parallel to a flat surface of the mesh material 203. For example, and referring to Figure 4, the CO2-laden gas stream 220 flows along a substantially horizontal direction, and the flat surface of the mesh material 203 is parallel to the plane of the drawing page showing Figure 4. A stream of liquid sorbent (such as CO2 capture solution 124) flows from the top of the mesh material 203, creating a liquid film through at least a portion of the pores of the mesh material 203.The CO2-laden gas stream 220 and the CO2 capture solution 124 come into contact in cross-flow mode, such that at least a portion of the CO2 in the CO2-laden gas stream 220 is absorbed into the CO2 capture solution 124 before the air stream leaves the mesh panels 202a, 202b and is released from the gas-liquid contactor as the CO2-poor air stream 230 through at least one outlet area.

[0194] Referring to Figure 5, the example of structural support system 500 includes multiple top rods 206 supported on, and extending between, support beams 204. Each support beam 204 is supported by, and extends between, support columns 214. The illustrated section of the mesh compaction 101 includes multiple mesh panels 202. Each mesh panel 202 is supported by one of the top rods 206, and extends between adjacent support beams 204. The mesh panels 202 have a vertical orientation. Mesh panels 202 can extend in a direction that is perpendicular to the ground. The CO2-laden gas stream 220 flows along a direction that is parallel to a flat surface of the mesh material 203 of each mesh panel 202. For example, and referring to Figure 5, the CO2-laden gas stream 220 flows along a direction that is perpendicular to a normal vector in the plane of mesh panel 202.Referring to Figure 5, the CO2-laden gas stream 220 flows along a second dimension defined along a direction that is parallel to the air displacement depth ATD defined by each of the mesh panels 202, where ATD is the distance of the mesh material 203 that is traversed by the airflow for the purposes of capturing CO2 from the CO2-laden gas stream 220. Referring to Figure 5, the mesh panels 202 of the mesh compact 101 are spaced from each other. In the mesh compact 101 configuration in Figure 5, the mesh panels 202 are spaced from each other. Petition 870260084693, dated 08 / 20 / 2026, pp. 151 / 196 42 / 73 others in a horizontal direction, or in a direction that is transverse or perpendicular to the ATD. Spaced mesh panels 202 define gas channels. For example, two adjacent mesh panels 202 are spaced along a first dimension. In the configuration of Figure 5, the first dimension is a gas channel spacing 207 that corresponds to a gas channel width 408 between the two adjacent mesh panels 202. The gas channels 408 are described below in more detail.

[0195] Other configurations of mesh pack 101 are possible. For example, and referring to Figure 6, mesh pack 101 has a substantially horizontal orientation, in which the planar surfaces formed by each mesh panel 202 are defined by a normal vector that has a vertical orientation. Mesh panels 202 are stacked one above the other to form mesh compact 101. The CO2-laden gas stream 220 flows along a direction that is parallel to a flat surface of the mesh material 203 of each mesh panel 202. The CO2-laden gas stream 220 flows along a direction that is parallel to the ATD defined by each of the mesh panels 202. A liquid sorbent stream, such as CO2 capture solution 124, flows from above the mesh material 203, creating a liquid film through at least some pores of the mesh material 203 of one or more mesh panels 202.In a co-current flow configuration, an example of which is shown in Figure 6, the CO2 capture solution 124 is transported to the mesh compact 101 along a direction that is parallel to the direction along which the CO2-laden gas stream 220 flows. In such a configuration, the CO2 capture solution 124 can be provided as a liquid-air mixture of fine particles (e.g., a mist provided by spraying, sprinkling, or cascading from one or more nozzles). In such a configuration, the CO2 capture solution 124 can be provided as a spray through nozzles so that droplets of the CO2 capture solution 124 are carried along in the CO2-laden gas stream 220. The composition of the CO2 capture solution 124 can be provided to the mesh panels 202 further along the ATD if necessary or desired.Regardless of its flow direction, the CO2 capture solution 124 wets the mesh material 203 of one or more of the mesh panels 202. The CO2-laden gas stream 220 comes into contact with the CO2 capture solution 124 on the mesh material 203, so that at least a portion of the CO2 in the CO2-laden gas stream 220 is absorbed. Petition 870260084693, dated 08 / 20 / 2026, pp. 152 / 196 43 / 73 in a CO2 capture solution 124 before the airflow leaves the mesh panels 202 and is discharged from the gas-liquid contactor outlet as CO2-poor air stream 230.

[0196] In some implementations, the mesh pack 101 (consisting of one or more mesh panels 202a, 202b) can be installed as multiple separate cells in a gas-liquid contactor 100 to further increase the gas-liquid surface area within the existing structure and housing of the gas-liquid contactor 100.

[0197] In some implementations, mesh panels 202a, 202b are replaceable with new or repaired mesh panels 202a, 202b if any part of the original mesh material 203 is damaged. In some cases, mesh panels 202a, 202b can be detached from rods 206, 208 when rods 206, 208 are decoupled from support beam 204.

[0198] The collinear orientation of mesh panel(s) 202a, 202b with the airflow direction allows for a largely unimpeded path (or channel) for air displacement, minimizing pressure drop. In other words, the less restricted air path, which is created by orienting mesh panels 202a, 202b parallel to the airflow, reduces the differential pressure along the ATD.

[0199] In some implementations, mesh panels 202a, 202b are themselves structural components that can be used as internal support for near-vertical solution film. In some cases, the weave pattern type for mesh material 203, which defines the pore shapes, can be configured to balance solution retention and film flow along mesh material 203. Furthermore, a wider mesh weave has a lower material density and can minimize the mass of mesh material 203 for a predetermined mesh area. In some implementations, there is a limiting mesh weave width beyond which the solution will no longer pass through the fibers to create a continuous film.

[0200] To fasten sheets of 203 mesh material so that they have a uniformly stretched (rigid) and tensioned surface, fasteners can be used. Some examples of fastener types that can be used include glue, staples, clips, mesh fasteners, brackets, or similar. In some cases, the tension of the 203 mesh material can be adjusted with fasteners at a number of anchor points. In some cases, the weight of the rods, spacers, or a combination thereof provides sufficient tension for the 203 mesh material. A Petition 870260084693, dated 08 / 20 / 2026, pp. 153 / 196 44 / 73 Sufficient tension can be achieved when the movement of mesh panels 202a, 202b is limited such that adjacent mesh panels 202a, 202b do not contact each other and impede airflow. In some cases, the support rods may be coupled to a tensioning structure that allows tension adjustment. For example, the tensioning structure may include a set of unistruts with expansion bolts that can be adjusted to move the rods to achieve the desired tension in the mesh material 203 which is inserted or clamped onto the rods.

[0201] In some cases, the 101 mesh compact is modular or compact and can be easily installed on existing gas-liquid contactors (or potentially cooling towers) without modifications. The 101 mesh compact can be installed above at least one bottom collection tank.

[0202] Mesh material 203 is selected to be compatible with CO2 capture solution 124. For example, mesh material 203 may be compatible with capture solutions that have a high pH, ​​hydroxide solutions (e.g., KOH, NaOH), bicarbonate / carbonate solutions, amine solutions, or combinations thereof.

[0203] In some implementations, a portion or all of the mesh compact 101 and / or the structural support components are made of materials that do not corrode, degrade, or deteriorate significantly in the presence of process fluids, thus avoiding premature replacement of the gas-liquid contactor. For example, beams 204 and columns 214 may be made of wood, metal, or plastic materials, while rods 206, 208 may be made of plastic or metallic materials (e.g., PVC, acrylonitrile butadiene styrene (ABS), or other thermoplastics), and the mesh material 203 may include metal, PVC, polymer, plastic, or organic materials. In applications that utilize strong alkaline chemistry, such as hydroxides, wetted materials (e.g., mesh material 203, rods 206, 208, beams 204 and columns 214) can be selected to resist degradation caused by exposure to these solutions.In some cases, these materials may include stainless steel, plastics, PVC, HDPE, PTFE, and similar materials.

[0204] In some implementations, the upper and lower support rods 206, 208 can be thin posts, strips, ropes, cables or similar to create a minimal gas channel while still accommodating direct sorbent flow, allowing a Petition 870260084693, dated 08 / 20 / 2026, pp. 154 / 196 45 / 73 film of liquid uniformly distributed over the 203 mesh material, and increased interface or reactive surface between the gas flow and the sorbent.

[0205] Figure 7 shows exemplary rod designs that can be implemented in structural support systems 800, 900 of Figures 8A and 9, respectively. In some implementations, the upper rods may include a plurality of grooves 703 etched into them to form grooved rods 702, and the grooves 703 may direct the capture solution 124 onto the mesh material 203. The mesh material 203 may be held between the grooved rods 702 so that the surfaces with the grooves 703 face each other. The grooves 703 allow the capture solution 124 to flow down onto the mesh material 203. In some implementations, the upper rods may be shaped or configured to interlock with each other. For example, the cross-sections of the upper rods 704 are C-shaped or arc-shaped, and the upper rods 206 can interlock with each other.In some implementations, the cross-sections of the upper rods are U-shaped, like upper rod 708, and may interlock with each other. In some implementations, the upper rods may taper in thickness from one end to the opposite end, such as tapered rod 706. This may allow mesh compaction 101 to be more easily installed in certain gas-liquid contactors (e.g., gas-liquid contactor structures that are rounded or cylindrical). Any of the rod designs 700 may be implemented as rods or spacers in the structural support system 800, 900 shown in Figures 8A and 9, respectively.

[0206] Figure 8A shows an exemplary mesh compact 801 and structural support system 800. This system is similar to previous embodiments in that the structural support system 800 includes one or more upper rods 206, one or more lower rods 208, one or more support columns 214, and one or more support beams 204. The structural support system 800 of Figure 8A includes one or more upper spacers 210 and one or more lower spacers 212. In some cases, the upper support rods 206 and the lower support rods 208 are maintained at a constant distance using one or more upper spacer(s) 210 and lower spacer(s) 212, respectively. Spacers 210, 212 can provide lateral and torsional stiffness to rods 206, 208. In some cases, the tension Petition 870260084693, dated 08 / 20 / 2026, pp. 155 / 196 46 / 73 of the mesh material 203 can be adjusted with anchor points 215. In some cases, the weight of the lower rods 208, lower spacers 212, or a combination thereof provides sufficient tension for the mesh material 203. In some cases, the upper support rods 206 and the lower support rods 208 can be coupled to a tensioning structure that allows tension adjustment. For example, the tensioning structure may include a set of unistruts with expansion bolts that can be adjusted to move the upper support rods 206, the lower support rods 208, or both to achieve the desired tension in the mesh material 203 that is inserted or secured in the rods. Spacers 210, 212 help to adjust the position of mesh material 203, for example, in order to maintain a constant distance between rods 206, 208 and mesh material 203.In some respects, the position of mesh material 203 relative to rods 206, 208 is adjustable so that mesh material 203 can be coupled to, in contact with, or spaced from rods 206, 208, for example, to maintain uniformity between adjacent mesh panels 202. In the mesh compact configuration 801 of Figure 8A, mesh compact 801 includes a single mesh panel 802. A single continuous sheet of mesh material 203 is inserted through the upper support rods 206 and the lower support rods 208 to form individual mesh panel segments 209 of the single mesh panel 802. Each mesh panel segment 209 is a portion of the continuous sheet of mesh material 203 set between the upper and lower support rods 206, 208. The continuous sheet of mesh material 203 can be inserted around the upper support rods. 206 and the lower support rods 208 to form the total volume of the mesh compaction 801.

[0207] The structural support system 800 also assists in forming a variety of gas channels 408 between the mesh panel segments 209. Each gas channel 408 is a defined volume between adjacent and spaced mesh panel segments 209, or is a defined volume between a mesh panel segment 209 and an inner wall of the gas-liquid contactor housing 104. Referring to Figure 8A, each pair of adjacent mesh panel segments 209 are spaced from each other in a first direction D1 to define a gas channel spacing 207 for each gas channel 408. The first direction D1 is transverse to the air displacement depth ATD (see Figure 5). The first direction D1 is defined in a plane that is normal to the air displacement depth ATD. In Petition 870260084693, dated 08 / 20 / 2026, pp. 156 / 196 47 / 73 embodiment of Figure 8A in which the mesh panel segments 209 have a vertical orientation (e.g., a vector normal to the mesh panel segments 209 has a horizontal orientation), the gas channel spacing 207 is a gas channel width 408. In an alternative embodiment, such as where the mesh panel segments 209 have a horizontal orientation (e.g., a vector normal to the mesh panel segments 209 has a vertical orientation), the gas channel spacing 207 (the first dimension) is a gas channel height 408. The gas channel spacing 207 can also be used to define other gas channel dimensions 408. Each mesh panel 202 delimits at least two gas channels 408, on opposite sides of the mesh panel segment 209.

[0208] Referring to Figure 5, the air displacement depth (ATD) is defined along a direction that is transverse. to gas channel spacing 207.Referring to Figure 5, the air displacement depth is defined on a plane that is normal to the gas channel spacing 207. Referring to Figure 5, the air displacement depth is defined on a plane that is perpendicular to a plane on which the gas channel spacing 207 is defined. In a possible configuration of the mesh pack 101 of Figure 5, the mesh panels 202 have a vertical orientation and the air displacement depth (ATD) is less than three orders of magnitude greater than the gas channel width 207. For example, mesh panels that have a width of 182.88 mm (6 ft) and a height of 243.84 mm (8 ft) can have gas channel widths of approximately 6.35 mm (0.25 inches). Other dimensions of mesh panel and gas channel widths are possible. In one possible configuration, the ATD air displacement depth is between one and two orders of magnitude greater than the gas channel width 207.In some implementations, the gas channel width may be 6.35 mm (0.25 inches) or greater. The use of the term air in ATD air displacement depth does not limit 408 gas channels to being used only for channeling air. Other gases may flow through 408 gas channels as well.

[0209] In the mesh compact configuration 101 of Figure 6 in which the mesh panels 202 have a vertical orientation, each gas channel 408 has a length / depth defined in a direction that is parallel to the air displacement depth, a width (i.e., gas channel spacing 207) defined in a direction that is perpendicular to the air displacement depth, and a height defined in a direction parallel to the vertical. Petition 870260084693, dated 08 / 20 / 2026, pp. 157 / 196 48 / 73

[0210] The structural support system 800 in Figure 8A can allow the mesh panels 202 to have different shapes and angles by adjusting the offset of the upper and lower rods 206, 208, adjusting the spacing between adjacent rods 206, 208, adjusting the rod diameter / width, and / or adjusting the insertion pattern, any of which can in turn affect the shape, size, and / or orientation of the gas channels 408. For example, the upper rods 206 can be offset laterally from the lower rods 208 so that the laterally adjacent mesh panels 802 are not parallel to each other. Alternatively, one or more of the mesh panels 802 can be offset at a non-zero angle from the vertical, which in turn changes the shape, or orientation from the vertical, respectively, of the gas channels 408.

[0211] A cross-sectional shape of each gas channel 408 is defined in a plane that is perpendicular to the ATD. In one embodiment, an example of which is shown in Figure 8A, the cross-sectional shape of each gas channel 408 is constant. In another embodiment, an example of which is shown in Figure 8A, the cross-sectional areas of the cross-sectional shapes are the same for each gas channel 408. In an alternative configuration, the cross-sectional shape of the gas channels 408 for a given mesh compact section 801 varies. Different cross-sectional shapes for the gas channels 408 are possible and within the scope of the present description. For example, and referring to Figure 8A, the configuration of rods 206, 208 allows each gas channel 408 to have a cross-sectional shape which tapers in the direction of either the upper rod 206 or the lower rod 208.The cross-sectional shape of the gas channels 408 may allow a reduced liquid flow rate of the CO2 capture solution 124, and the creation of a thin liquid film on at least one side of one or more of the mesh panels 802. In some cases, the configuration of the mesh panels 802 may allow a uniform distribution of the sorbent on both surfaces of the mesh material 203. Any suitable width for the gas channels 408 may be used. Some non-limiting examples of widths for the gas channels 408 include between 0.25 mm (0.01 inches) and 152.4 mm (6 inches). In some implementations, the maximum distance or width of the gas channels 408 is less than 152.4 mm (6 inches). In one embodiment, an example of which is shown in Figure 8A, the gas channel spacing 207 (e.g., width of... Petition 870260084693, dated 08 / 20 / 2026, pp. 158 / 196 49 / 73 gas channel in Figure 8A) decreases in a direction parallel to the distance between rods 206, 208.

[0212] A variety of potential gas channel configurations 408 are possible, which can be defined by the cross-sectional shape defined by the mesh panels 802. The cross-sectional shape of the gas channels 408 can be determined by the positioning and spacing of the upper support rods 206 and the lower support rods 208, and the upper and lower spacers 210 and 212, respectively. Non-limiting examples of cross-sectional shapes for gas channels 408 include triangular, rectangular, or inclined. Some examples are illustrated in Figures 8A-8J. For example, possible implementations may include gas channels 408 that have triangular cross-sectional shapes (as shown in Figures 8A, 8E, 8F, and 8H).Parallel rectangular cross-sectional shapes (as shown in Figures 8B, 8I, and 8J), offset triangular cross-sectional shapes (as shown in Figure 8E), and parallel and inclined rectangular cross-sectional shapes (as shown in Figure 8C). Horizontal configurations of cross-sectional shapes for 408 gas channels are also possible with the inclusion of lateral support rods. Examples of horizontal cross-sectional shapes for 408 gas channels are shown in Figure 8G (horizontal triangular) and Figure 8D (horizontal rectangular). In some implementations, 408 gas channels may have cross-sectional shapes that are not parallel and inclined, and may form asymmetrical cross-sectional shapes. It is understood that this list is not exhaustive and there could also be combinations and permutations of these configurations that could be used.

[0213] Referring to Figure 9, the illustrated structural support system 900 is similar to the preceding embodiments in that it includes one or more upper rods 206, one or more lower rods 208, one or more support columns 214, one or more support beams 204, one or more upper spacers 210, one or more lower spacers 212, and one or more sheets of mesh material 203. The structural support system 900 is configured to allow the insertion of a single sheet of mesh material 203 around the upper support rods 206 and the lower support rods 208 to form the total volume of the mesh compact 101. The structural support system 900 is also designed to allow the formation of a variety of gas channel shapes and angles 408 by adjusting the offset. Petition 870260084693, dated 08 / 20 / 2026, pp. 159 / 196 50 / 73 of the upper and lower rods, spacing between adjacent rods, rod diameter / width, and / or insertion pattern. Each 408 gas channel has a defined length in a direction that is parallel to the ATD, a defined width in a direction that is perpendicular to the ATD, and a defined height in a direction parallel to the vertical. A cross-sectional shape of each 408 gas channel is defined in a plane that is perpendicular to the ATD.

[0214] In some cases, the exemplary mesh compact and supporting structural components may be positioned in a gas-liquid contactor below a liquid distribution system, one or more upper tanks, or a combination thereof.

[0215] In some implementations, the mesh panels 202 are formed from a single piece of mesh material 203 which can be inserted, sometimes in an alternating pattern, between the upper rods 206 and the offset lower rods 208 to tension the mesh panels 202 and additionally provide an extended interfacial area. In some cases, the fastening of the mesh material 203 so that it has a uniformly stretched (rigid) and tensioned surface can be accomplished through the use of fasteners. For example, the types of fasteners that can be used to fasten the mesh material 203 are glue, staples, clips, mesh fasteners, brackets, or a combination thereof.

[0216] In some cases, the single inserted mesh material 203 is easily replaceable with a new mesh sheet if any part of the mesh material 203 is damaged. The mesh material 203 can be removed from the rods when decoupled from the support beam 204. In another possible configuration, each mesh panel 202 has its own mesh material 203, and each mesh panel 202 is individually mounted on the structural support system 401, 500, 800, 900.

[0217] In some implementations, mesh compact 101 is designed to be compatible with manufacturing at factories or manufacturer sites and to reduce the amount of on-site manufacturing required. Mesh compact 101 may be ready to install in a contactor housing 104 without significant modifications. Mesh compact 101 has reduced the amount of on-site work. Mesh compact 101 may also be installed in a contactor housing 104 designed to operate without existing cooling tower structural elements. In some cases, mesh compact 101 includes a lightweight, low-cost inserted mesh material 203 with durable structural integrity. Petition 870260084693, dated 08 / 20 / 2026, pp. 160 / 196 51 / 73

[0218] Figure 10 shows a front elevation view of an exemplary mesh compact 101 and structural support system 1000, viewed from one end of the mesh compact 101 where the CO2-laden air stream 120, 220 enters the mesh compact 101. A single sheet of mesh material 203 is inserted through the upper support rods 206 and the lower support rods 208. In this implementation, one or more upper support rods 206 are coupled to the support beam 204, and both the upper rods 206 and the lower rods 208 are configured to allow for easy guiding and insertion of the mesh material 203 through the support structure. The gas channels 408 have a substantially constant cross-sectional area and a substantially constant cross-sectional shape.

[0219] In some implementations, an upper distribution tank may include one or more openings to introduce the liquid capture solution on top of the mesh compact 101. The solution may be distributed into a partially enclosed space consisting of the upper edges of one or more sheets of mesh material 203, support beams 204, upper rods 206, and upper spacers 210. In some cases, the structural support system 1000 may be configured to evenly distribute the liquid capture solution over the mesh compact 101 and maintain an optimal space between the gas channel(s) 408. The even distribution of the liquid capture solution over the mesh material 203 creates a thin film of solution that moves in a gravity flow.

[0220] In some cases, the mesh material sheet 203 is inserted and alternated between the upper support rods 206 and the offset lower support rods 208, as shown in Figure 10. The collinear and parallel orientation of the mesh panels is in the direction of airflow, and the mesh compact structure 101 is maintained by providing tension in the vertical direction to the mesh material sheet 203.

[0221] In some implementations, the mesh material sheet 203 requires direct tensioning in order to provide the required surface area for gas-liquid contact. In some cases, one edge of the mesh material 203 may be attached to a first upper rod 206 and a second edge of the mesh material 203 may be attached to the last additional upper rod 206, or one edge of the mesh material 203 may be attached to a first lower rod 208 and a second edge of the mesh material 203 may be attached to the last additional lower rod 208, or other similar combinations. Petition 870260084693, dated 08 / 20 / 2026, pp. 161 / 196 52 / 73

[0222] The ease of installation and removal of mesh sheet 203 can be beneficial for large-scale DAC deployment. Mesh compaction 101 and structural support system 1000 allow for on-site application of large rolls of continuous sheets of mesh material 203. These rolls of mesh material can be inserted over and under upper rods 206 and lower rods 208, respectively, anchored and tensioned in place, allowing for simple installation (and replacement when necessary if soiled or damaged). In some implementations, the roll of mesh material 203 can be cut to size (e.g., approximately the height and width of the gas-liquid contactor inlet) to form a set of mesh panels, and each individual mesh panel can be attached to an upper rod 206 and a lower rod 208 by screws, fasteners, glue, or other adhesive to form a segment.Maintaining the 101 mesh compact can be advantageous compared to conventional gas-liquid contactor designs. If a specific mesh panel, rod, or spacer is damaged (e.g., torn, bent, detached), the segment containing the damaged element can be isolated from other segments of the mesh compact and removed for repair without requiring significant handling of the other gas-liquid contactor components. For example, if a specific mesh panel is damaged, the damaged mesh panel can be accessed through the gas inlet or plenum of the gas-liquid contactor and removed without needing to open the housing. If the mesh panels are glued to the rods or spacers, the damaged mesh panel can be removed, repaired, and then reattached (e.g., by gluing or retensioning / reinserting the mesh material) to the rod or spacer.In contrast, for a conventional compact, if a portion of the compact is damaged, the entire block or section of the conventional compact must be discarded. By comparison, for conventional gas-liquid contactor designs, maintenance or removal of the 101 mesh compact generally requires shutting down the entire unit.

[0223] In one embodiment, the mesh compact 101 is a unit which is prefabricated or pre-assembled off-site or away from the gas-liquid contactor 100, and which is assembled inside the gas-liquid contactor 100 as a single unit, for installation, repair or replacement purposes. In a possible example of such a prefabricated mesh compact 101, the mesh compact 101 includes one or more sheets of mesh material 203 mounted on support structures. Petition 870260084693, dated 08 / 20 / 2026, pp. 162 / 196 53 / 73 to create the mesh panels 202 and the gas channels 408. The support structures can then be coupled to structures within the gas-liquid contactor 100 to assemble the pre-molded mesh compact 101 within the gas-liquid contactor 100.

[0224] In some implementations, it may be advantageous to integrate the support system with an upper tank (e.g., to save on material costs by eliminating the need for a separate upper tank). An integrated support system can reduce the number of steps to install a gas-liquid contactor on site, as a separate self-supporting upper tank is eliminated and therefore will not need to be installed. The upper rods 206 and the upper spacers 210 can form at least a portion of the upper tank floor. For example, the upper rods 206 and the upper spacers 210 with intervening sheets of mesh material 203 can be pressed against each other to form the upper tank floor. In some cases, the upper rods 206, the upper spacers 210, the lower rods 208, the lower spacers 212, or a combination thereof can be integrally formed with the sheets of mesh material 203.For example, mesh material 203 could be coupled to the rods and spacers that form at least a portion of the upper tank, and the entire structure could be dipped or coated in resin. After the resin has cured, openings could be formed (e.g., punched or drilled) for the sorbent to flow from the upper rods and upper spacers into the mesh material 203. This proposal could lead to an integrally formed structure that integrates mesh compact 101, support system 1000, and upper tank together.

[0225] In some implementations, the mesh compact 101 and support system 1000 may include fiberglass-reinforced materials to increase stiffness while decreasing overall weight. For example, the upper rods 206, the upper spacers 210, the lower rods 208, the lower spacers 212, or a combination thereof, may include a fiberglass core that is at least partially covered with a PVC coating. In some cases, the PVC coating of the fiberglass may occur during the manufacture of the mesh material. For example, a fiberglass sheet that has pores may be dipped or coated in PVC, and then compressed air may be used to blow away the portion of PVC covering the pores, thereby forming a mesh material. Petition 870260084693, dated 08 / 20 / 2026, pages 163 / 196 54 / 73 fiberglass coated with PVC 203. For example, the rods and spacers, which may include fiberglass material, can be attached to the mesh material, and then the rods and spacers can be covered with PVC by vacuum forming or thermoforming. The PVC coating can bond each of the rods, spacers, and mesh material together to form an integrally formed structure.

[0226] In some cases, fiberglass reinforced materials may be at least partially covered in a resin coating to produce a fully formed mesh and support system. In some implementations, the PVC-coated or resin-coated fiberglass mesh material may be molded to include printed textures, such as those described in Figure 18A and Figure 18B.

[0227] In some implementations, the upper rods 206 may directly interface with or be constructed within a liquid solution distribution system, which may include a series of troughs or other channels that allow the liquid solution to be uniformly distributed along the length of the upper surface of the mesh material 203 and flow below its surface. In some cases, this solution flow is continuous in nature. In some cases, the solution flow is pulsed at intervals to wet the mesh material, allowing continued retention and capture until a subsequent pulse replenishes the mesh material with fresh sorbent, washing the CO2-rich sorbent into a lower collection tank, similar to one or more of the lower collection tanks 106 shown in Figure 1.

[0228] In some implementations, top rods 206 may include tubes or pipes that have evenly spaced openings that are sized to allow the capture solution to flow into the mesh material 203. For example, top rods 206 may include a tube with openings that are 1.58 mm (1 / 16 inch) in diameter and spaced 3.17 mm (1 / 8 inch) apart along the length of the tube. The tube or pipe may be configured to receive the capture solution at one end and be empty or capped with a vent tube at the opposite end. The vent tube vents air out of the tube while the tube fills with the capture solution. It may be advantageous to machine-form the openings to achieve higher accuracy compared with machine-formed openings. Petition 870260084693, dated 08 / 20 / 2026, pp. 164 / 196 55 / 73 manually cut, as slight differences in the sizes, angles and spacing of the openings can affect the overall flow pattern in the 203 mesh material.

[0229] Figure 11 and Figure 12 show another example of the 101 mesh compact and a liquid distribution system 1100, 1200. Here, one or more sheets of 203 mesh material are inserted through the upper support rods 206 and the lower support rods. The liquid distribution system 1100, 1200 may include one or more liquid distribution tubes or conduits 1150 for introducing the liquid solution on top of the mesh compact 101. The sorbent may be distributed to a partially enclosed space consisting of one or more support beams 204, upper support rods 206, and one or more liquid distribution facilitating devices (shown as distribution spacers 1140).

[0230] As can be seen in Figure 11 and Figure 12, one or more of the upper spacers can be combined with, for example, a perforated or mesh structure material, creating a distribution spacer 1140. This distribution spacer 1140 is configured to further promote uniform distribution of the sorbent over the mesh material 203, in addition to providing safe spacing of the upper support rods 206.

[0231] In some cases, one or more of the distribution spacers 1140, the upper rod 206 and / or the support beam 204 are optimized to receive the liquid sorbent 124 directly from the distribution conduit (e.g., pipe) 1150 and transfer it to the mesh material 203, without using nozzles or atomizing sprayers or other commonly known components for distributing liquids over the compacted material.

[0232] Figure 13 shows an exemplary integrated structural support system. 1300. It may be advantageous to integrate the support system with an upper tank to save on material costs by eliminating the need for a separate upper tank. The upper rods 206 and distribution spacers 1140 may form at least a portion of a floor of an upper tank 1302. For example, the floor of the upper tank 1302 may include upper rods 206 and distribution spacers 1140 with intervening mesh panels 202 that are pressed against each other to form a portion or the entire floor of the upper tank 1302. The upper rods 206 and distribution spacers 1140 may alternate with Petition 870260084693, dated 08 / 20 / 2026, pp. 165 / 196 56 / 73 the others. In some implementations, the pattern of alternating top rods 206 and distribution spacers 1140 may vary. For example, two top rods 206 may alternate with one distribution spacer 1140. In some implementations, the spaces between the top rods 206 and distribution spacers 1140 may be sized to achieve a certain liquid height (e.g., between 152.4 mm (6 inches) and 304.8 mm (12 inches)) in the top tank 1302 or to achieve a certain flow rate of the capture solution 124 in the mesh panels 202. This ensures that sufficient capture solution 124 is available to wet the mesh panels 202.

[0233] The spacing or spaces between the 206 rods can be selected to accommodate an air velocity ranging from 0 m / s to 2.5 m / s while maintaining a relatively low pressure drop (e.g., less than 5.08 mm (0.2 inches) of water column (in. WC)). In some cases, for systems using air velocities above 2.5 m / s, it may be advantageous for the 202 mesh panels to include a rigid or firm material to mitigate damage or vibrations. In some cases, the upper 206 rods may be spaced from each other by at least 25.4 mm (1 inch).

[0234] The sides of the upper tank 1302 may be formed from a set of walls 1304 coupled to the support beam and upper rods 206 and distribution spacers 1140. The set of walls 1304 may be sealed against one or more of the upper rods 206 and / or distribution spacers 1140, which may form at least a portion of the floor of the upper tank 1302, to reduce the amount of liquid drift at the edges of the upper tank 1302. Thus, edges where the sides of the upper tank 1302 join with the floor of the upper tank 1302 are at least partially sealed to reduce liquid drift from the capture solution 124.

[0235] In some cases, at least a portion of the upper tank floor 1302 can exclude distribution spacers so that the floor is formed only by top rods 206 that are pressed against each other. One or more mesh panels 202 can be positioned to intervene between the top rods 206. The thickness of the mesh panel 202 between the top rods 206 can define a space or opening between the top rods 206 that is large enough to allow the capture solution 124 to flow into the mesh panel 202. Spaces or openings between each of the top rods 206, defined by Petition 870260084693, dated 08 / 20 / 2026, pp. 166 / 196 57 / 73 mesh panel thickness 202, can be sized to achieve a specific solution flow rate (e.g. 1 L / min to 4 L / min).

[0236] In some cases, the lower portion of the support system may have a configuration symmetrical to the upper portion. For example, at least a portion of the lower tank may be formed of lower rods pressed against each other with mesh material intervening. In some implementations, the lower portion of the support system may include lower distribution spacers between the lower rods. Spaces or openings between the lower rods, lower distribution spacers, or a combination thereof may be sized to allow sufficient airflow with a relatively low pressure drop. A collection tank or lower tank may be positioned below the support system to collect the capture solution from the mesh compact.

[0237] Referring to Figure 11 and Figure 12, in some cases, the liquid sorbent 124 passes through the distribution spacer(s) 1140 and disperses over the upper portion of the mesh material 203. The uniform distribution of the liquid sorbent over the mesh material 203 creates a thin film of solution, which moves in gravitational flow.

[0238] In some cases, a combination of gravity and properties of the mesh material itself 203 will work to pull the solution into a lower tank (e.g., lower tank 106 of Figure 1). The sorbent 124 reacts with the CO2-laden air inlet 220, capturing at least a portion of the CO2 (which it absorbs into the capture solution) and the resulting CO2-poor air stream 130 exits the mesh compact 101.

[0239] In some cases, one or more of the upper rods 206 or the distribution spacer 1140, or a combination thereof, may be configured to either evenly distribute the sorbent 124 over the mesh compact 101 or to maintain an optimum space between the gas channel(s) 408.

[0240] In some cases, the 1140 distribution spacers may be formed from a plurality of plastic tubes that have been compressed at one end to form a conical shape. The 1140 distribution spacers may narrow in cross-section from one end to the opposite end, making them more easily installable on certain structures (e.g., rounded or cylindrical structures).

[0241] In some cases, the 1100, 1200 liquid distribution system is Petition 870260084693, dated 08 / 20 / 2026, pp. 167 / 196 The 58 / 73 configuration allows the solution flow to be either continuous or pulsed at intervals to wet the 203 mesh material. In some cases, pulsed flow allows sufficient containment for continued capture until a subsequent pulse replenishes the 203 mesh material with fresh sorbent, discharging the CO2-rich sorbent into a lower collection tank (such as the lower tank 106 shown in Figure 1). In some cases, this configuration allows for continuous, but significantly lower, liquid flow rates, which also works to reduce liquid distribution capital and associated operating costs.

[0242] As discussed above, two general wetting techniques, a cross-through technique and a capillary technique, are possible when using water-based liquid capture sorbents, which are dictated by the material characteristics of the fibers of the mesh material 203 that makes up a mesh compact. 101. The cross-through technique, described in more detail with reference to Figure 14, occurs when the mesh material 203 is more hydrophobic in nature, and results in solution cross-through between the fibers. The capillary technique, described in more detail with reference to Figure 15, occurs when the fibers of the mesh material 203 are more hydrophilic in nature. Using the capillary action technique, instead of solution cross-through, pulls the solution along the fiber surface.

[0243] Figures 14A-14C show illustrations of an exemplary hydrophobic mesh material 1400.Figure 14A shows an exemplary illustration of a moistened hydrophobic mesh material 1400 with mesh pores 1410 that have a rectangular shape and which are bounded by interconnected mesh fibers 1430. The mesh pores 1410 are an open volume. In one embodiment, and referring to Figure 14A, mesh pores 1410 are openings formed in mesh material 1400. When moistened, a liquid film 1425 forms over the mesh material 1400. The liquid film 1425 extends over and covers some or all of the mesh pores 1410, thereby traversing the mesh fibers 1430. Figure 14B shows a cross-section of a liquid film 1425 traversing or extending through a mesh pore 1410 defined between vertically spaced upper and lower circular mesh fibers 1430 in a single square pore 1410 (rotated 90 degrees from the view in Figure 14A).Figure 14C shows an example of a pore width W that is wide enough to overcome the properties of the given capture solution 124, so that no cross-film can be established. Petition 870260084693, dated 08 / 20 / 2026, pp. 168 / 196 59 / 73 between vertically adjacent mesh fibers 1430.

[0244] As mentioned above, the traversal technique occurs when hydrophobic fibers 1430 result in a liquid solution traversing between the fibers 1430 to form multiple traversed mesh pores which collectively form a liquid film 1425 (illustrated in Figure 14B). The formation of the liquid film 1425 may be due to the minimization of the surface energy of the liquid capture sorbent 124 at the interface of the liquid 124 with the compacted fibers 1430 combined with the surface tension of the liquid capture sorbent 124. The dimensions of the traversed solution may be defined by the diameter of the fibers 1430, spacing (width W of mesh pores 1410), hydrophobicity of fiber material, and surface tension of the solution. The liquid film 1425 that passes through the mesh pores 1410 defines a gas-liquid interface 1452 along which the CO2-laden air 220 is absorbed by the liquid capture solution 124.It may be desirable to maximize the height H of the gas-liquid interface 1452. A maximized gas-liquid interface 1452 can be achieved by optimizing the above parameters for a given capture solution composition and gas-liquid contactor operating parameters, and is desirable since larger gas-liquid interfaces 1452 provide more available surface area for increased mass transfer of CO2 into the liquid capture sorbent 124. Referring to Figure 14B, in configurations of the wetted mesh panel 1401 where solution traversal occurs between mesh fibers 1430, the height H of a gas-liquid interface 1452 is equal to or greater than the dimension (e.g., the width W in Figure 14B) between adjacent mesh fibers 1430.

[0245] Using the traversal technique, and referring to Figure 14B, the surface of the hydrophobic mesh fiber 1430 itself will remain largely unwetted and therefore does not contribute significantly to the gas-liquid interface 1452 by virtue of its hydrophobic nature. Therefore, an optimized hydrophobic mesh panel 1401 can maximize the gas-liquid interface 1452 by adjusting the fiber diameters (dictated in part by the structural integrity of the tensioned mesh panel 1401) and the spacing between the mesh fibers 1430 that define the mesh pores 1410. However, a very large fiber spacing will result in the disruption of sorbent traversals (for a given solution surface tension), where the liquid traversal height H will no longer traverse the Petition 870260084693, dated 08 / 20 / 2026, pp. 169 / 196 60 / 73 pore width W, as shown in Figure 14C. Referring to Figure 14C, in configurations of the wetted mesh panel 1401 where no cross-linking occurs between mesh fibers 1430, the height H of the gas-liquid interface 1452 is smaller than the dimension (e.g., the width W in Figure 14C) between adjacent mesh fibers 1430.

[0246] In some implementations, the hydrophobic material improves liquid droplet breakup and uniform liquid dispersion is optimized to perform efficient CO2 capture from dilute gas concentrations. In some implementations, the hydrophobic properties of the mesh panel 1401 can create a relatively uniform liquid film 1425 across the mesh pores 1401, producing a gas-liquid interface 1452 on both sides of the mesh pores 1410, as can be seen in Figure 14B. Having the gas-liquid interface 1452 on both sides of the mesh pores 1410 increases (i.e., doubles) the interfacial surface area of ​​the liquid sorbent 124 that is available to absorb CO2 from CO2-laden air 120, which can improve the efficiency of the mesh panel 1401 in capturing CO2.

[0247] In some implementations, PVC-coated fiberglass, plastic, or metallic materials are used to produce the woven, twill, basketweave, or herringbone patterns for the mesh material, and the mesh material may have hydrophobic wetting techniques.

[0248] Figures 15A-15C show an exemplary hydrophilic mesh material 1500. Figure 15A shows an exemplary illustration of a moistened hydrophilic mesh material 1500 with mesh pores 1510 closed or bounded by rectangular mesh fibers 1530, when a capture solution is flowing down to form a liquid film 1535. Figure 15B shows the same hydrophilic mesh material 1500 without any liquid solution flowing over the surface of the mesh material 1500. The capture solution lies on the surface of the mesh fibers 1530 to form a partial or complete liquid film 1535. Figure 15C shows an exemplary cross-section of the liquid capture solution forming a liquid film 1535 flowing along the mesh fibers 1530 of the mesh material 1500 in Figure 15A (rotated 90 degrees from the view in Figure 15A).

[0249] The capillary wetting technique occurs when the mesh fibers 1530 are hydrophilic in nature or adapted to be hydrophilic. In some cases, capillary action, instead of solution passage, attracts the solution to Petition 870260084693, dated 08 / 20 / 2026, pp. 170 / 196 61 / 73 along the surface of the mesh fiber 1530. The gas-liquid interface 1552 will subsequently be defined by the wetted fiber area 1530 and the liquid sorbent layer thickness 1535, which will be defined by the hydrophilicity of the fiber material and the liquid sorbent flow rate 1551 below the mesh material 1500. Using this capillary technique, the mesh pores 1510 may or may not be fully wetted depending on the liquid sorbent layer thickness and the compacted fiber spacing. Therefore, the optimization of a more hydrophilic mesh material 1500 (using the capillary technique) will be different from that of a more hydrophobic mesh material 1400 (using a traversal technique).It will, however, be appreciated that solution penetration through the mesh pores 1510 can occur even when capillary action is the dominant wetting method for the mesh material 1500, such as in cases where the mesh material 1500 is fully saturated by the liquid sorbent, or in cases of high liquid sorbent flow rates 1551, flooding the mesh material 1500. For example, and referring to Figure 15A, the hydrophilic wetted mesh material 1500 includes a liquid film 1535 covering the mesh pores 1510 (i.e., solution penetration), and also includes surfaces of the mesh fibers 1530 wetted through capillary action.

[0250] Referring to Figure 15C, the gas-liquid interface 1552 is formed on the wetted outer surface of an interconnecting mesh fiber 1531 and along its length, and is also formed on the wetted periphery of the other mesh fibers illustrated, 1530, which have an orientation that is transverse to the orientation of the interconnecting mesh fiber 1531. Referring to Figure 15C, the CO2 capture solution 124 flows along the outer surface of the hydrophilic mesh fibers 1530. Having the gas-liquid interface 1552 on many exposed surfaces of the wetted mesh material 1500 provides an increased surface area of ​​the liquid sorbent 124 that is available to absorb CO2 from the incoming CO2-laden air, which can improve the efficiency of the mesh material 1500 in capturing CO2.In the configuration of the moistened mesh material 1500 of Figure 15C, a single surface of the mesh fibers 1530, that is, an exposed outer surface, is available to receive the liquid sorbent 124 to form the gas-liquid interface 1552.

[0251] In some implementations, nonwoven mesh materials 1500, which consist of materials such as nylon, metal, organic fabrics such as jute, hemp Petition 870260084693, dated 08 / 20 / 2026, pp. 171 / 196 62 / 73 or cellulose or a combination of similar materials may have hydrophilic wetting mechanisms. Nonwoven materials may include, but are not limited to, any material that is not interwoven in a regular pattern. This may include randomly interwoven organic or synthetic fabrics such as felt (jute is specifically woven) or sheets of a single material with perforations or holes or intrinsic absorption characteristics. Nonwoven materials may also consist of an ordered network of fibers which, instead of interfacing through a weft pattern, are bonded to each other through some other means, either mechanically or chemically (e.g., through bonding or solvent bonding or other means).

[0252] In some cases, hydrophilic designs can improve the wetting of the 101 mesh compact with the capture solution. Improved wetting of the 1500 mesh material, which has hydrophilic properties (e.g., by increasing the wetted surface area of ​​the 1500 mesh material), can be achieved by at least two proposals. The first proposal is to increase the surface hydrophilicity of the 1500 mesh material by increasing the surface free energy, which is a material property of the 1500 mesh material. The second proposal is to increase the surface roughness of the 1500 mesh material and the apparent contact angle. These proposals can be used independently or in combination with each other.

[0253] Since the wetted surface area determines the amount of CO2 capture solution exposure in the air, and a hydrophilic material surface maximizes the wetted area for a given solution volume, hydrophilic materials can be included in 101 mesh compact for gas-liquid contactor applications. In some cases, hydrophilicity can be incorporated into 1500 mesh material when it is produced, or it can be introduced as a post-production coating. Hydrophilic coatings increase surface energy and decrease the contact angle. In some cases, certain surface treatments that expose a material to a change in bonds on its surface can achieve similar hydrophilic results.

[0254] In an exemplary implementation, the hydrophilic mesh material 1500 may include a coating applied to the mesh fibers 1530 to increase hydrophilicity. In some cases, the hydrophilic coating on the mesh material 1500 fully wets with a minimal solution flow. This may result in Petition 870260084693, dated 08 / 20 / 2026, pp. 172 / 196 63 / 73 higher capture rates with significantly reduced solution flows.

[0255] In some implementations, and referring to Figure 15A, the hydrophilic mesh material 1500 is wetted with the capture solution, soaking the hydrophilic material until the mass / volume of liquid exceeds a limiting saturation level of the mesh material 1500 and forms droplets that flow along the mesh fibers 1530 into the mesh pores 1510 to produce a liquid film 1535 within the mesh pores 1510, in addition to the wetted surface of the hydrophilic mesh material 1500 itself. This is different from the hydrophobic wetting technique of Figures 14A-14C, which relies on the mesh material repelling the liquid to force the droplets away from the mesh fibers 1430 and into the mesh pores 1410.

[0256] In some implementations, the 1500 mesh material may include material additives to further optimize hydrophilicity and decrease the contact angle between the liquid-solid interface in at least a portion of the 1500 mesh material.

[0257] In addition to or as an alternative to the previous examples of hydrophilic mesh material, the surface roughness of the mesh fiber can also be modified to increase hydrophilicity.

[0258] In some implementations, the 1500 mesh material contains at least a portion that has hydrophilic properties. In some cases, this can increase the CO2 capture flux (e.g., by at least 10%) through an increase in the wetting fraction of the 1500 mesh material.

[0259] In some implementations, the 1500 mesh material contains at least one portion that has hydrophilic properties and at least one other portion that has hydrophobic properties. Thus, in one embodiment, the 1500 mesh material may have both hydrophilic and hydrophobic properties. In some implementations, the hydrophilic 1500 mesh material may be used as a float eliminator in a gas-liquid contactor to mitigate the discharge of capture solution droplets into the environment. The hydrophilicity of the 1500 mesh material in float eliminators may attract the capture solution droplets to the mesh fibers, thereby preventing them from flowing downstream.

[0260] In both hydrophobic and hydrophilic mesh material wetting techniques, the reduction in the amount of mesh material required can be Petition 870260084693, dated 08 / 20 / 2026, pp. 173 / 196 64 / 73 achieved by leveraging the surface tension properties of liquid to achieve a high gas-liquid interface area to material mass ratio. Based on the given liquid solution surface tension, sorbent solution films can traverse the mesh pores resulting in a total reactive gas-liquid interfacial area greater than the surface area of ​​the mesh compact alone. In these cases, the wetting fraction ε, which is defined as the ratio of liquid surface area to mesh material surface area (excluding the area of ​​the mesh pores), is greater than 100%. Therefore, when the mesh material is wet and the solution traverses the open mesh pores 1410, the gas-liquid interfacial area is greater than the total surface area of ​​the mesh fibers 1430.Furthermore, the open nature of the mesh pores 1410 coupled with solution traversal provides an interfacial area on both sides of wet mesh panels 1401. This is in contrast to some standard heat exchange compact surfaces or structured compact, where a uniform air-liquid film interface is formed on both sides of the mesh compact surface 101 described herein. In some cases, the mesh material can be thought of as an internal support for a nearly uniform solution film.

[0261] Both hydrophobic and hydrophilic wetting techniques can be used with mesh material to produce 101 mesh compact that has lower pressure drop, optimal CO2 capture efficiency, and lower capital and operating costs. Furthermore, when configured as described in this description, mesh material sheets created with either of these wetting techniques can decrease pressure drop, reduce air path depth, and reduce overall gas-liquid energy consumption. Although these two techniques use slightly different characteristics to achieve the results, both techniques can be configured to produce mesh material sheets with the desired performance.

[0262] In a typical mesh compact design, the mesh fiber diameter can range from 0.025 mm (0.001 inches) to 12.7 mm (0.5 inches), with the mesh fiber spacing ranging from 0.025 mm (0.001 inches) to 12.7 mm (0.5 inches).

[0263] In some implementations, the 1400, 1500 mesh material is selected to be a material compatible with the CO2 capture solution, for example, Petition 870260084693, dated 08 / 20 / 2026, pp. 174 / 196 65 / 73 high pH solutions, hydroxide solutions such as KOH, NaOH, or carbonate / bicarbonate solutions, and the like. The optimum range of sorbent concentrations will depend on operating conditions and environmental conditions. In some cases where the capture solution contains sorbents such as NaOH, KOH, the solutions may have an optimum range of hydroxide concentrations. For example, optimum hydroxide concentrations may range from 0.5 M up to the hydroxide saturation point under given operating conditions (e.g., temperature), at which point no additional CO2 can be absorbed. Similarly, for other sorbents, optimum sorbent concentrations may range from 0.5 M up to the sorbent saturation point.

[0264] Figures 16A-16C show front, side and plan views of an exemplary mesh compact 101 and support system test device 1600. The test device 1600 is similar to the support systems described above (such as support system 800 of Figure 8A) in that it includes one or more upper rods 206, one or more lower rods 208, one or more support columns 214, one or more support beams 204, one or more upper spacers 1140, one or more lower spacers 212 and one or more mesh panels 202. Figure 16A shows the inserted mesh panel (woven) 202, alternating between the upper and lower rods 206 and 208 offset.

[0265] In some cases, the example shape of the gas channels 408 formed by the mesh panels 202 in the test device 1600 are rectangular as shown in Figure 16B. In some cases, the shape of the channels 408 may be triangular, circular, or rectangular. The shapes of gas channels 408 may be selected based on a predetermined surface tension, sorbent flow pattern, mesh material surface size, reactive gas-liquid interfacial area, and liquid sorbent performance of the mesh top of the channels. In some cases, the space between the mesh panels 202 (the gas channel width 207) is less than 152.4 mm (6 inches) and allows for uniform sorbent distribution on both sides of the mesh material surface.In some cases, the gas channels 408 may be positioned at an angle determined by the spacing between the upper rod 206 and the lower rod 208, in combination with the insertion pattern of the mesh panels 202.

[0266] The 1600 test device shown in Figures 16A-16C can be used, in combination with the equations described below, to evaluate the performance of mesh compact 101. Experimental test conditions and results Petition 870260084693, dated 08 / 20 / 2026, pp. 175 / 196 66 / 73 of the tests performed using the 1600 test device are described in more detail below, and the preliminary test results are illustrated in Figure 17.

[0267] Figure 17 shows a graph 1700 illustrating the effective mass transfer coefficient Keff versus air velocity for a variety of sorbent loading rates using aqueous KOH capture solution through the air displacement depth (ATD) of the mesh compact 101 trapped in the test device 1600 shown in Figures 16A-16C.

[0268] A sample of mesh compact was tested in a laboratory-scale gas-liquid contactor. The compact had an SSA of 200 m2. Tests were performed with air velocities in the range of 1.0 to 2.5 m / s under ambient air conditions (temperature ranging from approximately 5°C to 15°C, and an inlet CO2 concentration of approximately 400 ppm) using aqueous KOH solutions as capture sorbent. Identical concentrations of KOH capture sorbent were used for all tests. During the tests, the inlet and outlet CO2 concentrations were measured and the Keff was subsequently calculated for a given inlet area and ATD using the method outlined below. The following other constants are readily available in laboratory textbooks, the ideal gas constant having a value of 8.314 and the molar mass of CO2 being 44.01 kg / kmol.

[0269] Calculating molar air and CO2 flow rate: (3600')PatmVairAiniet kmol dir ' ' =-----RT~------[^^]^'CO2 = ^^air([C02]in— [C02]out) * 10-3[^0^0] nr

[0270] Calculating the mass flow of CO2: A-rnjMrn., Jco2= 2C02[kgco2 / hr / m2] ^Inlet

[0271] Calculating effective mass transfer coefficients: [ [C02]in\ vair z smm [-T]

[0272] In standard tests, samples of each of the readings were collected at each setpoint to develop a large pool of samples to use statistics to manage any measurement accuracy issues. Petition 870260084693, dated 08 / 20 / 2026, pp. 176 / 196 67 / 73 From this dataset, the mean and 95% confidence interval (CI) were determined and used to statistically test the differences in compaction performance.

[0273] This preliminary evaluation of the mesh compact demonstrated empirically measured effective mass transfer coefficients in the range of approximately 1.0 to 2.0 mm / s for an initial prototype, which is considered sufficient for the economical design of CO2 capture gas-liquid contactors. Furthermore, the tests illustrate that the mesh compact design shows improved (higher) mass transfer coefficients in reference to published data on conventional compact (e.g., cooling tower compact), providing effective mass transfer coefficients closer to the known target of 2 mm / s, which are economically advantageous for large-scale DAC applications.

[0274] Figure 18A and Figure 18B show examples of 1800 molded mesh materials. 1800 molded mesh materials can be sheet or panel in form and include a plurality of protruding portions 1804 that collectively form a texture or topography of the 1800 molded mesh material, and which extend outward from flat portions 1806 of the 1800 molded mesh materials. The flat portions 1806 define parallel planes, and the protruding portions 1804 extend outward from the parallel planes for airflow between adjacent mesh panels. In some implementations, the 1800 molded mesh material can allow for increased interfacial surface area, improving the traversing or capillary effects of the mesh material with enhanced wetting effects resulting from variations in the surface topography of the mesh material.Similar to increasing the surface roughness of mesh material (e.g., increasing the roughness of the mesh fibers) to decrease the liquid contact angle, a flat sheet of mesh material can be formed, pressed, molded, deformed, or shaped to affect the flow pattern of the capture solution. Given that the 180° molded mesh material defines the gas channel, it does not form a significant impediment to airflow, as the spacing of the gas channels can be selected to accommodate airflow, and pores that have no liquid film or only a partial liquid film can allow air to pass through. Considering the gas channel spacing, 180° protrusions can be formed to minimize restrictions to airflow in the gas channels and minimize... Petition 870260084693, dated 08 / 20 / 2026, pp. 177 / 196 68 / 73 pressure drop through the mesh compact. In some cases, the molded mesh material 1800 may be suitable for use as mist eliminators that are downstream of the gas-liquid contactor compact. The protruding portions 1804 can impede the movement of capture solution droplets so that they are not discharged into the environment.

[0275] Figure 18A shows an example of molded mesh material 1800 where the protruding portions 1804 include rounded protrusions or bumps extending outward from the flat portions 1806 (sections of mesh material 1800 that are flat surfaces) of the mesh material 1800. Although the rounded protrusions 1804 are illustrated as generally uniformly sized and evenly spaced, in some cases it may be beneficial to vary the sizes, spacing, shape, and number of the protruding portions 1804 to influence solution flow. For example, in cases where a flat sheet of mesh material has a dry spot or dead spot that is difficult to wet with capture solution, the areas of mesh material that are adjacent to the dry spot or dead spot can be shaped to include the rounded protruding portions 1804 to promote solution flow over the dry spot or dead spot.

[0276] Figure 18B shows another example of the molded mesh material 1800 where the protruding portions 1804 include ridges, folds, or corrugations. The protruding portions 1804 of Figure 18B are planar bodies that define planes that are oblique or not parallel to the planes defined by the planar portions 1806 of the mesh material 1800. These ridges, folds, or corrugations can be sized or positioned to influence the solution flow.

[0277] Although Figure 18A and Figure 18B show rounded protrusions and ridges as exemplary textures, a variety of other shapes are also possible, including herringbone, corrugations, flutes, or channels. In some cases, the 1800 molded mesh material may include sheets of mesh material that are formed to emulate the patterns of conventional rigid compaction sheets or panels in structured compaction sections. In some cases, the 1800 molded mesh material may be formed to form textures or structures that allow mesh compaction sections to interlock with one another (e.g., through plug receiving structures). The 1800 molded mesh material may be formed from flexible mesh material that is easily installed in the support system above or in a support system that allows the Petition 870260084693, dated 08 / 20 / 2026, pp. 178 / 196 69 / 73 1800 molded mesh material hangs freely from the upper support rods. In some implementations, the 1800 molded mesh material may be formed from rigid mesh material that has a thicker or stiffer insert that allows the 1800 molded mesh material to stand upright. Adjacent sheets or panels of the 1800 molded mesh material may have the same shape and be spaced from each other to define 408 gas channels that have consistent gas channel width / height along the ATD. In another possible implementation, adjacent sheets / panels of the 1800 molded mesh material may have different shapes and be spaced from each other to define 408 gas channels that converge or are compressed along the ATD, or that diverge from each other along the ATD.

[0278] Figure 19 shows exemplary flow patterns 1900 of CO2 capture solution 1909 at varying solution flow rates over mesh material 1902. When distributing CO2 capture solution 1909 in a dry mesh material 1902, at certain solution flow rates, the CO2 capture solution 1909 can form sinuous streams 1911, indicating that the mesh material 1902 is fully wetted or saturated. As the sinuous streams 1911 of CO2 capture solution 1909 flow downwards from the mesh material 1902, the sinuous streams 1911 will also flow laterally in a direction that is transverse to their downward flow direction over the mesh material 1902.The sinuous currents 1911 can move laterally back and forth through the mesh material 1902 in a sinuous or serpentine path (e.g., from one side to the opposite side of the mesh material 1902 and back) while a CO2 capture solution 1909 flows down the mesh material 1902. The sinuous currents 1911 typically appear when there is an underlying layer of CO2 capture solution 1909 over the mesh material 1902. Thus, a wide sinuous path of sinuous currents 1911 indicates that a significant portion of the mesh material 1902 has been wetted, and the sinuous currents 1911 maintain flow of CO2 capture solution 1909 in the wetted portion.For example, on mesh material 1902, at a low flow rate (e.g., approximately 1 L / min), flow pattern 1904 may include a plurality of flows that are relatively straight and evenly spaced (e.g., 5.08 mm (0.2 inches) to 50.8 mm (2 inches)) apart. At twice the low flow rate (e.g., approximately 2 L / min), flow pattern 1906 may include one or... Petition 870260084693, dated 08 / 20 / 2026, pp. 179 / 196 70 / 73 more streams that have a flow path that meanders slightly along the mesh material 1902. At three times the low flow rate (e.g., approximately 3 L / min), one or more streams may merge, resulting in a flow pattern 1908 that includes at least one stream that meanders more widely than the streams of flow pattern 1906 at twice the low flow rate, thereby forming a sinuous stream 1911 that wets a larger area of ​​the mesh material 1902. At four times the low flow rate (e.g., approximately 4 L / min), a significant portion of the mesh material 1902 is flooded by at least one sinuous stream 1911 of flow pattern 1910 that meanders more widely than the streams of flow pattern 1906 at twice the low flow rate.At four times the low flow rate, the CO2 capture solution 1909 of flow pattern 1910 takes a wider path than at two or three times the low flow rate, thereby wetting a larger surface area of ​​the mesh material 1902. The meandering currents 1911 typically indicate that the portion of the mesh material covered by the flow path is fully saturated with CO2 capture solution 1909. In some cases, the meandering currents 1911 of flow patterns 1908, 1910 may move laterally across the width of the mesh material 1902, thereby increasing wetting compared to flow patterns 1904, 1906 at lower flow rates.In some implementations, in a flow cycle where the CO2 capture solution 1909 flows into the mesh material 1902 at a low pulse flow rate (or zero flow) for a first duration of time and at a high discharge flow rate for a second duration of time, the high flow rate may be three or four times the low / pulse flow rate. In some implementations, in a flow cycle, the CO2 capture solution 1909 does not flow into the mesh material 1902 for a first duration of time and flows into the mesh material 1902 at a solution flow rate that varies between 1 L / min and 2 L / min for a second duration of time.The thickness and direction of the sinuous currents 1911 depend on the flow rate of the CO2 capture solution 1909, but in some cases, they may also be affected by a combination of other factors including the tension on the mesh material 1902, the surface tension of the CO2 capture solution 1909, and the hydrophobicity or hydrophilicity of the mesh material 1902.

[0279] Referring to Figure 20, the 2002 mesh panels of a compacted Petition 870260084693, dated 08 / 20 / 2026, pp. 180 / 196 71 / 73 mesh 2001 panels can be oriented relative to the CO2-laden air 120 to optimize wetting of the mesh 2003 material. In the mesh 2001 compact configuration of Figure 20, each of the mesh 2002 panels has a vertical orientation and a leading edge 2005 that faces the CO2-laden air 120. The leading edges 2005 are the portions of the mesh 2002 panels that are positioned furthest upstream relative to the flow of CO2-laden air 120. The leading edges 2005 of one or more of the mesh 2002 panels are inclined at an angle θ relative to the vertical, in a downstream direction. The angle θ has a magnitude greater than zero.For vertical mesh panels without inclined leading edges, it may occur that the CO2 capture solution introduced at or near the top of the leading edge is displaced laterally by the CO2-laden air along the mesh material in the direction of the CO2-laden air, specifically for high CO2-laden air flow velocities, such that the lower portions of the mesh material adjacent to the leading edge are not adequately wetted. In contrast, leading edges 2005 that are inclined relative to the vertical in the downstream direction may allow a lower portion 2013 of the mesh material 2003 adjacent to the leading edge 2005 to be adequately wetted when the CO2 capture solution 124 is introduced at or near the top of the leading edge 2005, even for high CO2-laden air flow velocities 120.The angled leading edges 2005 of the mesh panels 2002 can thus allow all portions of the mesh material 2003 to be adequately wetted by the CO2 capture solution 124.

[0280] Referring to Figure 21, the gas-liquid contactor 2111 with the mesh pack is part of a direct air capture (DAC) installation 2100 for capturing CO2 directly from atmospheric air, according to one possible and non-limiting example of a use for the gas-liquid contactor 2111. The gas-liquid contactor 2111 absorbs some of the CO2 from atmospheric air 2103 using the CO2 capture solution 124 to form a CO2-rich solution 2102. The CO2-rich solution 2102 flows from the gas-liquid contactor 2111 to a granule reactor 2110 of the DAC installation 2100. A calcium hydroxide paste 2104 is injected into the granule reactor 2110. As the Ca2+ reacts with CO32 in the reactor 2110 granules, this drives the dissolution of calcium hydroxide to return a stream of aqueous alkaline solution as the CO2 capture solution 124, and to precipitate calcium carbonate (CaCO3) onto calcium carbonate particles in the reactor. Petition 870260084693, dated 08 / 20 / 2026, pp. 181 / 196 72 / 73 granules 2110. Further processing of calcium carbonate solids, including but not limited to filtering, dewatering or drying, may occur before the calcium carbonate solids are sent to downstream processing units. A stream 2106 of calcium carbonate solids is conveyed from the granule reactor 2110 to a calciner 2120 of the DAC plant 2100. The calciner 2120 calcines the calcium carbonate from stream 2106 of the granule reactor 2110 to produce a gaseous CO2 stream 2108 and a calcium oxide (CaO) stream 2101, possibly by oxycombustion of a fuel source in the calciner 2120. The gaseous CO2 stream 2108 is processed for sequestration or other uses, thereby removing some of the CO2 from the atmospheric air 2103 processed in the gas-liquid contactor 2111.The calcium oxide (CaO) stream 2101 is quenched with water in a fire extinguisher 2130 of the DAC 2100 facility to produce the calcium hydroxide paste 2104 which is supplied to the granule reactor 2110.

[0281] Figure 22 shows a schematic illustration of an example of the gas-liquid contactor 2200. The gas-liquid contactor 2200 includes a housing 2204 having a plurality of housing walls 2209 delimiting an interior of the housing 2204. The gas-liquid contactor 2200 includes a mesh compact 2201. The mesh compact 2201 includes a single mesh panel 2202 which has mesh material 2203. Two gas channels 2208 are formed within the housing 2204. Each gas channel 2208 is formed on one side of the mesh panel 2202 between the mesh panel 2202 and one or more housing walls 2209. The single mesh panel 2202 of Figure 22 has a vertical orientation. In another possible implementation of the 2200 gas-liquid contactor, the 2202 single mesh panel has a horizontal orientation.In another possible implementation of the 2200 gas-liquid contactor, the 2202 single mesh panel has an orientation that is inclined relative to the vertical or a horizontal plane.

[0282] Figure 23 shows a schematic illustration of an example of the gas-liquid contactor 2300, viewed from one end of the gas-liquid contactor 2300. The gas-liquid contactor 2300 includes a cylindrical housing 2304 which has a housing wall 2309 delimiting an interior of the housing 2304. The gas-liquid contactor 2200 includes a mesh compact 2301. The mesh compact 2301 includes a mesh panel 2302 having mesh material 2303. The mesh panel 2302 is positioned inside the housing and against the housing wall 2309. A single gas channel 2308 is formed within the housing. Petition 870260084693, dated 08 / 20 / 2026, pp. 182 / 196 73 / 73 2304. The gas channel 2308 is formed on one side of the mesh panel 2302, and is entirely enclosed by the mesh panel 2302. The mesh panel 2302 may be a cylindrical body defined around a central geometric axis. The orientation of the central geometric axis may be vertical, horizontal, or at an angle between vertical and horizontal. The mesh panel 2302 in Figure 23 is a single or continuous body. In another possible implementation, the mesh panel 2302 is a set of circumferentially extending or arched mesh panel segments which are mounted on the housing wall 2309 and / or on each other. Referring to Figure 23, the first dimension is a diameter measured between diametrically opposite points of the mesh panel 2302.

[0283] It will be clear to anyone skilled in the art that further variations to the specific details described herein may be made, resulting in other embodiments that are within the scope of the description. All parameters, dimensions, materials and configurations described herein are examples only and may be changed depending on the specific embodiment. Petition 870260084693, dated 08 / 20 / 2026, pages 183 / 196

Claims

1 / 5 CLAIM 1. A compact for capturing carbon dioxide (CO2) from a dilute gas source, the compact characterized in that it comprises: a plurality of panels (202, 2002, 2202, 2302), wherein adjacent panels of the plurality of panels (202, 2002, 2202, 2302) are spaced from each other in a first direction (207) and each of the panels comprises: a mesh material (1500, 1800, 1902, 2203) comprising a hydrophilic material configured to be wetted by a CO2 capture solution, the mesh material (1500, 1800, 1902, 2203) comprising a plurality of fibers (1530) defining a plurality of mesh pores (1510), the mesh material (1500, 1800, 1902, 2203) configured to be wetted by the CO2 capture solution (1204, 1909) to cause the CO2 capture solution to fill at least part of the pores of the mesh of the plurality of pores of the wetted mesh material, and define a gas-liquid interface,Two adjacent panels of the plurality of panels (202, 2002, 2202, 2302) are spaced to define a gas channel (408, 2208, 2308) that has a first dimension defined along a first direction (D1) and a second dimension defined along a surface of the mesh material (1500, 1800, 1902, 2203) in a second direction different from the first direction, the gas channel (408) being configured to receive a CO2-laden gas stream from the diluted gas source in the second direction and contact the CO2-laden gas stream with the CO2 capture solution on the mesh material (1500, 1800, 1902, 2203).

2. Compacted, according to claim 1, characterized in that the first direction is transverse to the air displacement depth and defined in a plane that is normal to the air displacement depth.

3. Compacted, according to claim 2, characterized in that each panel of the adjacent panels defines a flat surface, the flat surfaces of the adjacent panels being parallel to each other.

4. Compacted, according to claim 2 or 3, characterized in that at least one panel of the adjacent panels includes a plurality of Petition 870260084693, dated 20 / 08 / 2026, p. 184 / 196 2 / 5 flat portions and a plurality of protruding portions (1804), the pluralities of flat portions defining parallel planes, the plurality of protruding portions (1804) extending outward from the parallel planes in the first direction (207) and into the respective gas channels (408, 2208, 2308).

5. Compacted, according to any one of claims 2 to 4, characterized in that each panel of the adjacent panels has the same shape.

6. Compacted, according to any of the preceding claims, characterized in that at least one panel of the plurality of panels is formed from a continuous sheet of mesh material (1500, 1800, 1902, 2203).

7. Compacted, according to claim 6, characterized in that the continuous sheet of mesh material (1500, 1800, 1902, 2203) comprises a plurality of panel segments spaced apart in the first direction (207) and which define the gas channel (408).

8. Compacted, according to any of the preceding claims, characterized in that the plurality of panels (202, 2002, 2202, 2302) defines a plurality of gas channels (408, 2208, 2308) between adjacent panels of the plurality of panels (202, 2002, 2202, 2302), at least one gas channel (408) of the plurality of gas channels (408, 2208, 2308) is defined by the first dimension comprising a first width, and at least one other gas channel (408) of the plurality of gas channels (408, 2208, 2308) is defined by the first dimension comprising a second width different from the first width.

9. Compacted, according to any of the preceding claims, characterized in that the first dimension is 15.2 cm (6 inches) or less.

10. Compacted, according to any of the preceding claims, characterized in that at least one panel has a vertical orientation, and the second dimension is less than three orders of magnitude larger than the first dimension.

11. Compacted, according to claim 1, characterized in that the hydrophilic material is a hydrophilic coating disposed over at least a portion of the mesh material (1500, 1800, 1902, 2203). Petition 870260084693, dated 20 / 08 / 2026, pp. 185 / 196 3 / 5 12. Compacted, according to any of the preceding claims, characterized in that the hydrophilic material comprises at least one of a non-woven material or an organic material, optionally, wherein the organic material comprises at least one of jute, hemp or cellulose.

13. Compacted, according to any of the preceding claims, characterized in that each of the plurality of fibers (1530) has a diameter ranging from 0.0001 mm to 10 mm.

14. Compacted, according to any of the preceding claims, characterized in that it further comprises the CO2 capture solution, wherein the CO2 capture solution is a high pH hydroxide solution, a bicarbonate / carbonate solution, an amine solution or a combination thereof.

15. Compacted, according to claim 14, characterized in that the gas-liquid interface comprises a first side disposed on a first side of the mesh material (1500, 1800, 1902, 2203) and a second side disposed on a second side of the mesh material (1500, 1800, 1902, 2203), opposite the first side of the mesh material (1500, 1800, 1902, 2203).

16. Compacted, according to claim 15, characterized in that the first side of the gas-liquid interface and the second side of the gas-liquid interface, together, define a total reactive gas-liquid interfacial area that is larger than a surface area of ​​the corresponding fibers of the mesh material (1500, 1800, 1902, 2203).

17. Compacted, according to claim 14 or 15, characterized in that a wetting fraction of the mesh material (1500, 1800, 1902, 2203) is greater than 100%.

18. Compacted, according to any of the preceding claims, characterized in that the mesh pores (1510) have a size ranging from 0.1 mm to 30 mm.

19. Compacted, according to any of the preceding claims, characterized in that the gas channel (408) is collinear with the second direction of the CO2-containing gas flow. Petition 870260084693, dated 20 / 08 / 2026, pp. 186 / 196 4 / 5 20. Compacted, according to claim 15, characterized in that adjacent panel segments of the plurality of panel segments have a non-parallel orientation to each other.

21. Compacted, according to claim 7 or 20, characterized in that it further comprises a structural support (1000) configured to support the continuous sheet of mesh material (1500, 1800, 1902, 2203), the structural support (1000) comprising one or more support rods, a first subset of rods among one or more support rods being displaced relative to a second subset of rods among one or more support rods, the second subset of rods being spaced from the first subset of rods in a direction perpendicular to the first dimension and the second dimension, the continuous sheet of mesh material being tensioned around the first subset of rods and around the second subset of rods to form the plurality of panel segments.

22. Compacted, according to claim 21, characterized in that adjacent panel segments of the plurality of panel segments are spaced apart in the first direction (207) and define the gas channel, decreasing the first dimension in a direction parallel to a distance between the first subset of rods and the second subset of rods.

23. Compacted, according to claim 21 or 22, characterized in that the mesh material (1500, 1800, 1902, 2203) is suspended by one or more support rods.

24. Compacted, according to claim 23, characterized in that it further comprises one or more spacers, each spacer among one or more spacers being interposed between adjacent support rods among one or more support rods.

25. Compacted, according to claim 24, characterized in that one or more spacers comprise one or more distribution spacers (1140).

26. Compacted, according to claim 24 or 25, characterized in that at least one spacer among one or more spacers comprises at least one tube having a tapered end. Petition 870260084693, dated 08 / 20 / 2026, pp. 187 / 196 5 / 5 27. Compacted, according to any of the preceding claims, characterized in that the plurality of mesh pores (1510) has one or more shapes comprising at least one of hexagonal, rectangular or circular.

28. Compacted, according to any of the preceding claims, characterized in that the plurality of fibers (1530) has a surface texture.

29. Compacted, according to any of the preceding claims, characterized in that the mesh material (1500, 1800, 1902, 2203) is shaped to form a plurality of printed textures comprising at least one of rounded protrusions, ribs, corrugations or herringbone pattern.

30. Compacted, according to any of the preceding claims, characterized in that at least a portion of the mesh material (1500, 1800, 1902, 2203) comprises a fiberglass core at least partially coated with a PVC coating. Petition 870260084693, dated 20 / 08 / 2026, pp. 188 / 196

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