High throughput mobile panel direct air capture system

Abstract

Systems and methods of direct air capture are described. The system includes a plurality of moving adsorber panels in a linear direction (or in a circular configuration) and one or more fans configured to move air through the adsorber panels; such adsorber panels may be oriented vertically or horizontally relative to the ground. A system may include a separate regeneration tank including a system of headers, conduits, and valves configured to deliver and remove a plurality of gases to and from the regeneration tank. The regeneration box contains a plurality of chambers such that steps such as oxygen removal and panel cooling can be performed independently and concurrently with panel thermal preheating and desorption of CO2 on the panel. The desorption panels may be configured to achieve countercurrent flow with respect to hot gas for thermal preheating and desorption. A multi-stage heat pump can facilitate recycling of waste heat and decarburization required by process heating.

Description

Technical Field

[0001] The subject matter described herein relates to systems and methods for direct air capture. Background Art

[0002] Direct air capture (DAC), a method of capturing CO2 directly from the atmosphere, is one of several means of mitigating anthropogenic greenhouse gas emissions. The advantage of DAC is that it can address emissions from distributed sources (e.g., cars, airplanes) rather than being attached to a specific emitting source such as a specific factory.

[0003] The main challenge for DAC is low cost, high efficiency air contact.The challenges of current DAC processes include providing a system with the ability to handle large volume flows of carbon dioxide laden air, and means for providing energy for regeneration at an acceptable cost.

[0004] Older DAC systems rely on connected adsorber panels (in a "series") to be mechanically moved in a discontinuous process around an elliptical track and along that same track into a single zone regeneration chamber. This requires (i) the need to move a large amount of mass (discontinuously), (ii) a relatively complex movement system, and (iii) a regeneration box having only a single zone within which a wide range of desorption functions are performed over an extended period of time. It is desirable to provide a DAC system that has a sufficiently simplified design to allow capture of carbon dioxide on a reliable and repeatable basis and that is both cost-effective and scalable. In addition, there is a need for a system that minimizes the risks associated with the mechanical movement of the panels and also improves the process continuity and efficiency of the regeneration of the individual panels. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a diagram of an exemplary adsorption / desorption and heat recovery cycle.

[0006] Figure 2A An exemplary adsorption / desorption process unit is shown.

[0007] Figure 2B A more detailed view of an exemplary adsorption system is provided.

[0008] Figure 3 is an example diagram of an alternative design of the adsorption / desorption process.

[0009] Figure 4 is an example diagram of a larger scale design consisting of several integrated adsorption / desorption process units.

[0010] FIG. 5A to FIG. 5B is an example diagram of a regeneration box with multiple zones.

[0011] FIG. 6A to FIG. 6Bis an exemplary illustration of a continuous steaming section contained within an alternative regeneration tank design.

[0012] FIG. 7A to FIG. 7B An exemplary panel movement system is shown.

[0013] Figure 7C An exemplary adsorption / desorption process unit is shown in 3-D.

[0014] FIG. 8A to FIG. 8B An exemplary process flow diagram is shown, including downstream processes for CO2 and heat recovery.

[0015] Fig. 9 An alternative continuous steam regeneration design is shown.

[0016] Fig.10 A possible configuration of doors to enable continuous panel movement within a vacuum system is shown.

[0017] Fig.11 A regeneration box is shown that is loaded and unloaded from both sides to facilitate faster stepping of panels through the steam section.

[0018] FIG. 12A to FIG. 12B A system is shown in which two panels are collected and loaded into the regeneration box simultaneously and in which an odd number of panels are held in the steaming section.

[0019] FIG. 13A to FIG. 13B An alternative possible layout of a 6-adsorber box process with lateral and transverse steamer boxes is shown.

[0020] Fig.14 Possible door movements are shown.

[0021] Fig.15 An exemplary embodiment of a continuously moving adsorber wall with a batch regeneration system is shown.

[0022] Fig.16 An exemplary embodiment is shown in which the panel moves around a curve when moving from one wall to another.

[0023] Fig.17A An exemplary rotation of the panel is shown.

[0024] FIG. 17B to FIG. 17E An exemplary embodiment of a panel is shown.

[0025] Fig.18 Options for panel preheating and drying / cooling are shown.

[0026] FIG. 19A to FIG. 19B The components from which the panel can be constructed are shown.

[0027] FIG. 20A to FIG. 20BA side view of a possible configuration of a double-layer adsorption system with horizontally oriented panels is shown.

[0028] Fig.21 A configuration of parallel horizontal panels at the same height is shown.

[0029] Fig. 22 A side view of a configuration for panel regeneration in a horizontal orientation is shown.

[0030] FIG. 23A to FIG. 23C An exemplary layout of a single track horizontal panel adsorption system and possible interactions of these systems with the regeneration steps are shown.

[0031] FIG. 24A to FIG. 24C Exemplary configurations of dual-track horizontal adsorption systems and the interaction of these systems with regeneration are shown.

[0032] FIG. 25A to FIG. 25C Other exemplary configurations of the interaction between the adsorption and desorption systems of the horizontal panel are shown.

[0033] Fig.26 An exemplary configuration of a single-track horizontal adsorption system interacting with a dual-chamber vacuum regeneration step is shown.

[0034] FIG. 27A to FIG. 27B An exemplary arrangement of fans in a horizontal adsorption system is shown.

[0035] FIG. 28A to FIG. 28B An exemplary arrangement of filters in a horizontal adsorption system is shown.

[0036] FIG. 29A to FIG. 29C An exemplary manner in which precipitation may be deflected away from a panel in a horizontal orientation is shown.

[0037] FIG. 30A to FIG. 30D An exemplary manner in which an array of adsorbers may be supported in a horizontally oriented frame using edge supports is shown.

[0038] FIG. 31A to FIG. 31B An exemplary manner in which an array of adsorbers may be supported in a horizontally oriented frame using mesh and wires is shown.

[0039] Fig.32 An exemplary manner in which an array of adsorbers may be supported in a horizontally oriented frame using collars is shown.

[0040] Fig.33 The possibility of changing the edge shape of the adsorber unit to facilitate support in a horizontally oriented frame is shown.

[0041] Fig.34 An exemplary manner in which an array of adsorbers may be supported in a horizontally oriented frame using spring clamps as edge supports is shown.

[0042] FIG. 35A to FIG. 35C An exemplary manner in which an array of adsorbers may be supported in a horizontally oriented frame using edge supports is shown.

[0043] FIG. 36A to FIG. 36B An exemplary configuration of a monocoque frame having sealing surfaces between each row of monocoque bricks is shown.

[0044] Fig.37A , Figure 37B-1 to Figure 37B-3 and Figure 37C-1 to Figure 37C-2 An exemplary seal for use between a panel frame and a cavity is shown.

[0045] Fig.38 An exemplary single-plane version of the adsorption and regeneration system in a horizontal orientation is shown.

[0046] Fig.39 An exemplary single-plane continuous version of a horizontally oriented system with parallel regeneration zones is shown.

[0047] Fig.40A A plan view of an exemplary portion of an aftercooling gas recovery system is shown.

[0048] Fig.40B is along Fig.40A Cross-sectional view along plane AA of an exemplary portion of an aftercooling gas recovery system.

[0049] Fig.41 An exemplary single-plane, continuous, horizontally oriented system with a single regeneration zone is shown.

[0050] FIG. 42A to FIG. 42E A side view of an exemplary mesh support system is shown.

[0051] Fig.43A is a cross-sectional view of an exemplary storm water mitigation embodiment including a storm water deflection ring.

[0052] Fig.43B yes Fig.43A A perspective view of an exemplary stormwater mitigation implementation.

[0053] FIG. 44A to FIG. 44D Exemplary embodiments of possible configurations of fully continuous annular systems and adsorption blocks are shown. Summary of the invention

[0054] The main object of the present invention is to provide a simplified and scalable direct air capture (DAC) system which will capture CO2 from air or gas and will produce a CO2 product with purity >95%. The system of the present invention will lead to a reduction in the cost of DAC.

[0055] In many embodiments, an advanced DAC process designed to reduce the cost of capturing CO2 from air and gases containing carbon dioxide and the energy burden associated with the capture process is described. The process includes a simplified, continuous movement of individual adsorber panels (each panel having multiple adsorber units, which can be monomeric or alternative configurations) in an air stream, in a single plane, or alternatively in more than one plane compared to one or more early generation processes, which require the connected adsorber panels to move in a discontinuous manner around the rather complex movement of an elliptical structure. It is expected that the use of continuously moving individual adsorber panels in an air stream (and in some embodiments, in a regeneration zone) substantially eliminates the relative complexity required to start and stop connected panels - thereby eliminating the need to move a large amount of mass with significant inertia, and significantly reducing the overall mechanical and process risks of the plant. In addition, the reduced complexity of the mechanical movement of the adsorber panels allows greater flexibility in the configuration and total volume of the substrate and adsorbent, thereby significantly improving the throughput of the system. These advantages will lead to greater plant reliability, improved scalability, and lower capital costs per unit throughput. In the following description, the phrase "continuously moving" or "continuous movement" may refer to one or more panels moving at a substantially constant speed.

[0056] In many embodiments, mobile systems for capturing carbon dioxide are also described. Thus, the practice of the processes or methods described herein can be performed by one or more types of equipment and should be considered to fall within the scope of the present invention. The use of the term "process" in this context is meant to include or be synonymous with the term "method".

[0057] The system and process utilizes simplified movement of individual adsorber panels, whereby instead of mechanical movement of connected adsorber panels in a discontinuous manner around an ellipse, such panels are moved individually, continuously, across a single plane (or alternatively in more than one plane) in the air flow for performing the process and capturing carbon dioxide.

[0058] In addition, the process separates the panel movement required for the carbon capture phase from the panel movement required for the regeneration phase, thereby providing greater flexibility to optimize the size of the regeneration box and the area within the box (without affecting the key carbon capture step within the air flow in any way). Compared to one or more early generation processes that use a regeneration box with only a single multifunctional area to carry out the entire desorption process, this allows the current design and method to utilize a regeneration box with multiple separate areas to carry out the various steps required for carbon dioxide desorption. It is expected that the use of multiple areas for different steps of the regeneration process will bring many benefits, including (i) the ability to make each area more efficiently dedicated to a specific function (removing air, preheating, desorbing CO2, cooling adsorber), and (ii) greater continuity of gas flow. In addition, by regenerating multiple panels simultaneously, this increases capacity compared to a single panel, single-area regeneration box system. These advantages will result in lower energy requirements, improved scalability, and lower operating and capital costs per unit throughput. DETAILED DESCRIPTION

[0059] Adsorption / desorption cycle

[0060] like Figure 1 As seen in the 进 ) can be adsorbed onto the solid adsorbent so that the CO2 concentration in the air stream after adsorption ([CO2] 出 ) is lower ([CO2] 进 >[CO2] 出) .

[0061] CO2 can then be desorbed from the adsorbent contained in a solid adsorbent support structure such as a monomer or other form of adsorber unit (where several such adsorber units are arranged together in a panel), and the CO2 can be extracted. The desorption of CO2 can be performed by: temperature variation, for example by condensing steam directly onto the panel; or by reducing the CO2 partial pressure in the desorption chamber, for example by flushing the desorption chamber with another gas such as steam or by evacuating the desorption chamber; or by a combination of these measures. Alternatively, the temperature variation can be performed by indirect heating. Steps can be performed before and after this to maintain the adsorbent life and achieve high CO2 purity. Figure 1 A flow chart of an exemplary regeneration cycle is included. Arrows indicate relative movement of panels through the system. For convenience, the system will be described as a series of steps in which panels move from one area to the next in a stepwise manner, but it can be easily seen that these descriptions can be applied to systems that move continuously.

[0062] During regeneration, the panel moves through multiple zones where it encounters different conditions. Figure 1In the example shown, the panel

[50] enters a first chamber in area

[10] , which can be isolated by closing doors

[25] and

[26] at either end of the chamber. The O2 concentration in the surrounding void space can then be reduced by: pulling a deep vacuum in the first chamber to about 0.025 bara to 0.4 bara, or alternatively about 0.05 bara to 0.2 bara; or by introducing steam, nitrogen or another inert gas to displace the remaining volume of air; or a combination of both. In an optional step, steam can be introduced into the first chamber in area

[10] while the first chamber is maintained in vacuum to displace any remaining air or other inert gas. One advantage of introducing atmospheric steam into a vacuum environment is that the steam will superheat under vacuum conditions and can therefore displace a portion of the air before condensing. Even if some steam does condense, the temperature at which the steam can condense limits the extent to which the panel can be heated due to the vacuum environment, thereby minimizing undesirable CO2 release during this step.

[0063] In another embodiment, the chamber may be flushed with an inert gas such as N2 to completely or partially displace the air prior to applying vacuum or using steam

[10] .

[0064] In a subsequent step, the vacuum may be released from the first chamber in zone

[10] by introducing a gas. The gas may be fresh steam, steam combined with CO2 from an alternative zone

[11] , or an alternative gas such as CO2 or nitrogen. The temperature may be raised to a temperature between about 70°C and about 115°C, alternatively between about 70°C and about 105°C, alternatively between about 80°C and about 105°C, alternatively between about 90°C and about 103°C, alternatively between about 95°C and about 100°C by condensation of the steam. When the pressure of the first chamber approaches atmospheric pressure, the door

[26] of the adjacent zone may be opened and the panel

[50] may be moved into the first steaming zone

[11] .

[0065] In zone

[11] , gas can flow through panels

[50] , completing the heating phase and desorbing the CO2. The desorption can be done with steam, a mixture of steam and CO2 from an alternative zone, or with some other gas. Figure 1In the depicted example, a mixture of CO2 and steam from region

[12] is used to heat the panels to a temperature between about 70°C and about 125°C, alternatively between about 80°C and about 115°C, alternatively between about 80°C and about 105°C, alternatively between about 90°C and about 103°C, alternatively between about 95°C and about 100°C. The steam-containing CO2 can be recovered and the water vapor condensed in a heat pump cycle to boil the refrigerant. The steam-containing CO2 can contain between about 2 vol% and 70 vol% CO2, alternatively between about 10 vol% and 40 vol% CO2.

[0066] After a given period of time, the panel

[50] may then move to the next area - e.g. Figure 1 In the example shown, a second steaming zone

[12] is shown. In the second steaming zone

[12] , the panels

[50] are kept hot to promote CO2 desorption, for example by introducing live steam into the plenum chamber which promotes uniform flow distribution through the panels. Figure 1 As shown, steam and desorbed CO2 leaving region

[12] may be allowed to flow upstream relative to the movement of the panels and flow back through the panels in region

[11] . The advantage of this countercurrent flow distribution is that the adsorber panels in region

[12] are subjected to a lower CO2 partial pressure than the panels in region

[11] , thereby promoting desorption of CO2 from the panels in region

[12] .

[0067] Steam and desorbed CO2 leaving zone

[11] may be allowed to flow upstream relative to the movement of the panel and through stop valve

[29] (see FIG. 5A to FIG. 5B ) flows back into zone

[10] . The advantage of applying steam-containing CO2 from zone

[11] to the chambers in zone

[10] is that most of the panel heating will be performed using steam that has already been used to desorb panels further along the sequence, thereby reducing the overall steam usage for regeneration. In addition to this, the CO2 content will allow the system to reach ambient pressure at a lower temperature (compared to using live steam), thereby allowing the transfer door to open more quickly in the cycle. Although some additional CO2 may be adsorbed onto panel

[50] as the CO2 partial pressure increases, this CO2 will be released again in zones

[11] and

[12] .

[0068] The ratio of CO2 adsorbed into the panel and the concentration of CO2 in the vapor phase generally equilibrates to a consistent value over time, which is affected by factors including the amount of adsorbent in the panel and the temperature of the system. A set of adsorption isotherms can be derived, which represents a set of curves relating the amount of CO2 per mass of adsorbent to the concentration of CO2 in the vapor phase at a given temperature. Generally, the equilibrium loading of CO2 on the panel decreases as temperature increases and the vapor concentration of CO2 decreases.

[0069] When equilibrium conditions are left, for example by heating the panels and reducing the vapor phase CO2 concentration by flowing steam through the loaded panels, a "driving force" is established. This driving force represents how far the system is from equilibrium and can be expressed as the difference between the current CO2 concentration in the gas phase and the CO2 concentration in the gas phase that would be in equilibrium with the current loading of CO2 on the panels at the current system temperature. The rate at which CO2 moves from one phase (e.g., adsorbed) to another phase (e.g., vapor) is generally proportional to this driving force.

[0070] If the loaded panels are desorbed in a simple batch process—a single chamber where steam is supplied and removed as a mixture of steam and desorbed CO2—then at the beginning of the desorption process, there will be a high driving force. The adsorbed CO2 concentration is high, and the CO2 in the vapor phase is relatively low. In this case, flowing the steam faster will increase the driving force (because the additional steam dilutes the desorbed CO2), while flowing the steam slower will reduce the driving force. Over time, assuming a consistent flow rate of steam into the chamber, the driving force will weaken—the concentration of adsorbed CO2 will continue to drop as the CO2 desorbs. Therefore, in order to achieve complete desorption, the steam must continue to flow for a long enough period of time so that the vapor phase concentration of CO2 becomes sufficiently low.

[0071] Countercurrent flow of steam through one or more panels can be characterized as a system in which the freshest steam flows through the most desorbing panels / panel sections (having lower amounts of adsorbed CO2) before the steam flow contacts the less desorbing portions of the panels. A key advantage of the system described herein is that countercurrent flow can be achieved, for example by stepping multiple panels through the steam (e.g. Fig. 9 as shown) or by passing steam back and forth through the panel (as Fig. 6A ). Countercurrent flow is desirable in this process because it provides a means of "reusing" steam that has already contacted the panels and desorbed some CO2 while maintaining a good driving force for CO2 desorption.

[0072] Consider a simple example of two panels (a first panel and a second panel) in countercurrent flow. The first fully loaded panel, in the first position closest to the steam inlet, contacts the fresh steam that has not yet contacted the panel. The second panel contacts the steam that has passed through the first panel after the first panel - so the steam in contact with the second panel has a small concentration of CO2 in it, so the driving force for desorbing steam from the second panel is slightly weakened. However, if the incoming steam for the second panel is 1% CO2 and the balance is 10% CO2, the loss of driving force is relatively small (10-1=9 instead of 10-0=10), and the "used" steam will still be able to desorb CO2 from the second panel. When the second panel moves into the first position closest to the steam inlet, it will have been partially unloaded. In the first position, the panel will now be exposed to fresh steam - the panel in the first position will experience a similar time curve to the equivalent panel in simple batch desorption, but because the panel starts in a partially unloaded state, the panel will reach a given desorption level faster than the equivalent simple batch panel (and experience less fresh steam). Thus, overall, countercurrent flow will allow the panel to reach an equal level of desorption while using less steam (or more completely desorb the panel with the same amount of steam).

[0073] While this simple example considers only two panels, it is easy to understand how the general principles can be extended to systems with more countercurrent stages. An advantage of the invention described herein is a range of methods by which such countercurrent flow can be achieved, thereby allowing for more efficient use of steam and / or more efficient desorption of CO2 from the adsorber panels. In some embodiments, such countercurrent flow can be applied to any other desorption step described herein, including but not limited to replacing air with an inert gas or cooling / drying the desorbing panels.

[0074] When the final steam cycle in region

[12] is completed, the door

[27] to the adjacent chamber in the downstream region

[13] is opened and the panel

[50] moves to the next step in the regeneration cycle. In region

[13] , the panel

[50] can be dried and / or cooled by evaporating condensed water on the panel surface. The drying and / or cooling can be achieved by reducing the partial pressure of water in the chamber in region

[13] , for example by introducing an inert gas such as nitrogen or by evacuating. The target partial pressure of water in region

[13] can be between about 0.02 bara and about 0.4 bara; alternatively, between about 0.05 bara and about 0.2 bara; alternatively, between about 0.08 bara and about 0.12 bara.

[0075] The phrase "cooling" a panel, as discussed in detail below with reference to a "cooling section" or "cooling zone"

[13] , may refer to drying and / or cooling of the panel. Thus, the term "cooling zone"

[13] may refer to a drying / cooling area that may provide drying and / or cooling of the panel.

[0076] Figure 1 A 4-zone regeneration box is shown, but it is clear that additional zones may be added. For example, the pre-purge zone

[10] may include one or more chambers to further reduce the risk of air entering the hot zone, reduce the risk of CO2 loss when the next panel is introduced, and / or increase the number of panels to complete the air purge / preheating step in a given time. In addition, additional zones may be added to the central steam section (between zone

[11] and the final cooling zone

[13] ) to further expand the countercurrent steam flow in that section. In addition, the steam flow may be moved in series through several "sub-zones" within a given panel to provide another level of countercurrent steam flow. Finally, the final cooling section zone

[13] may be divided into two or more chambers to better isolate the hot panel (which comes from the desorption section) from the ambient air (to reduce the risk of adsorbent deactivation) and / or increase the number of panels cooled in a given time.

[0077] In another embodiment, the entry zone

[10] or exit zone

[13] can be operated continuously by using multiple doors. These doors can be placed closer together than one panel length apart to reduce the overall size of the unit. One possible embodiment of this approach is Fig.10 25a to d], as it can be applied to the initial inertial purge step. At time t1, the newly loaded panel

[50] can enter the purge area

[10] through the opened door [25a to d]. Then the door 25a can be closed, and the panel 50 can start to move forward slowly while evacuating. The rate of panel movement and the rate of evacuation can be timed so that the panel

[50] arrives at the door [26a] and leaves the door [25b] (shown at time t2, for example, after about 2 seconds from t1) at the desired pressure. Then the door [25b] can be closed and the door [26a] can be opened. In some embodiments, steam can be allowed to flow into the chamber formed between the door [25b] and [26b] while maintaining the vacuum, thereby eliminating the last oxygen. At time t3 (for example, about 4 seconds after t1), the steam purge can be completed, and the chamber can be slightly pressurized. Then the door [25c] can be closed and the door [26b] can be opened, and the resulting chamber can be re-pressurized. At time t5 (eg, approximately 8 seconds after t1), panel

[50] may be near the end of purge zone

[10] and at the same pressure as the downstream steamer in zone

[11] , ready to be released through door [26d].

[0078] Other embodiments of the system may have more or fewer doors, and space them differently. Fig.10 A "knife-style" door is shown, but other styles of doors may be used. In another continuously moving embodiment, instead of a door, a seal may be applied to the panel surface so that the panel continuously moves through different areas and the seal contacts different parts of the panel frame, thereby creating a tightly enclosed space, similar to the effect of opening and closing a door in an alternative embodiment.

[0079] In one embodiment, if Fig. 6A As shown, the panels in the desorption zone

[11] are continuously moved by a stream of steam that is forced through the panels multiple times. Figure 6B The steam flow section at t1 is shown in more detail. Fig. 6A As seen in FIG. 1 , at the beginning of a cycle, a new panel [50c] may be quickly moved out of the oxygen removal chamber (area

[10] ) and into the steaming chamber (area

[11] ) to align with the panels [50a to 50b] already in place. The three panels may then be moved at a constant rate through a stream of steam that flows back and forth through the panels in a countercurrent manner. The pattern of steam flow may typically be serpentine or alternate to different sides of the chamber, forcing the steam and gas to circulate through each panel multiple times. For example, as Figure 6B As seen in FIG. 1 , there may be a plenum

[22] having a width set to about 1 / 4 of the length of the panel and separated by baffles

[24] . Steam may flow from back to front in the second and fourth quarters of the panel

[50] , and from front to back in the first and third quarters of the panel. The three panels [50a to c] may then move smoothly through the steam flow in a cyclic process. In this embodiment, at time t1 and with reference to FIG. Figure 6B, the leading edge of the panel [50a] may be exposed to fresh steam flowing from the inlet plenum

[21] to the transfer plenum [22a] on the opposite side of the chamber, the second quarter of the leading panel [50a] may be exposed to steam flowing from the transfer plenum [22b] to the transfer plenum [22c] on the opposite side of the chamber and some CO2 collected from the leading edge, and so on. Steam may then flow from the transfer plenum [22c] to the transfer plenum [22d] on the same side of the chamber. Steam may then flow from the transfer plenum [22d] through the panel to the transfer plenum [22e] on the opposite side of the chamber. Steam may then flow from the transfer plenum [22e] to the transfer plenum [22f] on the same side of the chamber. Steam may then flow from the transfer plenum [22f] through the panel to the transfer plenum [22g] on the opposite side of the chamber. Steam may then flow from the transfer plenum [22g] to the transfer plenum [22h] located on the same side of the chamber. Steam may then flow from the transfer plenum [22h] through the panel to the transfer plenum [22i] located on the opposite side of the chamber. Steam may then flow from the transfer plenum [22i] to the transfer plenum [22j] located on the same side of the chamber. Steam may then flow from the transfer plenum [22j] through the panel to the transfer plenum [22k] located on the opposite side of the chamber. Steam may then flow from the transfer plenum [22k] to the transfer plenum [22l] located on the same side of the chamber. Steam may then flow from the transfer plenum [22l] through the panel to the transfer plenum [22m] located on the opposite side of the chamber. Steam may then flow from the transfer plenum [22m] to the transfer plenum [22n] located on the same side of the chamber. At the end of the panel sequence, the trailing quarter of panel [50b] is exposed to steam and gas flowing from the transfer plenum [22n] to the exhaust plenum

[23] . This steam and gas has passed through the panel seven times (moving from

[21] to [22a to m] and then to [22n]), so a large amount of CO2 has been collected. Fig. 6AAt time t3 in , half of the leading panel [50a] may have moved out of the steam flow, and a third quarter of the leading panel [50a] may be exposed to fresh steam. At t4, panel [50a] has moved completely out of the effective steam flow, and the leading quarter of the middle panel [50b] is in the fresh steam flow. The cycle is complete in terms of steaming the leading panel [50a], with the remaining time for panel [50a] to move forward into the cooling chamber and the next panel [50d] to move into position to restart the cycle. One advantage of this form of continuously moving panels is that the flow of steam and CO2 is more nearly continuous than with a batch or step-wise approach, and all sections of the panel experience very similar time / temperature / CO2 concentration profiles. Another attractive feature is that multi-stage countercurrent steam flow can be achieved using an appropriate number of panels maintained in the steaming zone. Although reference is made to FIG. FIG. 6A to FIG. 6B Eight passes of steam and gas through a plurality of panels are described, but the system may alternatively have a plenum system in which the gas passes through a subset of the panels at least about 3 times, alternatively at least about 4 times, alternatively at least about 5 times, alternatively at least about 6 times, alternatively at least about 7 times, alternatively at least about 8 times, alternatively at least about 9 times, alternatively at least about 10 times, alternatively at least about 11 times, alternatively at least about 12 times. In some embodiments, the system may alternatively have a plenum system in which the gas passes through a single panel at least about 2 times, alternatively at least about 3 times, alternatively at least about 4 times, alternatively at least about 5 times, alternatively at least about 6 times, alternatively at least about 7 times, alternatively at least about 8 times.

[0080] In an alternative embodiment where the steam flows through the panel in a serpentine manner, the steam may be delivered around the panel so that the steam always approaches the same face of the panel. Thus, instead of entering back and forth (from one face to another), the steam may move in a "spiral" fashion, from top to bottom or from bottom to top (if the panel is in a horizontal orientation); or the panel may move in a vertical orientation from right to left (or always from left to right) in a consistent manner. Maintaining the direction of the gas flow through the panel may improve the performance of the system, particularly as the panel movement rate increases and the gas flow decreases.

[0081] In another alternative embodiment with a consistent flow direction of gas relative to the panel, such as Fig. 9In the embodiment shown in, this continuous steam flow can be realized by changing the moving direction in the steaming area. In this embodiment, the panel enters the region

[10] from the left side at the bottom of the figure and moves to the steaming region

[11] , in which the panel moves upward and then passes through the vacuum cooling region

[13] from right to left. The difference between this embodiment and other versions is that the steaming region

[12] realizes the lateral panel movement and the countercurrent flow of steam and panel. These panels can be spaced apart (as shown in the figure) or can be loaded more densely. They can be moved continuously or as a series of steps. The steaming chamber can be filled up completely (as shown in the figure), or the panel can be concentrated in a part of the steaming region (for example, near the steam source or near the steam removal point). In a typical cycle, the newly loaded panel [50i] can be loaded into O2 to remove or vacuum chamber (region

[10] ) and vacuum and / or gas purge to remove oxygen. The vacuum can then be broken and the panels moved into a steaming chamber (region

[11] ) where panels 50b to 50h are in a parallel stack such that the faces of adjacent panels 50b to 50h are parallel to each other, and then the panels are gradually moved in a lateral direction toward the end of the parallel stack near the steam inlet. As the panels move through the steam flow toward the cooling chamber (region

[13] ), the panels will experience a gradually decreasing concentration of CO2, thereby promoting desorption of CO2 from the panels. Once at the end of the steaming region

[11] , the panels will move into a cooling chamber (region

[13] ) where a vacuum and / or purge gas can be used to reduce the temperature of the panels, and then the panels are balanced with ambient pressure and unloaded from the cooling chamber in region

[13] . The arrows indicate the relative movement of the panels through the system.

[0082] One advantage of the present invention is the possibility of countercurrent movement of steam to the panels in the steaming zone. This allows the steam with the lowest CO2 concentration to contact the panels on which the lowest residual levels of CO2 are adsorbed, which reduces the total amount of steam required to desorb the panels. The degree of improvement is a function of the adsorption isotherm (the curve representing the equilibrium concentration of CO2 in the gas phase compared to the adsorbed phase), but in most cases increasing the number of countercurrent stages will reduce the overall steam usage. A compounding effect is that at elevated temperatures, particularly in the presence of oxygen, the adsorbent may decompose, so holding the panels at temperature for extended periods of time may have the opposite effect. Therefore, increasing the number of panels in countercurrent flow may be limited. Therefore, there is the additional advantage of limiting the amount of time the panels spend in the steaming zone - this is achieved, for example, by spacing the panels apart (e.g. Fig. 9 ) or by moving the steam back and forth through the panel (as shown in FIG6 ).

[0083] In some embodiments, the limitation on the rate at which panels can be stepped through the system may be the time required to open a door, move panels into and out of different zones, or the time required to complete oxygen scavenging or panel cooling activities. Fig.11 One possible approach to alleviating such constraints is shown - two inlet chambers [10a and 10b] and two outlet chambers [13a, 13b] may be connected to a single steaming chamber (zone

[11] ). The chambers in zones [10a] and [13a] may be connected to one adsorber box, while zones [10b] and [13b] may be connected to a second adsorber box that operates out of phase with the first adsorber box. It should be noted that the term "adsorber box" may refer to any structure (i.e., "adsorber structure") in which adsorption occurs on adsorber panels

[50] . Panels

[50] may be loaded alternately from zones [10a] and [10b] so that panels

[50] enter the chamber of steaming zone

[11] at twice the frequency at which they may be processed in either zone [10a and 10b]. Similarly, panels are alternately unloaded into cooling chambers in zones [13a] and [13b] so that panels

[50] leave steaming zone

[11] at twice the frequency at which they could be processed in cooling zones [13a and 13b]. Having a higher stepping frequency in steaming zone

[11] compared to loading / unloading zones

[10] ,

[13] allows for more levels of countercurrent steam / panel contact in the steamer without increasing the average time a given panel spends in the steaming zone. Arrows indicate relative movement of panels through the system.

[0084] Although Fig.11 Embodiments are contemplated in which both two purge or vacuum chambers in region

[10] and two cooling chambers in region

[13] are contemplated, but alternative configurations can be easily envisioned—for example, one inlet and two outlets or two inlets and one outlet are also possible. Furthermore, configurations can be easily envisioned in which more than one inlet or outlet chamber can be connected to one or both sides of the steamer.

[0085] Fig. 12A Another possible variation is shown which would allow for a relatively long oxygen purge in zone

[10] or a relatively long cooling step in zone

[13] , but would allow for a greater number of panels in the steaming zone

[11] while maintaining a moderate panel residence time in the steaming zone

[11] . In this embodiment, two panels [50a, 50b] can be loaded into the chamber in the oxygen purge zone

[10] simultaneously and complete their cycles together. The two panels [50a, 50b] can then be loaded into the chamber in the steaming zone

[11] together and stepped through the steam until unloaded into the cooling zone

[12] . The arrows indicate the relative movement of the panels and steam through the system.

[0086] In an alternative embodiment, an odd number of panels may be maintained in the chamber in the steaming zone

[11] . This would mean that the trailing panel [50b] at the inlet would have one extra step period in the steam and during that extra period it would experience fresh steam. In such an embodiment, the trailing panel [50b] would not be as consistently exposed to steam having a higher CO2 concentration than the leading panel [50a] as it would be in an embodiment where there were an even number of panels in the chamber of zone

[11] .

[0087] Although Fig. 12A An embodiment is shown in which two panels are loaded at a time, but alternative arrangements in which more than two panels are loaded at a time can be easily envisioned. Fig. 12A An embodiment is shown in which there are an odd number of panels in the steaming zone, but alternative arrangements can be easily envisioned in which an even number of panels are maintained. In the event that more than two panels are loaded at a time, it is also envisioned to adjust the number of panels maintained in the steaming zone in order to achieve an unloading pattern that maximizes uniformity of panel desorption.

[0088] Fig. 12B A possible time series of events is shown which would enable a single adsorber wall or panel row

[54] to supply panels [50a to e] to Fig. 12A The double-width panel loading system

[62] shown. The panel

[50] can move along the adsorber wall

[54] , gradually protruding beyond the end of the adsorber wall

[53] into a waiting area or waiting area (for example, as shown in Figure 2). Once the panel [50a] is completely disengaged from the adsorption and has left the adsorber box

[60] , the panel [50a] can be transferred to the lateral transfer device

[62] . The loaded first panel [50a] can then be moved within the lateral transfer device

[62] to allow the second panel [50b] to be loaded onto the freed space. The two panels can then be loaded together into the oxygen removal area

[10] of the regeneration box. In this embodiment, the panel moves with the lateral transfer device; a system in which the lateral transfer device remains stationary while the panel moves on its surface can be easily envisioned.

[0089] Moving the panels quickly offers the potential to reduce the frequency of steps in the regeneration chamber and thus improve both capital efficiency and the number of stages of countercurrent flow in the steaming zone for a given residence time. At the same time, tall, thin panels (with a high aspect ratio) can allow for shorter adsorber walls of the same area, which can provide capital savings. Unfortunately, the high aspect ratio can make it challenging to accelerate the panels for rapid movement in and out of the regeneration system because there is the potential for twisting forces on the panel frame and the risk of panel tipping is increased.

[0090] In an alternative embodiment, if Fig.17AAs seen in , the panel

[50] that leaves the panel track can be loaded onto a device that rotates the panel 90° so that the panel can be loaded into the regeneration chamber at a much lower aspect ratio. Advantageously, the door in the regeneration chamber can be smaller and therefore easier to seal with these rotating panels.

[0091] In an alternative embodiment, the adsorber panel

[50] may be made of subunits

[78] . Once the panel leaves the adsorption box, the panel may be split and rearranged into a shape that is more convenient for regeneration. In one embodiment, Fig. 17B The panel

[50] in can be divided into subunits [78a to c], such as Fig. 17C These subunits can then be rearranged so that the maximum surface areas are aligned to form a block that is 1 subunit high, 1 subunit long, and 3 subunits wide (e.g. Fig.17D Alternatively, the subunits may be arranged so that their edges touch (as in Fig.17E ) to form a block that is 1 subunit high, 3 subunits long, and 1 subunit wide. Any of these configurations may be better suited to higher acceleration forces than the original orientation of the panel.

[0092] Although Fig. 17B A panel is shown that can be divided into three sub-units, but in alternative embodiments, the panel can be divided into as few as 2 sub-units or as many as 10 or even more sub-units. Fig. 17B All subunits are shown reconfigured to be processed at the same time, but in alternative embodiments the subunits may be processed independently (one at a time) or in some other convenient grouping (e.g., two at a time).

[0093] In another embodiment, the concept of loading multiple panels into the oxygen removal chamber in zone

[10] or the final cooling chamber in zone

[13] can be combined with the concept of uniform panel steaming by adding a waiting area between oxygen removal

[10] and steaming

[11] and / or between steaming

[11] and cooling

[13] . This will enable, for example, two panels to be discharged from the oxygen removal at the same time. One panel will then enter the steam flow directly, while the other panel will wait for half a step and then move into the steam flow. Similarly, at the other end of the steaming box

[11] , one panel can leave the steam flow in half a step to enter the waiting area to be joined by the second panel in a full step, thereby allowing two panels to enter the cooling zone

[13] together. It is easy to understand how this example can be extended to process three, four or more panels together in zones

[10] and / or

[13] while maintaining a uniform time / temperature distribution of the panels in the steam zone

[11] .

[0094] Fig. 9One possible advantage of the side steaming system shown is that it may allow the regeneration chambers to be kept relatively close together. Fig. 13B It is shown how the lateral flow regeneration chambers [61a to 61f] allow the adsorber boxes [60a to 60f] and lateral transfer units [62a to 62f] to be arranged in a star pattern, thereby maintaining good separation of the adsorber boxes [60a to 60f] while also keeping the regeneration chambers [61a to 61f] close to each other. Keeping the regeneration chambers [61a to 61f] close together minimizes the length of low pressure gas piping required to allow multiple regeneration units to share common downstream processing equipment.

[0095] Isolation doors

[26] and

[27] at the entrance and exit of areas

[11] and

[13] are Fig. 9 Shown in FIG as a swinging door, other designs are contemplated, including a "gate" or knife-type door that slides into position, or a "rotating barrel" that rotates on a vertical axis to move a chord of a circle into position to act as a seal.

[0096] Fig.14 Some possible embodiments of the door are shown. A swing door

[70] rotates about a pivot

[71] so that when open it is not in the path of movement of the panel, but when closed it seals against the wall. In the case of a knife or gate door

[72] , the door will be outside the path of movement of the panel in its open position, but then slides into position to close the chamber in the closed position. Optionally, the door seal can be improved by rotating a cam

[73] that pushes the sliding door

[72] against the frame. A drum or revolving door

[74] rotates about a pivot

[75] . The door

[75] is connected to the pivot by one or more mounting arms

[76] that are outside the movement area of ​​the panel. When open, the drum door is outside the movement area and then rotates into position to form a seal. Optionally, the pivot point

[75] can be mounted on a moving system, allowing the door to swing into position and then push tightly against the door frame to improve the seal.

[0097] In other embodiments of the process, the panel may be moved between different zones in a continuous manner, and this may be accomplished by forming a seal against the surface of the moving panel, as seen in FIG. 36 . Fig.36AA side view of one possible configuration is shown. The lower support strut

[111] can be designed so that it is flush (in the same plane) with the entire panel frame

[95] to provide a continuous flat surface against which the lower seal is formed. On top of the panel, a sealing strut

[128] can be added so that its upper surface is flush with the upper surface of the outer frame so that it can provide a continuous flat sealing surface. The sealing strut

[128] can be a single element that contacts the sealant

[92] located between the panels. In some embodiments, the sealing strut

[128] may have an extension

[129] that both minimizes gas flow between the panel rows (e.g., [94a] and [94b] or [94b] and [94c]) and provides rigidity to the sealing surface

[128] .

[0098] Fig.36B A plan view of the adsorber unit support and panel configuration is shown. The adsorber units

[90] are supported by a mesh supported by support struts

[110] . Individual adsorber units

[90] may be arranged in a linear array ( Fig.36B The array may be arranged in a manner such that support struts

[110] extend between the arrays. The space between the arrays and the support struts

[110] and frame

[95] may be filled with a deformable sealant

[92] which both prevents air flow around the adsorber units

[90] while also providing some cushioning to the brittle adsorber units from any thermal expansion or movement stresses to which the panel is subjected. The sealant

[92] may also allow for some variation in the size of individual adsorber units

[90] . The sealant

[92] may also be used between individual adsorber units

[90] and between adsorber units

[90] and support struts

[110] . As Fig.36A As shown, the support strut

[110] may be aligned with the lower sealing strut

[111] and the upper sealing strut

[128] .

[0099] exist Fig.37A Some possible embodiments of mechanisms within the structure of a closure panel that can be used to accomplish sealing in a continuously moving system are identified in Figures 1 through 3. Fig.37AAn embodiment is shown in which a sealing block

[125] is in contact with at least one sealing strut

[128] . The sealing block

[125] is intended to prevent gas from moving from one array of adsorber units

[94] in the panel to an adjacent array by creating a contact point between the sealing block

[125] and the upper sealing strut

[128] (the same seal is created between the sealing block

[125] and the lower sealing strut

[111] at the bottom of the panel). This contact seal creates a separation between multiple groups of adsorber unit arrays

[94] so that gas, such as air, can flow through one group of arrays without mixing with gas flowing through another group of arrays. The sealing block

[125] can be made of metal, polymer, or some other material that provides a smooth surface and enables contact with a certain length of the sealing strut

[128] . Light pressure can be applied in a direction perpendicular to the movement of the panel to improve the contact and seal between the upper sealing strut

[128] or the lower sealing strut

[111] and the sealing block

[125] . The sealing block

[125] material may have a low coefficient of friction relative to the panel frame

[95] and the sealing pillars

[128] . The width of the sealing block

[125] may be at least wide enough so that when the panel

[50] is in a given position, the sealing block

[125] contacts at least two sealing pillars

[111] or

[128] . This ensures that when the panel moves, at least one sealing pillar

[111] or

[128] can always contact the sealing block

[125] . To improve the seal, the sealing block

[125] can be made large enough to contact two, three, four or more sealing pillars

[111] or

[128] at a time. In some embodiments, the sealing block

[125] can be stationary and the panel can be movable.

[0100] Figures 37B-1 to 37B-3 An alternative embodiment is shown in which the stationary sealing block ( Fig.37A in

[125] ). Figure 37B-2 and 37B-3 As shown in , multiple roller seals can be grouped together and positioned so that they conform to the surface of the panel. For example, the multiple roller seals

[126] can contact an array of adsorber units (e.g. Fig.36A The roller seals may be positioned so that they are in contact with the mesh support

[103] and deform to accommodate the raised sealing posts

[128] . Alternatively, the roller seals may be positioned so that they are in contact with the mesh support

[103] and deform to accommodate the lower support / sealing posts

[111] , or they may be positioned so that they only contact the sealing posts (top

[128] and bottom

[111] ). Several rollers may be used so that at least one of them is in contact with the sealing posts in a given section of the panel housing. One possible advantage of using roller seals is that the wear rate and friction associated with forming the seal may be less than using a stationary sealing block (such as Fig.37AThe case in

[125] ).

[0101] Figure 37C-1 and Figure 37C-2 Another possible embodiment is shown in which the seal is formed by a continuous strip

[127] . The strip

[127] may be long enough to cover at least two sealing struts

[128] , or it may cover three, four or more sealing struts. Figures 37B-1 to 37B-3 Like the rollers shown in , belt seals

[127] allow for reduced wear and friction. Figure 37C-1 and 37C-2 In plan view ( Figure 37C-1 ) and side view ( Figure 37C-2 ) shows one possible embodiment of the belt. The upper belt [127a] may be in contact with the three upper sealing struts

[128] , and the lower belt [127b] may be in contact with the three lower support struts

[111] .

[0102] The discussion of Figure 37 applies to systems in which the adsorber unit arrays

[94] are arranged on horizontal panels. Designs with horizontal panels supported on a mesh (as shown in Figure 36) or supported in other ways (as shown in Figures 30 and 32) or with vertically oriented panels can be easily envisioned.

[0103] In yet another embodiment, the horizontal panels may be arranged in a circle in the form of a large "disc" or "ring", e.g. Fig.44A In this embodiment, there are two adsorber trains

[54] and two regeneration stations

[61] , but fewer (one of each type) or more (3, 4, 5 or more) adsorber trains and regeneration stations are contemplated. Fig.21 In comparison, one advantage of this configuration is that it eliminates the need for a transfer station

[62] at the end of the linear adsorber track [54a], since each panel [50a] will move continuously in a circular manner, eliminating the need for different "tracks" [54a and 54b] or the need to transfer between tracks. In addition, the forces on the panels [50a, 50b, and 50c] will remain continuous. The advantage of continuous motion is that it eliminates the forces that accelerate and decelerate the panel [50a] as it moves from the track [50a] to the lateral transfer station

[62] ; the forces that accelerate and decelerate the panel [50b] as it moves to align with the track [54b]; and the forces that accelerate the panel

[50] so that it leaves the lateral transfer station

[62] and enters the adsorption track [54b]. This elimination of acceleration and deceleration forces in normal operation can reduce the power requirements of the system and can allow the use of lighter panel frames with lower thermal inertia.

[0104] exist Fig.44B In the embodiment shown, each panel

[50] may be in the form of a "slice" of a disk / ring. Fig.44CIn another embodiment depicted, since there is no longer any discontinuous movement, the concept of the panel

[50] can even be eliminated, so that the disk can be composed of a wide segment of an adsorber unit

[90] with upper sealing struts

[128] and lower sealing struts

[111] . The disk can be composed of radial rows

[133] or spokes of adsorber units

[90] , with sealing surfaces separating adjacent rows (see Fig.44D , rows [133a] to [133e]). Thus, instead of 120 panels each 12 adsorber units

[90] wide, the circular system may have 1440 spokes each one adsorber unit

[90] wide. Fig.44A

[61] ), air removal, vapor desorption, cooling and other possible areas can be configured with similar shapes to fully conform to each segment in terms of sealing and gas exchange.

[0105] Because the adsorption step uses ambient air, the temperature of the air supply may vary with the time of day or season. This may introduce uncontrolled disturbances into the system and may result in greater heating demands at certain points (e.g., at night in winter) than at other points (e.g., at noon in summer). Fig.18 One way to mitigate this variability is depicted in , which shows an embodiment of preheating some of the air used for adsorption. Because the air contains oxygen that can cause adsorbent degradation, the degree to which the panel [50a] is preheated can be limited to, for example, less than 40°C, less than 30°C, or less than 20°C, or between about 20°C and about 40°C, alternatively between about 20°C and about 30°C, alternatively above 20°C, alternatively about 25°C, alternatively about 30°C. In the embodiment shown, the air delivered by the fan

[80] to the last panel [50a] in the panel track

[54] can be preheated in a heat exchanger

[81] with warm water diverted from a cooling tower. Using this waste heat stream ensures that the air cannot be heated to a temperature that could damage the adsorbent (cooling tower return water can always be <45°C) and also reduces the load on the cooling tower (saving energy). In warmer weather such as the summer, this air preheating may not significantly increase the panel temperature, but in the winter it may preheat the panel from about 2°C to about 25°C or more. A key advantage of this approach may be that the temperature of the panel [50b] entering regeneration may be more consistent throughout the year. It may also reduce the amount of steam required to desorb the panel in the chamber

[11] , thereby reducing the amount of water condensing into the panel during this step. This may be beneficial for the rate of mass transfer to / from the panel during desorption

[11] , vacuum cooling

[13] and subsequent adsorption in the adsorber box

[60] . In order to compensate for the pressure drop across the air preheater

[81] , Fig.18 Indicates that a supplemental fan

[80] may be required to keep the air flow through the heated panel [50a] balanced with the other panels in the panel track

[54] .

[0106] Fig.18 Another possible and complementary embodiment of panel heating is also shown in . Once most of the oxygen has been eliminated from the panel and its surroundings in the air removal area

[10] , the panel [50c] can be heated without causing excessive oxidation of the adsorbent. In an optional step, the panel can be preheated in a preheating chamber

[14] using a hot inert gas (such as CO2). The advantage of preheating the panel is that less steam may be required in the steaming area

[11] , so less water can condense onto the surface of the panel [50d to 50g], and the mass transfer step can continue unimpeded. In this exemplary embodiment, the CO2 can be heated with steam in the exchanger

[83] and recirculated over the panel by a fan

[82] to minimize the total use of hot gas and allow the condensed steam to be recovered directly from the heat exchanger

[83] (thereby allowing hotter uncontaminated water to be returned to the boiler). If the panel [50c] is not fully loaded when it leaves adsorption, some of the CO2 used for preheating may be adsorbed onto the panel, providing additional heating - the CO2 can be rapidly desorbed in the subsequent steaming step

[11] . The panel leaving this section may be preheated to about 50°C to 95°C, alternatively about 60°C to 85°C, alternatively about 70°C to 80°C.

[0107] Because residual water on the panel [50k] that re-enters the adsorption can limit mass transfer and because elevated temperatures can make the adsorbent more susceptible to oxidation, an optional process step for panel cooling can be employed. Fig.18 As seen in FIG. 1 , an additional cooling chamber

[15] may be used to enclose a panel [50i] that has been partially cooled in the vacuum cooling zone

[13] . In the additional cooling chamber

[15] , a gas such as nitrogen or air is recirculated through a heat exchanger

[85] by a fan

[84] and cooled using a cooling fluid such as water or ethylene glycol. The cooling gas may then flow through the warm panel [50i], resulting in both additional water evaporation (by reducing the vapor pressure of water on the panel surface) and direct cooling, thereby reducing both the temperature of the panel and residual condensate. The water evaporated from the panel [50i] may then be recondensed and recovered in the heat exchanger

[85] , where it may be returned to the boiler system. The benefit of this optional additional step is that the panel [50k] returned to the adsorption system will be cooler (thereby reducing adsorbent oxidation) and have less liquid water in its internal pore structure (thereby minimizing mass transfer limitations). The panels exiting the supplemental cooling station may be about 10°C to 40°C, alternatively about 20°C to 30°C, or alternatively about 25°C.

[0108] Optionally, Figure 1As shown in , internal heat integration can be achieved by condensing water vapor and cooling other heat sources throughout the system to produce a warm fluid in one or more condensers

[40] . The energy in this fluid can be upgraded via a series of compressors

[44] so that it can release its heat at a higher temperature to form fresh steam in a boiler

[43] . The recycling of heat that can be achieved by using a heat pump significantly reduces the overall energy use of the process. Condensation of most of the water vapor from the process stream also allows water to be recycled from the condenser

[40] to the boiler

[43] , thereby significantly reducing the process water footprint.

[0109] One advantage of using a mixture of steam (or other easily condensable gas) and vacuum for the CO2 recovery step is that it facilitates heat recovery. A large amount of energy can be recovered by condensing steam from the CO2 product gas (and in the case of transferring this energy to a heat pump). For example, the steam-containing CO2 leaving area

[11] can be used to heat water from 60°C to 70°C, thereby condensing most of the water vapor. The 70°C water can then be used to boil butane liquid to form medium-pressure butane gas. Electricity can then be used to compress the butane gas to produce high-pressure butane vapor, which can be condensed into high-pressure butane liquid at 110°C, which can be used to boil hot water at 105°C into low-pressure steam. The condensed high-pressure butane liquid can then be flashed into medium-pressure butane gas and continued to circulate. Similarly, by using a heat exchanger to cool the CO2 and condense most of the water vapor, the vacuum stream can be used to produce 40°C water from 30°C water. Removing this vapor not only recovers energy, but also greatly reduces the load on the vacuum system. As before, warm water can be cooled and recycled by boiling a low-pressure refrigerant (e.g., ammonia, propane, or butane) to produce vapor that can be compressed and then condensed at a higher temperature - in this system, for example, they can provide additional 70°C water to the high-pressure loop.

[0110] The product of this process can be a mixture of CO2, water and other gases (such as inert gases). The concentration of inert gases can be controlled by the vacuum depth on region

[10] and by using purge steam in region

[10] . The concentration of water in the CO2 leaving the recovery condenser can be controlled by the temperature and pressure at which the gas is cooled. The concentration of product CO2 can be about 90% by weight or more of CO2 products, alternatively about 93% by weight or more of CO2 products, alternatively about 95% by weight or more of CO2 products, alternatively about 97% by weight or more of CO2 products, alternatively about 99.9% by weight or more. The concentration of water vapor can be about 10% by weight, alternatively about 5% by weight, alternatively about 2% by weight, or alternatively about 0.1% by weight. The concentration of inert gases can be about 5% by weight, alternatively about 2% by weight, alternatively about 0.5% by weight, or alternatively about 0.1% by weight.

[0111] Universal Plant Design Concept

[0112] Desorption can occur much faster than adsorption, and therefore, the plant is designed to take into account the desorption: adsorption time ratio by utilizing multiple adsorption panels

[50] (typically 60 to 100, although they can be as few as 8 or less, or as many as 140 or more) with a single regeneration tank - thereby allowing the adsorber panels

[50] to last their required adsorption time in multiple regeneration cycles of the individual panels. This design has the advantage of allowing the capital associated with the CO2 recovery equipment to have a higher utilization factor, thereby reducing the capital cost per ton of CO2 produced.

[0113] Historical design approaches for these panel-based systems have required physically moving a "series" of connected adsorber panels into and out of an online regeneration zone in a discontinuous manner. However, a series of connected panels has considerable mass, and thus there may be certain mechanical challenges, particularly in moving the system in a discontinuous process. Furthermore, panel movement designs to date have required movement around an elliptical or circular "track" - thereby creating potential risks in the reliability of such systems with relatively high mass levels in outdoor conditions with varying wind loads and other conditions, across multiple cycles, and challenges associated with sealing flat panels across a curved track (to prevent air flow loss). An early batch production method is disclosed in U.S. Patent No. 10,512,880, entitled "Rotating multi-monolith bed movement system for removing carbon dioxide from the atmosphere," which patent is hereby expressly incorporated by reference in its entirety for all purposes.

[0114] Figure 2A An exemplary configuration of an adsorption / desorption system is shown, showing an adsorber box

[60] , a regeneration box

[61] , and a transfer station

[62] in which the panel

[50] moves. The adsorber box may have two rows of adsorber panels

[50] arranged side by side in a straight line (these two rows of adsorber panels form two long walls

[54] ), and two short solid walls

[53] arranged perpendicular to the two long walls

[54] , which are used to prevent air from short-circuiting to the top fan

[51] . In one embodiment, an air filter

[52] can be used to minimize the impact of dust and other small particles on the system. The air filter

[52] can be arranged parallel to the long wall

[54] of the adsorber panel

[50] and facing the outer surface of the long wall.

[0115] The panel

[50] is configured to move continuously through at least a portion of the adsorber box

[60] . For example, the panel

[50] moving within the adsorber box

[60] may move along a track within the adsorber box

[60] at a substantially constant speed. In one embodiment, the adsorber box

[60] may include one or more sequences of continuously moving panels

[50] therein at a time.

[0116] The horizontally movable panel design proposed herein attempts to eliminate the potential problems caused by indexing the panels through start-stop motions by moving the adsorber panels

[50] individually (unconnected) within the air flow on a continuous basis, across a flat horizontal dimension (or alternatively, across an additional dimension). This confers a major advantage in terms of the movement of much less mass than a "sequence" of connected adsorber panels when regenerating the panels. In addition, the horizontally movable panel design allows the adsorber panels

[50] to move continuously, eliminating the start / stop motion required in alternative designs. The sealing system for regenerating the vacuum is also highly reliable, utilizing a relatively narrow door that is only slightly wider than the shortest dimension of the panel. Compared to sealing systems involving circular surfaces, or to sealing systems involving very large mass movements that require precise alignment, the flat door is closed by an actuator (such actuators are electric, pneumatic or hydraulic in various alternative schemes) against a fixed flat surface. In an alternative embodiment, the vacuum chamber / door is eliminated, allowing the entire process to move continuously, which further simplifies movement throughout the system.

[0117] Another advantage of the greater simplicity of the horizontally moving panel system is that it provides greater flexibility to load larger volumes of substrate and sorbent - resulting in significantly higher throughput. Overall, this offers the potential for lower capital expenditure (and total cost) per ton of CO2 delivered.

[0118] In addition, in contrast to historical designs in which the regeneration box had only a single zone for completing the full range of steps required for desorption, the present design provides multiple separate zones - thereby dividing the regeneration cycle into a series of specialized zones, whereby individual panels are then moved from one zone to another to complete their desorption process. The range of steps (each of which may occur in a single zone, in more than one zone, or in combination with the next step in a given zone) includes: (i) removing air (and oxygen, which may be harmful to the adsorbent at high heat) from the adsorber panel via vacuum or purging the air with steam or an inert gas (such as nitrogen), (ii) breaking the vacuum (or removing the nitrogen or other inert gas) using steam, CO2, or some alternative gas, (iii) heating the adsorber panel via steam (or other means, such as indirect heat or hot CO2), and (iv) cooling the adsorber panel via some combination of vacuum, application of an inert gas (such as nitrogen), or a range of other direct or indirect cooling methods. Dividing the regeneration box into multiple zones also facilitates the introduction of additional process steps, such as panel preheating

[14] or panel cooling

[15] , as Fig.18 shown.

[0119] It is expected that the use of multiple zones for different steps of the regeneration process will confer many benefits. First, this allows a given zone to be specifically designed to optimize a specific process (oxygen removal, steam application, cooling, etc.), thereby ensuring higher efficiency for a given process step. Secondly, dividing the regeneration process into separate zones / segments allows greater continuity of gas flow - thereby reducing / eliminating discontinuous flows that can produce inefficiencies (and / or functional problems) in the operation of auxiliary equipment such as heat pumps, vacuum pumps, compressors, etc. By regenerating multiple panels at a time, this increases capacity compared to a single panel, single zone regeneration box system. In addition, having multiple panels in the hot / steaming zone (zones 11 and 12) allows a countercurrent flow pattern that allows the panels near the ends of the steaming / desorption section to encounter a lower CO2 partial pressure (high steam flow), but then "reuse" the steam to be applied to the heating and desorption panels early in the regeneration cycle. This countercurrent steam flow provides the advantage of utilizing high steam concentration to promote maximum desorption of the CO2-depleted panels near the end of steaming, but then achieving efficiencies by reusing the steam for application to earlier panels within the steaming section - in contrast to the higher cost / inefficiency of using the steam only once (as would be experienced in a single-zone, batch regeneration).

[0120] These advantages will result in lower energy requirements, improved scalability, and lower operating and capital expenses per unit of throughput.

[0121] Another advantage of the proposed embodiment is that it provides an inherently scalable design. The simplified mobile system lends itself easily to larger-scale units due to its relatively low mechanical risk. Second, it is highly space-efficient, not only enabling the transport of large quantities of CO2 within a relatively modest footprint, but also the potential for stacking units, providing greater potential for increased CO2 capture relative to land area. Finally, given the modularity of this design, there are clear opportunities to move toward greater scale—not only by scaling upwards, but also outwards—utilizing components that are well suited to high-volume production, which both accelerates the rate of feasible scaling and reduces the cost per ton over time.

[0122] In one possible plant layout, the regeneration box

[61] can be placed close to each other in the center of two sets of adsorber boxes [60a, b], such as Figure 2A As shown. The advantage of this arrangement is that larger, more expensive equipment such as heat pumps and CO2 compressors can be placed close to the regeneration tank, thereby minimizing the length of low pressure / vacuum ducting required. To achieve this, the adsorber panels

[50] can travel along two flat "panel-walls"

[54] - on one panel-wall the panels will travel away from the regeneration tank, and on the other panel-wall the panels will return. The panels can be switched from one side to the other at some form of lateral transfer station

[62] . Figure 2A The solution shown in will have a conveying system that moves the panels at 90° relative to the direction of movement along the wall. The panel

[50] leaving the adsorber / fan unit

[60] will be moved into a waiting area until it is completely out of the air flow. The panel will then slide into a support frame supported on a mobile trolley. The trolley and the support with the enclosed panel will then be moved sideways to the other side of the adsorber / fan unit and the panel will be unloaded into the waiting area and then collected by the mobile system, which transports the panel into the air flow. Figure 2B An enlarged view of the adsorber / fan unit is shown. The arrows indicate the relative movement of the panels through the system.

[0123] In another embodiment, Figure 3 A variation of this process is shown with a regeneration box

[61] and a lateral transfer station

[62] at each end of the adsorber / fan unit

[60] . The arrows indicate the relative movement of the panels through the system. It is also possible to envision a system with curved tracks for connecting from one side to the other so that the panels always move along the same axis.

[0124] exist Fig.16In another embodiment, a curved track

[64] may be used instead of a lateral transfer station. In this case, the panel

[50] will move along the adsorber wall [54a] from left to right until the end is reached. The panel will then be transferred to one side of the regeneration station [60b] to complete the desorption cycle. The panel will then move onto the transfer rail [64a] to be transferred to the inlet of the adsorber wall [54b]. The panel may be supported by rails or tracks at the bottom of the panel, or the panel may be suspended from rails at the top of the panel, or both.

[0125] In an alternative embodiment, the linearly movable wall may be combined with a device having two doors (such as Fig.16 as shown) or with a single door (as Fig.15 A single chamber batch regeneration box combination (shown in FIG. 1 ) is provided. In a single chamber, the entrance door can be opened and the panel can be loaded into the chamber. The door can then be closed and air can be purged from the chamber, for example by applying a vacuum and / or using a purge gas such as steam. A desorption steam can then be initiated, for example by releasing the vacuum with steam and heating the chamber to a temperature at which CO2 can be desorbed from the panel. The desorbed CO2 can be removed from the chamber and recovered, for example by purging additional steam through the chamber. Once sufficient desorption is achieved, the panel can be cooled, for example, by applying a vacuum or using an inert purge gas such as nitrogen. Once the cooling step is completed and (if necessary) the vacuum is released, the entrance door (in the case of a single door chamber) or the exit door (in the case of a double door chamber) can be opened and the panel is removed, thereby resetting the system for the next cycle. In the case of a double door chamber, both doors can be opened simultaneously and a new panel can be loaded while the previous panel is removed.

[0126] exist Fig.15 In the illustrated embodiment, the panel

[50] may be moved along the adsorber wall [54a] until the end of the wall is reached. The loaded panel

[50] may be transferred through the lateral transfer unit [62a] and into the regeneration tank [61a]. The door [25a] of the chamber [61a] may then be closed and the panel may pass through its regeneration cycle. After regeneration is complete, the panel

[50] may leave the regeneration chamber [61a] and be loaded onto a transfer station [62a] which may move the panel across to align with the adsorber wall [54b]. The panel may then travel along the wall [54b] until the regeneration cycle is repeated in the regeneration tank [61b] / transfer system [62b]. Fig.16In the embodiment shown, a double-door regeneration box

[61] is depicted. In this case, the panel

[50] can be moved along the adsorber wall [54a] until it reaches the end of the wall. At this point, the panel can be loaded into the regeneration box 61a through the first door [25a], where the panel will be closed and complete the regeneration cycle. The second door [25b] can then be opened to allow the panel

[50] to advance along the transfer rail [64a] to join the adsorber wall 54b. The panel

[50] can then be moved along the adsorber wall [54b] until it reaches the end of the wall. The panel can then be loaded into the regeneration chamber [61b] for regeneration through the door [25b]. The panel will then leave through the door [28b] to be transported back to the adsorber wall [54a] by the transfer rail [64b].

[0127] Fig.19A Possible configurations of the panel

[50] are shown, and some possible components are identified. The panel

[50] is a larger, structurally integrated element that can be moved as a single unit. It includes a large number of individual adsorber units, such as monoblocks

[90] , each of which may include a porous substrate with a high area-to-volume ratio that supports a CO2 adsorbent. Monoblocks are substrate materials that have been formed to have air flow channels running through them in one direction, and these air flow channels have a medium size (millimeter scale) separated by porous walls. The holes in the wall are coated with an adsorbent that temporarily binds CO2. An array may include a row of 1, 2, 3, 4 or 5 adsorber units. In some embodiments, the array may be 2 adsorber units x 2 adsorber units, 2 adsorber units x 3 adsorber units or 2x 4 adsorber units, and the array may be 3x 3 adsorber units. The holes may have a very small diameter so that the entire system has a high surface area relative to its total volume. The substrate may be a ceramic material.

[0128] These individual adsorber units

[90] can be assembled into arrays

[94] to facilitate assembly and operation of the panel

[50] . In this embodiment, the panel

[50] includes a group of adsorber arrays

[94] that are in contact with each other or separated by a support shelf or support frame

[91] . Fig.19A As depicted, the panel

[50] includes thirty-six cell arrays

[94] , and each cell array includes six adsorber units

[90] . The support shelves 91 provide structural rigidity to the panel frame 95 and prevent the weight of the upper cell arrays from compressing the lower cell arrays. Fig.19BAn enlarged view of a single monomer array

[94] is shown. In this embodiment, the highlighted monomer array comprises six (6) adsorber units

[90] separated by sealant

[92] . The sealant

[92] eliminates size non-uniformity of the individual adsorber units

[90] ; provides some relief for stresses caused by thermal expansion and movement of the frame

[95] and shelf

[91] ; and bonds the panels in position relative to each other. The monomer array

[94] may be held in position and supported by an array frame

[93] , which may be made of a rigid material such as steel or aluminum; or made of a more plastic material such as silicone foam to absorb deformation of the steel frame

[91] caused by thermal expansion or panel movement.

[0129] Alternative orientation of panels: horizontal (vs. vertical)

[0130] Many of the embodiments described utilize panels in a vertical orientation so that the plane of the panel surface is perpendicular to the ground and the gas flows through the panel in a horizontal path. In another embodiment, the panel is oriented horizontally so that the plane of the panel is parallel to the ground and the gas flows through the panel in a vertical path.

[0131] A key advantage of having a horizontal panel (a panel in a horizontal orientation) is that it has substantially greater stability - the panel can be supported at multiple points and so the risk of tipping is greatly reduced (compared to a vertical orientation). The weight of the panel is also more widely distributed and the centre of gravity is at a similar level to those support points.

[0132] In one configuration, such as FIG. 20A to FIG. 20B (side view), the panels run together continuously at different levels but in the same vertical plane. In this configuration, the panels can be configured so that air enters the system from the sides (entry page) between the panels and exits through the panels in an upward and downward direction ( Fig. 20A ), or exit through two or more panel layers ( Fig. 20B ). In both cases, panel [50a] will move along the track at one level and then as panel [50b] leaves the adsorber box

[60] and is lifted ( Fig. 20A ) or reduce ( Fig. 20B ), and then returns to the air flow on the other track (panel [50c]). Fig. 20B In the embodiment shown, the freshest air will flow through the bottom more loaded panels first (maximizing the load on those panels), then through the less loaded panels (to capture some of the remaining CO2 in the air, thereby maximizing the overall potential CO2 capture). FIG. 20A to FIG. 20BThe embodiment presented in shows only two horizontal tracks, but alternative embodiments may have 3, 4, 5 or more layers. Air may be blown in through opposing walls by fans facing each other so that air may escape only upward or downward through the panels. Alternatively, the walls may be open and fans may draw air upward through the panels. Alternatively, the air flow may change direction because the volume between or below the panels may have a higher pressure than the volume above (and below) the panels. Alternatively, blades or other devices may be used to redirect the air flow from an incoming horizontal direction to a vertical direction.

[0133] Fig.21 An alternative possible arrangement is shown, in which the panel

[50] moves in opposite directions (see arrows) at the same height in parallel adsorption tracks

[54] . In this embodiment, the panel moves continuously along the panel track [54a] in the adsorption area, wherein the air blows through the panel in the vertical direction. When a given panel [50a] reaches the end position in the adsorption track [54a], it moves to the lateral transfer station

[62] , as seen in the case of panel [50b]. The panel can move across from one track to another track at the same height, and then return to the starting position of the second track [54b] as panel [50c]. This embodiment shows two tracks, but in alternative embodiments, there may be only one track, or alternatively, there may be 3, 4, 5 or more parallel tracks.

[0134] Fig. 22 One possible embodiment of a regeneration system in a horizontally oriented system is shown, and a side view of the system is shown. Panel [50a] may exit the adsorption system and enter the air removal zone

[10] at the same height as the adsorption track. The panel may then exit the air removal zone

[10] and enter the preheating zone

[14] at the same height as the air removal zone. Panel [50b] may then descend through the heated gas, and more than one panel may be enclosed in this zone (see, for example, [50c]), allowing countercurrent heating to occur. Panel [50d] may then move from the preheating zone

[14] to the steaming zone

[11] at a reduced height, and then move upward through the downward steam flow. As Fig. 22 As seen in FIG. 1 , the panels in the steaming zone

[11] can be moved in the opposite direction of the steam flowing into the chamber. In one embodiment, more than one panel (such as panels [50e] and [50f] in this illustration) can be enclosed in the steaming zone

[11] and raised until they reach the height of the adsorption system. The top panel [50f] can then be transferred from the steaming zone

[11] to the cooling zone

[13] at the height of the adsorption system. After cooling is completed, the panel [50g] can be transferred from the cooling zone

[13] to the panel return system, which transports the panel back to the adsorption track.

[0135] The key advantage of operating more than one panel in the preheat box

[14] is that it increases the time available to preheat a single panel in a system with a fixed cadence - if a new panel enters the heating system once a minute and there is only one panel in the heating system, the maximum time available to heat that panel is 1 minute. If there are two panels with a 1 minute cadence, the maximum heating time is 2 minutes, and so on. Therefore, with more panels in the heating zone and a fixed cadence, the amount of energy that can be transferred to a given panel should be increased. In addition, having the gas flow in countercurrent through the panels means that the cooler gas contacts the coolest panel and the gas leaving the heating chamber will remain cooler throughout the cycle, thereby maximizing the driving force on the external air heater.

[0136] Fig. 22 Another advantage of horizontally oriented panels is shown in Figure 1—there is no need to match the length of the steaming area

[11] to the spacing of the panel walls as in the vertical orientation. This allows for a smaller steaming chamber and makes it easier to bring the panel frames closer or in contact with each other. This makes it easier to seal the gaps between panels and therefore minimize the flow of hot air / steam bypassing the interior of the frame.

[0137] Fig. 22 Only one possible embodiment of the regeneration system is shown. In alternative embodiments, additional operating steps may be applied (such as additional panel cooling), and / or where panel preheating occurs independently of height changes. In other embodiments, the steam chamber exhaust height may be at a different height than the panel track, and where additional means are present to change the height of the panel. Fig. 22 A linear design is also shown, which is similar to Figure 2A This is particularly useful in the "2 adsorber" configuration shown. In other embodiments, a lateral transfer device may be used to allow some of the regeneration steps to be performed in concert with the second adsorption track. Fig.23A Figures 1 through 3 show some possible implementations of this approach, providing a top view of the approximate location of the equipment.

[0138] exist Fig.23AIn one embodiment, the panel may move along the panel track [54a] toward the unloading area, then move into the air removal area

[10] and then into the preheating chamber

[14] . In one embodiment, the panel may move downward in the preheating chamber

[14] and then exit on a lower level track and in a direction orthogonal to the direction it entered the chamber, thereby moving into the steaming chamber

[11] . The panel may then be raised while moving through the steaming chamber

[11] and then move through the door into the cooling chamber

[13] . In this embodiment, the direction of travel out of the steaming chamber is orthogonal to the direction of entry so as to minimize the total space required and the travel distance of the panel. After cooling, the panel may move through the staging area and then return to the adsorption system on the track [54b].

[0139] Fig. 23B An alternative arrangement is shown in which the panels can move along the adsorption track [54a] on their long axis and then exit into a staging area that allows lateral movement into the air purge chamber

[10] with movement in the direction of its second axis. After exiting the purge chamber, the panel moves through the staging area in which it makes another change of direction to enter the preheat chamber

[14] at the same height as the adsorption track. The panel can then be lowered in the preheat chamber

[14] and then moved to the steaming chamber

[11] where it can be raised. The panel can then be transferred to the cooling chamber

[13] and after completing the cooling step, it can enter the staging area and return to exit the adsorption track [54b].

[0140] Fig.23C Another possible embodiment is shown, in which the adsorption tracks [54a] and [54b] can be separated from each other by a larger distance. In this configuration, the panel can leave the panel track [54a] and enter a transfer area, which allows the panel to move off the panel track [54a] and then enter the clearance area

[10] in an orthogonal direction; from the clearance area, the panel can move through the upper horizontal door into the preheating chamber

[14] , where the panel can be lowered and preheated, and then the panel can move through the door at the lower level into the steaming area

[11] . The panel can then leave the steaming chamber

[11] through the door at the upper level and enter the cooling chamber

[13] . The panel can move from the cooling chamber

[13] to the transfer area to achieve an orthogonal change in direction, and the panel can be reloaded onto the exit adsorption track [54b].

[0141] FIG. 24A to FIG. 24C Some possible implementations of multi-track adsorption systems are shown. Fig.24AIn the embodiment shown, there may be two parallel adsorption tracks [54a] extending side by side to parallel transfer areas. The panels may then be loaded into two separate but parallel air removal areas

[10] and loaded into independent preheat chambers

[14] . Continuing to move in the same direction, the panels then enter the steam desorption chamber

[11] and then finally enter the cooling chamber

[13] . The panels may then be collected in the transfer area and returned to leave the parallel adsorption tracks [54b]. The advantage of this configuration is that the panels move in the same direction through all regeneration steps and isolation doors, and lateral movement is delayed to a single end station, but this approach may require more space and may require additional travel distance / time to return to the panel track.

[0142] Fig. 24B An embodiment is shown in which the center two tracks [54a] can perform a "return" trip and can move panels from the adsorption zone through the transfer zone and into the parallel purge zone

[10] . The panels on these parallel tracks can be staggered in their sequencing so that they can enter and leave the air purge zone

[10] at different times so that they can be transferred to the common preheat zone

[14] at different times. If the preheat zone lowers the panel, the subsequent panels can be "stacked" vertically so that they can move in the same vertical plane at any given time but occupy different heights. The panels may or may not be in physical contact with each other. These panels can then leave the preheat chamber

[14] and enter the steam desorption zone

[11] where they can rise through the downward flow of hot gas (e.g., steam or a steam / CO2 mixture). These panels can be withdrawn from the steaming zone

[11] in alternating directions for transfer to a separate cooling chamber

[13] and can then be transported back to the "leaving" panel track [54b], which in this embodiment occupies the outer two tracks. The advantage of this configuration is that the door size of the vacuum chambers

[10] and

[13] can be kept relatively small, while the common preheat chamber

[14] and / or steaming chamber

[11] can enclose more panels and achieve a more continuous countercurrent flow without increasing the overall residence time of a single panel in the hot zone.

[0143] Fig.24C An alternative configuration of a dual track adsorption

[54] / air purge

[10] / cooling

[13] system with a common preheat

[14] and desorption

[12] system is shown, where both the exit [54b] and return [54a] adsorption tracks can be adjacent to each other. The layout of these stations is also configured to minimize the number of locations where the panels change direction in the enclosed space.

[0144] FIG. 25A to FIG. 25CSome embodiments are shown where a dual track adsorption system is combined with separate vacuum zones (

[10] and

[13] ) and a common preheat

[14] and steaming

[11] system. All of these embodiments are also configured so that the panel does not change direction in the horizontal plane while inside the processing step - all lateral movement occurs on the tracks outside the processing zone. Fig.25A In the adsorption orbital [54b], it has been extended so that Fig.24C The long transfer region shown in can be used for additional CO2 capture. Fig.25B In this case, part of this space can be used to perform secondary cooling

[15] , similar to Fig.18 Described in. Fig.25C In the figure, multi-chamber cooling in the region

[13] is depicted, similar to Figure 6B Described in .

[0145] Fig.26 Another embodiment of the process combining a monorail adsorption system with a separate vacuum step is shown. The panel can move along the return adsorption track [54a] and then enter a transfer area, in which the panel can move forward to an air removal area [10b] or move sideways and then move to different air removal areas [10a]. The operation of these air removal areas can be staggered in time to allow the panel to move continuously in the adsorption track [54a] and enter a common preheating chamber

[14] . Additional transfer station space can be used to allow the panel to have time to move through these processing steps while maintaining a fast pace, thereby allowing the panel to have a longer transfer distance (and therefore transfer time, such as traveling to the air removal area [10a] instead of [10b]) to keep pace with the panel with a short transfer. In this embodiment, the panel can move from the air removal area

[10] to the common preheating area

[14] and the steaming area

[11] , and the panels from different air removal areas in the common preheating area and the steaming area can be stacked to improve countercurrent flow performance. After the steam zone

[11] , the panels can be separated again to pass through a separate cooling chamber

[13] and then move back onto the same exit panel track [54b].

[0146] Fig.38 A plan view of another possible embodiment of a horizontally oriented system is shown. In this configuration, the CO2 preheating zone [14a to c] and the steaming zone [11a to f] are arranged in a horizontal orientation to avoid Fig. 22 Instead, the gas flow in these areas can be arranged to flow back and forth across different planes of the chamber through continuously moving panels (as shown in Figure 6), but it should be noted that the gas flow can also be conveyed around the panels between passes so that the gas flow through the panels is always in the same direction.

[0147] exist Fig.38 In the embodiment of the present invention, the panel can be continuously moved throughout the adsorption sequence [90a], and the last panel in the sequence can gradually leave the air flow to fill the transition zone [65a]. When the panel is completely out of the air flow, the panel can be quickly moved into the air removal chamber [10a], where oxygen can be removed by a combination of evacuation, replacement with steam, N2 or some other inert gas, and heating. The panel can be quickly moved out of the air removal chamber [10a] to another transition zone [65b], after which the panel can be continuously moved into the (optional) CO2 preheating zone [14a to c], where heated CO2 / steam can flow through sub-sections of the panel to achieve countercurrent flow of the panel relative to the hot gas (as detailed in Figure 6). For example, the hot gas can move upward through zone [14c], then downward through zone [14b], and then upward again through [14a]. Alternatively, the hot gas may flow upward through [14c], be conveyed around the sequence and flow upward through [14b], be conveyed around again and then flow upward through [14a]. The preheated panel may then continue directly into the steaming zone [11a] (or directly from the air purge chamber into the steaming zone if the optional CO2 preheating zone is not used), where again steam may flow through the panels in a series of sub-chambers, so that a countercurrent flow pattern is achieved. For example, the panel may move from zone [11a] to [11f] while steam flows sequentially into [11f], then into [11e], [11d], [11c], [11b] and [11a]. When the panel leaves the steaming zone [11f], it may enter the transition zone [65c], and once completely free of the steam, the panel may move rapidly into the cooling chamber [13a], where a combination of vacuum, nitrogen, air or other gases may be used to cool and dry the panel so that water evaporates and the panel temperature is reduced. Once the cooling cycle is complete, the panel can move to the transition zone [65d] where it can join the sequence of panels in the adsorption system [90b]. Fig.38 In the depicted embodiment, there are two adsorption trains [90a and 90b] and two parallel desorption trains, but other configurations similar to those depicted in Figures 24 to 27 (such as where there is only one desorption train) can be easily envisioned. Similarly, Fig.38 A design is shown in which there are three preheating subchambers and six steaming subchambers in each desorption train. Embodiments with fewer (0 to 2) or more (4 to 10) preheating subchambers and fewer (1 to 5) or more (7 to 14) steaming subchambers can be easily envisioned.

[0148] Fig.41 An exemplary single-plane, continuous, horizontally oriented system with a single regeneration zone is shown. Fig.41 As shown, the system may include three adsorption train sections [90a to 90c], two lateral transfer units [62a and 62b], and a single regeneration chamber

[61] . The panel may move continuously from the first adsorption train [90a] through the first lateral transfer unit [62a], the second adsorption train [90b], the third adsorption train [90c], and the second lateral transfer unit [62b], and then to the regeneration chamber

[61] . In other embodiments, the movement may be in the opposite direction. The illustrated layout including a single regeneration chamber

[61] along one of the two parallel tracks in the DAC system may be suitable for smaller DAC operations, such as when the total adsorption track is relatively short.

[0149] Fig.39 Another exemplary embodiment of the process is shown, in which the panels are continuously moved through the system, and an inert gas

[115] such as nitrogen can be used instead of vacuum to (i) displace the air in the purge step

[10] and (ii) provide cooling in the cooling step

[13] . The advantage of a continuous regeneration system is that the panels do not need to be accelerated in and out of the vacuum chamber, thereby increasing the overall rhythm of panel movement. In this embodiment, the panels can be continuously moved out of the adsorption area

[90] and directly into the countercurrent air displacement area

[10] , where an inert gas such as nitrogen can be used to displace the air in the void space around and inside the panels. Because each adsorber unit is composed of a series of narrow air flow channels, it can be expected that the displacement of air is close to piston flow in nature - the air flow channels are almost like a series of parallel straws. In this embodiment, the air displacement chamber can be divided into two sub-chambers separated by a gas seal [120b] - an upstream region [10a] and a downstream region [10b]. Fresh inert gas [115a] may enter the downstream subchamber [10b] and displace the gas in the interstitial space of the panel. The flow rate of the gas may be set so that a given volume of gas is introduced into the same subchamber in the time required for a point in the panel to move through the downstream subchamber [10b]. The volume of gas introduced may be between one and two times the interstitial volume of the enclosed subchamber so that all of the incoming gas in the interstitial space is displaced, but the volume of gas may also be between 1 / 2 and one times the interstitial volume, or between two and three times the interstitial volume—or more.

[0150] Gas introduced into the downstream sub-chamber [10b] of the air purge section can displace gas into the upstream sub-chamber [10a], which in turn displaces air in the panel out of the system. If the flow rates of the gases are carefully balanced, the nitrogen in the downstream sub-chamber [10b] can displace gas in the panel entering that sub-chamber, so that the gas flowing from downstream to the upstream sub-chamber [10a] is primarily air with a small amount of nitrogen. The gas flowing into the upstream sub-chamber [10a] can completely displace the incoming air, so that very little nitrogen escapes from the upstream sub-chamber [10a] along with the displaced air, thereby reducing nitrogen losses. Although Fig.39 Two sub-chambers are depicted, but more chambers may be included.

[0151] The panel is connected by a set of seals [120c] (such as Figure 37A to Figure 37C-2 10a, 10b] to the nitrogen recovery chamber

[121] . Optionally, the nitrogen recovery chamber [121a, 121b] can be operated under a slight vacuum (0.5 bara, alternatively 0.25 bara to 0.75 bara, alternatively 0.05 bara to 0.95 bara) to facilitate nitrogen recovery and removal. This reduced pressure can be achieved with a fan or vacuum pump [122a] so that the recovered nitrogen partially replaces the need for fresh N2.

[0152] The displacement of nitrogen may be accomplished with steam, CO2, or a mixture of steam and CO2 such as may be recovered from steaming chamber

[11] . Steaming chamber

[11] may have a plurality of subchambers [11a] to [11f]. The displacement is similar to that described for air displacement in chamber

[10] - the displacement gas mixture enters the downstream subchamber [121b] at a rate sufficient to displace 1 to 2 pore volumes (or in an alternative process, less than 1 pore volume, or 2 to 3 pore volumes or more) per panel transition time. Thus, the panel void space exiting chamber [121b] may comprise primarily steam, while the gas exiting chamber [121b] and entering [121a] may comprise primarily displaced N2. This N2-rich mixture will then displace the N2 gas entering the upstream subchamber [121a], where the panel is from subchamber [10b].

[0153] Because the panels entering the N2 recovery chamber

[121] may be relatively cool and already adsorbed with ambient air, the CO2 and steam mixture may interact with the panels - some CO2 may adsorb and some steam may condense, thereby heating the panels. While the N2 displacement may not be as direct as that observed in an air displacement chamber

[10] , the same basic principles will apply - a "standing wave" will be established where most of the N2 is displaced and only a small amount of CO2 and water vapor escapes to the nitrogen recovery fan [122a].

[0154] A potential advantage of operating the N2 recovery chamber under a slight vacuum

[121] is that the temperature at which the vapor can condense is more limited. For example, at 0.5 bara, the condensation temperature of pure water is 81°C, which is the maximum temperature that the panel can reach through the action of vapor condensation. It may be advantageous to keep the panel temperature below the level at which significant CO2 desorption occurs.

[0155] Because short-circuiting and back-mixing of gases between subchambers can be detrimental to the overall performance of the system, sealing between the gas spaces of the subchambers may be required; as the pressure differential across the different sections increases, the flow through any gaps in the seal will increase. Therefore, it may be beneficial to have larger, multi-contact seals [120a] around the vacuum sections.

[0156] From the N2 recovery section

[121] , the panel moves through seal [120e] into the continuous steaming section

[11] , in which steam flows from subchamber [11f] through subchambers [11e], [11d], [11c] and [11b] to subchamber [11a], countercurrent to the direction of movement of the panel (the panel flows from [11a] to [11f] in sequence through seals [120f] to [120j]) to achieve efficient desorption of CO2 and minimize the residual level of CO2 on the panel leaving the desorption area. The steam flow through the panel can be "meandering" (through different sides) as shown in Figure 6, or the gas can be conveyed in a "spiral" manner around the chamber containing the panel so that the gas always enters the panel from the same side (as shown here).

[0157] After steaming, the panel may be moved continuously into cooling chamber [13a] and sequentially through [13b], [13c] and [13d], where again the panel encounters a countercurrent flow of inert gas [115b] flowing from [13d] to [13a]. In this illustration, four cooling stages in four sub-chambers [13a] to [13d] are envisioned, but fewer or more stages may be included. The purpose of cooling chamber

[13] is to cool and dry the panel by flowing a warm, dry, oxygen-free gas (such as nitrogen) over the hot, wet panel. As the panel moves forward from [13a] to [13d], the gas moves in the opposite direction (from [13d] to [13a]). The incoming gas may be at low humidity and may be heated to 20°C to 30°C or 15°C to 40°C or 10°C to 50°C by heater

[123] . Because the gas flowing into the cooling chamber [13d] has low humidity, water can evaporate from the surface of the panel, thereby cooling the panel and the gas. When the gas flows into the sub-chamber [13c], the gas can encounter warmer panel sections, so that the gas may warm up and water can evaporate further.

[0158] Optionally, the gas flowing into [13a], [13b] and [13c] can be reheated. This can increase the amount of evaporation and therefore increase the moisture content and temperature of the gas entering condenser 124. It can also reduce the gas flow rate required to achieve a given residual water load on the panel leaving region 130 and re-entering adsorption region 90.

[0159] The flow and incoming temperature of the gas can be carefully managed so that the gas leaving the incoming panel sub-chamber [13a] can be hot (65°C to 85°C or 55°C to 90°C or 45°C to 100°C) and close to saturation, while the gas leaving the panel sub-chamber [13d] can be cold (20°C to 30°C or 15°C to 40°C or 10°C to 50°C) and have a low moisture level. The hot and humid gas leaving the sub-chamber [13a] can be sent to the condenser

[124] and cooled to a low temperature (5°C to 10°C or 0°C to 25°C or -5°C to 45°C) to condense out a portion of the water vapor and supply energy to the heat pump. The dried gas can then be recirculated to the gas heater

[123] via the fan [122b].

[0160] The void space in the panel leaving the last cooling sub-chamber [13d] may be filled with the gas injected into the cooling chamber

[13] . This gas, for example N2, may be partially recovered by counter-flow displacement with air via a fan [122c] to minimize overall nitrogen losses. FIG. 40A to FIG. 40B One possible implementation of a gas recovery system is shown.

[0161] FIG. 40A to FIG. 40B An embodiment of an apparatus is shown which is intended to recover a large portion of the inert cooling gas

[115] in the void space entering with the panel

[50] from the upstream cooling zone

[13] while minimizing contamination of that gas by the air used to displace the void space. This separation is achieved by forming a tortuous path for the displacing air to follow so that the flow in the displacement zone is generally in a direction opposite to that of the panel, but is locally forced to pass through the panel a number of times. The resulting flow pattern is thus similar to Fig. 6A The flow pattern shown. This flow pattern is produced by forming a set of seals on opposite sides of the panel, wherein the seals are offset from each other in the direction of panel movement by at least one air flow channel. The set of seals form sub-chambers that are separated from each other in the direction of panel movement but connected by air flow channels connecting opposite faces of adsorber units within the panel

[50] . The entire system is configured so that the rate of gas flow through the panel void space (air flow channel) is approximately equal to the rate at which the void space moves forward through the panel movement.

[0162] FIG. 40A to FIG. 40BA plan view and a cross-sectional view of an embodiment are shown in which the panel moves continuously from the cooling area

[13] through the seal group [120a to 120d], which isolates the mostly airless cooling area

[13] from the final gas recovery area. The seal group [120a to 120d] helps guide the air flow through the panel 50 in opposite vertical directions. The seal group [120a to 120d] includes a plurality of seals. As shown in FIG. Fig.40B As shown in FIG. 1 , the plurality of seals may include a full seal [120a] including sealing members on both sides of the panel and a plurality of half seals [120b to 120d] having sealing members on only a single side of the panel. FIG. 40A to FIG. 40B As seen in FIG. 5 , the semi-seals [120a, 120b] are located on the lower face of the panel

[50] , and the semi-seal [120c] is located on the upper face of the panel

[50] . The seal sets [120a to 120d] together with the side walls

[139] , the chamber floor

[135] and the chamber ceiling or ceiling

[137] form a plurality of sub-chambers (130, 131, 132) through which air can flow after passing through the panels. For example, Fig.40B As seen in FIG. 1 , the subchamber

[130] is composed of a chamber bottom plate

[135] , a bottom surface of the panel

[50] , a seal [120a], a seal [120b] and a surrounding wall

[139] ( Fig.40B ) are defined.

[0163] In some embodiments, the semi-seal may contact only a single face of the panel

[50] . In embodiments having two or more semi-seals, the first semi-seal may contact the first face of the panel

[50] , and the second semi-seal may contact the second face of the panel

[50] (opposite to the first face), so that the incoming gas is forced to displace the gas in the panel void space. In embodiments having three or more semi-seals, one semi-seal may contact the first face of the panel, and the second and third semi-seals may contact the second face of the panel (opposite to the first face), so that the gas is forced to flow through the panel first in a first direction orthogonal to the plane defined by the panel

[50] , and then through the face of the panel

[50] , so that the entire panel and the gas flow are in opposite directions. The flow rate of the gas in one direction may approximately match the movement of the panel void space in the opposite direction, so that a standing wave may be established, and most of the gas in the panel void space entering the area is recovered with minimal mixing of the displacing gas.

[0164] Panel 50 continues to move through the recovery area past seal [120b], which is shown here only on the bottom of the panel. Semi-seal [120b] prevents gas from flowing from subchamber

[132] to subchamber

[130] , while allowing gas to flow upward through panel

[50] from subchamber

[132] to subchamber

[131] . Because there is no seal on the top surface of the panel opposite [120b], gas can flow freely into subchamber

[131] . Panel

[50] can then move past semi-seal [120c] on the top surface of the panel, and finally past semi-seal [120d] on the lower surface of the panel.

[0165] exist FIG. 40A to FIG. 40B In the example, when the panel moves from left to right, the air moves from right to left. Fig.40B As seen in the cross-sectional view in , the system may be arranged so that air may enter the panel air flow passages between seals [120c] and [120d] and flow downwardly through the panel in a direction normal or perpendicular to the plane defined by the panel

[50] , thereby displacing gas in these passages. The system may be operated so that the air pushes gas within the panel void space through the panel

[50] into the subchamber

[132] , after which the air is pushed through different sections of the panel into the subchamber

[131] in a direction normal or perpendicular to the plane defined by the panel

[50] but in a direction opposite to the air flow entering the subchamber

[132] . From the subchamber

[131] , the air is pushed through another portion of the panel void space into the subchamber

[130] in a direction normal or perpendicular to the plane defined by the panel

[50] but in a direction opposite to the air flow entering the subchamber

[131] . With appropriate flow rates, as the gas moves from subchamber

[132] to

[131] and on to

[130] , the composition of the gas may increase in the inert purge gas

[115] concentration such that subchamber

[130] may be primarily filled with the inert cooling gas

[115] .

[0166] Air flows into the gas flow channel in the adsorber unit contained in the panel

[50] in the space in front of the semi-seal [120c] and flows through the panel

[50] in an orthogonal direction. The air displaces the gas in the panel void space in the gas flow channel into the subchamber

[132] . The gas can flow upward from the subchamber

[132] through the panel flow channel, thereby displacing the gas in these channels into another subchamber

[131] . Finally, after the subchamber

[131] , the air can displace the gas into the subchamber

[130] through the gas flow channel. From the subchamber

[130] , the vacuum pump

[122] can draw gas from the subchamber

[130] , and at least a portion of the recovered gas can be directed back into the cooling area

[13] .

[0167] The gas displaced into the sub-chamber

[131] may also include gas

[115] fed toward the sub-volume

[130] through the gas flow channel of the panel

[50] , such as Fig.40B As seen in . The gas

[115] can be an inert gas, such as N2. In some embodiments, the void space or gas flow channel in the panel moving through the seal [120a] can be filled with N2, and the subchamber

[130] can also be filled with N2. Therefore, the gas in the subchamber

[130] can include N2, which can be recycled to the cooling area

[13] to reduce the use of fresh N2

[115] . In some embodiments, the gas in the subchamber

[130] can be substantially pure N2. If the semi-seal [120c] is slightly leaky or if there is some back mixing of the gas displaced from the subchamber

[132] into the subchamber

[131] , the gas in the subchamber

[131] may include gases other than N2, but overall the risk of these gases returning to the cooling area

[13] can be minimized. Similarly, the gas in subchamber

[132] should be N2 and it should displace gas containing primarily the same gas as in subchamber

[131] back into subchamber

[131] . If the semi-seal [120d] leaks, if air flows into the passage above subchamber

[132] , or if there is excessive mixing of gases within the panel flow passage, the gas in subchamber

[132] may be slightly contaminated. However, any impurities may be within the moving panel and may move forward with the panel if the gas flow is properly controlled, and they may then flow into subchamber

[131] .

[0168] exist FIG. 40A to FIG. 40B In the illustrated embodiment, for purposes of illustration, the subchambers [130 to 132] are depicted as having different sizes; however, they may of course be the same size or have relative sizes different from those depicted. The system is shown as having three subchambers, but similar systems may be envisioned as having one, two, five, or more partitions. The seals [120a to d] are depicted as being large enough to seal only one seal strut

[128] , but as described elsewhere, they may be larger.

[0169] In another embodiment of a fully continuous process, the horizontal panels may be arranged in a circle (e.g. FIG. 44A to FIG. 44C ), thereby eliminating the need for a transfer station at the end of the linear array and allowing a constant force to be applied throughout the process.

[0170] In different embodiments of the design, it is possible to orient the fans so that the blades rotate in a vertical or horizontal plane (or indeed at some other angle). FIG. 27A to FIG. 27BSome possible embodiments of fan arrangements for operating panels in a horizontal plane are shown in , which shows four elevated panel rails [54a to 54b] supported by a set of structural support elements

[55] . The panel rails are depicted end to end so that they flow into or out of the page in this illustration. Fig.27A In the embodiment, the fan 51a can be mounted horizontally below the panel tracks [54a and 54b] in a forced air mode, thereby pushing air upward through the panel tracks [54a and 54b]. This can provide the advantage of keeping the fan motor mass close to the ground and can allow the stresses associated with the rotating equipment to be decoupled from the mechanical support of the panel. Fig.27A An alternative embodiment is also shown in which fans 51b can be mounted above the panels in panel tracks [54c and 54d] in a horizontal plane in an induced draft pattern, thereby pulling air through the panels. This can provide a fan mounting area that is roughly equal to the panel area, and this design can accommodate larger fan diameters. One possible advantage of induced draft fans is that they can minimize turbulence in the air flowing through the panel and can allow higher exhaust air velocities from the system without the need for additional equipment. Higher vertical exhaust velocities can be advantageous in terms of the air flow pattern of the system and can reduce the amount of spent air that is recirculated to the adsorber inlet.

[0171] In yet another embodiment, Fig.27B As shown, the fan [51c] can be mounted in a vertical orientation in the wall of a building and operated in a forced air mode. This keeps the mass of the fan and its rotating equipment closer to the ground. The fan in this embodiment can be away from the panel tracks [54a and 54b] and can be upstream of the rain screen and filter [not shown] so that the turbulence of the fan wake can be dissipated before the air encounters the panel. In another embodiment, as shown Fig.27B As shown, a larger diameter fan 51d may be mounted in a vertical orientation, but at a distance from the edge of the panel track 54d with the building transition to redirect the air flow.

[0172] FIG. 28A to FIG. 28B Several possible embodiments of the placement of the air filter are shown. The four panel rails [54a to 54d] are shown in a side view from the end of the rails. In this embodiment, the panel rails [54a to 54d] are raised and supported by structural elements

[55] . Fig.28A, filters [52a] may be placed in a vertical orientation in the wall of the building, or filters [52b] may be placed in a horizontal orientation below the panel tracks [54c and 54d]. Placing filters [52a] in the wall may allow them to be relatively far away from the panel tracks [54a] and they may be downstream of the fans [not shown], and thus filters [52a] may help dissipate the wake from the fans. Placing filters [52b] below the panels may allow more available area for filters, thus mitigating the pressure drop caused by air filtration.

[0173] Fig.28B Two possible embodiments are shown to allow for a larger filtration area while maintaining some separation of the filter

[52] from the panel track

[54] . The filter [52c] may be set at an angle, while the filter [52d] may be oriented vertically but set back from the edge of the panel track [54d]. The fan may be mounted upstream of the filter, between the filter and fan, or downstream of both the filter and fan, so a variety of arrangements of fan and filter options can be easily envisioned.

[0174] With the panels in a horizontal orientation, the likelihood of precipitation impinging on the air transfer surface increases and some form of flashing may be required. FIG. 29A to FIG. 29C Several possible embodiments of the flashing are shown. Fig.29AIn the embodiment, a set of chevaux

[96] can be used to capture precipitation and direct it into a rainwater collection chevaux / trough

[98] . In this embodiment, the chevaux can be placed between the panel track

[54] and the exhaust fan

[51] to maintain the highest possible vertical fan exhaust velocity, but it is easy to envision a system in which the fan is below the chevaux or in which the chevaux is used in conjunction with a vertical or horizontal induced ventilation fan below the panel. An advantage of having chevaux

[96] and

[98] between the fan

[51] and the panel track

[54] can be that any lubricant from the fan or any small parts that fall during maintenance can avoid hitting the panel track

[54] . In embodiments in which the fan is located below the chevaux or in induced ventilation mode, the chevaux can also serve as the roof of the building. In some embodiments, the system can replace the upward facing chevaux

[96] with a flat roof, wherein the fan

[51] operates in a cutout in the roof. The downward facing chevaux

[98] can be widened to have a width greater than the fan diameter in order to capture water droplets. In some embodiments, the downward facing chevrons

[98] may extend along the width of the building. In some embodiments, the troughs may have the shape of a circular disk or inverted cone to cover a diameter slightly larger than the projected diameter swept by the fan, and with drainage means to remove any water that accumulates in a rainstorm. In some embodiments, the cross-section of the trough may be generally chevron-shaped (as shown), or may be generally V-shaped, generally L-shaped, generally U-shaped, generally straight, or irregular. In some embodiments, the cross-section of the trough may include a shallow concave dish along its upward facing surface. In some embodiments, the troughs and / or chevrons may be angled relative to the vertical, spaced apart from each other, and / or overlap each other in the vertical direction in a manner that allows air to flow through them while preventing rainwater from flowing through them. The chevrons or troughs may extend across the building (perpendicular to the direction of movement of the panels) or along the building (parallel to the direction of movement of the panels). The slots / chevrons may have different lengths, such as to approximate a circular fan opening (where the longer slots are aligned with the center of the opening and the shorter slots are closer to the sides of the opening. Other shapes and arrangements than those shown and discussed herein may be used for the slots without departing from the scope of the present disclosure.

[0175] Fig.29BTwo alternative arrangements are shown in which chimneys or sleeves [97a, 97b] are used. Rainwater tends to fall at an angle, and the fan exhaust will tend to create some vortices, so precipitation may hit the walls of the chimney

[97] and flow downward to be collected in the trough

[98] at the bottom of the chimney. Two possible embodiments of the chimney are shown - [97a] is shown as operating with an induced draft fan (but it can also operate with forced draft). The top of the chimney can be tapered inward to reduce the discharge area, thereby increasing the air velocity leaving the system. This increased velocity (and elevated discharge point) can help minimize air recirculation (i.e., minimize the situation where the CO2-depleted air leaving the system is drawn back into the inlet air flow). The chimney [97b] is shown with an induced draft fan

[51] and no discharge taper. The wall of the rainwater collection trough

[98] can be positioned at a sufficiently low height so that any rain that penetrates beyond the fan will likely impact the side walls of the chimney [97b] and flow into the trough

[98] .

[0176] Fig.29B A separate panel rail (e.g. Fig.23C

[0063] An alternative arrangement of the chimney

[97] is shown with a panel mounted hood (shown). The chimney

[97] is relatively narrow and collects air from two separate suction rails [54a and b] in a relatively large open space. Rain falling through the chimney can be captured in a rainwater collection trough

[98] . As shown, a forced draft fan is envisioned, but it is also possible to mount an induced draft fan above the panel or in a narrower portion of the chimney

[97] .

[0177] FIG. 43A to FIG. 43B An alternative embodiment of a rainwater mitigation system is shown having a wide rainwater collection funnel

[98] below the fan

[51] . The rainwater collection funnel

[98] may be circular or rectangular when viewed from above and may have a diameter / width equal to or greater than the diameter of the fan

[51] . Further rain protection may be provided by the building roof

[117] and by a fairing

[118] around the fan

[51] which also improves the pattern of air flowing through the fan

[51] . In the event that precipitation falls at an angle, further protection may be provided by including a plurality of rain deflection rings [99a to 99c] which may collect raindrops falling at an angle and direct them downward into the rain collection funnel

[98] . The plurality of rainwater deflection rings [99a to 99c] may be located above or below the fan

[51] . The profile of the rainwater deflection rings in the direction of air flow may be quite narrow so that they provide minimal resistance to air flow. FIG. 43A to FIG. 43B Three rain mitigation rings [99a to 99c] are shown, but more or fewer rings may be included. The rings may have the same or different heights (e.g. Fig.43A) to minimize the possibility of rainwater entering the panel array

[54] . In some embodiments, these rings can be concentric. These rainwater mitigation rings are shown as being above the fan, but these rings can also be located below the fan

[51] but above the collection funnel

[98] .

[0178] refer to Fig.19A , the forces acting on the adsorber units

[90] in the panel

[50] will be different when the panel is in a horizontal versus vertical orientation. Specifically, in a horizontal orientation, the impact of gravity can cause the adsorber units

[50] to be pulled downward and out of the plane of the face of the panel

[50] . A number of different approaches can be applied to address this problem. Fig.19A In the embodiment, the support shelf

[91] can be connected with Fig.19B The adhesive acts as a frame for the array

[93] , thereby effectively gluing the array

[94] into place; as a further measure, the glue may be supplemented with physical support.

[0179] FIG. 30A to FIG. 30D Several possible embodiments of the physical support structure are shown. Arrays [94a] and [94b] may comprise a single adsorber unit or several adsorber units bonded together, for example in groups of 2x1, 2x2 or 2x3 adsorber units. To the extent that the arrays may be of slightly different sizes, the support system will be designed to accommodate this variability. Fig. 30A A side view of an embodiment is shown in which a single cell array [94a] or [94b] is supported from below by a combination of vertical supports

[100] and edge supports

[101] . In this example, the edge supports may be sized large enough to accommodate both the larger array [94a] and the smaller array [94b]. The edge supports

[101] may be connected directly to the vertical supports

[101] , or it may be connected via a spring loaded clamp that conforms to the size variations of the adsorber arrays [94a or 94b]. The support may be a two part structure having a vertical member 100 and a horizontal member 101.

[0180] Fig. 30B Plan views of three different possible embodiments of edge supports are shown. Support [101a] embodies a shelf that supports the entire length of the array on all four sides. Additional variations of this system are also contemplated where only 1, 2, or 3 sides are supported (see, e.g. FIG. 35A to FIG. 35C ). Support [101b] illustrates an embodiment where only the corners of an array (not shown) may be supported, and support [101c] embodies an example where edge supports do not extend the entire length of the array edge. FIG. 35A to FIG. 35CAdditional variations are shown in which only 1, 2 or 3 corners may be supported, and in which only 1, 2 or 3 sides may be supported. The advantage of covering less of the lower surface area of ​​the array is that more of the surface is open to air flow and can therefore aid in CO2 adsorption. The advantage of having a larger support area is that the array

[94] is held more securely in place.

[0181] Fig. 30C A side view of an alternative embodiment is shown in which a tapered support

[102] is used. In this embodiment, the larger array [94a] can be located slightly higher than the smaller array [94b]. The advantage of this approach is that the air flow surface is not blocked. Fig.30D A plan view of the arrangement is shown. Fig. 30C A continuous taper is shown, but a stepped profile is contemplated.

[0182] Fig.34 An alternative embodiment for supporting the panels is shown. A spring clamp

[108] may be used to support the bottom of the array

[94] , which spring clamp may be attached to the vertical support at a first end and form a support flange with a second end.

[0183] Fig.31A and Fig.31B An alternative embodiment for supporting the panel from below is shown. Fig.31A In the embodiment of the present invention, a mesh

[103] of fine elements can be formed and supported between vertical supports

[100] that provide rigidity to the mechanism and maintain sufficient tension in the mesh

[103] to minimize sagging. A cutout

[104] can be used to partially remove the mesh near the center of the array

[94] to minimize interaction between the mesh

[103] and the array. In some embodiments, the array

[94] can be located above the cutout. In this embodiment, the mesh

[103] extends parallel and perpendicular to the supports

[100] ; in alternative embodiments, the mesh will extend diagonally so that each strand is supported by the frame

[100] . Additional vertical supports

[100] extending perpendicular to those shown or omitting the mesh

[103] of strands extending parallel to the supports

[100] are also contemplated.

[0184] Fig.31B Another embodiment of this concept is shown, where the support wires

[105] are more widely spaced and extend at an angle to the support

[100] . The advantage of using fewer support wires

[105] is that less of the surface of the array

[94] is blocked; the advantage of using more support wires

[105] is that the individual strands retain less weight and can therefore be thinner.

[0185] Fig.32Another approach for supporting the array

[94] is shown. A collar

[106] coupled to or resting on a support may be coupled to the array

[94] , for example, by a tension fit or with glue. The collar

[106] may be located on the support

[100] , or the collar

[106] may be glued to the support, or the support may be inserted into the collar, or the support may have a spring clamp (one embodiment of which may be similar to Fig.34 ) to hold it in place and accommodate size variations. The height of the collar can be a fraction of the array height (as shown), but it can be a greater fraction of the total height or even greater than the array height. The width of the collar

[106] can be sufficient to account for variations in the width of the array

[94] so that the lower surface of the collar can rest in the upper surface of the support

[100] , or the variation can be accommodated by an elastic or spring connection (e.g., Fig.34 The spring clamp shown in FIG. Fig.32 Also shown is an element that can be readily envisioned for use with other embodiments described herein—sealant

[92] can be used to provide a buffer between arrays

[94] and prevent gas from bypassing the internal gas channels of array 94.

[0186] Fig.33 Another embodiment of a variation for supporting the adsorber unit

[90] is shown. In this embodiment, the manufacturing process can be adapted to include a support surface

[107] in the edge of the adsorber unit

[90] . In this embodiment, the corners can be enlarged to mate with edge supports [101b] (such as Fig. 30B those shown in ) are joined.

[0187] FIG. 42A to FIG. 42E Several possible embodiments of the connection between the net

[103] and the support struts

[110] are shown. Fig.42A 36 , the net

[103] may be sandwiched between support struts

[110] and lower struts

[111] which may be located below the net. In this embodiment, the support struts

[110] may be located above the net

[103] and may be connected to the panel frame (

[95] in FIG. 36 ), but the struts

[110] may be located below the net. The lower support struts

[111] are shown as being free floating and attached to the upper support struts

[110] , but it may be the primary support and may also serve as a lower sealing surface for the seal shown in FIG. 37 . Fig.42A An advantage of the design shown is that the net remains flat and the volume of space below the lower face of the net

[103] and lower struts

[111] is minimized.

[0188] FIG. 42B to FIG. 42D Three other possible configurations of the interaction between the upper support struts

[110] and the lower support struts

[111] are shown. Fig.42BIn the embodiment shown, the lower support struts [111a] have a triangular shape which can be set into appropriately shaped openings in the upper support struts [110a]. This arrangement has the advantage that it reduces the void space below the mesh, but has the potential disadvantage of requiring deformation of the support mesh

[103] . Fig.42C An alternative arrangement is shown in which the lower support strut [111b] takes the profile of a truncated ellipse. Fig.42D Another possible configuration is shown where the larger support struts [111c] are flush with the lower face of the adsorber unit

[94] , with the net

[103] deforming around the lower struts. One advantage of this configuration is that if the lower struts [111c] are attached to the panel frame (

[95] in Figure 36), then the upper struts [110c] may not need to bear any load and may serve primarily to prevent the net from moving. Thus, the upper struts [110c] may be omitted and the overall weight of the panel reduced.

[0189] Fig.42E Yet another embodiment of a mesh support system is shown in which the support struts

[110] take the form of "n" shaped members that curl around the edges of two sections of the mesh

[103] .

[0190] Horizontally shifted panel DAC system

[0191] In many embodiments, direct air capture systems are described that continuously move individual adsorber panels in an air stream in a linear fashion and then move each panel out of the air stream into a regeneration box having multiple zones for the desired desorption phase to occur.

[0192] In many embodiments, such as Figure 2A As seen in FIG. 5 , each adsorber panel

[50] of the system may be moved along a given panel wall, track or row [54a], then enter a multi-zone regeneration box [61a], then enter an adjacent panel wall, track or row [54c], after exiting via lateral movement in a lateral transfer station [62b] for transport to an opposite / adjacent panel wall, track or row [54d], return along the entire face, then enter a second multi-zone regeneration box [61b], then enter an adjacent panel wall, row or row [54b], exit via lateral movement in a lateral transfer station [62a], and repeat the entire process. In some embodiments, as Figure 2AAs seen in the drawings, the panels

[50] can be arranged end to end with each other, served by a fan

[51] above (or alternatively, at the opposite end). One advantage of this design is that the parallel units in this configuration make them easier to form into a relatively standard rectangular enclosure. Another significant advantage is that given the significant lengths that the adsorber panels extend (up to 250 feet or more), having a fan above the panel (or at the opposite end) greatly facilitates the movement of air through the entire length of the adsorber panel. The fan draws air upward, causing the fresh air to flow through the filter and then through the panels in the adsorber box. The air flow is turned from horizontal (through the filter / panel) to vertical (through the fan) in the adsorber box.

[0193] Figure 2A One possible configuration is shown that combines multiple fans

[51] and multiple sets of mobile adsorber panels

[50] / multi-zone regeneration boxes [61a, b] (which will form two operating units). For example, Figure 2A As seen in , the adsorber box [60a] may be rectangular having a width of 10 feet to 100 feet and a height of 10 feet (alternatively about 20 feet, alternatively about 30 feet, alternatively about 40 feet, alternatively about 50 feet, alternatively about 60 feet, alternatively about 70 feet), alternatively having a width between about 70 feet and about 320 feet (alternatively between about 120 feet to about 640 feet, alternatively between about 240 feet and 1280 feet). In one embodiment, the adsorber wall ( Figure 2B

[54] ) can be approximately 240 feet wide x 19 feet high, 180 feet wide x 25 feet high, or alternatively 40 feet to 640 feet wide and 5 feet to 50 feet high. Alternatively, the adsorber wall can be 240 feet to 12,800 feet wide and 25 feet to 100 feet high. In other configurations, alternative configurations can also cluster the adsorber wall. The number of fans

[51] can be between 5 and 20, or alternatively between 1 and 6, or alternatively between 15 and 60, or more.

[0194] according to Figure 3 , alternative embodiments may include a regeneration tank

[61] at either end of the adsorber tank

[60] . Alternative embodiments ( Figure 4 ) may have additional adsorber boxes [60a to f] in parallel, thereby allowing the adsorber boxes [60a to 60f] and the regeneration boxes [61a, 61b] to share common and centralized downstream equipment (vacuum pumps, heat pumps, compressors). Other alternative embodiments may have a greater number of regeneration boxes (3 or more). In some embodiments, multiple adsorber walls (54) may be stacked vertically in any of these configurations with multiple fans. In other embodiments, multiple adsorber boxes are in a parallel pattern ( Fig.13A ) or non-parallel patterns (such as Fig. 13B star structure shown).

[0195] Other embodiments may include utilizing Fig.21 The panel rails are oriented horizontally as shown (or, alternatively, using FIG. 44A to FIG. 44C The horizontal panels shown are arranged across the circular track, utilizing Fig.27A and Fig.27B The fan can be operated by a fan [51b] oriented horizontally above the panel or a fan [51a] oriented horizontally below the panel as shown, or by a fan [51c or 51d] oriented vertically below the panel tracks [54a to 54d].

[0196] exist Figure 4 In the illustrated embodiment, the regeneration box [61a, b] is shown serving six separate adsorber boxes [60a to 60f] in parallel - the panels from each of the adsorber boxes [60a to 60f] are regenerated simultaneously and oriented so that the faces of the panels in the adsorber boxes [60a to 60f] are in a parallel configuration. The arrows indicate the relative movement of the panels through the system. In an alternative embodiment, these adsorber boxes [60a to 60f] may be oriented end-to-end in a longer, thinner regeneration box.

[0197] The number of panels

[50] in adsorption mode will typically be significantly greater than the number of panels in desorption or regeneration mode. The ratio of panels in adsorption mode: panels in desorption or regeneration mode may be as small as 2:1, alternatively between 2:1 and 12:1, alternatively between 12:1 and 36:1, alternatively between 36:1 and 144:1, or greater. Using a large number of panels in adsorption mode allows each panel to spend additional time in adsorption before desorption, which results in desorption of additional CO2 in each regeneration cycle. This may have benefits in terms of capital efficiency as well as energy efficiency because a larger amount of CO2 is produced per unit of regeneration energy. The design also allows for efficient heat recovery and transfer throughout the system.

[0198] Having multiple panels in regeneration simultaneously also provides benefits in terms of capital and energy efficiency. In terms of capital efficiency, having a single regeneration box with multiple zones containing a large number of adsorber panels can greatly increase throughput, reducing capital cost per unit of output. In addition, by applying steam to a specific zone and then applying the same steam to other panels in other zones, considerable thermal energy efficiencies are created compared to requiring fresh steam for each panel.

[0199] Figure 2AShown is how multiple sets of panels

[50] and regeneration boxes [61a, b] can be arranged adjacent to each other. In some embodiments, multiple layers of panels can be served by overhead fans

[51] [(or alternatively, by fans at each end of the building)]. In alternative embodiments, there can be 3, 4, 5 or more layers of panels; there can also be different configurations of fans. There can be multiple fans in the horizontal direction (and / or more fans in the horizontal direction). The ratio of panels to fans can be varied to optimize air flow, panel loading, pressure drop and / or fan efficiency.

[0200] The adsorber box

[60] may include a series of fans

[51] to move air across the adsorber panels.

[0201] regeneration chamber

[0202] In some cases, the regeneration process can be a simple batch operation where panels are loaded and then a series of regeneration steps are performed (e.g. Fig.15 and Fig.16 ). These steps may include air removal, panel heating, CO2 desorption, and panel cooling. These steps may be performed by enclosing the panel

[50] in a chamber by enclosing the panel between a set of moving wall elements (e.g., clamshells) or by placing it in a fixed container and closing a door to isolate it from its surroundings.

[0203] In one embodiment, if Figure 5AAs seen in FIG. 5 , a plurality of panels [50a to 50d] may be enclosed in a fixed structure. Panels [50a to 50d] are inserted from the narrow end, thereby minimizing the size of the door

[25] and the required sealing area. The regeneration box

[61] may include a plurality of chambers (or zones). In this embodiment, the regeneration box

[61] includes an initial purge zone

[10] , two steaming zones

[11] and

[12] , and a final cooling zone

[13] . Possible circulation in zone

[10] may include opening door

[25] and sliding in newly loaded panels

[50] while closing door

[26] to steaming zone

[11] . The chamber in the initial purge zone

[10] may then be evacuated of air by evacuation. Optionally, steam may be allowed to enter the chamber while applying the vacuum to purge out the remaining air. The vacuum valve may then be closed and the chamber

[10] may be re-pressurized with CO2, fresh steam, or by connecting zone

[10] to a discharge port in zone

[11] . Once the chamber in area

[10] is repressurized, the door

[26] may be opened and the panel

[50] may be moved forward into area

[11] with the fresh steam port opened to backfill the void space created by the removal of the panel. The door

[26] may then be closed and area

[10] will be ready to receive the next panel. Optionally, while the next panel is being loaded, a port to a heat recovery system may be opened so that steam in the void space of the chamber in area

[10] may be recovered as the new panel enters. Alternatively, air may be purged through the chamber in area

[10] to remove steam (and optionally recover it) prior to loading the fresh panel

[50] , followed by loading the next panel.

[0204] In alternative embodiments, the initial purge section may be divided into two, three, or more zones to separate the purge step into distinct portions - vacuum followed by initial steam break, etc. This may provide several benefits, including (i) reducing any loss of steam or CO2 to the atmosphere, (ii) reducing the risk of air infiltration onto hot panels in subsequent zones, and (iii) increasing the speed at which panels are moved per zone to better align the timing of this step with the timing required for multiple panels in the steaming (and other) steps.

[0205] exist Figure 5B, two steaming zones

[11] and

[12] are shown in enlargement. In other embodiments, a different number of steam zones may be used. The steam may be distributed to a plenum

[21] separated from the panel by a perforated wall (e.g., made of sintered metal or woven material) that is used to help evenly distribute the steam flow. In this embodiment, steam enters the second steam zone

[12] and is forced to flow through the adsorber panel

[50] to the plenum

[22] on the far side next to the baffle

[24] that separates zone

[11] from zone

[12] on one side of the regeneration box. The steam then flows through the plenum

[22] to zone

[11] , through the panel

[50] contained in the chamber, and then exits through the plenum

[23] .

[0206] In other configurations, the steaming section may be longer (e.g., 3, 4, 5, or 6 to 10 zones long, or longer); additional baffles may be installed in the plenum to encourage steam to move through individual panels more than once (e.g., flow in one direction through the first half of the panel and back through the other half; or the flow may divide the panel into thirds, fourths, fifths, etc.). In another configuration, some of the steaming chambers may be empty, allowing the panels to move continuously (as illustrated in FIG. 6 ). FIG. 6 shows an embodiment in which there is a single steaming zone

[11] in which three panels are enclosed in a chamber approximately 4 panels long. Steam may be supplied to the two middle panels and passed through each of these panels eight times—each pass of the steam will flow through a width of approximately one-quarter of the length of the panel. Three panels [50a, 50b, 50c] are loaded into the zone and they are gradually moved through the steam during the entire step. The five rows in FIG. 6 show the position of the panels at different times (t1 to t5) during the steaming process, with the last row showing the steamed panel [50a] leaving and the new panel [50d] entering from the left. By moving the panels through a continuous stream of steam in this manner, all portions of the panel can experience the same (or similar) steam profile in terms of time, temperature, and CO2 loading. In alternative embodiments, different numbers of panels and zones can be used for this continuous panel movement through steam, from as few as one panel and two zones, or alternatively two to five panels and three to six zones, or alternatively six to ten panels (or more) and seven to eleven zones (or more).

[0207] In some embodiments, the steam zone may be designed to accept higher pressures, up to 2 bara or 3 bara or more, to allow the use of steam at higher heating values. In these cases, both the walls of the regeneration box and the doors between zones require additional support and associated mechanisms to provide adequate resistance (and sealing) to handle those higher positive pressures.

[0208] exist FIG. 5A to FIG. 5B In the process, the steamed panels

[50] leaving the zone

[12] enter the vacuum cooling zone

[13] through the door

[27] . The valve connecting the zone

[13] to the vacuum source is then opened to evacuate the chamber, causing a pressure drop. The reduced pressure causes some of the hot condensate in the panel

[50] to evaporate, causing the panel

[50] to be cooled and dried. In order to reduce the load on the vacuum pump, the generated vapor can be condensed in a heat exchanger so that only the non-condensable load flows through the vacuum pump. And because most of the non-condensable load from the zone

[13] will be rich in CO2, the vacuum pump discharge can be recovered as a product. Once the panels in the zone

[13] reach a temperature of less than 60°C or more preferably less than 40°C or less than 30°C, the port to the ambient air can be opened to break the vacuum. The last door

[28] can then be opened and the cold, exhausted panel

[50] removed. The door

[28] is then closed and ready for the next cycle.

[0209] In alternative embodiments, the cooling section may be divided into two, three or more zones to separate the cooling of the panels into different parts - initial vacuum cooling, continued vacuum cooling and vacuum breaking with air. This may provide several benefits, including (i) reducing any risk of loss of CO2 to the atmosphere, (ii) reducing the risk of air infiltration onto hot panels in subsequent zones, and (iii) increasing the speed at which panels are moved per zone to better align the timing of this step with the timing required for multiple panels in the steaming (and other) steps.

[0210] like Figure 5A As seen in Figure 1, the vacuum chambers in both area

[10] and area

[13] have two doors (as opposed to a single door). The vacuum chamber with two doors allows for "flow-through" of panels - one panel can enter the area while the second panel is being moved out. The productivity of the entire process is constrained by the speed at which CO2 can be removed from the panels, so minimizing the time required to move the panels maximizes the time available for CO2 removal. With a single door, one panel would have to be unloaded before the next panel could be loaded; and it would require the void space within the vacuum chamber

[10] or

[13] to be filled with a gas (usually air). By having two doors and a "flow-through" design, a panel can be moved in while the previous panel is being moved out, thereby reducing the overall cycle time and minimizing the filling of the void space with unwanted gas.

[0211] Combining this double door design with a multi-zone regeneration box has further benefits. These include the opportunity to minimize the void space around the panels, which is particularly beneficial for the inlet

[10] and outlet

[13] zones where air ingress can have serious deleterious effects. It also allows the hot steam zone to remain warm at all times (minimizing the stress and expense of thermal cycling) and allows for larger steam distribution plenums in the steam zone without adding void space to the vacuum zone (as would be required in a single zone design). In addition, by having more than one panel in the steaming zone, it is possible to operate in a mode where the steam and panels flow in opposite directions. The closer the system is to true countercurrent operation, the more efficiently the steam is used and the higher the concentration of CO2 that can be delivered to the downstream process.

[0212] In some embodiments of the system, such as Figure 5A As seen in FIG. 1 , doors

[26] ,

[27] , and

[28] can be opened simultaneously, allowing panels in regions

[10] ,

[11] , and

[12] to move simultaneously into regions

[11] ,

[12] , and

[13] , while the panel in region

[13] leaves the system. In other embodiments, the panel

[50] in region

[13] can be moved out with door

[27] closed, thereby filling the void space with air. Door

[28] can then be closed and the air purged by evacuating and repressurizing with steam or some other inert gas; or the air can simply be replaced by flushing the void space with steam. In other embodiments, the panels in regions

[11] and

[12] can be moved while door

[26] is still closed, so that movement out of region

[10] occurs later. In yet another embodiment, all four doors may be opened simultaneously and panels may be loaded into area

[10] while the panels are moved from

[10] to

[11] , from

[11] to

[12] , from

[12] to

[13] , and out of the regeneration tank from

[13] .

[0213] In other embodiments, the size of the regeneration box can be set to allow more panels to be parallel in the direction of movement or in movement. For example, the regeneration box can keep roughly four panels long, but accommodate 2,3,4 or more panel widths, wherein each panel is loaded face to face with each other. In another embodiment, the regeneration box can have a longer length so that a plurality of panels are located end to end in each zone, and then in each step, each panel in these panels advances together. For example, each zone can accommodate two panels, alternatively between three and five panels, or alternatively between five equally ten panels (or more), and in each case, the total number of panels in each zone can be moved from one zone to the next zone.

[0214] System Overview

[0215] The DAC system removes carbon dioxide from ambient air using a chemical adsorption process that is provided with an air handling system integrated within the system's packaging envelope. The chemical adsorption process is a reversible reaction that is regenerated by using steam distribution and recovery.

[0216] like Figure 2A and Figure 2B As seen in the figure, a series of adsorber panels

[50] move continuously within the air flow in a linear plane or row (or alternatively, an additional plane) that forms a "wall" of panels [54a, 54b]. At the end of the adsorber box [60a], each panel in the panel

[50] exits the air flow generated by the fan

[51] in the adsorber box

[60] and enters the multi-zone regeneration box [61a]. After the panel

[50] leaves the regeneration box [61a], the panel

[50] reenters the adjacent adsorber box [60b] and joins the "wall" of panel [54c]. At the end of the adsorber box [60b], the panel

[50] exits the air flow, moves to the opposite side of the adsorber box [60b] via the lateral movement system [62b] and joins another panel [54d] "wall", and reenters the air flow in the adsorber box [60b]. After leaving the air flow in the adsorber box [60b], the panel

[50] enters the next regeneration box [61b].

[0217] Fig. 7A is an exemplary embodiment of a panel movement system. The panels

[50] can each be continuously moved across a track

[63] while in the air flow in the adsorber box

[60] . Such movement can be accomplished using a stepper motor or alternatively a hydraulic, pneumatic, electric or other drive mechanism, and can include a chain or alternative mechanism to facilitate such movement across the entire length of the track.

[0218] At the distal end of each adsorber box

[60] , after exiting the air stream, each panel

[50] may enter a lateral side movement unit

[62] to move the panel

[50] to the opposite wall

[54] of the adsorber panel. Figure 7B An exemplary embodiment of a lateral transfer station or lateral unit

[62] is shown. Such lateral unit

[62] may include an A-frame and other mechanisms to secure the panels

[50] for such lateral movement. The panels

[50] may remain open to ambient conditions during the adsorption phase, but may be sealed from any ambient conditions during the regeneration phase, which allows for an optimal environment to facilitate subsequent desorption of the captured atmospheric CO2.

[0219] Figure 7CAn exemplary embodiment of an adsorption box

[60] is shown. Air flow can be provided to the panel

[50] from a single or multiple fans

[51] , which can typically be of induced draft design, but can alternatively be forced draft. The diameter of the fan can be as small as 10', or alternatively 10' to 30', alternatively 30' to 50', or alternatively 50' to 70' (or larger). The fan can be oriented horizontally or vertically. The fans can be arranged one above the other, or side by side, or a combination of side by side and stacked. In some embodiments, the fans can be arranged in stacks of 3 or 4 (or more), in other embodiments, 3 or 4 (or more) can be arranged side by side, and in other embodiments, they can be arranged in a configuration of 2x2 fans, 3x3 fans, or 4x4 fans (or more). The fans may also be arranged in different numbers of height relative to width, such as 3 tall and 2 wide (3x2), 4x2, 4x3, 5x3, 6x3, 5x4, or any other combination where the number of fans tall ranges from 1 to 6 (or more) and the number of fans wide ranges from 1 to 6 (or more).

[0220] Once the air stream / panel CO2 adsorption cycle is complete (eg Figure 1 The panel is moved along the track into the regeneration box, whereupon the door is closed and sealed from the surrounding air, thereby preparing the panel to initiate the CO2 regeneration and removal steps. As noted above, this can be accomplished by removing the air using a vacuum pump, then applying steam or an inert gas to remove any remaining oxygen, and then applying steam to break the vacuum. After the panel next moves to the steaming area

[11] , additional steam is applied, and the panel is then moved to one or more additional areas to continue the steam application process. After the steam step, the panel moves to the final area (or areas

[13] ), where a vacuum can be drawn to facilitate any remaining CO2 removal and cooling of the panel. Subsequently, a valve can be introduced to break the vacuum, at which point the panel can leave the regeneration box along the track and move into position to reenter the air flow in the next panel wall in the adsorber box to restart the adsorption cycle.

[0221] At the re-entry point of the air stream and the panel wall, care may be taken to ensure that the panel is ready to re-enter the air stream immediately following the next moving panel to avoid any gaps that could negatively affect the air stream. Similarly, roller seals (or alternative types of seals) may be used at the point where the panel enters (and exits) to minimize the risk of air stream leaks.

[0222] The regeneration box can complete the entire desorption process through only a single zone or alternatively multiple separate zones (whereby a single panel

[50] moves from zone to zone to complete its desorption process). The steps range from: (i) removing air (and oxygen, which can be harmful to the adsorbent at high heat) from the panel

[50] by evacuating the chamber or purging the air through steam or an inert gas (such as nitrogen), (ii) breaking the vacuum using steam, CO2 or some alternative gas, (iii) heating the panel

[50] by steam or CO2 (or other means, such as indirect heating), and (iv) cooling the panel

[50] by some combination of vacuum, application of an inert gas (such as nitrogen), or a range of other direct or indirect cooling methods. As Figure 5A As seen in Figure 6, the regeneration box

[61] includes three sections: (i) a preliminary vacuum section (region

[10] ) in which air around the panels

[50] is removed via vacuum (or other means) and the vacuum is then broken with steam, (ii) a central steaming section (regions

[11] and

[12] ) in which steam is applied to two (or fewer or more) adsorber panels, and (iii) a cooling zone (region

[13] ) in which the panels

[50] are subjected to vacuum (or alternative means) to cool before being exposed to ambient conditions again. In alternative embodiments, a range of alternative means may be used to remove air, apply heat and / or cool the panels

[50] . Alternative embodiments may include different numbers of panels in each section, or additional zones in each section, or both. Furthermore, in certain embodiments, there may be less need to remove air or cool the panels

[50] , in which case the number and nature of these sections and / or zones and the number of panels in each section and / or zone may vary.

[0223] The doors

[25] ,

[26] ,

[27] and

[28] of the regeneration tank

[61] may be actuated by electrical, hydraulic or pneumatic means, with the actuators being located external to the regeneration tank

[61] itself. The seals for these doors may be single or double seals, and in the case of double seals may include the ability to fill the space between the seals with steam.

[0224] Gas may be delivered to (or removed from) a regeneration tank

[61] via a series of pipes (or conduits) and valves.

[0225] The entire regeneration process may take as little as 1 minute or as much as 4 minutes (or more), and each panel

[50] may move from segment to segment or from area to area within this total time limit, where the time for each segment represents as little as 10 to 15 seconds, or as much as 45 to 60 seconds, or alternatively a time period between 15 to 30 seconds or 30 to 45 seconds.

[0226] In some embodiments, additional steps may be required to further isolate the hot adsorber panel

[50] from exposure to air as the final panel

[50] exits; in this case, an additional step may be added to remove air (via vacuum or steam purge or both) from the cooling section (zone

[13] ) before advancing the hot panel to zone

[13] . In this case, this can be achieved by additional time to allow zone

[13] to be purged of air before advancing the hot panel

[50] , or alternatively adding another zone to the regeneration box to facilitate an additional buffer from exposure to incoming air.

[0227] The panels

[50] may be of any size in rectangular form, with the dimension on a given side ranging from as small as 2' to as large as 60' or more. Alternative shapes of panels and regenerated panels may also be used in embodiments, including polygons of varying sizes, or alternatively, circular or elliptical shapes. In an alternative embodiment, the panels are in the shape of a "slice" of a disk or ring ( Fig.44B ) is shown to accommodate continuous movement along a circular track ( Fig.44A ).

[0228] The entire DAC process units (adsorber tank

[60] and regeneration tank

[61] ) can also be placed alongside each other, allowing the DAC process units to share downstream processing equipment such as heat pumps and compressors.

[0229] In all cases where DAC units are adjacent to each other (either stacked or side by side), care must be taken to ensure that CO2-depleted air exhausted from one unit is not drawn into an adjacent unit. In some embodiments, ducting (guide vanes or other air flow deflection devices) may be introduced to ensure that CO2-depleted air is adequately exhausted away from adjacent units.

[0230] The scale of a single unit can be about 40,000 to 50,000 tons / year of CO2 captured, alternatively as small as 1,000 to 5,000 tons / year, alternatively 5,000 to 40,000 tons / year, alternatively 50,000 to 100,000 tons / year, alternatively 100,000 to 300,000 tons / year (or larger). Multiple units can be arranged (or stacked) adjacent to each other to achieve a total volume of 1 million tons / year, or up to 10 million tons / year, or more. Higher volumes have the potential to drive further cost reductions by (i) distributing the cost of shared process equipment (whose cost does not increase linearly with scale) to higher volumes, and (ii) moving towards increasingly "continuous" processes from a process flow perspective (due to a larger number of sub-units) resulting in more efficient process equipment operation and associated lower energy costs.

[0231] The system may also include accumulators to allow some of the process flows to operate in a more continuous manner. The system may also include mechanisms to prevent foreign materials from contaminating the operation of the panels. For example, the system may include a barrier to prevent insects from entering the system. The system may also include filters to reduce the accumulation of dirt, dust, and particulate matter. The system may also require periodic cleaning of the adsorber panels.

[0232] The system is designed to ensure that the entire regeneration cycle can be completed efficiently without excessive time allocation, excessive steam breakthrough, or other factors that would negatively impact throughput and / or operating costs.

[0233] The main fluid input includes air, steam, and in some embodiments one or more inert gases, such as but not limited to CO2 or N2, and make-up water. What leaves the plant is CO2 clean air containing water vapor and product CO2 (and possible N2 / air mixture containing water vapor).

[0234] The preferred embodiment uses steam to provide heat for desorption, reduction of the partial pressure of CO2, and motive force for transporting CO2 out of the regeneration chamber. Alternative embodiments can be easily envisioned. For example, heat can be provided by embedding heating elements in the adsorber panel. These heating elements can be electric heating wires or tubes containing hot fluids. Alternatively, steam can be replaced by another hot gas that can be easily condensed and separated from CO2 in downstream processes. Examples of such fluids can include "natural refrigerants" such as butane, pentane, hexane or other similar hydrocarbons; synthetic refrigerants such as fluorinated hydrocarbons; ammonia; or other similar gases. Reduced CO2 partial pressure can be achieved by applying a vacuum during the heating cycle. Obviously, the necessary steps of desorption can be achieved in a variety of different ways by creating an isolated regeneration space for the panel that can withstand vacuum, elevated temperatures and elevated pressures.

[0235] fan

[0236] When approaching the adsorber panel, an air velocity of about 3 m / s, alternatively between about 1 and about 5 m / s, alternatively between about 0.2 and about 10 m / s, or alternatively in excess of 12 m / s may be required. Each adsorber unit within the panel may include a large number of small channels, similar to a honeycomb structure, into which the air may need to be squeezed. As a result, the velocity of the air as it flows through the panel may increase, resulting in a velocity of the air flowing through the panel of between 0.2 and 20 m / s; alternatively, between 3 and 15 m / s; or alternatively between 4 and 10 m / s.

[0237] In some embodiments, air circulation may be provided with a single large fan or a series of fans that roughly match the length of the adsorber box

[60] . For example, for an adsorber box approximately 18 feet wide and 260 feet long, a series of 15 fans may be arranged on the top, each fan being approximately 16' in diameter.

[0238] Adsorbent

[0239] The adsorbent sets the productivity level and regeneration requirements. Adsorbents designed specifically for DAC can be used with the system. Adsorbents for use with DAC are described in US 2019 / 0291077, which is named "PCSTRUCTURES INCLUDING SUPPORTEDPOLYAMINES AND METHODS OF MAKING THE SUPPORTED POLYAMINES", which is expressly incorporated herein by reference in its entirety for all purposes. The adsorbent material may have a low molecular weight, highly branched polyethyleneimine (PEI) incorporated in the panel substrate. This will allow high volume amine loading (i.e., amine sites / adsorbent volume). Solid amine adsorbents interact with CO2 through a chemical adsorption mechanism, resulting in a high CO2 adsorption capacity at very low CO2 partial pressures and a selectivity for CO2 higher than other components of air such as water in the form of moisture. Polyethyleneimine (PEI) adsorbents may have a limited lifespan estimated to be 0.5 to 3 years (mainly due to oxidation and polymer leaching), at which time the adsorbent on the substrate will be replaced. Extensive existing research has been conducted to establish lifespan targets.

[0240] In other embodiments, other adsorbents may be used, including alternative forms of PEI, alternative forms of amine-based adsorbents, zeolites, metal organic frameworks (MOFs), and other materials that efficiently and selectively capture CO2.

[0241] Embodiments may also use other forms of substrates with adsorbents, including fibers impregnated with adsorbents, fabrics impregnated with adsorbents, flat surfaces of metal or other materials, or alternative configurations and materials designed to optimize CO2 adsorption while limiting pressure drop.

[0242] Downstream Process

[0243] FIG. 8A to FIG. 8BAn exemplary embodiment of downstream processing for a regeneration tank is shown. A large vacuum chamber

[46] enables air to be quickly exhausted from region

[10] or region

[13] while allowing the vacuum pump

[47] to operate at a relatively consistent load. Hot vapors from region

[11] (which may contain CO2 and water) are directed to a condenser

[40] where they can be condensed by a boiling refrigerant (such as butane or an alternative gas). The liquid water condensate from

[40] can be reused to produce more steam, while the remaining uncondensed gases can be directed to a second condenser

[41] operating at a lower temperature. The condenser can be cooled by boiling the refrigerant at a lower pressure. Similarly, water from the condenser

[41] can be returned to the boiler

[43] , while the remaining gas (now mainly CO2) can be sent to a product compressor

[49] .

[0244] The low pressure refrigerant from the condenser

[41] may be sent to the low stage heat pump compressor

[45] which may feed the accumulator vessel

[39] . The vapor from the medium pressure accumulator

[39] may be combined with the medium pressure refrigerant vapor from the condenser

[40] to feed the high stage compressor

[44] . The hot high pressure vapor from the compressor

[44] is collected in the accumulator

[38] and the vapor is condensed in the boiler

[43] to produce steam for the process.

[0245] The wet, CO2-rich vapor from zone

[13] can be sent to a condenser

[42] where most of the water vapor is removed as liquid and returned to the boiler, while the remaining vapor (mostly CO2) can be sent to a vacuum pump

[48] which can be discharged into the feed of a product compressor

[49] .

[0246] In previous designs, steam for desorption is produced by burning a fuel to form hot gases, which in turn boil water. The fuel is typically a fossil fuel, or preferably from a renewable source such as biomass or anaerobic digestion. Such systems are therefore conducive to the atmospheric CO2 that the DAC system described herein is designed to capture. The steam and CO2 produced by the desorption process are typically separated by condensing water vapor from the CO2 gas in a condenser, which is cooled by cooling water. The heat transferred to the cooling water is then discharged to the atmosphere by evaporating some of the water in the water in a cooling tower.

[0247] The process described herein may allow steam-containing CO2 exiting the desorption process to be condensed in two steps: a first step at a relatively high temperature (e.g., above 50°C, alternatively above 60°C, alternatively between about 50°C and about 80°C, alternatively about 70°C, alternatively about 75°C, alternatively about 77°C, alternatively about 78°C) and a second step at a lower temperature (e.g., between about 25°C and about 40°C, alternatively about 25°C, alternatively about 30°C).

[0248] Figure 8B A possible embodiment of this design is shown in FIG. The first condenser

[40] can recover most of the energy in the steam-containing CO2 at a higher temperature than usual. This higher temperature means that the energy can be effectively upgraded in the heat pump (

[38] ,

[40] ,

[43] and

[44] ) that produces steam. The heat pump uses electricity in the refrigerant compressor

[44] to increase the pressure of the refrigerant (and therefore the condensation temperature), thereby creating conditions that allow the refrigerant to condense at a high enough temperature to boil water and produce low-pressure steam

[43] . A key advantage of using a heat pump is that the amount of electricity required to run the compressor

[44] is significantly lower than the amount of energy that can be delivered to produce steam

[43] - the energy that goes into the steam is typically 1 part compression electrical energy and 2 to 5 parts thermal energy recovered in the process condenser

[40] . In addition, in some embodiments, the electricity to operate the heat pump can be generated without directly releasing CO2 (e.g., water, wind, solar energy), so that the heat supplied to the entire process is "decarbonized". As an added benefit, heat recovered into the heat pump can be reused directly in the process rather than being rejected to the cooling tower—thereby significantly reducing water usage in the cooling tower.

[0249] While it may be preferred to use electricity from processes that do not directly release CO2, the invention is not limited to this, and the improvements described herein may also be applied to systems powered by fossil fuels, fuels from renewable resources such as biomass and anaerobic digestion, etc., and such systems will also fall within the scope and spirit of the invention as disclosed herein.

[0250] In some embodiments, to further improve the overall process efficiency, and with the high temperature heat pump in place, a second stage heat pump can be economically added to the system and operated at a lower temperature / pressure range. The second stage heat pump (

[39] ,

[41] and

[45] and (where integrated)

[38] ) can collect energy from the product stream (exchanger 41) at a lower temperature, but can also collect energy from other low-grade heat sources such as dryer / cooler vapor from the drying / cooling section

[13] (in unit 42) and elsewhere (e.g., CO2 compressor discharge; refrigeration plant discharge). Although raising the temperature to produce steam from the lower temperature of the second condenser

[41] (e.g., nominally 30°C) is less efficient, the heat can be used to boil more butane at an intermediate pressure (in the accumulator

[38] ). By using this two-stage heat pump, the electricity required to boost the low temperature energy is still a healthy margin less than the energy recovered into the steam (e.g. 1 part electricity to 1.5 to 3 parts recovered heat), but it is less efficient than the high-stage heat pump itself (more energy is recovered but at a lower efficiency). In this system, the savings in cooling tower water usage are considerable.

[0251] The above implementation scheme and Figure 8B Only one possible configuration of the process is outlined. For example, the temperature at which heat exchangers

[40] and

[41] collect heat can be increased (thereby allowing more efficient heat recovery, but reducing the amount of energy collected) or decreased; the size of heat exchangers

[40] ,

[41] and

[43] can be increased (thereby allowing the temperature difference between the hot and cold sides to be reduced, but requiring more capital) or decreased; and the efficiency or cooling of the refrigerant compressors (

[44] and

[45] ) can be changed. The steam in this embodiment is shown as being produced at 110°C, but the discharge pressure of compressor

[44] can be reduced or increased to allow the steam temperature to vary, for example it can be as low as 90°C or as high as 140°C.

[0252] Figure 8B The refrigerant shown in is butane, but many other refrigerants or refrigerant mixtures may be used. Possible refrigerants include, but are not limited to, propane, isobutane, pentane or similar "natural" refrigerants or "synthetic" refrigerants such as R1336MZZ. FIG. 8A to FIG. 8BA refrigerant directly coupled to the process stream is shown, but a heat transfer fluid such as water may be used to keep the process and refrigerant isolated. In other embodiments, additional stages may be added to the heat pump—for example, collecting heat at 80°C, 50°C, and 20°C in a 3-stage heat pump. In other embodiments, different refrigerants may be used for different stages—for example, ammonia may be used for lower stages (increasing from 20 to 40°C or from 0 to 45°C or from -30 to 50°C to 70 to 80 or 65 to 85 or 60 to 90°C), and water vapor may be used for higher stages (increasing from 70 to 80 or 60 to 85 or 55 to 90°C to 105 to 110 or 102 to 120 or 100 to 140°C). Conventional refrigerants may also be used, and such systems will fall within the scope and spirit of the invention.

[0253] In an alternative embodiment, steam may be supplied by a conventional boiler or by waste heat from another process. Cooling may be provided by a conventional cooling tower or by integration with another process. In another alternative embodiment, condensers

[40] ,

[41] and

[42] may be water cooled, wherein the water releases its heat to a heat pump.

[0254] Adsorption process

[0255] The adsorption process combines contactors with very high surface area to volume ratios, adsorbents with high selectivity for CO2, and low pressure drops, all designed to facilitate the movement of large volumes of air to maximize carbon capture. Because CO2 adsorption is a function of the absorption curve, whereby the rate of CO2 adsorbed onto the adsorber decreases as the adsorbent becomes full, optimizing the adsorption cycle time relative to the desorption time can have a significant impact on the total CO2 capacity and cost per ton.

[0256] The adsorption capacity is a function not only of the adsorption time, but also of the dimensions of the panel (height, width and length), the porosity of the adsorber panel, the type of adsorbent and its attendant selectivity for CO2, the loading of the adsorbent in the adsorber panel matrix capable of adsorbing CO2, and the partial pressure of CO2 in contact with the adsorber panel (which in turn is a function of the flow rate of air and the CO2 concentration in that air). Furthermore, since the incremental adsorption capacity is a function of the amount of CO2 adsorbed on the adsorber panel, successful desorption also has a significant impact on the adsorption stage. The embodiment is designed to optimize the above characteristics in a manner that maximizes the throughput of CO2 in the system, thereby increasing capacity and reducing the cost per ton of captured CO2.

[0257] Regeneration process

[0258] The steps of the regeneration process that occurs in a regeneration tank (an example of which is shown in FIG. 5 ) are described in more detail below.

[0259] If exposed to oxygen at elevated temperatures well above ambient temperature (i.e. above 35 to 60°C), the adsorbent embedded in the panel

[50] is at risk of deactivation. Therefore, a partial or deep vacuum may be drawn by a pumping step prior to applying steam during regeneration. The vacuum may be between about 0.20 and 0.50 bar, alternatively between about 0.10 and 0.20 bar, alternatively between about 0.025 to 0.20 bar, alternatively between about 0.05 and 0.1 bar.

[0260] To further improve oxygen displacement, in an optional additional step, a purge gas may be applied to remove any oxygen (to minimize the risk of adsorbent deactivation as described above). In certain embodiments, the purge gas may be steam. In such cases, the steam may be applied at a temperature or rate or duration, or while the regeneration chamber is still under vacuum, to minimize heating of the adsorbent (which would otherwise risk deactivating the adsorbent).

[0261] The purge gas may also be nitrogen, which may be produced by a nitrogen generator at a concentration between about 96% and about 99.9999%. The nitrogen may then be recovered by a separate process and may be recirculated through the system.

[0262] In an alternative embodiment, the purge gas may be flue gas from a gas fired boiler, but this would require reducing the NO in the exhaust to x and SO x minimized, otherwise they can have a negative impact on the adsorbent media.

[0263] Alternatively, the carbon dioxide itself may be used as the purge gas, allowing for economical reuse and recovery of the carbon dioxide through multiple cycles.

[0264] In some embodiments, the system may allow for different purge gases to be applied so that process adjustments can be made based on performance / analysis.After the purge gas is delivered to the panel, the purge gas may then move through a recovery system to allow for reuse.

[0265] In the case where an inert gas is used for the initial purge, steam can be used as a secondary purge of non-condensable nitrogen and oxygen from any void space. This step is important because high levels of non-condensable nitrogen and oxygen with the original CO2 product for purification can make it more difficult to efficiently condense and recover the CO2. This application of steam can be combined with the application of a vacuum to both displace most of the inert gas and prevent the steam from condensing at temperatures high enough to accelerate oxidation or desorption of the CO2.

[0266] In addition to the above, certain next generation adsorbents may be available that will substantially eliminate the risk of adsorbent deactivation in the presence of oxygen and high heat. The use of such adsorbents will reduce the need for vacuum, purge gas, and cooling steps, greatly increasing the speed and efficiency of the process and substantially reducing the cost of the system.

[0267] After the O2 concentration around the adsorbent is reduced, heat is applied to the panel for the purpose of desorbing CO2. This can be achieved by applying steam delivered via a steam pipe / conduit attached to the regeneration tank. In each case, the gas is delivered / removed through a series of pipes and valves. The steam can be applied to the panel at a temperature between about 80°C and about 90°C, alternatively between about 90°C and about 100°C, alternatively between about 100°C and about 125°C, alternatively between about 120°C and about 150°C.

[0268] In some embodiments, it is advantageous to use steam to break the vacuum in the initial zone / chamber in the regeneration box. During this step, steam will flow into the chamber and condense on the inner surface of the cooler. This will draw in additional steam and warm the panel, and this can result in sufficient heating to start CO2 release. Once the internal volume of the regeneration chamber reaches an appropriate pressure, such as atmospheric pressure, the panel can be moved to the next zone / chamber. More steam can condense, thereby providing a temperature driving force to desorb more CO2, and excess steam will displace CO2 gas from the volume, thereby maintaining a low partial pressure and thus maintaining an attractive desorption driving force.

[0269] In other embodiments, a preheating step may be used whereby hot gas (between about 50°C and about 100°C) is recirculated through the chamber and reheated using an external heat exchanger. The recirculating hot gas may be CO2 or a CO2 and water vapor mixture. Preheating the panel with hot gas may reduce the amount of steam that condenses onto the panel in subsequent steps, and thus may reduce the amount of liquid condensate in the pores of the panel.

[0270] After applying steam and harvesting CO2, the adsorber panels will move to the next area / chamber where they will undergo a cooling step by evaporation of condensed water on the panel surface. This cooling step can be accomplished by drawing a deeper vacuum—down to between about 0.20 and 0.30 bar, alternatively down to between 0.10 and 0.20 bar, alternatively down to between 0.01 and 0.1 bar. This vacuum helps to evacuate any remaining gas from the system and reduce the amount of water remaining in the adsorber, as well as cooling the adsorber panels to a level that will help minimize potential oxidation of the adsorbent. In some embodiments, the adsorber panels may need to be cooled to less than about 60°C, alternatively about 40°C, alternatively about 25°C.

[0271] Additionally, or alternatively, nitrogen may be applied to facilitate cooling and remove residual water from the panels. The nitrogen may also be moved through a recovery system to allow for reuse. Alternatively, a gas such as air or nitrogen may be used after the initial vacuum cooling step, and the gas may be recycled through the cooler / condenser.

[0272] The duration of the cooling step may vary depending upon: (i) the target temperature level and residual water percentage to be achieved, and (ii) the size of the vacuum pump and / or blower used to facilitate the cooling step.

[0273] The CO2 that leaves the system will be mixed with water vapor (or in other embodiments with another easily condensable gas) and inert, most of non-condensable gases (such as N2 or O2). The steam (or other easily condensable gases) can be condensed by cooling and / or pressurizing the product stream, so that the condensable gas is recovered as a liquid stream. The heat released by condensing the steam will be recovered in the process fluid that can be used to supply the heat pump. In all cases, the water condensate (and excess nitrogen, which is used as a part of the cooling step to some extent) from the product stream can be recovered and reused. The product stream leaving the cooling / compression stage can be 80 wt % to 99 wt % CO2 and can be directly recovered as a product. It can also be further cooled with CO2 concentration further increased to 95 wt % to 99.9 wt %.

[0274] The regenerated and recovered CO2 can then enter the liquefaction / purification step, whereby the CO2 enters a series of compression and cooling steps to increase the concentration of CO2 and liquefy it. The compressed CO2 can have a purity between about 95% by weight and about 99.99% by weight. The harvested CO2 can be used immediately in products (such as materials used in chemicals, plastics, concrete, carbon fibers, food and beverages, etc.), or alternatively sealed underground. Alternatively, the harvested CO2 can be stored in high-pressure, low-temperature tanks, ready to be transported to locations regularly to utilize CO2 in products or alternatively sealed underground.

[0275] Once the panel is below a temperature at which rapid adsorbent deactivation may occur in the presence of oxygen, and the water remaining in the void space decreases to less than a threshold amount, the panel may be released from the regeneration box and begin moving along its track again to allow resumption of the air movement and adsorption phases.

[0276] Heat pumps, heat recovery and other downstream processes

[0277] Conventional methods of operating a DAC system may involve burning fuel to generate steam to power the process and sending waste heat to a cooling tower. This is relatively inefficient in terms of energy usage and may affect the carbon reduction impact of a DAC plant.

[0278] In some embodiments, the systems described herein may use heat pumps instead of fuel-burning boilers and cooling towers. Heat pumps are devices that capture low-grade heat leaving the process and upgrade it for reuse by using electric motors to power compressors. In certain embodiments, the electric motors may be powered by renewable electricity, thereby reducing the operational carbon footprint of the entire process. Heat pumps also eliminate the load on cooling towers, thereby reducing the water footprint.

[0279] Although it may be preferred to operate the heat pump using electricity from a process that does not directly release CO2, the invention is not limited to this, and the improvements described herein may also be applied to systems powered by fossil fuels, fuels from renewable resources such as biomass and anaerobic digestion, etc., and such systems will also fall within the scope and spirit of the invention disclosed herein.

[0280] The process design is set up to capture waste heat at two temperature levels to improve the efficiency of energy upgrading. Integrating a heat pump with a lower than normal cooling step in the regeneration system improves water recovery (less water lost to atmosphere / make-up to steam system) and allows cooler panels to transfer from regeneration to adsorption (less adsorber degradation at high temperature / O2).

[0281] Optionally, the process is designed to allow for optimized heat recovery to reduce energy requirements. A heat pump can be used to deliver most of the heat required in the process, thereby recovering and reapplying heat throughout the system. This can be achieved using a heat pump with a combination of medium and high temperature units based on a suitable refrigerant, such as butane, or alternatively isobutane, propane, pentane or hexane or similar hydrocarbons; or a perfluorocarbon such as R1336mzz. A water tank can be used to facilitate heat transfer between the various components of the heat pump and to temporarily store heat, thereby facilitating the interaction of the batch CO2 adsorption / desorption process and the continuous heat pump.

[0282] By recovering heat throughout the system (including from steam recovery, hot gases from the drying / cooling cycle and excess heat from the liquefaction / purification steps), and then upgrading that heat to over 100°C, a heat pump can be able to generate nearly all of the heat necessary to form the required steam - thereby eliminating the need for a gas boiler (and avoiding emissions resulting from gas-based CO2 production).

[0283] In the event that a given embodiment cannot deliver a continuous flow of gas, the equipment may be designed to be oversized to account for the up / down flipping of the equipment, or alternatively, an accumulator may be added to smooth the gas flow. The accumulator may be used to accumulate gas when needed. Alternatively, in the case of a vacuum pump, a vacuum accumulator may allow for more continuous operation of the pump, as well as continuous availability of the vacuum, and the benefit of reducing the amount of time required to achieve a certain level of vacuum in the system. The accumulator may be coupled to a heat pump so that discontinuous heating from panel regeneration may be coupled to a continuously operating heat pump.

[0284] With regard to heat pump systems, an effective accumulator can be realized by means of a water tank connected to such a system. Heat recovery also allows water recovery in the form of condensate that can be returned to the boiler. Therefore, in addition to recovering energy, the system also reduces the water footprint.

[0285] Operational Details

[0286] The present invention not only significantly advances the state of the art in DAC technology, but also significantly reduces the cost per ton of captured carbon dioxide and, optionally, enables sequestration.

[0287] Embodiments described herein include systems, apparatus and methods for capturing carbon dioxide from ambient air and gas mixtures, some of which include, but are not limited to, ambient air. In one embodiment of the invention disclosed herein, carbon dioxide is captured from the atmosphere using a continuously moving panel system coupled to a multi-zone regeneration box system described throughout this article. In another embodiment, a separate unit may be dedicated to capturing carbon dioxide from air, while other units are dedicated (using specially optimized adsorber panels) to capturing carbon dioxide from a combined gas stream of air and flue gas, which flue gas may include effluent from an energy source for a direct air capture unit. In yet another embodiment, the adsorber panels in all separate units may be dedicated to capturing carbon dioxide via a combined gas stream of air and flue gas.

[0288] Various aspects of the subject matter are set forth below in the process of reviewing and / or supplementing the embodiments described so far, wherein emphasis is placed on the interrelationship and interchangeability of the following embodiments. In other words, emphasis is placed on the fact that each feature of these embodiments can be combined with each and every other feature, unless otherwise expressly stated or logically implausible. The embodiments described herein are restated and expanded upon in the following paragraphs without explicit reference to the accompanying drawings.

[0289] In many embodiments, a system for removing carbon dioxide from ambient air comprises: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels comprises a face and a substrate configured to capture CO2 from the atmosphere, and wherein each panel of the plurality of adsorber panels is configured to move independently; at least one adsorber structure, the at least one adsorber structure comprising at least one fan configured to circulate air through a portion of the plurality of adsorber panels; and at least one regeneration unit, the at least one regeneration unit comprising at least one oxygen removal section, at least one CO2 desorption section, and at least one drying / cooling section.

[0290] In some embodiments, the plurality of adsorber panels are configured to move continuously through at least a portion of the at least one adsorber structure and through at least a portion of the at least one regeneration unit. In some embodiments, the plurality of adsorber panels are configured to move continuously through all portions of the at least one adsorber structure and through all portions of the at least one regeneration unit.

[0291] In some embodiments, the plurality of adsorber panels are configured to move through multiple sections of the at least one regeneration unit, and wherein one or more sections of the at least one regeneration unit are configured to provide a countercurrent flow of one or more gases relative to a direction of travel of the plurality of adsorber panels within the section.

[0292] In some embodiments, the at least one oxygen removal section comprises a sealable chamber and a first outlet, wherein the at least one CO2 desorption section comprises a desorption chamber, a gas inlet, and a gas outlet, and wherein the at least one drying / cooling section comprises a drying / cooling chamber, a first drying / cooling inlet, and a first drying / cooling outlet.

[0293] In some embodiments, the plurality of adsorber panels are configured to move through the desorption chamber, and the gas is configured to flow from the gas inlet to the gas outlet such that the gas first contacts the more desorbing adsorber panels before contacting the less desorbing adsorber panels.

[0294] In some embodiments, the plurality of adsorber panels are configured to move in a first direction from the at least one oxygen removal section toward the at least one drying / cooling section through the plurality of sections of the at least one regeneration unit, and wherein, in each of the plurality of sections of the at least one regeneration unit, the section is configured to cause one or more gases to flow through the section in a second direction opposite to the first direction.

[0295] In some embodiments, the plurality of adsorber panels are configured to move serially through each of the plurality of chambers in the CO 2 desorption section.

[0296] In some embodiments, the plurality of adsorber panels are configured to move serially through the sealable chamber of the CO 2 desorption section.

[0297] In some embodiments, the plurality of adsorber panels are configured to move in a first direction through the plurality of sections of the at least one regeneration unit from the at least one oxygen removal section toward the at least one drying / cooling section, and wherein one or more gases are configured to flow through each of the plurality of sections of the at least one regeneration unit in a second direction opposite to the first direction.

[0298] In some embodiments, the plurality of adsorber panels are configured to move through the drying / cooling chamber, and the gas is configured to flow from the first drying / cooling inlet to the first drying / cooling outlet such that the gas first contacts the more cooled adsorber panels before contacting the less cooled adsorber panels.

[0299] In some embodiments, the at least one oxygen scavenging section further comprises a first inlet and a first outlet, wherein the plurality of adsorber panels are configured to move through the sealable chamber, and the gas is configured to flow from the first inlet to the first outlet such that the gas first contacts adsorber panels that scavenged more oxygen before contacting adsorber panels that scavenged less oxygen.

[0300] In some embodiments, the at least one regeneration unit further comprises at least one gas recovery section, wherein the plurality of adsorber panels are configured to move from the oxygen removal section through the gas recovery section to the CO2 desorption section, and wherein the gas is configured to flow from a gas recovery inlet of the gas recovery section at a position closer to the CO2 desorption section to a gas recovery outlet of the gas recovery section closer to the oxygen removal section.

[0301] In some embodiments, the plurality of adsorber panels are configured to move through the desorption chamber, and the gas is configured to flow from the gas inlet to the gas outlet such that the gas first contacts the more desorbing adsorber panels before contacting the less desorbing adsorber panels.

[0302] In some embodiments, the system further comprises a first door, a second door, a third door, and a fourth door, wherein the first door is located at a first end of at least one oxygen removal section, the second door is located between at least one oxygen removal section and at least one CO2 desorption section, and the third door is located between at least one CO2 desorption section and at least one drying / cooling section, and the fourth door is located at an end of at least one drying / cooling section.

[0303] In some embodiments, the plurality of adsorber panels are configured to move continuously through the at least one oxygen removal section, the at least one CO2 desorption section, and the at least one drying / cooling section, wherein each panel of the plurality of adsorber panels comprises a plurality of arrays held together, and a plurality of sealing struts, wherein a pair of sealing struts among the plurality of sealing struts provide a continuous flat sealing surface for engaging one or more seals to prevent gas from moving between adjacent arrays.

[0304] In some embodiments, the first outlet of the at least one oxygen scavenging section is connected to a vacuum source.

[0305] In some embodiments, the plurality of adsorber panels are configured to periodically move through at least a portion of the at least one adsorber structure and / or through at least a portion of the at least one regeneration unit.

[0306] In some embodiments, the at least one oxygen removal section further comprises a second inlet connected to a purge gas source. In some embodiments, the purge gas is steam, nitrogen, CO2, or a combination thereof.

[0307] In some embodiments, the inlet gas is steam.

[0308] In some embodiments, the first drying / cooling outlet of the at least one drying / cooling section is connected to a vacuum source.

[0309] In some embodiments, the first drying / cooling inlet of the at least one drying / cooling section is connected to a purge gas source. In some embodiments, the purge gas is steam, nitrogen, or a combination thereof.

[0310] In some embodiments, the system further includes a plurality of tracks configured to transport the plurality of adsorber panels into, through, and out of the at least one adsorber structure and the at least one regeneration unit.

[0311] In some embodiments, the system further comprises a plurality of tracks configured to transport the plurality of adsorber panels into, through, and out of the at least one regeneration unit. In some embodiments, the plurality of tracks are configured as a circle, wherein each track in the plurality of tracks forms a portion of the circle. In some embodiments, the panel in the plurality of adsorber panels comprises two arcs on opposite sides of the panel and two straight edges on opposite sides of the panel. In some embodiments, the system comprises a plurality of adsorber units arranged in a plurality of rows, each row extending radially. In some embodiments, a plurality of rows in the plurality of rows are arranged as spokes of a wheel-shaped member.

[0312] In some embodiments, the at least one CO 2 desorption section further comprises an additional desorption chamber and a plenum between the desorption chamber and the additional desorption chamber, wherein the plenum is configured to allow steam from the additional desorption chamber to flow into the desorption chamber.

[0313] In some embodiments, the first drying / cooling inlet of the at least one drying / cooling section is in communication with a source of inert gas.

[0314] In some embodiments, the plurality of tracks in the at least one adsorber structure include a first track and a second track, each of which extends in a longitudinal direction into, through, and out of the at least one adsorber structure. In some embodiments, the system further includes at least one lateral transfer unit configured to move at least one panel from the first track to the second track. In some embodiments, the first track is substantially parallel to the second track.

[0315] In some embodiments, the system further comprises at least one holding area between the at least one adsorber structure and the at least one lateral transfer unit.

[0316] In some embodiments, the at least one lateral transfer unit is configured to include at least two panels of the plurality of adsorber panels.

[0317] In some embodiments, the at least one CO2 desorption section is configured to laterally move multiple panels at a time from the at least one oxygen removal section to the at least one drying / cooling section, wherein the at least one oxygen removal section and the at least one drying / cooling section are each configured to include two panels of the plurality of adsorber panels, and wherein the at least one CO2 desorption section is configured to include an odd number of panels of the plurality of panels.

[0318] In some embodiments, the sealable chamber of the at least one oxygen scavenging section is configured to contain at least two panels of the plurality of adsorber panels.

[0319] In some embodiments, the desorption chamber is configured to contain at least two panels of the plurality of adsorber panels.

[0320] In some embodiments, the desorption chamber is configured to include between about 2 and about 10 panels of the plurality of adsorber panels.

[0321] In some embodiments, the drying / cooling chamber is configured to contain at least two panels of the plurality of adsorber panels.

[0322] In some embodiments, the desorption chamber is configured to contain between 3 and 20 panels of the plurality of adsorber panels.

[0323] In some embodiments, the sealable chamber is configured to contain a plurality of panels, and wherein the desorption chamber is configured to contain a number of panels that is not an integer multiple of the number of panels in the sealable chamber. In some embodiments, the sealable chamber is configured to contain 7 panels, and wherein the desorption chamber is configured to contain 2 panels.

[0324] In some embodiments, the at least one fan is configured to move air through at least a portion of the panels of the plurality of adsorber panels at a speed between about 0.2 m / s to about 15 m / s.

[0325] In some embodiments, the system includes two adsorber structures and two regeneration units, wherein the two regeneration units are located between the two adsorber structures.

[0326] In some embodiments, the at least one regeneration unit is located at a first end of the at least one adsorber structure and the at least one lateral transfer section is located at a second end of the at least one adsorber structure.

[0327] In some embodiments, the at least one CO2 desorption section also includes a first plenum associated with a first wall of the desorption chamber and a second plenum associated with a second wall of the desorption chamber, wherein the first wall of the desorption chamber is opposite to the second wall of the desorption chamber, wherein the first plenum is connected to a steam source. In some embodiments, the second plenum is configured to release steam from the desorption chamber to a recovery system. In some embodiments, the at least one CO2 desorption section also includes a first at least one baffle placed in the first plenum and a second at least one baffle placed in the second plenum.

[0328] In some embodiments, the at least one CO2 desorption section also includes a first plurality of plenums associated with a first wall of the desorption chamber and a second plurality of plenums associated with a second wall of the desorption chamber, wherein the first wall of the desorption chamber is opposite to the second wall of the desorption chamber. In some embodiments, each plenum in the second plurality of plenums is connected to an adjacent plenum in the second plurality of plenums. In some embodiments, the first plurality of plenums includes a first plenum, a last plenum, and at least one plenum in between, and wherein the first plenum in the first plurality of plenums is connected to a gas inlet and the last plenum in the first plurality of plenums is connected to a gas outlet.

[0329] In some embodiments, the gas inlet is connected to a steam source.

[0330] In some embodiments, the second plurality of plenums include a first plenum, a last plenum, and at least one plenum in the middle. In some embodiments, the first plenum in the second plurality of plenums is configured to receive gas from the first plenum in the first plurality of plenums and transfer the received gas to at least one plenum in the middle of the second plurality of plenums. In some embodiments, at least one plenum in the middle of the second plurality of plenums is configured to transfer the received gas to at least one plenum in the middle of the first plurality of plenums. In some embodiments, at least one plenum in the middle of the first plurality of plenums is configured to transfer the received gas to the last plenum in the second plurality of plenums. In some embodiments, the last plenum in the second plurality of plenums is configured to transfer the received gas to the last plenum in the first plurality of plenums.

[0331] In some embodiments, at least one of the middle plenum chambers in the second plurality of plenum chambers comprises at least 2 plenum chambers. In some embodiments, at least one of the middle plenum chambers in the second plurality of plenum chambers comprises 6 plenum chambers. In some embodiments, at least one of the middle plenum chambers in the first plurality of plenum chambers comprises at least 2 plenum chambers. In some embodiments, at least one of the middle plenum chambers in the first plurality of plenum chambers comprises 6 plenum chambers.

[0332] In some embodiments, the steaming chamber further comprises a third wall, and wherein the at least one adsorber structure and the at least one regeneration unit are connected to the steaming chamber along the third wall.

[0333] In some embodiments, the steaming chamber further comprises a third wall and a fourth wall, and wherein the at least one adsorber structure is connected to the steaming chamber along the third wall, and the at least one regeneration unit is connected to the steaming chamber along the fourth wall.

[0334] In some embodiments, the system further comprises at least one holding area between the at least one adsorber structure and the at least one regeneration unit.

[0335] In some embodiments, the at least one regeneration unit includes a first end and a second end, and wherein the first adsorber structure is coupled to the first end of the at least one regeneration unit and the second adsorber structure is coupled to the second end of the at least one regeneration unit.

[0336] In some embodiments, the system further comprises a first lateral transfer unit and a second lateral transfer unit, and wherein the first lateral transfer unit is coupled to an end of the first adsorber structure and the second lateral transfer unit is coupled to an end of the second adsorber structure.

[0337] In some embodiments, the at least one regeneration unit is located at an end of the at least one adsorber structure and at least one lateral transfer section is located on a side of the at least one regeneration unit opposite the at least one adsorber structure.

[0338] In some embodiments, the adsorber structure further comprises a preheater configured to heat the air before the air is circulated through the portion of the panel by the at least one fan.

[0339] In some embodiments, the regeneration unit further comprises a preheating section comprising a preheating inlet connected to a source of heated gas. In some embodiments, the preheating section further comprises a preheater outlet, wherein the plurality of adsorber panels are configured to move through the preheating section and the gas is configured to flow from the preheating inlet to the preheater outlet, so that the gas first contacts the more heated adsorber panels before contacting the less heated adsorber panels. In some embodiments, the heated gas comprises CO2, nitrogen, or a combination thereof at a temperature of at least 40°C. In some embodiments, the heated gas comprises CO2, nitrogen, or a combination thereof at a temperature of at least 100°C or higher. In some embodiments, the preheating section is configured to hold two or more adsorber panels.

[0340] In some embodiments, the at least one drying / cooling section of the at least one regeneration unit comprises a first drying / cooling section and a second drying / cooling section. In some embodiments, the first drying / cooling section is a vacuum drying / cooling section, and the second drying / cooling section comprises a drying / cooling inlet connected to a cooling gas source.

[0341] In some embodiments, the plurality of adsorber panels are oriented vertically in the at least one regeneration unit. In some embodiments, the system further comprises a plurality of tracks configured to transport the plurality of adsorber panels into, through, and out of the at least one adsorber structure and the at least one regeneration unit, and wherein each of the plurality of adsorber panels oriented vertically is transported on a single track.

[0342] In some embodiments, the plurality of adsorber panels are oriented horizontally in the at least one regeneration unit. In some embodiments, the system further comprises a plurality of tracks configured to transport the plurality of adsorber panels into, through, and out of the at least one adsorber structure and the at least one regeneration unit, and wherein each of the plurality of adsorber panels oriented horizontally is transported on a track comprising at least two guide rails.

[0343] In some embodiments, the plurality of tracks include a first section at a first height and a second section at a second height. In some embodiments, the at least one fan of the at least one adsorber structure is located above the top surface of the at least one panel in the plurality of adsorber panels. In some embodiments, the at least one fan of the at least one adsorber structure is located below the bottom surface of the at least one panel in the plurality of adsorber panels. In some embodiments, the at least one fan of the at least one adsorber structure is located at the end of the at least one adsorber structure in a vertical orientation. In some embodiments, the at least one adsorber structure also includes a filter below the bottom surface of at least one panel in the plurality of adsorber panels. In some embodiments, the at least one adsorber structure also includes a filter oriented vertically. In some embodiments, the at least one adsorber structure also includes a filter oriented at an angle between 0 and 90 degrees relative to the ground.

[0344] In some embodiments, the at least one adsorber structure further comprises a chimney located above the plurality of adsorber panels.

[0345] In some embodiments, the at least one adsorber structure further comprises a plurality of slots located beneath the plurality of adsorber panels.

[0346] In some embodiments, each panel in the plurality of adsorber panels comprises a plurality of monomer arrays held together by a support structure. In some embodiments, the system further comprises a deformable sealant between the plurality of monomer arrays and the support structure. In some embodiments, the sealant is located between individual monomer arrays in the plurality of monomer arrays.

[0347] In some embodiments, the support structure includes a frame and at least one sealing post, and wherein the frame and the sealing post have surfaces in a common plane that can form a moving gas seal with a surface in the housing.

[0348] In some embodiments, the system further comprises a plurality of sealing struts, wherein a sealing strut in the plurality of sealing struts is located between adjacent monomer arrays in the plurality of monomer arrays.

[0349] In some embodiments, the system further includes a sealing surface, wherein the sealing surface is coupled to the support structure, wherein the sealing surface is configured to contact at least one sealing post of the plurality of sealing posts.

[0350] In some embodiments, the sealing surface is a stationary block and the plurality of arrays of cells are configured to move relative to the sealing block.

[0351] In some embodiments, the sealing surface is configured to move along the length of the support structure. In some embodiments, the sealing surface includes a plurality of rollers. In some embodiments, the sealing surface includes a belt. In some embodiments, the sealing surface is configured to contact at least two of the plurality of sealing struts.

[0352] In some embodiments, the sealing surface includes a first opening at a first end and a second opening at a second end, wherein the openings are configured to allow gas to flow over or through a portion of the plurality of monomer arrays contained within a space defined by the sealing surface and the at least one sealing post in contact with the sealing block.

[0353] In some embodiments, the support structure includes a vertical member and a horizontal member, wherein the vertical member is configured to be located between adjacent arrays of the plurality of monomer arrays, and wherein the horizontal member is configured to be located below a bottom surface of an array of the plurality of monomer arrays.

[0354] In some embodiments, the sealing surface includes a first portion and a second portion, wherein the first portion contacts at least one of the plurality of sealing struts on a first side of a panel in the plurality of adsorber panels, and wherein the second portion contacts at least one of the plurality of sealing struts on a second side of the panel in the plurality of adsorber panels.

[0355] In some embodiments, the sealing surface comprises a plurality of seals, wherein each seal of the plurality of seals contacts a single face of a panel of the plurality of adsorber panels. In some embodiments, the plurality of seals comprises at least two seals, and wherein at least one seal of the at least two seals contacts a first face of the panel of the plurality of adsorber panels, and another seal of the at least two seals contacts a second face of the panel of the plurality of adsorber panels, wherein the second face is opposite to the first face.

[0356] In some embodiments, the horizontal member is a spring clamp.In some embodiments, the vertical member and the horizontal member are in a single structure.

[0357] In some embodiments, the support structure comprises four sides, and wherein each of the four sides is configured to support a side of an array in the plurality of monomer arrays.

[0358] In some embodiments, the support structure includes at least one support member located at at least one corner of the quadrilateral configuration, wherein each support member of the at least one support member is configured to support a corner of an array in the plurality of monomer arrays.

[0359] In some embodiments, the support structure includes a plurality of spaced-apart flanges positioned along a perimeter of a quadrilateral configuration, wherein each flange of the plurality of spaced-apart flanges is configured to support an edge of an array of the plurality of monomer arrays.

[0360] In some embodiments, the support structure comprises a plurality of tapered supports having a base width, a first side surface and a second side surface, and a top edge, wherein the first side surface and the second side surface are configured to support a bottom edge of an array in the plurality of monomer arrays. In some embodiments, the first side and the second side of the tapered supports have a stepped configuration, and wherein the steps of the stepped configuration are configured to support a bottom edge of an array in the plurality of monomer arrays.

[0361] In some embodiments, the support structure includes a first vertical support and a second vertical support and a net connected to the first vertical support and the second vertical support, wherein the plane of the net is perpendicular to the plane of the first vertical support or the second vertical support, wherein the net also includes an opening configured to receive an array of the plurality of monomer arrays.

[0362] In some embodiments, the support structure includes a plurality of groups of upper support struts and lower support struts and a net connected to the plurality of upper support struts and lower support struts. In some embodiments, the net is sandwiched between each group of the plurality of groups of upper support struts and lower support struts. In some embodiments, the upper support struts of the plurality of groups of upper support struts and lower support struts include a concave interface, and the lower support struts of the plurality of groups of upper support struts and lower support struts include a convex interface, wherein the concave interface of the upper support strut is configured to receive the convex interface of the lower support strut.

[0363] In some embodiments, the male interface of the lower support strut is triangular. In some embodiments, the male interface of the lower support strut is shallow concave dished. In some embodiments, the female interface of the upper support strut is U-shaped.

[0364] In some embodiments, the top sides of the lower support struts in the plurality of sets of upper and lower support struts are at the same level as the bottom surfaces of the lowest rows of the plurality of monomer arrays.

[0365] In some embodiments, the at least one adsorber structure further comprises a funnel below the at least one fan.

[0366] In some embodiments, the system further includes a cowling surrounding the at least one fan.

[0367] In some embodiments, the system further comprises at least one ring attached to the fairing above the at least one fan. In some embodiments, the system further comprises at least one ring attached to the fairing below the at least one fan.

[0368] In some embodiments, the system further comprises a slot below the at least one fan. In some embodiments, the at least one ring is a plurality of rings, and wherein the plurality of rings comprises at least two rings having different diameters. In some embodiments, the at least two rings have different lengths. In some embodiments, the at least two rings have different heights.

[0369] In some embodiments, the support structure includes a first vertical support member and a second vertical support member and a plurality of support lines connected to the first vertical support member and the second vertical support member, wherein the plurality of support lines include at least one pair of intersecting support lines, wherein the intersection of the intersecting support lines is configured to be positioned adjacent to a surface of an array in the plurality of monomer arrays.

[0370] In some embodiments, the support structure includes a collar coupled to a plurality of vertical supports, wherein the collar is configured to surround a perimeter of an array in the plurality of arrays.

[0371] In some embodiments, the support structure is incorporated into an array in the plurality of arrays, and wherein the support structure includes enlarged corners that extend beyond an outer surface of an array in the plurality of monomer arrays.

[0372] In many embodiments, a method of direct air capture includes the steps of: circulating air through a plurality of adsorber panels using at least one fan, wherein each panel of the plurality of adsorber panels is configured to move independently; enclosing at least one panel of the plurality of adsorber panels in a first chamber of at least one purge section of at least one regeneration unit; reducing the concentration of oxygen contained in the first chamber of the at least one purge section of the at least one regeneration unit; enclosing the at least one panel in a second chamber of at least one CO2 desorption section of the at least one regeneration unit; harvesting CO2 from the at least one panel enclosed in the second chamber; enclosing the at least one panel in a third chamber of at least one drying / cooling section of the at least one regeneration unit; and drying and / or cooling the at least one panel enclosed in the third chamber.

[0373] In some embodiments, the at least one panel enclosed in the CO2 desorption section includes at least a first panel and a second panel, wherein the first panel enters the desorption section before the second panel, and wherein the desorption gas is flowed through the desorption section so that the desorption gas first contacts the first panel and then contacts the second panel.

[0374] In some embodiments, the oxygen concentration contained in the first chamber is reduced by evacuating the first chamber with a vacuum source. In some embodiments, the oxygen concentration contained in the first chamber is further reduced by adding steam to the first chamber while evacuating the first chamber with a vacuum source.

[0375] In some embodiments, CO2 is harvested from the second chamber by applying steam to the at least one panel in the second chamber. In some embodiments, the at least one panel has a first face and a second face, and wherein the applied steam flow flows transversely from the first face to the second face through the at least one panel in a serpentine manner or in a spiral manner and returns one or more times. In some embodiments, the at least one panel has a first face and a second face, and wherein when the at least one panel moves through the first chamber, the second chamber and / or the third chamber, one or more airflows of one or more gases flow transversely from the first face to the second face through the at least one panel in a serpentine manner or in a spiral manner and return one or more times. In some embodiments, the at least one panel has a first face and a second face, and wherein the applied steam flow flows through the at least one panel in the second chamber in a first direction, thereby entering the first face and leaving the second face. In some embodiments, the applied steam flow also flows in the second direction in the second chamber, thereby entering the second face and leaving the first face of the at least one panel.

[0376] In some embodiments, the at least one panel has a first side and a second side, and wherein the applied steam flow flows back and forth through the first side and the second side of the at least one panel at least once while the at least one panel is in the second chamber.

[0377] In some embodiments, the at least one panel has a first side and a second side, and wherein the applied steam flow flows over at least a first portion of the first side, then over a first portion of the second side, then over a second portion of the first side.

[0378] In some embodiments, the at least one panel includes a first portion, a second portion, and a third portion, and wherein the applied steam flow flows through the first portion in a first direction, then flows through the second portion in a second direction, and then flows through the third portion in a third direction, wherein the second direction is substantially opposite to the first direction and the third direction. In some embodiments, the at least one panel also includes a fourth portion, and wherein the applied steam flow flows through the fourth portion in a fourth direction, wherein the fourth direction is substantially opposite to the first direction and the third direction.

[0379] In some embodiments, the method further comprises the steps of: enclosing the at least one panel in at least one additional chamber of the at least one CO2 desorption section of the at least one regeneration unit; and harvesting CO2 from the at least one panel enclosed in the at least one additional chamber.

[0380] In some embodiments, CO2 is harvested from the at least one additional chamber by applying steam to the at least one panel in the at least one additional chamber. In some embodiments, the steam applied to the at least one panel in the at least one additional chamber flows through a plenum between the second chamber and the at least one additional chamber and is applied to the at least one panel in the second chamber to harvest CO2.

[0381] In some embodiments, the at least one panel is dried and / or cooled by evacuating the fourth chamber with a vacuum source.

[0382] In some embodiments, the at least one panel moves from the first chamber to the second chamber on a track extending through the at least one regeneration unit.

[0383] In some embodiments, air is circulated on the surface of the plurality of adsorber panels using at least one fan in the adsorber structure. In some embodiments, the plurality of adsorber panels move along a plurality of tracks in the adsorber structure. In some embodiments, the plurality of tracks include a first track and a second track, and wherein the first track is parallel to the second track. In some embodiments, the plurality of adsorber panels move from the first track to the second track via a lateral transfer section.

[0384] In some embodiments, the method further comprises the step of rotating the at least one panel by about 90° prior to enclosing the at least one panel in the second chamber of the at least one CO2 desorption section.

[0385] In some embodiments, each of the plurality of panels in the cycling step comprises a plurality of subunits configured in a first configuration, the method further comprising, before enclosing at least one of the plurality of panels in the first chamber of the at least one purge section, rearranging the at least one panel from the first configuration to a second configuration. In some embodiments, the second configuration has a lower aspect ratio than the first configuration.

[0386] In some embodiments, the at least one panel enclosed in the second chamber of at least one CO2 desorption section of the at least one regeneration unit is two panels, and wherein CO2 is harvested from the two panels enclosed in the second chamber.

[0387] In some embodiments, the method further comprises the step of moving the at least one panel of the plurality of adsorber panels along a track into the first chamber of the at least one purge section after circulating the air around the plurality of adsorber panels.

[0388] In some embodiments, the method further comprises the step of moving the at least one panel of the plurality of adsorber panels along the track into the second chamber of the at least one CO2 desorption section after reducing the oxygen concentration in the first chamber of the at least one purge section.

[0389] In some embodiments, the method further comprises the step of moving at least one panel of the plurality of adsorber panels along a track into a third chamber after harvesting CO2 from the at least one panel enclosed in the second chamber.

[0390] In some embodiments, the method further comprises the step of heating the air prior to circulating the air through the plurality of adsorber panels.

[0391] In some embodiments, the method further comprises the step of circulating a heated gas through the plurality of adsorber panels in the additional chamber of the at least one regeneration unit prior to enclosing the at least one panel in the second chamber. In some embodiments, the heated gas comprises CO2, nitrogen, or a combination thereof at a temperature of at least 40°C. In some embodiments, the heated gas comprises CO2, nitrogen, or a combination thereof at a temperature of at least 100°C.

[0392] In some embodiments, the method further comprises the steps of: enclosing the at least one panel in a fourth chamber of the at least one regeneration unit; and cooling and drying the at least one panel in the fourth chamber. In some embodiments, the step of cooling and drying the at least one panel in the fourth chamber comprises circulating cooling gas through the at least one panel in the fourth chamber. In some embodiments, the step of cooling and / or drying the at least one panel in the third chamber comprises circulating gas exiting the fourth chamber into the third chamber. In some embodiments, the method further comprises heating the gas exiting the fourth chamber and circulating the heated gas into the third chamber.

[0393] In some embodiments, the plurality of adsorber panels are oriented vertically in the at least one regeneration unit. In some embodiments, the plurality of adsorber panels are oriented horizontally in the at least one regeneration unit.

[0394] In some embodiments, each panel of the plurality of adsorber panels comprises a plurality of cell arrays held together by a support structure.

[0395] In some embodiments, the support structure includes a vertical component and a horizontal component, wherein the vertical component is configured to be located between adjacent arrays in the plurality of monomer arrays, and wherein the horizontal component is configured to be located below the bottom surface of an array in the plurality of monomer arrays. In some embodiments, the horizontal component is a spring clamp. In some embodiments, the vertical component and the horizontal component are in a single structure.

[0396] In some embodiments, the support structure comprises a quadrilateral shape, and wherein each side of the quadrilateral shape is configured to support a side of an array in the plurality of arrays of monomers.

[0397] In some embodiments, the support structure includes at least one support member located at at least one corner of the quadrilateral configuration, wherein each support member of the at least one support member is configured to support a corner of an array in the plurality of monomer arrays.

[0398] In some embodiments, the support structure includes a plurality of spaced-apart flanges positioned along a perimeter of a quadrilateral configuration, wherein each flange of the plurality of spaced-apart flanges is configured to support an edge of an array of the plurality of monomer arrays.

[0399] In some embodiments, the support structure comprises a plurality of tapered supports having a base width, a first side surface and a second side surface, and a top edge, wherein the first side surface and the second side surface are configured to support a bottom edge of an array in the plurality of monomer arrays. In some embodiments, the first side and the second side of the tapered supports have a stepped configuration, and wherein the steps of the stepped configuration are configured to support a bottom edge of an array in the plurality of monomer arrays.

[0400] In some embodiments, the support structure includes a first vertical support and a second vertical support and a net connected to the first vertical support and the second vertical support, wherein the plane of the net is perpendicular to the plane of the first vertical support or the second vertical support, wherein the net also includes openings configured to support an array in the plurality of monomer arrays.

[0401] In some embodiments, the support structure includes a first vertical support member and a second vertical support member and a plurality of support lines connected to the first vertical support member and the second vertical support member, wherein the plurality of support lines include at least one pair of intersecting support lines, wherein the intersection of the intersecting support lines is configured to be positioned adjacent to a surface of an array in the plurality of monomer arrays.

[0402] In some embodiments, the support structure includes a collar coupled to a plurality of vertical supports, wherein the collar is configured to surround a perimeter of an array in the plurality of arrays.

[0403] In some embodiments, the support structure is incorporated into an array in the plurality of arrays, and wherein the support structure includes enlarged corners that extend beyond an outer surface of an array in the plurality of monomer arrays.

[0404] In many embodiments, a adsorber structure includes: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels includes a surface and a substrate configured to capture CO2 from the atmosphere, and wherein each panel of the plurality of adsorber panels is configured to move independently; a plurality of fans, wherein the plurality of fans are configured to circulate air around the plurality of adsorber panels; at least one track, wherein the at least one track is configured to transport the plurality of adsorber panels near the plurality of fans; and a first air filter and a second air filter located on opposite sides of the at least one track.

[0405] In some embodiments, the at least one track includes a first track and a second track that each extend in a longitudinal direction below the plurality of fans.

[0406] In some embodiments, the at least one track includes a first track and a second track each extending in a longitudinal direction above the plurality of fans. In some embodiments, the first track is substantially parallel to the second track. In some embodiments, the system further includes at least one lateral transfer unit configured to move a panel from the first track to the second track.

[0407] In many embodiments, a regeneration unit comprises: at least one oxygen removal section, the at least one oxygen removal section comprising a sealable chamber and a first outlet; at least one CO2 desorption section, the at least one CO2 desorption section comprising a desorption chamber, a steam inlet and a gas outlet; and at least one drying / cooling section, the at least one drying / cooling section comprising a drying / cooling chamber and a first drying / cooling outlet.

[0408] In some embodiments, the first outlet of the at least one oxygen scavenging section is connected to a vacuum source.

[0409] In some embodiments, the at least one oxygen scavenging section further comprises an inlet connected to a source of purge gas. In some embodiments, the purge gas is steam, nitrogen, or a combination thereof.

[0410] In some embodiments, the first drying / cooling outlet of the at least one drying / cooling section is connected to a vacuum source.

[0411] In some embodiments, the first drying / cooling inlet of the at least one drying / cooling section is connected to a purge gas source. In some embodiments, the purge gas is steam, nitrogen, or a combination thereof.

[0412] In some embodiments, the at least one CO2 desorption section further comprises an additional desorption chamber and a plenum between the desorption chamber and the additional desorption chamber, wherein the plenum is configured to allow steam from the additional steaming chamber to flow into the steaming chamber.

[0413] In many embodiments, a system for removing carbon dioxide from ambient air includes: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels includes a substrate configured to capture CO2 from the atmosphere, and wherein each panel of the plurality of adsorber panels is configured to move independently; at least one adsorber structure, the at least one adsorber structure including at least one fan configured to move air through a first portion of a panel of the plurality of adsorber panels; at least one regeneration unit, the at least one regeneration unit including at least one chamber, the at least one chamber configured to remove air from a second portion of a panel of the plurality of panels, desorb CO2 from a second portion of a panel of the plurality of panels, and dry and / or cool a second portion of a panel of the plurality of panels; and at least one transfer unit, the at least one transfer unit configured to move the second portion of the plurality of panels from the at least one adsorber structure to the at least one regeneration unit.

[0414] In some embodiments, air is purged from the at least one chamber by applying a vacuum to the at least one chamber.

[0415] In some embodiments, CO2 is desorbed from a second portion of the panels in the plurality of panels by flowing steam into the at least one chamber, wherein the at least one chamber is heated to at least 65°C.

[0416] In some embodiments, the at least one transfer unit includes a first transfer unit and a second transfer unit configured to move a second portion of the plurality of panels from the at least one regeneration unit to the at least one adsorber structure.

[0417] In some embodiments, the second portion of panels is a single panel.

[0418] In some embodiments, the first portion of panels comprises a different number of panels than the second portion of panels.

[0419] In some embodiments, the first portion of panels comprises more panels than the second portion of panels.

[0420] In some embodiments, the at least one chamber of the at least one regeneration unit comprises a first chamber, a second chamber, and a third chamber, wherein the first chamber is configured to remove air from a second portion of the panels in the plurality of panels, wherein the second chamber is configured to desorb CO2 from a second portion of the panels in the plurality of panels, and wherein the third chamber is configured to dry and / or cool a second portion of the panels in the plurality of panels.

[0421] In many embodiments, a regeneration unit for desorbing CO2 includes: at least one chamber including a first wall and a second wall; a gas inlet located on the first wall; a gas outlet located on the second wall; at least one track, the at least one track being configured to move at least one panel from the second wall to the first wall in a first direction, wherein the at least one chamber is configured to cause a gas flow to flow in a flow path from the gas inlet to the gas outlet in a second direction, wherein the second direction is opposite to the first direction.

[0422] In some embodiments, the unit includes at least two tracks.

[0423] In some embodiments, the at least one face plate has a face defining a plane, and wherein the plane of the face is perpendicular to gas flow from the gas inlet to the gas outlet.

[0424] In some embodiments, the gas is steam.

[0425] In some embodiments, the system further includes an outlet connected to a vacuum source.

[0426] In many embodiments, a method for desorbing CO2 from multiple panels, the multiple panels including a substrate configured to capture CO2 from the atmosphere, wherein the multiple panels include a first portion panel and a second portion panel adjacent to the first portion, the method comprising the following steps: causing a gas flow to flow in a first chamber along a first direction from a gas inlet through the first portion panel and the second portion panel of the multiple panels, wherein the first portion panel is closer to the gas inlet than the second portion panel; removing the first portion panel from the first chamber; moving the multiple panels toward the gas inlet in the first chamber in a second direction so that the second portion panel is in front of the gas inlet, wherein the second direction is different from the first direction; and causing a gas flow to flow in the first chamber along the first direction through the second portion panel of the multiple panels.

[0427] In some embodiments, the gas is steam.

[0428] In some embodiments, the first direction is opposite to the second direction.

[0429] In some embodiments, the first portion of the panel and the second portion of the panel each comprise a single panel.

[0430] In some embodiments, the first portion of panels and the second portion of panels each include at least two panels.

[0431] In some embodiments, the plurality of panels includes at least two panels.

[0432] In some embodiments, the method further comprises the step of purging oxygen from the plurality of panels prior to flowing the gas stream through a second portion of the plurality of panels.

[0433] In some embodiments, the step of purging oxygen is performed in the second chamber.

[0434] In some embodiments, the method further comprises the step of drying and / or cooling the plurality of panels in a third chamber after flowing the gas stream through the first portion of the plurality of panels.

[0435] In some embodiments, the plurality of panels also include a third portion panel adjacent to the second portion panel, wherein the method further includes the following steps: causing a gas flow to flow in the first chamber along the first direction from the gas inlet through the first portion panel, the second portion panel, and the third portion panel of the plurality of panels; removing the second portion panel from the first chamber; moving the plurality of panels toward the gas inlet in the second direction in the first chamber so that the third portion panel is in front of the gas inlet; and causing a gas flow to flow in the first chamber along the first direction through the third portion panel of the plurality of panels.

[0436] In many embodiments, a regeneration unit for desorbing CO2 includes: at least one chamber, the at least one chamber including a first wall and a second wall; at least one panel, the at least one panel including a substrate configured to capture CO2 from the atmosphere; a gas inlet located on the first wall; at least one gas collecting chamber located on the second wall, wherein the second wall is opposite to the first wall; a gas outlet; at least one track oriented substantially parallel to the first wall, the at least one track configured to move at least one panel in a first direction, wherein the at least one chamber is configured to cause a gas flow from the gas inlet to flow through a face of the at least one panel in a first flow path to the at least one gas collecting chamber located on the second wall, wherein the at least one chamber is configured to cause a gas flow from the at least one gas collecting chamber located on the second wall to flow again through the face of the panel or through the opposite face of the at least one panel in a second flow path, the first flow path and the second flow path forming a serpentine flow path or a spiral flow path.

[0437] In some embodiments, the gas flows from the gas inlet to the gas outlet in a direction substantially opposite to the first direction such that the gas first contacts the more desorbed panels before contacting the less desorbed panels.

[0438] In some embodiments, the unit also includes at least one plenum located on the first wall or the second wall, wherein the at least one plenum located on the first wall or the second wall is configured to receive the gas flow from the second flow path and allow the gas flow to flow through the surface of the at least one panel in a third flow path to the at least one plenum located on the second wall.

[0439] In some embodiments, the first direction of the at least one track is perpendicular to the direction of the first flow path.

[0440] In some embodiments, the at least one plenum located on the second wall includes four plenums.

[0441] In some embodiments, the at least one plenum located on the second wall comprises eight plenums. In some embodiments, the at least one plenum located on the first wall comprises four plenums. In some embodiments, the at least one plenum located on the first wall comprises eight plenums.

[0442] In many embodiments, a method for desorbing CO2 from multiple panels, the multiple panels including a substrate configured to capture CO2 from the atmosphere, the method comprising the steps of: flowing a gas flow from a gas inlet in a first flow path through a face of at least one panel of the multiple panels; flowing the gas flow in a second flow path through an opposite face of the at least one panel of the multiple panels; flowing the gas flow in a third flow path through the face of the at least one panel of the multiple panels; and flowing the gas flow in a fourth flow path through the opposite face of the at least one panel of the multiple panels, wherein the first flow path and the third flow path are in a first direction, wherein the second flow path and the fourth flow path are in a second direction, and wherein the first direction is opposite to the second direction.

[0443] In many embodiments, a method for desorbing CO2 from multiple panels, the multiple panels including a substrate configured to capture CO2 from the atmosphere, the method comprising the steps of: flowing a gas flow from a gas inlet in a first flow path through a face of at least one panel of the multiple panels; flowing the gas flow in a second flow path through an opposite face of the at least one panel of the multiple panels; flowing the gas flow in a third flow path through the face of the at least one panel of the multiple panels; and flowing the gas flow in a fourth flow path through the opposite face of the at least one panel of the multiple panels, wherein the first flow path and the third flow path are in a first direction, wherein the second flow path and the fourth flow path are in a second direction, and wherein the first direction is the same as the second direction.

[0444] In some embodiments, the first flow path flows from the gas inlet to the first plenum. In some embodiments, the gas flow flows from the first plenum to the second plenum, and wherein the second flow path flows from the second plenum to the third plenum. In some embodiments, the gas flow flows from the third plenum to the fourth plenum, wherein the third flow path flows from the fourth plenum to the fifth plenum. In some embodiments, the gas flow flows from the fifth plenum to the sixth plenum, wherein the fourth flow path flows from the sixth plenum to the seventh plenum. In some embodiments, the first plenum, the second plenum, the fifth plenum, and the sixth plenum are located in the second wall of the chamber, and wherein the third plenum, the fourth plenum, and the seventh plenum are located in the first wall of the chamber, wherein the second wall is opposite to the first wall.

[0445] In some embodiments, the first flow path flows through a first portion of the at least one panel, the second flow path flows through a second portion of the at least one panel, the third flow path flows through a third portion of the at least one panel, and the fourth flow path flows through a fourth portion of the at least one panel.

[0446] In some embodiments, the method further includes the steps of: causing the gas flow to flow in a fifth flow path through the face of at least one additional panel among the plurality of panels; causing the gas flow to flow in a sixth flow path through the opposite face of the at least one additional panel among the plurality of panels; causing the gas flow to flow in a seventh flow path through the face of the at least one additional panel among the plurality of panels; and causing the gas flow to flow in an eighth flow path through the opposite face of the at least one additional panel among the plurality of panels, wherein the fifth flow path and the seventh flow path are in the first direction, and wherein the sixth flow path and the eighth flow path are in the second direction.

[0447] In some embodiments, the gas flow flows from a seventh plenum to an eighth plenum, wherein the fifth flow path flows from the eighth plenum to a ninth plenum.

[0448] In some embodiments, the gas flow flows from the ninth plenum to the tenth plenum, wherein the sixth flow path flows from the tenth plenum to the eleventh plenum. In some embodiments, the gas flow flows from the eleventh plenum to the twelfth plenum, wherein the seventh flow path flows from the twelfth plenum to the thirteenth plenum. In some embodiments, the gas flow flows from the thirteenth plenum to the fourteenth plenum, wherein the eighth flow path flows from the fourteenth plenum to the fifteenth plenum. In some embodiments, the ninth plenum, the tenth plenum, the thirteenth plenum, and the fourteenth plenum are located in the second wall of the chamber, and wherein the eighth plenum, the eleventh plenum, the twelfth plenum, and the fifteenth plenum are located in the first wall of the chamber, wherein the second wall is opposite to the first wall.

[0449] In some embodiments, the fifth flow path flows through a first portion of the additional at least one panel, the sixth flow path flows through a second portion of the additional at least one panel, the seventh flow path flows through a third portion of the additional at least one panel, and the eighth flow path flows through a fourth portion of the additional at least one panel.

[0450] In many embodiments, a method for desorbing CO2 from multiple panels, the multiple panels including a substrate configured to capture CO2 from the atmosphere, the method comprising the steps of: flowing a gas flow from a gas inlet to a gas outlet through the multiple panels in a chamber; removing a first portion of the panels from the chamber that is closest to the gas inlet, thereby leaving a remaining portion of the panels in the chamber; moving the remaining portion of the panels in the chamber toward the gas inlet; and adding a second portion of the panels to the remaining portion of the panels at a position in the chamber that is closest to the gas outlet.

[0451] In some embodiments, the remaining panels are moved continuously through the chamber.

[0452] In some embodiments, the remaining portions of the panel are periodically moved through the chamber.

[0453] In some embodiments, the gas inlet is on a first wall of the chamber and the gas outlet is on a second wall of the chamber, wherein the second wall is opposite to the first wall, and wherein the remaining panels are moved stepwise from the second wall to the first wall. In some embodiments, the stepwise movement comprises between about 2 steps and about 30 steps. In some embodiments, the stepwise movement comprises moving two panels of the remaining panels together in the stepwise movement.

[0454] In some embodiments, the gas stream continues to flow during the step of moving the remaining partial panels in the chamber, during the step of removing the first partial panel, and during the step of adding the second partial panel.

[0455] In some embodiments, the gas flow continues to flow during the step of removing the first portion of the panels.

[0456] In some embodiments, the gas flow continues to flow during the step of adding the second portion of the panel.

[0457] In some embodiments, the first portion of panels includes between about 1 and about 5 panels.

[0458] In some embodiments, the second portion of panels includes between about 1 and about 5 panels.

[0459] In some embodiments, the remaining portion of the panels includes between about 1 and about 40 panels.

[0460] In some embodiments, each panel of the plurality of panels includes a face, and wherein the gas flow flows in the chamber through each face of the plurality of panels.

[0461] In some embodiments, the plurality of panels in the chamber include a first end panel, a last end panel, and at least one panel in the middle, the first end panel being closer to a gas inlet than the at least one panel in the middle, the last end panel being closer to a gas outlet than the at least one panel in the middle, and the gas stream flows through the first end panel before flowing through the at least one panel in the middle. In some embodiments, the gas stream flows through the at least one panel in the middle before flowing through the last end panel.

[0462] In some embodiments, the first portion of the panel is removed in a direction orthogonal to a direction from the gas inlet to the gas outlet.

[0463] In some embodiments, the second partial panel is moved in a direction orthogonal to the direction from the gas inlet to the gas outlet to add the second partial panel to the remaining partial panels.

[0464] In many embodiments, a system for removing carbon dioxide from ambient air comprises: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels comprises a substrate configured to capture CO2 from the atmosphere; at least one regeneration unit, the at least one regeneration unit comprising at least one chamber, the at least one chamber comprising a gas inlet and a gas outlet, wherein the at least one regeneration unit is configured to desorb CO2 from the plurality of adsorber panels, wherein the plurality of adsorber panels are configured to continuously move through the at least one CO2 desorption chamber; and a heat pump, the heat pump coupled between the gas outlet and the gas inlet of the at least one chamber of the at least one regeneration unit.

[0465] In some embodiments, the heat pump includes: a first condenser, which is connected to the gas outlet of the at least one chamber and is configured to receive gas vapor containing steam and CO2 from the at least one chamber of the at least one regeneration unit and condense the gas vapor; a boiler, which is connected to the first condenser and is configured to receive liquid water from the first condenser, wherein the boiler is connected to the gas inlet and is configured to output steam to the at least one chamber of the at least one regeneration unit; and a first compressor and a first accumulator, which are connected between the first condenser and the boiler for circulating refrigerant through the heat pump.

[0466] In some embodiments, the first condenser is configured to condense gas vapor received from the gas outlet, wherein heat from the first condenser is transferred to the refrigerant to deliver a vapor form of the refrigerant to the first compressor at a first refrigerant pressure; the first compressor is configured to compress the vapor form of the refrigerant; the first accumulator is configured to receive the compressed vapor form of the refrigerant and separate the vapor form of the refrigerant from the liquid form of the refrigerant; and the boiler is configured to receive the vapor form of the refrigerant from the first accumulator, boil liquid water to produce steam output to the at least one chamber and condense the refrigerant, and output the liquid form of the refrigerant to the first accumulator.

[0467] In some embodiments, the first condenser is configured to condense gas vapor against a boiling refrigerant.

[0468] In some embodiments, the system also includes an evaporator, wherein the first condenser is configured to condense the gas vapor relative to a transfer fluid to heat the transfer fluid, and wherein the evaporator is configured to receive the heated transfer fluid and the refrigerant, boil the refrigerant, and cool the transfer fluid for reuse.

[0469] In some embodiments, the system further comprises another accumulator and a second compressor, wherein the first condenser is configured to condense the gas vapor relative to a transfer fluid so as to heat the transfer fluid, and wherein the another accumulator is configured to receive the heated transfer fluid, reduce its pressure and allow at least a portion of the transfer fluid to boil, and wherein the vapor form of the transfer fluid is compressed by the second compressor and the remaining transfer fluid is cooled for reuse.

[0470] In some embodiments, the first condenser is configured to condense the gas vapor relative to a transfer fluid, wherein the transfer fluid is used to transfer heat to the refrigerant in the first condenser.

[0471] In some embodiments, the heat pump further comprises a second condenser coupled to the first condenser, wherein the first condenser is configured to output gas vapor that has not condensed into liquid water to the second condenser, and wherein the second condenser is configured to condense gas vapor that has not condensed into liquid water in the first condenser and output the liquid water to the boiler.

[0472] In some embodiments, the heat pump also includes a third condenser coupled to the drying / cooling section of the at least one regeneration unit, wherein the output gas vapor flows from the drying / cooling section to the third condenser, and wherein the third condenser is configured to condense a portion of the gas vapor to output liquid water to the boiler to transfer heat to the refrigerant at a second refrigerant pressure that is lower than the first refrigerant pressure.

[0473] In some embodiments, the second condenser is configured to transfer heat to the refrigerant at a second refrigerant pressure that is lower than the first refrigerant pressure and output the refrigerant in vapor form.

[0474] In some embodiments, the liquid water from the second condenser is output at a lower temperature than the temperature of the liquid water output from the first condenser.

[0475] In some embodiments, the other process stream is cooled by transferring heat to the refrigerant at the second pressure to output the refrigerant in vapor form.

[0476] In some embodiments, the system includes: at least one regeneration unit, the at least one regeneration unit including at least one chamber, the at least one chamber including a gas inlet and a gas outlet, wherein the at least one regeneration unit is configured to desorb CO2 from at least one panel, the at least one panel including a substrate configured to capture CO2 from the atmosphere; a first condenser, the first condenser configured to condense a gas vapor relative to a refrigerant at a first pressure, wherein the first condenser is connected to the gas outlet of the at least one chamber and is configured to receive a gas vapor comprising steam and CO2 from the at least one chamber, wherein the first condenser is configured to output liquid water and a vapor form of the refrigerant at a first refrigerant pressure; a first compressor, the first compressor configured to compress the vapor form of the refrigerant, wherein the first compressor is configured to receive the vapor form of the refrigerant at the first refrigerant pressure. a first accumulator configured to separate the refrigerant vapor form and the refrigerant liquid form, wherein the first accumulator is configured to receive the compressed refrigerant vapor form at the third refrigerant pressure, and is configured to output the refrigerant vapor form and the refrigerant liquid form at the third refrigerant pressure; and a boiler configured to boil water to generate steam and condense the refrigerant, wherein the boiler is configured to receive liquid water from the first condenser and the refrigerant vapor form at the third refrigerant pressure from the first accumulator, and wherein the boiler is configured to output steam to the at least one chamber of the at least one regeneration unit, and output the liquid form of the refrigerant to the first accumulator.

[0477] In some embodiments, the first condenser is further configured to output gas vapor that has not condensed into liquid water in the first condenser, and the system also includes: a second condenser, which is configured to condense the gas vapor that has not condensed into liquid water in the first condenser relative to the refrigerant at a second pressure, wherein the second pressure is lower than the first pressure of the first condenser, wherein the second condenser is configured to receive the gas vapor that has not condensed into liquid water in the first condenser from the first condenser and receive the refrigerant in vapor form and liquid form, wherein the second condenser is configured to output liquid water and the vapor form of the refrigerant to the boiler.

[0478] In some embodiments, the liquid water from the second condenser is output at a lower temperature than the temperature of the liquid water output from the first condenser.

[0479] In some embodiments, the system also includes: a second compressor configured to compress the refrigerant vapor form from the second condenser, wherein the second compressor is configured to receive the refrigerant vapor form from the second condenser and is configured to output a compressed form of the refrigerant vapor form from the second condenser at a higher pressure than the pressure of the refrigerant vapor form from the second condenser.

[0480] In some embodiments, the system further includes: a second accumulator configured to separate the vapor form of the refrigerant and the liquid form of the refrigerant, wherein the second accumulator is configured to receive a compressed form of the vapor form of the refrigerant at a higher pressure from the second compressor and is configured to output the vapor form of the refrigerant to the first compressor and the liquid form of the refrigerant to the second condenser.

[0481] In some embodiments, the refrigerant is butane.

[0482] In many embodiments, a unit for desorbing CO2 from adsorber panels includes a desorption chamber through which a plurality of adsorber panels move, and through which a desorption gas flows such that the desorption gas first contacts a more desorbing panel among the plurality of adsorber panels before contacting a less desorbing panel among the plurality of adsorber panels.

[0483] In many embodiments, a system for removing carbon dioxide from ambient air comprises: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels comprises a face and a substrate configured to capture CO2 from the atmosphere, and wherein each of the plurality of adsorber panels is horizontally oriented with its face aligned with a horizontal plane; at least one adsorber structure, the plurality of panels being configured to move through the at least one adsorber structure; and at least one regeneration unit, the at least one regeneration unit comprising at least one CO2 desorption chamber; wherein the plurality of adsorber panels are configured to move continuously through the at least one CO2 desorption chamber.

[0484] In some embodiments, the plurality of adsorber panels include a first adsorber panel and a second adsorber panel, wherein the first adsorber panel and the second adsorber panel are configured to continuously move through the CO2 desorption chamber while at least a portion of the first adsorber panel or a portion of the second adsorber panel is outside the CO2 desorption chamber.

[0485] In some embodiments, each panel of the plurality of adsorber panels includes a plurality of arrays held together, and a plurality of sealing struts, wherein a sealing strut of the plurality of sealing struts is located between adjacent arrays of the plurality of arrays, and wherein a sealing strut of the plurality of sealing struts provides a continuous flat sealing surface for engaging one or more seals to prevent gas from moving between the adjacent arrays.

Claims

1. A system for removing carbon dioxide from ambient air, the system comprising: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels comprises a face and a substrate configured to capture CO2 from the atmosphere, and wherein each panel of the plurality of adsorber panels is configured to move independently; at least one adsorber structure, the at least one adsorber structure comprising at least one fan configured to circulate air through a portion of the plurality of adsorber panels; and At least one regeneration unit, the at least one regeneration unit comprising at least one oxygen removal section, at least one CO2 desorption section and at least one drying / cooling section.

2. The system of claim 1, wherein the plurality of adsorber panels are configured to move continuously through at least a portion of the at least one adsorber structure and through at least a portion of the at least one regeneration unit.

3. The system of claim 1, wherein the plurality of adsorber panels are configured to move continuously through all portions of the at least one adsorber structure and through all portions of the at least one regeneration unit.

4. The system of claim 1 , wherein the at least one oxygen scavenging section comprises a sealable chamber, wherein the at least one CO2 desorption section comprises a desorption chamber, a gas inlet, and a gas outlet, and wherein the at least one drying / cooling section comprises a drying / cooling chamber, a first drying / cooling inlet, and a first drying / cooling outlet.

5. The system of claim 4, wherein the plurality of adsorber panels are configured to move through the desorption chamber, and the gas is configured to flow from the gas inlet to the gas outlet such that the gas first contacts adsorber panels with more desorption before contacting adsorber panels with less desorption.

6. The system of claim 1 , wherein the plurality of adsorber panels are configured to move through a plurality of sections of the at least one regeneration unit, and wherein one or more sections of the at least one regeneration unit are configured to provide a countercurrent flow of one or more gases relative to a direction of travel of the plurality of adsorber panels within the sections.

7. The system of claim 1, wherein the plurality of adsorber panels are configured to move through a plurality of sections of the at least one regeneration unit in a first direction from the at least one oxygen scavenging section toward the at least one drying / cooling section, and wherein, In each of the plurality of sections of the at least one regeneration unit, the section is configured to cause one or more gases to flow through the section in a second direction opposite to the first direction.

8. The system of claim 4, wherein the plurality of adsorber panels are configured to move sequentially through each of a plurality of chambers in the CO2 desorption section.

9. The system of claim 4, wherein the plurality of adsorber panels are configured to move serially through the sealable chamber of the CO2 desorption section.

10. The system of claim 9, wherein the plurality of adsorber panels comprises a first adsorber panel and a second adsorber panel, wherein the first adsorber panel and the second adsorber panel are configured to continuously move through the desorption chamber while at least a portion of the first adsorber panel or a portion of the second adsorber panel is outside the desorption chamber.

11. The system of claim 4, wherein the at least one CO2 desorption section further comprises an additional desorption chamber and a plenum between the desorption chamber and the additional desorption chamber, wherein the plenum is configured to allow steam from the additional desorption chamber to flow into the desorption chamber.

12. The system of claim 4, wherein the first drying / cooling inlet of the at least one drying / cooling section is in communication with an inert gas source.

13. The system of claim 4, wherein the gas inlet is connected to a steam source.

14. The system of claim 4, further comprising a first door, a second door, a third door, and a fourth door, wherein the first door is located at a first end of the at least one oxygen removal section, the second door is located between the at least one oxygen removal section and the at least one CO2 desorption section, and the third door is located between the at least one CO2 desorption section and the at least one drying / cooling section, and the fourth door is located at an end of the at least one drying / cooling section.

15. The system of claim 4, wherein the first outlet of the at least one oxygen scavenging section is connected to a vacuum source.

16. The system of claim 1, wherein the plurality of adsorber panels are configured to periodically move through at least a portion of the at least one adsorber structure and / or through at least a portion of the at least one regeneration unit.

17. The system of claim 4, wherein the first drying / cooling outlet of the at least one drying / cooling section is connected to a vacuum source.

18. The system of claim 1, wherein the system comprises two adsorber structures and two regeneration units, wherein the two regeneration units are located between the two adsorber structures.

19. The system of claim 1, wherein the adsorber structure further comprises a preheater configured to heat the air before the air is circulated through the portion of the panels by the at least one fan.

20. The system of claim 1, further comprising a plurality of tracks configured to transport the plurality of adsorber panels into, through, and out of the at least one adsorber structure and the at least one regeneration unit.

21. A system as claimed in claim 20, wherein the multiple tracks in the at least one adsorber structure include a first track and a second track, each of the first track and the second track extending into, through and out of the at least one adsorber structure in a longitudinal direction, and wherein the system also includes at least one lateral transfer unit, the at least one lateral transfer unit being configured to move at least one panel from the first track to the second track.

22. The system of claim 21, wherein the system further comprises at least one holding area between the at least one adsorber structure and the at least one lateral transfer unit.

23. The system of claim 21, wherein the at least one regeneration unit is located at a first end of the at least one adsorber structure and at least one lateral transfer section is located at a second end of the at least one adsorber structure.

24. The system of claim 21, wherein the first track is substantially parallel to the second track.

25. The system of claim 1, further comprising a plurality of tracks configured to transport the plurality of adsorber panels into, through, and out of the at least one regeneration unit.

26. The system of claim 1, wherein the plurality of adsorber panels are oriented horizontally in the at least one regeneration unit.

27. A system as described in claim 26, wherein the system further comprises a plurality of tracks configured to transport the plurality of adsorber panels into, through and out of the at least one adsorber structure and the at least one regeneration unit, and wherein each of the plurality of horizontally oriented adsorber panels is transported on tracks comprising at least two guide rails.

28. The system of claim 1, wherein the plurality of adsorber panels are oriented vertically in the at least one regeneration unit.

29. The system of claim 1, wherein the regeneration unit further comprises a preheat section including a preheat inlet connected to a source of heated gas.

30. A system as described in claim 1, wherein each of the plurality of adsorber panels comprises a plurality of monomer arrays held together by a support structure, wherein the support structure comprises a first vertical support and a second vertical support and a net connected to the first vertical support and the second vertical support, wherein a plane of the net is perpendicular to a plane of the first vertical support or the second vertical support, and wherein the net also includes openings configured to receive arrays of the plurality of monomer arrays.

31. A system as described in claim 1, wherein each panel of the plurality of adsorber panels includes a plurality of monomer arrays held together by a support structure, wherein the system further includes a plurality of sealing struts, and wherein sealing struts of the plurality of sealing struts are located between adjacent monomer arrays of the plurality of monomer arrays.

32. The system of claim 31 , wherein the system further comprises a sealing surface, wherein the sealing surface is coupled to the support structure, wherein the sealing surface is configured to contact at least one sealing post of the plurality of sealing posts.

33. The system of claim 32, wherein the sealing surface is a stationary block and the plurality of arrays of cells are configured to move relative to the sealing block.

34. A system as described in claim 32, wherein the sealing surface includes a first opening at a first end and a second opening at a second end, wherein the openings are configured to allow gas to flow over or through a portion of the plurality of monomer arrays contained within a space defined by the sealing surface and the at least one sealing post in contact with the sealing block.

35. A system as described in claim 32, wherein the sealing surface includes a first portion and a second portion, wherein the first portion contacts at least one of the plurality of sealing struts on a first side of a panel in the plurality of adsorber panels, and wherein the second portion contacts at least one of the plurality of sealing struts on a second side of the panel in the plurality of adsorber panels.

36. The system of claim 32, wherein the sealing surface comprises a plurality of seals, wherein each seal of the plurality of seals contacts a single face of a panel of the plurality of adsorber panels.

37. A system as described in claim 36, wherein the plurality of seals includes at least two seals, and wherein at least one of the at least two seals contacts a first side of the panel of the plurality of adsorber panels, and another of the at least two seals contacts a second side of the panel of the plurality of adsorber panels, wherein the second side is opposite to the first side.

38. A system as described in claim 1, wherein each panel of the plurality of adsorber panels comprises a plurality of monomer arrays held together by a support structure, wherein the system further comprises a deformable sealant positioned between the plurality of monomer arrays and the support structure, wherein the support structure comprises a frame and at least one sealing strut, and wherein the frame and the sealing strut have surfaces within a common plane.

39. The system of claim 38, wherein the sealant is located between individual monomer arrays in the plurality of monomer arrays.

40. A method of direct air capture, the method comprising the steps of: circulate air through a plurality of adsorber panels using at least one fan, wherein each panel of the plurality of adsorber panels is configured to move independently; enclosing at least one panel of the plurality of adsorber panels in a first chamber of at least one purge section of at least one regeneration unit; reducing a concentration of oxygen contained in the first chamber of the at least one purge section of the at least one regeneration unit; enclosing the at least one panel in a second chamber of at least one CO2 desorption section of the at least one regeneration unit; harvesting CO2 from the at least one panel enclosed in the second chamber; enclosing the at least one panel in a third chamber of at least one drying / cooling section of the at least one regeneration unit; and The at least one panel enclosed in the third chamber is cooled and / or dried.

41. A method as claimed in claim 40, wherein the at least one panel enclosed in the CO2 desorption section includes at least a first panel and a second panel, wherein the first panel enters the desorption section before the second panel, and wherein the desorption gas is flowed through the desorption section so that the desorption gas first contacts the first panel and then contacts the second panel.

42. The method of claim 40, wherein the CO2 is harvested from the second chamber by applying steam to the at least one panel in the second chamber.

43. The method of claim 42, wherein the at least one panel has a first side and a second side, and wherein the applied steam flow flows transversely through the at least one panel from the first side to the second side and back one or more times in a serpentine or spiral manner.

44. A method as claimed in claim 40, wherein the at least one panel has a first side and a second side, and wherein when the at least one panel moves through the first chamber, the second chamber and / or the third chamber, one or more gas streams of one or more gases flow laterally from the first side through the at least one panel to the second side and back one or more times in a serpentine manner or in a spiral manner.

45. The method of claim 40, further comprising the step of heating the air prior to circulating the air through the plurality of adsorber panels.

46. ​​The method of claim 40, further comprising the steps of: enclosing the at least one panel within a fourth chamber of the at least one regeneration unit; and The at least one panel in the fourth chamber is cooled and / or dried.

47. The method of claim 46, wherein the step of cooling and / or drying the at least one panel in the fourth chamber comprises circulating a cooling gas through the at least one panel in the fourth chamber.

48. The method of claim 47, wherein the step of cooling and / or drying the at least one panel in the third chamber comprises circulating the gas exiting the fourth chamber into the third chamber.

49. The method of claim 48, further comprising heating the gas exiting the fourth chamber and circulating the heated gas into the third chamber.

50. The method of claim 40, wherein the plurality of adsorber panels move along a plurality of tracks in the adsorber structure.

51. The method of claim 50, wherein the plurality of tracks comprises a first track and a second track, and wherein the first track is parallel to the second track, and wherein the plurality of adsorber panels are moved from the first track to the second track via a lateral transfer section.

52. The method of claim 40, wherein the plurality of adsorber panels are oriented horizontally in the at least one regeneration unit.

53. The method of claim 40, wherein each panel of the plurality of adsorber panels comprises a plurality of cell arrays held together by a support structure.

54. A method as claimed in claim 53, wherein the support structure includes vertical components and horizontal components, wherein the vertical components are configured to be located between adjacent arrays in the plurality of monomer arrays, and wherein the horizontal components are configured to be located below the bottom surface of an array in the plurality of monomer arrays.

55. A method as claimed in claim 53, wherein the support structure includes a first vertical support member and a second vertical support member and a net connected to the first vertical support member and the second vertical support member, wherein the plane of the net is perpendicular to the plane of the first vertical support member or the second vertical support member, and wherein the net also includes openings configured to support an array in the plurality of monomer arrays.

56. The method of claim 53, wherein the support structure comprises at least one of: a quadrilateral shape, and wherein each side of the quadrilateral shape is configured to support a side of an array of the plurality of arrays of cells; at least one support member located at at least one corner of a quadrilateral configuration, wherein each of the at least one support member is configured to support a corner of an array of the plurality of monomer arrays; or A plurality of spaced apart flanges are positioned along a perimeter of the quadrilateral configuration, wherein each flange of the plurality of spaced apart flanges is configured to support an edge of an array of the plurality of cell arrays.

57. A regeneration unit for desorbing CO2, comprising: at least one chamber, the at least one chamber comprising a first wall and a second wall; at least one panel comprising a substrate configured to capture CO2 from the atmosphere; a gas inlet, the gas inlet being located on the first wall; at least one plenum located on the second wall, wherein the second wall is opposite the first wall; Gas outlet; at least one track oriented substantially parallel to the first wall and configured to move at least one panel in a first direction, wherein the at least one chamber is configured to allow a gas flow from the gas inlet to flow in a first flow path through a face of the at least one panel to the at least one plenum located on the second wall, Wherein the at least one chamber is configured to allow the gas flow from the at least one plenum located on the second wall to flow again through the surface of the panel or through the opposite surface of the at least one panel in a second flow path, and the first flow path and the second flow path form a serpentine flow path or a spiral flow path.

58. A unit as described in claim 57, wherein the gas flows from the gas inlet to the gas outlet in a direction substantially opposite to the first direction so that the gas first contacts the panels with higher desorption before contacting the panels with lower desorption.

59. A unit as described in claim 57, wherein the unit further includes at least one plenum located on the first wall or on the second wall, wherein the at least one plenum located on the first wall or on the second wall is configured to receive the gas flow from the second flow path and allow the gas flow to flow through the surface of the at least one panel in a third flow path to the at least one plenum located on the second wall.

60. The unit of claim 57, wherein the first direction of the at least one track is perpendicular to the direction of the first flow path.

61. A system for removing carbon dioxide from ambient air, the system comprising: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels comprises a substrate configured to capture CO2 from the atmosphere; at least one regeneration unit, the at least one regeneration unit comprising at least one chamber, the at least one chamber comprising a gas inlet and a gas outlet, wherein the at least one regeneration unit is configured to desorb CO2 from the plurality of adsorber panels, wherein the plurality of adsorber panels are configured to move continuously through the at least one CO2 desorption chamber; and A heat pump is coupled between the gas outlet and the gas inlet of the at least one chamber of the at least one regeneration unit.

62. The system of claim 61, wherein the heat pump comprises: a first condenser coupled to the gas outlet of the at least one chamber and configured to receive a gas vapor comprising steam and CO 2 from the at least one chamber of the at least one regeneration unit and to condense the gas vapor; a boiler coupled to the first condenser and configured to receive liquid water from the first condenser, wherein the boiler is coupled to the gas inlet and configured to output steam to the at least one chamber of the at least one regeneration unit; and A first compressor and a first accumulator are coupled between the first condenser and the boiler for circulating a refrigerant through the heat pump.

63. The system of claim 61, wherein: the first condenser being configured to condense the gas vapor received from the gas outlet, wherein heat from the first condenser is transferred to the refrigerant to deliver a vapor form of the refrigerant to the first compressor at a first refrigerant pressure; the first compressor being configured to compress the vapor form of the refrigerant; the first accumulator being configured to receive a compressed vapor form of the refrigerant and separate the vapor form of the refrigerant from a liquid form of the refrigerant; and The boiler is configured to receive the vapor form of the refrigerant from the first accumulator, boil the liquid water to generate the steam output to the at least one chamber and condense the refrigerant, and output the liquid form of the refrigerant to the first accumulator.

64. A system as described in claim 63, wherein the heat pump further includes a second condenser connected to the drying / cooling section of the at least one regeneration unit, wherein the output gas vapor flows from the drying / cooling section to the second condenser, and wherein the second condenser is configured to condense a portion of the gas vapor to output liquid water to the boiler to transfer heat to the refrigerant at a second refrigerant pressure lower than the first refrigerant pressure, and output the refrigerant in vapor form.

65. A unit for desorbing CO2 from adsorber panels, the unit comprising a desorption chamber, a plurality of adsorber panels moving through the desorption chamber, and a desorption gas flowing through the desorption chamber so that the desorption gas first contacts a more desorbed panel among the plurality of adsorber panels before contacting a less desorbed panel among the plurality of adsorber panels.

66. A system for removing carbon dioxide from ambient air, the system comprising: a plurality of adsorber panels, wherein each panel of the plurality of adsorber panels comprises a face and a substrate configured to capture CO2 from the atmosphere, and wherein each adsorber panel of the plurality of adsorber panels is horizontally oriented with its face aligned with a horizontal plane; at least one adsorber structure, the plurality of panels being configured to move through the at least one adsorber structure; and at least one regeneration unit, the at least one regeneration unit comprising at least one CO2 desorption chamber; Wherein the plurality of adsorber panels are configured to move serially through the at least one CO2 desorption chamber.

67. A system as described in claim 66, wherein the plurality of adsorber panels include a first adsorber panel and a second adsorber panel, wherein the first adsorber panel and the second adsorber panel are configured to continuously move through the CO2 desorption chamber while at least a portion of the first adsorber panel or a portion of the second adsorber panel is outside the CO2 desorption chamber.

68. A system as described in claim 66, wherein each panel of the plurality of adsorber panels includes a plurality of arrays held together, and a plurality of sealing struts, wherein sealing struts of the plurality of sealing struts are located between adjacent arrays of the plurality of arrays, and wherein the sealing struts of the plurality of sealing struts provide a continuous flat sealing surface for engaging one or more seals to prevent gas from moving between the adjacent arrays.

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