Method for operating direct air capture process including fractal network layout

Abstract

Embodiments of the disclosed subject matter provide a method for operating a direct air capture (DAC) process including a fractal network layout. The method may include providing a plurality of base units, each base unit may include a plurality of DAC modules and a primary node. Each primary node may be connected to each of the DAC modules within the base unit by a process connection and / or a utility connection. The secondary unit may include the plurality of base units. The secondary unit may include a secondary node that may be connected to each of the primary nodes by a process connection and / or a utility connection. The method may include receiving an air flow at each of the DAC modules, contacting the air flow with an adsorbent material, generating an outlet flow comprising CO2 from each of the DAC modules, and transmitting the outlet flow to the secondary node.

Description

Technical Field

[0001] The present invention relates to a direct air capture (DAC) process for capturing carbon dioxide (CO2) from the atmosphere. More specifically, the present invention relates to a process for capturing carbon dioxide (CO2) from the atmosphere using a large direct air capture array comprising a fractal network layout. Background Art

[0002] Direct air capture (DAC) of carbon dioxide from air has been proposed as a way to address human-induced climate change. The current estimated global atmospheric carbon dioxide content is about 420 parts per million. It is expected that this ratio will rise to around 900 parts per million by the end of the 21st century. Thus, DAC represents one of a series of technologies that can be used to reduce the environmental impact of greenhouse gases such as carbon dioxide and help the global transition to a low-carbon economy.

[0003] An attractive option for direct air capture of CO2 is a process that uses a solid adsorbent to capture CO2 from the atmosphere. Typical DAC systems employ a large volume of air (or gaseous atmosphere under other conditions), which is pumped as a feed stream through a unit containing an adsorbent material that removes carbon dioxide from the feed stream. Over time, the adsorbent becomes saturated with the captured carbon dioxide. Subsequently, in a regeneration step, the carbon dioxide captured in the adsorbent is extracted from the adsorbent. Regeneration can involve a thermal process or a chemical process, depending on the type of adsorbent material chosen for the DAC method. When regenerated, the captured carbon dioxide is released from the adsorbent and can be used to produce sustainable fuels, chemicals, for food and beverage production, or for carbon capture and sequestration (CCS) in order to produce a net-negative carbon process. The energy input to the DAC system can include thermal energy in the form of steam, as well as electrical energy for the absorption (to pass air through the DAC unit) and regeneration (to regenerate CO2 from the adsorbent) steps.

[0004] Due to the low concentration of CO2 in air, it is necessary to process a very large volume of air to extract an industrially significant volume of CO2. For example, an industrial facility with a capacity of 1000 kta will typically consist of an array of many adsorption DAC modules distributed over several square kilometers. This is required to ensure that a sufficient volume of air passes through the array under the influence of the wind current. However, each DAC module requires a supply of stripping gas (usually steam) to remove the adsorbed CO2. In addition, the released CO2 needs to be collected in a central system for use or sequestration. This results in an extensive piping network for both the stripping gas and the released CO2, which can have a total length of several hundred kilometers. Therefore, the optimization of these piping networks is important for minimizing capital costs and maintaining the best (high) productivity of the DAC module array operation. Summary of the Invention

[0005] According to an embodiment of the disclosed subject matter, a method for operating a direct air capture process including a fractal network layout may include: a plurality of base units, where each base unit includes a plurality of direct air capture (DAC) modules. The method may include a plurality of first-level nodes and each base unit may include a first-level node, and each first-level node may be connected to each of the DAC modules within the base unit via process connectors and / or utility connectors. The method may include a second-level unit, and the second-level unit may include the plurality of base units. A second-level node may be located within the second-level unit, and the second-level node may be connected to each of the first-level nodes within the second-level unit via process connectors and / or utility connectors. The method may further include receiving an air stream at each of the direct air capture (DAC) modules, contacting the air stream with an adsorbent material located within each of the direct air capture (DAC) modules. An outlet stream containing CO2 may be generated from each of the direct air capture (DAC) modules and the outlet stream may be transmitted to the second-level node.

[0006] Embodiments of the disclosed subject matter provide a method for operating a direct air capture process including a fractal network layout. The disclosed subject matter allows for optimization of the piping network and cost reduction throughout the DAC process. Additional features, advantages, and embodiments of the disclosed subject matter may be listed or will be apparent by considering the following detailed description, the drawings, and the claims. Further, it should be understood that the foregoing summary and the following detailed description are both examples and are intended to provide further explanation without limiting the scope of the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The drawings, which are included to provide a further understanding of the disclosed subject matter, are incorporated in and constitute a part of this specification. The drawings also illustrate embodiments of the disclosed subject matter and, together with the detailed description, are used to explain the principles of the embodiments of the disclosed subject matter. No attempt is made to show structural details more detailed than are necessary for a fundamental understanding of the disclosed subject matter and the various ways in which it may be practiced.

[0008] Figure 1 An exemplary direct air capture process including a base unit is shown in accordance with an embodiment of the disclosed subject matter.

[0009] Figure 2 An exemplary direct air capture process including a fractal network layout is shown in accordance with an embodiment of the disclosed subject matter.

[0010] Figure 3Shows an exemplary direct air capture (DAC) module according to an embodiment of the disclosed subject matter.

[0011] Figure 4 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter.

[0012] Figure 5 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter.

[0013] Figure 6 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter.

[0014] Figure 7 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter.

[0015] Figure 8 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter.

[0016] Figure 9 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter.

[0017] Figure 10 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter. Detailed Description

[0018] Generally, an attractive option for direct air capture of CO2 is a process that uses a solid adsorbent to capture CO2 from the atmosphere. Since the concentration of CO2 in air is low, a very large volume of air needs to be processed to extract an industrially significant volume of CO2. As an example, an industrial facility with a capacity of, for example, 1000 kta will typically consist of an array of many adsorption modules distributed over several square kilometers of area. This is needed to ensure that a sufficient volume of air passes through the array under the influence of the air flow. However, each DAC module requires a supply of stripping gas (usually steam) to remove the adsorbed CO2. In addition, the released CO2 needs to be collected in a central system for use or sequestration. This results in an extensive piping network for both the stripping gas and the released CO2, which can have a total length of several hundred kilometers. Therefore, the optimization of these piping networks is important for minimizing the capital cost. The present invention addresses this problem by implementing a fractal network layout into the method for operating an array process of DAC modules.

[0019] According to the present invention, it has been found that applying a fractal network layout optimizes the piping network. Generally, the cost of a pipeline is proportional to the "inch-km" of the piping, that is, the pipe diameter in inches multiplied by the length in kilometers. According to the present invention, implementing a fractal layout minimizes the total "inch-km" of the network, thereby reducing materials, costs, etc.

[0020] As an example, for a square array with 4 DAC modules, these can be connected to the central point with diagonal pipes. For an array with 16 DAC modules, the central points of each 4-DAC-module array can be connected to the central point. For an array with 64 DAC modules, the central points of each 16-module array can be connected to the central point. For example, this can be extended to 256, 1024, 4096 modules, etc., and so on. For an intermediate number of DAC modules, some DAC modules around the perimeter of the array can be eliminated, but the fractal interconnection of the remaining DAC modules can remain unchanged.

[0021] Additionally, another advantage of the disclosed subject matter is that the total cost can be optimized by, for example, installing distributed facilities for generating stripping gas at a given node level of the fractal network, or by installing a distributed CO2 compressor station at a given node level of the fractal network.

[0022] According to an embodiment, the present invention minimizes the overall piping and electrical connections required in a method for operating a DAC process including an array of DAC modules. The DAC process according to the present invention is designed in such a way that the use of a fractal network layout minimizes the total "inch-km" parameter of the network, thereby reducing the total cost of pipelines, electrical connections, equipment, etc.

[0023] A DAC module can be a module that removes CO2 from the atmosphere by contacting an air stream with an adsorbent material for absorbing CO2. Generally speaking, a fractal is an irregular geometric shape that has the same degree of irregularity at all scales and is self-similar at different scales. They are created by repeatedly repeating a simple process in a continuous repeating pattern.

[0024] According to an embodiment of the present invention, a method for operating a direct air capture process including a fractal network layout may include providing a plurality of base units. Each base unit may include a plurality of direct air capture (DAC) modules. The method may include providing a plurality of first-level nodes and each base unit may include a first-level node. Each first-level node may be connected to each of the DAC modules within the base unit by process connectors and / or utility connectors. The method may include providing a second-level unit, and the second-level unit may include the plurality of base units. A second-level node may be located in the second-level unit, and the second-level node may be connected to each of the first-level nodes within the second-level unit by process connectors and / or utility connectors.

[0025] The method may include the steps of receiving an air stream at each of the direct air capture (DAC) modules, contacting the air stream with an adsorbent material located within each of the direct air capture (DAC) modules, generating an outlet stream containing CO2 from each of the direct air capture (DAC) modules, and transporting the outlet stream to the second-level node.

[0026] In an embodiment, a method for operating a direct air capture process including a fractal network layout may further include providing a plurality of second-level units and a plurality of second-level nodes, each second-level unit may have a second-level node. The method may further include providing a third-level unit, and the third-level unit includes the plurality of second-level units and the plurality of second-level nodes. A third-level node may be located in the third-level unit, and the third-level node may be connected to the plurality of first-level nodes and the plurality of second-level nodes within the third-level unit by process connectors and / or utility connectors.

[0027] According to an embodiment, a method for operating a direct air capture process including a fractal network layout may further include providing a plurality of third-level units and a plurality of third-level nodes, each third-level unit having a third-level node. The method may further include providing a fourth-level unit, and the fourth-level unit may include the plurality of third-level units and the plurality of third-level nodes. A fourth-level node may be located within the fourth-level unit, wherein the fourth-level node may be connected to the plurality of first-level nodes, the plurality of second-level nodes, and the plurality of third-level nodes within the fourth-level unit by process connectors and / or utility connectors.

[0028] In an embodiment, a process connection may include a piping section between any of a DAC module, a first - level node, a second - level node, a third - level node, and a fourth - level node. Each piping section may have a pipe length measured in km and a pipe diameter measured in inches, where each piping section has a piping section value that is the product of the pipe length * the pipe diameter (km * inches). An advantage of the present invention is that, relative to a DAC process without a fractal network layout, the sum of all piping section values in the fractal network layout is minimized. For example, a network connecting 1024 DAC modules without a fractal layout may have 1056 piping sections of 10 different diameters, where the sum of all piping section values is 794 km * inches. On the other hand, according to the present invention, a fractal network layout connecting the same 1024 DAC modules may have 1024 piping sections of 5 different diameters, where the sum of all piping section values is 544 km * inches. Since the cost of the piping network is proportional to the total number of km * inches, the advantage of using the disclosed fractal network is that it reduces the total cost of the piping relative to an operation without the disclosed fractal network.

[0029] In an embodiment, a utility connection may include a cable section between any of a DAC module, a first - level node, a second - level node, a third - level node, and a fourth - level node. Each cable section may have a cable length measured in km and a cable diameter measured in inches. Each cable section may have a cable section value that is the product of the cable length * the cable diameter (km * inches). Relative to a DAC process without a fractal network layout, the sum of all cable section values in the fractal network layout may be minimized. For example, a network connecting 16 DAC modules without a fractal layout may have 20 cable sections of 4 different diameters, where the sum of all cable section values is 1.75 km * inches. On the other hand, according to the present invention, a fractal network connecting the same 16 DAC modules may have 16 cable sections of 3 different diameters, where the sum of all cable section values is 1.16 km * inches. Since the cost of the cable network is proportional to the total number of km * inches, the advantage of using the disclosed fractal network is that it reduces the total cost of the cable relative to an operation without the disclosed fractal network.

[0030] Various utilities, equipment, etc. may be located at nodes within the fractal network layout. In an embodiment, a method for operating a direct air capture process including a fractal network layout may include providing at least one steam generator located at one or more of a first - level node, a second - level node, a third - level node, and a fourth - level node for supplying steam to more than one DAC module via a process connection and / or a utility connection.

[0031] In an embodiment, a method for operating a direct air capture process including a fractal network layout may include providing at least one intermediate compressor located at one or more of a primary node, a secondary node, a tertiary node, and a quaternary node for receiving an outlet stream containing CO2 from more than one DAC module via a process connection. Although not explicitly shown in the figures, the fractal network layout may include any number of primary nodes, secondary nodes, tertiary nodes, quaternary nodes, and may include higher order nodes, such as a fifth order node, a sixth order node, a seventh order node, etc. that may be included in a direct air capture process having a fractal network layout according to the subject matter of the present disclosure.

[0032] In an embodiment, at least one condenser may be provided and located at one or more of a primary node, a secondary node, a tertiary node, and a quaternary node for receiving an outlet stream containing CO2 from more than one DAC module via a process connection.

[0033] According to an embodiment, at least one energy storage unit may be provided and located at one or more of a primary node, a secondary node, a tertiary node, and a quaternary node for supplying stored energy to more than one DAC module via a process connection and / or a utility connection.

[0034] According to an embodiment, a method for operating a direct air capture process including a fractal network layout may include providing any one or more of the following: an electric boiler, an energy storage unit including a liquid heat storage medium, an air cooler, a liquid ring pump, a substation, and a power transformer. One or more of these items may be located at one or more of a primary node, a secondary node, a tertiary node, and a quaternary node for supplying a process stream or a utility stream to more than one DAC module and / or receiving these process streams or utility streams via a process connection and / or a utility connection.

[0035] To facilitate an understanding of the principles of the present invention, reference will now be made to the embodiments shown in the drawings, which will be described in greater detail below. The embodiments disclosed herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. The present invention includes any changes and further modifications of the shown devices and described methods, as well as further applications of the principles of the present invention as set forth in the claims.

[0036] Figure 1 An exemplary direct air capture process fractal network layout according to an embodiment of the disclosed subject matter is shown. In particular, Figure 1The base unit 30 is shown. As shown, the base unit 30 may include a plurality of direct air capture (DAC) modules 10. The base unit 30 may include a first-level node 20. As shown, the first-level node 20 may be connected to each of the DAC modules 10 within the base unit 30 via a process connection 11 and / or a utility connection 12.

[0037] Figure 2 An exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter is shown. In particular, Figure 2 A second-level unit 50 is shown, and the second-level unit 50 may include a plurality of base units 30. Each base unit 30 may include a plurality of DAC modules 10. Additionally, each base unit 30 may include a first-level node 20. As shown, each first-level node 20 may be connected to each of the DAC modules 10 within each base unit 30 via a process connection 11 and / or a utility connection 12. Also as Figure 2 shown, a second-level node 40 may be located in the second-level unit 50, and the second-level node 40 may be connected to each of the first-level nodes 20 via a process connection 21 between the first-level node 20 and the second-level node 40 and / or via a utility connection 22 between the first-level node 20 and the second-level node 40.

[0038] Figure 3 An exemplary direct air capture (DAC) module according to an embodiment of the disclosed subject matter is shown. Specifically, Figure 3 The DAC module 10 is shown. In an embodiment, the method may include the steps of receiving an air stream 13 at the DAC module 10, contacting the air stream 13 with an adsorbent material 14 located within the DAC module 10, generating an outlet stream 19 containing CO2 from the DAC module 10, and transporting the outlet stream 19 to the second-level node 40 ( Figure 3 not shown). As shown, the DAC module 10 may be connected to a first-level node ( Figure 3 not shown) via a utility connection 12 ( Figure 3 also not shown).

[0039] Figure 4 An exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter is shown. In particular, Figure 4 A plurality of second-level units 50 and a plurality of second-level nodes 40 are shown, where each second-level unit 50 may include a second-level node 40. Also as Figure 4As shown, the tertiary unit 70 may include a plurality of secondary units 50 and a plurality of secondary nodes 40. The tertiary node 60 may be located in the tertiary unit 70. The tertiary node 60 may be connected to a plurality of primary nodes 20 (not shown) and secondary nodes 40 within the tertiary unit 70 through a process connection member 41 between the secondary node 40 and the tertiary node 60 and / or through a utility connection member 42 between the secondary node 40 and the tertiary node 60.

[0040] Figure 5 An exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter is shown. In particular, Figure 5 A plurality of tertiary units 70 and a plurality of tertiary nodes 60 are shown, where each tertiary unit 70 may include a tertiary node 60. Also as Figure 5 shown, the quaternary unit 90 may include a plurality of tertiary units 70 and a plurality of tertiary nodes 60. The quaternary node 80 may be located within the quaternary unit 90. The quaternary node 80 may be connected to any one of a plurality of primary nodes, a plurality of secondary nodes, and a plurality of tertiary nodes (( Figure 5 20, 40) 60 not shown in) within the quaternary unit 90 through a process connection member 61 and / or a utility connection member 62.

[0041] Figure 6 An exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter is shown. In particular, Figure 6 A plurality of tertiary units 70 and a plurality of tertiary nodes 60 are shown, each tertiary unit 70 having a tertiary node 60. Also as Figure 6 shown, the quaternary unit 90 may include a plurality of tertiary units 70 and a plurality of tertiary nodes 60. The quaternary node 80 may be located within the quaternary unit 90. Figure 6 Elements within the secondary unit 50 are further shown, and the secondary unit 50 may include a plurality of base units 30. Each base unit 30 may include a plurality of DAC modules 10. In addition, each base unit 30 may include a primary node 20. As shown, each primary node 20 may be connected to each DAC module among the DAC modules 10 within each base unit 30 through a process connection member 11 and / or a utility connection member 12. Also as Figure 6 shown, the secondary node 40 may be located in the secondary unit 50, and the secondary node 40 may be connected to each primary node among the primary nodes 20 through a process connection member 21 between the primary node 20 and the secondary node 40 and / or through a utility connection member 22 between the primary node 20 and the secondary node 40. The quaternary node 80 may be connected to any one of a plurality of primary nodes, a plurality of secondary nodes, and a plurality of tertiary nodes (20, 40, 60) within the quaternary unit 90 through a process connection member 61 and / or a utility connection member 62.

[0042] Figure 7 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter. In particular, Figure 7 Shows a base unit 30, which may include a process connection 11 to a first-level node 20 or a process connection 21 to a second-level node 40. In an embodiment, the process connections 11, 21 may be pipe segments between any of the DAC modules, first-level nodes, second-level nodes, third-level nodes, and fourth-level nodes. As Figure 7 shown, when the process connection 11 is a pipe segment, it may have a pipe length 15 measured in km and a pipe diameter 16 measured in inches. Also as Figure 7 shown, when the process connection 21 is a pipe segment, it may have a pipe length 25 measured in km and a pipe diameter 26 measured in inches. Each pipe segment may have a pipe segment value, which is the product of the pipe length * the pipe diameter (km * inches). The sum of all pipe segment values in the fractal network layout is minimized relative to a DAC process without a fractal network layout. For example, a network connecting 1024 DAC modules without a fractal layout may have 1056 pipe segments of 10 different diameters, where the sum of all pipe segment values is 794 km * inches. On the other hand, according to the present invention, a fractal network layout connecting the same 1024 DAC modules may have 1024 pipe segments of 5 different diameters, where the sum of all pipe segment values is 544 km * inches.

[0043] Figure 8 Shows an exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter. In particular, Figure 8 Shows a base unit 30, which may include a utility connection 12 connecting the DAC unit 10 to the first-level node 20. Also shown is that the base unit 30 may include a utility connection 22 connecting the first-level node 20 to the second-level node 40. In an embodiment, the utility connections 12, 22 may be cable segments between any of the DAC modules, first-level nodes, second-level nodes, third-level nodes, and fourth-level nodes. As Figure 8 shown, when the utility connection 12 is a cable segment, it may have a cable length 17 measured in km and a cable diameter 18 measured in inches. Also as Figure 8As shown, when the utility connection 22 is a cable segment, it may have a cable length 27 measured in km and a cable diameter 28 measured in inches. Each cable segment may have a cable segment value that is the product of the cable length * the duct diameter (km * inches). The sum of all cable segment values in the fractal network layout is minimized relative to the DAC process without a fractal network layout. For example, a network connecting 16 DAC modules without a fractal layout may have 20 cable segments of 4 different diameters, where the sum of all cable segment values is 1.75 km * inches. In one aspect, according to the present invention, a fractal network layout connecting the same 16 DAC modules may have 16 cable segments of 3 different diameters, where the sum of all cable segment values is 1.16 km * inches.

[0044] Various utilities, equipment, etc. may be located at nodes within the fractal network layout. In an embodiment, a method for operating a direct air capture process including a fractal network layout may include at least one steam generator located at one or more of a primary node, a secondary node, a tertiary node, and a quaternary node for supplying steam to more than one DAC module via process connectors and / or utility connectors.

[0045] Figure 9 An exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter is shown. As Figure 9 shown, a method for operating a direct air capture process including a fractal network layout may include a steam generator 110 located at a secondary node 40 to provide heat and stripping gas. The secondary node 40 including the steam generator 110 may be connected to a plurality of primary nodes 20 via a process connector 21 between the secondary node 40 and the primary node 20. As Figure 9 shown, each primary node 20 may also be connected to a plurality of DAC modules 10a via a process connector 11. It is also shown that some DAC modules 10b may be connected to the secondary node 40 via a process connector 21.

[0046] Figure 10 An exemplary direct air capture process including a fractal network layout according to an embodiment of the disclosed subject matter is shown. As Figure 10 shown, a method for operating a direct air capture process including a fractal network layout may include an intermediate compressor 120 for increasing the pressure of an outlet stream containing CO2 that is supplied to the suction inlet of a main compressor ( Figure 10 not shown). This intermediate compressor 120 may be located at the secondary node 40. The secondary node 40 including the intermediate compressor 120 may be connected to a plurality of primary nodes 20 via a process connector 21 between the secondary node 40 and the primary node 20. As Figure 10As shown, each first-level node 20 can also be connected to a plurality of DAC modules 10a through process connectors 11. It is also shown that some DAC modules 10b can be connected to a second-level node 40 through process connectors 21. The second-level node 40 and the intermediate compressor 120 can be connected to a third-level node ( Figure 10 not shown in the figure).

[0047] Although not shown in Figure 9 or Figure 10 , various utilities, equipment, etc. can be located at any of the nodes within the fractal network layout. For example, a condenser can be located at one or more of the first-level node, second-level node, third-level node, and fourth-level node to receive an outlet stream containing CO2 from more than one DAC module via process connectors. In an embodiment, at least one energy storage unit is located at one or more of the first-level node, second-level node, third-level node, and fourth-level node to supply stored energy to more than one DAC module via process connectors and / or utility connectors.

[0048] In addition, according to an embodiment, a method for operating a direct air capture process including a fractal network layout may include providing any one or more of the following: an electric boiler, an energy storage unit including a liquid heat storage medium, an air cooler, a liquid ring pump, a substation, and a power transformer. One or more of these items can be located at one or more of the first-level node, second-level node, third-level node, and fourth-level node to supply a process stream or a utility stream to more than one DAC module and / or receive these process streams or utility streams via process connectors and / or utility connectors. The process stream can be, for example, steam directly supplied from a boiler to an adsorbent, or an outlet stream containing CO2 supplied to an intermediate compressor. The utility stream can be, for example, steam supplied from a boiler for indirectly heating an adsorbent, electricity supplied from a power transformer for heating an adsorbent, or electricity supplied from a substation for powering other equipment in a DAC module.

[0049] To facilitate an understanding of the principles of the present invention, reference will now be made to examples executed from various embodiments of the present invention, which will be described in more detail below. The examples and embodiments disclosed herein are not intended to be exhaustive or to limit the present invention to the exact forms disclosed in the following examples. The present invention includes any changes and further modifications to the provided examples and the described methods, as well as further applications of the principles of the present invention set forth in the claims.

[0050] Embodiment :

[0051] Comparative Example 1. The steam piping network was calculated for an array of 1024 DAC modules in a 2 km x 2 km square array with a central steam generator. The total steam flow rate was 800 tons per hour, the pressure at the steam generator was 3 bara, and the pressure drop to the farthest DAC module was 0.2 bar. The steam piping network was calculated for a network with a main piping section passing through the center of the array parallel to one side, where 64 sub-piping sections were orthogonal to the main piping section, and each sub-piping section reached 16 DAC modules. For this orthogonal network, the total length of the piping was 66 km, and the sum of all piping section values was 794 km-inches.

[0052] Example 1. The steam piping network was calculated for the same array as in Comparative Example 1, i.e., an array of 1024 DAC modules in a 2 km x 2 km square array with a central steam generator. The total steam flow rate was 800 tons per hour, the pressure at the steam generator was 3 bara, and the pressure drop to the farthest module was 0.2 bar. The fractal piping network according to the present invention connects the steam boiler to four four-level nodes and intermediate three-level nodes, two-level nodes, one-level nodes, and DAC modules. Each four-level node is connected to three other three-level nodes and intermediate two-level nodes, one-level nodes, and DAC modules. Each three-level node is connected to three other two-level nodes and intermediate one-level nodes and DAC modules. Each two-level node is connected to three other one-level nodes and an intermediate DAC module. For this fractal piping network, the total length of the piping was 60 km, and the sum of all piping section values was 544 km-inches.

[0053] Comparison of the results of Comparative Example 1 and Example 1 demonstrates at least one of the advantages of the present invention. As described above, the orthogonal network in Comparative Example 1 required 794 km-inches of piping section values. While the fractal network layout according to the present invention required 544 km-inches of piping section values in Example 1. This shows that by utilizing the fractal network layout according to the present invention, the piping sections required to operate the same DAC module array are reduced by more than 30%. Since the cost of the piping network is proportional to the sum of all piping sections in km-inches, the comparison of these results shows that the cost of the fractal piping network is less than 70% of the cost of the orthogonal network.

[0054] Comparative Example 2. The cable network was calculated for an array of 16 DAC modules in a 0.5 km x 0.5 km square array with a central transformer. The total power supply was 1170 kW at 400 V. The cable network was calculated for a network with a main cable section passing through the center of the array parallel to one side, where 8 sub-cable sections were orthogonal to the main cable section, and each sub-cable section reached two DAC modules. For this orthogonal network, the total length of the cable was 2.5 km, and the sum of all cable section values was 1.75 km-inches.

[0055] Example 2. The cable network was calculated for the same array as in Comparative Example 2, i.e., an array of 16 DAC modules in a 0.5 km * 0.5 km square array with a central transformer. The total power supply is 1170 kW at 400 V. The fractal network layout has cables connecting the central transformer located at the secondary node to four primary nodes and the intermediate DAC modules. Each primary node is connected to three additional DAC modules. For this fractal network layout, the total length of the cables is 1.8 km, and the sum of all cable segment values is 1.16 km * inches.

[0056] Comparison of the results of Comparative Example 2 and Example 2 demonstrates at least one advantage of the present invention. As described above, the orthogonal network in Comparative Example 2 requires 1.75 km * inches of cable segment values. While the fractal network layout according to the present invention requires 1.16 km * inches of cable segment values in Example 2. This shows that by utilizing the fractal network layout according to the present invention, the cable segments required to operate the same DAC module array are reduced by more than 30%. Since the cost of the cable network is proportional to the sum of all cable segments in km * inches, the comparison of these results shows that the cost of the fractal cable network is less than 70% of the cost of the orthogonal network.

[0057] Example 3. The steam piping network was calculated for the same array as in Example 1, i.e., an array of 1024 DAC modules in a 2 km * 2 km square array, except that the location of the steam boiler varies among the primary node, secondary node, tertiary node, and quaternary node. The total heating load required is 512 MW, and the steam generator consists of multiple boilers, where the maximum capacity of a single boiler is 32 MW. The cost of a 32 MW boiler is $2 million, and the cost of a boiler with a capacity lower than 32 MW is 2 million dollars multiplied by the 0.65th power of the ratio of the lower capacity to 32 MW. The piping cost in the fractal network is $100,000 per km * inch, including all interconnections at the nodes and DAC modules. The following table shows the total costs for various cases where the boiler is located at different hierarchical nodes.

[0058] Location of the boiler Primary node Secondary node Tertiary node Quaternary node Array center Cost of the piping $11,434,917 $22,338,950 $32,973,528 $43,637,949 $54,364,890 Cost of the boiler $84,448,506 $51,984,153 $32,000,000 $32,000,000 $32,000,000 Total cost $95,883,423 $74,323,103 $64,973,528 $75,637,949 $86,364,890

[0059] Table 1: Exemplary costs of steam boiler locations in a fractal network layout according to the disclosed subject matter 。

[0060] An examination of the results in Example 3 shows that as the steam boiler location changes from the center of the array to the fourth-level node, then to the third-level node, then to the second-level node, and then to the first-level node, the piping cost gradually decreases. Conversely, the cost of the steam boiler remains the same between the center of the array, the fourth-level node, and the third-level node. Then, as the steam boiler location changes to the second-level node and the first-level node, the cost of the steam boiler increases. As shown in Table 1 above, the total cost (piping + steam boiler) is lower when the steam boiler is located at the second-level node, the third-level node, or the fourth-level node compared to being located at the first-level node and the center of the array. In this example above, the optimal location is at the third-level node.

[0061] For purposes of explanation, the foregoing description has been made with reference to specific embodiments. However, the above illustrative discussion is not intended to be exhaustive or to limit the embodiments of the disclosed subject matter to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to explain the principles of the embodiments of the disclosed subject matter and their practical application so that others skilled in the art may utilize those embodiments and various embodiments with various modifications that may be suited to the particular use contemplated.

Claims

1. A method for operating a direct air capture process including a fractal network layout, the method comprising: a) providing a plurality of base units, wherein each base unit includes a plurality of direct air capture (DAC) modules; b) providing a plurality of first-level nodes, wherein each base unit includes a first-level node, and wherein each first-level node is connected to each of the DAC modules within the base unit by a process connection and / or a utility connection; c) providing a second-level unit, wherein the second-level unit includes the plurality of base units; d) providing a second-level node located within the second-level unit, wherein the second-level node is connected to each of the first-level nodes within the second-level unit by a process connection and / or a utility connection; e) receiving an air stream at each of the direct air capture (DAC) modules; f) contacting the air stream with an adsorbent material within each of the direct air capture (DAC) modules; and g) generating an outlet stream containing CO2 from each of the direct air capture (DAC) modules and transporting the outlet stream to the second-level node.

2. The method for operating a direct air capture process including a fractal network layout according to claim error! Reference source not found, wherein the method further comprises: a) providing a plurality of second-level units and a plurality of second-level nodes, each second-level unit having a second-level node; b) providing a third-level unit, wherein the third-level unit includes the plurality of second-level units and the plurality of second-level nodes; c) providing a third-level node located within the third-level unit, wherein the third-level node is connected to the plurality of first-level nodes and the plurality of second-level nodes within the third-level unit by a process connection and / or a utility connection.

3. The method for operating a direct air capture process including a fractal network layout according to claim 2, wherein the method further comprises: a) providing a plurality of third-level units and a plurality of third-level nodes, each third-level unit having a third-level node; b) providing a fourth-level unit, wherein the fourth-level unit includes the plurality of third-level units and the plurality of third-level nodes; c) providing a fourth-level node within the fourth-level unit, wherein the fourth-level node is connected to the plurality of first-level nodes, the plurality of second-level nodes, and the plurality of third-level nodes within the fourth-level unit by a process connection and / or a utility connection.

4. The method for operating a direct air capture process including a fractal network layout according to claim 3, wherein one or more of the process connections include a piping section between any of the DAC modules, the first-level nodes, the second-level nodes, the third-level nodes, and the fourth-level nodes, wherein each piping section has a pipe length measured in km and a pipe diameter measured in inches, and wherein each piping section has a piping section value that is the product of the pipe length * the pipe diameter (km * inches).

5. A method for operating a direct air capture process including a fractal network layout according to claim 3, wherein one or more of the utility connectors include a cable segment between any of the DAC modules, the primary nodes, the secondary nodes, the tertiary nodes, and the quaternary nodes, wherein each cable segment has a cable length measured in km and a cable diameter measured in inches, and wherein each cable segment has a cable segment value that is the product of the cable length * the cable diameter (km * inches).

6. A method for operating a direct air capture process including a fractal network layout according to any one of claims 1 to 3, wherein the method further includes providing at least one steam generator located at one or more of the primary nodes, the secondary nodes, the tertiary nodes, and the quaternary nodes for supplying steam to more than one DAC module via the process connectors.

7. A method for operating a direct air capture process including a fractal network layout according to any one of claims 1 to 3, wherein the method further includes providing at least one intermediate compressor located at one or more of the primary nodes, the secondary nodes, the tertiary nodes, and the quaternary nodes for receiving the outlet stream containing CO2 from more than one DAC module via the process connectors.

8. A method for operating a direct air capture process including a fractal network layout according to any one of claims 1 to 3, wherein the method further includes providing at least one condenser located at one or more of the primary nodes, the secondary nodes, the tertiary nodes, and the quaternary nodes for receiving the outlet stream containing CO2 from more than one DAC module via the process connectors.

9. A method for operating a direct air capture process including a fractal network layout according to any one of claims 1 to 3, wherein the method further includes providing at least one energy storage unit located at one or more of the primary nodes, the secondary nodes, the tertiary nodes, and the quaternary nodes for supplying stored energy to more than one DAC module via the process connectors and / or the utility connectors.

10. A method for operating a direct air capture process including a fractal network layout according to any one of claims 1 to 3, wherein the method further includes providing at least one selected from the group consisting of: an electric boiler located at one or more of the primary nodes, the secondary nodes, the tertiary nodes, and the quaternary nodes, an energy storage unit including a liquid heat storage medium, an air cooler, a liquid ring pump, a substation, and a power transformer for supplying a process stream or a utility stream to more than one DAC module and / or receiving the process stream or the utility stream via the process connectors and / or the utility connectors.

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