Bidirectional mass fluid delivery device with surface topology

Abstract

Pollution control systems, articles, and methods having a surface topology for bi-directional fluid delivery. The pollution control system includes at least one article including a surface feature having at least three critical portions or critical points of a surface topology. The surface topology may include a channel along a first direction, where the channel is configured to direct fluid flow substantially along a particular direction.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to Provisional Patent Application No. 63 / 490,879 filed on March 17, 2023 and Provisional Patent Application No. 63 / 435,392 filed on December 27, 2022, the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0002] The present disclosure relates to the field of pollution control systems and methods for removing chemical compounds and fine particulate matter from gas streams. Background Art

[0003] Coal-fired power plants, municipal waste incinerators, and oil refineries generate large quantities of flue gases containing a wide variety of environmental pollutants, such as sulfur oxides (SO2 and SO3), nitrogen oxides (NO and NO2), mercury vapor (Hg), and particulate matter (PM). Consequently, there is a need for improved control systems and methods for removing sulfur oxides, mercury vapor, and fine particulate matter from industrial flue gases, such as coal-fired power plant flue gases. Summary of the Invention

[0004] The following summary is a high-level overview of various aspects and introduces some concepts that are further described in the detailed description below. This summary is not intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood with reference to appropriate portions of the entire specification, any or all of the drawings, and each claim.

[0005] In some embodiments, an article includes a two-dimensional array configuration having a three-dimensional surface topology. The article includes a first two-dimensional sheet having an upper surface and a lower surface, wherein the first sheet has a three-dimensional surface topology, wherein the surface topology of both the upper surface and the lower surface includes a two-dimensional array of regular surface corrugations, each corrugation having a first set of at least three critical portions. The corrugations add a third dimension to the two-dimensional array. In some embodiments, each of the at least three critical portions is one of (a) a minimum portion, (b) a saddle portion, or (c) a maximum portion.

[0006] In some embodiments, the surface topology includes channels along a first direction, wherein the channels are configured to direct fluid flow substantially along the first direction.

[0007] In some embodiments of the article, the first sheet material comprises a filter material; a heat exchange surface; an active material; a reactive material; or a combination thereof.

[0008] In some embodiments of the article, the channel can be substantially linear along the first direction.

[0009] In some embodiments of the article, the surface topology is configured such that the fluid flow can be a substantially uniform flow.

[0010] In some embodiments of the article, the channel is configured such that the fluid flow can be a substantially uniform flow.

[0011] In some embodiments of the article, the minimum portion, the saddle portion, and the maximum portion are partially along a second direction, wherein the second direction is different from the first direction.

[0012] In some embodiments of the article, the article is configured such that the fluid flow along the second direction can be a substantially non-uniform flow.

[0013] In some embodiments of the article, at least one of each of the three critical portions is a critical point.

[0014] In some embodiments of the article, the surface topology further comprises a straight edge connecting at least two of the at least three critical portions.

[0015] In some embodiments of the article, the surface topology further comprises a curved portion connecting at least two of the at least three critical portions.

[0016] In some embodiments of the article, the surface topology comprises a geometric wave cross-section.

[0017] In some embodiments of the article, the geometric wave cross-section includes a sinusoidal wave cross-section; a non-sinusoidal periodic wave cross-section; a triangular wave cross-section; a rectangular wave cross-section; a square wave cross-section; or combinations thereof.

[0018] In some embodiments of the article, the filter material comprises a sorbent polymer composite.

[0019] In some embodiments of the article, the filter material comprises a sorbent material; and a polymeric material.

[0020] In some embodiments of the article, the adsorbent material comprises at least one of activated carbon, silica gel, zeolite, or a combination thereof.

[0021] In some embodiments of the article, the polymeric material comprises at least one of polytetrafluoroethylene; polyfluoroethylene propylene; polyperfluoroacrylate; polyvinylidene fluoride; tetrafluoroethylene terpolymer; hexafluoropropylene-vinylidene fluoride; polychlorotrifluoroethylene, or a combination thereof.

[0022] In some embodiments, the article includes a second sheet coupled to at least a portion of the first sheet.

[0023] In some embodiments of the article, the second sheet has a second surface topology comprising at least one flat portion.

[0024] In some embodiments, the second sheet material comprises a two-dimensional array structure having a three-dimensional surface topology. The second sheet material is supplemented with a second two-dimensional sheet material having an upper surface and a lower surface, wherein the second sheet material has a three-dimensional surface topology, wherein the surface topology of both the upper surface and the lower surface comprises a two-dimensional array of regular surface corrugations, each corrugation having a second set of at least three critical portions. These corrugations add a third dimension to the two-dimensional array. Thus, in some embodiments, the second sheet material is also a two-dimensional sheet material having an upper surface and a lower surface, wherein the second sheet material has a three-dimensional surface topology, wherein both the upper surface and the lower surface of the second sheet material comprise a two-dimensional array of three-dimensional surface topologies of corrugations having peaks and valleys, each corrugation having a first set of at least three critical portions. In some embodiments, each of the at least three critical portions of the second sheet material surface topology comprises (a) a minimum portion, (b) a saddle portion, and (c) a maximum portion. In some embodiments, the second sheet material comprises a second filter material; a heat exchange surface; an active material; a reactive material; or a combination thereof.

[0025] In some embodiments of the article, at least one of the at least three critical portions of the first sheet is coupled to the second sheet.

[0026] In some embodiments of the article, the first sheet is coupled to the second sheet by an adhesive, ultrasonic welding, heat welding, laser welding, or a combination thereof.

[0027] In some embodiments of the article, the first sheet is coupled to the second sheet by an adhesive.

[0028] In some embodiments, the article further comprises a modular frame, wherein the first sheet and the second sheet are connected to the modular frame.

[0029] In some embodiments, the module comprises a plurality of sheets, wherein each of the plurality of sheets has a surface topology comprising at least three critical portions, wherein each of the at least three critical portions is (a) a minimum portion, (b) a saddle portion, or (c) a maximum portion.

[0030] In some embodiments of the module, each of the plurality of sheets comprises a filter material; a heat exchange surface; an active material; a reactive material; or a combination thereof.

[0031] In some embodiments of the module, the filter material comprises a sorbent polymer composite.

[0032] In some embodiments of the module, the filter material comprises a sorbent material; and a polymer material.

[0033] In some embodiments, a method of producing an article disclosed herein includes obtaining a sheet; rolling the sheet on a roller having a roller mold; and forming a surface topology on the sheet, wherein the surface topology includes at least three critical portions, wherein each of the at least three critical portions is (a) a minimum portion, (b) a saddle portion, or (c) a maximum portion.

[0034] In some embodiments of the method, the method includes adding a filter material; a heat exchange surface; an active material; a reactive material; or a combination thereof to the sheet material.

[0035] In some embodiments, the method further includes obtaining a second sheet; rolling the second sheet on a roller having a roller mold; and forming a second surface topology on the second sheet, wherein the second surface topology includes at least three critical portions, wherein each of the at least three critical portions is one of (a) a second minimum portion, (b) a second saddle portion, or (c) a second maximum portion; and the method includes combining at least a portion of the sheet and at least a portion of the second sheet together.

[0036] In some embodiments of the method, the portion of the sheet comprises one of at least three critical portions of the sheet.

[0037] In some embodiments of the method, the portion of the second sheet includes one of the at least three critical portions of the second sheet.

[0038] In some embodiments of the method, the portion of the second sheet includes one of the at least three critical portions of the second sheet. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Reference is made to the accompanying drawings, which form a part of this disclosure and which illustrate embodiments in which the systems and methods described herein may be practiced.

[0040] Figure 1A is a schematic top view of a surface topology according to an embodiment.

[0041] Figure 1B yes Figure 1A Schematic side view of the surface topology shown.

[0042] Figure 1C yes Figure 1A Another schematic side view of the surface topology shown.

[0043] Figure 2 is another schematic top view of a surface topology according to an embodiment.

[0044] Figure 3 is a schematic side view of several sheets bonded together.

[0045] Figure 4 is a schematic top view of a surface topology according to an embodiment.

[0046] Figure 5 is a schematic top view of a surface topology according to an embodiment.

[0047] Figure 6 is a schematic top view of a surface topology according to an embodiment.

[0048] Figure 7 is a schematic top view of a surface topology according to an embodiment.

[0049] Figure 8 is a schematic diagram of a method for making an embodiment of one or more articles described herein.

[0050] Figure 9 Non-limiting embodiments of pollution control systems having any of the article(s) described herein are depicted.

[0051] The same reference numbers are used throughout to refer to the same or like parts. DETAILED DESCRIPTION

[0052] Among the benefits and improvements already disclosed, other objects and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings. Detailed embodiments of the present disclosure are disclosed herein; however, it should be understood that the disclosed embodiments are merely illustrative of the present disclosure that can be implemented in various forms. Furthermore, each example given with respect to the various embodiments of the present disclosure is intended to be illustrative and not restrictive.

[0053] Throughout the specification and claims, unless the context clearly dictates otherwise, the following terms take the meanings explicitly associated with the present invention. As used herein, the phrases "in one embodiment," "in an embodiment," and "in some embodiments" do not necessarily refer to the same embodiment, but they may refer to the same embodiment. Additionally, as used herein, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, but they may refer to different embodiments. All embodiments of the present disclosure are intended to be combinable without departing from the scope or spirit of the present disclosure.

[0054] The term "between" as used herein does not necessarily require being directly adjacent to other elements. Generally, the term refers to a structure in which something is sandwiched between two or more other objects. At the same time, the term "between" can describe something that is directly near two opposing objects. Therefore, in any one or more embodiments disclosed herein, a specific structural component disposed between two other structural elements can be: directly disposed between the two other structural elements so that the specific structural component is in direct contact with both of the other structural elements; directly disposed near one of the two other structural elements so that the specific structural component is in direct contact with one of the two other structural elements; indirectly disposed near one of the two other structural elements so that the specific structural component is not in direct contact with one of the two other structural elements, and there is another element that juxtaposes the specific structural component with one of the two other structural elements; indirectly disposed between the two other structural elements so that the specific structural component is not in direct contact with the two other structural elements, and other features can be disposed between them; or any combination thereof.

[0055] According to some embodiments, an article (e.g., a device or a component of a device) includes a thin material that can be described as a sheet (or also referred to as a sheet-like material). As a sheet, it has an upper surface and a lower surface and has an original center plane orientation before forming. The sheet has a specific shape or morphology on its main surface or upper surface, which can be described as a surface topology. In some embodiments, the surface topology can be in the form of a regularly repeated two-dimensional array with a three-dimensional topology, wherein the third dimension includes a group of at least three critical parts. These critical parts can include critical points (if these parts are small enough, they can be described as roughly a point). As used herein, a critical part is a mathematical definition of a surface area in which the local two-dimensional shape changes relative to the original center plane orientation of the unformed sheet material. In some embodiments, each of the at least three critical parts is (a) a minimum part; (b) a saddle, i.e., an inflection point area where the surface slope is zero; or (c) a maximum part, i.e., a peak. In other words, when viewed from a specific perspective, the surface topology can include a "low part" or a "low point." For example, when viewed along a particular cross-section, a sheet may have one or more spaced-apart "minima" or "low" points. Similarly, when viewed from a particular viewing angle, a surface topology may include "highs" or "high points." For example, when viewed along a particular cross-section, a sheet may have one or more "maxima" or "high" points.

[0056] As described below, the amplitude of these "low" or "high" portions can be measured or mathematically determined as "amplitude" parameters, which in some embodiments describe the surface topology. Further, the surface topology can include "saddles" (also called "minmax"), which describe portions of the surface where the slopes (i.e., derivatives) along orthogonal directions are all zero (critical points), but the portion is not a local extremum of the function. An example of a saddle point (or saddle-shaped surface portion) is the presence of a critical point (or region) that has a relative minimum along one axial direction (between peaks) and a relative maximum along the cross axis. However, the saddle does not have to be of this form. These configurations of the sheet surface topology can form channels along a specific direction of the sheet so that these channels can guide the fluid to flow substantially along that direction. In some embodiments, the surface topology of the sheet can cause the fluid to flow substantially uniformly along a specific direction (e.g., via channels). These channels or paths along the sheet surface topology are generally not straight, but rather guide the fluid around adjacent features of the topology.

[0057] In certain embodiments, the surface topology of sheet material can cause fluid to flow in an uneven manner along another direction or at the edge portion of the surface topology. In certain embodiments, the shape and position of these surface topology features can cause mobile phase to split repeatedly, thereby causing higher degree mixing, heat transfer to hot material or mass transfer to reaction surface (for example, the material of sheet material can be or include reactive materials or compounds that can react with the fluid that flows through, flows through, passes sheet material or its combination). In certain embodiments, gas phase flow is orthogonal to gravity vector (horizontal or azimuthal flow). Gas flow path includes surface topology so that flow is regularly interrupted (for example, uneven). There is a second liquid phase (produced by reaction or dripping from the top), wherein liquid flow path includes the pipeline for smooth, gravity-driven drainage (for example, substantially uniform flow). When liquid product is produced by the trickle structure in the gaseous reactant and / or gas / liquid exchanger in the catalytic solid phase, this embodiment can be very useful.

[0058] According to some embodiments, the surface topology can increase or maximize the yield of liquid products without increasing the pressure drop of the gas phase flowing across the reaction surface (i.e., catalytic surface). These embodiments can achieve this by promoting liquid drainage, because the sheet portions (or surface areas) with high surface shear forces generated by the flowing gas phase can enhance the displacement of liquid into stagnant areas, thereby achieving gravity-driven drainage (e.g., via channels on the surface topology).

[0059] Figure 1A 、 1B Shown in 1 and 1C is an exemplary sheet 100 having a surface topology 102 according to one embodiment. Figure 1A 1 shows a top view of the surface topology 102, wherein various repeating pyramidal features 104 with maximum peaks 106 (e.g., largest portions or points) can be seen. These maximum peaks 106 areas are also Figure 1B and 1C . Further, the surface topology 102 includes a minimum valley 108 (eg, a minimum portion or point). The surface topology 102 includes a saddle 110 (surface or point) positioned between the nearest neighbor maximum peak 106 and the minimum valley 108. The saddle 110 is located between the nearest neighbor maximum peak 106 and the minimum valley 108. Figure 1B Easier to see.

[0060] Figure 1B The sheet 100 is along the first direction 112 (eg Figure 1A 10 and 110, and the surface topology 102 is wavy along the direction 112 from the minimum point 108 to the saddle point 110. According to some embodiments, the transition along the direction 112 is relatively smooth. This can be described as a "channel" for fluid flow, and this configuration can promote substantially uniform fluid flow along the direction 112.

[0061] Figure 1C The diagram shows the direction 114 (eg Figure 1A ), where the flow path along this direction 114 encounters sharp or sharper edges depending on the smallest valleys 108 and largest peaks 106 of the surface topology 102. These features may contribute to uneven flow of the fluid as it flows along this direction 114.

[0062] although Figures 1A-1C The illustrated embodiment includes pyramidal features 104, but other geometric configurations are possible. For example, instead of or in combination with the pyramidal features 104, the surface topology embodiment may also include a sinusoidal cross-section, a non-sinusoidal periodic wave cross-section, a triangular wave cross-section, a rectangular wave cross-section, a square wave cross-section, or a combination thereof.

[0063] In other embodiments, the "peak" may be Figure 2 As shown, the peaks of the pyramidal features 204 are flattened or truncated. As an example, these flattened peak areas can be used to couple to another sheet. In this embodiment of the sheet 200 having another surface topology 202, the peaks of the pyramidal features 204 are flattened or truncated, thereby having flattened surface portions 206. In addition, the sheet 200 is Figures 1A-1CThe sheet material shown is similar. In other words, the surface topology 202 has various repeated pyramidal features 204, which have flat peaks 206. The surface topology 202 includes a minimum valley 208 (e.g., a minimum portion or point), which can also be flattened or truncated. The surface topology 202 includes a saddle 210 (surface or point) positioned between the nearest flat peak 206 and the minimum valley 208. The surface topology 202 is corrugated from the minimum point 208 to the saddle 210 along one direction. According to some embodiments, the transition along this direction is relatively smooth. This can be described as a "channel" for fluid flow, and this configuration can promote substantially uniform flow of the fluid along this direction. Along different directions, the flow path encounters sharp or sharper edges / ridges. When the fluid flows along this direction, these features may promote uneven flow of the fluid. The flat peak 206 can be used to combine (e.g., connect) the sheet material 200 to another sheet material.

[0064] Figure 3 is a schematic side view of several sheets bonded together. In other words, when Figure 2 When similar embodiments of the sheets 200 shown are stacked together, the flat peaks 206 can serve as connecting areas between the multiple sheets. Some of the sheets 300 can be flat, and these flat sheets 300 can be positioned on a surface having a surface topology (e.g., Figure 2 Between sheets 200 having a surface topology 202 as shown.

[0065] In some embodiments of the surface topology, at least some of the surface features include a repeating pattern. Some of these repeating patterns can include multiple parameters to define the repeating pattern. These parameters can be four or more. Examples of parameters include: amplitude, frequency, orientation, and function. Amplitude is the height or depth of the surface topology. Frequency can be determined as the inverse of the distance between peaks. Orientation can refer to the two main directions or axes that produce the surface topology, and the tilt angle between these two directions or axes (the two directions do not have to be perpendicular). Function refers to the shape of the ripple function (e.g., sine wave, square wave, sawtooth wave, etc.). These parameters can be varied to optimize differentiated gas flow and liquid flow with the same surface topology.

[0066] For example, Figure 4 FIG4 is a schematic perspective top view of a surface topography 400 according to one embodiment. A first axis 402 and a second axis 404 are defined herein as being perpendicular to each other. However, the surface topography 400 herein forms various maxima 406, minima 408, and saddles 410. Furthermore, along one direction 412, channels 414 are shaped to promote substantially uniform flow. Along another direction 416, peaks 406 and valleys 408 enhance substantially non-uniform flow.

[0067] Figure 5 FIG2 is a schematic perspective top view of a surface topology 500 according to one embodiment. A first axis 502 and a second axis 504 are defined as being perpendicular to each other. However, the surface topology 500 here forms various maxima 506, minima 508, and saddles 510. Furthermore, along one direction 512, the surface topology 500 has a corrugated shape to improve uniform or smooth fluid flow. Along another direction 514, peaks 506 and valleys 508 enhance uneven flow.

[0068] Figure 6 FIG2 is a schematic perspective top view of a surface topology 600 according to one embodiment. A first axis 602 and a second axis 604 are defined as being perpendicular to each other. However, the surface topology 600 here forms various maxima 606, minima 608, and saddles 610. Furthermore, along one direction 612, the surface topology 600 has a corrugated shape to improve uniform or smooth flow. Along another direction 614, peaks 606 and valleys 608 enhance uneven flow.

[0069] Figure 7 FIG2 is a schematic perspective top view of a surface topology 700 according to one embodiment. A first axis 702 and a second axis 704 are defined as being perpendicular to each other. However, the surface topology 700 here forms various maxima 706, minima 708, and saddles 710. Furthermore, along one direction 712, the surface topology 700 has a corrugated shape to improve uniform or smooth flow. Along another direction 714, peaks 706 and valleys 708 enhance uneven flow.

[0070] Figure 8 is a schematic diagram of a method 800 for making one or more embodiments of the articles described herein. In some embodiments, the method for producing an article having a surface topography as described herein can be performed by obtaining a sheet of material and rolling the sheet on a roller having a roller mold 802 to form a surface topography on the sheet, such as Figure 8 As shown. Additional steps for producing multiple sheets include obtaining another sheet and, if the second sheet is flat, not forming a surface topology on the second sheet, and bonding the first sheet having the surface topology described herein to the flat second sheet. If the second or third sheet does include a surface topology, rolling the sheet on a roller having a roller mold 802 and bonding the sheets together, as shown. Figure 8An additional step in producing a module for the system includes attaching the plurality of sheets bonded together to a module frame. Each sheet may include a filter material; a heat exchange surface; an active material; a reactive material; or a combination thereof.

[0071] Figure 9 A non-limiting embodiment of a pollution control system 900 comprising at least one of the articles described herein is depicted. Some non-limiting uses of the pollution control system 900 may be for controlling air pollutant emissions to comply with various air pollutant emission standards. The pollution control system 900 may be configured to capture elemental mercury and oxidized gas phase mercury from industrial flue gases. The pollution control system 900 may include discrete stackable modules 902 that may be installed downstream of a particle collection system. In some embodiments, the modules 902 may be configured with one or more embodiments of the articles 904 described herein (e.g., Figure 9 ). Thus, in some embodiments, one or more embodiments of article 904 are coupled to module frame 906 of module 902.

[0072] In some embodiments, the pollution control system 900 may include several articles (according to one or more of the embodiments described herein) formed into multiple channels. In such embodiments, the airflow can flow between the channels so that the airflow is in direct contact with at least a portion of the reactant material. In some embodiments, the multiple channels of the device can promote the flow of reactants such as gaseous components on one or more surfaces of the system and promote the drainage of at least one liquid product. In some embodiments, when the flue gas flows (for example, on or through the material), the system can capture both elemental mercury and oxidized mercury in the flue gas flow. Mercury can be firmly bound to the article material via chemical adsorption. SO2 can also be adsorbed and / or absorbed and catalyzed (via a SO2 oxidation catalyst) into liquid sulfuric acid, which can form droplets and be discharged from the article. The droplets can flow downward on the surface of the article via gravity.

[0073] Some embodiments of the present disclosure relate to devices comprising an adsorbent polymer composite. As used herein, "adsorbent polymer composite" is defined as an adsorbent material embedded in a polymer material matrix. In some embodiments, the polymer material of the adsorbent polymer composite comprises at least one of: polyfluoroethylene propylene (PFEP); polyperfluoroacrylate (PPFA); polyvinylidene fluoride (PVDF); a terpolymer of tetrafluoroethylene, hexafluoropropylene-vinylidene fluoride (THV) or polychlorotrifluoroethylene (PCFE), or a combination thereof. In some embodiments, the polymer material comprises polytetrafluoroethylene (PTFE). In some embodiments, the polymer material comprises expanded polytetrafluoroethylene (ePTFE). In some embodiments, the adsorbent material of the adsorbent polymer composite comprises at least one of: activated carbon, coal-derived carbon, lignite-derived carbon, wood-derived carbon, coconut-derived carbon, silica gel, zeolite, or a combination thereof. In some embodiments, the adsorbent polymer composite further comprises a halogen source. In some embodiments, the halogen source can be incorporated into the adsorbent polymer composite by any suitable technique, including, but not limited to, imbibing, impregnating, adsorbing, mixing, sprinkling, spraying, dipping, painting, coating, ion exchanging, or otherwise applying the halogen source to the adsorbent polymer composite. In some embodiments, the halogen source can be located within the adsorbent polymer composite, such as within any pores of the adsorbent polymer composite. In some embodiments, the halogen source can be provided in the form of a solution that can contact the adsorbent polymer composite in situ under system operating conditions.

[0074] In some embodiments, the halogen source is selected from at least one of sodium chloride, potassium chloride, sodium bromide, potassium bromide, sodium iodide, potassium iodide, tetramethylammonium iodide, tetrabutylammonium iodide, tetraethylammonium iodide, tetrapropylammonium iodide, tetramethylammonium bromide, tetraethylammonium bromide, tetrapropylammonium bromide, tetrabutylammonium bromide, tetramethylammonium chloride, tetraethylammonium chloride, tetrapropylammonium chloride, tetrabutylammonium chloride, I2, Cl2, Br2, or a combination thereof.

[0075] Additional configurations of the adsorbent polymer composites described herein and additional examples of the halogen sources described herein are described in US Pat. Nos. 9,827,551 to Hardwick et al. and 7,442,352 to Lu et al., the entireties of which are incorporated herein by reference.

[0076] Some embodiments of the present disclosure are referred to as "side-flow" or "cross-flow" systems because the reactants (e.g., at least one gaseous component) flow beside, over, through, or along a surface of a device comprising an adsorbent polymer composite. This is in contrast to a "flow-through" or "dead-end" system, in which the reactants flow through the adsorbent polymer composite. In some embodiments, the adsorbent polymer composite is in the form of at least one sheet. In some embodiments, the at least one sheet includes a first surface and a second surface opposite the first surface. In some embodiments, the first surface is constructed such that when a flue gas stream having at least one gaseous component flows over (and past) the first surface of the at least one sheet, the at least one gaseous component reacts within the adsorbent polymer composite of the at least one sheet to form at least one liquid product. In some embodiments, the at least one gaseous component flows over (and past) the first surface and the second surface of the at least one sheet.

[0077] In some embodiments, the at least one gaseous component comprises at least one of: mercury vapor, at least one SO x compounds, hydrogen sulfide, or a combination thereof. In some embodiments, the at least one liquid product comprises at least one of the following: sulfuric acid, liquid elemental sulfur, or a combination thereof. For at least one SO x Compound,SO x The removal of SO may be a complex process, requiring sufficient SO x , O2 and H2O to generate H2SO4 (sulfuric acid) through oxidation. In order to overcome SO x The adsorbent polymer composite can act as a “reverse sponge” to remove the sulfuric acid due to the accumulation of sulfuric acid caused by oxidation.

[0078] Certain devices made from adsorbent polymer composites may face significant challenges due to liquid accumulation. As liquid forms a percolating network within the adsorbent polymer composite, its performance may degrade over time. Eventually, this network may become continuous with the surface of the adsorbent polymer composite, and further liquid accumulation forces the liquid to drain away from the surface of the adsorbent polymer composite. Due to the lower solubility and diffusivity of contaminants, the performance of the liquid-wetted surface portions of the adsorbent polymer composite may be lower than that of areas that remain dry. Therefore, in some embodiments, the adsorbent material in the adsorbent polymer composite removes the target contaminant to the greatest extent possible.

[0079] In some embodiments, the device comprises a plurality of sheets forming a plurality of channels. In some embodiments, the plurality of sheets are configured to allow at least one liquid product to be drained through each of the plurality of channels. In some embodiments, the plurality of channels comprises a plurality of adjacent channels, wherein each of the plurality of adjacent channels is connected.

[0080] In some embodiments, the article or device can be configured to provide efficient mercury capture with a pressure drop less than that achieved through a bed of sorbent-packed particles of a sorbent polymer composite. In other words, the plurality of channels of the device can facilitate the flow of reactants, such as gaseous components, across one or more surfaces of at least one sheet and facilitate the drainage of at least one liquid product. In some embodiments, the device comprises a plurality of corrugated sheets and a plurality of flat sheets in an alternating configuration.

[0081] Examples and Comparison Data

[0082] The following table shows comparative characteristics detected and measured from exemplary embodiments.

[0083] Table 1A

[0084] Table 1B

[0085] To evaluate and compare the performance of the examples and geometries, a series of computational fluid dynamics experiments were conducted using the SOLIDWORKS Flow Simulation Suite (Dessault Systemes, Waltham, Massachusetts, USA). All simulations were run at a velocity of 3.6 m / s and an air temperature of 60 degrees Celsius.

[0086] An equilateral triangle channel with a height of 10 mm was used as the basis for comparison. All calculation results were also compared with the common flow geometry between parallel plates.

[0087] Span refers to the characteristic dimension between the center planes of adjacent geometric shapes that form a channel, and is expressed in millimeters (mm). When the geometric shapes with the aforementioned corrugations form channels in multiple directions, periodic boundary conditions are used.

[0088] Pressure drop (dP) is defined as the difference in fluid pressure between the fluid inlet and outlet, measured in inches of water. The transport ratio is the calculated geometric heat transfer coefficient relative to the performance of a triangular channel (e.g., Example 3 shows a 68% increase in heat transfer). Based on the Colburn-Chilton relationship, this transport ratio is directly applicable to mass transfer operations such as reactive-advective systems.

[0089] The FOM ("Figure of Merit") parameter divides the delivery ratio by the pressure drop, yielding a "delivery efficiency" where the energy used to move the fluid is an important consideration.

[0090] The weight ratio is the amount of material contained per unit volume of a geometric shape. The weight-to-weight ratio (to-weight ratio) indicates the ratio of material delivered per unit volume, which can be significant in cases where the material is of very high value. Because the area density is constant, this ratio also indicates the amount of material delivered per unit surface area.

[0091] According to one embodiment, the geometry of Example 1 is sinusoidal. The out-of-plane amplitude in both directions is 6 mm (the total height of the geometry is 12 mm). The wavelength is 50 mm in the first direction (flow direction) and 20 mm in the second direction (perpendicular to the flow direction). The corrugated geometry is connected to a flat sheet between the repeating corrugated geometry, such as Figure 3 As shown in sheet 300.

[0092] According to one embodiment, the geometry of Example 2 is sinusoidal. The out-of-plane amplitude in both directions is 3.5 mm (the total height of the geometry is 7 mm), and the wavelength is 50 mm in the first direction (flow direction) and 20 mm in the second direction (perpendicular to the flow direction). This corrugated geometry is connected to similar corrugated geometries, such as Figure 3 200. The peaks of the corrugated sheet are aligned with each other.

[0093] According to one embodiment, the geometry of Example 3 is sinusoidal. The out-of-plane amplitude in both directions is 3.5 mm (the total height of the geometry is 7 mm). And the wavelength is 50 mm in the first direction (flow direction) and 20 mm in the second direction (perpendicular to the flow direction). The corrugated geometry is connected to a flat sheet between the repeating corrugated geometry, such as Figure 3 As shown in sheet 300.

[0094] As can be seen in Tables 1A-1B above, all three examples demonstrate enhanced performance compared to the comparative example. The transport ratio is 33% to 68% higher than the triangular channel shape, and the FOM parameter is improved by more than 100% even with less material used.

[0095] Table 2A

[0096] Table 2B

[0097] To confirm the observed simulation results, mercury and SO₂ removal efficiency experiments were conducted using a standard adsorbent polymer composite (SPC). The SPC was prepared under laboratory conditions and consisted of 65.5% activated carbon (Norit PAC20BF, Cabot Inc., TX, USA), 20% polytetrafluoroethylene (PTFE), 9% tetrabutylammonium iodide, and 5.5% sulfur. Composite samples were prepared using the general dry-mixing method described in U.S. Patent No. 7,791,861. These SPC materials were then formed into the following geometries according to the present invention.

[0098] The SPC sheet was pleated using a blade pleating machine and oriented next to a flat plate to form a triangular channel 10 mm high. The parallel plate geometry was formed by placing two flat SPC sheets adjacent to each other and using multiple polypropylene posts and neoprene O-rings (available from McMaster-Carr, Elmhurst, Illinois, USA) as spacers to form a 6 mm parallel plate channel.

[0099] According to one embodiment, the SPC sheet geometry of Example 4 has a sinusoidal profile. The out-of-plane amplitude is 3.5 mm in both directions (with a total geometric height of 7 mm), and the wavelength is 50 mm in the first direction (the flow direction) and 20 mm in the second direction (perpendicular to the flow direction). This corrugated SPC sheet is joined to the 10 mm equilateral triangular pleated SPC sheet described above, forming a layered geometry composed of corrugated and pleated SPC sheets.

[0100] According to one embodiment, the geometry of the SPC sheet of Example 5 has a sinusoidal shape. The out-of-plane amplitude in both directions is 3.5 mm (the total geometric height is 7 mm), and the wavelength is 50 mm in the first direction (flow direction) and 20 mm in the second direction (perpendicular to the flow direction). This corrugated SPC sheet is connected to a similar corrugated SPC sheet, such as Figure 3 As shown in sheet 200.

[0101] According to one embodiment, the geometry of the SPC sheet of Example 6 has a sinusoidal shape. The out-of-plane amplitude in both directions is 6.2 mm (the total geometric height is 12.4 mm). And the wavelength is 100 mm in the first direction (flow direction) and 12.7 mm in the second direction (perpendicular to the flow direction). The corrugated SPC sheet is connected to a flat SPC sheet between the repeating corrugated geometric shapes, such as Figure 3 As shown in sheet 300.

[0102] Mercury and SO2 removal efficiency tests were performed using the following apparatus: (1) an air supply regulated by a blower. The humidity level of the airflow was controlled by passing it through a humidification system consisting of a gas preheater and a heated humidification chamber; (2) a mercury supply generated by blowing a small amount of nitrogen through a container of liquid mercury placed in a temperature-controlled bead bath; (3) an SO2 supply from an SO2 generation system. SO2 was generated by mixing concentrated sulfuric acid with a sodium metabisulfite solution delivered by a small nitrogen purge; (4) a gas mixing zone where a stream of humidified air was mixed with the mercury and SO2 supply streams; (5) a sample cell equipped with gas sampling ports before and after the sample and located in an oven; (6) a mercury analyzer that measured total mercury (the gas sampling line passed through a stannous chloride / HCl bubbler before entering the analyzer to convert any oxidized mercury to elemental mercury); and (7) an SO2 detection analyzer.

[0103] Efficiency is reported as the difference between the inlet mercury concentration (bypassing the sample) and the outlet mercury concentration (through the sample). Percent efficiency is defined as follows: % efficiency = 100 × [concentration (入口) -concentration (出口) ] / [concentration (入口) ]

[0104] The sample cell consisted of a horizontal tube measuring 50 mm x 50 mm x 300 mm. The term "horizontal" refers to the direction of airflow being perpendicular to the direction of gravity, allowing for the diversion of the generated sulfuric acid phase to influence overall performance. The face velocity was 3.6 m / s, with an inlet SO2 concentration of 100 ppm and the remainder being fully saturated moist air. The inlet mercury concentration, expressed as elemental mercury, was approximately 15 μg / m 3 .

[0105] The removal efficiency test results are summarized in Tables 2A-2B. The dry SPC weight refers to the amount of material contained within the pipe. The wet weight refers to the amount of liquid that forms, in contrast to the CFD results, adhering to the SPC material, which affects the airflow.

[0106] Both SO₂ and mercury were added to evaluate performance. Elemental mercury has limited solubility and is easily affected by the liquid phase, which hinders its contact with the reactants. In contrast, SO₂ has high solubility in the liquid acid phase and is less affected by the presence of the liquid. All three example geometries demonstrated higher removal efficiencies compared to the two comparative geometries tested.

[0107] aspect

[0108] Various aspects are described below. It should be understood that any one or more features described in the following aspects may be combined with any one or more other aspects.

[0109] Aspect 1. A product comprising: The first sheet, wherein the first sheet has a surface topology, wherein the surface topology comprises a first group of at least three critical parts, wherein each of the at least three critical parts is: (a) Minimum part, (b) saddle, or (c) Largest part.

[0110] Aspect 2. The product according to Aspect 1 wherein the surface topology comprises channels along a first direction, The channel is configured to guide the fluid to flow substantially in a first direction.

[0111] Aspect 3. The article according to aspect 2, wherein the first sheet comprises: filter materials; heat exchange surfaces; active materials; reactive materials; or Its combination.

[0112] Aspect 4. The article of aspect 3, wherein the surface topology is substantially uniform along the first direction.

[0113] Aspect 5. The article of aspect 3, wherein the channel is configured such that the fluid flow is a substantially uniform flow.

[0114] Aspect 6. The article of aspect 4, wherein the minimum portion, the saddle portion, and the maximum portion are along a second direction, wherein the second direction is different from the first direction.

[0115] Aspect 7. The article of aspect 6, wherein the surface topology is configured such that fluid flow along the second direction is a substantially non-uniform flow.

[0116] Aspect 8. The article of aspect 1, wherein at least one of each of the three critical portions is a critical point.

[0117] Aspect 9. The article of any one of aspects 1-8, wherein the surface topology further comprises a straight edge connecting at least two of the at least three critical portions.

[0118] Aspect 10. The article of any one of aspects 1-9, wherein the surface topology further comprises a curved portion connecting at least two of the at least three critical portions.

[0119] Aspect 11. The article of any one of aspects 1-10, wherein the surface topology comprises a geometric wave cross-section.

[0120] Aspect 12. The article of aspect 11, wherein the geometric wave cross-section comprises: Sine wave cross section; Non-sinusoidal periodic wave cross section; Triangular wave cross section; rectangular wave cross section; square wave cross section; or Its combination.

[0121] Aspect 13. The article of any one of aspects 3-12, wherein the filter material comprises an adsorbent polymer composite.

[0122] Aspect 14. The article of aspect 13, wherein the adsorbent polymer composite comprises: Adsorbent materials; and Polymer material.

[0123] Aspect 15. The article of aspect 14, wherein the adsorbent material comprises at least one of activated carbon, silica gel, zeolite, or a combination thereof.

[0124] Aspect 16. The article of any one of aspects 14-15, wherein the polymeric material comprises at least one of polytetrafluoroethylene; polyfluoroethylene propylene; polyperfluoroacrylate; polyvinylidene fluoride; tetrafluoroethylene terpolymer; hexafluoropropylene-vinylidene fluoride; polychlorotrifluoroethylene, or a combination thereof.

[0125] Aspect 17. The article of any of aspects 1-16, further comprising a second sheet connected to the first sheet.

[0126] Aspect 18. The article of aspect 17, wherein the second sheet has a second surface topology comprising a flat portion.

[0127] Aspect 19. The article of aspect 17, wherein the second sheet has a second surface topology,

[0128] wherein the second surface topology comprises a second set of at least three critical portions, wherein each of the at least three critical parts is: (a) the second smallest part, (b) a second saddle, or (c) The second largest part.

[0129] Aspect 20. The article of aspect 19, wherein the second sheet material comprises a second filter material.

[0130] Aspect 21. The article of aspect 20, wherein at least one of the at least three critical portions of the first sheet is coupled to the second sheet.

[0131] Aspect 22. The article of aspect 21, wherein the first sheet is coupled to the second sheet by an adhesive, ultrasonic welding, or a combination thereof.

[0132] Aspect 23. The article of aspect 21, wherein the first sheet is coupled to the second sheet by an adhesive.

[0133] Aspect 24. The article according to any one of aspects 17-23, further comprising a module frame,

[0134] Wherein, the first sheet and the second sheet are connected to the module frame.

[0135] Aspect 25. A module comprising: Multiple sheets, wherein each of the plurality of sheets has a surface topology comprising at least three critical portions, wherein each of the at least three critical portions is: (a) Minimum part, (b) saddle, or (c) Largest part.

[0136] Aspect 26. The module of aspect 25, wherein each of the plurality of sheets comprises a filter material.

[0137] Aspect 27. The module of aspect 26, wherein the filter material comprises an adsorbent polymer composite.

[0138] Aspect 28. The module according to aspect 27, wherein the adsorbent polymer composite comprises: Adsorbent materials; and Polymer material.

[0139] Aspect 29. A method of producing an article according to any one of aspects 1-28, comprising: Get sheet material; rolling the sheet on a roller having a roller mold; and forming a surface topology on the sheet, The surface topology comprises at least three critical portions, wherein each of the at least three critical portions is: (a) Minimum part, (b) saddle, or (c) Largest part.

[0140] Aspect 30. The method according to aspect 29, wherein the sheet material comprises: filter materials; heat exchange surfaces; active materials; reactive materials; or Its combination.

[0141] Aspect 31. The method according to any one of aspects 29-30, further comprising: Obtaining a second sheet; rolling the second sheet on the roller having the roller mold; and forming a second surface topology on the second sheet, wherein the second surface topology comprises at least three critical portions, wherein each of the at least three critical portions is: (a) the second smallest part, (b) a second saddle, or (c) the second largest portion; and At least a portion of the first sheet is bonded together with at least a portion of the second sheet.

[0142] Aspect 32. The method of aspect 31, wherein the portion of the sheet comprises one of the at least three critical portions of the sheet.

[0143] Aspect 33. The method of aspect 32, wherein the portion of the second sheet comprises one of the at least three critical portions of the second sheet.

[0144] Aspect 34. The method of aspect 31, wherein the portion of the second sheet comprises one of the at least three critical portions of the second sheet.

[0145] All prior patents and publications cited herein are incorporated by reference in their entirety.

[0146] The terms used herein are intended to describe embodiments and are not intended to be limiting. The terms "a", "an" and "the" also include plural forms, unless expressly stated otherwise. When used in this specification, the terms "include" and / or "including" specifically refer to the presence of the stated features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements and / or parts. As used herein, the term "based on" is not exclusive and allows for being based on additional factors that are not described, unless the context clearly dictates otherwise. In addition, the meaning of "in" includes "in" and "on".

[0147] It should be understood that changes may be made in detail, especially in the materials of construction employed and the shapes, sizes, and arrangements of parts without departing from the scope of the present disclosure. The specification and described embodiments are examples, with the true scope and spirit of the disclosure being indicated by the following claims.

Claims

1. A product comprising: The first sheet, wherein the first sheet has a surface topology, wherein the surface topology comprises a first group of at least three critical parts, Wherein, each of the at least three critical parts is one of the following: (a) Minimum part, (b) saddle, or (c) Largest part.

2. The product according to claim 1, It is characterized by: The surface topology includes flow channels along a first direction, The channel is configured to guide the fluid to flow substantially along the first direction.

3. The product according to claim 1, characterized in that The first sheet material comprises: filter materials; heat exchange surfaces; active materials; reactive materials; or Its combination.

4. The product according to any one of claims 1 to 3, characterized in that The surface topology is substantially linear along the first direction.

5. The product according to any one of claims 1 to 4, characterized in that The channel is configured such that the fluid flow is a substantially uniform flow.

6. The product according to claim 2, characterized in that The minimum portion, the saddle portion, and the maximum portion are along a second direction, wherein the second direction is different from the first direction.

7. The product according to claim 6, characterized in that The surface topology is configured such that fluid flow along the second direction is a substantially non-uniform flow.

8. The product according to claim 1, characterized in that At least one of each of the three critical parts is a critical point.

9. The product according to any one of claims 1 to 8, characterized in that The surface topology further includes a straight edge connecting at least two of the at least three critical portions.

10. The product according to any one of claims 1 to 9, characterized in that The surface topology further includes a curved portion connecting at least two of the at least three critical portions.

11. The product according to any one of claims 1 to 10, characterized in that The surface topology includes a geometric wave cross-section.

12. The product according to claim 11, characterized in that The geometric wave cross section includes: Sine wave cross section; Non-sinusoidal periodic wave cross section; Triangular wave cross section; rectangular wave cross section; square wave cross section; or Its combination.

13. The product according to any one of claims 3 to 12, characterized in that The filter material comprises an adsorbent polymer composite.

14. The product according to claim 13, characterized in that The adsorbent polymer composite material comprises: Adsorbent materials; and Polymer material.

15. The product according to claim 14, characterized in that The adsorbent material includes at least one of activated carbon, silica gel, zeolite or a combination thereof.

16. The product according to any one of claims 14-15, characterized in that The polymer material includes at least one of polytetrafluoroethylene, polyfluoroethylene propylene, polyperfluoroacrylate, polyvinylidene fluoride, tetrafluoroethylene terpolymer, hexafluoropropylene-vinylidene fluoride, polychlorotrifluoroethylene or a combination thereof.

17. The product according to any one of claims 1 to 16, characterized in that Also included is a second sheet connected to the first sheet.

18. The product according to claim 17, characterized in that The second sheet has a second surface topology including a flat portion.

19. The article according to claim 17, wherein the second sheet having a second surface topology, wherein the second surface topology comprises a second set of at least three critical portions, wherein each of the at least three critical parts is: (a) the second smallest part, (b) a second saddle, or (c) The second largest part.

20. The article according to claim 19, wherein The second sheet material includes a second filter material; heat exchange surfaces; active materials; reactive materials; or Its combination.

21. The article according to claim 20, characterized in that At least one of the at least three critical portions of the first sheet is coupled to the second sheet.

22. The article according to claim 21, characterized in that The first sheet is coupled to the second sheet by adhesive, ultrasonic welding, or a combination thereof.

23. The article according to claim 21, wherein The first sheet is coupled to the second sheet by an adhesive.

24. The article according to any one of claims 17 to 23, characterized in that Also includes the module framework, Wherein, the first sheet and the second sheet are connected to the module frame.

25. A module comprising: Multiple sheets, wherein each of the plurality of sheets has a surface topology comprising at least three critical portions, wherein each of the at least three critical portions is: (a) Minimum part, (b) saddle, or (c) Largest part.

26. The module according to claim 25, characterized in that Each of the plurality of sheets comprises a filter material; a heat exchange surface; active materials; reactive materials; or Its combination.

27. The module according to claim 26, characterized in that The filter material comprises an adsorbent polymer composite.

28. The module according to claim 27, characterized in that The adsorbent polymer composite material comprises: Adsorbent materials; and Polymer material.

29. A method of producing an article according to any one of claims 1 to 28, comprising: Get sheet material; rolling the sheet on a roller having a roller mold; as well as forming a surface topology on the sheet, The surface topology comprises at least three critical portions, wherein each of the at least three critical portions is: (a) Minimum part, (b) saddle, or (c) Largest part.

30. The method according to claim 29, wherein The sheet material comprises: filter materials; heat exchange surfaces; active materials; reactive materials; or Its combination.

31. The method according to any one of claims 29-30, characterized in that Also includes: Obtaining a second sheet; rolling the second sheet on the roller having the roller mold; as well as forming a second surface topology on the second sheet, wherein the second surface topology comprises at least three critical portions, wherein each of the at least three critical portions is: (a) the second smallest part, (b) a second saddle, or (c) the second largest portion; and At least a portion of the first sheet is bonded together with at least a portion of the second sheet.

32. The method according to claim 31, characterized in that A portion of the sheet includes one of the at least three critical portions of the sheet.

33. The method according to claim 32, characterized in that The portion of the second sheet includes one of the at least three critical portions of the second sheet.

34. The method according to claim 31, wherein The portion of the second sheet includes one of the at least three critical portions of the second sheet.

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