Adsorption section for direct air capture unit

Abstract

An adsorption section (304) comprises a filter plate (414) and a frame (402), the filter plate (414) folded in the frame (402), the filter plate (414) comprising a filter layer (602), the filter layer (602) comprising: a first mesh (604) having a first thickness, the first mesh (604) defining a plurality of first flow channels through the first thickness, the plurality of first flow channels being selected to allow a gas flow (122) to pass therethrough; a second mesh (606) having a second thickness, the second mesh (606) defining a plurality of second flow channels through the second thickness, the plurality of second flow channels being selected to allow an airflow (122) to pass therethrough, the second mesh (606) in combination with the first mesh (604) to define a plurality of pockets (608), each pocket (608) being separate from the remaining pockets (608); and an adsorbent (610) positioned in each pocket (608) and selected to be capable of adsorbing carbon dioxide from the gas stream (122).

Description

BACKGROUND

[0001] Gas separation by adsorption is an industrial process to remove specific gas components from a gas mixture. One application is the removal of carbon dioxide (CO2) from a gas stream, such as flue gas or exhaust gas, industrial exhaust gas, biogas or even atmospheric air. The process of capturing CO2 from air is called direct air capture. Direct air capture processes use a solid adsorbent onto which CO2 molecules can be adsorbed by reaction with amine groups. During adsorption, air needs to move around the adsorbent to provide CO2 that can be adsorbed. During desorption, the adsorbent needs to be enclosed in a vessel in order to be able to capture the released CO2. For desorption, the temperature of the adsorbent vessel is increased and the partial pressure of CO2 is decreased. The decrease of the partial pressure of CO2 can be done by purging with another medium and / or decreasing the absolute pressure in the adsorbent vessel.

[0002] Typically, steam is used for both the purge and the heating of the adsorbent. At the beginning of the desorption phase, the air pressure in the adsorbent vessel is decreased by using a vacuum pump, thereby decreasing the amount of air mixed with the CO2 to be delivered by the direct air capture unit. The fan required to move the gas stream, such as ambient air, is one of the main power consumers. Another main consumption is the power required to provide the heat needed for desorption. The service cost for replacing the adsorbent in terms of labor and downtime of the direct air capture unit is another main recurring operating expense.

[0003] US2017 / 0326494A1 discloses an adsorbent filter for direct air carbon capture. The adsorbent filter comprises a frame and a fabric material for containing the adsorbent while allowing gas flow through the fabric and the adsorbent. The frame comprises an auxiliary heat transfer structure (fins) that can be incorporated to the fabric to increase rigidity. These embodiments are disclosed as being completely filled with adsorbent and in a horizontal or substantially horizontal configuration.

[0004] US6,402,811B1 discloses an adsorbent filter for direct air carbon capture comprising a flexible bag having a plurality of spaced-apart seams to form a plurality of storage areas. The storage areas are not independent of each other and adsorbent can migrate from one storage area to another.

[0005] It is an object of the present invention to propose a design that allows the use of an adsorbent material that swells when exposed to humidity. SUMMARY

[0006] The object is achieved by an adsorption section comprising a filter sheet and a frame, the filter sheet being folded in the frame, the filter sheet comprising a filter layer, the filter layer comprising: a first mesh having a first thickness, the first mesh defining a plurality of first flow channels through the first thickness, the plurality of first flow channels being configured to allow a gas stream to pass through; a second mesh having a second thickness, the second mesh defining a plurality of second flow channels through the second thickness, the plurality of second flow channels being configured to allow the gas stream to pass through, the second mesh being combined with the first mesh to define a plurality of pockets, each pocket being separate from the rest of the pockets; and an adsorbent, the adsorbent being positioned in each pocket and being configured to adsorb carbon dioxide from the gas stream, wherein the frame comprises a first closed side, a second closed side opposite the first closed side in a width direction, a first open side, a second open side opposite the first open side in a length direction, wherein the filter sheet is mounted in the length direction, the plurality of pockets are partially filled with the adsorbent, the adsorbent defines a cavity within each of the plurality of pockets.

[0007] In one embodiment of the adsorption section, wherein the width of the filter layer varies along the length direction, thereby defining a plurality of narrowest portions and a plurality of widest portions, and wherein the filter sheet further comprises a second filter layer, the second filter layer being attached to the filter layer, wherein the plurality of narrowest portions of the second filter layer are aligned with the plurality of widest portions of the first filter layer.

[0008] In one embodiment of the adsorption section, wherein the filter layer comprises a plurality of walls disposed between the first mesh and the second mesh, thereby combining the first mesh with the second mesh and defining the plurality of pockets and the cavity.

[0009] In one embodiment of the adsorption section, wherein the plurality of pockets form a pattern, and wherein the pattern is selected from a group comprising a horizontal pattern, a vertical pattern, a cross pattern, a herringbone pattern, a honeycomb pattern, and an elongated honeycomb pattern.

[0010] In one embodiment of the adsorption section, wherein each pocket contains an amount of the adsorbent, the adsorbent being configured to have a first volume when the adsorbent is dry, wherein the adsorbent is configured to have a second volume when the adsorbent is soaked, and wherein the second volume is greater than the first volume.

[0011] In one embodiment of the adsorption section, wherein the first mesh and the second mesh are made of a stretchable material to allow the volume of the pockets to change.

[0012] In one embodiment of the adsorption section, wherein a portion of each pocket of the plurality of pockets is covered by a solid sheet, the solid sheet being configured to prevent the gas stream from entering the cavity.

[0013] In one embodiment of the adsorption section, wherein the filter layer comprises a peripheral border, the peripheral border being formed by firmly combining peripheral regions of the first mesh and the second mesh.

[0014] In one embodiment of the adsorption section, wherein the frame comprises a plurality of first bars disposed between the first closed side and the second closed side at the first open side, a plurality of second bars disposed between the first closed side and the second closed side at the second open side, wherein the filter plates are single continuous plates and are folded alternately over the plurality of first bars and the plurality of second bars, thereby forming a wavy profile.

[0015] In one embodiment of the adsorption section, wherein the plurality of first bars and the plurality of second bars are offset from each other along the first open side and the second open side. BRIEF DESCRIPTION OF DRAWINGS

[0016] For ease of understanding the discussion of any particular element or act, the most significant digits in a reference number identify the figure in which that element is first introduced.

[0017] Figure 1 An external perspective view of the direct air capture unit is shown.

[0018] Figure 2 An internal perspective view of the direct air capture unit of Figure 1 is shown.

[0019] Figure 3 A perspective view of the adsorption vessel of the direct air capture unit of Figure 1 is shown.

[0020] Figure 4 A perspective view of the adsorption section of the adsorption vessel of Figure 3 is shown.

[0021] Figure 5 A cross-sectional view of the adsorption section of Figure 4 is shown.

[0022] Figure 6 A cross-sectional view of the filter plate of the adsorption section of Figure 4 is shown.

[0023] Figure 7 A cross-sectional view of another filter plate of the adsorption section of Figure 4 is shown.

[0024] Figure 8 A cross-sectional view of yet another filter plate of the adsorption section of Figure 4 is shown.

[0025] Figure 9 A cross-sectional view of yet another filter plate of the adsorption section of Figure 4 is shown.

[0026] Figure 10 A pattern of pockets of the filter plate of the adsorption section of Figure 4 is shown.

[0027] Figure 11 A pattern of pockets of a filter plate of an adsorption section of a filter is shown. Figure 4

[0028] Figure 12 A pattern of pockets of a filter plate of an adsorption section of a filter is shown. Figure 4

[0029] Figure 13 A pattern of pockets of a filter plate of an adsorption section of a filter is shown. Figure 4

[0030] Figure 14 A pattern of pockets of a filter plate of an adsorption section of a filter is shown. Figure 4

[0031] Figure 15 A pattern of pockets of a filter plate of an adsorption section of a filter is shown. Figure 4

[0032] Figure 16 A perspective view of an apparatus for manufacturing a filter plate is shown.

[0033] Figure 17 A perspective view of an apparatus for manufacturing a filter plate is shown. DETAILED DESCRIPTION

[0034] Before any embodiments of the application are explained in detail, it is to be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The application is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and not of limitation.

[0035] Various techniques related to systems and methods will now be described with reference to the drawings, wherein like reference numerals refer to like elements throughout. The drawings discussed below and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure can be implemented in any suitably arranged device. It should be understood that functions described as being performed by certain system elements can be performed by multiple elements. Similarly, for example, one element can be configured to perform functions described as being performed by multiple elements. The various innovative teachings set forth herein could be implemented in exemplary but non-limiting embodiments.

[0036] ​​​​​Also, it should be understood that the words or phrases used herein should be construed broadly, unless expressly limited in some examples. For example, the terms “including,” “having,” and “comprising” and variations thereof as used herein are intended to be open-ended and to mean that there is no limitation on the scope of a composition, process, method, or article of manufacture described. Also, the terms “a” and “an” and “the” used herein mean “one or more” unless expressly stated otherwise. Further, the term “and / or” used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term “or” is inclusive, meaning and / or, unless the context clearly indicates otherwise. The phrases “associated with” and “associated therewith” as used herein are intended to mean to include, be

[0037] Also, while the terms “first,” “second,” “third,” etc. can be used herein to describe various elements, information, functions, or acts, such elements, information, functions, or acts should not be limited by these terms. Rather, these numeric adjectives are used to distinguish one element, information, function, or act from another element, information, function, or act. For example, a first element, information, function, or act can be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act can be termed a first element, information, function, or act, without departing from the scope of the disclosure.

[0038] Also, the term “adjacent” can refer to an element being relatively close to, but not touching another element, or the element being in contact with another part, unless the context clearly dictates otherwise. Also, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. The term “about” or “substantially” or similar terms are intended to cover variations in values within standard industry manufacturing tolerances for that dimension. If no industry standard is available, a variation of 20% will fall within the meaning of these terms, unless otherwise stated.

[0039] Figure 1 An external perspective view of a direct air capture unit 100 is shown. The direct air capture unit 100 includes a housing 102 that encloses a plurality of components, including a heat exchanger 104, a compressor 106, a carbonator 108, a filter 110, and a carbonator 112, as shown in FIG. 2. The direct air capture unit 100 also includes a fan 114, a controller 116, and a power supply 118. Figure 2The diagram shows several internal components. In the illustrated embodiment, the direct air trapping unit 100 is a cuboid. In other embodiments, the direct air trapping unit 100 may have a shape different from a cuboid, such as a cube, pentagonal prism, hexagonal prism, cylinder, etc.

[0040] The housing 102 has a bottom surface 104, a top surface 106 opposite to the bottom surface 104, and a side surface 108 extending between the bottom surface 104 and the top surface 106. The bottom surface 104 is disposed on the ground surface 110. The top surface 106 has an opening 112 in which a fan 114 is disposed. A louver panel 116 is also disposed in the opening 112 to prevent water from entering the housing 102. The side surface 108 has a plurality of louver slides 118 disposed adjacent to each other. Each of the plurality of louver slides 118 has a plurality of gaps 120 to allow airflow 122 to enter the housing 102. The airflow 122 includes ambient air.

[0041] Figure 2 It shows Figure 1 An internal perspective view of the direct air capture unit 100, with the housing 102 removed for illustrative purposes. The direct air capture unit 100 has an adsorbent bed 202. A central axis 206 extends from the center of the adsorbent bed 202. The adsorbent bed 202 has a circular shape, but other configurations are also possible, such as rectangular, square, elliptical, etc.

[0042] The adsorbent bed 202 has a plurality of pores 204 circumferentially distributed in the adsorbent bed 202 relative to a central axis 206. Each of the plurality of pores 204 has a cylindrical shape, but other configurations are also possible, such as cuboids, cubes, pentagonal prisms, hexagonal prisms, etc. The plurality of pores 204 are circumferentially arranged in two different circles in the adsorbent bed 202. In other embodiments, the plurality of pores 204 may be circumferentially arranged in one or more circles in the adsorbent bed 202. Adsorption container 300 (e.g. Figure 3 (As shown) can be installed in each hole 204 for adsorbing carbon dioxide in the gas flow 122 when the gas flow 122 flows through the adsorption container 300.

[0043] Figure 3 It shows Figure 1 A perspective view of the adsorption container 300 of the direct air capture unit 100. The adsorption container 300 has a housing 302. The housing 302 is a solid structure. The housing 302 is made of corrugated steel, but other materials are also possible. The adsorption container 300 has a cylindrical shape. In other embodiments, the adsorption container 300 can have different shapes, such as cuboids, cubes, pentagonal prisms, hexagonal prisms, etc.

[0044] The adsorption vessel 300 has a plurality of adsorption sections 304 arranged within the housing 302. In the illustrated embodiment, the adsorption vessel 300 has twenty adsorption sections 304. In other embodiments, the adsorption vessel 300 can have more or less than twenty adsorption sections 304 as desired.

[0045] Figure 4 A perspective view of one of the plurality of adsorption sections 304 is shown. Figure 3 The adsorption section 304 includes a frame 402. The frame 402 has a first closed side 404 and a second closed side 406 opposite the first closed side 404. A hollow interior 408 is defined between the first closed side 404 and the second closed side 406.

[0046] The frame 402 has a first open side 410 and a second open side 412 opposite the first open side 410 for the flow of gas 122 through the adsorption section 304. A filter panel 414 is mounted in the hollow interior 408 of the frame 402.

[0047] Figure 5 A cross-sectional view of the adsorption section 304 along the A-A direction is shown. Figure 4 The adsorption section 304 has a plurality of first bars 502 disposed between the first closed side 404 and the second closed side 406 at the first open side 410 and a plurality of second bars 504 disposed between the first closed side 404 and the second closed side 406 at the second open side 412. The plurality of first bars 502 and the plurality of second bars 504 are offset from each other along the first open side 410 and the second open side 412.

[0048] The filter panel 414 is a single continuous panel. The filter panel 414 is alternately folded over the plurality of first bars 502 and the plurality of second bars 504, thereby forming a wavy profile along the first open side 410 and the second open side 412. Two adjacent portions of the filter panel 414 form a V-shape between the first open side 410 and the second open side 412. The thickness of the filter panel 414 is between 5 mm and 25 mm, preferably between 5 mm and 15 mm, other dimensions are possible.

[0049] Figure 6 A cross-sectional view of the adsorption section 304 along the A-A direction is shown. Figure 4a cross-sectional view of a filter plate 414 of the adsorption section 304. The filter plate 414 is mounted in the frame 402 along a vertical direction. The filter plate 414 includes a filter layer 602 having a first mesh 604 and a second mesh 606. The first mesh 604 has a first thickness, and the second mesh 606 has a second thickness. The first mesh 604 is made of a first porous material having a plurality of first apertures across the first thickness, the plurality of first apertures defining a plurality of first flow channels. The second mesh 606 is made of a second porous material having a plurality of second apertures across the second thickness, the plurality of second apertures defining a plurality of second flow channels. The first mesh 604 and the second mesh 606 include wire having a diameter between 0.05 mm and 0.2 mm, and the plurality of first apertures and the plurality of second apertures have a diameter between 0.2 mm and 0.5 mm, although other dimensions are possible. The first mesh 604 and the second mesh 606 can be made of the same material, such as a polyamide synthetic fiber mesh, a stainless steel mesh, an aluminum mesh, etc. The first mesh 604 and the second mesh 606 can be made of different materials.

[0050] The first mesh 604 and the second mesh 606 are bonded together along a length direction 614 at a plurality of bond locations 616 that are spaced apart. The plurality of pockets 608 are defined between the first mesh 604 and the second mesh 606 and are separated from each other by the plurality of bond locations 616. The first mesh 604 and the second mesh 606 can be bonded together by any suitable method, such as ultrasonic welding, heat staking, stitching, or gluing.

[0051] Each pocket 608 of the plurality of pockets 608 is filled with an amount of adsorbent 610. When the adsorbent 610 has not adsorbed water, the adsorbent 610 fills a first volume within the pocket 608. When the adsorbent 610 has adsorbed water, the adsorbent 610 expands. The adsorbent 610 then fills a second volume within the pocket 608. The second volume is greater than the first volume. In Figure 6 In the illustrated embodiment, the adsorbent 610 is completely filled within the pocket 608. The volume of the pocket 608 changes as the volume of the adsorbent 610 changes, which changes as the water content changes. The first mesh 604 and the second mesh 606 are made of a stretchable material that allows the volume of the pocket 608 to change. The adsorbent 610 contains a granular material and an amine-based material, although other materials are possible. The adsorbent 610 is formed in a bead type, such as a spherical bead type, although other types are possible. The spherical bead type has a diameter between 0.1 mm and 1.5 mm, although other dimensions are possible.

[0052] The filter layer 602 has a width defined between the first mesh 604 and the second mesh 606 along the width direction 618. The gas stream 122 passes through the filter layer 602 along the width direction 618. The width varies along the length direction 614 with a plurality of narrowest portions and a plurality of widest portions in an alternating fashion. The plurality of narrowest portions are located at the plurality of bonded locations 616. The plurality of widest portions are located between adjacent narrowest portions.

[0053] A peripheral border 612 is defined at a peripheral region of the filter layer 602. The peripheral border 612 is formed by bonding the first mesh 604 and the second mesh 606 together by a designed length without the recess 608 between the first mesh 604 and the second mesh 606. The peripheral border 612 can be used for the embedding of structural elements (e.g. steel wires).

[0054] Figure 7 A cross-sectional view of another filter plate 414 of the adsorption section 304 is shown. Figure 4 The filter plate 414 is mounted in the frame 402 along a vertical direction. The filter plate 414 includes a first filter layer 602 and a second filter layer 602. The first filter layer 602 and the second filter layer 602 are identical, other configurations are also possible. The second filter layer 602 is attached to the first filter layer 602 with the plurality of narrowest portions of the filter layer 602 aligned with the plurality of widest portions of the first filter layer 602 in the width direction 618. Thus, compared to the filter plate 414 with a single filter layer 602 in Figure 6 The filter plate 414 has a substantially uniform width along the length direction 614 compared to the filter plate 414 with a single filter layer 602 in Figure 7 The filter plate 414 of the adsorption section 304 reduces the possibility of the gas stream 122 bypassing the adsorbent 610.

[0055] Figure 8 A cross-sectional view of another filter plate 414 of the adsorption section 304 is shown. Figure 4 The filter plate 414 is mounted in the frame 402 along a horizontal direction. The filter plate 414 has a filter layer 602. The filter layer 602 includes a first mesh 604 and a second mesh 606 bonded together by a plurality of walls 802 disposed between the first mesh 604 and the second mesh 606. A plurality of recesses 608 are defined between the first mesh 604, the second mesh 606, and the plurality of walls 802. The plurality of walls 802 cause the filter layer 602 to have a substantially uniform width along the length direction 614. In Figure 8 In the embodiment shown, the plurality of walls 802 have a linear shape between the first mesh 604 and the second mesh 606 and are perpendicular to the first mesh 604 and the second mesh 606. In other embodiments, the plurality of walls 802 can have a non-linear shape between the first mesh 604 and the second mesh 606 and / or have an inclination angle with respect to the first mesh 604 and the second mesh 606, respectively.

[0056] Figure 9 A cross-sectional view of another filter plate 414 of the adsorption section 304 is shown. Figure 4 The filter plate 414 is mounted in the frame 402 along a vertical direction. The filter plate 414 has a filter layer 602. The filter layer 602 includes a plurality of pockets 608 between a first mesh 604 and a second mesh 606. Each pocket 608 of the plurality of pockets 608 is filled with an adsorbent 610. The gas stream 122 passes from the first mesh 604 through the adsorbent 610 to the second mesh 606.

[0057] The pocket 608 is partially filled with the adsorbent 610, which defines a cavity 902 within the pocket 608. When the adsorbent 610 has adsorbed water, the adsorbent 610 expands. The cavity 902 allows the adsorbent 610 to expand. The volume of the pocket 608 does not change with the volume change of the adsorbent 610. This feature brings benefits when the first mesh 604 and the second mesh 606 are made of a relatively hard material.

[0058] A portion of the pocket 608 is covered by a solid plate 904. The portion is a portion of the edge of the cavity 902 of the first mesh 604. The solid plate 904 blocks the gas stream 122 from flowing through the cavity 902 and forces the gas stream 122 to pass through the adsorbent 610. In Figure 9 In the illustrated embodiment, the solid plate 904 is mounted on an inner surface of the first mesh 604 that is inside the pocket 608. The solid plate 904 can be mounted on an outer surface of the first mesh 604 that is outside the pocket 608.

[0059] Figures 6 to 9 The filter plate 414 is shown mounted in the frame 402 along a vertical direction or a horizontal direction. In other embodiments, the filter plate 414 can be oriented in an inclined direction or any desired direction.

[0060] The plurality of pockets 608 forms a pattern on the filter plate 414. Figure 10 The plurality of pockets 608 is shown forming a horizontal pattern. Figure 11 The plurality of pockets 608 is shown forming a vertical pattern. Figure 12 The plurality of pockets 608 is shown forming a cross pattern. Figure 13 The plurality of pockets 608 is shown forming a herringbone pattern. Figure 14 The plurality of pockets 608 is shown forming a honeycomb pattern. Figure 15 The plurality of pockets 608 is shown forming an elongated honeycomb pattern. The pockets 608 can also form any other desired pattern.

[0061] Figure 16 A cross-sectional view of another filter plate 414 of the adsorption section 304 is shown. Figure 4a perspective view of an apparatus 1600 of the filter plates 414 of the adsorption section 304 of the filter 300. The apparatus 1600 includes a plurality of first rollers 1602 and a plurality of second rollers 1604. The plurality of first rollers 1602 are separated from each other and arranged adjacent to each other. The plurality of second rollers 1604 are separated from each other and arranged adjacent to each other.

[0062] Each first roller 1602 of the plurality of first rollers 1602 includes a first circumferential edge 1606 and a first circumferential area 1608 having a diameter smaller than the first circumferential edge 1606. The first circumferential area 1608 is located between the first circumferential areas 1608 of adjacent first rollers 1602. Each second roller 1604 of the plurality of second rollers 1604 includes a second circumferential edge 1610 and a second circumferential area 1612 having a diameter smaller than the second circumferential edge 1610. The second circumferential area 1612 is located between the second circumferential edges 1610 of adjacent second rollers 1604. The plurality of first rollers 1602 and the plurality of second rollers 1604 are positioned adjacent to each other such that each first circumferential edge 1606 is aligned with a respective second circumferential edge 1610 and each first circumferential area 1608 is aligned with a respective second circumferential area 1612. The plurality of first rollers 1602 and the plurality of second rollers 1604 are V-shaped rollers, other configurations are possible.

[0063] A plurality of tubes 1614 is positioned between the plurality of first rollers 1602 and the plurality of second rollers 1604. Each tube 1614 of the plurality of tubes 1614 is positioned at one first circumferential area 1608 of the plurality of first circumferential areas 1608 and at one second circumferential area 1612 of the plurality of second circumferential areas 1612.

[0064] A seal 1616 is positioned at a distance from the plurality of first rollers 1602 and the plurality of second rollers 1604. The seal 1616 can be any suitable sealing mechanical device for sealing the first web 604 and the second web 606.

[0065] During the manufacturing process, the first web 604 and the second web 606 are fed between the plurality of first rollers 1602 and the plurality of second rollers 1604. The plurality of first circumferential edges 1606 and the plurality of second circumferential edges 1610 join the first web 604 with the second web 606, thereby forming a plurality of first seal portions. A plurality of pockets 608 is formed between the first web 604, the second web 606, and the plurality of first seal portions. The adsorbent 610 is filled into the plurality of pockets 608 through the plurality of tubes 1614. When the pockets 608 reach a design length, the seal 1616 seals the first web 604 and the second web 606, thereby forming a second seal portion. The second seal portion is not parallel to the first seal portions. When the filter plate 414 reaches a design length, the filter plate 414 is cut.

[0066] Figure 17 an apparatus 1600 for manufacturingFigure 4 Perspective view of the device 1700 of the filter sheet 414 of the adsorption stage 304 of FIG. 1. The device 1700 includes a third roller 1702 and a fourth roller 1704 disposed a distance from the first roller 1602 and the second roller 1604. The third roller 1702 and the fourth roller 1704 are oriented perpendicular to the first roller 1602 and the second roller 1604. The tube 1614 is disposed between the third roller 1702 and the fourth roller 1704 and the first roller 1602 and the second roller 1604.

[0067] The third roller 1702 includes a third circumferential edge 1706. The fourth roller 1704 includes a fourth circumferential edge 1708. The third roller 1702 and the fourth roller 1704 are positioned adjacent to each other such that the third circumferential edge 1706 and the fourth circumferential edge 1708 are aligned with each other. The third roller 1702 and the fourth roller 1704 are V-shaped rollers, although other configurations are possible.

[0068] During manufacturing, a web 1710 is fed between the third roller 1702 and the fourth roller 1704. The web 1710 is folded by the third circumferential edge 1706 and the fourth circumferential edge 1708 into the first web 604 and the second web 606. The first roller 1602 and the second roller 1604 combine the first web 604 with the second web 606, thereby forming the first seal. The pocket 608 is formed between the first web 604, the second web 606, and the first seal. The adsorbent is filled into the pocket 608 through the tube 1614. When the pocket 608 reaches a design length, the seal 1616 seals the first web 604 and the second web 606, thereby forming the second seal. The second seal is not parallel to the first seal. When the filter sheet 414 reaches a design length, the filter sheet 414 is cut.

[0069] The device 1700 includes one first roller 1602 and one second roller 1604 to form a single pocket 608 in a row. The device 1700 can also have multiple first rollers 1602 and multiple second rollers 1604 to form multiple pockets 608 in a row.

[0070] During operation, the airflow 122 is drawn by the fan 114 through the louvers 118 into the housing 102 of the direct air capture unit 100. The airflow 122 is then drawn by the fan 114 into the plurality of frames 402 of the plurality of adsorption stages 304. The airflow 122 contacts the adsorbent 610 installed in the filter sheet 414 in the plurality of adsorption stages 304 to adsorb CO2. After adsorption, the airflow 122 is drawn by the fan 114 to exit the direct air capture unit 100 through the opening 112.

[0071] Each of the plurality of frames 402 allows the filter panel 414 to be easily installed inside the adsorption vessel 300 and quickly replaced when needed. During replacement, the filter panel 414 is removed from the frame 402 and a new filter panel 414 is installed into the frame 402, thereby reusing the frame 402. The quick replacement of the filter panel 414 reduces the downtime of the direct air capture unit 100 and reduces the installation time of a new or refurbished direct air capture unit 100. When the adsorption process is performed in some of the adsorption stages 304 or some of the adsorption vessels 300, the filter panels 414 in the remaining adsorption stages 304 or the remaining adsorption vessels 300 can be replaced.

[0072] The filter panel 414 is installed in the frame 402 with a wavy profile around the plurality of first rods 502 and the plurality of second rods 504, which allows more mass of the adsorbent 610 to be housed within the frame 402 and, at the same time, the filter panel 414 has a smaller thickness and a smaller pressure drop. For example, the thickness of the filter panel 414 is between 5 mm and 15 mm, the pressure drop through the filter panel 414 is between 100 Pa and 350 Pa, preferably between 100 Pa and 250 Pa, and the area of the filter panel 414 and the mass of the adsorbent 610 within the frame 402 are increased due to the wavy profile. In this way, based on the area and thickness of the filter panel 414, the electrical power required to operate the direct air capture unit 100 is reduced. The wavy profile of the filter panel 414 also allows a higher mass ratio of the adsorbent 610 to the frame 402, which reduces the thermal mass inside the frame 402. This allows more energy to be saved during the desorption process.

[0073] The design of the filter panel 414 allows the filter panel 414 to operate under harsh conditions and withstand media such as water, steam, CO2, ambient air, etc. during the cycle process. The cycle process can be repeated thousands of times per year, for example, more than 8000 cycles per year. The operating temperature of the filter panel 414 can be between -20°C and 100°C, and the absolute operating pressure can be between 0.02 bar and 1 bar.

[0074] During operation, the adsorbent 610 can be replaced in a shorter period of time, for example, every one to three years. The frame 402, the first mesh 604, and the second mesh 606 can be replaced in a longer period of time, for example, every twenty to twenty-five years.

[0075] The apparatus 1600 and the apparatus 1700 allow the filter panel 414 to be automatically and continuously filled with the adsorbent 610 and manufactured. Therefore, the production cost of the filter panel 414 is reduced.

[0076] While exemplary embodiments of the disclosure have been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements can be made to the disclosure without departing from the spirit and scope of the disclosure in its broadest form.

[0077] No description in the present application is to be interpreted as implying any particular element, step, action, or function is an essential element of the patentable subject matter claimed: the scope of patentable subject matter is defined only by the claims. Moreover, these claims are not intended to be limited to the scope of any such elements, but rather are intended to cover all changes and modifications that come within the scope and spirit of the claims.

Claims

1. An adsorption section (304), the adsorption section (304) comprising: a filter panel (414), the filter panel (414) comprising a filter layer (602), the filter layer (602) comprising: a first mesh (604) having a first thickness, the first mesh (604) defining a plurality of first flow channels through the first thickness, the plurality of first flow channels configured to allow a gas stream (122) to pass through; a second mesh (606) having a second thickness, the second mesh (606) defining a plurality of second flow channels through the second thickness, the plurality of second flow channels configured to allow the gas stream (122) to pass through, the second mesh (606) in combination with the first mesh (604) to define a plurality of pockets (608), each pocket (608) separated from the remaining pockets (608); an adsorbent (610) positioned in each pocket (608) and configured to adsorb carbon dioxide from the gas stream (122); and a frame (402), the filter panel (414) folded in the frame (402), wherein the frame (402) comprises: a first enclosed side (404), a second enclosed side (406) opposite the first enclosed side (404) in a width direction, a first open side (410), a second open side (412) opposite the first open side (410) in a length direction (612), wherein the filter panel (414) is installed in the length direction (612), the plurality of pockets (608) partially filled with the adsorbent (610), the adsorbent (610) defining a cavity (902) within each of the plurality of pockets (608).

2. The adsorption stage (304) according to claim 1, wherein a width of the filter layer (602) varies along a length direction (614) to define a plurality of narrowest portions and a plurality of widest portions, and wherein the filter panel (414) further comprises a second filter layer (602) attached to the filter layer (602), wherein the plurality of narrowest portions of the second filter layer (602) are aligned with the plurality of widest portions of the first filter layer (602).

3. The adsorption stage (304) according to claim 1 or 2, wherein the filter layer (602) comprises a plurality of walls (802) disposed between the first mesh (604) and the second mesh (606), thereby combining the first mesh (604) with the second mesh (606) and defining the plurality of pockets (608) and cavities (902).

4. The adsorption stage (304) according to any one of claims 1 to 3, wherein the plurality of pockets (608) form a pattern, and wherein the pattern is selected from a group comprising a horizontal pattern, a vertical pattern, a cross pattern, a herringbone pattern, a honeycomb pattern, and an elongated honeycomb pattern.

5. The adsorption stage (304) according to any one of claims 1 to 4, wherein Each pocket (608) contains an amount of adsorbent (610) configured to have a first volume when the adsorbent (610) is dry, wherein the adsorbent (610) is configured to have a second volume when the adsorbent (610) is wet, and wherein the second volume is greater than the first volume.

6. The adsorption stage (304) according to any one of claims 1 to 5, wherein The first mesh and the second mesh are made of stretchable material to allow the volume of the pockets (608) to change.

7. The adsorption stage (304) according to any one of claims 1 to 6, wherein A portion of each pocket (608) of the plurality of pockets (608) is covered by a solid plate (904) configured to prevent the airflow (122) from entering the cavity (902).

8. The adsorption stage (304) according to any one of claims 1 to 7, wherein The filter layer (602) comprises a peripheral border (612) formed by firmly joining peripheral areas of the first mesh (604) and the second mesh (606).

9. The adsorption stage (304) according to any one of claims 1 to 8, wherein The frame (402) comprises: a plurality of first bars (502) disposed at the first open side (410) between the first closed side (404) and the second closed side (406), a plurality of second bars (504) disposed at the second open side (412) between the first closed side (404) and the second closed side (406), wherein the filter plate (414) is a single continuous plate and is alternately folded over the plurality of first bars (502) and the plurality of second bars (504) forming a wavy profile.

10. The adsorption stage (304) according to claim 9, wherein The plurality of first bars (502) and the plurality of second bars (504) are offset from each other along the first open side (410) and the second open side (412).

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