Direct air capture (DAC) demonstrator system improved serviceability

Abstract

A lift system for use with a direct air carbon capture unit includes, a plurality of track segments defining a segmented ring, a hoist supported by and translatable around the segmented ring, a frame of a direct air carbon capture unit attached to the plurality of track segments, where the lift system is arranged within the direct air carbon capture unit and above a plurality of contactors and the lift system can translate to any one of the plurality of contactors along the segmented ring, where the lift system can operate while at least one of the plurality of contactors is in the desorption cycle and or at least one of the plurality of contactors is in the absorption cycle.

Description

Docket No. 2023PF12273 DIRECT AIR CAPTURE (DAC) DEMONSTRATOR SYSTEM IMPROVED SERVICEABILITY CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of US provisional application number 63 / 528,558 filed on July 24, 2023. BACKGROUND

[0002] Removing CO2from the atmosphere, commonly referred to as carbon capture or direct air carbon capture (DAC) has been implemented on small and industrial scales. The economics of carbon capture are driven by the energy costs of the processes used and the filter or sorbent material used in the carbon capture process. Two of the main methods of DAC are liquid and solid sorbent DAC. Solid sorbents, such as a solid base material coated with a liquid amine solution(s). The base material and liquid amine coating can optionally be bonded together. Amine formulations can be produced to coat beads or spheres of plastic, polymer, or other suitable material. Some of the issues involved in the use of amine coated or impregnated sorbent material is the service life of the filter material or sorbent due to degradation of the amine material. The present invention provides a cost-effective and energy-effective way of continuously operating a direct air capture (DAC) apparatus using a solid sorbent.

[0003] Different methods of capturing CO2from the atmosphere or air streams are available, but the method of direct air capture by use of a solid sorbent in a direct air capture unit or other suitable sorbent configuration is discussed in detail below.

[0004] Typical DAC methods involve flowing atmosphere across a sorbent filter media typically referred to simply as a "filter" in an absorption cycle. The filter is contained within a sealable container typically referred to as an air contactor or simply a contactor, as the filter contacts the air flow of atmosphere within the “contactor.” Once sorbent filter media has reached a designated level of absorption, typically between 50 and maximum absorption for the sorbent media, a desorption cycle is initiated. The desorption of a solid sorbent currently requires a temperature swing or vacuum swing to release the captured CO2from the sorbent media. Temperature swing desorption uses a heat source and a heated working fluid. Any number of known industrial methods of heating can be used, including but not limited to resistive heating of the working fluid. Heating of the working fluid generally represents the majority of the energyDocket No. 2023PF12273 required by the desorption cycle. Prior to introducing the heated working fluid within the contactor during the desorption cycle, a vacuum is required within the contactor to remove the atmosphere or air within the contactor to lower the level of Oxygen. Current amine and other solid sorbent materials deteriorate when exposed to Oxygen and the rate of degeneration is increased with the temperature of the sorbent. Typically, sorbent medias designed for DAC units utilizing atmospheric air flows, ~21% O2at ambient temperature ranges, and are designed to last a service interval that is based on atmospheric / ambient conditions. The service life of the sorbent filter is determined by the amount of degradation that occurs in every absorption and desorption cycle. Service life can be increased by limiting the temperature and the amount of O2 that the sorbent media is exposed to during each absorption and desorption cycles. Current methods of desorption can use steam as the working fluid. When steam is used as the working fluid, the contactor is a sealable pressure vessel that needs to resist collapsing under a vacuum and the pressures generated by the steam, which may be superheated. The structural requirements of a contactor used with steam as the working fluid are significant and generally required the use of corrosion resistant materials with sufficient material properties for the particular application, such as stainless steel. Even with the use of metals such as stainless steel or similar metals contactors have significant structural requirements that translates into a significant volume / mass of material which needs to be heated up with the filters to bring the filters to the desired desorption temperature, the inverse is also true, the contactor will need to be cooled back to the desired absorption temperature for a particular application. The thermal mass of the contactor and sorbent media is directly related to the amount of energy required for the desorption cycle of a DAC-unit.

[0005] One process for capturing CO2from ambient air uses a solid sorbent that is manufactured as a solid bead or sphere that is coated with a sorbent material, such as an amine. The solid sorbent can absorb CO2molecules via reactions with amine groups coating the bead or other suitable configuration known in the art. During adsorption, air or atmosphere needs to be circulated around the sorbent to facilitate the removal or absorption of CO2 from the air that is circulated across or around the solid sorbent. During desorption or the process of removing the absorbed CO2 from the sorbent, the sorbent needs to be pneumatically sealed in a container so that the CO2released from the sorbent can be isolated and collected. To desorb the CO2from the sorbent, the contactor acts as a pressure vessel, the contactor is pneumatically sealed and the pressure within the contactor is reduced to create a partial vacuum. As discussed above, theDocket No. 2023PF12273 sorbent material will decompose in the presence of Oxygen and the rate of decomposition is increased by the temperature of the sorbent, this issue is typically addressed by reducing the amount of Oxygen in contact with the sorbent during the desorption cycle. The latter can be done by purging the contactor with another medium and / or lowering the absolute pressure in the contactor. Typically, steam is used for both purging and heating of the sorbent. After O2and or CO2levels have been reduced within the contactor, the contactor is then purged or filled with steam, which raises the temperature of the sorbent and the structure of the contactor. At the start of the desorption cycle, the air pressure in the contactor is lowered by use of a vacuum pump, thereby lowering the amount of air and or Oxygen that is mixed with the CO2 produced or separated from the sorbent during the desorption process of the DAC-unit.

[0006] The current challenges of configurations of sorbent filters designed for use with a solid amine loaded sorbent are the significant amount of heat and electricity demand required to operate both the adsorption and desorption phases. As discussed above steam can be used to heat the contactor, a DAC-unit that minimizes the amount of heat and or electricity required for operation is desirable. In order to minimize heat and or electrical requirements of a DAC-unit, a low thermal mass and enclosed volume reduces the amount of energy needed for heating the contactor and sorbent media, reduces the amount of work required by a vacuum pump during desorption, and lowers the pressure drop through the sorbent filter which reduces the flow rate requirements of the fans used during the adsorption cycle to circulate air around the sorbent.

[0007] Current DAC-units pressurize the contactor and other components of the system to pressures well above atmospheric pressure. Thermodynamic constraints of converting water into steam at pressures above atmospheric, such as boiling water in a stove or super heating steam requires significant amounts of energy or heat to overcome the latent heat of vaporization of water. As discussed above, heating of the sorbent during the desorption cycle represents the majority of energy required to capture atmospheric carbon with a solid sorbent using a temperature swing. Current DAC-units do not attempt to perform the temperature swing required by the desorption cycle at sub-atmospheric pressures or under vacuum due to the increased technical difficulties required by a system that conducts the desorption cycle under vacuum or at sub-atmospheric pressures.

[0008] One of the technical difficulties created by performing the temperature swing under vacuum is the temperatures and pressures required to condense sub-atmospheric steam. Condensing steam at sub-atmospheric pressures, particularly in volumes or mass flow ratesDocket No. 2023PF12273 greater than what can be accomplish at laboratory scale is generally limited by the operation of the condenser used to cool the steam back into water. More particularly, the heat exchange fluid used to remove heat from the sub-atmospheric steam needs to be at a temperature significantly below the phase change temperature of steam at the operating pressure of the DAC-unit. In a sub-atmospheric DAC, as steam condenses to water, the pressure drops (increases the amount of vacuum in a sub-atmospheric DAC-unit due to the decrease in volume of steam), and so does the temperature required for the phase change of steam into water. As pressure within the DAC-unit approaches 0.05bar(a), the phase change temperature of water approaches 30C. For a DAC-unit to operate the desorption cycle under vacuum, for example at 0.05bar(a), the temperature required to convert steam into water is ~30°C. In order to effectively condense all of the steam in the DAC-unit, the heat exchange fluid must be at a significantly lower temperature than the steam. For sub-atmospheric DAC units, this temperature is typically at our below ambient conditions, requiring uneconomical and / or inefficient heat rejection cycles that utilize refrigerant based heat exchangers or chillers to maintain operating temperatures. Conventional heat exchangers or condensers are designed to operate at or above atmospheric pressure with water or other refrigerant acting as the heat exchange fluid. Condensation can be supplemented by the use of mechanical steam compressors but similar to conventional heat exchangers, these are designed to operate at pressures above atmospheric.

[0009] The desorption cycle is typically conducted after a vacuum cycle or purge of the contactor to reduce or eliminate the amount of Oxygen exposed to the sorbent material to reduce degradation or decomposition. Conventional vacuum pumps are not designed with vapor tolerances compatible with temperatures at or below 30C. Specifically, conventional vacuum pumps are not compatible with sub-atmospheric steam due to the inherent amount of water vaper and the temperatures at which sub-atmospheric steam exits. BRIEF SUMMARY

[0010] It is therefore a goal of the present invention to provide a carbon capture system that overcomes the above-mentioned disadvantage(s). In particular, a carbon capture system that integrates a lift system within the carbon capture system that allows for replacement and servicing of the sorbent filters or contactors while the carbon capture system is in operation.

[0011] The object of the invention is achieved by, a system for continuous operation of a direct air carbon capture unit for use with a solid sorbent includes, a plurality of supportsDocket No. 2023PF12273 arranged on a base structure, a plurality of segments arranged in an array defined by the base structure, the plurality of supports, and an interlocking structure, a plurality of contactors individually arranged within the plurality of segments, a sealing system configured to translate to each of the plurality of contactors as defined by the array, at least one of the plurality of sorbent filters are within one of the plurality of contactors, a desorption cycle initiated within any one of the plurality of contactors that is sealed by the sealing system as defined by an operating sequence of the system, a lift system integrated within the carbon capture system and configured to translate to any of the plurality of contactors.

[0012] In one embodiment the system for continuous operation may also include where an absorption cycle occurs in any one of the plurality of contactors not in the desorption cycle. This advantageously decreases operating cost as the carbon capture system can operate concurrently with routine maintenance and the absorption cycle(s) of the other contactors.

[0013] In one embodiment the system for continuous operation may also include where anyone of the plurality of sorbent filters within each of the plurality of contactors can be lifted or removed by the lift system. This advantageously allows for cost and time savings by only removing the sorbent filters and not the entire contactor during maintenance.

[0014] In one embodiment the system for continuous operation may also include where the lift system further comprises a hoist configured to lift any one of the plurality of contactors or sorbent filters within the direct air carbon capture unit. This advantageously reduces the complexity of rigging or securing the contactor or sorbent filter during maintenance as the hoist is a permeant part of the lift system.

[0015] In one embodiment the system for continuous operation may also include where the lift system further comprises a lift arm configured to lift any one of the plurality of contactors or sorbent filters within the direct air carbon capture unit. This advantageously reduces the complexity of rigging or securing the contactor or sorbent filter during maintenance as the lift arm is a permeant part of the lift system.

[0016] In one embodiment the system for continuous operation may also include where the lift system further comprises a lift track configured to translate over any one of the plurality of contactors. This advantageously allows for reduced maintenance time when translating the lift system from one contactor to another.

[0017] In one embodiment the system for continuous operation may also include where the lift system can operate while at least one of the plurality of contactors is in the desorption cycleDocket No. 2023PF12273 and or at least one of the plurality of contactors is in the absorption cycle. This advantageously achieves a goal of the invention by reducing operating costs, complete shutdowns are not necessary for routine maintenance, allowing for continuous operation of the carbon capture system.

[0018] In one embodiment, a lift system for use with a direct air carbon capture unit includes, a plurality of track segments defining a segmented ring, a hoist supported by and translatable around the segmented ring via a lift track, a frame of a direct air carbon capture unit attached to the plurality of track segments, where the lift system is arranged within the direct air carbon capture unit and above a plurality of contactors and the lift system can translate to any one of the plurality of contactors along the segmented ring. The lift system can advantageously lift or remove anyone of the plurality of contactors or a sorbent filter within anyone of the plurality of contactors.

[0019] In one embodiment, a method of using a lift system within a carbon capture system includes the steps, removing any one of the side walls of the carbon capture system, translating the integrated lift system to a location above a contactor selected for replacement, attaching the sorbent filter within the contactor to the integrated lift system, if necessary decoupling the sorbent filter from the contactor, lifting the sorbent filter out of the contactor via the integrated lift system, translating the sorbent filter to the location of the removed side wall, transferring the sorbent filter to an exterior lifting apparatus, removing the sorbent filter from the carbon capture system, transferring a new sorbent filter to the integrated lift system via the external lifting apparatus located near the location of the removed side wall, translating the new sorbent filter to an empty contactor, lowering the new sorbent filter into the empty contactor, attaching the sorbent filter to the contactor, where the method can be repeated for any additional sorbent filters requiring replacement or the side wall can be reinstalled. The lift system can advantageously lift or remove anyone of the plurality of contactors or a sorbent filter within anyone of the plurality of contactors.

[0020] In one embodiment the method of using a lift system within a carbon capture system may also include where the lift system further comprises a hoist configured to lift any one of the contactors within the carbon capture system. The lift system can advantageously lift or remove anyone of the plurality of contactors or a sorbent filter within anyone of the plurality of contactors.Docket No. 2023PF12273

[0021] In one embodiment the method of using a lift system within a carbon capture system may also include where the lift system further comprises a lift arm configured to lift any one of the contactors within the carbon capture system. The lift system can advantageously lift or remove anyone of the plurality of contactors or a sorbent filter within anyone of the plurality of contactors.

[0022] In one embodiment the method of using a lift system within a carbon capture system may also include where the lift system further comprises a lift track configured to translate over any one of the plurality of contactors.

[0023] In one embodiment the method of using a lift system within a carbon capture system may also include where the lift system can operate while at least one of the plurality of contactors is in the desorption cycle and or at least one of the plurality of contactors is in the absorption cycle.

[0024] In one embodiment a lift system within a carbon capture system may also include where the sorbent filter and the contactor are configured to be removable as an assembly.

[0025] Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0026] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0027] FIG. 1 illustrates a DAC-system in accordance with an embodiment of the present invention.

[0028] FIG. 2 illustrates a DAC-system in accordance with one embodiment.

[0029] FIG. 3 illustrates a continuous DAC-system in accordance with one embodiment.

[0030] FIG. 4A is an enlargement of a section of the embodiment of FIG. 3 with attachment structures removed.

[0031] FIG. 4B is an enlargement of a section of the embodiment of FIG. 3.

[0032] FIG. 5 is a view in cross section of the embodiment of FIG. 3.

[0033] FIG. 6A is an embodiment of a lift system for use with an embodiment.

[0034] FIG. 6B is another view of the lift system of FIG. 6A.Docket No. 2023PF12273

[0035] FIG. 7 is another embodiment of a DAC-system with an integrated hoist. DETAILED DESCRIPTION

[0036] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in this description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of 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 should not be regarded as limiting.

[0037] Various technologies that pertain to apparatus and methods will now be described with reference to the drawings, where like reference numerals represent 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 may be implemented in any suitably arranged apparatus.

[0038] It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0039] 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,” as well as derivatives thereof, mean inclusion without limitation. The singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, the term “and / or” as 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 well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.Docket No. 2023PF12273 Furthermore, while multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc. described with regard to one embodiment are equally applicable to other embodiments absent a specific statement to the contrary.

[0040] Also, although the terms "first", "second", "third" and so forth may be used herein to refer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

[0041] Also, unless specified or limited otherwise, the terms “mounted”, “connected”, “supported”, and “coupled” and variations thereof are used broadly and encompass direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

[0042] In addition, the term "adjacent to" may mean: that an element is relatively near to but not in contact with a further element; or that the element is in contact with the further portion, unless the context clearly indicates otherwise. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms “about” or “substantially” or like terms are intended to cover variations in a value that are within normal industry manufacturing tolerances for that dimension. If no industry standard as available a variation of 20 percent would fall within the meaning of these terms unless otherwise stated.

[0043] FIG. 1 is an elevated view of an embodiment of a carbon capture system 200 that includes a frame 110 assembled on a base 104 and configured to be sealed such that the carbon capture system 200 has an inlet 102 and an outlet 108 for an air flow 206. The inlet 102 and outlet 108 are positioned for this particular embodiment but a person skilled in the art will know that the direction of flow or other design choices would require reversal or repositioning of the inlet 102 and or outlet 108.

[0044] Figure 2 is a schematic view of an embodiment of a DAC-system or carbon capture system 200 in accordance with an embodiment of the invention. The carbon capture system 200 is designed to capture CO2 from a flow of atmospheric air or air flow 206 that is directed from the inlet 102 through an air contactor or contactor 202. The contactor 202 is a pressure vesselDocket No. 2023PF12273 that is configured to receive a first flow or air flow 206 and a second flow or steam flow 208. The carbon capture system 200 requires several cycles to extract pure or high concentration CO2 gas from the air flow 206, cycles including an absorption, desorption, cooling and a collection cycle and other necessary cycles to complete the process of the DAC-system. The carbon capture system 200 includes a variety of lines or piping, valves 218 and pumps 214 typically required of a filtration / circulation system involving two or more fluid flows. Depending on the application the valves 218 can be one way, two-way, three-way or whatever configuration is required by a particular application, as practiced in the art. The carbon capture system 200 includes a pressure vessel or contactor 202 which is configured to hold a sorbent filter assembly 706 that is designed to absorb CO2 when exposed to the air flow 206. Generally, a fan, which can be configured as part of the inlet 102, is used to push the air flow 206 through the contactor 202 and sorbent filter during the absorption cycle of the carbon capture system 200. In an embodiment, a blower or other known method or device can be configured as part of the outlet 108 and used to pull the air flow 206 through the contactor 202 and sorbent filter during the absorption cycle of the carbon capture system 200. In an embodiment, the contactor 202 can be substantially cylindrical or barrel shaped with open ends that allow fluid flow through the contactor 202. During the absorption cycle the valves 218 that control the second flow or steam flow 208 are in the closed position and the air flow 206 enters one end of the contactor 202 and exits the other end. Prior to and during the absorption cycle the contactor 202 is at or near ambient temperature, rather the same or near the temperature of the incoming air flow 206. Once the air flow 206 has been passed through the contactor 202 it is discharged from the carbon capture system 200 via an exhaust or outlet 108. The positioning of the inlet 102, outlet 108, and valves 218 in figures 1 and 2 is for clarity and a person skilled in the art would know that other configurations are possible.

[0045] At a predetermined point, which can be determined by absorption time, the capacity of the sorbent filter, or any other limitation of the carbon capture system 200, the carbon capture system 200 enters a desorption cycle. The carbon capture system 200 can include a single or several contactors 202 arranged in a sequence or array to allow for continuous operation of the carbon capture system 200. As seen in Figure 4, the carbon capture system 200 can be arranged around a central axis with the arrangement of contactors 202 evenly distributed around a central axis 402. During the desorption cycle, one or a group of contactors 202 are pneumatically sealed and a vacuum can be initiated within the contactor 202 to extract theDocket No. 2023PF12273 remaining air within the contactor 202 from the absorption cycle. Alternatively, or in addition, the contactor 202 can be purged with the steam flow 208 prior to the desorption cycle and the heating of the contactor 202.

[0046] During the desorption cycle the steam flow 208 passes through the contactor 202. Once the steam flow 208 has been discharged from the contactor 202 a collection cycle begins by cooling the steam flow 208. The combined flow 308 of steam, water vapor, and released CO2gas enters a heat exchanger 300. The heat exchanger 300 can be a single pass or multi pass heat exchanger as well as a series of sequential heat exchangers. The heat exchanger 300 cools thesteam flow 208 until the steam condenses into water which separates the CO2 gas released bythe sorbent material. The CO2 gas is discharged into a containment vessel 212 for storage of the CO2 by the operation of pump 214 and valve 218, which can be located upstream or downstream of the containment vessel 212 or both. The containment vessel 212 in FIG. 2 is shown for clarity and a person skilled in the art would know that the CO2 gas can be directed to another process, such as a compressor. A flow of condensate water can be returned to the steam generator 204 or a sequential heat exchanger 300, via drain 216.

[0047] Referring to FIG. 2 and FIG. 5, the desorption cycle is completed once the steam flow 208 has circulated through the contactor 202 and sorbent filter for a predetermined amount of time or the sorbent filter has reached a predetermined temperature. The valves 218 that control the steam flow 208 are closed and the contactor 202 is allowed to cool or return to ambient temperature. Any residual water that remains or forms within the contactor during the cooling cycle exits the contactor 202 via drain 216 to limit or prevent contact between the water and the sorbent filter media. Once the contactor 202 has reached a predetermined temperature, the end caps 602 are removed from the desorbed contactor 202 and the absorption cycle for the contactor 202 can begin again. The end caps 602 are moved to another contactor 202 within the carbon capture system 200 according to a predetermined sequence or service schedule, to begin another desorption cycle of the continuous operation of the carbon capture system 200.

[0048] FIG. 3 is an embodiment of a carbon capture system 200 that includes a lower support ring 414 attached to a base 104. In this embodiment the lower support ring 414 supports a plurality of segmented sections 406, each of which contains a contactor 202. The lower support ring 414 is configured to create a ring of segmented sections and contactors 202, which in this embodiment is made up of six segments containing a single contactor 202 but other embodiments can include additional segments or increased number of contactors 202 perDocket No. 2023PF12273 segment. Additionally, the shape of the carbon capture system 200 is not limited to a ring or circular design, any shape that can be configured around a central axis 402 can be used. The frame 110 includes an upper support ring 416 and a lower support ring 414 attached to the vertical supports 412. A series of track segments 406 are attached to the upper support ring 416 and lower support ring 414 completing an upper track 418 and a lower track 420 respectively. An upper swingarm 408 is configured to revolve around the upper track 418, similarly a lower swingarm 410 is configured to revolve around the lower track 420. The upper swingarm 408 is supported by the track segments 406 that complete the upper track 418 and is configured to translate around central axis 402 on the path defined by the upper track 418. Similarly, the lower swingarm 410 is supported by the track segments 406 that complete the lower track 420 and is configured to translate around the central axis 402 on the path defined by the lower track 420. The upper swingarm 408 and lower swingarm 410 can be configured to move in unison or independently to any particular segmented section and the contactor(s) 202 contained within the segment. The upper swingarm 408 and lower swingarm 410 can be supported by a central hub 422 located at the center of the frame 110 of the carbon capture system 200. The upper swingarm 408 and lower swingarm 410 are part of a sealing system that allows for the pressurization of at least one contactor 202. Additionally, the sealing system allows for the reduction of pressure, sub-atmospheric pressures, within the contactor 202 during at least the desorption process.

[0049] As seen in FIG. 4A and 4B, an enlargement of a portion of one segmented section of the frame 110 can be seen, this particular enlargement shows a portion of the lower support ring 414 and a portion of a track segment 406. The radial slots 508 in the vertical portion of the lower support ring 414 are spaced to correspond with the alignment slots 506 in the horizontal portion of the lower support ring 414. The lower support ring 414 is configured with a series of ribs or gussets 510 that attach the vertical and horizontal portions of the lower support ring 414. The track segment 406 is attached to the lower support ring 414 with a series of attachment structures 404 which in this embodiment are a bar and clip combination. This configuration allows for the track segments 406 to be supported by or hung from the lower support ring 414. The radial slots 508 and alignment slots 506 are configured to allow for movement or alignment of the track segments 406 with sufficient tolerancing that allows for standard or minimal tolerancing of the individual track segments 406.Docket No. 2023PF12273

[0050] Similarly, the upper support ring 416 is configured with radial slots 508 and alignment slot 506 to allow for the installation and alignment of the track segments 406. Track segments 406 attached to the upper support ring 416 and rest on the horizontal section of the upper support ring 416. The configuration of the radial slots 508 and alignment slots 506 allows for the track segments 406 to be interchangeable between the upper and lower tracks. The upper support ring 416 and lower support ring 414 are aligned and attached to each other by a series of vertical supports 350.

[0051] In one embodiment seen in FIG. 5, a system for continuous operation 400 is facilitated by arrangement of a series of contactors 202 arranged around a central hub 422 and an upper swingarm 408 and lower swingarm 410, all of which are part of the sealing system, facilitates the desorption of one or multiple contactors 202 in a defined sequence, for example a continuous loop around the central hub 422. When a contactor 202 enters the desorption cycle, both of the ends of the contactor 202 are pneumatically sealed with end caps 602. The contactor 202 is substantially cylindrical in shape and has an upper flange and lower flange, each configured to mate with a main flange of an end cap 602. A seal is installed between the contactor 202 and end cap 602, in this embodiment the seal is an o-ring that is installed in an o- ring groove between the upper or lower flange of the contactor 202 and an end cap 602. A person skilled in the art will know that other methods of sealing between the contactor 202 and end cap 602 are possible, such as gaskets, tapered interfaces and v-band configurations. The upper swingarm 408 and lower swingarm 410 each have a series of actuators 612 that moves the end cap 602 towards or away from the contactor 202. In an embodiment, the actuator 612 is limited to movement in the vertical direction, along the axial length of the central axis 402. The end cap 602 is attached to the piping at the orifice 606 via flange 610 via conventional methods, such as mechanical bolting. The actuators 612 move the end cap 602 and piping toward the contactor 202 in unison or independently with only requiring sealing between the contactor 202 and end caps 602 to complete the fluid circuit. The actuator 612 is able to move or press the end cap 602 against the contactor 202 with sufficient contact pressure to create a pneumatic seal. The interface between the contactor 202 and end cap 602 can have alignment features that center the end cap 602 on the contactor 202. The piping 604 rotates with the swing arms 408 and 410 and may have additional connections that are necessary to facilitate translation to another contactor 202 within the carbon capture system 200.Docket No. 2023PF12273

[0052] The carbon capture system 200 operates continuously by having multiple segmented sections undergoing the various cycles of the DAC-system simultaneously. The carbon capture system 200 can be enclosed with exterior paneling or side walls 106 to allow for pre-filtration of the air flow 206 prior to entering the contactors 202. The direction of air flow 206 is dependent on the design requirement of the carbon capture system 200 but in this embodiment the air flow 206 enters from the bottom of the frame 110 near the base 104 via the inlets 102. Any segmented section 406 or the contactors 202 contained within can undergo the desorption cycle by rotating the upper swingarm 408 and lower swingarms 410 in position over the contactors 202. Once in position the actuators 612 move the end caps 602 toward the contactor 202 and create a pneumatic seal with the aid of a sealing feature, in this embodiment an O-ring. The steam pipes 604 are configured to rotate around the central hub 422 with the swingarms 408 and 410 and sealing the contactor 202 with the end caps 602 is all that is required to complete the steam flow 208 circuit. Once sealed the contactor 202 can be evacuated with a vacuum pump or steam injector that is placed in fluid communication with the contactor 202 via the valves 218. The steam flow 208 enters the contactor 202, once the CO2has been released from the sorbent filter 706, the condensation system 300 is place in fluid communication with the contactor 202 and the combined flow 308 of steam and CO2 is drawn into the condensation tanks 314 by the use of water injectors 304. A person skilled in the art will know that a conventional heat exchanger can be used in place of the condensation system 300. Once the combined flow 308 has been evacuated from the contactor 202, the cooling cycle of the sorbent filter 706 and contactor 202 begins. The end caps 602 can remain in place during the cooling cycle to prevent or limit the exposure of the sorbent filter 706 to Oxygen at elevated temperatures. Once the sorbent filter 706 and contactor 202 have reached a designated temperature or a predetermined time interval has elapsed, the actuators 612 of the upper swingarm 408 and lower swingarm 410 retract the end caps 602 and the swingarms rotate to another contactor 202. In one embodiment the sequence of the desorption cycle of the contactors 202 follows the radial order of the segmented sections, but other sequences are possible. Once at another contactor 202, the end caps 602 can seal the next contactor 202 and begin the desorption cycle for that particular contactor 202. The absorption cycle for the rest of the contactors 202 is simultaneously and continuously occurring during the desorption cycle of any contactor 202. Advantageously, the air flow 206 will inherently cool the frame 110 and the attached contactors 202 to the temperature of the air flow 206, specifically ambient temperature, which in turn will actively cool a contactor 202 that is in the cooling cycle.Docket No. 2023PF12273 Additionally, heat sinks such as fins can be added to the exterior of the contactor 202 to take advantage of the surrounding air flow 206 and accelerate the cooling cycle of the contactor 202.

[0053] The continuous operation of the carbon capture system 200 is facilitated by the radial sequence of the segmented sections which allows for the simultaneous occurrence of absorption cycles and desorption / cooling cycles. The embodiment of FIG. 3 includes one set of upper swingarm 408 and lower swingarm 410 but multiple swingarms are possible to maximize the output of the carbon capture system 200. For example, a “Y” shaped swing arm array that can service three segmented sections at once and can be switched between absorption and desorption of all six segments of the embodiment seen in FIG. 3 with only one radial movement.

[0054] In another embodiment of the present invention seen in FIG. 6A and FIG. 6B, a lift system 700 is attached to the top of the frame 110 of the carbon capture system 200. The lift system 700 uses a series of track segments configured to form a lift track 708 that is designed to position a hoist 702 over the contactors 202 of the carbon capture system 200. In this embodiment the lift track 708 is a circular track or ring that positions the hoist 702 above the central axis of the cylindrical contactors 202. The lift track 708 can be attached to the top of the frame 110 in a similar manner as the upper track 418 and lower track 420 used to support the upper swingarm 408 and lower swingarm 410 respectively. The hoist 702 can be translated around the lift track 708 to the central axis of any particular contactor 202. The contactors 202 are configured to hold a sorbent filter 706 inside of the contactor 202. The contactors 202 are cylindrical in shape with a central axis, when installed the sorbent filter 706 is sealed between the inner cavity of the contactor 202 and the support structure of the sorbent filter 706. The sorbent filter 706 can be installed or removed from the contactor 202 by the hoist 702 as seen in the arrows 704. The operation of the carbon capture system 200 can continue while any particular contactor 202 has its sorbent filter 706 removed and replaced.

[0055] The lift system 700 is independent of the upper swingarm 408 and lower swingarm 410, allowing for separate segmented sections and the contactors 202 within being serviced by the lift system 700 to accommodate the operating sequence of the carbon capture system 200. In one embodiment, the operating sequence is predetermined to stagger or schedule the replacement of the sorbent filter 706 on a maintenance interval that minimizes the amount of time a segmented section or the contactors 202 within are not available for operation.Docket No. 2023PF12273 Regardless, the operation of the carbon capture system 200 can continue with any number of segmented sections or contactors 202 undergoing maintenance, such as replacement of the sorbent filter 706 or seals. Once lifted out of a contactor 202, the sorbent filter 706 can be removed from the carbon capture system 200 as an assembly and a replacement sorbent filter 706 can be installed immediately. The sorbent filter 706 can be removed from the carbon capture system 200 by any known method, such as via a forklift, hoist, crane or other known method. The sorbent filter 706 can be refurbished outside of the carbon capture system 200.

[0056] An embodiment seen in FIG. 7, has a lift arm 802 attached to the upper portion of the frame 110. The lift arm 802 can be located at the center of the frame 110 or at any location that allows the lift arm 802 to reach and service the individual contactors 202, such as removal and replacement of the sorbent filter 706. The lift arm 802 can be fixed at a central location or movable, such as being mounted on a track system. The lift arm 802 can be configured to extend outside of the carbon capture system 200 to facilitate maintenance, such as being able to place used sorbent filter 706 outside of the carbon capture systems 200 and picking up the replacement sorbent filter 706 without the need of an intermediary step or additional equipment.

[0057] Although various embodiments that incorporate disclosed concepts have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these disclosed concepts. Disclosed embodiments are not limited to the specific details of construction and the arrangement of components set forth in the description or illustrated in the drawings. Disclosed concepts may be implemented by other implementations, and of being practiced or of being carried out in various ways, which now would become apparent to one skilled in the art.

[0058] None of the description in the present application should be read as implying that any particular element, step, act, or function is an essential element, which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke a means plus function claim construction unless the exact words "means for" are followed by a participle.

Claims

Docket No. 2023PF12273 CLAIMS What is claimed is:

1. A system for continuous operation (400) of a direct air carbon capture unit (200) for use with a plurality of sorbent filters (706) comprising, a plurality of supports (412) arranged on a base structure (104), a plurality of segments (406) arranged in an array defined by the base structure (418, 420), the plurality of supports (412), and an interlocking structure (414, 416), a plurality of contactors (202) individually arranged within the plurality of segments (406), a sealing system (408,410) configured to translate to each of the plurality of contactors (202) as defined by the array, at least one of the plurality of sorbent filters (706) are within one of the plurality of contactors (202), a desorption cycle initiated within any one of the plurality of contactors (202) that is sealed by the sealing system (408, 410) as defined by an operating sequence of the system, a lift system (700) integrated within the carbon capture system (200) and configured to translate to any of the plurality of contactors (202).

2. The system for continuous operation (400) of claim 1 wherein an absorption cycle occurs in any one of the plurality of contactors (202) not in the desorption cycle.

3. The system for continuous operation (400) of any of the preceding claims, wherein the lift system (700) is configured to lift or remove any one of the plurality of contactors (202) within the direct air carbon capture unit (200).

4. The system of continuous operation (400) of any of the preceding claims, wherein anyone of the plurality of sorbent filters (706) within each of the plurality of contactors (202) can be lifted or removed by the lift system (700).

5. The system for continuous operation (400) of any of the preceding claims, wherein the lift system (700) further comprises a hoist (702) configured to lift any one of the plurality of contactors (202) or sorbent filters (706) within the direct air carbon capture unit (200).Docket No. 2023PF12273 6. The system for continuous operation (400) of any of the preceding claims, wherein the lift system (700) further comprises a lift arm (802) configured to lift any one of the plurality of contactors (202) or sorbent filters (706) within the direct air carbon capture unit (200).

7. The system for continuous operation (400) of any of the preceding claims, wherein the lift system (700) further comprises a lift track (708) configured to translate over any one of the plurality of contactors (202).

8. The system for continuous operation (400) of any of the preceding claims, wherein the lift system (700) can operate while at least one of the plurality of contactors (202) is in the desorption cycle and or at least one of the plurality of contactors (202) is in the absorption cycle.

9. A lift system (700) for use with a direct air carbon capture unit (200) comprising, a plurality of track segments (406) defining a segmented ring (418, 420), a hoist (702) supported by and translatable around the segmented ring (418, 420) via a lift track (708), a frame (110) of a direct air carbon capture unit (200) attached to the plurality of track segments (406), wherein the lift system (700) is arranged within the direct air carbon capture unit (200) and above a plurality of contactors (202) and the lift system (700) can translate to any one of the plurality of contactors (202) along the segmented ring (418, 420).

10. The lift system (700) of claim 9 wherein the lift system (700) can operate while at least one of the plurality of contactors (202) is in the desorption cycle and or at least one of the plurality of contactors (202) is in the absorption cycle.

11. A method of using a lift system (700) within a carbon capture system (200) comprises the steps, removing any one of the side walls (106) of the carbon capture system (200), translating the integrated lift system (700) to a location above a contactor (202) selected for replacement, attaching the sorbent filter (706) within the contactor (202) to the integrated lift system (700), if necessary, decoupling the sorbent filter (706) from the contactor (202),Docket No. 2023PF12273 lifting the sorbent filter (706) out of the contactor (202) via the integrated lift system (700), translating the sorbent filter (706) to the location of the removed side wall (106), transferring the sorbent filter (706) to an exterior lifting apparatus, removing the sorbent filter (706) from the carbon capture system (200), transferring a new sorbent filter (706) to the integrated lift system (700) via the external lifting apparatus located near the location of the removed side wall (106), translating the new sorbent filter (706) to an empty contactor (202), lowering the new sorbent filter (706) into the empty contactor (202), attaching the sorbent filter (706) to the contactor (202), wherein the method can be repeated for any additional sorbent filters (706) requiring replacement or the side wall (106) can be reinstalled.

12. The method of claim 11, wherein the lift system (700) further comprises a lift arm (802) configured to lift any one of the contactors (202) within the carbon capture system (200).

13. The method of claim 11, wherein the lift system (700) further comprise a hoist (702) configured to lift any one of the contactors (202) within the carbon capture system (200).

14. The method of claim 11, wherein the lift system (700) further comprises a lift track (708) configured to translate over any one of the plurality of contactors (202).

15. The method of claim 11, wherein the lift system (202) can operate while at least one of the plurality of contactors (202) is in the desorption cycle and or at least one of the plurality of contactors (202) is in the absorption cycle.

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