Superior Adsorption Contactor

Abstract

Contactor structures are provided that allow for improved thermal management while reducing or minimizing the possibility of contamination of the process gas stream by the heat transfer fluid. The contactor structure may include one or more sets of flow paths for a process gas stream, such as a gas stream introduced to allow adsorption of a component from a gas stream or a gas stream introduced to facilitate desorption of a previously adsorbed component into a purge gas stream. The process gas flow paths may correspond to flow paths defined by the material of construction of the monolithic structure. The monolithic structure may represent the entire contactor, or the monolithic structure may represent a monolith forming a portion of the contactor. The contactor structure may also include one or more sets of flow paths for a heat transfer fluid. The heat transfer fluid flow paths may also be defined by the material of construction of the monolithic structure.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application is a Patent Cooperation Treaty (PCT) application of U.S. Patent Application No. 63 / 191,640, filed May 21, 2021, and claims priority under PCT Article 8 thereto, the entirety of which is incorporated by reference herein as if set forth in its entirety below. (Technical field)

[0002] An adsorption contactor with integrated heat transfer fluid management features and a method for making such a contactor are provided. [Background technology]

[0003] Mitigating CO2 emissions and / or concentrations from various types of CO2 sources (industrial scale, small scale, and direct air capture) is a current area of ​​interest. One type of strategy for mitigating CO2 emissions is to use adsorbents or absorbents to remove CO2 from potential exhaust gas streams and then desorb this CO2 as part of a stream that can be treated to reduce, minimize, or eliminate the release of CO2 into the atmosphere.

[0004] Nos. 8,784,534 and 8,858,683 describe examples of methods for adsorbing components from a gas phase stream by a swing adsorption process. In general, a combination of temperature and pressure changes can be used to cycle between adsorption / absorption of a component from a first process gas stream and then desorption of the adsorbed component into a purge gas stream. The adsorbed component can then be separated from the purge gas stream.

[0005] Although swing temperature and / or pressure variations may generally affect the performance of sorption / desorption cycles, there are various practical problems that must be overcome to perform CO2 sorption / desorption on an industrial scale. Some challenges relate to selecting an adsorbent or absorbent that can selectively remove CO2 from a gas stream and then release the adsorbed CO2 into a second fluid stream. Other challenges may relate to engineering problems that arise when attempting to perform CO2 removal on a larger scale. For example, some challenges for using adsorption or absorption for CO2 removal may relate to reducing or minimizing the volume of the adsorbent / absorbent structure required to allow the CO2-containing gas stream to contact a large number of adsorption sites. If the volume of the adsorbent / absorbent structure is large, the equipment footprint required for the adsorbent module may increase rapidly and the energy costs to operate the adsorbent module may be correspondingly high. Other challenges may relate to managing the temperature within the adsorbent / absorbent structure during the sorption / desorption cycle. This may include avoiding contamination of the process stream within the adsorbent module by any heat transfer fluid within the module. Still other challenges may relate to managing flow to and from the adsorbent module, such as avoiding excessive pressure drop and reducing or minimizing the difficulty of directing fluid flow throughout the entire volume of the adsorbent module.

[0006] Conventionally, contactors can be used for a variety of applications, including catalytic and adsorbent / desorbent applications. One type of conventional contactor structure is the packed bed. In this type of configuration, the packed bed can be made of particles (e.g., catalyst or adsorbent / absorbent particles). Optionally, inert particles or other types of particles can be mixed to form the bed to control the catalyst or adsorbent density. A process fluid (typically a gas) is then passed through the packed bed. Packed beds can be an effective structure to provide a high density of catalyst or adsorbent / absorbent sites within a given volume. However, due to the lack of a direct flow path, a pressure drop can occur through the packed bed that is relatively larger than the gas flow rate.

[0007] Another type of conventional contact structure is the monolith. Monolith structures typically contain multiple channels through which process gas flows. The surfaces of the channels can be coated with catalysts or adsorbents. One difficulty with monolith structures is the number of sites available for contact with the process gas, since the number of sites often corresponds only to the number of sites that can be coated on the inner surfaces of the channels. This is less of a concern in catalytic applications, where the catalyst sites are only used temporarily to catalyze a reaction.

[0008] An additional consideration for contactor structures is temperature management. In some adsorbent / absorbent applications, it may be beneficial to cool the contactor or to both heat and cool it. Cooling (or both heating and cooling) can be achieved through the use of a heat transfer fluid. However, traditionally, it is often desirable to avoid mixing the heat transfer fluid with the process gas being treated using the contactor. Maintaining separate flows for the process gas and the heat transfer fluid while retaining the benefits of a given type of contactor structure presents a variety of difficult engineering challenges.

[0009] There is a need for an adsorbent contactor that can provide a high density of sorption / desorption sites in an industrial scale module that reduces or minimizes the difficulties in thermal management and / or reduces or minimizes the difficulties in managing fluid flow within the module.

[0010] US Patent No. 8,133,308 describes a sorbent fiber composition that can be used in a temperature swing adsorption process. It also describes disposing a plurality of sorbent fibers in an apparatus. The sorbent fiber corresponds to a polymer matrix, and the sorbent is supported in the polymer matrix. The central lumen of the fiber is sealed from the polymer matrix by a barrier layer. In some embodiments, a plurality of sorbent fibers can be disposed in an apparatus for adsorbing components (such as CO2) from a gas phase stream. In such embodiments, a plurality of fibers are contained in a conduit. Process gas can flow in cross-flow into the conduit through holes in the outer surface of the conduit. After adsorbing the desired components, the remainder of the process gas can enter a central tube for exhaust from the conduit. A header at the end of the conduit can be used to flow a heat transfer fluid through the central lumen of one or more of these fibers, so that the process gas does not mix with the heat transfer fluid. It should be noted that the flow path for the process gas is at least partially defined by the shape of the conduit used to house the plurality of fibers. This is because the walls of the conduit provide at least a portion of the containment for the process gases to flow towards the central exhaust of the conduit.

[0011] No. 8,673,059 describes a temperature swing adsorption contactor for gas separation. The contactor includes a support material capable of corresponding to or acting as a support for an adsorbent material. The contactor further includes microtubes supported on or between layers of the support material. The microtubes are capable of carrying a heat transfer fluid for temperature management.

[0012] US Patent No. 9,011,583 describes a monolithic structure that includes multiple fluid flow paths. The monolith may be used as part of an adsorbent contactor. During operation, a separate cap or superstructure may be placed on top of the monolith to block process gas from entering selected flow paths. The selected flow paths are then available for transporting heat transfer fluid during operation. The superstructure also helps to define a header for introducing heat transfer fluid into selected flow paths in the monolith without introducing the heat transfer fluid into the flow paths containing the process gas stream. This may be achieved, in part, by removing walls from some of the selected flow paths, so that the selected flow paths are in fluid communication with the region of the header defined by the combination of the monolith and the superstructure. The selected flow paths may be coated to prevent the heat transfer fluid from exiting the selected flow paths.

[0013] No. 6,746,515 describes a modularly configurable adsorption system that corresponds to multiple layers that are configured such that a heat transfer fluid layer can be placed above and / or below the adsorbent layer, and that the modular adsorption system can be configured using shims so that the desired materials can be selected for each type of layer in the modular system. Summary of the Invention

[0014] In one aspect, a sorption module is provided. The sorption module includes a plurality of first process gas flow paths defined by a structural material of the monolithic structure. The structural material includes at least one sorbent component. The sorption module further includes a plurality of second heat transfer fluid flow paths defined by the structural material of the monolithic structure. The sorption module further includes one or more process gas inlet headers in fluid communication with the process gas flow paths. The sorption module further includes one or more heat transfer fluid inlet headers in fluid communication with the heat transfer fluid flow paths. In various aspects, at least one of the one or more process gas inlet headers and the one or more heat transfer fluid inlet headers are defined by the structural material of the monolithic structure. Thus, at least one process gas inlet header may be defined by the structural material, or at least one heat transfer fluid inlet header may be defined by the structural material, or at least one of these inlet headers may be defined by the structural material. Additionally, the sorption module includes at least one outlet header in fluid communication with the process gas flow paths or the heat transfer fluid paths.

[0015] In another aspect, an adsorption module is provided. The adsorption module comprises a monolith including a plurality of first process gas flow paths and a plurality of second heat transfer fluid flow paths. The adsorption module further comprises a shell including a first shell piece and a second shell piece. The first shell piece is a unitary structure including a polymer structural material, the first shell piece includes a process gas inlet header, the monolith is at least partially within a volume defined by the first shell piece and the second shell piece, and the plurality of first process gas flow paths are in fluid communication with the process gas inlet header. Additionally, the adsorption module includes at least one outlet header in fluid communication with the process gas flow paths or the heat transfer fluid paths.

[0016] In yet another aspect, a method of forming a barrier layer within a flow path of an adsorption contactor is provided. The method comprises providing a monolithic structure including a first set of flow paths in fluid communication with one or more first contactor inlets and one or more first contactor outlets, and a second set of flow paths in fluid communication with one or more second contactor inlets and one or more second contactor outlets. The first set of flow paths and the second set of flow paths are defined by a structural material of the monolithic structure, the structural material comprising a polymeric material. The method further comprises directing a solution including a polymeric barrier component into the first set of flow paths. The method further comprises directing a purge stream through the first set of flow paths to form a barrier layer on a surface of the first set of flow paths. Additionally, the method further includes, during at least one of the steps of directing the solution into the first set of flow paths and flowing the purge stream through the first set of flow paths, reducing the pressure in the second set of flow paths to a pressure of at least 5 kPa-a lower than the lower of i) the average pressure at the one or more first contactor inlets and ii) the average pressure at the one or more first contactor outlets. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 is a schematic diagram illustrating an example of a flow path configuration within an adsorption contactor.

[0018] [Diagram 2] FIG. 2 is a cross-sectional view based on a plane defined by the interface between the process flow path and the process gas inlet header for a contactor having the flow path configuration according to FIG.

[0019] [Diagram 3] FIG. 3 is a perspective view of a contactor configuration including a contactor integral structure.

[0020] [Figure 4] FIG. 4 is a perspective view showing a modular contactor configuration.

[0021] [Diagram 5] FIG. 5 shows an example of a monolith including a widening channel configuration and a narrowing channel configuration.

[0022] [Figure 6] FIG. 6 shows CO2 adsorption breakthrough curves for the expanding and contracting channel contactor configurations.

[0023] [Figure 7] FIG. 7 shows CO2 adsorption breakthrough curves for expanded channel and packed bed contactor configurations.

[0024] [Figure 8] FIG. 8 shows the pressure drop through the contactor for various contactor configurations.

[0025] [Figure 9A] FIG. 9A is a diagram illustrating a method for defining the central volume. [Figure 9B] FIG. 9B is a diagram illustrating a method for defining the central volume. [Figure 9C] FIG. 9C is a diagram illustrating a method for defining the central volume. [Figure 9D] FIG. 9D is a diagram illustrating a method for defining the central volume. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] All numerical values ​​in the detailed description and claims herein are intended to be modified to "about" or "approximately" the numerical value indicated to account for experimental error and variations that would be expected by one of ordinary skill in the art. [overview]

[0027] In various aspects, contactor structures are provided that can allow for improved thermal management during sorption / desorption cycles while reducing or minimizing the possibility of contamination of the process gas stream by the heat transfer fluid. The contactor structure includes one or more sets of flow paths for the process gas stream, such as a gas stream introduced to allow adsorption of a component from a gas stream or a gas stream introduced to facilitate desorption of a previously adsorbed component into a purge gas stream. The process gas flow paths can correspond to flow paths defined by the structural material of the monolith. This is in contrast to simply having open spaces defined by various structures in the contactor (e.g., open spaces between multiple hollow fibers) or having the adsorbent correspond to a general porous structure through which the fluid flows. The monolith can correspond to the entire contactor, or the monolith can correspond to a monolith that forms a portion of the contactor. Optionally, the structural material can be porous, allowing the process gas to enter, at least to a limited extent, from the process gas flow paths into the bulk structural material. The contactor structure can also include one or more sets of flow paths for the heat transfer fluid. The heat transfer flow paths may also be defined by the structural material of the monolithic structure.

[0028] In various aspects, the orientation of the process gas flow paths and the heat transfer fluid flow paths can be selected to increase or maximize the thermal interaction of the various types of flow paths. For example, the average flow direction for the process gas flow paths and the heat transfer fluid flow paths can be substantially aligned with at least a portion of the flow path of the process gas flow paths within the monolithic structure, e.g., substantially parallel within the central volume of the contactor structure. This substantial alignment of the process gas flow paths and the heat transfer fluid flow paths can be achieved while reducing or minimizing the possibility of the heat transfer fluid penetrating the process gas flow paths. As an example, in some aspects, after the heat transfer fluid flow paths are formed, a barrier layer can be added to the heat transfer fluid flow paths to reduce or minimize the possibility of the heat transfer fluid mixing with the process fluid.

[0029] Additionally or alternatively, in some aspects, the dimensions of the process gas flow passages may vary within the contactor structure. Surprisingly, it has been found that increasing the dimensions of the process gas flow passages downstream of the flow passages can provide an increased amount of process gas that can be processed before substantial breakthrough of the components adsorbed in the contactor structure. Without being limited to any particular theory, it was previously believed that increasing the dimensions of the process gas flow passages would shorten the breakthrough time because increasing the flow passage dimensions would decrease the surface area to volume ratio of the flow passages. However, as described herein, it has been found that in the case of a porous flow passage structure in which the adsorbent is dispersed throughout the structural material, increasing the dimensions of the process gas flow passages downstream of the flow passage dimensions can extend the processing time before breakthrough of a given flow rate of process gas.

[0030] In some aspects, the contactor is a monolithic structure. In such aspects, the monolithic structure can be formed from a structural material. The structural material of the monolithic structure can define the process gas flow path, the heat transfer fluid flow path, and at least one header. The at least one header defined by the structural material of the monolithic structure can be at least one header for the process gas, at least one header for the heat transfer fluid, or headers for both the process gas and the heat transfer fluid can be defined by the structural material. Additionally or alternatively, an outlet header for the process gas and / or an outlet header for the heat transfer fluid can be defined by the structural material of the monolithic structure.

[0031] Having at least one header defined by the structural material of the monolithic structure allows the header to be located downstream from the beginning of the process gas or heat transfer fluid flow path. This can help to maintain separate flow paths for the process gas and heat transfer fluid. For example, if an inlet header for the heat transfer fluid is located downstream from the beginning of the process gas flow path, the heat transfer fluid flow path can also begin downstream. This eliminates the need for a separate blockage of the process gas from entering the heat transfer fluid flow path, since the heat transfer fluid flow path does not begin until the process gas is dispersed into the process gas flow path. Additionally, having a monolithic structure means that the structure does not have gaps or seams where fluid can leak between the separate volumes when the mating pieces are brought together. Similar benefits can be obtained by having an outlet header located upstream from the end of the process gas or heat transfer fluid flow path. Combined with the addition of a barrier layer to the heat transfer fluid flow path, mixing of the process gas and the heat transfer fluid can be reduced, minimized, or eliminated over substantially the entire length of each fluid's path in the contactor.

[0032] Alternatively, the contactor may represent a plurality of structures, including at least one monolith and one or more shell pieces that at least partially contain the at least one monolith. In this type of configuration, at least one of the one or more shell pieces may include an inlet for process gas, an inlet for heat transfer fluid, or both an inlet for process gas and an inlet for heat transfer fluid. If the inlets for process gas and the inlets for heat transfer fluid are part of the same shell piece, these inlets may be part of the same face of the shell piece or may be part of different faces. Optionally, if at least one monolith is only partially present within the shell piece, the process gas and / or the heat transfer fluid may be at least partially routed directly into the monolith without passing through the shell piece.

[0033] In some aspects, when the contactor corresponds to at least one monolith at least partially enclosed in one or more exterior pieces, the monolith may correspond to a unitary structure including the process gas flow path and the heat transfer fluid flow path. Optionally, the monolith may further include at least one header and / or at least one outlet header defined by the structural material of the monolith.

[0034] Additionally or alternatively, when the contactor includes one or more external pieces, the external pieces can include a header defined by the structural material of the external pieces. For example, one configuration for a contactor can be to have a monolith (which can correspond to a conventional ceramic monolith) that is at least partially contained in multiple external pieces. In such a configuration, one of the external pieces can include a header comprised of multiple flow paths that can match multiple flow paths present in the monolith.

[0035] One option for preparing a monolith, contactor, or shell piece corresponding to the monolith described herein is to use additive manufacturing, sometimes referred to as three-dimensional (3D) printing. The ink for 3D printing corresponds to a polymer-containing solution. After removing the solvent, the resulting polymeric structural material may correspond to a porous structural material. In some aspects, the polymeric structural material may function as an adsorbent. Optionally, a separate adsorbent may be included in the ink to enhance the adsorption performance of the resulting polymeric structural material.

[0036] It is noted that, in the definitions set forth herein, some monoliths may fit the definitions of both a contactor and a monolith. This may occur when a monolith includes all of the characteristics of a contactor as set forth herein, but is also at least partially contained within one or more outer pieces, where at least one of the process gas or heat transfer fluid must pass through a hole or opening in one of the outer pieces to enter the monolith. It is noted that, in the definitions set forth herein, if all of the process gas and all of the heat transfer fluid are passed directly into the monolith, such a monolith is defined herein as a contactor, and not as a monolith, even if such a contactor is partially present within other structural pieces through which the process gas and heat transfer fluid do not pass.

[0037] [Definition]

[0038] In this discussion, a monolithic structure formed from a structural material is defined as a structure in which any two points on or within the surface of the structural material can be connected by a curve that does not pass through a seam, gap, or other discontinuity in the structural material. The curve does not have to be a straight line, and therefore the curve can pass around channels, headers, or other fluid paths / openings defined by the structural material of the monolithic structure. This is in contrast to a structure formed by two pieces that are then physically joined, for example, by screws, rivets, or welds that comprise a material different from the structural material. This is also in contrast to a structure in which one piece of structure can be inserted into another piece of structure, and the relative position of the pieces is maintained by tabs, frictional engagement, or other mechanical / physical means. In some aspects, a contactor can represent a monolithic structure. In other aspects, a monolith in a contactor can represent a monolithic structure.

[0039] For the purposes of this discussion, unrestricted flow is defined as flow through an open volume within a structure, where the open volume provides a cross-sectional flow area of ​​0.3 mm or greater in the flow path. Note that an unrestricted flow path may cause a pressure drop for a fluid flowing along the unrestricted flow path due to features such as curves in the flow path or turbulence in the flow path. Unrestricted flow is the antonym of restricted flow, which corresponds to various types of flow such as flow through a packed bed, diffusion through a porous material, or permeation into a membrane.

[0040] In this discussion, a volume in a monolithic structure that is "defined by a structural material" is defined herein as a volume in which an unrestricted flow path for a fluid within the volume is defined by the structural material. For example, one type of volume that may be defined by a structural material is a flow path, such as a process gas flow path or a heat transfer fluid flow path. For a flow path, the unrestricted flow path corresponds to a path from an initial opening of the flow path on one side of the structure to an outlet of the flow path. The structural material of the monolithic structure defines such a flow path when the walls of the flow path are defined by the structural material. As defined herein, the diffusion of a fluid through a material corresponds to restricted flow, and thus a porous material may be used to define an unrestricted flow path for a flow path. Additionally, to the extent that a barrier material is used to coat the walls of the porous structural material in the flow path, under the definition provided herein, such a coated flow path is still defined by the structural material, as long as the coating material does not substantially change the cross-sectional shape of the flow path.

[0041] As another example, a header in a monolithic structure is defined by the structural material of the monolithic structure if all surfaces of the header correspond to the structural material. This is in contrast to a situation where the volume of the header is defined by the volume between two separate pieces that are brought together such that at least one interior surface of the header is a surface of the first piece and at least a second interior surface of the header is a surface of the second piece.

[0042] In this discussion, the cross-sectional area at a given location in a channel is defined as the smallest cross-sectional area achievable by penetrating a plane through the channel at the given location. In this discussion, the average cross-sectional area of ​​a channel can be defined for the portion of the channel that lies between any two parallel planes. The average cross-sectional area of ​​multiple channels is defined as the average of the average cross-sectional areas for the portions of the channels between any two parallel planes.

[0043] For the purposes of this discussion, sorption is defined to include both adsorption and absorption. Adsorption refers to the physical association of a component with a surface or active site, e.g., physical sorption of CO2 on a solid surface. Absorption refers to the physical or chemical incorporation of a component into a different phase, e.g., gas phase CO2 in a complex with a liquid phase amine. Desorption is defined as the separation of an adsorbed or absorbed component from the adsorbing surface or adsorbing phase.

[0044] In this discussion, the surface area of ​​a polymeric material is defined as the BET (Brunauer, Emmett, and Teller) surface area measured according to ASTM D3663. In this discussion, the pore volume can be measured according to ASTM D4641 (N2 pore volume) or ASTM D4284 (Hg pore volume).

[0045] In this discussion, zeotype is defined to refer to crystalline materials with a porous framework structure formed by tetrahedral atoms connected by bridging oxygen atoms. Examples of known zeotype structures are described in "Atlas of Zeolite Frameworks" published on behalf of the Structure Committee of the International Zeolite Society (6th revised edition, Ch. Baerlocher, LB McCusker, DH Olson, eds., Elsevier, New York (2007)) and the corresponding website http: / / www.iza-structure.org / databases / . In this definition, zeolite specifically refers to aluminosilicates with a zeotype framework structure. In this definition, zeotype can refer to aluminosilicates (i.e. zeolites) with a zeotype framework structure and a crystalline structure containing oxides of heteroatoms other than silicon and aluminum. Such heteroatoms may include any heteroatom generally known to be suitable for inclusion in a zeotype framework, such as gallium, boron, germanium, phosphorus, zinc, and / or other transition metals capable of substituting silicon and / or aluminum in the zeotype framework, etc. It is noted that, for purposes of this definition, zeotypes may include materials such as silicoaluminophosphate (SAPO) or aluminophosphate (AlPO) materials.

[0046] [Example of contactor structure]

[0047] FIG. 1 is a schematic diagram of an example of a flow path configuration in an adsorbent contactor. In FIG. 1, flow paths 130 correspond to flow paths for a process gas stream. It is noted that although three process gas flow paths 130 are illustrated in FIG. 1, any suitable number of process gas flow paths may be provided. For convenience, the process gas flow paths 130 are illustrated as a two-dimensional array, but it will be understood that many types of contactor configurations may include a three-dimensional array of process gas flow paths. In operation, process gas enters the contactor 110 through a process gas inlet 132 on a face or wall 121 of the contactor 110. The process gas enters into a process gas inlet header 140. The gas is then dispersed into the process gas flow paths 130. In the example configuration shown in FIG. 1, the process gas flow paths lead into a process gas outlet header 145. This mixed process gas exhaust then exits the contactor through a process gas outlet 138 on another wall or face 123 of the contactor. However, multiple process gas inlets 132 and / or multiple process gas outlets 138 may be used, if desired. Similarly, the process gas inlet header 140 may be multiple headers and / or the process gas outlet header 145 may correspond to multiple manifolds.

[0048] The flow paths 160 correspond to flow paths for the heat transfer fluid. Although four heat transfer fluid flow paths 160 are shown in FIG. 1, any suitable number of heat transfer fluid flow paths 160 may be provided. For convenience, the heat transfer fluid flow paths 160 are illustrated as a two-dimensional array, but it will be understood that many types of contactor configurations may include a three-dimensional array of heat transfer fluid flow paths. In the example configuration shown in FIG. 1, a heat transfer fluid inlet 162 enters the contactor 110 at a perpendicular angle to the flow direction of the process gas flow path 130 from the second side 122 of the contactor 110. In other configurations, the heat transfer fluid inlet 162 may be located on the same wall or face as the process gas inlet 132 and / or the heat transfer fluid inlet 162 may be located on a face that is bent at an angle other than perpendicular. A heat transfer fluid inlet header 170 may be used to distribute the heat transfer fluid to the heat transfer flow paths 160. In the example configuration shown in FIG. 1, the heat transfer fluid flow paths lead to a heat transfer fluid outlet header 175. This mixed heat transfer fluid exhaust then exits the contactor through a heat transfer fluid outlet 168 formed in another wall or surface 124. Note that multiple heat transfer fluid inlets 162 may be used and / or multiple heat transfer fluid outlets 168 may be used, if desired. Similarly, the heat transfer fluid inlet header 170 may be multiple headers and / or the heat transfer fluid outlet header 175 may correspond to multiple branching pipes. Note that the heat transfer fluid header 170 is shown as a conduit with multiple heat transfer flow paths 160 branching off of the conduit. In other aspects, the heat transfer fluid header 170 can correspond to a larger header volume, such as the larger header volume shown for the process gas header 140.

[0049] 1, the process gas flow paths 130 and the heat transfer fluid flow paths 160 are generally parallel for the majority of the flow path length of the process gas flow paths. As described in more detail below, in various embodiments, within the central volume of the contactor, the average direction of flow in the process gas flow paths 130 may differ from the average direction of flow in the heat transfer flow paths 160 by 30° or less, or by 20° or less, or by 10° or less.

[0050] It should be noted that the process gas flow paths 130 and the heat transfer fluid flow paths 160 are shown in Figure 1 as being substantially straight and of substantially constant dimensions. In other embodiments, any suitable type of flow path may be used. Additionally or alternatively, the dimensions of the flow paths may be varied in any suitable manner.

[0051] Figure 2 is a cross-sectional view of the interior of the process gas flow path 130 where the process gas inlet header 140 interfaces with the process gas flow path 130. The cross-sectional view of Figure 2 is perpendicular to the inflow and outflow of heat transfer fluid as indicated by the location of the heat transfer fluid inlet 162 and heat transfer fluid outlet 168. Because the heat transfer fluid header 170 of Figure 1 is located downstream from the process gas inlet header 140 of Figure 1, in the cross-sectional view shown in Figure 2 all gas flow path openings correspond to the process gas flow path 130.

[0052] Figure 3 is a perspective view of an example of a contactor structure capable of implementing the types of configurations shown in Figures 1 and 2. In Figure 3, the contactor shell 301 (top of the figure) and the corresponding internal monolith 320 (bottom of the figure) are shown as separate structures for purposes of illustrating these structures. However, it will be understood that the shell 301 and the internal monolith 320 may be formed as a unitary structure, for example, by using 3D printing to form the unitary structure. In yet other aspects where the contactor is not a unitary structure, the shell 301 may be formed using multiple shell pieces (not shown) such that one or more monoliths 320 can be inserted into the shell 301.

[0053] In FIG. 3, the shell 301 includes several openings. A process gas inlet 332 and a heat transfer fluid outlet 368 are shown in FIG. 3. The process gas inlet 332 provides fluid communication between the externally incoming flow and a process gas inlet header 340. The process gas inlet header 340 corresponds to the volume between the inner monolith 320 and the shell 301. The process gas inlet header 340 allows the process gas to be distributed to the multiple process gas flow paths 330. In the example shown in FIG. 3, the contactor includes two types of headers associated with the outflow of the heat transfer fluid. A first group of heat transfer fluid headers 375 represents the heat transfer fluid headers in the monolith portion 320 of the contactor structure. The heat transfer fluid headers 375 deliver the heat transfer fluid perpendicular to the direction of flow of the process gas flow paths, so that the heat transfer fluid flow can be substantially parallel to the process gas flow in the monolith, but still be able to exit the contactor along a direction perpendicular to the flow. The second heat transfer fluid header 395 represents another volume between the inner monolith 320 and the outer shell 301. The second heat transfer fluid outlet header 395 allows the heat transfer fluid exiting the first group of heat transfer fluid headers 375 to be collected in a common volume for discharge through an external heat transfer fluid discharge conduit 380.

[0054] In addition to the process gas inlet 332 and heat transfer fluid outlet 368, a process gas outlet 338 and a heat transfer fluid inlet 362 are also provided in the shell 301, although these openings are not visible in the perspective view provided in Figure 3. The process gas outlet 338 allows for fluid communication between the outlet of the process gas flow passage 330 and an external process gas exhaust conduit via a process gas outlet header (not shown). The heat transfer fluid inlet 362 allows for fluid communication between the beginning of the heat transfer fluid flow passage 360 ​​and an external heat transfer fluid inlet conduit via a heat transfer fluid inlet header (not shown).

[0055] More generally, in embodiments where the contactor corresponds to an assembly including at least one monolith at least partially contained within one or more exterior pieces, the header(s) for the contactor may correspond to a volume defined between an exterior piece and a monolith. In such embodiments, the volume between the exterior piece and the monolith may be in fluid communication with one or more openings in the exterior piece and one or more openings in the monolith. Additionally, in embodiments where the contactor is a monolithic structure, the header(s) within the contactor may correspond to a header defined by the structural material of the monolith.

[0056] The configurations shown in Figures 1-3 may be formed, for example, using 3D printing to form various monolithic structures from polymeric structural materials. Optionally, in some aspects, at least one structure in the contactor can be formed by an alternative method, for example, using a ceramic monolith partially contained in one or more shell pieces, where at least one shell piece is formed using 3D printing. Yet another option is to use a 3D printed monolith partially contained in one or more shell pieces, where at least one shell piece is formed by a method other than 3D printing.

[0057] FIG. 4 shows an example of another type of contactor configuration. In the example shown in FIG. 4, the contactor is a modular contactor assembly including one or more monoliths 420 and a shell consisting of two or more shell pieces, such as an upper shell 411 and a lower shell 412. In FIG. 4, the monolith 420 includes multiple flow paths. A first portion of the flow paths corresponds to the process gas flow paths 430, and a second portion of the flow paths corresponds to the heat transfer fluid flow paths 460. The upper shell 411 may correspond to a unitary structure providing a process gas inlet header and a heat transfer fluid inlet header. This allows the process gas inlet 432 to be in fluid communication with the process gas flow paths 430 and the heat transfer fluid inlet 462 to be in fluid communication with the heat transfer fluid flow paths 460, preventing the respective flows from mixing. Mixing may be further reduced, minimized, or eliminated by providing a barrier layer within the heat transfer fluid flow paths 460, as described below.

[0058] [Mean axis of flow about the flow path]

[0059] In this study, it is possible to define the mean axis of flow for the process gas and heat transfer fluid flow paths within the central volume of the contactor. To determine the central volume, the following procedure can be used: First, a process gas flow path is defined as a flow path that connects a process gas inlet header and a process gas outlet header. If the process gas inlet corresponds to the edge of the structure, for purposes of this definition, the edge of the structure is defined as the process gas header. Similarly, if the process gas flows directly from the flow path to the exterior of the structure, the edge of the structure is defined as the outlet header. Next, a rectangular bounding box (with right angles between the height, width, and length dimensions) can be generated for the process gas flow path. The rectangular bounding box is defined as the smallest rectangular box that contains all the process gas flow paths.

[0060] A center point can then be defined for the bounding box for the process gas flow path. Since the bounding box is a rectangular box, the center point is defined as a point having coordinates of the midpoint of each side of the rectangular box. After defining the center point of the bounding box, a smaller rectangular box can be defined that has the same center point but is approximately half the volume. The smaller (approximately half the volume) rectangular box corresponds to a box with the same center point but with the length of each side reduced by 20%.

[0061] After defining the reduced volume box for the process gas flow path, a similar procedure can be used to define a reduced volume box based on the heat transfer fluid flow path. The heat transfer fluid flow path is defined as a flow path connecting a heat transfer fluid inlet header and a heat transfer fluid outlet header. Based on this, a rectangular bounding box can be defined for the heat transfer fluid flow path. Then, a center point can be determined, and then a reduced volume box (i.e., a box with the length of each side reduced by 20%) can be determined.

[0062] After defining a box with a reduced volume based on the process gas flow paths and a box with a reduced volume based on the heat transfer fluid flow paths, it is possible to define a central volume, which is defined as the overlapping volume between the two reduced volume boxes.

[0063] 9A-9D illustrate the process of identifying a common volume. For ease of illustration, FIGS. 9A-9D use two-dimensional views to illustrate the process. In FIG. 9A, a contactor is shown with a process gas flow path 930 and a heat transfer fluid flow path 960. The process gas flow path 930 provides fluid communication between a process gas inlet header 940 and a process gas outlet header 945. The heat transfer fluid flow path 960 provides fluid communication between a heat transfer fluid inlet header 970 and a heat transfer fluid outlet header 975.

[0064] FIG. 9B illustrates the process of creating a box associated with the process gas flow path 930. In FIG. 9B, the process gas flow path is contained within a bounding box 1001. Bounding box 1001 is intended to represent a rectangular box of minimum dimensions that contains all of the process gas flow paths. However, the edges of bounding box 1001 are slightly offset to make bounding box 1001 clearly distinguishable from the flow paths and headers in the figure. Bounding box 1001 has a center point 1005. A reduced volume box 1009 is a box that has the same center point 1005 but has sides that are 20% shorter than bounding box 1001.

[0065] Similarly, Figure 9C shows a bounding box 1011 based on a rectangular box containing the heat transfer fluid flow paths. Figure 9C also shows a center point 1015 of the bounding box 1011 and a reduced volume box 1019 having the same center point 1015.

[0066] Figure 9D shows an overlap 1025 between box 1009 and box 1019. The overlap volume 1025 corresponds to the central volume of the contactor shown in Figures 9A-9D.

[0067] Once the central volume is determined, the average axis of flow for different types of flow paths within the central volume can be determined. To determine the average axis of flow for the process gas flow paths, the flow axis is determined for a portion of the process gas flow paths that are present within the central volume. For most flow paths, the flow paths enter the central volume only once and exit the central volume only once. However, if a process gas flow path enters the central volume more than three times or exits the central volume more than three times, the process gas flow path is eliminated from consideration.

[0068] For each process gas flow path in the central volume, the flow axis of that flow path is a straight line vector that corresponds to the average direction of fluid flow in the flow path. This straight line vector corresponds to a line that minimizes the least square distance from the straight line vector of the process gas flow path to the midline. The midline of the flow path corresponds to a line that passes through the geometric center of the flow path along the flow path. Of course, in a straight flow path, the flow axis will simply correspond to the midline of the flow path. As another example, a spiral flow path will have a mean flow direction that corresponds approximately to the central axis of the spiral. This vector has a starting point that corresponds to the starting point of the corresponding process gas flow path in the central volume. The end point is where the vector touches another surface of the central volume. The mean flow axis can then be determined. The mean flow axis corresponds to a vector that is the average of the flow axis vectors for the individual process gas flow paths in the central volume.

[0069] To determine the mean axis of flow for the heat transfer fluid flow passages within the central volume, the above procedure can be repeated for the heat transfer fluid flow passages.

[0070] The mean axis of flow of the process gas flow passages and the mean axis of flow of the heat transfer fluid passages can then be used to determine the angle between the vectors. This angle represents the difference in flow direction for the process gas flow passages and the heat transfer fluid passages within the central volume. In various embodiments, the angle between the mean axis of flow of the process gas flow passages and the mean axis of flow of the heat transfer fluid passages can be 30° or less, or 20° or less, or 10° or less, for example, until the vectors are nearly aligned or parallel (i.e., 0°).

[0071] [Structural materials for integral structures]

[0072] One example of a method for forming a monolithic structure is the use of additive manufacturing, specifically solvent-based additive manufacturing (SBAM). In SBAM, additive manufacturing inks can be used to form structures based on polymeric structural materials. The inks can include a solvent for the polymeric material, and the structures formed as the solvent is removed from the ink. The inks can optionally include one or more adsorbents. This allows for the formation of polymeric structures with the adsorbents dispersed throughout the structure. In this discussion, "polymeric material" refers simply to the polymer portion of the structure, while "structural material" or "polymeric structural material" refers to a polymer and any added components (such as adsorbents) integrated into a polymer matrix.

[0073] In various aspects, the contactor may represent one or more monolithic structures of a structural material and a sorbent. In some aspects, the structural material may represent a polymeric material that functions both as a structural material and as a sorbent (or at least partially as a sorbent). In some aspects, the structural material may represent a composite of a polymeric material and a separate sorbent incorporated into the polymeric material. The monolithic structure may be formed from the polymeric structural material by any suitable method. In some aspects, the monolithic structure may be formed by solvent-based additive manufacturing. One example of a component that may be sorbed by a sorbent integrated into the polymeric material and / or the structural material is CO2.

[0074] In some embodiments, after a structure is formed from the polymeric structural material, the polymeric structural material has a relatively large surface area, which can increase the number of potential adsorption sites per volume of structural material exposed to process gases. For example, in some embodiments, the surface area of ​​the polymeric structural material can be 50 m2 / g or more, or 100 m2 / g or more, or 200 m2 / g or more, or 500 m2 / g or more, such as up to 3000 m2 / g or even more in some cases.

[0075] In some embodiments, the structural material may have sufficient microporosity to allow the process gas to diffuse into the polymeric material, thereby allowing adsorption through various portions (e.g., up to substantially the entire volume) of the volume of the structural material used to form the monolithic structure. In such embodiments, the structural material may have a pore volume (determined by nitrogen physisorption) between 0.3 cm3 / g and 1.3 cm3 / g and / or a pore volume (determined by mercury porosimetry) between 1.0 cm3 / g and 3.0 cm3 / g. In other embodiments, the structural material may have a relatively low microporosity, and the volumes in which adsorption may occur primarily correspond to the flow channels and / or other open volumes within the monolithic structure connected to the flow channels.

[0076] Various types of polymers can be used as the polymeric material in the structural material. Examples of polymers that can be used as the polymeric material in the structural material include, but are not limited to, cellulose acetate, polyvinylpyrrolidone, polysulfone, polyether sulfone, epichlorohydrin, polyetheramide block copolymers, polyimides, polyolefins, polypropylene, polyethylene, polyamide, poly(tetrafluoroethylene), polyvinylidene chloride (PVDC), polystyrene, polyisobutylene, polybutadiene, polyurethane, elastomers, copolymers thereof, or combinations thereof. Other examples of polymers can include materials corresponding to polymers of inherent porosity (PIMs). In some embodiments, the polymers in the structural material can include, but are not limited to, cellulose acetate, polyimines (such as Matrimid 5218), polyamide-imides (such as Torlon®), polyether sulfones (PES), derivatives of PIM-1 (such as amidoximated PIM-1), and other polymers with inherent steric frustration that affect microporosity.

[0077] Where the polymeric structural material represents a composite of the polymeric material and the incorporated adsorbent, various adsorbent materials can be used as the adsorbent. Some examples of adsorbents can be metal-organic framework (MOF) materials, activated carbon, porous aromatic framework materials, covalent organic framework materials, porous organic polymers, and cage materials, or combinations thereof. Examples of MOF materials include EMM-44, EMM-67, and HKUST-1. Other types of adsorbents can include, but are not limited to, adsorbents having zeotype framework structures. More generally, any suitable type of particulate adsorbent can be used. Such adsorbents can be incorporated in any suitable manner. For example, when the monolithic structure is formed by 3D printing, the 3D printing ink can include both the polymeric material and nanoparticles of the adsorbent material. Additionally or alternatively, the adsorbent can be added to the interior surface of the process gas flow path by adding one or more layers of a coating containing the adsorbent using a washcoat.

[0078] In some alternative embodiments, one or more structures in the contactor may represent structures formed from a structural material different from a polymeric material. For example, in some embodiments, the outer shell may be formed from a polymeric material and at least one inner monolith may be formed from a structural material corresponding to a ceramic or metallic material. In embodiments in which the contactor is a monolithic structure, the structural material is preferably a polymeric material and / or a composite of a polymeric material and one or more adsorbents.

[0079] In various embodiments, the ink composite for forming the polymer contactor structure including the additional sorbent particles may include at least one solvent, at least one structure-forming component (non-solvent and / or pore-forming component), a polymeric material dissolved in the solvent, and particles of the sorbent material dispersed and / or suspended in the solution. In some embodiments, the sorbent particles may correspond to MOF materials, optionally water-sensitive MOFs, etc. Additionally or alternatively, the sorbent particles may correspond to materials having a zeotype framework structure, activated carbon, or other types of sorbent particles.

[0080] In various embodiments, polymer ink composites containing significant amounts of adsorbent material can be used to form polymer structures by 3D printing by depositing the polymer as a solution in combination with a solvent and structure-forming components (i.e., non-solvents and / or pore-forming components) and then using phase inversion as the solvent evaporates to form the polymer structure.

[0081] When 3D printing is performed using an ink composition, the ink composition can be selected so that the ink composition corresponds to a homogeneous phase, but the ink composition can cross the binodal line when the solvent evaporation reaches a target amount, which causes phase inversion. During 3D printing, the ink can be deposited in an atmosphere that contains a solvent, so that solvent evaporation is reduced or minimized until after the ink composition is "printed" onto the desired surface. For example, the print head for depositing the ink may include one or more additional nozzles for dispersing additional solvent as the printing occurs, so that phase inversion does not occur until the ink is deposited onto the surface. After a layer of the ink composition is deposited or printed, the solvent is allowed to evaporate. As the solvent concentration is reduced, the solvent system eventually becomes unstable and the polymer dissolved in the solvent condenses to form a continuous polymer skeleton. The structure-forming components and any residual solvent form separate phases, which can promote the formation of additional pore volume in the polymer structure. The structure-forming components and residual solvent can then be removed during the manufacturing process, possibly by performing an additional drying step.

[0082] In some embodiments, it is possible to use ink compositions having a weight ratio of sorbent to polymer of 1.0 or more (i.e., a 1:1 weight ratio of sorbent to polymer), or 1.5 or more, or 2.0 or more, or 3.0 or more, such as up to 6.0 or even more. Additionally or alternatively, the ink composition can contain 10 wt% or more, or 15 wt% or more, or 20 wt% or more, such as up to 50 wt% or even more, of sorbent by weight of the ink composition. Additionally or alternatively, the combined weight of polymer and sorbent in the ink composition can represent 25 wt% or more, or 30 wt% or more, or 40 wt% or more, such as up to 60 wt% or more, or even more, by weight of the ink composition. Additionally or alternatively, the ink composition can include 7.0 wt% to 15 wt%, or 10 wt% to 15 wt%, or 12 wt% to 15 wt% of polymer by weight of the ink composition. Additionally, the ink composition may contain a sufficient amount of polymer such that phase inversion can occur.

[0083] In other embodiments, the ink composition may have a weight ratio of sorbent to polymer of 0.3 to 6.0, or 0.5 to 6.0, or 1.0 to 6.0, or 1.5 to 6.0, or 2.0 to 6.0, or 3.0 to 6.0. At lower sorbent to polymer ratios, the benefits of incorporating sorbent materials are reduced, but the differences between such ink compositions and conventional ternary ink compositions are also reduced. In such embodiments, the ink composition may include 3.0 wt% or more, or 5.0 wt% or more, or 10 wt% or more, or 15 wt% or more, or 20 wt% or more, for example up to 50 wt% or more, by weight of the ink composition.

[0084] A variety of metal-organic framework materials can be incorporated into the ink composition for forming structures by 3D printing. Metal-organic frameworks (MOFs) are a relatively new class of porous materials consisting of metal ion / oxide secondary building blocks linked by organic bonding of ligands through covalent bonds. MOFs are characterized by low density, high internal surface area, and uniformly sized pores and channels. MOFs are typically crystalline materials. Some types of MOF materials can include zeolitic imidazole frameworks (sometimes called "ZIFs"), unconventional MOFs (sometimes called "UMOFs"), and SIFSIX MOFs.

[0085] Various MOFs have been characterized for their CO2 adsorption capabilities. For example, Mg-MOF-74 corresponds to a metal-organic framework based on Mg2+ ions and 2,5-dihydroxyterephthalic acid. As another example, MOF-274 corresponds to a metal-organic framework based on Mg2+ metal ions combined with 4,4'-dioxidobiphenyl-3,3'-dicarboxylate. As another example, EMM-67 corresponds to a metal-organic framework based on Mg2+ and Mn2+ metal ions combined with 4,4'-dioxidobiphenyl-3,3'-dicarboxylate. MOF-274 and EMM-67 are further enhanced by adding functionalities such as diamines, N,N'-dimethylethylenediamine, or 2-aminomethylpiperidine to produce structures such as EMM-44. As yet another example, MIL-101(Cr) is a metal-organic framework consisting of three chromium trigonal nodes and at least 13 oxygen atoms bridged by benzene-dicarboxylate linkages in the MTN (IZA code) topology. Yet another example is EMM-42. EMM-42 is a metal-organic framework with the same secondary building units as MIL-101(Cr), i.e., a unit in which the three chromium atom trigonal nodes have some or all of the benzene-dicarboxylate ligands connecting adjacent chromium nodes replaced by ligands that bind phenylene bisphosphonic acid. Yet another example is HKUST-1, also called MOF-99. The HKUST-1 framework is formed from dimeric metal units connected by benzene-1,3,5-tricarboxylic acid linker molecules. The paddlewheel unit is a structural motif commonly used to describe the coordination environment of a metal center and is also called the secondary building unit (SBU) of the HKUST-1 structure. The paddlewheel is composed of four benzene-1,3,5-tricarboxylic acid linker molecules bridging two metal centers.

[0086] To form polymeric structures during 3D printing, the ink composition can include a polymer. Some examples of polymers that can be included in the ink composition are polymers of intrinsic microporosity. Polymers of intrinsic microporosity (PIMs) are new materials of interest for critical gas separations. Spiro centers integrated into the polymer backbone prevent efficient packing and induce micropores in the polymer. The micropores can be useful for forming contactor structures because they allow process gases flowing through channels in the contactor structure to access different parts of the contactor volume.

[0087] Other types of porous polymers may be used to form the ink composition. In some embodiments, the polymers in the ink composition can include, but are not limited to, cellulose acetate, polyimines (e.g., Matrimid 5218), polyamide-imide polymers, polyether sulfones (PES), derivatives of PIM-1 (e.g., amidoximated PIM-1), and other polymers that have inherent steric frustration that affects microporosity.

[0088] In some aspects, the solvent may be tetrahydrofuran, acetone, and / or N-methylpyrrolidone. More generally, the solvent may be a solvent that has high solubility for the polymer in the ink composition. There are many ways to determine the level of solubility of the polymer in the volatile solvent compound. For example, in some aspects, the Hildebrand solubility parameters of the polymer and the volatile solvent compound may be measured. In some embodiments, the Hildebrand solubility parameters of the polymer and the volatile solvent compound may differ by 3.6 MPa / 2 or less. One skilled in the art will appreciate that such an embodiment will provide a volatile solvent compound that can melt the polymer to produce a substantially homogeneous solution. In some embodiments, potential solvents can include, but are not limited to, acetaldehyde, acetic acid, acetone, acetonitrile, butanediol, butoxyethanol, butyric acid, diethanolamine, diethylenetriamine, dimethylacetamide (DMAc), dimethylformamide (DMF), dimethoxyethane, dimethylsulfoxide (DMSO), dioxane, ethanol, ethylamine, ethylene glycol, formic acid, furfuryl alcohol, glycerol, methanol, methyldiethanolamine, methyl isocyanide, N-methyl-2-pyrrolidone (NMP), propanol, propanediol, propanoic acid, propylene glycol, pyridine, tetrahydrofuran (THF), triethylene glycol, dimethylhydrazine, hydrazine, hydrofluoric acid, hydrogen peroxide, nitric acid, sulfuric acid, pentane, cyclopentane, hexane, cyclohexane, benzene, toluene, chloroform, diethyl ether, dichloromethane, or combinations thereof.

[0089] In the embodiment in which the ink composition includes a non-solvent as a structure-forming component, the non-solvent can be a compound that has low or minimal solubility for the polymer in the ink composition. There are many ways to determine the level of solubility of the polymer in the non-solvent compound. In some embodiments, the non-solvent can be selected by first measuring the measurable Hansen solubility parameters of the polymer and the non-solvent compound. For example, the polymer and the non-solvent can be selected such that the relative energy difference calculated from the Hansen solubility parameters of the polymer and the non-solvent compound can be 1 or more. Those skilled in the art will understand that such an embodiment will provide a non-solvent compound that cannot melt the polymer.

[0090] In some embodiments, the non-solvent can correspond to toluene, dimethylacetamide, or a combination thereof. In some embodiments, the non-solvent can be N-methyl-2-pyrrolidone (NMP). In some embodiments, the non-solvent can be and / or include water. In other embodiments, the non-solvent can be substantially free of water (less than 0.1 wt%), which allows for the use of water-sensitive MOFs in the ink composition. HKUST-1 is an example of a water-sensitive MOF. In some embodiments, the non-solvent can be an alcohol, such as methanol, ethanol, isopropanol, or n-propanol. It should be noted that under conditions that will exist after depositing the ink composition, the evaporation rate of the solvent can be faster than the evaporation rate of the non-solvent, because otherwise phase inversion to form the polymer structure cannot occur.

[0091] Additionally or alternatively, a pore-forming component may be included as a structure-forming component. LiNO3 is one example of a pore-forming component that may be used in the ink composition. The pore-forming component may be added in a relatively small amount, for example, an amount corresponding to 0.1 wt% to 20 wt%, or 0.1 wt% to 10 wt%, or 0.1 wt% to 5.0 wt%, or 1.0 wt% to 20 wt%, or 1.0 wt% to 10 wt% of the ink composition.

[0092] Table 1 lists examples of combinations of polymers, solvents, and non-solvents or pore-forming components (i.e., structure-forming components) that can be used to form 3D printing ink compositions. The final column of Table 1 lists specific solvents that may cause problems when used in combination with the listed polymer to form 3D printing ink compositions. [Table 1]

[0093] An example of a printer for forming structures with an ink composition can be a direct ink-write printer. For example, in some aspects, the printer can include an ink holding vessel, an ink nozzle configured to be attached to the ink holding vessel, a vapor nozzle, and a movable stage for the substrate. In some aspects, the movable stage can be configured to be removably attached to the substrate. The distance between the ink nozzle and the movable stage can include a gap substantially enclosed by the control volume shell. For example, the control volume shell can include a cylindrical shell having an opening to accommodate the vapor nozzle. The control volume shell can have any hollow shape to substantially enclose the ink nozzle and the gap. The hollow shapes include, but are not limited to, cylindrical, conical, rectangular, frusto-conical, elliptical, or any combination thereof. In some alternative aspects, additional solvent can be dispersed as vapor into the control volume shell during layer formation to help manage the amount of evaporation immediately after the layer of ink composition is deposited.

[0094] In some embodiments, the bed or surface on which the ink composition is deposited to form the 3D structure can be a heated bed or surface. The use of a heated bed or surface can assist in the evaporation of the solvent and cause phase inversion to form the polymer structure. In some embodiments, the bed or surface on which the ink composition is deposited to form the 3D printed structure can be heated to a temperature of 40°C to 80°C. [Barrier layer]

[0095] In various embodiments, barrier layers can be added to the process gas flow paths and / or the heat transfer fluid flow paths. In embodiments where the adsorbent is dispersed throughout the volume of the polymeric structural material, barrier layers can optionally, but preferably, be added to the heat transfer flow paths.

[0096] Any suitable type of barrier layer can be used. The barrier layer can be a material with reduced or minimized microporosity so that diffusion of heat transfer fluids and / or process gases through the barrier is reduced or minimized. Examples of suitable materials for the barrier layer can include, but are not limited to, polyvinylidene chloride (PVDC), latex, polyacrylonitrile, epichlorohydrin, polyetheramide block copolymers, and mixtures and / or copolymers of the above. However, other barrier layers, such as ceramic, glass, or metal oxide barrier layers, may also be suitable depending on the structure of the monolith.

[0097] One of the difficulties in adding a barrier layer to a monolith is selectively adding the barrier layer to only the desired flow paths. Traditionally, adding a barrier layer to a monolith has typically been done by dip coating the entire monolith into a solution of the barrier layer. While this can be effective, it applies the barrier layer to both the process gas flow paths and the heat transfer fluid flow paths. In embodiments where the adsorbent is distributed throughout the volume of the monolith that contains the process gas flow paths and the heat transfer fluid flow paths, it is desirable for the heat transfer fluid flow paths to have a barrier layer, while the process gas flow paths may still be substantially free of the barrier layer.

[0098] One option for selectively adding a barrier layer to the heat transfer fluid flow passages is to selectively flow a suitable polymer solution into the heat transfer fluid flow passages to form a barrier layer. To add a barrier layer, the desired flow passages (e.g., heat transfer fluid flow passages) of the monolithic structure are first saturated with water or a solvent. A latex solution (or other barrier polymer solution) can then be flowed through the passages to coat the walls. Air or N2 (or, more specifically, any gas that does not interact with the barrier polymer solution) can then be flowed down the passages to minimize or avoid the formation of blockages in the passages. Flowing air or N2 can be suitable to induce drying of the latex. Humid air / N2 can be used, and improved quality of the passage barrier can be seen. This process of flowing latex (or other polymer solution) followed by air or N2 is repeated until the desired barrier thickness is achieved. In some embodiments, the orientation of the monolithic structure can be reversed each time another cycle of polymer addition is started to ensure good attachment of the barrier layer to both ends of the monolithic structure.

[0099] As another example, in embodiments where the structural material defining the heat transfer fluid flow passages and the process gas flow passages is a porous material, the properties of the contactor described herein can be used to assist in forming an improved barrier layer in the heat transfer fluid flow passages. In this type of example, the process can be started by optionally saturating the heat transfer fluid flow passages with water or a solvent. The polymer solution for forming the barrier layer can then be introduced. The barrier polymer solution can be introduced into the contactor using one heat transfer fluid inlet (or multiple heat transfer fluid inlets) in fluid communication with the heat transfer fluid flow passages. This means that the contactor's distribution system can be used to selectively introduce the polymer solution into the desired (heat transfer fluid) flow passages. During the introduction of the barrier polymer solution, the process gas inlet and the process gas outlet can be connected to a pump, so that the pressure in the process gas flow passages is reduced below the pressure in the heat transfer fluid flow passages. The pressure difference between the process gas flow passages and the heat transfer fluid flow passages can enhance the diffusion of the barrier polymer solution into the bulk structural material defining the heat transfer fluid flow passages. This allows a substantially complete barrier layer to be formed in the heat transfer fluid flow passages while reducing or minimizing loss of flow passage diameter because the resulting increased portion of the barrier layer is within the material of construction.

[0100] The configuration shown in FIG. 1 can be used to illustrate this principle of selectively incorporating a barrier layer, for example, only in the heat transfer fluid paths. In the example configuration shown in FIG. 1, separate headers are provided to manage the flow in the process gas path 130 and the heat transfer fluid path 160. In FIG. 1, the process gas path 130 is incorporated into a flow path that includes a process gas inlet 132, a process gas inlet header 140, a process gas path 130, a process gas outlet header 145, and a process gas outlet 138. Thus, there is fluid communication between all elements in this flow path. A separate flow path is provided for the heat transfer fluid path 160. The flow paths for fluid communication with the heat transfer fluid path 160 include a heat transfer fluid inlet 162, a heat transfer fluid inlet header 170, a heat transfer fluid path 160, a heat transfer fluid outlet header 175, and a heat transfer fluid outlet 168. With these separate flow paths available, the polymer solution can be introduced into selected flow paths, such as the flow path that includes the heat transfer fluid path 160. Optionally, other flow paths (i.e., the flow path including the process gas flow path 130) can be exposed to reduced pressure to further enhance the barrier layer penetrating into the pores around the selected flow path including the heat transfer fluid flow path 160. In such an example, during introduction of the barrier polymer solution and / or the subsequent drying / purging step, one of the heat transfer fluid inlets 162 or heat transfer fluid outlets 168 in the fluid is open to allow the drainage of excess polymer solution or the drainage of drying / purging gas (this open end is different from the inlet or outlet through which the barrier polymer solution or drying / purging gas is introduced). During introduction of the barrier polymer solution and / or during the drying / purging gas step, this open inlet or outlet of the heat transfer fluid system will typically represent the lowest pressure in the heat transfer fluid flow path. In various embodiments, the pressure in the process gas flow path can be reduced such that the pressure in the process gas flow path (e.g., process gas flow path 130) is 5.0 kPa or more lower than the pressure at the open end of the heat transfer fluid system (e.g., heat transfer fluid inlet 162 or heat transfer fluid outlet 168), or by 10 kPa or more, or by 20 kPa or more, for example, up to about 100 kPa. [Flow path configuration]

[0101] In various aspects, the process gas flow paths and the heat transfer flow paths can be configured to enhance or maximize the potential for heat transfer between the flow paths. One option is to have an array of flow paths that enhances or maximizes the overall heat transfer from the multiple process gas flow paths to the multiple heat fluid transfer flow paths. Another option is to have a flow path configuration that enhances or maximizes the interaction between the individual flow paths and the individual heat transfer flow paths. Yet another option can include a combination of improving the interaction between the individual flow paths and the interaction between the array of flow paths. Any suitable combination of flow path arrangements can be used. For example, another option is a three-dimensional arrangement of a set of helically intertwined process gas flow paths and heat transfer fluid flow paths. This can optionally further include linear additional heat transfer fluid flow paths and / or a distributed array of process gas flow paths. Yet another option can be a helical structure of independent but intertwined flow paths.

[0102] In the configuration shown in Figure 1, the process gas flow paths and the heat transfer flow paths are shown as being relatively constant in size and the heat transfer fluid inlet and outlet headers are shown as being substantially parallel in position. This is equivalent to having two three-dimensional arrays of flow paths distributed throughout. This can potentially provide heat transfer between the heat transfer fluid in multiple heat transfer fluid flow paths and any given process gas flow path. Various ratios of process gas flow paths to heat transfer fluid flow paths can be used in this type of configuration.

[0103] 1 shows parallel linear flow paths, other types of flow path configurations may be used. For example, transfer between a pair of flow paths could potentially be increased by using an intertwined helical configuration for the process gas and heat transfer fluid flow paths.

[0104] Yet another option for the flow channel configuration is to allow the dimensions to vary over the length of the flow channel. The dimensions of the flow channels can be described based on the cross-sectional area of ​​the flow channels. Traditionally, contactors have used flow channels with a nearly constant cross-sectional area. Traditionally, it was expected that reducing the cross-sectional area of ​​the downstream part of the flow channel to the extent that the dimensions of the flow channels can be varied would be advantageous in order to compensate for the reduction in the concentration of the adsorbed components as the process gas flows towards the end of the flow channel. However, it was unexpectedly found that improved adsorption can be achieved by increasing the cross-sectional area of ​​the downstream part of the flow channel.

[0105] The increase in cross-sectional area of ​​the downstream portion of the flow path can be accomplished in any suitable manner. One option is to have a continuous increase in cross-sectional area along the length of the flow path, for example, a linear increase in cross-sectional area as the flow path progresses through the material of construction. Another option can be to have one or more step increases in cross-sectional area. Yet another option can be to use a combination of continuous or step increases. Yet another option can be to initially maintain the flow path dimensions and then begin a continuous and / or step increase in cross-sectional area at a downstream location. [Example - Change in process gas flow path dimensions]

[0106] To investigate the effect of mass transfer contactor geometry on kinetic adsorption performance, three adsorption contactors were 3D printed. The three adsorption monolith modules represented a narrow channel monolith, a medium channel monolith, and a wide channel monolith. The wide channel monolith contained square process gas channels with a width of 333 μm. The medium channel monolith contained square process gas channels with a width of 115 μm. The narrow channel monolith had channels with a width of 52 μm.

[0107] The adsorption contactors were fabricated layer by layer. For each contactor, multiple layers of fibers were packed in the z-direction, with each layer consisting of the same number of fibers. Fibers from adjacent layers were deposited in orthogonal directions. To make the adsorption performances fairly comparable, the three adsorption modules had the same overall dimensions (0.9 cm × 0.9 cm × 0.9 cm) and were loaded with the same material (0.27 g of PIM-1). Since the adsorbents were fabricated by the same solution-based additive manufacturing (SBAM) protocol, each fiber of the adsorption modules had the same microporosity (40%) associated with hierarchical pores in the 3D printed adsorbent fibers. The apparent density of the produced PIM-1 fibers was 0.6 g / mL, and the void ratio of each adsorption module was 0.383, as examined by mercury porosimetry. Thus, in this example, the main parameter affecting the kinetic adsorption performance was the contactor structure.

[0108] The adsorption modules were individually packaged in dedicated stainless steel cubes. 16 μm aluminum foil was used to seal the gaps between the stainless steel housing and the structured adsorbent to prevent leak paths. Glass wool was packed between the adsorption modules to prevent radial variations in gas composition.

[0109] FIG. 5 shows two examples of contactor configurations formed using monolith modules. In the first configuration, a medium flow path monolith module and a wide flow path monolith module were inserted into the contactor in a configuration with the medium flow path monolith module located upstream. This is shown in the top part of FIG. 5. For ease of explanation, this adsorbent assembly strategy (shown in the top part of FIG. 5) is called "expanded flow path". This is because the medium flow path adsorbent has a smaller fluid path (115 μm wide) than the wide flow path adsorbent (333 μm wide). In the second configuration, two identical monolith modules were inserted into the contactor, but in a configuration with the wide flow path monolith module located upstream. This is shown in the bottom part of FIG. 5. This adsorbent assembly strategy is called "reduced flow path".

[0110] The adsorption performance of the enlarged and reduced channel assemblies was tested using a simulated flue gas with a composition of 12.5 vol% CO2, 12.5 vol% He, and 75 vol% N2. The PIM-1 material used to form the monolith module adsorbs CO2 but not He or N2. After placing the suitable assembly in the contactor, the simulated flue gas was flowed through the contactor at flow rates of about 10 cm3 / min, 20 cm3 / min, 30 cm3 / min, and 40 cm3 / min. The composition of the exhaust from the contactor was observed, and the CO2 concentration in the contactor exhaust as a function of time was measured. To provide a consistency check, the concentration of He in the flue gas was also observed. Figure 6 shows the results of the adsorption test at an inflow rate of 20 cm3 / min. As shown in Figure 6, the CO2 capacity at 5.0 vol% breakthrough capacity of the enlarged channel assembly was almost doubled compared to the CO2 capacity at 5.0 vol% breakthrough for the reduced channel assembly. Increased breakthrough capacity was also observed at higher flow rates.

[0111] The adsorption contactor assembly with the expanded channel design was also compared to an adsorbent based on a conventional packing material. The expanded channel design used for this comparison was a "3-fold expanded" configuration, including narrow, medium, and wide modules. This was compared to a contactor containing a packed bed of PIM-1-based packing material. To eliminate the effect of internal mass transfer resistance, a multicomponent PIM-1 solution was printed by SBAM to create a random coil, which was then cut into 1 cm long fibers. Due to the identical process history, the PIM-1 fibers and the PIM-1 adsorption contactor modules have the same porosity and therefore the same internal mass transfer coefficient. The PIM-1 fibers were then infiltrated with 25 wt% PEI and packed into the same stainless steel housing.

[0112] In the first set of experiments, a packed bed contactor containing PEI / PIM-1 packing material was compared to the extended channel design. The packed bed was created by randomly packing PEI / PIM-1 fibers into the bed. The PEI / PIM-1 (0.18 g / 0.54 g) packed bed (0.9 cm × 0.9 cm × 1.8 cm) was tested with the same simulated flue gas at 20 cm3 / min. As shown in Figure 7, the packed bed adsorbent and the extended channel assembly exhibited very different CO2 breakthrough curves, even though these two contactors have the same void ratio, the same amount of adsorbent, and the same overall dimensions. The packed bed adsorbent exhibited a slightly earlier CO2 breakthrough (59 s) and a sharper CO2 concentration increase from 0 to 9.8% at 100 s. In comparison, the extended channel assembly exhibited a delayed CO2 breakthrough (77 s) and a slower CO2 concentration increase from 0 to 9.8% at 250 s. Without being bound to any particular theory, it is believed that the faster CO2 breakthrough of the packed bed adsorber is due to bypassing in loosely packed regions in the packed bed. The curved fluid dispersion paths in the packed bed also allow for more efficient mass transfer, which results in a rapid increase in CO2 concentration. The packed bed adsorber shows a longer and flatter CO2 breakthrough tail than the expanded channel assembly, indicating less efficient heat removal in the packed bed adsorber. The packed bed adsorber shows a 5% breakthrough capacity of 0.43 mmol and a total capacity of 1.08 mmol. In comparison, the expanded channel assembly shows a 33% increase in CO2 capacity for the 5% breakthrough threshold.

[0113] Another advantage of the modular adsorption contactor is the low pressure drop. Figure 8 shows the normalized pressure drop for modular adsorption contactor assemblies and fiber beds packed in two different ways when exposed to nitrogen at superficial velocities ranging from 0.16 cm / s to 1.83 cm / s. In one type of packing, the fibers were randomly packed. In the other type of packing, aligned fibers were used to form the bed. When packed into very short adsorbents (1.8 cm long), aligned fiber packings typically exhibit bypass effects. A random fiber packing adsorbent eliminates the challenge of fluid bypass, but offers higher resistance to the fluid. No difference in pressure drop could be observed between the expanding and contracting channel assemblies. This is consistent with predictions. Since the length of the individual adsorption modules is greater than the diameter of the channels, fully developed flow is expected in most of the assemblies. As a result, inlet effects due to expansion and contraction should not play a large role, and therefore the order of the modules should not be important with respect to flow resistance. Further embodiments

[0114] EMBODIMENT 1 a plurality of first process gas flow paths defined by a monolithic material of construction, the material of construction including at least one adsorbent component; a plurality of second heat transfer fluid flow paths defined by a structural material of the monolithic structure; one or more process gas inlet headers in fluid communication with the process gas flow path; one or more heat transfer fluid inlet headers in fluid communication with the heat transfer fluid flow paths, at least one of the one or more process gas inlet headers and the one or more heat transfer fluid inlet headers being defined by a material of construction of the monolithic structure; at least one outlet header in fluid communication with the process gas flow path or the heat transfer fluid path.

[0115] EMBODIMENT 2 2. The adsorption module of embodiment 1, wherein a mean axis of flow for the process gas flow path differs from a mean axis of flow for the heat transfer fluid flow path by no more than 30° within a central volume of the monolithic structure.

[0116] EMBODIMENT 3 20. The adsorption module of claim 19, wherein a first portion of the process gas flow path has an average cross-sectional area that is smaller than a cross-sectional area of ​​a second portion of the process gas flow path, the second portion of the process gas flow path being downstream from the first portion of the process gas flow path, and the average cross-sectional area of ​​the process gas flow path optionally increases continuously along at least a portion of the process gas flow path.

[0117] EMBODIMENT 4 the monolithic structure includes a contactor; The adsorption module comprises: a process gas outlet header in fluid communication with the process gas flow path, the process gas outlet header being defined by the monolithic material of construction; An adsorption module as described in any one of the above-mentioned embodiments, comprising: a heat transfer fluid outlet header in fluid communication with the heat transfer fluid flow path, the heat transfer fluid outlet header being defined by the structural material of the monolithic structure.

[0118] EMBODIMENT 5 i) the adsorption module comprises a secondary inlet header defined by the structural material of the monolithic body, the heat transfer fluid inlet header providing fluid communication between the secondary inlet header and the heat transfer fluid flow path; or ii) the adsorption module comprises a further inlet header defined by the structural material of the monolith, the process gas inlet header providing fluid communication between the further inlet header and the process gas flow path; or iii) An adsorption module according to embodiment 4, in which a combination of i) and ii) is provided.

[0119] EMBODIMENT 6 An adsorption module described in any one of the above-mentioned embodiments, wherein the integral structure comprises a monolith, and the adsorption module further comprises a plurality of shell pieces, and the monolith is at least partially contained within the plurality of shell pieces.

[0120] EMBODIMENT 7 a) the adsorption module comprises a secondary inlet header including a volume between the monolith and at least one of the plurality of shell pieces, the heat transfer fluid inlet header providing fluid communication between the secondary inlet header and the heat transfer fluid flow path; or b) the adsorption module comprises a further inlet header including a volume between the monolith and at least one of the shell pieces, the heat transfer fluid inlet header providing fluid communication between the further inlet header and the process gas flow path; or c) An adsorption module according to embodiment 6, in which a combination of a) and b) is provided.

[0121] EMBODIMENT 8 The adsorption module of any one of the preceding embodiments, wherein the structural material comprises a composite material of a polymeric material and the at least one adsorbent component, and the at least one adsorbent component of the structural material optionally comprises a metal-organic framework material, a material comprising a zeotype framework structure, a polymeric material, or a combination thereof.

[0122] EMBODIMENT 9 4. The sorption module of any one of the preceding embodiments, wherein the material of construction comprises cellulose acetate, polyvinylpyrrolidone, polyether sulfone, polysulfone, epichlorohydrin, polyetheramide block copolymers, polyimide, polyolefin, polypropylene, polyethylene, polyamide, poly(tetrafluoroethylene), polyvinylidene chloride (PVDC), polystyrene, polyisobutylene, polybutadiene, polyurethane, elastomers, copolymers thereof, polymers of inherent microporosity, or combinations thereof.

[0123] EMBODIMENT 10 4. The adsorption module of any one of the preceding embodiments, wherein the heat transfer fluid inlet header and the heat transfer fluid flow passages further comprise a barrier layer.

[0124] EMBODIMENT 11 The adsorption module of any one of the preceding embodiments, wherein the at least one adsorbent component comprises at least one adsorbent for CO2.

[0125] EMBODIMENT 12 1. A method for forming a barrier layer within a flow channel of an adsorption contactor, comprising the steps of: Providing an adsorption module according to any one of claims 1 to 11; directing a solution including a polymeric barrier component into the heat transfer fluid flow path; flowing a purge flow through the heat transfer fluid flow passages to form a barrier layer on surfaces of the heat transfer fluid flow passages; and during at least one of the steps of directing the solution into the heat transfer fluid flow path and flowing the purge stream through the heat transfer fluid flow path, reducing the pressure in the process gas flow path to a pressure of at least 5 kPa-a below an average pressure associated with the heat transfer fluid path during the step of flowing the purge stream.

[0126] EMBODIMENT 13 13. The method of embodiment 12, further comprising repeating the steps of directing the solution, flowing the purge flow, and reducing the pressure a plurality of times.

[0127] EMBODIMENT 14 a monolith including a plurality of first process gas flow paths and a plurality of second heat transfer fluid flow paths; a shell comprising a first shell piece and a second shell piece, the first shell piece being a unitary structure comprising a polymeric structural material, the first shell piece comprising a process gas inlet header, the monolith at least partially residing within a volume defined by the first shell piece and the second shell piece, the plurality of first process gas flow passages being in fluid communication with the process gas inlet header; at least one outlet header in fluid communication with the process gas flow path or the heat transfer fluid path.

[0128] EMBODIMENT 15 15. The adsorption module of embodiment 14, wherein the monolith comprises a ceramic monolith, a metal monolith, or a combination thereof, the monolith optionally comprising an adsorbent coated thereon.

[0129] While the present invention has been described and illustrated with reference to specific embodiments, those skilled in the art will recognize that the present invention is useful in variations not necessarily illustrated herein, and therefore, reference should be made solely to the appended claims in order to determine the true scope of the present invention.

Claims

1. a plurality of process gas flow paths defined by a monolithic material of construction, the material of construction including at least one adsorbent component; a plurality of heat transfer fluid flow passages defined by a structural material of the monolithic structure; one or more process gas inlet headers in fluid communication with the process gas flow path; one or more heat transfer fluid inlet headers in fluid communication with the heat transfer fluid flow paths; at least one of the one or more process gas inlet headers and the one or more heat transfer fluid inlet headers are defined by a material of construction of the monolithic structure; The adsorption module further comprises at least one outlet header in fluid communication with the process gas flow path or the heat transfer fluid flow path.

2. 2. The adsorption module of claim 1, wherein a mean axis of flow for said process gas flow passages differs from a mean axis of flow for said heat transfer fluid flow passages by no more than 30[deg.] within a central volume of said monolithic structure.

3. 2. The adsorption module of claim 1, wherein a first portion of the process gas flow path has an average cross-sectional area that is smaller than a cross-sectional area of ​​a second portion of the process gas flow path, the second portion of the process gas flow path being downstream from the first portion of the process gas flow path, and wherein the average cross-sectional area of ​​the process gas flow path optionally increases continuously along at least a portion of the process gas flow path.

4. the monolithic structure includes a contactor; The adsorption module comprises: a process gas outlet header in fluid communication with the process gas flow path, the process gas outlet header being defined by the monolithic material of construction; 2. The adsorption module of claim 1, further comprising: a heat transfer fluid outlet header in fluid communication with said heat transfer fluid flow passages, said heat transfer fluid outlet header being defined by a structural material of said monolithic body.

5. i) the adsorption module comprises a secondary inlet header defined by the structural material of the monolithic body, the one or more heat transfer fluid inlet headers providing fluid communication between the secondary inlet header and the heat transfer fluid flow path; or ii) the adsorption module comprises a further inlet header defined by the structural material of the monolith, the one or more process gas inlet headers providing fluid communication between the further inlet header and the process gas flow path; or iii) A combination of i) and ii) is provided according to claim 4.

6. 10. The adsorption module of claim 1, wherein the unitary structure comprises a monolith, the adsorption module further comprising a plurality of shell pieces, the monolith being at least partially contained within the plurality of shell pieces.

7. a) the adsorption module comprises a secondary inlet header including a volume between the monolith and at least one of the shell pieces, the one or more heat transfer fluid inlet headers providing fluid communication between the secondary inlet header and the heat transfer fluid flow path; b) the adsorption module comprises a further inlet header including a volume between the monolith and at least one of the shell pieces, the one or more heat transfer fluid inlet headers providing fluid communication between the further inlet header and the process gas flow path; or 7. The adsorption module of claim 6, wherein a combination of a) and b) is provided.

8. 2. The adsorption module of claim 1, wherein the structural material comprises a composite material of a polymeric material and the at least one adsorbent component, the at least one adsorbent component of the structural material optionally comprising a metal organic framework material, a material comprising a zeotype framework structure, a polymeric material, or a combination thereof.

9. 2. The adsorption module of claim 1, wherein the material of construction comprises cellulose acetate, polyvinylpyrrolidone, polyether sulfone, polysulfone, epichlorohydrin, polyetheramide block copolymers, polyimide, polyolefin, polypropylene, polyethylene, polyamide, poly(tetrafluoroethylene), polyvinylidene chloride (PVDC), polystyrene, polyisobutylene, polybutadiene, polyurethane, elastomers, copolymers thereof, polymers of inherent microporosity, or combinations thereof.

10. The adsorption module of claim 1 , wherein the one or more heat transfer fluid inlet headers and the heat transfer fluid flow passages further comprise a barrier layer.

11. The at least one sorbent component comprises at least one CO ２ The adsorption module of claim 1 comprising an adsorbent for

12. 1. A method for forming a barrier layer within a flow channel of an adsorption contactor, comprising the steps of: Providing an adsorption module according to any one of claims 1 to 11; directing a solution including a polymeric barrier component into the heat transfer fluid flow path; flowing a purge flow through the heat transfer fluid flow passages to form a barrier layer on surfaces of the heat transfer fluid flow passages; during at least one of the steps of directing the solution into the heat transfer fluid flow path and flowing the purge stream through the heat transfer fluid flow path, reducing the pressure in the process gas flow path to a pressure of at least 5 kPa-a below an average pressure associated with the heat transfer fluid flow path during the step of flowing the purge stream.

13. 13. The method of claim 12, further comprising repeating the steps of directing the solution, flowing the purge flow, and reducing the pressure a plurality of times.

14. a monolith including a plurality of first process gas flow paths and a plurality of second heat transfer fluid flow paths; a shell comprising a first shell piece and a second shell piece, the first shell piece being a unitary structure comprising a polymeric structural material, the first shell piece comprising a process gas inlet header, the monolith at least partially residing within a volume defined by the first shell piece and the second shell piece, the plurality of first process gas flow passages being in fluid communication with the process gas inlet header; at least one outlet header in fluid communication with the process gas flow path or the heat transfer fluid flow path.

15. 15. The adsorption module of claim 14, wherein the monolith comprises a ceramic monolith, a metal monolith, or a combination thereof, the monolith optionally comprising an adsorbent coated thereon.

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