An efficient and fully automated catalytic direct air capture system for carbon dioxide

Abstract

An efficient, low-energy carbon dioxide removal system includes an automated air moving device equipped with sensor devices for measuring flow, volume, level, pressure, temperature and concentration. A packing material and an air-liquid distributor are used in a multi-stage catalytic reactor. The multi-stage catalytic reactor processes ambient air to produce pure carbon dioxide gas and produces and releases exhaust gas to the ambient air. During operation, the air is contacted with a basic solution in the presence of a catalyst through the air moving device, distributor and packing material. The air reacts with the basic solution to produce a basic solution containing carbon dioxide and an exhaust is produced (adsorption reaction). The exhaust is then released from the reactor. A catalyst is then added and heat is added to the basic solution containing carbon dioxide to produce carbon dioxide and a basic solution without carbon dioxide (desorption reaction).

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit under 35 U.S.C. § 120 of U.S. Nonprovisional Patent Application No. 18 / 091,315, filed December 29, 2022, entitled “EFFICIENT AND FULLY AUTOMATED CATALYTIC DIRECT AIR CARBON DIOXIDE CAPTURE SYSTEM.” U.S. Nonprovisional Patent Application No. 18 / 091,315 claims the benefit under 35 U.S.C. § 119 of U.S. Provisional Patent Application No. 63 / 295,942, filed on January 2, 2022, entitled “FULLY AUTOMATED DIRECT AIR CAPTURE CARBON DIFFERENTIAL TREATMENT SYSTEM.” This application also claims the benefit under 35 U.S.C. § 120 of U.S. Nonprovisional Patent Application No. 17 / 948,492, filed September 20, 2022, entitled “FULLY AUTOMATED DIRECT AIR CAPTURE CARBON DIFFERENTIAL TREATMENT SYSTEM.” U.S. Nonprovisional Patent Application No. 17 / 948,492 claims the benefit under 35 U.S.C. § 119 of U.S. Provisional Patent Application No. 63 / 295,942, entitled “Fully Automated Direct Air Capture Carbon Dioxide Treatment System,” filed on January 2, 2022. This application also claims the benefit under 35 U.S.C. § 119 of U.S. Provisional Patent Application No. 63 / 295,942, filed January 2, 2022, entitled “FULLY AUTOMATED DIRECT AIR CAPTURE CARBON DIFFERENTIAL TREATMENT SYSTEM.” The subject matter of each of the above-listed documents is incorporated herein by reference.

[0002] (Technical field) The present invention relates generally to a scalable, large-scale, industrial carbon dioxide removal processing system, and more particularly to a system for efficiently removing carbon dioxide from air. [Background technology]

[0003] In chemical manufacturing plants and downstream refinery processes, acid gases including H2S and CO2 are often removed from exhaust gas mixtures at concentrations between 15 and 50% by weight using amines or metal carbonates such as those used in natural gas desulfurization processes. The amines or carbonates react with CO2 gas to form salts that can be reversibly decomposed at moderately elevated temperatures into the starting amine or carbonate and acid gases. This process is used in industrial-scale removal of exhaust gases carrying H2S or carbon dioxide (CO2) in manufacturing plants, but has not been applied to the direct removal of CO2 from air, where the concentration of CO2 is limited to anywhere between 200 and 1000 ppm. Summary of the Invention

[0004] In various exemplary embodiments, a system is disclosed that provides a scalable, efficient, and fully automated catalytic direct air capture of carbon dioxide. In one embodiment, the carbon processing system includes an air moving device, packing material, fully automated remote sensing devices for flow, pressure, temperature, and level, a water condensation system, and a multi-stage reactor. The multi-stage reactor processes ambient air to produce carbon dioxide and produces exhaust gases to be released to the environment. The produced carbon dioxide can be used in sequestration, as mobile and stationary refrigerants for low global warming, as industrial refrigerants for low global warming, as cement, as a raw material, or as a starting material for the production of useful chemicals including urea, methanol, formaldehyde, esters, ethers, hydrocarbons, polymers, plastics, carbon monoxide, or in the production of carbon dioxide derived commodity materials such as dry ice.

[0005] Therefore, in liquid solvents including water, alcohol and glycol solutions, in the presence of packing materials, adsorption catalysts and desorption catalysts, M2 2+ CO3 2- ("M" stands for K + , Na + , Li + , NH4 + , Quaternary ammonium+ A novel process is provided that captures CO2 directly from air with high conversion and selectivity using a carbon-based catalyst (such as a fluorine-containing catalyst, a salt of an amino acid, or melamine). The carbon treatment system uses a base medium that is regenerated during the novel process and reused during each carbon treatment cycle. This provides significant automation capabilities and scalability of the carbon treatment system.

[0006] In one embodiment, a method for carbon processing is provided. First, an air flow is generated above a packing material. The packing material provides a distributed surface area to receive a base medium. The packing material is produced using additive or subtractive manufacturing techniques, such as a three-dimensional (3D) printing process. The packing material is then successively coated with a base medium until the base medium acquires a first carbon dioxide concentration. The base medium with the first carbon dioxide concentration is then heated to remove carbon dioxide.

[0007] In one embodiment, an apparatus for carbon processing is provided. The apparatus includes an air moving device, a pump, and a heating reservoir. The air moving device generates an air flow above the packing material. The pump continuously coats the packing material with a base medium until the base medium acquires a first carbon dioxide concentration. The heating reservoir heats the base medium having the first carbon dioxide concentration to remove carbon dioxide.

[0008] Further details and embodiments and methods are described in the following detailed description. This summary is not intended to define the invention, which is defined by the claims.

[0009] In the accompanying drawings, where like numerals refer to like elements, an embodiment of the present invention is illustrated. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram of a carbon processing system.

[0011] [Diagram 2] FIG. 2 is a functional schematic of the first stage (adsorption stage) of the carbon processing system.

[0012] [Diagram 3] FIG. 3 is a functional schematic diagram of the second stage (desorption stage) of the carbon processing system.

[0013] [Figure 4] FIG. 4 is a detailed embodiment of a carbon processing system.

[0014] [Diagram 5] FIG. 5 is a flow chart of a method for treating carbon according to one embodiment of a carbon treatment system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Reference will now be made in detail to several embodiments of the invention, examples of which are illustrated in the accompanying drawings.

[0016] 1 is a schematic diagram of a carbon processing system 10. The carbon processing system 10 includes an air mover 27 and a multi-stage reactor having a first stage 11 and a second stage 19. The first stage 11 includes a packing material 13, a distributor 12, a collection vessel 15, and a pump 17. The second stage 19 includes a reservoir 21 and a make-up system 22. The system 10 also includes a controller 26 that receives inputs from various sensors and provides outputs to valves and other control mechanisms to control the operation and processing of the first stage 11 and the second stage 19.

[0017] In one embodiment, carbon processing system 10 employs direct air capture technology. For example, carbon processing system 10 uses air moving device 27 to supply air 14 to system 10 for processing. Air moving device 27 includes at least one of a compressor, a blower, a fan, a turbofan, a pump, a diaphragm pump, an air contactor, a falling film evaporator, or an air absorber. A multi-stage reactor includes a single vessel or two or more vessels that provide multiple stage functions.

[0018] The multi-stage reactor contains a base medium 25. The base medium is a mixture of water, alcohol, and M2 2+ CO3 2- In this general chemical formula, the symbol "M" is a cationic species, for example K + , Na + , Li + , NH4 + , or N(CH3) 4+ , N(ethylmethyl)4 + , N(butyl)4 + or mixtures thereof.

[0019] In another embodiment, the base medium 25 contains a catalyst or accelerator. Sodium, potassium or ammonium salts of amino acids such as glycine, proline, arginine and guanidine are used as accelerators to double and in some cases triple the rate of the adsorption reaction. A concentration of 0.1-5% by weight is sufficient. Alternatively, 40-60% of the aqueous solution is also used as base in the absence of carbonate.

[0020] During operation, the air moving device 27 moves air 14 containing less than 800 PPM CO2 above the packing material 13. The pump 17 pumps the base medium 25 from the collection vessel 15 to the distributor 12, which distributes the base medium 25 evenly above the packing material 13. Any excess base medium 25 above the packing material 13 flows back into the collection vessel 15. Thus, the pump 17 continuously circulates the base medium 25 from the collection vessel 15 to the distributor 12 and above the packing material 13.

[0021] As the base media 25 is dispersed above the packing material 13, the air flow 14 across the packing material 13 results in CO2 being removed from the air flow 14. As a result, CO2 is captured within the base media 25. The CO2 concentration of the base media 25 in the collection vessel 15 begins to increase and the CO2 concentration in the exhaust air 18 decreases.

[0022] In one embodiment, the CO2 detector 16 detects the CO2 concentration in the base medium 25. When the CO2 concentration reaches a threshold level, the base medium 25 in the collection vessel 15 is moved to the reservoir 21 of the second stage 19. In one embodiment, additional base medium is then added to the collection vessel 15.

[0023] In the second stage 19, heat 24 is applied to the carbon dioxide-rich base medium to extract carbon dioxide 23. A catalyst is used to facilitate the desorption process. The output of the reservoir 21 flows through a make-up system 22 which regenerates the carbon dioxide-free base medium 25, which then flows back to the collection vessel 15. The carbon dioxide-free base medium 25 can be reused in treating new air. The extracted carbon dioxide 23 is then output from the second stage 19. The adsorption reaction in the first stage 11 and the desorption reaction in the second stage 19 are reversible reactions, so that the base medium is regenerated to the state it was in before contacting the air.

[0024] The carbon processing system 10 is highly scalable and consumes less processing power than required by many conventional carbon processing techniques.

[0025] 2 is a functional schematic diagram of the first stage 11 (adsorption stage) of the carbon processing system 10. During operation, air 14 contacts the base medium and carbon dioxide is extracted to form a base medium 20 with a high concentration of CO2. Exhaust air 18 with reduced CO2 levels is discharged. The base medium 20 with a high concentration of CO2 is transferred to the second stage 19 of the reactor.

[0026] 3 is a functional schematic diagram of the second stage 19 (desorption step) of the carbon processing system 10. During operation, heat 24 is applied to the base medium 20 containing a high concentration of CO2 to extract carbon dioxide 23. The base medium 25 is returned to its original, CO2-free state and returned to the first stage 19.

[0027] FIG 4 is a detailed embodiment of carbon processing system 10. FIG 4 shows the first stage reactor 11 and the second stage reactor 19 of carbon processing system 10. The first stage reactor 11 includes a fan 11, a distributor 12, a packing material 13, a condenser 402, a mist eliminator 404, a collection vessel 15, and a pump 17. The second stage reactor 19 includes a reservoir 21 and a make-up system 22.

[0028] In various embodiments, the packing material 13 comprises a film fill designed to expose as much of the base media surface area as possible to as much air as possible for as long as possible. The film fill allows the base media to form a thin, flowing sheet, exposing as much of the base media surface area as possible to the interacting air stream. A variety of commercially available film fill products are suitable for use with embodiments of the carbon treatment system 10.

[0029] In various embodiments, the base medium is formed in one or more different forms and includes one or more catalysts to promote CO2 adsorption. The controller 26 operates to output control signals used to control various operations of the first stage 11 and the second stage 19. The controller 26 also receives sensor inputs from various sensors (e.g., CO2, temperature, etc.) and detectors used to monitor the operation of the first stage 11 and the second stage 19.

[0030] During operation, the pump 17 draws the base medium having a low CO2 concentration 25 from the collection vessel 15 and supplies the base medium 25 to the distributor 12. The distributor 12 distributes the base medium 25 evenly over the packing material 1. The fan 11 moves the air across the packing material 13 so that the CO2 in the air is captured by the base medium 25 flowing over the packing material 13. After the airflow passes through the packing material 13, it moves through the condenser 402. The condenser 402 condenses any media in the air and returns it to the collection vessel 15. The mist eliminator 404 removes any mist of base medium that may remain in the airflow. The exhaust air 18 is released with a low concentration of CO2 or no CO2.

[0031] When the CO2 concentration in the base medium 25 reaches a threshold level, the base medium with high CO2 concentration 20 is transferred to the reservoir 21 of the second stage reactor 19. A catalyst is also added to the reservoir 21 to facilitate CO2 absorption. Heat 24 is applied to the reservoir 21 to extract a portion of the base medium 25 with low CO2 concentration and the base medium 406 with high CO2 concentration. The make-up system 22 separates the CO2 410 from the base medium 25, which is returned to the first stage reactor 11. The make-up system 22 compensates for the loss of liquid volume by adding liquid medium to the base medium 25 with low CO2 concentration. The CO2 410 extracted from the base medium 25 is compressed in stages in the compression system 450 to become supercritical carbon dioxide or liquid carbon dioxide 23. The carbon dioxide 23 is fed to a sequestration system, used as a low global warming refrigerant, or output for use in any suitable application.

[0032] 5 is a flow chart of a method 500 for treating carbon in accordance with one embodiment of a carbon processing system. The method 500 includes operations performed by a first stage (adsorption) 11 and an operation performed by a second stage (desorption) 19. In one embodiment, the method 500 is performed by the carbon processing system 10.

[0033] At block 502, a base medium is generated and placed in a collection vessel of a first stage of a carbon processing system. For example, base medium 25 is generated according to any of the embodiments disclosed herein and placed in collection vessel 15 of first stage reactor 11.

[0034] At block 504, a pump circulates the base medium from the collection vessel to a distributor, which distributes the base medium above the packing material. For example, pump 17 distributes base medium 25 to distributor 12, which distributes base medium 25 above the packaging material 13.

[0035] In block 506, an air moving device is activated to move air above the packing material. For example, a fan 11 moves air having a certain CO2 concentration above the packing material 13 covered with the base medium 25.

[0036] In block 508, the air comes into contact with the base medium. For example, the air comes into contact with the base medium 25 on the packing material 13, and CO2 in the air is captured by the base medium 25.

[0037] In block 510, the exhaust air is condensed to recover the base medium, for example, air exiting the packing material 13 passes through a condenser 402 and the base medium 20 received by the condenser 402 is returned to the recovery vessel 15.

[0038] In block 512, the exhaust air is de-misted and released. For example, air leaving the condenser 402 is de-misted by the mist eliminator 404, and air 18 with zero or reduced CO2 concentration is released.

[0039] At block 514, it is determined whether the CO2 concentration of the base media meets a threshold level. For example, the controller 26 receives various sensor inputs to determine when the CO2 concentration in the base media meets the threshold level. The threshold level can be set to any suitable level. For example, the controller 26 receives CO2 detection levels in the collection vessel 15, the input air stream, and the exhaust air stream 18. The controller 26 uses the detected CO2 levels to determine when the base media has a CO2 concentration that meets the threshold level. The controller 26 also receives various sensor inputs, such as temperature sensor, liquid level sensor, and other sensor inputs, and uses these inputs to determine the operation of the system to determine when the base media meets the threshold level of CO2 concentration. If the CO2 concentration of the base media does not exceed the threshold level, the method proceeds to block 504. If the CO2 concentration of the base media exceeds the threshold level, the method proceeds to block 516.

[0040] In block 516, the base medium having a CO2 concentration above a threshold level is heated with a catalyst to produce a CO2-rich medium, e.g., the CO2-rich medium 406 is produced.

[0041] At block 518, the carbon dioxide and base medium are separated from the CO2 rich medium. For example, the resupply system 22 separates the carbon dioxide 23 and base medium 25 from the CO2 rich medium 406.

[0042] In block 520, the recovered base medium is returned to the first stage. For example, the base medium 25 with a low CO2 concentration is returned to the first stage 11.

[0043] At block 522, the CO2 is collected and used for any suitable purpose. For example, CO2 23 is collected for further use.

[0044] Thus, the method 500 operates to provide carbon dioxide processing to remove CO2 from air. It should be noted that the operations of the method 500 are exemplary and that operations may be added, deleted, rearranged, or otherwise modified within the scope of the embodiments.

[0045] Various embodiments for producing base media and catalysts for use in the novel carbon processing system are described below, with minor modifications and adjustments clearly existing within the scope of the embodiments.

[0046] <Embodiment #1> In a first embodiment, the base medium is 1 kg mole of M2 2+ CO3 2- ("M" stands for K + , Na + , Li + , NH4 + , or a quaternary ammonium cation +) A base is mixed with water to produce an aqueous solution having a concentration between 1% and 100% by weight. More specifically, the concentration is 20% to 80% by weight, or 20% to 40% by weight. A catalyst including an amino acid salt such as glycine is added to the aqueous solution at 0.1 to 5% by weight.

[0047] One kilogram mole of pure CO2 (99.9% purity) is contacted with the aqueous solution in an autoclave under stirring at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 60°C, or between 40°C and 70°C. Once most of the CO2 has been absorbed by the aqueous solution, the autoclave overhead pressure is released. General chemical formula: MO-(OH) n is added at 0.1-5 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0048] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-130°C or between 70-125°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 100% and 100%, respectively. The conversion and selectivity in the desorption step were about 90-100% and 99.99%, respectively.

[0049] <Embodiment #2> In a second embodiment, the base medium is 1 kg mole of M2 2+ CO3 2- ("M" stands for K + , Na + , Li + , NH4 + , or a quaternary ammonium cation +) A base is mixed with water to produce an aqueous solution having a concentration between 1% and 100% by weight. More specifically, the concentration is 20% to 80% by weight, or 20% to 40% by weight. A catalyst including an amino acid salt such as glycine is added to the aqueous solution at 0.1 to 5% by weight.

[0050] One kg mole of CO2 in an air stream with a CO2 concentration of 400 ppm is contacted with the aqueous solution over time in a continuous flow reactor at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 60°C, or between 40°C and 50°C. Once most of the CO2 has been absorbed by the aqueous solution, the overhead pressure is released. General chemical formula: MO-(OH) n is added at 0.1-5 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0051] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-130°C or between 70-125°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 30-70% and 99%, respectively. The conversion and selectivity in the desorption step were about 70-100% and 99%, respectively.

[0052] <Embodiment #3> In a third embodiment, the base medium is 1 kg mole of M2 2+ CO3 2- ("M" stands for K + , Na + , Li + , NH4 + , or a quaternary ammonium cation +) A base is mixed with water to produce an aqueous solution having a concentration between 1% and 100% by weight. More specifically, the concentration is 20% to 80% by weight, or 20% to 40% by weight. A catalyst including an amino acid salt such as glycine is added to the aqueous solution at 0.1 to 5% by weight.

[0053] The equivalent of 1 kg mole of CO2 in a flue gas stream with a CO2 concentration of 10-35 wt% is contacted with the aqueous solution over time in a continuous flow reactor at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 60°C, or between 40°C and 70°C. Once most of the CO2 has been absorbed by the aqueous solution, the overhead pressure is released. General Chemical Formula MO-(OH) n is added at 0.1-5 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0054] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-130°C or between 70-125°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 30-70% and 99%, respectively. The conversion and selectivity in the desorption step were about 70-100% and 99%, respectively.

[0055] <Embodiment #4> In the fourth embodiment, the configuration is the same as the second embodiment (#2), but instead of using an air liquid contactor, a bubble column reactor was used, and conversions of 85-90% and selectivities of 99% were achieved.

[0056] <Embodiment #5> In the fifth embodiment, the setup is the same as the second embodiment (#2) except that a 50%-50% by weight mixture of water and glycol is used as the solvent instead of 100% water. The conversion and selectivity to CO2 were similar to the second embodiment (#2), but the water loss was minimized to 1-3% instead of the usual 5-7%.

[0057] <Embodiment #6> In the sixth embodiment, the setup is the same as the second embodiment (#2), except that a 50%-50% mixture of water and alcohol was used as the solvent instead of 100% water. The conversion and selectivity to CO2 were comparable to the second embodiment (#2).

[0058] <Embodiment #7> In the seventh embodiment, the setup is the same as the second embodiment (#2), except that a 50 wt%-50 wt% mixture of water and PGMEA was used as the solvent instead of 100% water. The conversion and selectivity to CO2 were comparable to the second embodiment (#2), but the water loss was limited to 3%.

[0059] <Embodiment #8> In an eighth embodiment, the base medium has a Q of 1 kg mole + X - ("Q" is a tetramethyl quaternary ammonium, tetraethyl quaternary ammonium, ethyl trimethyl quaternary ammonium, tetrabutyl quaternary ammonium, methyl tributyl quaternary ammonium, or methyl ethyl dibutyl quaternary ammonium cation, and "X" is OH. - ) A base is mixed with water to produce an aqueous solution having a concentration between 1% and 100% by weight. More specifically, the concentration is 20% to 80% by weight, or 20% to 40% by weight. A catalyst including an amino acid salt such as glycine is added to the aqueous solution at 0.1 to 5% by weight.

[0060] The equivalent of 1 kg mole of CO2 in an air stream with a CO2 concentration of 400 ppm is contacted with the aqueous solution over time in a continuous flow reactor at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 60°C, or between 40°C and 50°C. Once most of the CO2 has been absorbed by the aqueous solution, the overhead pressure is released. General Chemical Formula MO-(OH) n is added at 0.1-5 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0061] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-130°C or between 70-120°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 50-90% and 99%, respectively. The conversion and selectivity in the desorption step were about 70-90% and 99%, respectively.

[0062] <Embodiment #9> In a ninth embodiment, the base medium has a Q of 1 kg mole + X - ("Q" is a tetramethyl quaternary ammonium, tetraethyl quaternary ammonium, ethyl trimethyl quaternary ammonium, tetrabutyl quaternary ammonium, methyl tributyl quaternary ammonium, or methyl ethyl dibutyl quaternary ammonium cation, and "X" is OH. - ) A base is mixed with water and glycerol to produce an aqueous solution having a concentration between 1% and 100% by weight. More specifically, the concentration is 20% to 80% by weight, or 20% to 40% by weight. A catalyst including an amino acid salt such as glycine, proline, or guanidine is added to the aqueous solution at 0.1 to 5% by weight.

[0063] The equivalent of 1 kg mole of CO2 in a flue gas stream with a CO2 concentration of 5-35 wt% is contacted with the aqueous solution over time in a continuous flow reactor at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 60°C, or between 50°C and 75°C. Once most of the CO2 has been absorbed by the aqueous solution, the overhead pressure is released. General chemical formula: MO-(OH) n is added at 0.1-5 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0064] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-130°C or between 70-130°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 80-100% and 99%, respectively. The conversion and selectivity in the desorption step were about 90-100% and 99.9%, respectively.

[0065] <Embodiment #10> In the tenth embodiment, the configuration is the same as the eighth embodiment (#8), but instead of the air liquid contactor, a bubble column reactor is used, and a conversion rate of 85-90% and a selectivity of 99% are achieved.

[0066] <Embodiment #11> In the eleventh embodiment, the setup is the same as the eighth embodiment (#8) except that a 50%-50% by weight mixture of water and glycol is used as the solvent instead of 100% water. The conversion and selectivity to CO2 were similar to the eighth embodiment (#8), but the water loss was minimized to 1-3% instead of the usual 5-7%.

[0067] <Embodiment #12> In the twelfth embodiment, the configuration is the same as the eighth embodiment (#8), except that a 50%-50% by weight mixture of water and alcohol was used instead of 100% water as the solvent. The conversion and selectivity to CO2 were comparable to those of the eighth embodiment (#8).

[0068] <Embodiment #13> In the thirteenth embodiment, the setup is the same as the eighth embodiment (#8), except that a 50 wt%-50 wt% mixture of water and PGMEA was used as the solvent instead of 100% water. The conversion and selectivity to CO2 were similar to the eighth embodiment (#8), but the water loss was limited to 3%.

[0069] <Embodiment #14> In a fourteenth embodiment, the base medium is 1 kg mole of M2 2+ CO3 2- ("M" stands for K + , Na + , Li + , NH4 + , or a quaternary ammonium cation + ) A base, 0.1-1% by weight of glycine, and 0.1-1% by weight of tetrabutylammonium hydroxide are mixed with a solvent mixture of water and glycerol to produce an aqueous solution having a concentration between 1% and 100% by weight. More specifically, the concentration is 20% to 80% by weight, or 20% to 40% by weight.

[0070] One kg mole of CO2 in an air stream with a CO2 concentration of 400 ppm is contacted with the aqueous solution over time in a continuous flow reactor at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 75°C, or between 50°C and 70°C. Once most of the CO2 has been absorbed by the aqueous solution, the overhead pressure is released. General chemical formula: MO-(OH) n is added at 0.1-5 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0071] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-130°C or between 70-120°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 30-70% and 99%, respectively. The conversion and selectivity in the desorption step were about 70-100% and 99%, respectively.

[0072] <Embodiment #15> In a fifteenth embodiment, the base medium has a Q of 1 kg mole + X - ("Q" is a tetramethyl quaternary ammonium cation, a tetraethyl quaternary ammonium cation, an ethyltrimethyl quaternary ammonium cation, a tetrabutyl quaternary ammonium cation, a methyltributyl quaternary ammonium cation, a methylethyldibutyl quaternary ammonium cation, or an ammonium cation; and "X" is OH. - ) A base, 0.1-1% by weight of glycine, and 0.1-1% by weight of potassium hydroxide are mixed with a water-glycerol solvent mixture to produce an aqueous solution having a concentration between 1% and 100% by weight. More specifically, the concentration is 20% to 80% by weight, or 20% to 40% by weight.

[0073] One kg mole of CO2 in an air stream with a CO2 concentration of 400 ppm is contacted with the aqueous solution over time in a continuous flow reactor at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 75°C, or between 50°C and 70°C. Once most of the CO2 has been absorbed by the aqueous solution, the overhead pressure is released. General chemical formula: MO-(OH) n is added at 0.1-2 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0074] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-130°C or between 70-120°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 30-70% and 99%, respectively. The conversion and selectivity in the desorption step were about 70-100% and 99%, respectively.

[0075] <Embodiment #16> In a sixteenth embodiment, the basic medium comprises 1 kg mole of sodium, potassium, ammonium salts, or free forms of glycine, proline, guanidine, or mixtures thereof, in water or a water-glycerol solvent mixture, to form an aqueous solution with a concentration between 1% and 100% by weight, more specifically, 20% and 80% by weight, or 20% and 40% by weight.

[0076] One kg mole of CO2 in an air stream with a CO2 concentration of 400 ppm is contacted with the aqueous solution over time in a continuous flow reactor at a temperature between 5°C and 110°C. More specifically, the temperature is between 10°C and 75°C, or between 50°C and 70°C. Once most of the CO2 has been absorbed by the aqueous solution, the overhead pressure is released. General chemical formula: MO-(OH) n is added at 0.1-2 wt.% of the freshly prepared catalyst, where "M" is Cr, V, Ti, and / or Mo, and "n" is an integer between 1 and 6.

[0077] The steam jacketed desorber is then heated to between 50-150°C. More specifically, the desorber is heated to between 60-150°C or between 70-135°C to desorb CO2. Overhead pure CO2 is bottled for injection. The conversion and selectivity in the adsorption step were 60-70% and 99%, respectively. The conversion and selectivity in the desorption step were about 90-100% and 99%, respectively.

[0078] <Embodiment #17> In a seventeenth embodiment, a high surface area solid material, such as zeolites, molecular sieves, MOFs, etc., that is stable under wet conditions, is pretreated by soaking in an aqueous base solution containing one of the following: potassium or sodium carbonate, tetrabutylammonium hydroxide, or salts of amino acids such as glycine, proline, guanidine, etc., and drying. The base-impregnated solid surface is exposed to air in a continuous flow reactor to capture CO2, which is adsorbed and then desorbed by a temperature swing process to obtain pure CO2 gas as the product.

[0079] Although specific embodiments have been described above for purposes of illustration, the teachings of the patent documents have general applicability and are not limited to the specific embodiments described above. Thus, various modifications, adaptations, and combinations of the various features of the described embodiments may be practiced without departing from the scope of the invention as set forth in the claims.

Claims

1. generating an air flow above the packing material into the ambient air; continuously coating the packing material with the base medium until the base medium attains a first carbon dioxide concentration; heating the base medium having the first carbon dioxide concentration to remove the carbon dioxide; compressing the carbon dioxide removed from the base medium; Equipped with The air flowing along the output side of the packing material has less carbon dioxide than the air flowing along the input side of the packing material. A method characterized by:

2. The method involves capturing carbon dioxide directly from ambient air as a feedstock; The airflow is generated from the surroundings in a non-point source capture environment; The act of generating the airflow includes generating the airflow using an element selected from the group consisting of a compressor, a blower, a fan, a turbofan, a pump, a diaphragm pump, an air contactor, a falling film evaporator, and an air intake system.

2. The method of claim 1 .

3. The continuous coating operation includes uniformly distributing the base medium over the packing material.

2. The method of claim 1 .

4. measuring the first carbon dioxide concentration in situ using one or more automated sensing devices that measure conversion efficiency, flow rate, pressure, temperature, and carbon dioxide concentration in both the air stream and the exhaust air from the packing material.

10. The method of claim 1, further comprising:

5. maintaining the base medium in a collection vessel; dispensing the base medium from the collection vessel to continuously coat the packing material; collecting excess base medium from the packing material into the collection vessel; 10. The method of claim 1, further comprising:

6. The heating operation includes: producing a selected portion of the base medium having a carbon dioxide concentration less than the first carbon dioxide concentration; returning the selected portion of the base medium to the collection reservoir; 6. The method of claim 5, further comprising:

7. The heating operation includes: collecting the base medium having the first carbon dioxide concentration in a desorption chamber; applying a catalyst to the desorption chamber; heating the desorption chamber to extract the carbon dioxide and produce the selected portion of the base medium having a carbon dioxide concentration less than the first carbon dioxide concentration; 7. The method of claim 6, further comprising:

8. forming the catalyst to have the general structure M(O)x(OH)y at a concentration of 0.1 to 5 wt % which lowers the activation energy of the elimination reaction so that the reaction can be carried out at 95°C or below; 8. The method of claim 7, further comprising:

9. The act of heating the desorption chamber includes increasing the chamber temperature to less than 130° C.

8. The method of claim 7.

10. feeding the removed carbon dioxide into a sequestration system or a low global warming refrigerant generation system.

10. The method of claim 1, further comprising:

11. an adsorption reaction occurs when the air stream contacts the base medium; a desorption reaction occurs when heat is applied to the base medium having the first carbon dioxide concentration; The adsorption reaction and the desorption reaction are reversible reactions.

2. The method of claim 1 .

12. forming the base medium to comprise a mixture of solvent and water; Further provided with The solvent is a base comprising at least one of sodium carbonate, potassium carbonate, and lithium carbonate; Dissolved salts of the amino acids glycine, proline, arginine, guanidine, and melamine as catalysts or accelerators; Contains 2. The method of claim 1 .

13. c[M + ]d[Y - forming the base medium to contain a phase transfer catalyst comprising a quaternary ammonium cation having the structure: Further provided with The phase transfer catalyst reduces the interfacial surface tension between the bubbles and the water mist, thereby promoting mixing in a gas-liquid system or a gas-liquid-solid system; M is a cationic species; Y is an anionic species; c and d are integers such that the total charge is neutral 2. The method of claim 1 .

14. preparing the base medium to include a corrosion inhibitor, additive, or accelerator; Further provided with the corrosion inhibitor comprises vanadium pentoxide or other metal oxide; The additive or accelerator includes MEA (monoethanolamine), DEA (diethanolamine), ethylenediamine, TEA (triethanolamine), MDEA (methyldiethanolamine), piperazine, glycine, or any material that lowers the activation energy.

2. The method of claim 1 .

15. an air moving device for generating an air flow above the packing material; a pump that continuously coats the packing material with the base medium until the base medium attains a first carbon dioxide concentration; a heating reservoir for heating the base medium having the first carbon dioxide concentration to remove carbon dioxide; a compression system that compresses the carbon dioxide removed from the base medium; An apparatus comprising:

16. The air moving device is selected from the group consisting of a compressor, a blower, a fan, a turbofan, a pump, a diaphragm pump, an air contactor, a falling film evaporator, and an air intake device.

16. The device of claim 15.

17. a distributor for uniformly distributing the base medium above the packing material; 16. The apparatus of claim 15, further comprising:

18. a processor configured to measure the first carbon dioxide concentration using one or more automated sensing devices that measure conversion efficiency, flow rate, pressure, temperature, and carbon dioxide concentration in both the air stream and the exhaust air from the packing material.

16. The apparatus of claim 15, further comprising:

19. The processor: maintaining the base medium in a collection vessel; dispensing the base medium from the collection vessel to continuously coat the packing material; collecting excess base medium from the packing material into the collection vessel; 20. The apparatus of claim 18, wherein the apparatus performs:

20. The heating reservoir comprises: producing a selected portion of the base medium having a carbon dioxide concentration less than the first carbon dioxide concentration; returning the selected portion of the base medium to the collection reservoir; 16. The apparatus of claim 15, wherein the apparatus performs:

21. The heating reservoir comprises: collecting the base medium having the first carbon dioxide concentration; applying a catalyst to the base medium having the first carbon dioxide concentration; heating the base medium and the catalyst to extract the carbon dioxide and produce the selected portion of the base medium having a carbon dioxide concentration less than the first carbon dioxide concentration; 16. The apparatus of claim 15, wherein the apparatus performs:

22. The catalyst has the general structure M(O)x(OH)y and is present at a concentration of 0.1-5 wt % to lower the activation energy of the elimination reaction so that it can be carried out at temperatures below 95°C.

22. The apparatus of claim 21 .

23. The temperature of the heating reservoir is increased to less than 130°C.

16. The device of claim 15.

24. the air stream having a carbon dioxide concentration between 0 and 100%; The exhaust from the packing material has a lower carbon dioxide concentration 16. The device of claim 15.

25. an adsorption reaction occurs when the air stream contacts the base medium; a desorption reaction occurs when heat is applied to the base medium having the first carbon dioxide concentration; The adsorption reaction and the desorption reaction are reversible reactions.

16. The device of claim 15.

26. the basic medium comprises a mixture of a solvent and water; The solvent is a base comprising at least one of sodium carbonate, potassium carbonate, and lithium carbonate; Dissolved salts of the amino acids glycine, proline, arginine, guanidine, and melamine as catalysts or accelerators; Contains 16. The device of claim 15.

27. The base medium is c[M + ]d[Y - and a hydroxyl anion, The phase transfer catalyst reduces the interfacial surface tension between the bubbles and the water mist, thereby promoting mixing in a gas-liquid system or a gas-liquid-solid system; M is a cationic species; Y is an anionic species; c and d are integers such that the total charge is neutral 16. The device of claim 15.

28. the basic medium includes a corrosion inhibitor, additive, or accelerator; the corrosion inhibitor comprises vanadium pentoxide or other metal oxide; The additive or accelerator includes MEA (monoethanolamine), DEA (diethanolamine), ethylenediamine, TEA (triethanolamine), MDEA (methyldiethanolamine), piperazine, glycine, or any material that lowers the activation energy.

16. The device of claim 15.

29. generating an air flow above the packing material into the ambient air; continuously coating the packing material with the base medium until the base medium attains a first carbon dioxide concentration; heating the base medium having the first carbon dioxide concentration to remove the carbon dioxide; maintaining the base medium in a collection vessel; dispensing the base medium from the collection vessel to continuously coat the packing material; collecting excess base medium from the packing material into the collection vessel; capturing a portion of the base medium from air exiting the packing material; returning the portion of the base medium to the collection vessel; Equipped with The air flowing along the output side of the packing material has less carbon dioxide than the air flowing along the input side of the packing material. A method characterized by:

30. an air moving device for generating an air flow above the packing material; a pump that continuously coats the packing material with the base medium until the base medium attains a first carbon dioxide concentration; a heating reservoir for heating the base medium having the first carbon dioxide concentration to remove carbon dioxide; a processor configured to measure the first carbon dioxide concentration using one or more automated sensing devices that measure conversion efficiency, flow rate, pressure, temperature, and carbon dioxide concentration in both the air stream and the exhaust air from the packing material; An apparatus comprising: The processor: maintaining the base medium in a collection vessel; dispensing the base medium from the collection vessel to continuously coat the packing material; collecting excess base medium from the packing material into the collection vessel; Run The apparatus further comprises: a condenser that captures a portion of the base medium from the exhaust air exiting the packing and returns the portion of the base medium to the collection vessel; An apparatus comprising:

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