Gas separation contactor module assembly and method for fabricating a gas separation contactor module assembly - Patents.com

Abstract

A method of forming a gas separation contactor module assembly (625, 650, and 675) can include stacking and connecting a plurality of contactor modules (250), each formed by providing an adsorbent material (120) on a film (110), heat-treating the combined adsorbent material (120) and film (110), forming a first frame (610), sizing the treated adsorbent material (120) and film (110) to correspond to the first frame (610) to form a sized adsorbent unit (150), and forming an exposure module (260) by placing the adsorbent unit (150) on the top and bottom of the first frame (610). The method further includes disposing at least one of a two-way pipe (612) and a four-way pipe (614) at the corners of the exposure module (260), the two-way pipe (612) and the four-way pipe (614) configured to convey the gas to be treated and / or the heated gas to the gas separation contactor module assemblies (625, 650, and 675). The exposure modules (260) can be stacked vertically and / or horizontally, as can the contactor module assemblies (625, 650, 675).

Description

[Technical Field]

[0001] The present disclosure relates generally to gas separation contactor modules. More particularly, the present disclosure relates to direct air capture modules for adsorptive gas separation and methods for fabricating direct air capture modules and systems incorporating the same. [Background technology]

[0002] Adsorption gas separation processes and systems, such as temperature swing adsorption and partial pressure swing adsorption processes and separators, are known in the art for use in adsorption gas separation in industrial processes. Pressure swing adsorption (PSA) is a technique used to separate several gas species from a mixture of gases (typically air) under pressure according to the species' molecular properties and affinity for the adsorbent material. PSA operates at approximately ambient temperatures and is significantly different from cryogenic distillation, which is commonly used for gas separation. Selective adsorption materials (e.g., zeolites (also called molecular sieves), activated carbon, etc.) are used as trapping materials to preferentially adsorb the gas species of interest at high pressure. The process is then swung to a lower pressure, and the adsorbed gas is desorbed.

[0003] The temperature-vacuum swing (TVS) cycling process is used to separate several gas species from a gas mixture (typically air). TVS can be applied to amine-functionalized nanofibrillated cellulose adsorbents to simultaneously extract CO2 and water vapor from fluids. The promoting effect of relative humidity on the CO2 capture capacity and the amount of water simultaneously adsorbed is quantified.

[0004] Conventional temperature swing adsorption gas separation processes can typically employ two basic steps: an adsorption step and a regeneration or desorption step. In a typical adsorption step, a feed stream, such as a multicomponent gas mixture, can enter an adsorption separator and contactor containing an adsorbent material, which can adsorb components of the feed stream and separate the adsorbed components from the remaining components of the feed stream. In a typical subsequent regeneration step, a regeneration or desorption fluid stream, such as a heated air or steam stream, can be flowed through the adsorption separator and contactor to raise the temperature of the adsorbent material, thereby releasing or desorbing at least a portion of the adsorbed components from the adsorbent material to yield desorbed components, allowing for repeated reuse of the adsorbent material. Conventional adsorption gas separators typically use a single composition of one or more adsorbent materials throughout, such as in a conventional bed of beaded adsorbent or in an adsorbent contactor.

[0005] One type of industrial process in which gas separation may be desirable includes, for example, combustion processes in which an oxidant and a carbon-containing fuel are combusted to generate at least heat and a combustion gas stream (also known as a combustion flue gas stream), in which separation of at least one component from the combustion gas stream may be desirable, such as in post-combustion exhaust gas treatment systems.

[0006] Over the past decade, adsorbents have been used as a class of porous materials for applications in separation, air purification, catalysis, and sensing. Metal-organic frameworks (MOFs) have emerged as a class of adsorbents for applications in separation, air purification, catalysis, and sensing. The ability to tune the functionality and pore structure of MOFs allows unprecedented control at the nanoscale level, which translates into novel properties at the macroscale level. The development of MOF-based technologies depends not only on scaling-related issues but also on the ability to incorporate these highly active assemblies into industrially relevant engineering constructs, such as, but not limited to, granules and membranes. Active packings for applications in filtration and separation can include zeolites, metal oxides, and carbon. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] US Patent Application Publication No. 2011 / 0146487 Summary of the Invention

[0008] All aspects, examples and features described below can be combined in any technically possible manner.

[0009] One aspect of the present disclosure provides a method for forming a gas separation contactor module assembly, the method including: placing an adsorbent material on a film; heat-treating the adsorbent material on the film; sizing the adsorbent material on the film to correspond to the size of a first frame to form an adsorption unit; placing the adsorption unit in the first frame to form a first exposure module; forming second, third, and fourth exposure modules; and attaching at least one of a two-way pipe and a four-way pipe to corners of the first, second, third, and fourth exposure modules, the first exposure module being the upper exposure module and the fourth exposure module being the lower exposure module, the first exposure module being the upper exposure module and the fourth exposure module being the lower exposure module, the two-way pipe and the four-way pipe being positioned at the corners of the gas separation contactor module assembly.

[0010] Another aspect of the present disclosure includes any of the preceding aspects, and further includes stacking the gas separation contactor module assembly such that the gas separation contactor module assembly is connected with at least one other gas separation contactor module assembly to form a connected gas separation contactor module assembly.

[0011] Another aspect of the present disclosure includes any of the preceding aspects, wherein the gas isolation contactor module assemblies are connected at corresponding corners thereof.

[0012] Another aspect of the present disclosure includes any of the preceding aspects, wherein the gas isolation contactor module assemblies share at least one of two-way and four-way pipes located at the corners of the exposed module.

[0013] Another aspect of the present disclosure includes any of the preceding aspects, wherein the stacking includes vertically connecting at least two of the gas separation contactor module assemblies and omitting one of the upper exposed module of the lower one of the gas separation contactor module assemblies and the lower exposed module of the upper one of the gas separation contactor module assemblies.

[0014] Another aspect of the present disclosure includes any of the preceding aspects, wherein the stacking includes horizontally connecting at least two of the connected gas isolation contactor module assemblies.

[0015] Another aspect of the present disclosure includes any of the preceding aspects, wherein at least one of the two-way pipe and the four-way pipe is configured to carry at least one of the gas to be treated and the heated gas to the gas separation contactor module assembly.

[0016] Another aspect of the present disclosure includes any of the preceding aspects, wherein at least one of the two-way pipe and the four-way pipe is configured to alternately deliver the gas to be treated and the heated gas to the bed of adsorbent material.

[0017] Another aspect of the present disclosure provides a gas separation contactor module assembly, the gas separation contactor module assembly including a first adsorption unit and a second adsorption unit, each including an adsorption material disposed on a film, and a first frame, the first frame having a perimeter corresponding to the perimeter of each of the first and second sized adsorption units, at least three exposure modules in which the first and second adsorption units are disposed with their respective film layers facing each other, and at least one of a two-way pipe and a four-way pipe disposed at corresponding corners of the at least three exposure modules disposed at vertical intervals, the at least one of the two-way pipe and the four-way pipe disposed at a corner of the gas separation contactor module assembly.

[0018] Another aspect of the present disclosure includes any of the preceding aspects, wherein at least one gas separation contactor module assembly is configured to be connected with at least one other gas separation contactor module assembly to form a connected gas separation contactor module assembly.

[0019] Another aspect of the present disclosure includes any of the preceding aspects, wherein the gas isolation contactor module assemblies are connected at corners of the gas isolation contactor module assemblies.

[0020] Another aspect of the present disclosure includes any of the preceding aspects, wherein the gas isolation contactor module assemblies share at least one of a two-way pipe and a four-way pipe located at the corners of the exposed modules of the gas isolation contactor module assemblies.

[0021] Another aspect of the present disclosure includes any of the preceding aspects, wherein the connected gas separation contactor module assemblies include at least two vertically connected gas separation contactor module assemblies.

[0022] Another aspect of the present disclosure includes any of the preceding aspects, wherein the connected gas isolation contactor module assemblies include at least two horizontally connected gas isolation contactor module assemblies.

[0023] Another aspect of the present disclosure includes any of the preceding aspects, wherein the connected gas separation contactor module assemblies further include at least two vertically connected gas separation contactor module assemblies.

[0024] Another aspect of the present disclosure includes any of the preceding aspects, wherein at least one of the two-way pipe and the four-way pipe is configured to carry at least one of the gas to be treated and the heating gas.

[0025] Another aspect of the present disclosure includes any of the preceding aspects, and wherein the at least one gas separation contactor module assembly is a direct contact gas separation contactor module assembly, wherein at least one of a two-way pipe and a four-way pipe is configured to carry at least one of the gas to be treated and the heating gas, and the gas to be treated and the heating gas alternately flow across the respective adsorbent materials.

[0026] Another aspect of the present disclosure includes any of the preceding aspects, wherein at least one gas separation contactor module assembly is an indirect contact gas separation contactor module assembly in which only the gas to be treated flows across the respective adsorbent material.

[0027] Another embodiment of the present disclosure includes any of the preceding embodiments, wherein the first frame includes upper and lower portions that hold peripheral regions of the films of both the first and second adsorption units therebetween.

[0028] Two or more aspects described in this disclosure, including aspects described in this Summary section, may be combined to form an implementation not specifically described herein.

[0029] The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will become apparent from the description and drawings, and from the claims.

[0030] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure, taken in conjunction with the accompanying drawings illustrating various embodiments of the present disclosure. [Brief explanation of the drawings]

[0031] [Figure 1] 1 illustrates a method for forming a gas isolation contactor module according to an embodiment of the present disclosure. [Figure 2A] 1 illustrates a method for forming a subassembly of a scalable gas isolation contactor module according to an embodiment of the present disclosure. [Figure 2B] 1 illustrates a method for forming a subassembly of a scalable gas isolation contactor module according to an embodiment of the present disclosure. [Figure 3A] 1 shows a schematic diagram of another gas isolation contactor module according to an embodiment of the present disclosure. [Figure 3B] 1 shows a schematic diagram of another gas isolation contactor module according to an embodiment of the present disclosure. [Figure 4A] 1 shows a schematic diagram of another gas isolation contactor module according to an embodiment of the present disclosure. [Figure 4B] 1 shows a schematic diagram of another gas isolation contactor module according to an embodiment of the present disclosure. [Figure 5A] FIG. 1 is a schematic diagram of a gas isolation contactor module assembly according to an embodiment of the present disclosure. [Figure 5B] FIG. 1 is a schematic diagram of a gas isolation contactor module assembly according to an embodiment of the present disclosure. [Figure 6] FIG. 10 is a schematic diagram of components forming a further embodiment of a gas isolation contactor module according to an embodiment of the present disclosure. [Figure 7] FIG. 1 is a schematic front view of a prior art direct contact gas separation contactor module assembly. [Figure 8] FIG. 1 is a schematic front view of an indirect contact gas separation contactor module assembly according to an embodiment of the present disclosure. [Figure 9] FIG. 1 is a schematic front view of a pipe-integrated direct contact gas separation contactor module assembly according to an embodiment of the present disclosure. [Figure 10] FIG. 1 is a schematic front view of a pipe-integrated indirect contact gas separation contactor module assembly according to an embodiment of the present disclosure. [Figure 11] 1 illustrates an elevated front view of a gas isolation contactor module assembly according to an embodiment of the present disclosure. [Figure 12] 1 shows a schematic elevational front view of an implementation of multiple connected gas isolation contactor module assemblies according to an embodiment of the present disclosure. [Figure 13] 1 illustrates an elevated front view of an implementation of a direct contact gas separation contactor module assembly according to an embodiment of the present disclosure. [Figure 14] 1 illustrates an elevated side view of a direct contact gas separation contactor module assembly according to an embodiment of the present disclosure. [Figure 15] 1 illustrates an elevated front view of an implementation of multiple connected indirect contact gas separation modules according to an embodiment of the present disclosure. [Figure 16] 1 shows an elevated front view of an implementation of multiple connected direct contact gas separation module assemblies according to an embodiment of the present disclosure. [Figure 17] 1 illustrates an elevated front view of an implementation of multiple connected indirect contact gas separation modules according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0032] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to illustrate only typical aspects of the present disclosure and therefore should not be considered limiting of the scope of the present disclosure. In the drawings, like numbers represent like elements between the drawings.

[0033] As an initial matter, the clear description of the subject matter of the present disclosure necessitates the selection of specific terminology when referring to and describing the gas separation contactor modules, assemblies thereof, and related components of the process for fabricating the gas separation contactor modules and assemblies thereof, as embodied by the present disclosure. Wherever possible, common industry terminology will be used and utilized in a manner consistent with its generally accepted meaning. Unless otherwise specified, such terminology should be given a broad interpretation consistent with the context of this application and the appended claims. Those skilled in the art will recognize that, in many cases, a particular component can be referred to using several different or overlapping terms. What may be described herein as a single part may include multiple components and may be referred to as consisting of multiple components in other contexts. Alternatively, what may be described herein as including multiple components may be referred to as a single part elsewhere.

[0034] Additionally, several descriptive terms may be used repeatedly herein, and it will prove useful to define these terms at the beginning of this section. These terms and their definitions, unless otherwise specified, are as follows: As used herein, "downstream" and "upstream" are terms that indicate a direction with respect to fluid flow. The term "downstream" corresponds to the direction of fluid flow, and the term "upstream" refers to the direction opposite to the flow (i.e., the direction from which the fluid is flowing). The terms "forward" and "rear," unless otherwise specified, refer to directions, with "forward" or "front" referring to the front and "rear" or "rear" referring to the back.

[0035] In addition, as described below, some descriptive terms may be used repeatedly in this specification: the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to denote the location or importance of the individual components.

[0036] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. It will be further understood that the terms "comprise" and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or sets thereof. "Optionally" or "optionally" means that the event or circumstance described following the term may or may not occur, or the component or element described following the term may or may not be present, and that the description includes instances in which the event occurs or the component is present as well as instances in which the event does not occur or the component is not present.

[0037] When an element or layer is referred to as "overlying," "engaging," "connected," or "coupled" to another element or layer, it may be directly overlying, engaging, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as "directly overlying," "directly engaging," "directly connected," or "directly coupled" to another element or layer, there are no intervening elements or layers present. Other words used to describe relationships between elements should be interpreted similarly (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0038] Metal-organic frameworks (MOFs) are organic-inorganic hybrid crystalline porous materials that contain an ordered array of positively charged metal ions surrounded by organic "linker" molecules. The metal ions form nodes that connect the "arms" of the linker molecules to each other, thus forming a repeating cage-like structure. This cage-like structure forms or contains voids, which give MOFs extremely large internal surface areas. Synthesized MOFs can contain over 7,800 square meters of internal surface area per gram. To put this in perspective, the available surface area of ​​a single teaspoon of this material (approximately 1 gram of solid) would cover an entire football field.

[0039] In contrast to other porous materials, MOFs offer unique structural diversity, including at least uniform pore structure, atomic-level structural uniformity, tunable porosity, a wide variety of materials, good mechanical and thermal stability, and flexibility in the morphology, shape, dimensions, and chemical functionality of the network. This unique structural diversity allows for control of the morphology, porosity, and functionality of MOF structures. The unique structural design and tunability of MOFs can be attributed to their crystalline porous nature, which contains both organic and inorganic components in a rigid periodic network structure.

[0040] 1 and 2A-2B, a method 100 for forming a contactor module, such as a heating module 250, embodied by the present disclosure is described. The term "contactor module" is used for brevity as a contraction of "gas separation contactor module." A film 110 is provided, upon which a source of porous adsorbent material 120, including, for example, an adsorbent material such as a MOF, an additive, and at least one solvent, can be disposed. The film 110 can comprise any suitable material. A polymeric film is one exemplary film, and other films now known or later developed are within the scope of embodiments. For example, aspects of the embodiments include a film 110 comprising a metal component, a textile component, a synthetic component, an artificial component, a naturally occurring component, and combinations thereof.

[0041] As discussed above, the adsorbent material 120 embodied by the present disclosure may be any porous adsorbent material, including MOF materials, such as at least one of iron-based MOFs, zirconium-based MOFs (e.g., MOF-808, such as MOF-808-Gly), aluminum-based MOFs (e.g., MOF-303), zeolitic imidazolate frameworks (ZIFs), amine-containing MOFs, combinations, and other MOFs capable of adsorbing fluids and / or other materials from fluids as described herein. In certain embodiments, the adsorbent material 120 may include a polymeric resin, silica, a zeolite, an amine, or combinations thereof, now known or later developed.

[0042] Fluids used in the embodiments include the gas to be treated, which is carrying the material to be adsorbed, and a heated gas used to regenerate the adsorbent material 120. Typically, the gas to be treated is air and the material to be adsorbed is carbon dioxide, although other gases and materials can be used with appropriate modifications to the particular adsorbent material 120 used. Furthermore, the heated gas is typically steam or hot air, although other heated gases may be used as desired and / or needed. For convenience, "air" is used to describe the gas to be treated and "steam" is used to describe the heated gas, but it should be understood that these particular gases are non-limiting examples only, and other fluids can be used as desired and / or needed. Furthermore, for convenience, "carbon dioxide" is used to describe the material to be adsorbed, but it should be understood that this is a non-limiting example, and other materials can be adsorbed with appropriate modifications to the particular adsorbent material 120 used in the embodiments.

[0043] After the adsorbent material 120 is disposed on the film, the film 110 and adsorbent material 120 are advanced to a thermal treatment assembly 130. In the thermal treatment assembly 130, the adsorbent material 120 may contain liquid, such as moisture or solvent, which amount can be reduced or even removed, resulting in a drier form of the adsorbent material 120 that has less liquid content than when the adsorbent material 120 was originally disposed on the film 110. Additionally, in the thermal treatment assembly 130, the film 110 and adsorbent material 120 can be heated to improve adhesion of the adsorbent material 120 to the film 110.

[0044] The adsorbent material 120 on the film 110 can then be divided and formed into adsorbent units 150. The adsorbent units 150 can be divided at a station 160, for example, by cutting the film 110 so that the perimeter of the adsorbent unit 150 corresponds to the perimeter of a unit frame 220 described herein. As shown in FIG. 1 , the adsorbent unit 150 can include a margin 111 of the film 110 that does not include the adsorbent material 120. The margin 111 can allow for adhesion of the unit frame 220 to the adsorbent unit 150, as described below with respect to the unit frame 220.

[0045] The periphery of the suction unit 150 and the periphery of the unit frame 220 may be formed in a substantially equivalent configuration. Furthermore, as embodied by the present disclosure, the periphery of the unit frame 220 and the periphery of the suction unit 150 may be formed in a polygonal configuration. Furthermore, in a further aspect of the present disclosure, the periphery of the unit frame 220 and the periphery of the suction unit 150 may be formed in a rectangular configuration.

[0046] The method 100 further includes forming a unit frame 220 for fluid flow, as described below. The unit frame 220 includes a perforated pipe 200. The sections of the perforated pipe 200 can be connected by corner pieces 221 to form the unit frame 220. In this manner, the unit frame 220 includes a perimeter corresponding to the adsorption unit 150. The corner pieces 221 are pipes that carry a fluid, either air or steam, to the perforated pipe 200, causing the fluid to move within the unit frame 220 and through perforations 225 to a chamber 240 defined by the unit frame 220 and two adsorption units 150, as described below. Furthermore, as embodied by the present disclosure, the unit frame 220 can be formed in a polygonal configuration. Furthermore, as embodied by the present disclosure, the perimeter of the unit frame 220 can be formed in a rectangular configuration to align with the perimeter of the adsorption unit 150. The perforated pipe 200 for the unit frame 220 can include plastic perforated pipe 200, polymer perforated pipe 200, metal perforated pipe 200, composite perforated pipe 200, and other materials now known or later developed. As described herein, the perforations 225 in the pipe 200 and unit frame 220 allow fluid to flow into and out of the pipe 200 and unit frame 220. It should be noted that while perforated pipe is used in this example, embodiments can use non-perforated pipe or even solid members, so long as they are capable of delivering the gas to be treated and / or heated gas as needed.

[0047] Next, the method 100 positions and aligns the unit frame 220 with the suction unit 150. As embodied by the present disclosure, the unit frame 220 may be positioned on and within the margin 111 of the suction unit 150. Thus, according to this aspect of the present disclosure, the unit frame 220 may be permanently or removably adhered to the suction unit 150 at the margin 111. The unit frame 220 may be adhered to the suction unit 150 at the margin 111 by any suitable adhesion method, including adhesive, thermal bonding, welding, mechanical connection, removable fasteners, or any other fasteners now known or later developed.

[0048] The unit frame 220 includes an upper surface 202 and a lower surface 204 ( FIG. 1 ). As embodied by the present disclosure, the method 100 further includes forming a contactor module 250 ( FIG. 1 ). Forming the contactor module 250 includes attaching a sized adsorption unit 150 to the upper surface 202 of the unit frame 220 and attaching another sized adsorption unit 150 to the lower surface 204 of the unit frame 220, one adsorption unit 150 being positioned on each of the two surfaces 202, 204 such that the layer of film 110 contacts the unit frame 220 to define a chamber 240 together with the unit frame. By positioning the adsorbent material layer 124 as the outermost layer as shown, the contactor module 250 can function as a heating module that can pass steam or another hot gas through the unit frame 220 to heat the adsorbent material layer 124, thereby releasing adsorbed carbon dioxide and thereby “regenerating” the adsorbent material 120 within the adsorbent material layer 124. Thus, according to an embodiment of the present disclosure, the contactor module 250 includes a layer of a first adsorption unit 150 mounted on the upper surface 202 of the unit frame 220 and a second adsorption unit 150 mounted on the lower surface 204 of the unit frame 220, whereby the unit frame 220 and the two adsorption units 150 form the contactor module 250 with a frame chamber 240 therebetween. It should be appreciated that by alternatively positioning the adsorption material layers 124 opposite each other within the chamber 240, the contactor module 250 can be used as an exposure module through which carbon dioxide-containing gas can pass and carbon dioxide can be adsorbed by the adsorption material layers 124. Once the adsorption material layers 124 become "full" or saturated, the adsorption material layers 124 can be heated to release the adsorbed carbon dioxide as desired, thereby regenerating the adsorption material 120 within the adsorption material layers 124 for further adsorption of carbon dioxide.

[0049] Method 100 further includes forming a scalable gas separation contactor module assembly 500 (FIGS. 2A, 2B). As mentioned above, for simplicity, the gas separation contactor module assembly is referred to herein as a "contactor module assembly." Scalable contactor module assembly 500 includes a plurality of contactor modules 250, here configured as heating modules, and an air frame 400. Air frame 400 includes perforated pipe 410. Sections of perforated pipe 410 can be connected to form air frame 400 having a perimeter corresponding to that of heating module 250. Corner pieces 421 connect perforated pipes 410. In this manner, air frame 400 includes corner pieces 421 that channel fluid, either air or steam, to perforated pipe 410 and move the fluid within air frame 400, as described below. As embodied by the present disclosure, in a scalable contactor module assembly, adjacent heating modules 250 and air frames 400 may share corner pieces 221 and 421 where the sides of the scalable contactor module assembly 500 abut.

[0050] As embodied by the present disclosure, the air frame 400 can be formed in a polygonal configuration. Furthermore, as embodied by the present disclosure, the perimeter of the air frame 400 can be formed in a rectangular configuration to align with the contactor module 250. The perforated pipe 410 for the air frame 400 can include plastic perforated pipe 410, polymer perforated pipe 410, metal perforated pipe 410, composite perforated pipe 410, and other materials now known or later developed. As described below, perforations 415 in the pipe 410 and air frame 400 allow fluid to flow into and out of the pipe 410 and air frame 400. As mentioned above, portions of the air frame 400 may be replaced with other members, such as non-perforated pipes or solid members, as long as they can deliver the gas to be treated and / or the heated gas as needed.

[0051] The scalable contactor module assembly 500 (FIGS. 2A and 2B) includes an air frame 400 positioned between two heating modules 250. The scalable contactor module assembly 500 includes one heating module 250 positioned on each side of the air frame 400. When so positioned, the heating module 250 and the air frame 400 define an exposure chamber 420 therebetween, with the adsorbent material layer 124 located above and below the exposure chamber 420. The scalable contactor module assembly 500 is configured to flow steam through the heating module 250 and a carbon dioxide-containing gas, such as air, through the air frame 400 and through the exposure chamber 420. An example of operation can include passing air through the air frame 400 and the exposure chamber 420 until the adsorbent material layer 124 is “full” or saturated. A hot gas, such as steam, can then be passed through the heating module 250 to heat the adsorbent material layer 124 and release the stored carbon dioxide. Thereafter, carbon dioxide adsorption can be resumed.

[0052] The configuration of Figures 2A and 2B illustrates only one aspect of an embodiment. As embodied by the present disclosure, the scalable contactor module assembly 500 can include multiple stacked scalable contactor module assemblies 500. In this aspect of the disclosure, additional air frames 400 can be connected to one or both heating modules 250, and additional heating modules 250 can be connected to each additional air frame 400 to create an arrangement with alternating heating modules 250 and air frames 400. Such an arrangement can be repeated and can include as many heating modules 250 and air frames 400 as desired for a given use case. It may be advantageous to have heating modules 250 at the ends of such an arrangement; in embodiments, the outermost heating module 250 can have a film 110 on the outside if desired, and the adsorbent material layer 124 can be omitted if necessary.

[0053] 2A and 2B includes disposing a second scalable contactor module assembly 500 "to the side" of the scalable contactor module assembly 500. With respect to FIG. 2B, the additional scalable contactor module assembly 500 can be connected to either the left-most side 510 of the scalable contactor module assembly 500 or the right-most side 511 of the scalable contactor module assembly 500 (as shown in FIGS. 2A and 2B), although the additional module assembly 500 may be disposed on the "near-viewer" and / or "far-viewer" side of the scalable contactor module assembly 500. In this configuration, additional heating modules 250 of additional scalable contactor module assemblies 500 are aligned with each other, similar to the alignment of additional air frames 400 of additional scalable contactor module assemblies 500 with the air frames 400. In this manner, "layers" of scalable contactor module assemblies 500 can be formed left to right and toward or away from the viewer. This arrangement can be combined with the stacking described above to form three-dimensional structures of scalable contactor module assemblies 500 including as many heating modules 250 and air frames 400 as may be desired and / or appropriate for a particular application.

[0054] Thus, as embodied by the present disclosure, a contactor module 250, such as a heating module, includes first and second adsorbent units 150, 150, each including an adsorbent material layer 124 disposed on a film 110, and a unit frame 220 including an upper surface 202 and a lower surface 204. The unit frame 220, together with the film 110, forms a chamber 240 for fluid flow. According to certain aspects of the present disclosure, the chamber 240 is configured to allow vapor flow to heat the adsorbent material layer 124 and release trapped material.

[0055] 3A and 3B illustrate an alternative form of the contactor module of an embodiment referred to herein as an exposure module 260, in which the suction units 150 may be mounted to a solid frame 180. In embodiments, two suction units 150 may be mounted to the solid frame 180 with the layers of film 110 facing each other. In either case, the film 110 of the suction units 150 may be mounted to the solid frame 180 in much the same manner as described above with respect to mounting the suction units 150 to the unit frame 220 (FIG. 1). Alternatively, as seen in FIGS. 4A and 4B, the frame 180 of the exposure module 260 may include upper and lower portions 181 and 182 that may be positioned on either side of the film 110 of the suction units 150 to hold the film 110 therebetween. For example, the upper and lower portions 181 and 182 may include features that interlock and clamp the film 110 therebetween when assembled and force is applied. Such a multi-piece frame can be used with or without adhesive or other attachment means, as appropriate and / or desired. It should also be noted that two suction units 150 can be used with the multi-piece frame 180, if desired and / or appropriate. Furthermore, while a quadrilateral solid frame 180 is shown as an example, some embodiments can instead use two opposing members, such as in the example shown in Figures 4A and 4B, where each of the two opposing members is a two-part member.

[0056] 5A and 5B schematically illustrate an example of a stacked air frame 400, adsorption unit 150, and unit frame 220 configuration and fluid flow therein. In FIGS. 5A and 5B, opposite corners are gas sources and drains for each chamber. Thus, as shown in FIG. 5B, particularly with the top air frame 400 shown, a carbon dioxide-containing gas, such as air, can be supplied to a first corner 431, such that gas flows in a first direction into each exposure chamber 420, e.g., through perforations 415, through the chamber 420 to an opposite second corner 432, and out the second corner 432. Similarly, in Figure 5A, as particularly shown by the upper unit frame 220, a hot gas such as steam can be supplied to the third corner 433, so that steam flows in a second direction into each chamber 240, passes through the chamber 240, e.g., via perforations 225, to the opposite fourth corner 434, and exits at the fourth corner 434. In this configuration, the primary direction of flow through each chamber is diagonal, such that the steam and air flow essentially perpendicular to one another. The stacking and layer arrangements described above with respect to the example shown in Figures 2A and 2B can be applied to the example of Figures 5A and 5B to form a structure including any appropriate and / or desired number of air frames 400, adsorption units 150, and unit frames 220.

[0057] Figures 6 and 8-11 illustrate further embodiments of contactor module assembly configurations according to aspects of the present disclosure. Figure 6 illustrates components forming a component of a contactor module according to an embodiment of the present disclosure, referred to herein as an exposure module 260. Figure 7 illustrates a front view of an exemplary prior art direct-contact contactor module assembly 290. Figure 8 illustrates a front view of an exemplary indirect-contact pipe heating contactor module assembly 625 embodied in accordance with the present disclosure. Figure 9 illustrates a front view of a pipe-integrated direct-contact / heating contactor module assembly 650 according to an embodiment of the present disclosure. Figure 10 illustrates a front view of a pipe-integrated indirect-contact / heating contactor module assembly 675 according to an embodiment of the present disclosure. Figure 11 illustrates an elevated front view of the indirect-contact pipe heating contactor module assembly 625 of Figure 8. Figure 12 illustrates an elevated side view of multiple pipe-integrated indirect-heating contactor module assemblies 625 arranged and connected in two adjacent stacks according to an embodiment of the present disclosure. Figures 13 and 14 show implementations of a direct contact module assembly 625. Figures 15-17 show implementations of contactor module assemblies 625, 650, 675 according to embodiments of the present disclosure.

[0058] As embodied by the present disclosure, a contactor module assembly includes a sorbent material, such as a MOF, positioned in direct contact with a fluid containing the material to be captured. The sorbent material and the fluid "contact" or interact. A direct-contact contactor module assembly places a heat source, such as steam or another high-temperature fluid, in direct contact with the sorbent material to facilitate desorption and regeneration of the sorbent material so that the sorbent material can be reused for further capture. Conversely, an indirect-contact contactor module assembly has an intermediate element that separates the direct contact of the sorbent material from the heat source, such as steam or another high-temperature fluid. For example, as embodied by the present disclosure, a polymeric material can be positioned between the sorbent material and the heat carrier used to facilitate desorption to regenerate the sorbent material for further capture.

[0059] With reference to FIG. 6 , the suction unit 150 is provided, such as mounted to a frame 180, which may be the frame 180 shown in FIGS. 3A, 3B, 4A, and 4B, to form the exposure module 260. As noted above, some embodiments may use a frame 180 including at least two opposing members, while other embodiments may use a quadrilateral frame using four members, each of which may have one or two portions. As embodied by the present disclosure, the suction unit 150 may be any suitable suction unit. For ease of explanation, the descriptions of FIGS. 6-10 are provided with reference to the suction unit 150 described and provided with reference to the above embodiments and shown in FIGS. 1, 3, and 4. Accordingly, reference is made to the above description of the suction unit 150 for a discussion of the formation and configuration of the suction unit 150 and the exposure module 260.

[0060] FIG. 6 illustrates components forming the components of a contactor module assembly. In FIG. 6, a frame 610, such as frame 180 for adsorption unit 150, is provided. In an embodiment, frame 610 surrounds adsorption unit 150 and is attached to film 110. As with the previous embodiment, the perimeter of frame 610 and adsorption unit 150 can be formed in a polygonal configuration. Furthermore, in a further aspect of the present disclosure, the perimeter of frame 610 and the perimeter of adsorption unit 150 can be formed in a rectangular configuration. While two layers of adsorbent material 124 are shown, it should be noted that any layer of adsorbent material 124 may be omitted, such as at the top or bottom of exposure module 260 located at the top or bottom of the assembly. It is convenient to provide two adsorbent material layers 124 by attaching two adsorption units 150 with their film layers 110 engaged with each other.

[0061] It should be noted that contactor module 250 (FIG. 1) and exposure module 260 have some differences in operation. For example, contactor module 250 (FIG. 1) defines chamber 240 through which fluid passes for heating or for processing gas for adsorption, depending on the particular orientation of adsorption unit 150. In contrast, exposure module 260 is configured to have fluid pass through its exterior.

[0062] 7 illustrates a perforated technology direct contact contactor assembly having multiple contactor modules 292 disposed between sidewalls 294 and a support layer 296 bearing an adsorbent material 298. In operation, gas to be treated passes through the assembly 290 across the adsorbent material 298 of the contactor modules 290 in a direction into or out of the plane of the paper until the adsorbent material 298 is saturated, at which point heated gas is passed through the assembly 290 in a direction out or into the plane of the paper to regenerate the adsorbent material 298. Once the adsorbent material 298 is regenerated, gas to be treated passes through the assembly 290 in a direction into or out of the plane of the paper, and the cycle is repeated as desired.

[0063] FIGS. 8-11 show examples of contactor module assemblies 625, 650, and 675 that can be constructed using exposure modules 260, two-way pipes 612, and four-way pipes 614. In the embodiment of FIGS. 8-10, frame 610 does not convey fluid to adsorbent material bed 124. Rather, the gas to be treated, containing the material to be adsorbed, passes through the end of the assembly (not shown) in a direction into or out of the plane of the paper, and heated fluids or gases, such as steam and / or hot air, are conveyed to contactor module assemblies 625, 650, and 675 through one or more of two-way pipes 612 and four-way pipes 614. Two-way pipe 612 allows flow in two directions, two of which are vertical with respect to the figures, as shown in FIGS. 8-11. Four-way pipe 614 allows flow in four directions, as shown in FIGS. 9 and 10. The four directions are vertical and horizontal with respect to the figures.

[0064] 13 and 14 schematically illustrate implementation of a contactor module assembly 625 in a capture device 700. FIG. 13 illustrates an elevated end view, and FIG. 14 illustrates an elevated side view. The capture device 700 includes an enclosure 702 for the contactor module assembly 625. The enclosure 702 has side walls 704 that engage with and / or support the frame 610 of the contactor module assembly 625, as well as top and bottom walls 705. First and second plenums 706, 708 can be attached to opposite ends of the enclosure 702, each plenum having one of first and second valves 710, 712 (not shown in FIG. 14) for switching between the respective conduits. For example, in a capture cycle, the first valve 710 can be opened to a first source conduit 714, such as a source of gas to be treated, and the second valve 712 can be opened to a first drain conduit 720. In this configuration, the gas to be treated can enter the first plenum 706, pass through the contactor module assembly 625, and exit via the second plenum 708. Similarly, in a regeneration cycle, the second valve 712 can be opened to a second source conduit 716, such as a source of heating gas, and the first valve 710 can be opened to a second drain conduit 718. In this configuration, the heating gas can enter the second plenum 708, pass through the contactor module assembly 625, and exit via the first plenum 706. The flow directions are particularly shown in FIG. 14 , where an exemplary gas to be treated is air and an exemplary heating gas is steam.

[0065] The embodiments of Figures 8-11 further include the possibility of forming scalable contactor module assemblies 625, 650, and 675. The scalable contactor module assemblies 625, 650, and 675 include multiple contactor module assemblies 625, 650, and 675 arranged horizontally side by side and / or vertically on top of each other, depending on design needs, as shown schematically in Figures 12 and 15-17. The scalable contactor module assemblies 625, 650, and 675 can be combined, i.e., stacked either vertically or horizontally, with at least one other contactor module assembly 625, 650, and 675 to form stacked contactor module assemblies 625, 650, and 675.

[0066] In certain aspects of the embodiment, as shown in Figures 15-17, adjacently arranged contactor module assemblies 625, 650, and 675 can share either the two-way pipes 612 of the adjacent scalable contactor module assemblies 625, 650, and 675, or can share the four-way pipes 614 of the adjacent scalable contactor module assemblies 625, 650, and 675, with the shared pipe, either the two-way pipes 612 or the four-way pipes 614, being located at the corners of the adjacent scalable contactor module assemblies 625, 650, and 675. By placing either the two-way pipe 612 or the four-way pipe 614 at the corner of adjacent scalable contactor module assemblies 650 and 675, the flow of air and / or steam indicated by arrow F in the two-way pipe 612 or the four-way pipe 614 can be effectively conveyed to one or more of the adjacent scalable contactor module assemblies 650 and 675.

[0067] Additionally, in certain aspects of the embodiment, vertically stacked contactor module assemblies 625, 650, and 675 can share the two-way pipe 612 of either the lower or upper scalable contactor module assembly 625, 650, and 675, or can share the four-way pipe 614 of the lower or upper scalable contactor module assembly 625, 650, and 675. Furthermore, in certain embodiments, by locating either the two-way pipe 612 or the four-way pipe 614 at the corners of adjacent scalable contactor module assemblies 650 and 675, the flow of air and / or steam, as indicated by arrow F in the two-way pipe 612 or the four-way pipe 614, can be effectively conveyed to one or more of the vertically oriented and / or stacked scalable contactor module assemblies 650 and 675.

[0068] 8-10, which show embodiments of scalable contactor module assemblies 625, 650, and 675, the flow of heated gas, such as hot air and / or steam flow, is indicated by arrows F in two-way pipe 612 or four-way pipe 614. Also, the flow within scalable contactor module assemblies 625, 650, and 675, such as the flow of gas to be treated, such as air, enters the page as indicated by the trailing end of the arrow as an "x" within a circle, and exits the page as indicated by the leading end of the arrow as a circle with a dot in the center.

[0069] Thus, in FIG. 8 , heated gas is conveyed by pipe 612, and the gas to be treated is shown as entering the plane of the paper. For example, air can be passed between exposure modules 260 and across sorbent material layer 124 to allow carbon dioxide to be adsorbed by sorbent material layer 124. Once sorbent material layer 124 is saturated with carbon dioxide, the air flow can be stopped, and a hot gas, such as steam, can be conveyed through two-way pipe 612 to heat and regenerate sorbent material layer 124. Once sorbent material layer 124 has been sufficiently regenerated, air flow can be resumed, and air can be passed through sorbent material layer 124, for example, into the plane of the paper as shown in FIG. 8, to capture additional carbon dioxide. These processes can be repeated as desired. It will be understood that during regeneration, carbon dioxide is released into the air remaining between exposure modules 260, and this air can be directed to a carbon dioxide storage system known in the art. In embodiments, the air flow can continue during regeneration, and the air exiting exposure module 260 is directed to carbon dioxide storage.

[0070] Similarly, in Figure 9, heated gas is conveyed between exposure modules 260 by pipe 614 during a regeneration cycle, while gas to be treated is shown flowing into the page during a capture cycle. In this manner, for example, air can pass between exposure modules 260 and across sorbent material layer 124 to allow carbon dioxide to be adsorbed by sorbent material layer 124. Once sorbent material layer 124 is saturated with carbon dioxide, the air flow can be stopped and steam can be passed between exposure modules 260 via pipe 614 to heat and regenerate the sorbent material layer and carry the released carbon dioxide away from contactor module assembly 650. Once sorbent material layer 124 has been sufficiently regenerated, the steam flow can be stopped and air flow can be resumed until sorbent material layer 124 is saturated, and this cycle can be repeated as desired. It will be appreciated that during regeneration, carbon dioxide is released into the steam flowing between exposure modules 260, which can be directed to a carbon dioxide storage system as known in the art.

[0071] 10 , heated gas passes through pipes 612 and 614 between the top two and bottom two exposure modules 260 of contactor module assembly 675, while gas to be treated passes into the page between the middle two exposure modules 260. For example, during capture, air can pass between the middle two exposure modules 260 across the sorbent material layer 124 so that carbon dioxide can be adsorbed by the sorbent material layer 124. Once the sorbent material layer 124 is saturated with carbon dioxide, the air flow can be stopped and steam can be passed through pipe 614 between the top two and bottom two exposure modules 260 to heat and regenerate the sorbent material layer 124. Once the sorbent material layer 124 has been sufficiently regenerated, the steam flow can be stopped and the air flow can be resumed until the sorbent material layer 124 is saturated; these processes can be repeated as desired. It will be appreciated that during regeneration, carbon dioxide is released into the air remaining between the two central exposure modules 260, and this air may be directed to a carbon dioxide storage system as known in the art. In embodiments, the air flow may continue during regeneration, with the air exiting the exposure modules 260 being directed to carbon dioxide storage.

[0072] Referring now to FIG. 15 , an implementation of a capture device 700 includes a containment vessel 702 in which multiple indirect contactor module assemblies 625 are housed. As shown, the indirect contactor module assemblies 625 can be stacked, arranged side-by-side, and share pipes 612 at corners. The containment vessel 702 can include side walls 704 and top and bottom walls 705, as in FIGS. 13 and 14 . A first plenum 706 and a second plenum 708 can be attached to the ends of the containment vessel 702, where each plenum handles only the gas to be processed via a first source conduit 714 and a first drain conduit 720, respectively. A second source conduit 716 can be connected to one or more pipes 612, 614 ( FIGS. 6 , 8-11 ) that can carry heated gas between the assemblies 625 and further to a second drain conduit 718. Additional piping may be added to improve steam distribution as needed or desired. In this configuration, for example, air may be passed through contactor module assembly 625 to capture carbon dioxide, and steam may be passed through pipes to heat and regenerate the sorbent material within contactor module assembly 625. In embodiments, the air flow may be continuous, and air exiting apparatus 700 during regeneration is directed to storage.

[0073] In Figure 16, a capture device 700 uses multiple connected contactor module assemblies 650, which are pipe-integrated direct contact module assemblies. Most of the example in Figure 16 is the same as that shown in Figure 15, but here a four-way pipe 614 is used to allow steam to pass directly through the contactor module assemblies 650 during regeneration. Note that the air flow must be stopped during regeneration or sufficient heating for regeneration may not be possible.

[0074] In Figure 17, the capture device uses multiple connected contactor module assemblies 675, which are pipe-integrated indirect contactor module assemblies. Again, the structure is very similar to that of Figures 15 and 16, except that here, the two-way pipes 612 and four-way pipes 614 are configured as in Figure 10, and alternating heating and capture chambers are defined between the exposure modules of the contactor module assemblies 675. Additionally, baffles 722 can be incorporated to prevent air from entering the heating exposure modules of the contactor module assemblies 675. In the particular example, six contactor module assemblies 675 are shown in three adjacent stacks of two, sharing corner pipes. As in the examples of Figures 10 and 11, the chambers defined by the top two exposure modules, the bottom two exposure modules, and every other pair of exposure modules (vertically) are heating chambers, and the four-way pipes 614 allow steam passage during regeneration. Here, air flow can continue during regeneration, with air exiting the second plenum 708 during regeneration being directed to the carbon dioxide storage.

[0075] As will be appreciated, the technical effect of embodiments herein is to enable a relatively inexpensive and highly scalable modular assembly for capturing gaseous materials, such as carbon dioxide, from air. Lower costs are achieved by using less expensive materials, such as plastic pipes or frames. Scalability is achieved through the modularity of the assembly itself. While FIGS. 12 and 15-17 show a configuration of six assemblies, it should be understood that the stack, like the row, can be taller and wider. In other words, with appropriate modification of the containment, the connected assemblies of FIGS. 15-17 can themselves be replicated and connected in three axes to achieve enormous capture capacity.

[0076] As used herein throughout the specification and claims, approximation language may be applied to modify any quantitative expression that is permitted to vary without resulting in a change in the relevant basic function. Thus, values ​​modified by terms such as "approximately," "about," and "substantially" are not limited to the exact value specified. In at least some cases, approximation language may correspond to the precision of the instrument used to measure the value. Herein, throughout the specification and claims, range limitations are combinable and / or interchangeable, and unless the context or language dictates otherwise, such ranges are identified and include all subranges encompassed therein. The term "about," as applied to a particular value in a range, applies to both endpoints and may indicate + / - 10% of the stated value, unless otherwise dependent on the precision of the instrument used to measure the value.

[0077] The corresponding structure, material, acts, and equivalents of all means-plus-function or step-plus-function elements in the following claims are intended to include any structure, material, or act for performing the function in combination with other claimed elements that are specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The embodiments were selected and described in order to best explain the principles and practical applications of the disclosure and to enable those skilled in the art to understand the disclosure in various embodiments with various modifications as suited to the particular uses envisioned. [Explanation of symbols]

[0078] 100 Method for forming a contactor module 110 Film, film layer 111 Margin 112 Placement of adsorbent material on film 120 Adsorption materials 124 Adsorption material layer 130 Heat Treatment Assembly 150 suction units 160 stations 180 frames 181 Upper part 182 Lower part 200 Perforated Pipe 202 (unit frame) top surface 204 (Unit frame) bottom 220 unit frame 221 Corner piece 225 Perforation 240 Chamber 250 Contactor Module, Heating Module 260 Exposed Module 290 (Prior Art) Contactor Module Assembly, Contactor Module 292 Contactor Module 294 Side wall 296 Supporters 298 Adsorption Materials 400 Air Frame 410 Perforated Pipe 415 Perforation 420 Exposure Chamber 421 Corner piece 431 First corner 432 Second corner 433 Third Corner 434 Fourth Corner 500 Contactor Module Assembly 510 Left side (of contactor module assembly) 511 Right side (of contactor module assembly) 610 frames 612 Two-way pipe 614 Four-Way Pipe 625 Contactor Module Assembly 650 Contactor Module Assembly 675 Contactor Module Assembly 700 Capture Device 702 Containment / Containment Vessel 704 Side wall 705 Top and bottom walls 706 First Plenum 708 Second Plenum 710 First Valve 712 Second Valve 714 First Source Conduit 716 Second Source Conduit 718 Second Drain Conduit 720 First drain conduit 722 Baffle

Claims

1. A method of forming a gas separation contactor module assembly (625, 650, and 675), comprising: disposing an adsorbent material (120) on the film (110); heat treating (130) the adsorbent material (120) on the film (110); sizing the adsorbent material (120) on the film (110) to correspond to the size of a first frame (610) to form an adsorbent unit (150); placing the adsorption unit (150) on the first frame (610) to form a first exposure module (260); forming second, third, and fourth exposure modules; the first exposure module (260) is the upper exposure module (260), the fourth exposure module is the lower exposure module (260), and at least one of a two-way pipe (612) and a four-way pipe (614) is attached to corners of the first, second, third, and fourth exposure modules (260) that are arranged at intervals in the vertical direction; It contains The method, wherein at least one of the two-way pipes (612, 625, 675) and four-way pipes (614, 650, 675) are positioned at corners of the gas separation contactor module assemblies (625, 650, and 675).

2. stacking the gas separation contactor module assemblies (625, 650, and 675) so as to be connected with at least one other gas separation contactor module assembly (625, 650, and 675) to form a connected gas separation contactor module assembly (625, 650, and 675). The method of claim 1 further comprising:

3. The method of claim 2 , wherein the gas isolation contactor module assemblies (625, 650, and 675) are connected at their corresponding corners.

4. 2. The method of claim 1, wherein the gas isolation contactor module assemblies (625, 650, and 675) share at least one of the two-way pipes (612, 625, 675) and four-way pipes (614, 650, 675) located at corners of the exposure module (260).

5. 5. The method of claim 4, wherein the stacking step includes vertically connecting at least two of the gas separation contactor module assemblies (625, 650, and 675) and omitting one of the upper exposed module (260) of a lower gas separation contactor module assembly of the gas separation contactor module assemblies (625, 650, and 675) and the lower exposed module (260) of an upper gas separation contactor module assembly of the gas separation contactor module assemblies (625, 650, and 675).

6. The method of claim 4 , wherein the stacking comprises horizontally connecting at least two of the connected gas isolation contactor module assemblies (625, 650, and 675).

7. 7. The method of claim 1, wherein at least one of the two-way pipe and the four-way pipe is configured to convey at least one of the gas to be treated and the heating gas to the gas separation contactor module assembly (625, 650, and 675).

8. 8. The method of claim 7, wherein the at least one of the two-way pipe (612) and the four-way pipe (614) is configured to alternately deliver the gas to be treated and the heated gas to the adsorbent material bed (124).

9. A gas isolation contactor module assembly (625, 650, and 675) comprising: a first adsorption unit (150) and a second adsorption unit (150), each including an adsorption material (120) disposed on a film (110); at least three exposure modules (260), each including a first frame (610), the first frame (610) having a perimeter corresponding to the perimeter of each of the first and second adsorption units (150), the first and second adsorption units (150) being arranged on the first frame (610) with their respective layers of film (110) facing each other; at least one of two-way pipes (612) and four-way pipes (614) disposed at corresponding corners of the at least three vertically spaced exposure modules (260); It is equipped with Gas separation contactor module assemblies (625, 650, and 675), wherein at least one of the two-way pipe (612) and the four-way pipe (614) is located at a corner of the gas separation contactor module assembly (625, 650, and 675).

10. 10. The gas separation contactor module assemblies (625, 650, and 675) of claim 9, wherein at least one gas separation contactor module assembly (625, 650, and 675) is configured to be connected with at least one other gas separation contactor module assembly (625, 650, and 675) to form a connected gas separation contactor module assembly (625, 650, and 675).

11. 11. The gas isolation contactor module assemblies (625, 650, and 675) of claim 10, wherein the gas isolation contactor module assemblies (625, 650, and 675) are connected at the corners of the gas isolation contactor module assemblies (625, 650, and 675).

12. 10. The gas separation contactor module assemblies (625, 650, and 675) of claim 9, wherein the gas separation contactor module assemblies (625, 650, and 675) share at least one of the two-way pipes (612) and four-way pipes (614) located at corners of the exposure modules (260) of the gas separation contactor module assemblies (625, 650, and 675).

13. 13. The gas separation contactor module assembly (625, 650, and 675) of claim 12, wherein the connected gas separation contactor module assemblies (625, 650, and 675) comprise at least two vertically connected gas separation contactor module assemblies (625, 650, and 675).

14. 13. The gas separation contactor module assembly (625, 650, and 675) of claim 12, wherein the connected gas separation contactor module assemblies (625, 650, and 675) comprise at least two horizontally connected gas separation contactor module assemblies (625, 650, and 675).

15. 15. The gas separation contactor module assembly (625, 650, and 675) of claim 14, wherein the connected gas separation contactor module assemblies (625, 650, and 675) further comprise at least two vertically connected gas separation contactor module assemblies (625, 650, and 675).

16. 16. The gas separation contactor module assembly (625, 650, and 675) of any one of claims 9 to 15, wherein at least one of the two-way pipe (612) and the four-way pipe (614) is configured to carry at least one of a gas to be treated and a heating gas.

17. 10. The gas separation contactor module assembly (625, 650, and 675) of claim 9, wherein at least one of the two-way pipe (612) and the four-way pipe (614) is configured to carry at least one of a gas to be treated and a heating gas, and the gas to be treated and the heating gas alternately flow across the respective adsorbent materials (120).

18. 10. The gas separation contactor module assemblies (625, 650, and 675) of claim 9, wherein at least one of the gas separation contactor module assemblies (625, 650, and 675) is an indirect contact gas separation contactor module assembly in which only the gas to be treated flows across the respective adsorbent material (120).

19. 10. The gas separation contactor module assembly (625, 650, and 675) of claim 9, wherein the first frame (610) includes an upper portion (181) and a lower portion (182) that hold peripheral regions of the film (110) of both the first and second adsorption units (150) therebetween.

20. 2. The method of claim 1, wherein the first frame (610) includes an upper portion (181) and a lower portion (182) that hold peripheral regions of the film (110) of both the first and second suction units (150) therebetween.

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