Bidirectional material and fluid transport devices with surface topologies

Abstract

A pollution control system, article, and method having a surface topology for bidirectional fluid transport. The pollution control system includes at least one article including a surface feature having at least three critical portions or points of the surface topology. The surface topology can include channels along a first direction, the channels configured to direct fluid flow substantially along a particular direction.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of Provisional Application No. 63 / 490,879, filed March 17, 2023, and also claims the benefit of Provisional Application No. 63 / 435,392, filed December 27, 2022, which applications are incorporated by reference herein in their entirety for all purposes.

[0002] Field FIELD OF THE DISCLOSURE This disclosure relates to the field of pollution control systems and methods for removing chemical compounds and particulate matter from gas streams. [Background technology]

[0003] background Coal-fired power plants, municipal waste incinerators, and oil refineries emit large amounts of flu-gas, which contains large amounts of a wide variety of environmental pollutants, such as sulfur oxides (SO2, SO3), nitrogen oxides (NO, NO2), mercury (Hg) vapor, and particulate matter (PM). Therefore, improved control systems and methods are needed to remove sulfur oxides, mercury vapor, and particulate matter from industrial flu-gas, such as coal-fired power plant flu-gas. Summary of the Invention

[0004] Abstract The following summary is a high-level overview of various aspects and introduces some concepts that are further described in the detailed description section below. This summary should not be used alone to define the scope of the claims. The subject matter should be understood by reference to appropriate portions of the entire specification, some or all of the drawings, and each claim.

[0005] In some embodiments, an article comprises a two-dimensional array configuration having a three-dimensional surface topology. The article includes a first two-dimensional sheet having an upper surface and a lower surface, the first sheet having a three-dimensional surface topology, the surface topology of both the upper surface and the lower surface comprising a two-dimensional array of regular surface undulations, each undulation having a first set of at least three critical portions. These undulations add a third dimensionality to the two-dimensional array. In some embodiments, each of the at least three critical portions is either (a) a minimum, (b) a saddle, or (c) a maximum.

[0006] In some embodiments, the surface topology includes channels along a first direction, the channels configured to direct fluid flow substantially along the first direction.

[0007] In some embodiments of the article, the first sheet comprises a filter media, a heat exchange surface, an active material, a reactive material, or a combination thereof.

[0008] In some embodiments of the article, the channel can be substantially straight along a first direction.

[0009] In some embodiments of the article, the surface topology is configured to provide a substantially uniform flow of fluid.

[0010] In some embodiments of the article, the channels are configured to provide a substantially uniform flow of fluid.

[0011] In some embodiments of the article, the minima, saddles, and maxima lie along a second direction, the second direction being different from the first direction.

[0012] In some embodiments of the article, the article is configured to provide a substantially non-uniform fluid flow along the second direction.

[0013] In some embodiments of the article, at least one of each of the three critical portions is a critical point.

[0014] In some embodiments of the article, the surface topology further comprises a straight edge connecting at least two of the at least three critical portions.

[0015] In some embodiments of the article, the surface topology further comprises a curved portion connecting at least two of the at least three critical portions.

[0016] In some embodiments of the article, the surface topology comprises a geometric wavy cross section.

[0017] In some embodiments of the article, the geometric wave cross-section comprises a sinusoidal wave cross-section, a non-sinusoidal periodic wave cross-section, a triangular wave cross-section, a rectangular wave cross-section, a square wave cross-section, or a combination thereof.

[0018] In some embodiments of the article, the filter media comprises a sorbent polymer composite material.

[0019] In some embodiments of the article, the polymer composite comprises a sorbent material and a polymeric material.

[0020] In some embodiments of the article, the sorbent material comprises at least one of activated carbon, silica gel, zeolite, or a combination thereof.

[0021] In some embodiments of the article, the polymeric material comprises at least one of polytetrafluoroethylene, polyfluoroethylenepropylene, polyperfluoroacrylate, polyvinylidene fluoride, a terpolymer of tetrafluoroethylene, hexafluoropropylene and vinylidene fluoride, polychlorotrifluoroethylene, or a combination thereof.

[0022] In some embodiments, the article includes a second sheet connected to at least a portion of the first sheet.

[0023] In some embodiments of the article, the second sheet has a second surface topology that includes at least a flat portion.

[0024] In some embodiments, the second sheet includes a two-dimensional array configuration with a three-dimensional surface topology. The second sheet adds a second two-dimensional sheet having an upper surface and a lower surface, the second sheet having a three-dimensional surface topology, the surface topology of both the upper and lower surfaces including a two-dimensional array of regular surface undulations, each undulation having at least three critical portions of a second set. The undulations add a third dimensionality to the two-dimensional array. Thus, in some embodiments, the second sheet is also a two-dimensional sheet having an upper surface and a lower surface, the second sheet having a three-dimensional surface topology on both the upper and lower surfaces of the second sheet, including a two-dimensional array of third-dimensional surface topology with undulations having crests and troughs, each undulation having at least three critical portions of a first set. In some embodiments, each of the at least three critical portions of the second sheet surface topology includes (a) a minimum, (b) a saddle, and (c) a maximum. In some embodiments of the article, the second sheet comprises a second filter media, a heat exchange surface, an active material, a reactive material, or a combination thereof.

[0025] In some embodiments of the article, at least one of the at least three critical portions of the first sheet is connected to the second sheet.

[0026] In some embodiments of the article, the first sheet is connected to the second sheet by adhesive, ultrasonic welding, heat welding, laser welding, or a combination thereof.

[0027] In some embodiments of the article, the first sheet is connected to the second sheet by an adhesive.

[0028] In some embodiments, the article further comprises a modular frame, and the first sheet and the second sheet are connected to the modular frame.

[0029] In some embodiments, the module includes a plurality of sheets, each of the plurality of sheets having a surface topology including at least three critical portions, each of the at least three critical portions being (a) a minimum, (b) a saddle, or (c) a maximum.

[0030] In some embodiments of the module, each of the plurality of sheets comprises a filter media, a heat exchange surface, an active material, a reactive material, or a combination thereof.

[0031] In some embodiments of the module, the filter media comprises a sorbent polymer composite material.

[0032] In some embodiments of the module, the sorbent polymer composite comprises a sorbent material and a polymer material.

[0033] In some embodiments, a method of making an article as disclosed herein comprises obtaining a sheet, rolling the sheet over a roller having a roller mold, and forming a surface topology on the sheet, the surface topology comprising at least three critical portions, each of the at least three critical portions being (a) a minimum, (b) a saddle, or (c) a maximum.

[0034] In some embodiments of the method, the method includes adding a filter medium, a heat exchange surface, an active material, a reactive material, or a combination thereof to the sheet.

[0035] In some embodiments, the method further includes obtaining a second sheet, rolling the second sheet over a roller having a roller mold, and forming a second surface topology on the second sheet, the second surface topology including at least three critical portions, each of the at least three critical portions being one of (a) a second minimum, (b) a second saddle, or (c) a second maximum, and the method includes bonding at least a portion of the sheet and at least a portion of the second sheet.

[0036] In some embodiments of the method, the portion of the sheet includes one of at least three critical portions of the sheet.

[0037] In some embodiments of the method, the portion of the second sheet includes one of at least three critical portions of the second sheet.

[0038] In some embodiments of the method, the portion of the second sheet includes one of at least three critical portions of the second sheet. [Brief explanation of the drawings]

[0039] BRIEF DESCRIPTION OF THE DRAWINGS Reference is made to the accompanying drawings, which form a part of this disclosure and which illustrate exemplary embodiments in which the systems and methods described herein may be practiced.

[0040] [Figure 1A] FIG. 1A is a schematic perspective top view of a surface topology according to one embodiment.

[0041] [Figure 1B] FIG. 1B is a schematic side view of the surface topology shown in FIG. 1A.

[0042] [Figure 1C] FIG. 1C is another schematic side view of the surface topology shown in FIG. 1A.

[0043] [Figure 2] FIG. 2 is another schematic perspective top view of a surface topology according to one embodiment.

[0044] [Figure 3] FIG. 3 is a schematic side view of several sheets adhered together.

[0045] [Figure 4] FIG. 4 is a schematic perspective top view of a surface topology according to one embodiment.

[0046] [Figure 5] FIG. 5 is a schematic perspective top view of a surface topology according to one embodiment.

[0047] [Figure 6] FIG. 6 is a schematic perspective top view of a surface topology according to one embodiment.

[0048] [Figure 7] FIG. 7 is a schematic perspective top view of a surface topology according to one embodiment.

[0049] [Figure 8] FIG. 8 is a schematic diagram of a method for making one embodiment of one or more articles described herein.

[0050] [Figure 9] FIG. 9 illustrates a non-limiting embodiment of a pollution control system having any of the articles described herein.

[0051] Like numbers refer to like or similar parts throughout. DETAILED DESCRIPTION OF THE INVENTION

[0052] Detailed Description of the Drawings Among the benefits and improvements disclosed, other objects and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings. While detailed embodiments of the present disclosure are disclosed herein, it should be understood that the disclosed embodiments are merely exemplary of the present disclosure, which may be embodied in various forms. Moreover, the examples given of various embodiments of the present disclosure are intended to be illustrative and not limiting.

[0053] Throughout this specification and claims, the following terms have the meanings expressly associated therewith unless the context clearly dictates otherwise. As used herein, the phrases "in one embodiment," "in an embodiment," and "in some embodiments" do not necessarily refer to the same embodiment, although they may. Additionally, as used herein, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, although they may. It is intended that all embodiments of the present disclosure may be combined without departing from the scope or spirit of the disclosure.

[0054] As used herein, the term "between" does not necessarily mean that something is located immediately adjacent to another element. Generally, the term refers to a configuration in which something is sandwiched between two or more other objects. At the same time, the term "between" can also describe something being located immediately adjacent to two opposing objects. Thus, in any one or more of the embodiments disclosed herein, a particular structural component may be located between two other structural elements in the following ways: directly between both of the other two structural elements, such that the particular structural component directly contacts both of the other two structural elements; directly adjacent to only one of the other two structural elements, such that the particular structural component directly contacts only one of the other two structural elements; indirectly adjacent to only one of the other two structural elements, such that the particular structural component does not directly contact only one of the other two structural elements, but there is another element juxtaposing the particular structural component and one of the other two structural elements; indirectly between both of the other two structural elements, such that the particular structural component does not directly contact both of the other two structural elements, but another feature is located between the particular structural component and one of the other two structural elements, or any combination thereof.

[0055] According to some embodiments, an article (e.g., a device or device component) comprises a thin material that can be described as a sheet (or also referred to as a sheet-like material). As a sheet, the sheet has a top surface and a bottom surface and an original center-plane orientation before forming. The sheet has a particular shape or form on its major or top surface, which shape can be described as a surface topology. In some embodiments, the surface topology can be a regularly repeating two-dimensional array form having a three-dimensional topology, with the third dimension including a set of at least three critical portions. These critical portions can include critical points (where the portions are small enough to be roughly described as points). As used herein, a critical portion is a mathematical definition of a surface region where the local two-dimensional shape changes relative to the original center-plane orientation of the unformed sheet material. In some embodiments, each of the at least three critical portions is (a) a minimum, (b) a saddle, i.e., an inflection region where the slope of the surface is zero, or (c) a maximum, i.e., a peak. That is, the surface topology can include "low portions" or "low points" when viewed from a particular viewpoint. For example, when viewed along a particular cross section, a sheet may have one or more spaced apart "minimums" or "low" points. Similarly, a surface topology may include "high points" or "high points" when viewed from a particular viewpoint. For example, when viewed along a particular cross section, a sheet may have one or more "maximums" or "high" points.

[0056] As described below, the magnitude of these "low" or "high" portions can be mathematically measured or determined as an "amplitude" parameter that describes the surface topology in some embodiments. Additionally, the surface topology can include "saddles" (also called "minima"), which describe portions on the surface (critical points) where the slopes (i.e., derivatives) in orthogonal directions are all zero, but are not local extrema of the function. An example of a saddle point (or saddle-like surface portion) is when there is a critical point (or region) with a relative minimum along one axial direction (peak-to-peak) and a relative maximum along the cross axis. However, a saddle does not necessarily have to have this shape. These configurations of the sheet's surface topology can form channels along a particular direction of the sheet, such that the channels can direct fluid flow substantially along that direction. In some embodiments, the sheet's surface topology can induce a substantially uniform flow of fluid along a particular direction (e.g., through the channels). These channels or paths along the sheet's surface topology are typically not straight, but direct the fluid to bypass adjacent features of the topology.

[0057] Furthermore, in some embodiments, the surface topology of the sheet can induce non-uniform flow of fluid along different directions or at the edges of the surface topology. In some embodiments, the shape and location of these surface topology features can induce repeated division of the flowing phase, resulting in one or more of: enhanced mixing, heat transport for heating the material, or mass transport to a reactive surface (e.g., the material of the sheet can be or include a reactive material or compound that can react with fluid flowing over, over, through, or a combination thereof). In some embodiments, the gas phase flow is orthogonal to the gravity vector (horizontal flow or azimuthal flow). The gas flow path includes a surface topology such that the flow is regularly disrupted (e.g., non-uniform). A second liquid phase (produced by reaction or dripping from the top) is present, and the liquid flow path includes a line for smooth, gravity-driven drainage (e.g., substantially uniform flow). This embodiment can be very useful when liquid products are produced from gaseous reactants within a catalyst solid phase and / or in a trickling configuration such as a gas-liquid exchanger.

[0058] According to some embodiments, the surface topology can increase or maximize liquid product production without increasing the gas phase pressure drop across the reaction surface (i.e., the catalyst surface). These embodiments can achieve this by promoting liquid drainage, as portions (or surface areas) of the sheet with high surface shear forces driven by the flowing gas phase can promote displacement of the liquid to quiescent areas for gravity-driven drainage (e.g., via channels on the surface topology).

[0059] Illustrated in FIGS. 1A, 1B, and 1C is an exemplary sheet 100 having a surface topology 102 according to an embodiment. The surface topology 102 is shown in a top perspective view in FIG. 1A. Various repeating pyramidal features 104 having maximum peaks 106 (e.g., maximum portions or maximum points) are visible. These maximum peaks 106 are also shown in FIGS. 1B and 1C. Additionally, the surface topology 102 includes minimum troughs 108 (e.g., minimum portions or minimum points). The surface topology 102 includes saddles 110 (facets or points) located between the nearest maximum peaks 106 and minimum troughs 108. The saddles 110 are more easily visible in FIG. 1B.

[0060] 1B is a side view of sheet 100 viewed along a first direction 112 (as shown in FIG. 1A), along which surface topology 102 undulates from a minimum point 108 to a saddle point 110. The transition along this direction 112 is relatively smooth, according to some embodiments, which may be described as a "channel" for fluid flow, and this configuration may promote a substantially uniform flow of fluid along this direction 112.

[0061] 1C shows a view along a different direction 114 (as shown in FIG. 1A), where the flow path along this direction 114 encounters sharp or sharper edges depending on the minimum troughs 108 and maximum peaks 106 of the surface topology 102. These features can promote uneven flow of the fluid as it flows along this direction 114.

[0062] 1A-1C include pyramidal features 104, other geometric configurations are possible. For example, instead of or in combination with pyramidal features 104, surface topology embodiments can include sinusoidal cross-sections, non-sinusoidal periodic wave cross-sections, triangular wave cross-sections, rectangular wave cross-sections, square wave cross-sections, or combinations thereof.

[0063] In other embodiments, the "peaks" may be flattened or truncated, as shown in FIG. 2. For example, these flattened peak regions may be used to connect with other sheets. In this embodiment of sheet 200 having a different surface topology 202, the peaks of pyramidal features 204 are flattened or truncated to have flattened surface portions 206. Sheet 200 is otherwise similar to that shown in FIGS. 1A-1C. That is, surface topology 202 has various repeating pyramidal features 204 with flattened peaks 206. Surface topology 202 includes minimum troughs 208 (e.g., minima or points) that may also be flattened or truncated. Surface topology 202 includes saddles 210 (faces or points) located between the nearest adjacent flat peaks 206 and the minimum troughs 208. Surface topology 202 undulates from minimum points 208 to saddles 210 along one direction. According to some embodiments, the transition along this direction is relatively smooth. This can be described as a "channel" for fluid flow, and this configuration can promote a substantially uniform flow of fluid along this direction. Along a different direction, the flow path encounters sharp or sharper edges / ridges. These features can promote a non-uniform flow of fluid as the fluid flows along this direction. The flat peaks 206 can be used to join (e.g., connect) the sheet 200 to another sheet.

[0064] 3 is a schematic side view of several sheets joined together. That is, when embodiments of sheets 200 similar to that shown in FIG. 2 are stacked on top of each other, flat peaks 206 can be connection areas between multiple sheets. Some sheets 300 can be flat, and these flat sheets 300 can be placed between sheets 200 having a surface topology (e.g., surface topology 202 shown in FIG. 2).

[0065] In some embodiments of the surface topology, at least some of the surface features include a repeating pattern. Some of these repeating patterns can include several parameters to define the repeating pattern. The parameters can be four or more. Examples of parameters include amplitude, frequency, orientation, and function. Amplitude is the height or depth of the surface topology. Frequency can be determined as the reciprocal of the distance between peaks. Orientation can refer to the two main directions or axes that create the surface topology and the tilt angle between the two directions or axes (the two directions do not have to be perpendicular). Function refers to the shape of the waveform function (e.g., sine wave, square wave, sawtooth wave, etc.). These parameters can be varied to optimize the difference between gas flow and liquid flow in the same surface topology.

[0066] For example, Figure 4 is a schematic perspective top view of a surface topology 400 according to one embodiment. A first axis 402 and a second axis 404 are defined here as being orthogonal to one another. However, the surface topology 400 here forms various maxima 406, minima 408, and saddles 410. Additionally, along one direction 412, the channels 414 are shaped to improve substantially uniform flow. Along another direction 416, the peaks 406 and troughs 408 promote substantially non-uniform flow.

[0067] 5 is a schematic perspective top view of a surface topology 500 according to another embodiment. Here, a first axis 502 and a second axis 504 are defined as being orthogonal to one another. However, the surface topology 500 forms various maxima 506, minima 508, and saddles 510. Additionally, along one direction 512, the surface topology 500 has a wavy shape for improved uniform or smooth fluid flow. Along another direction 514, the peaks 506 and troughs 508 promote non-uniform flow.

[0068] 6 is a schematic perspective top view of a surface topology 600 according to another embodiment. A first axis 602 and a second axis 604 are defined here as being perpendicular to each other. However, the surface topology 600 here forms various maxima 606, minima 608, and saddles 610. Additionally, along one direction 612, the surface topology 600 has a wavy shape to improve uniform or smooth flow. Along another direction 614, the peaks 606 and troughs 608 promote non-uniform flow.

[0069] 7 is a schematic perspective top view of a surface topology 700 according to another embodiment. A first axis 702 and a second axis 704 are defined here as being perpendicular to each other. However, the surface topology 700 here forms various maxima 706, minima 708, and saddles 710. Additionally, along one direction 712, the surface topology 700 has a wavy shape to improve uniform or smooth flow. Along another direction 714, the peaks 706 and troughs 708 promote non-uniform flow.

[0070] FIG. 8 is a schematic diagram of a method 800 for manufacturing one or more embodiments of an article described herein. Some embodiments of the method for manufacturing an article having a surface topology described herein can be performed by obtaining a sheet and rolling the sheet over a roller having a roller mold 802 that forms a surface topology on the sheet, as shown in FIG. 8. An additional step for manufacturing multiple sheets includes obtaining another sheet, where a first sheet having a surface topology disclosed herein is bonded to a flat second sheet, without forming a surface topology on the second sheet if the second sheet is flat. If the second or third sheet includes a surface topology, the sheet is rolled over a roller having a roller mold to bond the sheets, as shown in FIG. 8. An additional step for manufacturing a module for a system includes connecting the bonded multiple sheets to a module frame. Each sheet can include a filter media, a heat exchange surface, an active material, a reactive material, or a combination thereof.

[0071] FIG. 9 illustrates a non-limiting embodiment of a pollution control system 900 incorporating at least one of the articles described herein. Some non-limiting applications of the pollution control system 900 include controlling air pollutant emissions to comply with various air pollutant emission standards. The pollution control system 900 can be configured to capture elemental mercury and oxidized gas-phase mercury from industrial flues. The pollution control system 900 can include individual stackable modules 902 that can be installed downstream of a particle collection system. In some embodiments, the modules 902 can be configured with one or more embodiments of the articles 904 (shown in an enlarged partial view in FIG. 9 ) described herein. Accordingly, in some embodiments, one or more embodiments of the articles 904 are connected to a module frame 906 of the module 902.

[0072] In some embodiments, the pollution control system 900 can include several articles (according to any one or more of the embodiments described herein) formed into multiple channels. In such embodiments, a gas stream can flow between the channels such that the gas stream directly contacts at least a portion of the reactant material. In some embodiments, the multiple channels of the device can facilitate the flow of reactants, such as gas components, over one or more surfaces of the system and the discharge of at least one liquid product. In some embodiments, the system can capture both elemental mercury and oxidized mercury from the flue gas stream as the flue gas passes (e.g., over or through the material). Mercury can be tightly bound within the material of the article by chemisorption. Additionally, SO2 can be adsorbed and / or absorbed and catalytically converted (via an SO2 oxidation catalyst) to liquid sulfuric acid, forming droplets that are discharged from the article. The droplets can flow downward along the surface of the article by gravity.

[0073] Some embodiments of the present disclosure relate to devices comprising a sorbent polymer composite. As used herein, a "sorbent polymer composite" is defined as a sorbent material embedded within a polymeric matrix. In some embodiments, the polymeric material of the sorbent polymer composite comprises at least one of polyfluoroethylene propylene (PFEP), polyperfluoroacrylate (PPFA), polyvinylidene fluoride (PVDF), a terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), or polychlorotrifluoroethylene (PCFE), or a combination thereof. In some embodiments, the polymeric material comprises polytetrafluoroethylene (PTFE). In some embodiments, the polymeric material comprises expanded polytetrafluoroethylene (ePTFE). In some embodiments, the sorbent material of the sorbent polymer composite comprises at least one of activated carbon, coal-derived carbon, lignite-derived carbon, wood-derived carbon, coconut-derived carbon, silica gel, zeolite, or a combination thereof. In some embodiments, the sorbent polymer composite further comprises a halogen source. In some embodiments, the halogen source can be incorporated into the sorptive polymer composite by any suitable technique, including, but not limited to, absorption, impregnation, adsorption, mixing, sprinkling, spraying, immersion, painting, coating, ion exchange, or applying the halogen source to the sorptive polymer composite. In some embodiments, the halogen source can be disposed within the sorptive polymer composite, for example, within any porosity of the sorptive polymer composite. In some embodiments, the halogen source can be provided in a solution that can contact the sorptive polymer composite in situ under system operating conditions.

[0074] In some embodiments, the halogen source is selected from at least one of sodium chloride, potassium chloride, sodium bromide, potassium bromide, sodium iodide, potassium iodide, tetramethylammonium iodide, tetrabutylammonium iodide, tetraethylammonium iodide, tetrapropylammonium iodide, tetramethylammonium bromide, tetraethylammonium bromide, tetrapropylammonium bromide, tetrabutylammonium bromide, tetramethylammonium chloride, tetraethylammonium chloride, tetrapropylammonium chloride, tetrabutylammonium chloride, I2, Cl2, Br2, or a combination thereof.

[0075] Further configurations of the sorbent polymer composite materials described herein, and further examples of the halogen sources described herein, are described in U.S. Pat. No. 9,827,551 to Hardwick et al. and U.S. Pat. No. 7,442,352 to Lu et al., each of which is incorporated by reference in its entirety.

[0076] Some embodiments of the present disclosure are referred to as "flow-by" or "cross-flow" systems because reactants (e.g., at least one gas component) flow near, over, across, or along a surface of a device containing a sorbent polymer composite. This contrasts with "flow-through" or "dead-end" systems, in which reactants flow through the sorbent polymer composite. In some embodiments, the sorbent polymer composite is in the form of at least one sheet. In some embodiments, the at least one sheet includes a first surface and a second surface opposite the first surface. In some embodiments, the first surface is configured such that when a flue gas stream having the at least one gas component flows over (and along) the first surface of the at least one sheet, the at least one gas component reacts within the sorbent polymer composite of the at least one sheet to form at least one liquid product. In some embodiments, the at least one gas component flows over (and along) both the first and second surfaces of the at least one sheet.

[0077] In some embodiments, the at least one gas component is mercury vapor, at least one SO x In some embodiments, the at least one liquid product comprises at least one of sulfuric acid, liquid elemental sulfur, or a combination thereof. x Regarding the compound, SO x Removal is achieved by oxidation to produce H2SO4 (sulfuric acid). x This can be a complex process requiring the transport of SO, O, and HO. x To overcome the effects of sulfate accumulation due to oxidation, the sorbent polymer composite can act as a "reverse sponge" and expel sulfate.

[0078] Certain devices formed from sorbent polymer composites can face significant challenges due to liquid accumulation. Performance can deteriorate over time as the liquid forms a permeable network within the sorbent polymer composite. Eventually, this network can become continuous with the surface of the sorbent polymer composite, and further liquid production causes the liquid to drain to the surface of the sorbent polymer composite. Due to the low solubility and diffusivity of contaminants, the liquid-wetted surface portions of the sorbent polymer composite can perform less well than areas that remain dry. Thus, in some embodiments, the adsorbent material of the sorbent polymer composite removes the greatest amount of target contaminants possible.

[0079] In some embodiments, the device includes a plurality of sheets forming a plurality of channels. In some embodiments, the plurality of sheets is configured such that at least one liquid product can be discharged through each of the plurality of channels. In some embodiments, the plurality of channels includes a plurality of adjacent channels, each adjacent channel of the plurality of adjacent channels being connected.

[0080] In some embodiments, the article or device can be configured to provide high efficiency mercury capture at a lower pressure drop than that achieved through a granular bed packed with the sorbent material of the sorbent polymer composite. That is, the multiple channels of the device can facilitate flow of reactants, such as gaseous components, over one or more surfaces of at least one sheet and facilitate discharge of at least one liquid product. In some embodiments, the device includes multiple pleated sheets and multiple flat sheets arranged in an alternating fashion. [Example]

[0081] Example and Comparative Example Data

[0082] The table below shows comparative properties detected and measured from an exemplary embodiment.

[0083] [Table 1]

[0084] [Table 2]

[0085] To evaluate and compare the performance of the various embodiments and geometries, a series of computational fluid dynamics experiments were performed using the SOLIDWORKS Flow Simulation Suite (Dessault Systemes, Waltham, MA, USA). All simulations were performed at a flow velocity of 3.6 m / s and an air temperature of 60°C.

[0086] A 10 mm high equilateral triangular channel was used as the reference for comparison. All calculations were also compared to a common geometry for flow between parallel plates.

[0087] Span refers to the characteristic dimension between the center planes of adjacent geometries that form a channel, measured here in millimeters (mm). When the aforementioned undulating geometries form channels in multiple directions, periodic boundary conditions were used.

[0088] Pressure drop (dP) is defined as the difference in fluid pressure between the fluid inlet and outlet, measured in inches of water column. Transport ratio refers to the calculated heat transfer coefficient of a geometry relative to the triangular channel performance (e.g., the example transfers 68% more heat). The Colburn-Chilton relationship allows this transport ratio to be directly applied to mass transport operations such as reactive-advective systems.

[0089] The FOM (Figure of Merit) parameter is the transport ratio divided by the pressure drop, giving a kind of "transport efficiency" where the energy used to move the fluid is an important consideration.

[0090] Weight ratio refers to the amount of material contained per unit volume in a geometric shape. The transport ratio per weight (transport / weight ratio) refers to the transport ratio per unit material and can be important when the material is valuable. Since areal density is a constant, it is also a measure of transport per surface area.

[0091] The geometry of Example 1 according to the embodiment has a sinusoidal shape, with an out-of-plane amplitude of 6 mm in both directions (total geometry height of 12 mm) and a wavelength of 50 mm in the first direction (flow direction) and 20 mm in the second direction (perpendicular to the flow direction). This wavy geometry is connected to a flat sheet between the repeating wavy geometries, as shown in sheet 300 in Figure 3.

[0092] The geometry of Example 2 according to the embodiment has a sinusoidal shape. The out-of-plane amplitude in both directions is 3.5 mm (total geometry height is 7 mm), and the wavelength is 50 mm in the first direction (flow direction) and 20 mm in the second direction (perpendicular to the flow direction). This wavy geometry is connected to a similar wavy geometry, as shown in sheet 200 in Figure 3. The peaks of the wavy sheets are aligned with each other.

[0093] The geometry of Example 3 according to the embodiment has a sinusoidal shape. The out-of-plane amplitude in both directions is 3.5 mm (total geometry height is 7 mm), and the wavelength is 50 mm in the first direction (flow direction) and 20 mm in the second direction (perpendicular to the flow direction). This wavy geometry is connected to a flat sheet between the repeating wavy shapes, as shown in sheet 300 in Figure 3.

[0094] As can be seen from Tables 1A-1B above, the three examples demonstrate improved performance compared to the comparative example: transport ratios are 33%-68% higher than the triangular channel geometry, and FOM parameters are over 100% greater despite using less material.

[0095] [Table 3]

[0096] [Table 4]

[0097] To confirm the observed simulation results, experiments were conducted on the mercury and SO2 removal efficiency using standard sorbent polymer composites (SPCs). Here, sorbent polymer composites (SPCs) containing 65.5% activated carbon (Norit PAC20BF, Cabot Inc., Texas, USA), 20% PTFE, 9% tetrabutylammonium iodide, and 5.5% sulfur were prepared using the general dry-blending method taught in U.S. Patent No. 7,791,861 to fabricate composite samples. These SPC materials were then molded into geometric shapes according to the present invention as follows:

[0098] Triangular channels were fabricated by pleating an SPC sheet using a blade pleater and placing it next to a flat sheet to form a 10 mm high triangular channel. Parallel plate geometry was fabricated by adjoining two flat SPC sheets and using multiple polypropylene posts and neoprene O-rings (commercially available from McMaster-Carr, Elmhurst, IL, USA) as spacers to form a 6 mm parallel plate channel.

[0099] The geometry of the SPC sheet in Example 4 according to the embodiment has a sinusoidal wave shape. The out-of-plane amplitude in both directions is 3.5 mm (total geometric height is 7 mm), and the wavelength is 50 mm in the first direction (machine direction) and 20 mm in the second direction (perpendicular to the machine direction). This wavy SPC sheet is connected to the 10 mm equilateral triangular pleated SPC sheet described above to form a layered geometry of wavy and pleated SPC sheets.

[0100] The geometry of the SPC sheet of Example 5 according to the embodiment has a sinusoidal shape. The out-of-plane amplitude in both directions is 3.5 mm (total geometric height 7 mm), and the wavelength is 50 mm in the first direction (machine direction) and 20 mm in the second direction (perpendicular to machine direction). This wavy SPC sheet is connected to a similar wavy SPC sheet, as shown in sheet 200 in Figure 3.

[0101] The geometry of the SPC sheet in Example 6 according to the embodiment has a sinusoidal wave shape. The out-of-plane amplitude in both directions is 6.2 mm (total geometric height 12.4 mm), and the wavelength is 100 mm in the first direction (machine direction) and 12.7 mm in the second direction (perpendicular to machine direction). This wavy SPC sheet is connected to a flat SPC sheet between the repeating wavy shapes, as shown in sheet 300 in Figure 3.

[0102] Hg and SO2 removal efficiency tests were conducted using the following equipment: (1) an air supply regulated by a blower. The humidity level of the air stream was controlled by passing it through a humidification system including a gas preheater and a heated humidification chamber. (2) a mercury supply generated by passing a small nitrogen purge through a liquid mercury container placed in a temperature-controlled bead bath. (3) a SO2 supply from an SO2 generation system. SO2 was generated by mixing concentrated sulfuric acid with a sodium metabisulfite solution and transported by a small nitrogen purge. (4) a gas mixing zone where the humidified air was mixed with the mercury and SO2 supply streams. (5) a sample cell fitted with gas sampling ports before and after the sample and placed inside the oven. (6) a mercury analyzer measuring total mercury (the gas sampling line passed through a tin chloride / HCl bubbler to convert oxidized mercury to elemental mercury before the analyzer). (7) a SO2 detection analyzer.

[0103] Efficiency is reported as the difference between the inlet mercury concentration (bypassing the sample) and the outlet mercury concentration (passing through the sample). Percent efficiency is defined as:

number

[0104] The sample cell contained a horizontal duct measuring 50 mm x 50 mm x 300 mm. Horizontal here refers to the direction of airflow perpendicular to the gravity vector, and the discharge of the generated sulfuric acid phase can affect overall performance. The face velocity was 3.6 m / s, the inlet SO2 concentration was 100 ppm, and the remainder was fully saturated moist air. The inlet mercury concentration was approximately 15 μg / m in elemental form. 3 It was.

[0105] The results of the removal efficiency tests are summarized in Tables 2A-2B. Dry SPC weight refers to the amount of material contained within the duct. Wet dP refers to the fact that, in contrast to the CFD results, an additional liquid phase forms on the SPC material, which affects airflow.

[0106] For performance evaluation, both SO2 and Hg were added. Elemental Hg has limited solubility and is significantly affected by the liquid phase, which inhibits access to the reactive material. On the other hand, SO2 is highly soluble in liquid-phase acid and is less affected by the presence of the liquid. All three example geometries show improved removal efficiency compared to the two comparative geometries tested.

[0107] Aspects

[0108] Various embodiments are described below. It should be understood that one or more of the features described in the following embodiments can be combined with one or more other embodiments.

[0109] Aspect 1. An article comprising a first sheet, the first sheet has a surface topology; the surface topology comprises a first set of at least three critical portions; Each of the at least three critical portions comprises: (a) Smallest part, (b) a saddle, or (c) maximum part; That is, an item.

[0110] Aspect 2. the surface topology includes channels along a first direction; 2. The article of embodiment 1, wherein the channel is configured to direct fluid flow substantially along the first direction.

[0111] Aspect 3. The first sheet is Filter media, heat exchange surface, active material, reactive materials, or Combinations of these, 3. The article of embodiment 2, comprising:

[0112] Aspect 4. 4. The article of embodiment 3, wherein the surface topology is substantially uniform along a first direction.

[0113] Aspect 5. 4. The article of embodiment 3, wherein the channel is configured to provide a substantially uniform flow of fluid.

[0114] Aspect 6. 5. The article of claim 4, wherein the minimum, the saddle, and the maximum are along a second direction, the second direction being different from the first direction.

[0115] Aspect 7. 7. The article of embodiment 6, wherein the surface topology is configured to provide a substantially non-uniform fluid flow along the second direction.

[0116] Aspect 8. 2. The article of embodiment 1, wherein at least one of each of the three critical portions is a critical point.

[0117] Aspect 9.

[0023] Aspect 9. The article of any of aspects 1-8, wherein the surface topology further comprises straight edges connecting at least two of the at least three critical portions.

[0118] Aspect 10.

[0023] Aspect 1. The article of any one of aspects 1-9, wherein the surface topology further comprises a curved portion connecting at least two of the at least three critical portions.

[0119] Aspect 11. 11. The article of any one of embodiments 1-10, wherein the surface topology comprises a geometric wavy cross-section.

[0120] Aspect 12. The geometric wave cross section is sinusoidal cross section, Non-sinusoidal periodic wave cross section, Triangular wave cross section, square wave cross section, Square wave cross section, or Combinations of these, 12. The article of embodiment 11, comprising:

[0121] Aspect 13. 13. The article of any one of embodiments 3-12, wherein the filtration media comprises a sorbent polymer composite material.

[0122] Aspect 14. The sorbent polymer composite material comprises: a sorbent material, and polymer materials, 14. The article of embodiment 13, comprising:

[0123] Aspect 15. 15. The article of embodiment 14, wherein the sorptive material comprises at least one of activated carbon, silica gel, zeolite, or a combination thereof.

[0124] Aspect 16. 16. The article of any one of embodiments 14-15, wherein the polymeric material comprises at least one of polytetrafluoroethylene, polyfluoroethylenepropylene, polyperfluoroacrylate, polyvinylidene fluoride, a terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride, polychlorotrifluoroethylene, or a combination thereof.

[0125] Aspect 17. 17. The article of any one of embodiments 1-16, further comprising a second sheet connected to the first sheet.

[0126] Aspect 18. 18. The article of embodiment 17, wherein the second sheet has a second surface topology including flat portions.

[0127] Aspect 19. the second sheet has a second surface topology;

[0128] the second surface topology includes a second set of at least three critical portions; Each of the at least three critical portions comprises: (a) the second smallest part; (b) a second saddle, or (c) the second largest part; 18. The article of embodiment 17, wherein

[0129] Aspect 20. 20. The article of embodiment 19, wherein the second sheet comprises a second filter medium.

[0130] Aspect 21. 21. The article of embodiment 20, wherein at least one of the at least three critical portions of the first sheet is connected to the second sheet.

[0131] Aspect 22. 22. The article of embodiment 21, wherein the first sheet is connected to the second sheet by adhesive, ultrasonic welding, or a combination thereof.

[0132] Aspect 23. 22. The article of embodiment 21, wherein the first sheet is connected to the second sheet by an adhesive.

[0133] Aspect 24. further comprising a module frame;

[0134] 24. The article of any one of aspects 17 to 23, wherein the first sheet and the second sheet are connected to the module frame.

[0135] Aspect 25. Contains multiple sheets, Each of the plurality of sheets has a surface topology including at least three critical portions, each of the at least three critical portions comprising: (a) Smallest part, (b) a saddle, or (c) maximum part; That is, the module.

[0136] Aspect 26. 26. The module of embodiment 25, wherein each of the plurality of sheets comprises a filter medium.

[0137] Aspect 27. 27. The module of embodiment 26, wherein the filter media comprises a sorptive polymer composite.

[0138] Aspect 28. The sorbent polymer composite material comprises: a sorbent material, and polymer materials, 28. The module of embodiment 27, comprising:

[0139] Aspect 29. Getting a seat, rolling the sheet over a roller having a roller mold; forming a surface topology on the sheet; wherein the surface topology comprises at least three critical portions, each of the at least three critical portions comprising: (a) Smallest part, (b) a saddle, or (c) maximum part; A method for producing an article according to any one of aspects 1 to 28,

[0140] Aspect 30. The sheet is Filter media, heat exchange surface, active material, reactive materials, or Combinations of these, 30. The method of embodiment 29, comprising:

[0141] Aspect 31. Obtaining a second sheet; rolling the second sheet over a roller having a roller mold; and forming a second surface topology on the second sheet; wherein the second surface topology comprises at least three critical portions, each of the at least three critical portions comprising: (a) the second smallest part; (b) a second saddle, or (c) the second largest part; and joining at least a portion of the sheet with at least a portion of the second sheet; 31. The method of any one of aspects 29 to 30, further comprising:

[0142] Aspect 32. 32. The method of embodiment 31, wherein the portion of the sheet comprises one of the at least three critical portions of the sheet.

[0143] Aspect 33. 33. The method of embodiment 32, wherein the portion of the second sheet comprises one of the at least three critical portions of the second sheet.

[0144] Aspect 34. 32. The method of embodiment 31, wherein the portion of the second sheet comprises one of the at least three critical portions of the second sheet.

[0145] All prior patents and publications referenced herein are hereby incorporated by reference in their entirety.

[0146] The terms used herein are intended to describe embodiments and are not intended to be limiting. The terms "a," "an," and "the" include the plural unless clearly indicated otherwise. As used herein, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or components. As used herein, the term "based on" is not exclusive and allows for the use of additional, unstated elements unless the context clearly indicates otherwise. Furthermore, the meaning of "in" includes "in" and "on."

[0147] It should be understood that changes may be made in details, particularly in matters of the materials of construction used, and the shape, size and arrangement of parts, without departing from the scope of the present disclosure. The specification and described embodiments are exemplary, the true scope and spirit of the present disclosure being indicated by the appended claims.

Claims

1. An article comprising a first sheet, the first sheet has a surface topology; the surface topology comprises a first set of at least three critical portions; Each of the at least three critical portions comprises: (a) minimum part, (b) a saddle, or (c) maximum part; An item is one of the following.

2. the surface topology includes flow channels along a first direction; The article of claim 1 , wherein the channel is configured to direct fluid flow substantially along the first direction.

3. The first sheet is Filter media, heat exchange surface, active material, reactive materials, or Combinations of these, The article of claim 1 , comprising:

4. The article of any one of claims 1 to 3, wherein the surface topology is substantially linear along the first direction.

5. The article of any one of claims 1 to 4, wherein the channels are configured to provide a substantially uniform flow of fluid.

6. 3. The article of claim 2, wherein the minimum, the saddle, and the maximum are along a second direction, the second direction being different from the first direction.

7. The article of claim 6 , wherein the surface topology is configured to provide a substantially non-uniform flow of fluid along the second direction.

8. The article of claim 1 , wherein at least one of each of the three critical portions is a critical point.

9. The article of any one of claims 1 to 8, wherein the surface topology further comprises straight edges connecting at least two of the at least three critical portions.

10. The article of any one of claims 1 to 9, wherein the surface topology further comprises a curved portion connecting at least two of the at least three critical portions.

11. The article of any one of claims 1 to 10, wherein the surface topology comprises a geometric wavy cross section.

12. The geometric wave cross section is sinusoidal cross section, Non-sinusoidal periodic wave cross section, Triangular wave cross section, square wave cross section, Square wave cross section, or Combinations of these, The article of claim 11 , comprising:

13. The article of any one of claims 3 to 12, wherein the filter media comprises a sorbent polymer composite material.

14. The sorbent polymer composite material comprises: a sorbent material, and polymer materials, The article of claim 13 comprising:

15. The article of claim 14 , wherein the sorptive material comprises at least one of activated carbon, silica gel, zeolite, or combinations thereof.

16. 16. The article of any one of claims 14-15, wherein the polymeric material comprises at least one of polytetrafluoroethylene, polyfluoroethylenepropylene, polyperfluoroacrylate, polyvinylidene fluoride, a terpolymer of tetrafluoroethylene, hexafluoropropylene and vinylidene fluoride, polychlorotrifluoroethylene, or a combination thereof.

17. The article of any one of claims 1 to 16, further comprising a second sheet connected to the first sheet.

18. The article of claim 17 , wherein the second sheet has a second surface topology that includes flat portions.

19. the second sheet has a second surface topology; the second surface topology includes a second set of at least three critical portions; Each of the at least three critical portions comprises: (a) a second minimum portion; (b) a second saddle; or (c) a second maximum portion; 18. The article of claim 17, wherein:

20. The second sheet is Second filter media, heat exchange surface, active material, reactive materials, or Combinations of these, 20. The article of claim 19, comprising:

21. 21. The article of claim 20, wherein at least one of the at least three critical portions of the first sheet is connected to the second sheet.

22. 22. The article of claim 21, wherein the first sheet is connected to the second sheet by an adhesive, ultrasonic welding, or a combination thereof.

23. 22. The article of claim 21, wherein the first sheet is connected to the second sheet by an adhesive.

24. further comprising a module frame; The article of any one of claims 17 to 23, wherein the first sheet and the second sheet are connected to the module frame.

25. Contains multiple sheets, Each of the plurality of sheets has a surface topology including at least three critical portions, each of the at least three critical portions comprising: (a) minimum part, (b) a saddle, or (c) maximum part; That is, the module.

26. Each of the plurality of sheets is Filter media, heat exchange surface, active material, reactive materials, or Combinations of these, 26. The module of claim 25, comprising:

27. 27. The module of claim 26, wherein the filter media comprises a sorbent polymer composite material.

28. The sorbent polymer composite material comprises: a sorbent material, and polymer materials, 28. The module of claim 27, comprising:

29. Getting a seat, rolling the sheet over a roller having a roller mold; forming a surface topology on the sheet; wherein the surface topology comprises at least three critical portions, each of the at least three critical portions comprising: (a) minimum part, (b) a saddle, or (c) maximum part; A method for producing an article according to any one of claims 1 to 28, wherein

30. The sheet is Filter media, heat exchange surface, active material, reactive materials, or Combinations of these, 30. The method of claim 29, comprising:

31. Obtaining a second sheet; rolling the second sheet over a roller having a roller mold; and forming a second surface topology on the second sheet; and joining at least a portion of the sheet with at least a portion of the second sheet; further comprising wherein the second surface topology comprises at least three critical portions, each of the at least three critical portions comprising: (a) a second minimum portion; (b) a second saddle; or (c) a second maximum portion; The method according to any one of claims 29 to 30, wherein

32. 32. The method of claim 31, wherein the portion of the sheet includes one of the at least three critical portions of the sheet.

33. 33. The method of claim 32, wherein the portion of the second sheet comprises one of the at least three critical portions of the second sheet.

34. 32. The method of claim 31 , wherein the portion of the second sheet comprises one of the at least three critical portions of the second sheet.

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