Compact adsorption system with rotating manifold for carbon capture

Abstract

The present application provides an adsorption system for flue gas carbon capture. The adsorption system can include a fixed adsorbent bed and a rotating manifold in communication with the fixed adsorbent bed.

Description

[Technical Field]

[0001] TECHNICAL FIELD This application and resulting patent relate generally to combustion systems such as gas turbine engines, and more particularly to a compact adsorption system with a rotating manifold for carbon capture and method thereof. [Background technology]

[0002] Generally described, many different types of combustion systems, such as gas turbine engines, burn fossil fuels, such as natural gas, to produce hot combustion gases that drive a turbine to produce mechanical work. While natural gas is cleaner than, for example, coal or oil, its combustion produces flue gases that include carbon dioxide.

[0003] To limit the impact of these flue gases on the environment, various types of carbon capture technologies are used. For example, various types of adsorption systems are known. Generally described, an adsorption system may use several fixed towers. In the first tower, flue gas from a combustion process flows through a solvent bed, which may at least partially remove carbon dioxide from the flue gas. The carbon dioxide-rich solvent flows at an elevated temperature to a regeneration tower, where it may release the carbon dioxide. The released carbon dioxide may be stored, sequestered, and / or processed for use. The regenerated solvent may then return to the first tower.

[0004] More recent carbon capture developments have focused on rotating bed systems using structured solid adsorbents. Given that structured adsorbents can have larger surface areas and lower overall pressure drops, rotating systems can be faster or more efficient than conventional towers. However, given the additional energy requirements for the rotating bed, the overall size and scale of such systems can be limited. Furthermore, rotating beds generally need to be shut down as needed to replace the adsorbent material therein. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent No. 9,352,269 Summary of the Invention

[0006] Thus, the present application and resultant patent provide an adsorption system for flue gas carbon capture. The adsorption system can include a fixed adsorbent bed and a rotating manifold in communication with the fixed adsorbent bed.

[0007] The present application and resultant patent further provide a method for removing carbon dioxide from a flue gas stream in an adsorption system, the method including the steps of flowing the flue gas into a first end of a rotary manifold of the adsorption system, delivering the flue gas stream to a flue gas stream of a fixed bed of the adsorption system, capturing carbon dioxide in the flue gas stream of the fixed bed, flowing a steam stream to a second end of the rotary manifold, delivering the steam stream to the flue gas stream of the fixed bed, releasing carbon dioxide in the steam stream in the flue gas stream of the fixed bed, and allowing the carbon dioxide to exit the second end of the rotary manifold.

[0008] The present application and resultant patent further provide an adsorption system for flue gas carbon capture. The adsorption system can include a fixed adsorption bed and a rotary manifold in communication with the fixed adsorption bed. The rotary manifold can include a first rotary manifold having a flue gas chamber for passing a flue gas flow therethrough and a nitrogen chamber for passing a nitrogen flow therethrough, and a second rotary manifold having a steam chamber for passing a steam flow therethrough and a carbon dioxide chamber for passing a carbon dioxide flow therethrough.

[0009] These and other features and improvements of the present application and the resulting patent will become apparent to those skilled in the art from a review of the following detailed description, taken in conjunction with the several drawings and the appended claims. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a schematic diagram of a gas turbine engine including a compressor, combustor, turbine, exhaust frame, and an external load. [Figure 2] FIG. 1 is a schematic diagram of an adsorption system as may be described herein, including a stationary casing, a rotating manifold, and a fixed bed. [Figure 3] FIG. 3 is a schematic diagram of a rotating manifold of the adsorption system of FIG. 2. [Figure 4] FIG. 3 is a further schematic diagram of the rotating manifold of the adsorption system of FIG. 2. [Figure 5] FIG. 2 is a further schematic diagram of an adsorption system that may be described herein. DETAILED DESCRIPTION OF THE INVENTION

[0011] Referring now to the drawings, wherein like numerals refer to like elements throughout the several views, FIG. 1 illustrates a schematic diagram of a gas turbine engine 10 that may be used herein. The gas turbine engine 10 may include a compressor 15. The compressor 15 compresses an incoming airflow 20. The compressor 15 delivers the compressed airflow 20 to a number of combustor cans 25. The combustor cans 25 mix the compressed airflow 20 with a pressurized fuel flow 30 and ignite the mixture to generate a hot combustion gas flow 35. Although only a single combustor can 25 is shown, the gas turbine engine 10 may include any number of combustor cans 25 positioned in a circumferential array, or the like. Alternatively, the combustor 25 may be an annular combustor. The combustion gas flow 35 is then delivered to a turbine 40. The combustion gas flow 35 drives the turbine 40 to generate mechanical work. The mechanical work generated in the turbine 40 drives the compressor 15 via a rotor shaft 45 and an external load 50, such as an electrical generator.

[0012] The combustion gas flow 35 is delivered from the turbine 40 to an exhaust frame 55 positioned downstream thereof in the form of spent flue gases 60. The exhaust frame 55 may contain and direct the flow of flue gases 60 to other components of the gas turbine engine 10. For example, the exhaust frame 55 may direct the flow of flue gases 60 to an exhaust plenum or an exhaust diffuser. Other configurations and components may be used herein.

[0013] The gas turbine engine 10 may use natural gas, various types of synthetic gas, liquid fuels, and / or other types of fuels and blends thereof. The gas turbine engine 10 may be any one of several different gas turbine engines offered by General Electric Company of Schenectady, New York, including, but not limited to, a 7-series or 9-series heavy-duty gas turbine engine and the like, and may be part of a simple-cycle or combined-cycle power generation system. The gas turbine engine 10 may have a different configuration and may use other types of components. Other types of gas turbine engines may also be used herein. Multiple gas turbine engines, other types of turbines, and other types of power generation equipment and / or other types of hydrocarbon fuel combustion systems may also be used together herein.

[0014] 2-5 illustrate an adsorption system 100 that may be used herein. The adsorption system 100 may remove a significant amount of carbon dioxide from a stream of flue gas 60. Thus, specifically, the adsorption system 100 may be in communication with a stream of flue gas 60 from a gas turbine engine 10 or several gas turbine engines 10.

[0015] Generally described, the adsorption system 100 can include a rotating manifold 110, a stationary casing 120, and a fixed bed 130. The rotating manifold 110 can include an upper rotating inner chamber 140 and an upper rotating outer chamber 150 of a first or upper rotating manifold 155, and a lower rotating outer chamber 160 and a lower rotating inner chamber 170 of a second or lower rotating manifold 175. The rotating manifold 110 can also include a drive shaft 180 extending therethrough. The drive shaft 180 can be rotated via a drive motor 190. The drive motor 190 can be any type of conventional drive device capable of providing rotational motion in any direction and at any speed.

[0016] The upper rotating inner chamber 140 and the lower rotating inner chamber 170 are attached to a drive shaft 180 and can rotate therewith. The upper rotating inner chamber 140 can include several manifold upper ports 200. The upper rotating outer chamber 150 can be connected to the upper rotating inner chamber 140 and can rotate therewith. The upper rotating outer chamber 150 can include several manifold upper passages 210 that communicate with the manifold upper ports 200. The lower rotating inner chamber 170 can include several manifold lower ports 220. The lower rotating outer chamber 160 can be connected to the lower rotating inner chamber 170 and can rotate therewith. The lower rotating outer chamber 160 can include several manifold lower passages 230 that communicate with the manifold lower ports 220. The rotating manifold 110 and its components can have any suitable size, shape, or configuration. Other components and configurations may be used herein.

[0017] The stationary casing 120 may include a first or stationary upper casing 240 and a second or stationary lower casing 250. The stationary upper casing 240 may include a number of first or upper casing ports 260. The upper casing ports 260 may align with the manifold upper ports 200 as the rotating manifold 110 rotates. The stationary lower casing 250 may include a number of second or lower casing ports 270. The lower casing ports 270 may align with the manifold lower ports 220 as the rotating manifold 110 rotates. The stationary casing 120 may be supported by any type of conventional support structure. The stationary casing 120 and its components may have any suitable size, shape, or configuration. Other components and configurations may be used herein.

[0018] The fixed bed 130 may be positioned between the upper and lower rotating outer chambers 150, 160 of the rotary manifold 110. The fixed bed 130 may be mounted around the drive shaft 180 via several bearing plates 275 or the like to support and secure the fixed bed 130 as the drive shaft 180 rotates. Other types of connection and support means may be used herein. The fixed bed 130 may include several segmented flows 280 or other types of passages through the fixed bed. As described in more detail below, each segmented flow 280 of the fixed bed 130 may temporarily align with the appropriate upper manifold passage 210 and lower manifold passage 230 of the rotary manifold 110 as the rotary manifold 110 rotates.

[0019] Each of the segmented flows 280 of the fixed bed 130 may include a carbon dioxide filter 290 therein. The carbon dioxide filter 290 may include a solid adsorbent material 300 therein. Specifically, the carbon dioxide filter 290 may include a metal-organic framework (MOF), a porous polymer network / MOF, an amine-doped silica, or the like. The carbon dioxide filter 290 may be a solid structure for low pressure drop and fast mass transfer for high-speed cycling of carbon dioxide adsorption and release. The carbon dioxide filter 290 may be segmented so that each segment is independently replaceable. Other types of filters 290, absorbers, and other types of adsorbent materials 300 may be used herein. The fixed bed 130 and its components may have any suitable size, shape, or configuration. Other components and configurations may be used herein.

[0020] In use, one of the lower casing ports 270 of the stationary lower casing 250 may be designated a flue gas port 310 in communication with the flow of flue gas 60. The flue gas port 310 may be in communication with a designated flue gas chamber 320 of the lower rotary inner chamber 170 and the lower rotary outer chamber 160 of the lower rotary manifold 175. The flue gas chamber 320 may be in communication with a designated flue gas stream 330 of the segmented flow 280 of the fixed bed 130. In the flue gas stream 330, the flue gas 60 may contact the adsorbent material 300 of the carbon dioxide filter 290. The flue gas 60 may be primarily composed of carbon dioxide 340 and molecular nitrogen 350 (CO + N), as well as O, H, and trace amounts of Ar, NO x , SO xThe flue gas 60, which may be carbon dioxide (CO₂) or carbon dioxide (CO₂) (such as CO₂) in the fixed bed 130, may flow through a carbon dioxide filter 290, where substantially all of the carbon dioxide 340 therein is captured by the adsorbent material 300, thereby leaving a largely spent, primarily nitrogen, stream 350. The spent nitrogen stream 350 may exit the flue gas stream 330 of the fixed bed 130 and flow through a designated spent stream chamber 360 in the upper rotary outer chamber 150 and upper rotary inner chamber 140 of the upper rotary manifold 155. The spent nitrogen stream 350 may then exit via a designated spent stream port 370 in the upper casing port 260 of the fixed upper casing 240. Other components and configurations may be used herein.

[0021] Similarly, one of the upper casing ports 260 of the stationary upper casing 240 can be designated a heating port 380 that communicates with a steam flow 390 or other type of heating stream. The heating port 380 can communicate with designated heating chambers 400 in the upper rotating inner chamber 140 and the upper rotating outer chamber 150 of the upper rotary manifold 155. As the rotary manifold 110 rotates, the heating chambers 400 can communicate with designated flue gas streams 330 in the segmented streams 280 of the fixed bed 130. In the flue gas stream 330, carbon dioxide 340 captured in the adsorbent material 300 of the carbon dioxide filter 290 can be released by the heat of the steam flow 290 or other type of heating stream. The carbon dioxide stream 340 can exit the flue gas stream 330 of the fixed bed 130 along with the steam flow 390 or other type of heating stream and flow through designated carbon dioxide chambers 410 in the lower rotating outer chamber 160 and the lower rotating inner chamber 170 of the lower rotary manifold 175. The carbon dioxide 340 stream may then exit through designated carbon dioxide port 420 in lower casing port 270 of stationary lower casing 250. The carbon dioxide 340 stream may then be captured, sequestered, treated, and / or otherwise utilized. Other components and configurations may be used herein.

[0022] One or more flows of coolant 430 may be used in addition to the flows of flue gas 60 and steam 390 or other types of heated flows. The coolant 430 may be ambient air, nitrogen, or the like. One or more designated coolant ports 440 may be used in the stationary upper casing 240 and / or the stationary lower casing 250, and one or more designated coolant chambers 450 may be used in the upper rotating inner chamber 140 and the upper rotating outer chamber 150 of the upper rotary manifold 155 and / or the lower rotating outer chamber 160 and the lower rotating inner chamber 170 of the lower rotary manifold 175. The coolant chambers 450 may supply a flow of coolant 430 to the designated flue gas flow 330 of the segmented flow 280 of the fixed bed 130 to cool and recharge the adsorbent material 300 of the carbon dioxide filter 290 as the rotary manifold 110 rotates. Other components and configurations may be used herein.

[0023] The direction of some of the flows herein may vary. Although a cross-flow configuration is described above, the flows may proceed in any direction. For example, all flows herein may proceed in the same direction.

[0024] In contrast to a typical three-column adsorption system (i.e., one column adsorbs carbon dioxide, and the other two columns are in regeneration and cooling modes, respectively), the adsorption system 100 described herein contains all three operations within a single, compact module, thereby reducing the overall footprint and therefore the overall capital investment. Similarly, overall complexity can be reduced. Furthermore, rotating the manifold 110 is easier than rotating an adsorption bed, requiring less parasitic load on the drive motor 190. As a result, the rotating manifold 110 can be scaled to a larger size. Furthermore, replacing the adsorption material 300 in the fixed bed 130 does not require shutting down the entire adsorption system 100.

[0025] It should be apparent that the foregoing relates only to particular embodiments of this application and the resulting patent. Numerous changes and modifications may be made herein by those skilled in the art without departing from the general spirit and scope of the invention as defined by the following claims and their equivalents.

[0026] Further aspects of the present invention are provided by the subject matter of the following clauses.

[0027] 1. An adsorption system for flue gas carbon capture comprising a fixed adsorbent bed and a rotating manifold in communication with the fixed adsorbent bed.

[0028] 2. The adsorption system of any one of the preceding clauses, further comprising a stationary casing in communication with the rotating manifold.

[0029] 3. An adsorption system according to any one of the preceding clauses, wherein the fixed casing comprises a fixed upper casing.

[0030] 4. An adsorption system according to any one of the preceding clauses, wherein the rotating manifold comprises one or more upper rotating chambers in communication with the stationary upper casing and the fixed adsorption bed.

[0031] 5. An adsorption system according to any one of the preceding clauses, wherein the one or more upper rotating chambers comprise a plurality of upper manifold ports in communication with a plurality of upper manifold passages.

[0032] 6. An adsorption system according to any one of the preceding clauses, wherein the fixed upper casing comprises a plurality of upper casing ports in communication with a plurality of manifold upper ports of one or more upper rotating chambers.

[0033] 7. An adsorption system according to any one of the preceding clauses, wherein the stationary casing comprises a stationary lower casing.

[0034] 8. An adsorption system according to any one of the preceding clauses, wherein the rotating manifold comprises one or more lower rotating chambers in communication with the stationary lower casing and the fixed adsorption bed.

[0035] 9. An adsorption system according to any one of the preceding clauses, wherein the one or more lower rotating chambers comprise a plurality of lower manifold ports in communication with a plurality of lower manifold passages.

[0036] 10. An adsorption system according to any one of the preceding clauses, wherein the stationary lower casing comprises a plurality of lower casing ports in communication with a plurality of manifold lower ports of one or more lower rotating chambers.

[0037] 11. An adsorption system according to any one of the preceding clauses, wherein the rotating manifold comprises a drive shaft.

[0038] 12. The adsorption system of any one of the preceding clauses, wherein the fixed adsorption bed comprises a carbon dioxide filter having an adsorbent material therein.

[0039] 13. An adsorption system according to any one of the preceding clauses, wherein the rotary manifold comprises a first rotary manifold having a heating chamber for passing the heating stream and a spent stream chamber for passing the spent stream.

[0040] 14. An adsorption system as described in any one of the preceding clauses, wherein the rotary manifold comprises a second rotary manifold having a flue gas chamber for passing the flue gas flow and a carbon dioxide chamber for passing the carbon dioxide flow.

[0041] 15. A method for removing carbon dioxide from a flue gas stream in an adsorption system, the method comprising: flowing the flue gas into a rotary manifold of the adsorption system; delivering the flue gas stream to a fixed bed flue gas stream of the adsorption system; capturing carbon dioxide in the flue gas stream in the fixed bed; flowing a vapor stream into the rotary manifold; delivering the vapor stream to the fixed bed flue gas stream; releasing carbon dioxide in the vapor stream in the fixed bed flue gas stream; and allowing the carbon dioxide to flow from the rotary manifold.

[0042] 16. An adsorption system for flue gas carbon capture comprising a fixed adsorption bed and a rotary manifold in communication with the fixed adsorption bed, the rotary manifold comprising a first rotary manifold having a heating chamber for passing a heating stream and a spent stream chamber for passing a spent stream, and a second rotary manifold having a flue gas chamber for passing a flue gas stream and a carbon dioxide chamber for passing a carbon dioxide stream.

[0043] 17. An adsorption system according to any one of the preceding clauses, further comprising a stationary casing in communication with the rotating manifold.

[0044] 18. An adsorption system according to any one of the preceding clauses, wherein the stationary casing comprises a plurality of first casing ports in communication with the first rotating manifold.

[0045] 19. An adsorption system according to any one of the preceding clauses, wherein the stationary casing comprises a plurality of second casing ports in communication with the second rotating manifold.

[0046] 20. An adsorption system according to any one of the preceding clauses, wherein the fixed adsorption bed comprises a carbon dioxide filter having an adsorbent material therein. [Explanation of symbols]

[0047] 10. Gas Turbine Engine 15 Compressor 20 Airflow 25 Combustor can 30 Fuel flow 35 Combustion gas flow 40 Turbine 45 rotor shaft 50 External Load 55 exhaust frame 60 flue gas 100 Adsorption System 110 Rotating Manifold 120 Fixed casing 130 Fixed floor 140 Upper rotating inner chamber 150 Upper rotating outer chamber 155 Upper rotating manifold 160 Lower rotating outer chamber 170 Lower rotating inner chamber 175 Lower Rotating Manifold 180 drive shaft 190 drive motor 200 Manifold upper port 210 Manifold upper passage 220 Manifold lower port 230 Manifold lower passage 240 Fixed upper casing 250 fixed lower casing 260 Upper Casing Port 270 Lower Casing Port 275 Bearing plate 280 Segmented Flow 290 Carbon Dioxide Filter 300 Solid adsorption material 310 Flue Gas Port 320 Flue Gas Chamber 330 Flue Gas Flow 340 Carbon dioxide flow 350 Spent Nitrogen Stream 360 Spent flow chamber 370 Used Flow Port 380 Heating Port 390 Steam Flow 400 Heating Chamber 410 Carbon Dioxide Chamber 420 Carbon Dioxide Port 430 Coolant 440 designated coolant port 450 designated coolant chamber

Claims

1. a fixed adsorbent bed (130); a rotating manifold (110) in communication with the fixed adsorbent bed (130); 1. An adsorption system (100) for flue gas carbon capture comprising:

2. The adsorption system (100) of claim 1, further comprising a stationary casing (120) in communication with the rotating manifold (110).

3. The adsorption system (100) of claim 2, wherein the stationary casing (120) comprises a stationary upper casing (240).

4. 4. The adsorption system (100) of claim 3, wherein the rotary manifold (110) comprises one or more upper rotary chambers (140, 150) in communication with the stationary upper casing (240) and the fixed adsorption bed (130).

5. The adsorption system (100) of claim 4, wherein the one or more upper rotation chambers (140, 150) comprise a plurality of upper manifold ports (200) in communication with a plurality of upper manifold passages (210).

6. 6. The adsorption system (100) of claim 5, wherein the stationary upper casing (240) comprises a plurality of upper casing ports (260) in communication with the plurality of manifold upper ports (200) of the one or more upper rotating chambers (140, 150).

7. The adsorption system (100) of claim 2, wherein the stationary casing (120) comprises a stationary lower casing (250).

8. 8. The adsorption system (100) of claim 7, wherein the rotary manifold (110) comprises one or more lower rotary chambers (160, 170) in communication with the stationary lower casing (250) and the fixed adsorption bed (130).

9. 9. The adsorption system (100) of claim 8, wherein the one or more lower rotation chambers (160, 170) comprise a plurality of lower manifold ports (220) in communication with a plurality of lower manifold passages (230).

10. 10. The adsorption system (100) of claim 9, wherein the stationary lower casing (250) comprises a plurality of lower casing ports (270) in communication with the plurality of manifold lower ports (220) of the one or more lower rotating chambers (160, 170).

11. The adsorption system (100) of claim 1, wherein the rotating manifold (110) comprises a drive shaft (180).

12. The adsorption system (100) of claim 1, wherein the fixed adsorbent bed (130) comprises a carbon dioxide filter (290) having an adsorbent material (300) therein.

13. 2. The adsorption system (100) of claim 1, wherein the rotary manifold (110) comprises a first rotary manifold (155) having a heating chamber (400) for passing the heating stream (390) and a spent stream chamber (360) for passing the spent stream (350).

14. 14. The adsorption system (100) of claim 13, wherein the rotary manifold (110) comprises a second rotary manifold (175) having a flue gas chamber (320) for the flow of flue gas (60) to pass therethrough and a carbon dioxide chamber (410) for the flow of carbon dioxide (340) to pass therethrough.

15. A method for removing carbon dioxide (340) from a stream of flue gas (60) in an adsorption system (100), comprising: flowing the flue gas (60) into a rotary manifold (110) of the adsorption system (100); delivering said flue gas (60) stream to a flue gas stream (330) of a fixed bed (130) of said adsorption system (100); capturing the carbon dioxide (340) in the flue gas stream (330) in the fixed bed (130); flowing a steam stream (390) into said rotary manifold (110); delivering said vapor stream (390) to said flue gas stream (330) in said fixed bed (130); releasing the carbon dioxide (340) in the vapor stream (390) in the flue gas stream (330) of the fixed bed (130); allowing the carbon dioxide (340) to flow out of the rotary manifold (110); A method comprising:

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