Fluid separation system, method of manufacturing the same, and method of use

Abstract

A device for separating fluid species is disclosed. The device comprises at least one header connected to a monoblock. The header uses a transition element to transition one or more fluid streams between a bulk flow and a multi-channel flow pattern. The header is mounted on a monoblock and modifies the raw process fluid stream by adjusting the temperature of the raw process fluid stream and / or separating at least a portion of one or more fluid species from it. Fluid separation is achieved by using a high-boiling-point liquid injected into the pore structure of the monoblock, the output of which is a modified process fluid stream and a discharge fluid stream. A method for manufacturing the device and a method for separating at least a portion of fluid species from a process fluid stream using the device are also disclosed.

Description

[Technical Field]

[0001] (Cross-reference to related applications) This application claims priority to U.S. Provisional Application No. 63 / 480093, filed on 16 January 2023, the contents of which are incorporated herein by reference in their entirety.

[0002] This disclosure generally relates to the field of fluid separation. This disclosure also relates to materials, devices, and apparatus for carrying this out. This disclosure further relates to methods of using such devices and apparatus in industrial processes, indoor air purification, heating, ventilation, and air conditioning ("HVAC") systems, and other fields. [Background technology]

[0003] Indoor air quality (IAQ) can be a crucial factor in maintaining a healthy and comfortable living or working environment under certain circumstances. Various IAQ factors are measured and maintained, often tailored to the specific needs of individual buildings, such as residences, office buildings, or warehouses. Indoor air problems are caused by a wide range of pollutants and, depending on the specific use, may include particulate matter (PM), formaldehyde, volatile organic compounds (VOCs), carbon dioxide (CO2), semi-volatile organic compounds, house dust mites, mold, bacteria, and associated health effects such as sick building syndrome, asthma, allergies, Legionnaires' disease, lung cancer, and airborne infections like SARS and COVID. Traditionally, IAQ has been partially addressed by introducing outside air into buildings. For example, outside air was introduced to reduce the concentrations of PM, VOCs, and CO2, or to control indoor humidity levels.

[0004] This disclosure was partially conceived in response to both the global coronavirus pandemic (COVID-19) and the increasing levels of outdoor pollution, prompting the inventors to question the industry-wide assumption that introducing outdoor air is the best way to control IAQ factors in building air.

[0005] When used for treating the air in a building, the innovations behind this disclosure can minimize, and in some cases eliminate, the need to introduce outdoor air into the building while maintaining IAQ factors at a comfortable level and complying with relevant IAQ standards.

[0006] In 2022, the American National Standards Institute (ANSI) and the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) revised their standards for ventilation and acceptable indoor air quality. See ANSI / ASHRAE Standard 62.1-2022: Ventilation and Acceptable Indoor Air Quality, ASHRAE (September 2022) (hereinafter referred to as "the Standard"). ANSI / ASHRAE Standard 62.1 is an accredited standard for the design of ventilation systems and acceptable indoor air quality (IAQ). The Standard specifies minimum ventilation rates and other measures to minimize adverse health effects on occupants. See ASHRAE Standards 62.1 and 62.2 (September 2022) (https: / / www.ashrae.org / technical-resources / bookstore / standards-62-1-62-2). The 2022 version of Standard 62.1 reflects how IAQ can exceed ventilation requirements. The standard specifies the procedure for determining the amount of outside air required to ensure that the concentrations of certain compounds and particulate matter ("PM2.5") with a diameter of 2.5 μm or less in an indoor environment comply with the standard's design limits. See sections 15, 25-26 of standard 62.1-2022. The standard's design limits for various compounds and PM2.5 are shown below, along with references to the relevant regulatory authorities.

[0007] [Table 1]

[0008] Some embodiments of this disclosure enable the reduction of the concentrations of these compounds within the design limits of the standard without dilution from the outdoor air.

[0009] Fluid separation technologies are important in various industries, and details will be discussed later. Gas separation technologies contribute to environmental advancements, particularly carbon capture. Furthermore, gas separation helps improve IAQ by selectively removing contaminants and regulating air composition. Conventional and current fluid separation technologies suffer from considerable drawbacks, including high energy input, complex mechanisms, high costs, and frequent maintenance. Current separation technologies are described below.

[0010] Physical absorption method. This method involves passing a gas through a liquid medium that acts as a solvent. Targeting specific gases with similar solubility characteristics is difficult, making precise separation challenging. Desorption from the liquid absorbent requires a large amount of energy, which affects overall efficiency.

[0011] Chemical reactions. Selective chemical reactions are used to form compounds for gas separation. However, the complexity of the process, along with the complex reaction mechanism, results in high operating and maintenance costs. Scaling up for industrial applications presents challenges, reducing efficiency and cost-effectiveness.

[0012] Membrane separation. This method uses semipermeable membranes to separate gases based on size, solubility, or diffusion rate. However, membranes face challenges such as degradation over time, contamination, and decreased efficiency. These limitations raise concerns about continuous processing.

[0013] Adsorption process. This method involves the adsorption of gas molecules onto a solid surface (adsorbent) through periodic fluctuations of pressure or temperature. Challenges include the saturation of the adsorbent, which leads to reduced efficiency, and the large amount of energy required for regeneration. The periodic nature complicates continuous processing.

[0014] Cryogenic distillation. This technique involves liquefying at temperatures below -150°C and separating the gas by its boiling point using a distillation column. This technique requires significant energy input, complex infrastructure, and the use of refrigerants with high global warming potential.

[0015] Existing fluid separation technologies face significant challenges, highlighting the growing need for innovation. Ideally, a fluid separation technology should possess robustness, durability, contamination resistance, energy efficiency, suitability for continuous processing, and environmental friendliness, depending on its application.

[0016] In light of long-standing industry demands, this technology addresses and overcomes one or more of the aforementioned problems. Thus, the innovative technology behind this disclosure makes it possible to minimize, and in some cases completely eliminate, the need for outside air intake into buildings, maintain IAQ factors at comfortable levels, and comply with relevant IAQ standards.

[0017] The disclosed monoblocks, materials, systems, and methods are designed to maintain or improve IAQ factors, overcome the aforementioned challenges and / or one or more other challenges of the prior art, and are also modular and adaptable to a variety of applications and industries. [Overview of the project] [Means for solving the problem]

[0018] In accordance with several disclosed embodiments, a header configured to split a bulk fluid flow into a multi-channel fluid flow is disclosed. The header may include at least one inlet, a transition element, a plurality of routing channels, and at least one outlet. In some embodiments, the first inlet is configured to receive a first bulk fluid flow, and the first outlet comprises a plurality of openings fluid-connected to a first fluid flow channel group. In some embodiments, the first fluid flow channel group and the second fluid flow channel group are located on a device attached to the header. In some embodiments, the transition element is configured to split the first bulk fluid flow into a first multi-channel fluid flow. In some embodiments, a plurality of first routing channels are configured to route the first multi-channel fluid flow to a first outlet, which may be fluid-connected to a first fluid flow channel group.

[0019] In accordance with some disclosed embodiments, an apparatus is disclosed that includes a monoblock for fluid separation. The monoblock apparatus may have a plurality of fluid flow channels including a first fluid flow channel group that is independent of a second fluid flow channel group. In some embodiments, the fluid flow channels are separated by channel walls that are porous, selectively permeable, and formed of the material from which the monoblock is formed. In some embodiments, the channel walls are impregnated with one or more high-boiling liquids and at least a portion of the first fluid flow channel group is adjacent to at least a portion of the second fluid flow channel group.

[0020] In accordance with some disclosed embodiments, a method is disclosed for reducing the concentration of components of a fluid stream. The method includes introducing a process fluid stream including a mixture of fluid species into a device. In some embodiments, the device may have at least one header having (a) at least one inlet, a transition element, a plurality of routing channels, and at least one outlet. In some embodiments, the first inlet is configured to receive a first bulk fluid flow, the first outlet includes a plurality of openings fluidly connected to a first fluid flow channel group, the transition element is configured to divide the first bulk fluid flow into a multi-channel fluid flow, and the plurality of first routing channels are configured to route the first multi-channel fluid flow to the first outlet.

[0021] In some embodiments, the device may further have (b) a monoblock having a plurality of fluid flow channels including a first fluid flow channel group and a second fluid flow channel group. The plurality of fluid flow channels are separated by channel walls that are porous, selectively permeable, and formed of the material from which the monoblock is formed, the channel walls are impregnated with one or more high-boiling liquids, and at least a portion of the first fluid flow channel group is adjacent to at least a portion of the second fluid flow channel group.

[0022] Consistent with some of the disclosed embodiments, a method of manufacturing a header is disclosed. In some embodiments, the method may include one or more of the following steps. (a) Providing a monoblock formed of a porous material, The monoblock has a plurality of fluid flow channels formed therein, The plurality of fluid flow channels are separated by channel walls, The channel walls are porous and selectively permeable. (b) Providing a negative mold having fingers configured to be aligned with a subset of the plurality of fluid flow channels. (c) Inserting the fingers of the negative mold into a subset of the plurality of fluid flow channels. (d) Introducing a liquid polymer material into the negative mold. (e) Curing the liquid polymer material. (f) Removing the negative mold to establish the header.

Brief Description of the Drawings

[0023] The accompanying drawings, which are incorporated herein and constitute a part hereof, illustrate the disclosed embodiments and serve to explain the disclosed embodiments together with the description herein. The details shown are by way of example and for purposes of illustrative description of embodiments of the present disclosure. The description in conjunction with the drawings will make apparent to those skilled in the art how embodiments of the present disclosure may be practiced.

[0024] [Figure 1A] A perspective view of a header structure consistent with some of the disclosed embodiments. [Figure 1B] A detailed view of a portion of the header structure shown in FIG. 1A. [Figure 1C] A detailed view of the channeling member of the header structure shown in FIG. 1A. [Figure 1D]Figure 1C is a detailed view of the channeling member shown. [Figure 2A] This is a perspective view of a header structure consistent with several disclosed embodiments. [Figure 2B] This is a perspective view of an alternative header structure shown in Figure 2A. [Figure 3A] This is a perspective view of a header structure consistent with several disclosed embodiments. [Figure 3B] This is a detailed diagram of a part of the header structure shown in Figure 3A. [Figure 4A] This is a perspective view of a header structure consistent with several disclosed embodiments. [Figure 4B] This is a detailed diagram of a part of the header structure shown in Figure 4A. [Figure 4C] This is a detailed diagram of a part of the header structure shown in Figure 4A. [Figure 5] This is a perspective view of a monoblock structure showing the fluid stream flow consistent with several disclosed embodiments. [Figure 6A] This is an exemplary arrangement of channels formed within a monoblock, consistent with several disclosed embodiments, showing channels arranged in a checkerboard pattern. [Figure 6B] This shows channels arranged in an offset checkerboard pattern. [Figure 6C] This shows channels arranged in a honeycomb pattern. [Figure 6D] This shows channels arranged in a diamond pattern. [Figure 6E] The channel is shown arranged in a diamond and triangle pattern. [Figure 6F] The channel is arranged in an alternating diamond and triangle pattern. [Figure 6G] This shows channels arranged in an equilateral triangle pattern. [Figure 6H] This shows channels arranged in an offset triangular pattern. [Figure 6I] This shows channels arranged in a right-angled triangle pattern. [Figure 6J] This shows channels arranged in a pattern of triangles and pentagons. [Figure 6K] This shows channels arranged in an alternating pattern of triangles and pentagons. [Figure 6L] This shows channels arranged in a pattern of triangles and hexagons. [Figure 7A] This is an exploded perspective view of a gas separation apparatus consistent with several disclosed embodiments. [Figure 7B] Figure 7A is a detailed view of the gas separation apparatus. [Figure 8] The diagram shows a channeling member that routes a fluid stream into and out of a monoblock, consistent with several disclosed embodiments. [Figure 9] This is a mechanism for target fluid flow through a monoblock channel wall, consistent with several disclosed embodiments. [Figure 10] This is a two-dimensional front view of a monoblock structure consistent with several disclosed embodiments. [Figure 11] This is a block diagram of two monoblocks arranged in series, consistent with several disclosed embodiments. [Figure 12A] This is a block diagram of a fluid control unit ("FCU") consistent with several disclosed embodiments. [Figure 12B] Figure 12A is a perspective view of the Line Replacement Unit ("LRU"), which is part of the FCU. [Modes for carrying out the invention]

[0025] (definition) As used here, "monoblock" generally refers to a structure made from a single, homogeneous material, or a composite compound material with some variation in the material composition throughout the entire structure.

[0026] The term "bulk flow" used here refers to a fluid stream that moves collectively within an integrated structure such as a pipe or manifold, as opposed to a scenario where the fluid stream traverses multiple different channels.

[0027] The term "fluid" as used here refers to a substance that flows and takes the shape of a container, and includes both liquids and gases.

[0028] The term "separation efficiency" used here refers to the percentage change in component fluid species between the process fluid stream and the adjusted process fluid stream. For example, if the process fluid stream has a CO2 concentration of 1.0 g / L and the adjusted process fluid stream has a CO2 concentration of 0.1 g / L, the separation efficiency is (1.0 g / L - 0.1 g / L) / (1.0 g / L) = 90%.

[0029] The term "process fluid stream" used here refers to a mixed stream of fluid types introduced into the monoblock.

[0030] As used herein, "tuned process fluid stream" means a process fluid stream that has been tuned by a monoblock in terms of temperature and / or separation of at least some of one or more fluid types.

[0031] As used herein, "discharge fluid stream" refers to the fluid stream leaving the monoblock that contains at least a portion of one or more fluid types separated from the process fluid stream.

[0032] The term "multi-channel flow" used here refers to a fluid stream moving within a pattern that includes simultaneous movement through multiple conduits and pipes.

[0033] In this context, "header" refers to a structural component that is placed adjacent to a second structure and intended to alter the flow of material to that second structure.

[0034] As used herein, "structurally different" means that the first structure is distinct from or dissimilar to the second structure in terms of material, function, location, or other attributes.

[0035] As used here, "fluidically connected" refers to a connection between two structures that allows for the movement of fluid from the first structure to the second structure, or through the second structure.

[0036] As used here, "route," when used as a verb, describes the action of guiding a fluid from one location or configuration to another specified location or configuration.

[0037] As used here, "porous" describes a property of a material or structure that allows fluid to pass through it through spaces or openings.

[0038] As used here, "selective permeability" describes the properties of a permeable material or structure that exhibits some selectivity for a particular fluid's passage, based on its physical, chemical, or a combination thereof. The selectivity for a particular fluid does not necessarily have to be strong; it simply needs to be statistically significant.

[0039] As used here, "high boiling point" refers to a liquid's characteristic of having remarkable resistance to boiling or evaporation, especially under high temperature or low pressure conditions. A "high boiling point" is established at a minimum of 100°C.

[0040] As used herein, "impregnation" refers to the incorporation of a material or substance into some structure. The term "impregnation" may also be illustrated by the impregnation of a sponge with water or the impregnation of an HVAC system with air.

[0041] As used here, "deactivate" means to inactivate (something, typically a biological component or a virus) by cutting, capturing, fixing, isolating, destroying, or killing it.

[0042] The term "pore size" used here refers to the size of the pore in terms of its dimensions when viewed from within, i.e., its width or diameter, not its depth.

[0043] As used here, "absorption" refers to the process of taking in, binding to, attaching to, drawing in, connecting to, or drawing in a substance through chemical or physical action.

[0044] The term "negative mold" used here refers to a mold (also called a female mold) that has the inverse shape of the desired object or part. Typically, casting material is poured into the negative mold to create the desired part.

[0045] As used here, "hardening" refers to a state in which a material has become physically harder or stronger, as is evident from factors such as a higher Rockwell hardness, increased modulus of elasticity, and increased resistance to deformation.

[0046] The term "introduce" used here means to place or bring something into another entity.

[0047] As used here, "to permit" means to provide the time or opportunity necessary for a specific purpose.

[0048] The term "subset" used here refers to any number of subsets up to the complete set, including the complete set.

[0049] As used here, "plenum structure" refers to a space used as a path for air distribution, including housings, manifolds, piping, chambers, air distribution boxes, and cavities. For example, in an HVAC system, the plenum is a closed space that provides air distribution or houses HVAC components, facilitating the uniform distribution of conditioned air throughout the building.

[0050] As used here, "decarbonization" means reducing or eliminating hydrocarbon emissions from processes such as manufacturing or energy production, or from the environment such as buildings or outdoors.

[0051] This disclosure generally relates to a monoblock having multiple channels formed inside, wherein the channel walls are porous. The porous channel walls are impregnated with a high-boiling-point liquid, thereby selectively allowing a subset of fluid species to pass from one channel through the porous channel walls into adjacent channels, where they are removed as an exhaust fluid stream.

[0052] For example, if the process fluid for separation is industrial flue gas and the target fluid is CO2, the flue gas flows into a first fluid flow channel group within the monoblock. At least a portion of the CO2 in the flue gas is then selected to have some affinity for CO2 and adsorbed by a high-boiling liquid impregnated into the channel walls. The CO2 absorbed by the high-boiling liquid diffuses across the channel walls to an adjacent second fluid flow channel group, where it desorbs from the high-boiling liquid and exits the monoblock as an exhaust fluid stream for downstream use or sequestration.

[0053] Thus, the technology disclosed herein has the capability to decarbonize industries, including agriculture, construction, transportation, military submarines, and heavy industry, and to reduce greenhouse gas emissions. The monoblock can also be combined with heated or cooled fluid streams, simultaneously regulating the temperature of the incoming fluid stream and separating unwanted fluid species. The monoblock may include a header attached thereto, which routes one or both of the process fluid stream to the monoblock for fluid separation and the discharge fluid stream from the monoblock.

[0054] The fluid separation monoblocks, related systems, and methods described herein are improvements over existing commercially available products. This is because they eliminate at least the following: (1) vapor compression cycles, (2) refrigerants with high global warming potential, (3) refrigerant compressors, (4) energy-intensive metals and associated corrosion, (5) condensate, (6) ice formation, and (7) hazardous refrigerant filling / disposal.

[0055] The technologies disclosed herein facilitate selective fluid separation while reducing the complexity required to achieve that separation compared to prior art. For example, the embodiments disclosed herein do not require the use of complex auxiliary equipment other than a single pump to introduce fluid into or remove fluid from a monoblock. The disclosed embodiments are also highly modular, allowing them to scale to operational needs and be easily constructed on-site, thus shifting the focus away from prior art. The various disclosed embodiments of the present invention address many of the shortcomings of current fluid separation technologies by being more robust, durable, fouling-resistant, energy-efficient, suitable for continuous processing, and not relying on materials with high global warming potential.

[0056] In some embodiments, novel fluid separation devices, methods, and systems have diverse applications in many fields, including industrial processes, healthcare, environmental advancements, indoor air purification, HVAC systems, oil and gas, recreational sports and activities, chemical and petrochemicals, food and beverage industries, aerospace, laboratories and research, and water treatment.

[0057] In some embodiments, industrial processes that benefit from this novel fluid separation apparatus, method, and system include the production of hydrogen and oxygen by ionizing water and separating the resulting hydrogen and oxygen, gas separation in the synthesis of ammonia (a major component in fertilizer production), production of oxygen by separating oxygen from air for use in combustion and oxygen combustion systems, purification of blast furnace gases, oxygen concentration to improve the efficiency of basic oxygen steelmaking, improved combustion for high-speed steel production, and removal of impurities to improve the quality of steel products, as well as the generation of nitrogen for inactivation applications such as explosion prevention and control of oxygen levels in tanks, thereby contributing to industrial and environmental safety.

[0058] In some embodiments, electronic equipment manufacturing processes that would benefit from this novel fluid separation apparatus, method, and system include semiconductor manufacturing (including maintaining a controlled, pure environment for chemical vapor deposition (CVD) and physical vapor deposition (PVD) and preventing impurities from affecting the quality of semiconductor materials), electronic equipment manufacturing (including generating inert gases such as nitrogen and argon to prevent oxidation and improve the precision of electronic components), and removing particulate matter and contaminants from the air to create a cleanroom environment for electronic equipment manufacturing and for manufacturing sensitive electronic devices.

[0059] In some embodiments, polymer manufacturing processes that benefit from this novel fluid separation apparatus, method, and system include removing impurities, unreacted monomers, and undesirable components from monomers to ensure monomer quality and purity before polymerization, capturing by-product gases for recycling or proper disposal, and controlling the composition and purity of input gases used in foaming or extrusion processes.

[0060] In some embodiments, healthcare applications that would benefit from this novel fluid separation apparatus, method, and system include the production of medical-grade gases including oxidative, nitrogen, and nitrous oxide; the concentration of oxygen gas for supply to patients with respiratory diseases; the production of anesthetic gases with precise concentration and purity for safe and effective use in medical procedures; the humidification of gases supplied to patients for respiratory care to prevent irritation; the analysis of blood gases including oxygen and carbon dioxide; the purification of gases used for cryopreservation of biological materials; the production of medical gases for hemodialysis processes; the production of high-purity gases for laboratory applications such as research, diagnostics, and medical testing; the purification of gases used in medical imaging techniques such as helium purification for magnetic resonance imaging; isotope separation for positron emission topography or single-photon emission computed tomography; the purification of xenon gas used as a contrast agent in xenon-enhanced computed tomography imaging; the concentration of gases required for mapping brain activity using functional magnetic resonance imaging; and the purification of hyperpolarizing noble gases such as helium-3 and xenon-129 for hyperpolarizing gas imaging.

[0061] In some embodiments, hyperbaric oxygen chambers benefit from this novel fluid separation apparatus, method, and system by producing oxygen gas with precise concentration and purity to supply hyperbaric oxygen to the hyperbaric oxygen chamber for therapeutic purposes. Hyperbaric oxygen chambers are known to have beneficial medical effects such as wound healing by increasing oxygen levels in tissues, stimulating the formation of new blood vessels (angiogenesis), and supporting the body's natural healing mechanisms. Hyperbaric oxygen therapy has anti-inflammatory effects, which are beneficial for many medical conditions. It also treats decompression sickness and carbon monoxide poisoning in divers by removing excess nitrogen and carbon monoxide from the body, respectively. It also has antibacterial properties, contributing to the suppression of certain infections by enhancing the body's immune response and promoting the activity of white blood cells. It has a positive effect on non-healing ulcers such as diabetic foot ulcers and helps supply oxygen to the brain in ischemic stroke. It is being studied as a potential adjunctive therapy for certain neurological disorders, including traumatic brain injury and neurological rehabilitation, and as an adjunctive therapy for cancer treatment. Generally, please refer to the following literature (Hyperbaric Oxygen Therapy, Johns Hopkins Med., https: / / www.hopkinsmedicine.org / health / treatment-tests-and-therapies / hyperbaric-oxygen-therapy; Yafit Hachmo et al., Hyperbaric Oxygen Therapy Increases Telomere Length and Decreases Immunosenescence in Isolated Blood Cells: a Prospective Trial, 12 AGING 22445 (2020)).

[0062] In some embodiments, the environmental advancements benefiting from this novel fluid separation apparatus, method, and system include the separation and capture of carbon dioxide emissions from industrial processes, the capture of NOx, SOx, mercury, VOCs and other compounds from industrial processes, the upgrading of biogas produced from organic waste to improve its quality for use in energy production or injection into natural gas pipelines, the capture of methane and other components from gases emitted from landfills, and the purification of oxygen for the production of liquid oxygen used in environmental remediation.

[0063] In some embodiments, indoor air purification applications that would benefit from this novel fluid separation apparatus, method, and system include capturing harmful or unwanted gases such as CO2, VOCs, odor-causing gases and vapors, and radon; purifying oxygen for supplying building air; reducing oxygen concentration from buildings for medical reasons such as sleep induction; controlling water vapor and thus humidity; inactivating pathogens, bacteria, and viruses; monitoring specific gas species in building air; and concentrating oxygen from outdoor air to increase indoor oxygen concentration and reduce indoor pollutants. These have significant health benefits, including improved sleep quality, mental capacity, productivity, overall health, athletic ability and recovery, high-altitude adaptation, healing, improved cognitive function, reduced sensitivity to allergens, and potential extension of life expectancy.Generally, refer to the following literature (J. B. West., Oxygen Enrichment of Room Air to Improve Well-Being and Productivity at High Altitude, 5 Int’l J. Occupational and Env’t Health 187 (1999); Jan Stepanek et al., Supplemental CO2 Improves Oxygen Saturation, Oxygen Tension, and Cerebral Oxygenation in Acutely Hypoxic Healthy Subjects, PHYSIOLOGICAL REP. (Jul. 29, 2020); Silvia Ulrich et al., Effect of Breathing Oxygen-Enriched Air on Exercise Performance in Patients With Precapillary Pulmonary Hypertension: Randomized, Sham-Controlled Cross-Over Trial, 38 Eur. Heart J. 1159 (2017); Robert J. Laumbach et al., Personal Interventions for Reducing Exposure and Risk for Outdoor Air Pollution: An Official American Thoracic Society Workshop Report, 18 Annals Am. Thoracic Soc’y 1435 (2021)).

[0064] In some embodiments, the oil and gas industry benefits from this novel fluid separation apparatus, method, and system in the following ways: sweetening natural gas by removing impurities such as hydrogen sulfide to meet environmental and safety standards; dehydrating natural gas to prevent hydrate formation; separating and capturing methane, ethane, propane, and other components of natural gas for various applications; removing heavy hydrocarbons from natural gas streams to prevent problems such as fouling and ensure gas quality for further processing; extracting helium from natural gas sources in the oil and gas industry; desalting crude oil by removing water and salt from oil-water mixtures and ensuring crude oil quality for further refining; and providing blankets in storage tanks to prevent explosions and produce nitrogen gas to inactivate processes.

[0065] In some embodiments, recreational sports and activities that would benefit from this novel fluid separation device, method, and system include a rebreather for scuba diving in which CO2 is separated from residual oxygen in a diver's exhaled breath and oxygen is delivered to the diver's inhalation; removing CO2 from inhaled air for snorkeling; and concentrating oxygen for replenishment during high-altitude activities such as paragliding, rock climbing, mountaineering, and skiing.

[0066] In some embodiments, chemical applications that would benefit from this novel fluid separation apparatus, method, and system include generating nitrogen for blanket or deactivation processes of flammable gases, removing specific chemical reaction product gases to drive chemical reaction processes, and the like.

[0067] In some embodiments, applications in the food and beverage industry that would benefit from this novel fluid separation apparatus, method, and system include reducing oxygen or nitrogen blankets for more effective packaging and preservation of food; producing pure CO2 or nitrogen gas for carbonation of beverages; removing CO2 in brewing processes to control carbonation of fermented products; removing oxygen from the processing of edible oils to prevent rancidity and extend the shelf life of oils; and removing hydrogen sulfide from sugar production processes to ensure quality and safety.

[0068] In some embodiments, aerospace applications that would benefit from this novel fluid separation apparatus, method, and system include maintaining oxygen concentration in high-altitude aerospace applications, purifying oxygen for oxygen storage, generating oxygen by ionizing water in space missions, generating high-purity oxygen for aircraft fuel cells, improving the efficiency and reducing emissions of fuel cell drive systems, removing CO2 from enclosed aerospace vehicles, generating nitrogen for aircraft tire inflation, improving safety and performance by preventing moisture-related problems in tires, recovering and purifying hydrogen from rocket exhaust, reusing it in propulsion systems and reducing waste, extracting carbon dioxide from spacesuits, supporting efficient propulsion by supplying high-purity oxygen for combustion in hypersonic aircraft, generating oxygen-concentrated air for high-altitude parachute jumps, and ensuring the safety and health of parachute jumpers at extreme altitudes.

[0069] In some embodiments, water treatment applications that would benefit from this novel fluid separation apparatus, method, and system include removing dissolved CO2 for pH adjustment, removing dissolved oxygen from boiler feedwater to prevent corrosion and ensure the lifespan and efficiency of boiler systems, removing certain dissolved gases such as methane, VOCs, and hydrogen sulfide from drinking water to prevent potential safety hazards and improve drinking water quality, generating ozone for water disinfection and microbial control, and removing ammonia from water to prevent algae-related problems.

[0070] (Monoblock structure) The basic structure of a monoblock is generally an extruded geometric shape, such as a cuboid, cylinder, or hexagon. The monoblock has a front surface with multiple cells extending into the monoblock to form a fluid flow channel. For example, in a cylindrical monoblock, the multiple cells are visible on the circular front surface of the monoblock, extending into the monoblock to form a parallel fluid flow channel along the length of the cylinder. At least a portion of the fluid flow channel formed within the monoblock extends through the entire monoblock, creating an open cell on the rear surface of the monoblock.

[0071] The monoblock includes multiple parallel fluid flow channels that extend along the length of the monoblock in the extrusion direction. Of these multiple parallel fluid flow channels, there are at least two independent fluid flow channel groups, each serving its own purpose.

[0072] The cells that appear on the front of the monoblock may be a certain geometric shape, or a set of shapes that can form a repeating pattern. For example, a checkerboard pattern, an offset checkerboard pattern, a honeycomb pattern, a four-leaf clover pattern, a rectangle pattern, a diamond pattern, a triangle pattern, a triangle and diamond pattern, a triangle and rectangle pattern, or a combination thereof, as long as the geometric shapes share a boundary.

[0073] The monoblock structure may be modified from commercially available monoblocks. The dimensions of such commercially available monoblocks are approximately 100mm x 100mm x 300mm, for example, 50mm x 50mm x 150mm. Commercially available cylindrical monoblocks may have a diameter of up to 400mm and vary in depth.

[0074] The cell density on the surface of the monoblock may be, for example, 200 cells / square inch to 1200 cells / square inch, or 350 cells / square inch to 550 cells / square inch. The ratio of open cells to the entire monoblock surface may be, for example, 0.6 to 0.95, or 0.75 to 0.95. The fluid flow channel length within the monoblock may be, for example, 50 mm to 500 mm, or 150 mm to 300 mm. The channel wall density is approximately 0.30 to 0.50. The volume of the fluid flow channel may be, for example, 0.012 cubic inches.

[0075] In some embodiments, depending on the application of the monoblock, the channel wall thickness may be about 2 to 15 mils (0.002 to 0.015 inches), for example, about 8 to 10 mils (0.008 to 0.010 inches), for low pressure drop and fast vapor permeation.

[0076] When designing a monoblock for fluid separation, there is a balance between geometric surface area and pressure drop. The pressure drop across the monoblock ("ΔP") depends linearly with flow velocity and length.

[0077] ΔP = 2 × f × l × ρ × v^2 × Gc × Dh, where f is the friction coefficient (dimensionless), Dh is the hydraulic diameter (cm), Gc is the gravitational constant, l is the monoblock length (cm), v is the velocity of the fluid flow through the channel (cm / s), and ρ is the fluid density (g / cm^3). This basic equation can assist those skilled in the art in designing the geometric parameters of a monoblock, such as cell density or wall thickness, and can satisfy constraints on external processing requirements such as spatial velocity, flow rate, and pressure drop.

[0078] (Monoblock material) Monoblocks are formed from absorbent, porous materials with a large surface area. In certain embodiments, the monoblock material may also have thermal stability, mechanical strength, and chemical resistance. The material may be activated carbon, inorganic material, clay, activated alumina, talc, or a combination thereof. Monoblocks may be made from a mixture of a binder, activated carbon, and ceramic material. For example, cordierite is a commercially available ceramic material with thermal stability and low thermal expansion. Depending on the application of the technology, the monoblock material may be selected for properties including the ability to withstand an operating temperature of 260°C, a pressure difference of 14.7 psi, and / or prolonged exposure to corrosive fluids.

[0079] The surface area of ​​the material selected for monoblock is, for example, approximately 200 m². 2 / g~1000m 2 / g or more, more preferably, for example, about 500m 2 / g ~ approx. 550m 2 / g is also acceptable. The geometric surface area is approximately 20 inches. 2 / inch 3 ~Approximately 200 inches 2 / inch 3 However, the pore volume of the material selected for the monoblock may be, for example, about 0.20 mL / g to about 1.0 mL / g, more preferably, for example, about 0.20 mL / g to about 0.30 mL / g.

[0080] The carbon source for activated carbon monoblock material may be wood, peat, coal, coconut, lignite, petroleum pitch, petroleum coke, coal tar pitch, fruit seeds, nut shells, sawdust, wood flour, synthetic polymers, polymers, or other carbon sources known to those skilled in the art, or a combination thereof. The carbon can be activated by chemical treatment, heat treatment, or other carbon activation treatments known to those skilled in the art. Carbon activation increases its surface area and porosity.

[0081] The inorganic monoblock material may include zeolite, porous silica, porous alumina, columnar clay, molecular sieve, porous polymer, and the like.

[0082] In some embodiments, the monoblock material may have charged functional groups or specific charges on its surface in order to enhance or modify the functionality of the ionic liquid.

[0083] Examples of useful anions within monoblocks include [BF4] tetrafluoroboric acid, [C(CN)3] tricyanomethanide, [DCA] dicyanamide, [Doc] bis(2-ethylhexyl) sulfosuccinate, [ESU] ethyl sulfate, [Et2PO4] diethyl phosphate, [SiO] ethoxyacetic acid, [FAP] trifluorophosphate, [Gly] glycolate, [Inda] indazolide, [Lac] L(+) lactate, [Lev] revulinate, [Mal] malonate, [Me2PO4] trimethyl phosphate, [PF6] hexafluorophosphate, [Pho] phenolate, [Pro] proline, [Pro] prolineate, The following may be included: Tf2N]bis(trifluoromethylsulfonyl)imide, TfA]trifluoroacetic acid, TfO]trifluoromethanesulfonic acid, Ac]acetic acid, B(CN)4 tetracyanoboric acid, BF4 tetrafluoroboric acid, C(CN)3 tricyanomethanide, DCA or N(CH)2 dicyanamide, PF6 hexafluorophosphate, RPO4 alkyl phosphate, RSO4 alkyl sulfate, Tf2N bis(trifluoromethylsulfonyl)imide, TfO trifluoromethylsulfonate, TFSI(=Tf2N) bis(trifluoromethylsulfonyl)imide, or other relevant negatively charged functional groups known to those skilled in the art.

[0084] Useful cations within a monoblock may include P phosphonium, R1R2Mor morpholinium cation with two alkyl substituents, R1R2Pip piperidinium cation with two alkyl substituents, R1R2Pyr pyridinium cation with two alkyl substituents, R1R2Pyrr pyrrolidinium cation with two alkyl substituents, R1R2R3Im imidazolium cation with three alkyl substituents, R1R2R3R4A ammonium cation with four alkyl substituents, R1R2R3R4Thi thiazolium cation with four alkyl substituents, R1R2R3S sulfonium cation with three alkyl substituents, R1R2R3Si silyl cation with three alkyl substituents, or other relevant positively charged functional groups known to those skilled in the art.

[0085] (Porous channel wall of monoblock) Because the cells have a repeating pattern, the fluid flow channels share common channel walls. These common channel walls are fabricated from the same porous material as the monoblock and are both porous and permeable. Depending on the material selected for the monoblock, the channel walls may have desirable mechanical, chemical, and thermal properties.

[0086] (Impregnation using high-boiling point liquids) The porous and permeable channel walls may be impregnated with a high-boiling point liquid. The type of high-boiling point liquid may include organic solvents / fluorinated solvents, Selexol, Rectisol, Purisol, amines, MEAs, ammonia, amino acid salts, ionic liquids, enzymes, and other high-boiling point liquids known to those skilled in the art.

[0087] The impregnation of monoblocks with high-boiling-point liquids may be achieved by dip coating, vacuum assistance, pressure assistance, or other techniques known in the art to achieve at least partial pore injection, more preferably complete pore injection.

[0088] The impregnation process may be carried out using high-boiling-point liquids of various concentrations, depending on the viscosity of the high-boiling-point liquid and the thickness required for the specific application. The concentration of the high-boiling-point liquid may be 100%, 5-95%, 10-90%, 15-85%, 20-80%, 25-75%, 30-70%, 35-65%, 40-60%, 45-55%, and more preferably 15-20%.

[0089] The concentration of the high-boiling point liquid may be adjusted by using a carrier liquid having a lower boiling point than the high-boiling point liquid. Such carrier liquids may include alcohol solutions, diethyl ether, acetone, ethyl acetate, hexane, methyl ethyl ketone (MEK), tetrahydrofuran (THF), dichloromethane, chloroform, carbon disulfide, petroleum ether, or other liquids known in the art that have a lower boiling point than the high-boiling point liquid, preferably being safe, non-toxic, commercially available, economically feasible, and / or having low greenhouse gas emissions.

[0090] By impregnating the monoblock with a diluted high-boiling-point liquid, a "thinner" liquid layer is created, increasing permeability to the pores of the monoblock material and reducing the cost of the ionic liquid. In one embodiment, the diluted high-boiling-point liquid is applied only to the first fluid flow channel group within the monoblock, allowing for the creation of an asymmetric film using the channel walls of the monoblock.

[0091] Following the coating process, a process is typically carried out to remove excess high-boiling point liquid, so that the high-boiling point liquid remains only within the pores of the channel walls and does not accumulate or clog the fluid flow channel. Subsequent processes also remove the carrier liquid by evaporation, leaving only the high-boiling point liquid.

[0092] Processes for removing excess high-boiling liquid and / or vaporizing or evaporating the carrier liquid may include shaking or rotating the monoblock, introducing pressurized air into the fluid flow channels of the monoblock, ultrasonic cleaning (the cleaning fluid is selected to be one that simply removes excess high-boiling liquid from the fluid flow channels, rather than being a solvent for the high-boiling liquid), manual or automatic brushing or scrubbing, introducing a pressurized liquid jet into the fluid flow channels (the liquid is selected to be one that simply removes excess high-boiling liquid from the fluid flow channels, rather than being a solvent for the high-boiling liquid), applying vacuum or suction to the monoblock, blasting the fluid flow channels of the monoblock with an abrasive such as sand or beads propelled by compressed air, introducing a laser into the fluid flow channels of the monoblock to selectively evaporate excess high-boiling liquid present in the fluid flow channels, and so on.

[0093] (Selection of high-boiling point liquids and ionic liquids) High-boiling point liquids may be selected or designed to have an affinity for a specific fluid species, or an affinity for chemical or physical properties shared by multiple fluid species. The affinity between the high-boiling point liquid and the target fluid species may include electrostatic forces, ionic affinity, van der Waals forces, hydrogen bonds, covalent bonds, magnetism, and opposite polarity.

[0094] The selected high-boiling-point liquid needs to have a high boiling point to extend its lifespan by minimizing liquid loss due to evaporation over time. The boiling point of the selected high-boiling-point liquid should be at least 100°C. The high-boiling-point liquid may also be selected to have a high affinity for the monoblock material, which can improve its lifespan by reducing the loss of the high-boiling-point liquid due to mechanical forces such as long-term fluid flow.

[0095] The target fluid species may include water vapor, carbon dioxide, inactivated viruses, inactivated bacteria, radon, formaldehyde, ethylene, acetaldehyde, acetic acid, acetone, naphthalene, heptane, toluene, carbon monoxide, ammonia, hydrogen sulfide, methanol, SOx, NOx, and / or other hydrocarbons.

[0096] One of the high-boiling-point liquids useful for impregnation into monoblock systems is the amine. Specific types of amines include monoethanolamine (MEA), methyldiethanolamine (MDEA), 2-amino-2-methylpropanol (AMP), piperazine (PIPA), diglycolamine (DGA), diethanolamine (DEA), and diisopropanolamine (DIPA).

[0097] Another class of high-boiling-point liquids useful for impregnation into monoblock systems is ionic liquids. Preferred ionic liquids have a boiling point of at least 100°C, more preferably at least 300°C, in order to minimize vapor pressure.

[0098] Ionic liquids may be selected or organized to have affinity for a particular target fluid. Another ionic liquid may be selected or organized to be a broad-spectrum ionic liquid, which means having affinity for multiple types of target fluids (which may or may not share certain chemical or physical properties).

[0099] Depending on the specific application, other properties of ionic liquids that may be beneficial for use in monoblocks may include ionic conductivity, low vapor pressure, low volatility, high heat resistance, high electrochemical stability, high solubility of gases and vapors, and / or low flammability.

[0100] In applications where the separation of CO2 from the process fluid stream is required, preferred ionic liquids have high CO2 solubility and low absolute enthalpy of dissolution of CO2, which increases the amount of CO2 transported through the monoblock channel wall and facilitates the desorption of CO2 on the exhaust fluid stream side.

[0101] The low absolute enthalpy of solubility of CO2 may correlate with low viscosity. Adding amines to ionic liquids reduces the viscosity of the ionic liquid, leading to faster absorption and mass transfer. In tests, mixing amines with ionic liquids and impregnating monoblocks increased carbon dioxide absorption. The presence of water in the amine-ionic liquid solution also increased carbon dioxide absorption.

[0102] The selected ionic liquid may be formed by combining a range of anions with larger cations. Those skilled in the art will select anion-cation combinations that reduce viscosity, lower manufacturing costs, reduce potential toxicity, and mitigate potential environmental impacts.

[0103] When two or more types of ionic liquids are impregnated into a monoblock, the affinity of each individual ionic liquid may be maintained. In other words, when two or more types of ionic liquids are impregnated into the same monoblock, one ionic liquid may not interfere with the specific affinity or broad spectral affinity of the other ionic liquids.

[0104] When a fluid is absorbed by an ionic liquid, latent heat is released. When a fluid desorbs from an ionic liquid, latent heat is absorbed. This process is isothermal. If the fluid is in the gas phase during absorption, it will also be in the gas phase when desorbing from the ionic liquid. Changes in partial pressure are the driving force behind absorption and desorption. Fluids tend to absorb under higher pressures and desorb under lower pressures.

[0105] Some ionic liquids can inactivate microorganisms and slow biofilm growth, addressing problems that have plagued membrane separation technologies.

[0106] Ionic liquids that are particularly effective in carbon scavenging may contain cations such as ammonium and / or imidazolium, and / or anions such as [Tf2N], [BF4], [PF6], [DCA], and / or acetic acid.

[0107] Ionic liquids that are particularly effective for detecting volatile components of beer, the aroma of coffee, the aroma of food such as nitro aromatic explosives, or specific gases and vapors such as those found in humidity sensors may contain anions such as [Tf2N], [BF4], [PF6], and [Cl].

[0108] Depending on the fluid separation application, the following ionic liquids, combinations thereof, or modifications thereof can be injected into the monoblock: [(SiOSi)C1MIM][C(CN)3]1-methyl-3-pentamethyldisyloxymethylimidazolium tricyanomethanide, [(SiOSi)C1MIM][Tf2N]1-methyl-3-pentamethyldisyloxymethylimidazolium bis(trifluoromethylsulfonyl)imide, [APTMS][Ac](3-aminopropyl)trimethoxysilane acetate, [BMIM][Ac]1-butyl-3-methylimidazolium acetate, [BMIM][BF4]1-butyl-3-methylimidazolium acetate Trafluoroborate, [BMIM][DCA]1-butyl-3-methylimidazolium dicyanamide, [BMIM][Doc]1-butyl-3-methylimidazolium bis(2-ethylhexyl) sulfosuccinate, [BMIM][Pho]1-butyl-3-methylimidazolium phenolate, [BMIM][Tf2N]1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, [BMIM][TfO]1-butyl-3-methylimidazolium trifluoromethanesulfonate, [C1C3MI [M][Tf2N]1-methyl-3-propylmethylimidazolium bis(trifluoromethylsulfonyl)imide, [C3C1MIM][Tf2N]1-propyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, [Choline][Gly]Colinium glycolate, [Choline][Lac]Colinium L(+) lactate, [Choline][Lev]Colinium levulinate, [Choline][Mal]Colinium malonate, [Choline][Pro]Colinium proline, [DMAPAH][ Depositphotos] 3-( Dimethylamino-1-propylammonium ethoxyacetate, [DMAPAH][TfA]3-dimethylamino-1-propylammonium trifluoroacetate, [EMIM][Ac]1-ethyl-3-methylimidazolium acetate, [EMIM][C(CN)3]1-ethyl-3-methylimidazolium tricyanomethanide, [EMIM][ESU]1-ethyl-3-methylimidazolium ethyl sulfate, [EMIM][Et2PO4]1-ethyl-3-methylimidazolium diethyl phosphate,[EMIM][FAP] 1-ethyl-3-methylimidazolium trifluorophosphate, [EMIM][Me2PO4] 1-ethyl-3-methylimidazolium trimethylphosphate, [EMIM][Tf2N] 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, [EMIM][TfA] 1-ethyl-3-methylimidazolium trifluoroacetate, [HMIM][Tf2N] 1-hexyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, [HmMIM][Tf2N ]1-Hexyl-2-methyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, [OMIM][Ac]1-Octyl-3-methylimidazolium acetate, [P222(101)][Inda]Triethyl(2-methoxymethyl)phosphonium indazolide, [P2225][Pro]Triethyl(pentyl)phosphonium prolineate, [P4444][Pro]Tetrabutylphosphonium prolineate, [Si-C1-C3-MIM][Tf2N]1-methyl-3-(2-methyl-3-(trimethylsilyl)propyl )Imidazolium bis(trifluoromethylsulfonyl)imide, [VBTMA[Ac]vinylbenzyltrimethylammonium acetate, [VOIM][PF6]1-vinyl-3-octylimidazolium hexafluorophosphate, 6FDA-TeMPD (hexafluoroisopropylidene) diphthalic anhydride and 2,3,5,6-tetramethyl-1,4-phenylenediamine polyimide, p(VDF-HFP)poly(vinylidene fluoride-co-hexafluoropropylene)fluoroelastomer, p[MABI][BF4]poly(1- [2-(methacryloyloxy)ethyl]-3-butylimidazolium)tetrafluoroborate, p[MATMA][BF4]poly[2-(methacryloyloxy)ethyl]trimethylammonium tetrafluoroborate, p[VBBI][BF4]poly(1-(p-vinylbenzyl)-3-butylimidazolium)tetrafluoroborate, p[VBIM][DCA]1-vinyl-3-butylimidazolium dicyanamide, p[VBTMA][BF4]poly[1-(para-vinylbenzyl)-triethylammonium tetrafluoroborate,p[VBTMA][PF6]Poly[1-(para-vinylbenzyl)-triethylammonium hexafluorophosphate], p[VBTMA][Tf2N]Poly[1-(para-vinylbenzyl)-triethylammonium bis(trifluoromethylsulfonyl)imide], p[VEIM][DCA]Polymerized 1-vinyl-3-ethylimidazolium dicyanamide], p[VHIM][DCA]1-vinyl-3-heptylimidazolium dicyanamide, P4VPPoly(4-vinylpyridine) ), PAA polyacrylic acid or sodium polyacrylate, PAH poly(allylamine) hydrochloride, PAMPS poly(2-acrylamido-2-methyl-1-propanesulfonic acid), PAN polyacrylonitrile, PBI polybenzimidazole, PC polycarbonate, PDADMAC poly(diallyldimethylammonium) chloride, PDMAA polydimethylacrylamide, PDMAEMA poly(N,N-dimethylaminoethyl methacrylate), PDMS polydimethyl Siloxane, PEG polyethylene glycol, PEI poly(ethyleneimide), PES polyethersulfone, PI polyimide, PMAPTAC poly(methacryloylaminopropyltrimethylammonium chloride), PMDA-ODAPI poly(pyromellilimide-co-4,40-oxydianiline) polyimide, PMMA polymethyl methacrylate, poly(SEOS) poly(styrene-block-ethyleneoxide-block-styrene), PSf polysulfone, PSS polystyrene sulfonic acid or sodium polystyrene sulfonate, PTFE polytetrafluoroethylene, PTMEG polytetramethylene ether glycol, PTMSP poly(1-trimethylsilyl-1-propyne), PU polyurethane, PVAc poly(vinyl) acetate, PVBC polyvinyl benzyl chloride, PVBTMAC poly(4-vinylbenzyltrimethylammonium) chloride, PVDF polyvinylidene fluoride, and PVP polyvinylpyrrolidone.

[0109] Tables 2 and 3 below show various types of ionic liquids and the fluid species with which they have specific affinities.

[0110] [Table 2]

[0111] [Table 3]

[0112] Phosphonium-based ionic liquids possess specific properties that make them favorable for certain applications. These properties include minimal VOC emissions into conditioned process fluid streams and exhaust fluid streams, the ability to absorb CO2 and all 14 pollutant design compounds of ASHRAE standard 62.1-2022 for indoor air quality, even after direct exposure to liquid water, and a low Henry's Law constant that makes them excellent absorbents. Furthermore, phosphonium-based ionic liquids have a highly stable structure, enabling them to absorb pollutants from high-temperature applications. Due to this stability, they exhibit service lives of 10 years or more in demanding applications such as dryers and press exhaust gas applications.

[0113] Tetrabutylphosphonium levulinic acid is an ionic liquid with a high CO2 absorption rate at low pressure, possessing a volume of 1.5 mmol / g at 303K and 2 bar, which is comparable to adsorbents such as N-ethyldiethanolamine (DEA) (approximately 1.8 mmol / g at 40°C and 1 bar) or solid amine adsorbents such as mesoporous silica with polyethyleneimine (2.6 mmol / g at 30°C and 1 bar).

[0114] Because tetrabutylphosphonium levulinic acid functions via physical surface area (non-chemical) bonding, it exhibits one of the lowest regeneration energies compared to other high-boiling point liquids. Furthermore, the viscosity of tetrabutylphosphonium levulinic acid at room temperature of 253 cP is beneficial for the energy transfer properties of monoblocks.

[0115] Furthermore, the monoblocks were tested using tetra-n-butylphosphonium-based amino acid ionic liquids containing L-glycinate, L-alaninate, L-serinate, and L-proline as anions. Some of these exhibited CO2 permeability and CO2 / N2 selectivity exceeding Robson's upper limit.

[0116] The ionic liquid EMIM BF4 has a high water permeability of 1.6E^-6.

[0117] Mixing multiple ionic liquids is another way to fine-tune absorption properties. An example mixture of ionic liquids includes the N-(2-aminoethyl)ethanolamine system IL([AEEA][X]) and 1-ethyl-3-methylimidazolium acetate ([emim][AcO]). This mixture is liquid at temperatures below 0°F, has a negligible vapor pressure, exhibits negligible losses from monoblock systems, and is inert to many chemicals present in process fluid streams. The two ionic liquids demonstrated service lives of over 15 years at prolonged temperatures above 400°C. This mixture exhibits high CO2 absorption and low absolute enthalpy of the CO2 solution. Without theoretical constraints, the mechanism of CO2 absorption by the mixture can be theorized as follows: [AEEA]-[X] acts as a CO2 carrier, and the Lewis base [emim][AcO] stabilizes the amphoteric / carbamate species, which exhibit a relatively low absolute solubility enthalpy compared to the carbamate species. The test results show a CO2 transmission rate greater than 26,000 Barre and a CO2 / N2 selectivity greater than 10,000 Barre.

[0118] The ionic liquid, 1-butyl-3-methylimidazolium dicyanamide ([bmim][DCA]), has the ability to capture both helium and carbon dioxide from a supply stream.

[0119] Ionic liquids can also be useful for separating radioactive compounds, including lanthanides, actinides, and fission products. Ionic liquids selected for this application preferably have low vapor pressure, high flammability, and a broad electrochemical window. RTILs with modified side-chain functional groups have been shown to be promising as "task-specific" ligands for selective compartments of metal ions. For example, imidazolium cations functionalized with uranium-selective amidoxime functional groups introduced into monoblocks can favorably capture radioactive materials in process fluid streams. Ionic liquids based on boron-containing anions have also been shown to be promising for this application because they provide intrinsic safety against criticality accidents. The hydrophobic ionic liquid 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide [C4mim][Tf2N] can be used as a diluent for β-diketone lanthanide extraction. Commonly available imidazolium anions include [Tf2N]-, [PF6]-, and [BF4]-.

[0120] Ionic liquids suitable for oxygen separation include Co(II) chelate ionic liquids, such as [P66614]2[NmGly]2[Co(salen)], [P66614]2[NmGly][Tf2N][Co(salen)], [Bmim][PF6], and / or other ionic liquids depending on the application.

[0121] Ionic liquids suitable for the separation of NOx and SOx include [P66614][Tetz], imidazolium-based ionic liquids, ionic liquids functionalized with anions (e.g., [FeCl4]2-), amine groups, sulfonate anions and carboxylate anions, or combinations of trihexyltetradecylphosphonium cations and benzimidazolide ([P66614][Benzim]) or tetrazolide ([P66614][Tetz]) anions, and / or other ionic liquids depending on the application.

[0122] (Fluid separation using monoblocks) The number of open cells N on the front of the monoblock can be divided into two or more groups. For example, there may be first and second fluid flow channel groups. In some embodiments, the number of fluid flow channels in the first and second fluid flow channel groups may be about N / 2 each. At least a portion of the first fluid flow channel group is adjacent to at least a portion of the second fluid flow channel group. For example, each of the fluid flow channels constituting the first fluid flow channel group may be adjacent to at least one of the fluid flow channels constituting the second fluid flow channel group.

[0123] A process fluid stream containing multiple fluid types, including one or more target fluids, flows into a first fluid flow channel group located at the front of the monoblock, under the influence of positive pressure optionally generated by a pump. Any fluid pump known in the art can be used. Alternatively, the process fluid stream may flow into the first fluid flow channel group after being generated by a chemical process, such as a flue gas stack. In one embodiment, the volumetric flow rate of the process fluid stream is about 9 cfm.

[0124] As the process fluid stream flows through the first fluid flow channel group, one or more target fluid species contained in the process fluid stream are attracted to the high-boiling point liquid impregnated within the channel. The high-boiling point liquid then absorbs at least a portion of the target fluid species.

[0125] At least one fluid flow channel from the second fluid flow channel group is adjacent to at least one fluid flow channel from the first fluid flow channel group and shares a common channel wall with it.

[0126] A monoblock system uses a chemical gradient, i.e., a concentration or pressure gradient, between two surfaces of the monoblock wall to separate fluid species from the process fluid to the exhaust side across the channel wall. Four different techniques can be used to generate a partial vapor pressure difference: feed compression, vacuum pumping, gas sweeping, and a combination of vacuum pumping and gas sweeping.

[0127] Feed compression uses a compressor to increase the pressure in a process fluid stream or a first fluid flow channel group. Vacuum pumping uses a vacuum pump to decrease the pressure in a discharge fluid stream or a second fluid flow channel group. Both feed compression and vacuum pumping require energy to produce higher or lower pressures.

[0128] A gas sweep adds an inert gas to the discharge fluid stream or second fluid flow channel group for dilution, resulting in a lower partial vapor pressure. A gas sweep operates the second fluid flow channel group at a higher total pressure, requiring additional compounds such as inert gas, nitrogen, or air, which can increase costs. Various embodiments of the monoblock separation system can employ a combination of a vacuum pump and a gas sweep, or a combination of a compression feed and a vacuum pump.

[0129] The pressure difference across the channel wall is the driving force behind the absorption and desorption of the target fluid species. Therefore, the target fluid species is absorbed on the higher-pressure side of the channel wall and desorbed on the lower-pressure side.

[0130] In other words, once a target fluid species is absorbed by a high-boiling point liquid, the target fluid species will diffuse through the high-boiling point liquid from the side with a higher target fluid species partial pressure to the side with a lower target fluid species partial pressure. Consequently, the absorbed target fluid species will diffuse from the process fluid stream side of the channel wall to the discharge fluid stream side of the channel wall due to the associated high-low partial pressure gradient.

[0131] Vacuum can compress air at 1 kPa to the standard atmospheric pressure of 101 kPa. The work W required for vacuum is calculated using the following formula. W = (nRT / ε)·ln(P outlet / P inlet ). In this formula, n is the total number of moles of the mixture sucked into the vacuum by the pump, R is the gas constant, T is the absolute temperature. Typically, P outlet is the atmospheric pressure, P inlet is the discharge fluid stream pressure, and ε is the efficiency of the vacuum pump, which can be assumed to be 0.65. The compression ratio (P outlet / P inlet ) of the vacuum pump determines the amount of work.

[0132] To reduce the energy requirement from the vacuum pump, one embodiment includes a vacuum pump installed between two monoblocks operating in series. The low-pressure side of the vacuum pump is designed such that the partial pressure of the discharge fluid stream is less than 1.25 kPa from the discharge fluid stream side of the first monoblock, and the high-pressure side of the vacuum pump is the partial pressure of the discharge fluid stream of 3.5 kPa, which is the supply side of the second monoblock. In this configuration, the vacuum pump does not need to compress the discharge fluid stream side of the first monoblock to the atmospheric pressure, but rather the fairly low partial pressure of the discharge fluid stream of 3.5 kPa. Thus, in this embodiment, due to the fairly small compression ratio of 3 to 5, the work used for the vacuum pump is only about one-third of the work used in the case of a typical compression ratio of 100.

[0133] The fluid flows out of the monoblock in two forms: a regulated process fluid stream and a discharge fluid stream.

[0134] The remainder of the process fluid stream that is not absorbed by the high-boiling point liquid ("tuned process fluid stream") continues to flow through a first fluid flow channel group that opens to the rear of the monoblock. Thus, the tuned process fluid stream flows out from the rear of the monoblock. In one embodiment, the process fluid stream flowing through the monoblock experiences a relatively low pressure drop due to the laminar flow passing through the monoblock. Therefore, the monoblock tunes the process fluid stream by separating the target fluid species from the process fluid stream.

[0135] After the target fluid species is desorbed from the high-boiling point liquid on the low-pressure side of the channel wall, the separated target fluid species ("discharge fluid stream") flows into the second fluid flow channel group. The discharge fluid stream then flows through the second fluid flow channel group and exits from the monoblock.

[0136] In one embodiment, one end of the second fluid flow channel group is constricted. The constricted end of the second fluid flow channel group allows a vacuum pump, optionally connected to the unconstricted end of the second fluid flow channel group, to more effectively generate negative pressure within these channels and extract the discharge fluid stream from the monoblock. The constricted end can take the form of a liquid-tight seal.

[0137] In one embodiment, the front of the second fluid flow channel group is constricted, and the discharge fluid stream flows out of the monoblock at the rear of the monoblock. In this embodiment, a header is optionally connected to the rear of the monoblock to separate the discharge fluid stream from the regulated fluid stream, as described later. In this embodiment, the end of the second fluid flow channel group at the front of the monoblock may be constricted. This constricted end of the second fluid flow channel group allows a vacuum pump, optionally connected to the rear of the second fluid flow channel group, to generate negative pressure more effectively.

[0138] In other embodiments, the rear of the second fluid flow channel group is constricted, and the discharge fluid stream exits the monoblock at the front of the monoblock. In this embodiment, as described later, a header is optionally positioned at the front of the monoblock to facilitate the inflow of the process fluid stream into the first fluid flow channel group and the discharge of the discharge fluid stream from the second fluid flow channel group. In this embodiment, the discharge fluid stream and the process fluid stream are countercurrent to each other.

[0139] Countercurrent exchange can be more efficient than co-current exchange because it maximizes the exchange duration while providing a consistent gain / loss gradient during the exchange process. For example, in the portion closest to the front of the monoblock, the process fluid stream has the highest concentration of the target fluid species, and the discharge fluid stream also has the highest concentration of the target fluid species. In the portion closest to the rear of the monoblock, the process fluid stream has the lowest concentration of the target fluid species, and the discharge fluid stream also has the lowest concentration of the target fluid species. Thus, this countercurrent exchange maximizes the partial pressure difference of the target fluid species across the channel walls along the entire length of the monoblock. In this embodiment, the end of the second fluid flow channel group at the rear of the monoblock is tapered to allow a vacuum pump, optionally connected to the second fluid flow channel group, to more effectively generate negative pressure.

[0140] In yet another embodiment, the middle of the second fluid flow channel group is constricted. In this embodiment, the discharge fluid stream and the process fluid stream flow both counter-current and parallel to each other. In this embodiment, in the first half of the monoblock, before the constriction of the second fluid flow channel group, the process fluid stream is introduced into the first fluid flow channel group, and a portion of the target fluid species in the process fluid stream is transferred through the channel walls to the second fluid flow channel group and extracted through the front of the monoblock using vacuum pressure as needed. After the initial separation pass, the regulated process fluid stream passes through the midpoint of the monoblock, where the second fluid flow channel group is constricted. A portion of the target fluid species not separated from the process fluid stream in the first half of the monoblock is transferred through the channel walls to the second half of the second fluid flow channel group and extracted through the rear of the monoblock using vacuum pressure as needed. Thus, in the first half of the monoblock, the discharge fluid stream flows counter-currently with the process fluid stream, and in the second half of the monoblock, the discharge fluid stream flows parallel to the process fluid stream. A header located at the front of the monoblock supplies the process fluid stream and extracts the first discharge fluid stream. A second header located at the rear of the monoblock extracts both the regulated process fluid stream and the second discharge fluid stream.

[0141] (Monoblock housing) In applications where continuous adjustment of process fluid streams is desirable, a fluid conditioning unit (FCU) may be provided, which includes a monoblock array for adjusting process fluid streams in parallel. The FCU may also include pipes or tubes necessary for routing the fluid flow, sensors, filters positioned upstream and / or downstream of the monoblocks, a power supply, scaffolding for organizing and supporting the monoblock array, distribution fans, pumps, and other components obvious to those skilled in the art.

[0142] A housing may be provided to enclose and seal at least one monoblock, a header, and the piping and channeling necessary for supplying and removing fluid streams to and from the monoblock. In this configuration, a single housing becomes a line-replaceable unit (LRU) that can be individually replaced in the event of component failure or routine maintenance during process fluid stream adjustment operations. The housing may be openable to access the enclosed monoblock and header.

[0143] The housing may have one or more ports for process fluid streams, regulated process fluid streams, and / or discharge fluid streams. Standard fluid stream ports known in the art can be used.

[0144] The housing may have connecting mechanisms such as snaps, clips, or latches, or other mechanisms or materials for detachably connecting to adjacent housings and / or structural scaffolding.

[0145] Each LRU may incorporate sensors within its housing to monitor the performance and operation of the monoblock. These sensors can communicate with a central processing unit (CPU) and may send an alert if an LRU requires replacement. Replacement may be performed automatically or manually. The CPU may be connected to a central controller and, if replacement is required, may divert the process fluid stream to another LRU. This diversion process can be achieved by controlling a fan or pump connected to each LRU, or by activating a damper or baffle to physically prevent fluid flow from entering the LRU requiring replacement.

[0146] (header) As mentioned above, the process fluid stream enters from the front of the monoblock and exits from the rear of the monoblock. The discharge fluid stream may exit through either the front or rear of the monoblock, either counterflowing or parallel flowing, respectively.

[0147] If a header is not present, a structure may use a plenum to guide the fluid flow toward one side of the monoblock, without routing the fluid through a specific fluid flow channel within the monoblock.

[0148] When the cell has a rectangular shape, the inlet and outlet fluid flow channels may be arranged in a checkerboard pattern, so that each inlet flow channel is surrounded by an outlet fluid flow channel, and vice versa. In complex arrangements such as checkerboard configurations, headers may be used to route process fluid streams into the first fluid flow channel group and discharge fluid streams out of the second fluid flow channel group, preventing the process and discharge fluid streams from mixing.

[0149] A header may be provided to transition the fluid stream between a bulk flow outside the monoblock and a multi-channel flow within a first or second fluid flow channel group inside the monoblock. Such a header can perform two different functions. The first function is to transition the fluid stream between the bulk flow and the multi-channel flow on side A of the header, and the second function is to establish a path for the multi-channel flow of the fluid stream to flow into or out of the relevant fluid flow channels of the monoblock.

[0150] The partitioner of the header performs a first function. The partitioner may have any ports known in the art to draw in or discharge a fluid stream on side A of the header. The partitioner transitions the fluid stream between bulk flow and multi-channel flow at the transition point between the partitioner and the channeling member portion of the header. The number of channels at the transition point is approximately equal to the number of fluid flow channels in the monoblock. In one embodiment, the multi-channel flow generated by the partitioner is in a laminar state.

[0151] The channeling component performs two functions: 1) route the multi-channel flow of process fluid to the first fluid flow channel group within the monoblock, or 2) extract the multi-channel flow of discharge fluid from the second fluid flow channel group within the monoblock to the partitioning component of the header. The number and arrangement of cells on the opposite side of the partitioning component from the channeling component (side B of the header) are approximately the same as the cells in the monoblock.

[0152] When a header is used to remove the discharge fluid stream from the front of the second fluid flow channel group of a monoblock, a header or plenum can be used to route the process fluid stream into the first fluid flow channel group. Alternatively, when a header is used to introduce the process fluid stream into the first fluid flow channel group of a monoblock, a header or plenum can be used to remove the discharge fluid stream from the front of the second fluid flow channel group.

[0153] Side B of the header may be attached to one or both sides of the monoblock. The header may be detachably attached to the monoblock by connection mechanisms such as snaps, clips, screws, latches, removable adhesives, or other mechanisms or materials that detachably connect the header to the monoblock. Alternatively, the header may be permanently attached to the monoblock by being formed directly onto the monoblock structure, for example, by permanent adhesives or rivets, or by other mechanisms or materials that permanently connect the header to the monoblock.

[0154] The geometry and materials of the header structure should preferably minimize the pressure drop between the bulk flow of the fluid and the resulting multi-channel flow of the fluid.

[0155] The header may be manufactured by micro-laser drilling, micro-CNC milling, 3D printing, micro-injection molding, urethane casting, or other methods known to those skilled in the art.

[0156] For the manufacture of headers using micro-CNC milling, all classes of materials, including ceramics, polymers, semiconductors, glass, and metallic materials, can be laser-perforated. Femtosecond and nanosecond lasers, using high power densities, vaporize rectangular channels, including single-pulse perforation, percussion perforation, trepanning, and helical perforation. Advantages of using laser perforation include non-contact with the header, high precision, and higher processing rates. Non-exclusive examples of such materials include EP (epoxy resin), ABS, PBT, PA, polycarbonate, polypropylene, polyethylene, PPS, polystyrene, polyimide, polyvinyl chloride, glass epoxy, stainless steel, iron, aluminum, nickel, copper, brass, bronze, ceramics, carbon, activated carbon, activated alumina, PEEK, polyetherimide (PEI), polyetheretherketone (PEEK), polybenzimidazole (PBI), and polydicyclopentadiene (pDCPD).

[0157] For the manufacture of headers using 3D printing, SLA 3D printing may be carried out using various formulations of monomers, oligomers, photoinitiators, and other additives that yield different material properties based on the intended use of the monoblock. Thermosetting polymers include PA, PLA, ABS, etc. Porous ceramics include activated carbon, activated alumina, etc. Additional 3D printing materials include other materials used or usable in 3D printing applications, such as aluminum, stainless steel, titanium, HIPS, PETG, nylon, carbon fiber, ASA, polycarbonate, polypropylene, metal fillers, wood fillers, carbon fillers, and PVA.

[0158] The manufacturing of headers using micro-injection molding may utilize materials including polyethylene, polypropylene, nylon, polycarbonate, Delrin, polysulfone, polybutylene terephthalate, acrylic, PEEK, Ultem, and liquid crystal polymers.

[0159] The manufacture of headers using urethane casting may also involve the use of polymers, biodegradable polymers, metals, and other materials that can be injected into and solidified in a negative mold.

[0160] (Multi-monoblock operation for regulating the air in a building) When multiple monoblocks are used in a single system, multiple aspects of the building's airflow can be adjusted simultaneously.

[0161] In one embodiment where a reduced water vapor concentration inside a building is desirable, a first monoblock can be impregnated with a liquid having a high affinity for water vapor, and a second monoblock can be impregnated with a liquid having a high affinity for CO2. When used in series, the first monoblock can take in indoor air and discharge the separated water vapor outdoors. The second monoblock can take in a conditioned process fluid stream from the first monoblock and reduce the CO2 concentration in the air. The separated CO2 can be discharged outdoors, used downstream, or isolated. The resulting conditioned process air stream with reduced water vapor and CO2 concentrations can be returned to the building.

[0162] In other embodiments where a high water vapor concentration is desired inside the building, a first monoblock impregnated with a liquid having a high affinity for water vapor takes in outside air, separates some of the water vapor in the outside air, and discharges that water vapor into the building. This increases the water vapor concentration in the air inside the building.

[0163] In other embodiments, the second monoblock can be impregnated with a liquid that has a high affinity for CO2 and other indoor air pollutants.

[0164] In other embodiments, the third monoblock can be impregnated with a liquid that has a high affinity for indoor air pollutants, subject to relevant regulatory standards that allow for partial or complete removal of outdoor air in the building's ventilation system. These indoor air pollutants and their associated maximum values, in accordance with ANSI / ASHRAE standard 62.1-2022, are reproduced in Table 4 below.

[0165] [Table 4]

[0166] In other embodiments, the monoblock can heat or cool the building's air in combination with a heated or cooled fluid. Heating or cooling the fluid stream can be achieved by tubes carrying the heated or cooled fluid, which are inserted into one or more fluid flow channels, so that the tubes are in contact with the channel walls but do not fill the volume of the fluid flow channels. Heat exchange is then possible between the fluid in the tubes and the building's air flowing through the monoblock.

[0167] Alternatively, the channel walls of one or more fluid flow channels in the second fluid flow channel group may be glassed, and heated or cooled fluid can be pumped through the fluid flow channels with glassed channel walls, thereby allowing heat to flow through the heat-conductive channel walls of the monoblock to regulate the temperature of the building's air. Alternatively, the monoblock may be placed on a heating or cooling surface, thereby heating or cooling the channel walls and providing heat transfer between the fluid stream and the channel walls.

[0168] Alternatively, the monoblock may be an electrocaloric device fabricated from a ferromagnetic material. The electrocaloric monoblock is exposed to an electric field, which triggers a change in material polarization, resulting in an increase in the material's temperature upon application of the electric field and subsequent cooling upon removal. (See reference aka Tusek, A Highly Efficient Solid-State Heat Pump, 383 SCI. 769, 769-770 (Nov. 17, 2023)). As the monoblock material heats or cools, heat is transferred between the fluid stream and the channel wall.

[0169] Therefore, a single monoblock can control both the temperature and concentration of the target fluid within the process fluid stream.

[0170] In line with the aforementioned applications, one embodiment discloses a header configured to split a bulk fluid flow into a multi-channel fluid flow. The bulk fluid may include air from the atmosphere, or air from a sealed environment such as a building, an air tank, or a vehicle including an automobile, submarine, or airplane. The header configured to split a bulk fluid flow into a multi-channel fluid flow may include at least one inlet, a transition element, a plurality of routing channels, and at least one outlet. In some embodiments, the at least one outlet comprises a plurality of openings fluid-connected to a plurality of fluid flow channels on a device attached to the header. In some embodiments, the transition element is configured to split a first bulk fluid flow into a first multi-channel fluid flow. In some embodiments, a plurality of first routing channels are configured to route the first multi-channel fluid flow to a first outlet. In some embodiments, the first outlet comprises a plurality of openings fluid-connected to a first fluid flow channel group.

[0171] In some embodiments, the header described herein may further include a second inlet having multiple openings fluidly connected to a second fluid flow channel group on a device attached to the header. The second inlet is typically configured to receive a second multichannel fluid flow from the second fluid flow channel group. In this embodiment, the second inlet is configured to receive a second multichannel fluid flow from the second fluid flow channel group. In some embodiments, multiple second routing channels are configured to route the second multichannel fluid flow from the second inlet to a transition element. In some embodiments, the transition element is configured to merge the second multichannel fluid flow with a second bulk fluid flow. In some embodiments, a second outlet is configured to discharge the second bulk fluid flow from the header. In some embodiments, the first fluid flow channel group is structurally different from the second fluid flow channel group, and the first routing channel is structurally different from the second routing channel and is not in fluid communication with the second routing channel.

[0172] In some embodiments, the header described herein may be configured to maintain a pressure difference between the first fluid flow channel group and the second fluid flow channel group.

[0173] In some embodiments, the header may further comprise a plenum structure and a second inlet fluid-connected to a second fluid flow channel group on a device attached to the header, the second inlet configured to receive a second multi-channel fluid flow from the second fluid flow channel group. In some embodiments, the plenum structure is configured to merge the second multi-channel fluid flows to form a second bulk fluid flow, the second outlet is configured to discharge BF2, and the first fluid flow channel group is structurally different from the second fluid flow channel group. The plenum structure used herein generally refers to a space that functions as an air distribution path. In an HVAC system, for example, the plenum is a sealed space used for air distribution or to house HVAC components. The plenum helps ensure uniform distribution of conditioned air throughout a building. In some embodiments, the plenum structure is selected from a group consisting of housings, manifolds, ductwork, chambers, air distribution boxes, and cavities.

[0174] In some embodiments, the header is at least partially fabricated from a polymer, a soluble polymer, a wax, a metal, or a combination thereof. Non-limiting examples of polymer materials usable herein include polyethylene, polypropylene, and polyvinyl chloride (PVC). Non-limiting examples of composite materials usable herein include fiber-reinforced composites such as polymer matrices reinforced with fibers (e.g., carbon fibers, glass fibers), or metal-matrix composites such as combinations of metal and ceramic materials.

[0175] In some embodiments, the first and second fluid flow channel groups (FC1 and FC2) on the device comprise 200 to 1200 channels per square inch and channels with lengths of 50 to 500 mm.

[0176] In some embodiments, one or both of the first and second fluid flow channel groups are housed within a monoblock. When both the first and second fluid flow channel groups are housed within a monoblock, they can be separated by channel walls formed from the material on which the monoblock is formed.

[0177] In some embodiments, the channel walls are porous and selectively permeable. In some embodiments, the selectively permeable channel walls of the fluid flow channel walls may be impregnated with one or more high-boiling point liquids, which may include ionic liquids, hydrocarbons, and amines.

[0178] In accordance with several disclosed embodiments, a device is disclosed comprising a monoblock having a plurality of fluid flow channels, including a first fluid flow channel group independent of a second fluid flow channel group. In some embodiments, the first fluid flow channel group is structurally different from the second fluid flow channel group. For example, in one embodiment, the second fluid flow channel group (FC2) is capped at one end, while the first fluid flow channel group (FC1) is open at both ends.

[0179] The monoblock may be configured to maintain a pressure difference between the first fluid flow channel group and the second fluid flow channel group. In some embodiments, the multiple fluid flow channels may be separated by channel walls, which are formed of a porous, selectively permeable material on which the monoblock is formed.

[0180] In some embodiments, the channel wall is impregnated with a high-boiling point liquid by a process including the following steps. (a) Select a high-boiling point liquid having a boiling point of at least 100°C. (b) The step of selecting a carrier liquid having a lower boiling point than the selected high-boiling-point liquid. (c) A step of mixing a high-boiling point liquid with a carrier to produce a solution with a concentration of approximately 15% to approximately 20% of the high-boiling point liquid. (d) A step of impregnating at least a portion of a plurality of fluid flow channels with the solution using a process that performs at least partial pore injection.

[0181] In some embodiments, the channel walls are impregnated with one or more high-boiling liquids, and at least a portion of the first fluid flow channel group is adjacent to at least a portion of the second fluid flow channel group. Non-limiting examples of one or more high-boiling liquids include ionic liquids, hydrocarbons, and amines. In some embodiments, these high-boiling liquids preferentially absorb one or more components of the process fluid stream introduced into the first fluid flow channel group. As an addition or alternative, the high-boiling liquids are configured to inactivate at least a portion of viruses, germs, fungal spores, or other biological contaminants from the process fluid stream introduced into the first fluid flow channel group (FC1).

[0182] In one embodiment, one or more high-boiling-point liquids include one or more ionic liquids adapted to preferentially absorb one or more fluids selected from the group consisting of CO2, oxygen, water vapor, CO, SOx, and NOx.

[0183] In some embodiments, the monoblock is configured to maintain a pressure difference between the first and second fluid flow channel groups. For example, in one embodiment, the first fluid flow channel group is under a higher pressure than the second fluid flow channel group. In another embodiment, the first fluid flow channel group is under a positive gauge pressure, and the second fluid flow channel group is under a negative gauge pressure.

[0184] In some embodiments, two or more independent fluid flow channel groups extend along the length of the porous monoblock. These also extend approximately 20 inches. 2 / inch 3~Approximately 200 inches 2 / inch 3 The surface area-to-volume ratio is within the range of [specify range]. The porous and selectively permeable walls of two or more independent fluid flow channel groups may have pore volumes in the range of approximately 0.10 mL / g to approximately 1.0 mL / g.

[0185] In some embodiments, the device further includes a header attached to one or both ends of a monoblock, having at least one inlet, a transition element, a plurality of routing channels, and at least one outlet. The first inlet of the header may be configured to receive a first bulk fluid flow. In one embodiment, the at least one outlet comprises a plurality of openings fluidly connected to a plurality of fluid flow channels in the monoblock. In one embodiment, the transition element is configured to split the first bulk fluid flow into a multi-channel fluid flow, the plurality of first routing channels are configured to route the first multi-channel fluid flow to a first outlet, the first outlet comprises a plurality of openings fluidly connected to a first fluid flow channel group but not to a second fluid flow channel group, and the at least one header is attached to at least one end of the monoblock.

[0186] In some embodiments, the first fluid flow channel group (FC1), independent of the second fluid flow channel group (FC2), is arranged in repeating patterns such as, for example, a checkerboard pattern, an offset checkerboard pattern, a honeycomb pattern, a four-leaf clover pattern, a rectangle pattern, a diamond pattern, a triangle pattern, a triangle and diamond pattern, and a triangle and rectangle pattern.

[0187] In some embodiments, the apparatus further includes a device configured to isolate the discharge fluid stream from the second fluid flow channel group. In some embodiments, the monoblock may have a separation efficiency of 50% or more, 75% or more, or even 98% or more.

[0188] A method for reducing the concentration of components in a fluid stream is disclosed, consistent with several disclosed embodiments. The method includes introducing a process fluid stream containing a mixture of fluid species into the following device: The device has (a) at least one header having at least one inlet, a transition element, a plurality of routing channels, and at least one outlet, the first inlet being configured to receive a first bulk fluid flow, the at least one outlet having a plurality of openings fluid-connected to a plurality of fluid flow channels, the transition element being configured to split the first bulk fluid flow into a multi-channel fluid flow, the plurality of first routing channels being configured to route the first multi-channel fluid flow to a first outlet, the first outlet having a plurality of openings fluid-connected to a first fluid flow channel group. The method also includes having a monoblock, as described above.

[0189] In one embodiment, a method for reducing the concentration of components in a fluid stream includes using a header having a second inlet with a plurality of openings fluid-connected to a second fluid flow channel group. The second inlet is configured to receive a second multichannel fluid flow from the second fluid flow channel group. In one embodiment, a plurality of second routing channels are configured to route the second multichannel fluid flow from the second inlet to a transition element. The transition element is configured to merge the second multichannel fluid flow with a second bulk fluid flow. A second outlet is configured to discharge the second bulk fluid flow from the header. The first fluid flow channel group is structurally different from the second fluid flow channel group, and the first routing channels are structurally different from the second routing channels and are not fluid-connected.

[0190] In some embodiments, the header may be configured to maintain a pressure difference between the first fluid flow channel group and the second fluid flow channel group.

[0191] In some embodiments, the header has a plenum structure with a second inlet fluid-connected to a second fluid flow channel group on a device attached to the header. The second inlet of the plenum is configured to receive a second multi-channel fluid flow from the second fluid flow channel group. The plenum is configured to merge the second multi-channel fluid flows to form a second bulk fluid flow, and a second outlet is configured to discharge the second bulk fluid flow, with the first fluid flow channel group being structurally different from the second fluid flow channel group.

[0192] A method for manufacturing a header is disclosed in accordance with several disclosed embodiments. In some embodiments, this method may include one or more of the following steps: (a) A step of preparing a monoblock made of a porous material. The monoblock has a plurality of fluid flow channels formed inside. The plurality of fluid flow channels are separated by channel walls. The channel walls are porous and selectively permeable. (b) A step of preparing a negative mold having fingers configured to align with a subset of fluid flow channels. (c) A step of inserting the negative mold fingers into a portion of multiple fluid flow channels. (d) A step of introducing liquid polymer material into the negative mold. (e) A step of curing the liquid polymer material. (f) Step of removing the negative mold and establishing the header.

[0193] In the disclosed method, to facilitate alignment, the negative mold fingers may be inserted into at least a subset of the monoblock channels before the monoblock hardens.

[0194] In some embodiments, the liquid polymer introduced into the negative mold enters at least partially into the pores of the porous monoblock, and as a result, when the negative mold is removed, the formed header is attached to the porous monoblock by the polymer inserted into the pores of the porous monoblock.

[0195] In some embodiments, the negative mold is made from a material selected from the group consisting of metals, waxes, polymers, and soluble polymers.

[0196] (Detailed explanation of the drawing) Figure 1A is a perspective view of a header structure 100 consistent with several disclosed embodiments. The header 100 includes a plurality of partition members 110 on side A 120 of the header. In this embodiment, the partition members 110 are arranged to connect to linear fittings. The partition members 110 may also be process stream partition members 111 that divide the bulk flow of a process fluid stream into a multichannel fluid flow at a transition point 150 on side A 120 of the header. Alternatively, the partition members 110 may be exhaust stream partition members 112 that merge the multichannel fluid flow of an exhaust fluid stream with the bulk flow at side A 120 of the header at the transition point 150 and discharge it from the system. The partition members 110 connect to a channelizer 130 at the transition point 150. The channelizer 130 routes the multichannel fluid flow from the transition point 150 into or out of the associated fluid flow channel group of a monoblock located on side B 140 of the header 100.

[0197] Accordingly, the process fluid stream flows into the system through the process stream partitioning member 111, is divided into a multi-channel process fluid flow at the transition point 150, enters the channeling member 130, and is routed to the first fluid flow channel group within the monoblock. Similarly, the discharge fluid stream flows out of the monoblock through the second fluid flow channel group and enters the channeling member 130, which routes the multi-channel discharge fluid flow to the transition point 150 and to the discharge stream partitioning member 112, and merges the multi-channel discharge fluid flow with the bulk flow of discharge fluid removed from the system at side A 120.

[0198] Figure 1B is a detailed view of a part of the header structure 100 shown in Figure 1A, and in particular focuses on the channeling member 130 that routes the multi-channel fluid flow into or out of the associated fluid flow channel of the monoblock located on the B side 140 of the header 100 at the transition point 150.

[0199] Figure 1C is a detailed view of the channeling member 130 located on side B 140 of the header structure 100 shown in Figure 1A. Side B 140 of the channeling member 130 is connected to a monoblock. The arrangement of the routing channels 160 corresponds to the arrangement of channels formed in the monoblock. As can be seen from the side view 170 of the channeling member 130, the routing channels 160 are non-linear and route multi-channel fluid flow between the transition point 150 and the associated fluid flow channels in the monoblock. The routing channel 160 may also be a first routing channel 161, which routes multi-channel process fluid flow from the transition point 150 to the first fluid flow channel group in the monoblock. Alternatively, the routing channel 160 may be a second routing channel 162, which routes the discharge fluid stream from the second fluid flow channel group in the monoblock to the transition point 150 for discharge from the system. In this embodiment, the first route setting channel 161 and the second route setting channel 162 each form a checkerboard pattern.

[0200] Figure 1D is a detailed view of the channeling member shown in Figure 1C. The arrangement of the routing channels 160 corresponds to the arrangement of the fluid flow channels formed within the monoblock. The routing channels 160 are non-linear and route multi-channel fluid flows between the transition point 150 and the associated fluid flow channels within the monoblock. The routing channel 160 may also be a first routing channel 161, which routes multi-channel process fluid flows from the transition point 150 to a first fluid flow channel group within the monoblock. Alternatively, the routing channel 160 may be a second routing channel 162, which routes the discharge fluid stream from a second fluid flow channel group within the monoblock to the transition point 150 for discharge from the system. In this embodiment, the first routing channel 161 and the second routing channel 162 each form a checkerboard pattern.

[0201] Figure 2A is a perspective view of a header structure 200 consistent with several disclosed embodiments. The header 200 includes a plurality of partition members 210 on the A1 side 220 and A2 side 221 of the header. The partition members 210 may also be process stream partition members 211, which divide the bulk flow of process fluid streams on the A1 side 220 of the header into a multi-channel process fluid flow at the transition point 240. Alternatively, the partition members 210 may also be discharge stream partition members 212, which merge the multi-channel discharge fluid flow from the transition point 240 with the bulk flow of discharge fluids on the A2 side 221 of the header for discharge from the system. In this embodiment, the pressure drop between the bulk flow and the multi-channel fluid flow is reduced. The partition members 210 are connected to the channeling member 130 at the transition point 230, as shown in Figure 1C.

[0202] Figure 2B is an alternative perspective view of the header structure 200 shown in Figure 2A. This figure shows the A2 side 221 and the discharge stream partitioning member 212. The transition point 240 shows alternating rows of multi-channel discharge fluid flow and multi-channel process fluid flow. The partitioning member 210 is connected to the channeling member 130 at the transition point 230, as shown in Figure 1C.

[0203] Figure 3A is a perspective view of a header structure 300 consistent with several disclosed embodiments. The header 300 includes a plurality of partition members 310 on the A1 side 320 and A2 side 321 of the header. In this embodiment, the partition members 310 are arranged to connect to rectangular fittings on either or all of the A1 side 320 and A2 side 321. The partition members 310 may also be process stream partition members 311, which divide the bulk flow of process fluid streams on the A1 side 320 of the header into a multichannel fluid flow at the transition point 340. Alternatively, the partition members 310 may also be exhaust stream partition members 312, which merge the multichannel exhaust fluid flow from the transition point 340 into the bulk flow of exhaust fluids on the A2 side 321 of the header for discharge from the system. The partition members 310 connect to a channeling member 130 at the transition point 330, as shown in Figure 1C.

[0204] Figure 3B is a detailed view of the header in Figure 3A. This figure shows the A2 side 321 and the discharge stream partitioning member 312. The transition point 340 shows the discharge stream partitioning member 312 which forms a multi-channel discharge fluid flow in a row, and the process stream partitioning member 311 which forms a multi-channel process fluid flow in an adjacent row. The partitioning member 310 is connected to the channeling member 130 at the transition point 340, as shown in Figure 1C.

[0205] The transition point 340 indicates the discharge stream partitioning member 312 and the process stream partitioning member 311, generating alternating rows of multi-channel discharge fluid flow and multi-channel process fluid flow. The partitioning member 310 is connected to the channeling member 130 at the transition point 340, as shown in Figure 1C.

[0206] Figure 4A is a perspective view of a header structure 400 consistent with several disclosed embodiments. The header 400 includes a plurality of partition members 410 on side A 420 of the header. In this embodiment, the partition members 410 are arranged to connect to linear joints. The partition members 410 may also be process stream partition members 411, which divide the bulk flow of process fluid streams on side A 420 of the header into a multichannel fluid flow at the transition point 450. Alternatively, the partition members 410 may also be exhaust stream partition members 412, which merge the multichannel fluid flow from the transition point 450 into the bulk flow on side A 420 of the header for discharge from the system. The partition members 410 connect to a channeling member 430 at the transition point 450. The channeling member 430 establishes a multichannel fluid flow path between the transition point 450 and the associated fluid flow channel in the monoblock on side B 440 of the header 400.

[0207] Accordingly, the process fluid stream flows into the system through the process stream partitioning member 411, is divided into a multi-channel process fluid flow at the transition point 450, enters the channeling member 430, and is routed to a first fluid flow channel group within the monoblock. Similarly, the discharge fluid stream flows out of the monoblock through the second fluid flow channel group and enters the channeling member 430, which routes the multi-channel discharge fluid flow to the transition point 450 and to the discharge stream partitioning member 412, transitioning the multi-channel discharge fluid flow into a bulk flow of discharge fluid discharged from the system at side A 420 of the header.

[0208] Figures 4B and 4C are detailed views of a part of the header structure 400 shown in Figure 4A, and in particular focus on the channeling member 430 that routes the multi-channel fluid flow between the transition point 450 and the associated fluid flow channel of the monoblock.

[0209] Figure 5 is a perspective view of a monoblock structure 500 showing the flow of a fluid stream 530, consistent with several disclosed embodiments. The figure of the monoblock structure 500 shows a plurality of fluid flow channels 510 formed within the monoblock 500. The fluid flow channels 510 may or may not extend entirely through the monoblock structure 500. The fluid flow channels 510 include a first fluid flow channel group 511 and a second fluid flow channel group 512, which are separated by channel walls 520. The channel walls 520 are fabricated from substantially the same material as the monoblock structure 500 but are impregnated with a high-boiling point liquid. The figure shows the fluid stream 530, which includes a process fluid stream 531 and a discharge fluid stream 532.

[0210] Figures 6A to 6L show exemplary arrangements of fluid flow channels formed within a monoblock, consistent with several disclosed embodiments. Figure 6A shows channels 600 arranged in a checkerboard pattern, with each channel separated by a channel wall 610. Figure 6B shows channels 600 arranged in an offset checkerboard pattern, with each channel separated by a channel wall 610. Figure 6C shows channels 600 arranged in a honeycomb pattern, with each channel separated by a channel wall 610. Figure 6D shows channels 600 arranged in a diamond pattern, with each channel separated by a channel wall 610. Figure 6E shows channels 600 arranged in a diamond and triangle pattern, with each channel separated by a channel wall 610. Figure 6F shows channels 600 arranged in an alternating diamond and triangle pattern, with each channel separated by a channel wall 610. Figure 6G shows channels 600 arranged in an equilateral triangle pattern, with each channel separated by a channel wall 610. Figure 6H shows that the channels 600 are arranged in an offset triangular pattern, with each channel separated by a channel wall 610. Figure 6I shows that the channels 600 are arranged in a right-angled triangular pattern, with each channel separated by a channel wall 610. Figure 6J shows that the channels 600 are arranged in a triangular and pentagonal pattern, with each channel separated by a channel wall 610. Figure 6K shows that the channels 600 are arranged in an alternating triangular and pentagonal pattern, with each channel separated by a channel wall 610. Figure 6L shows that the channels 600 are arranged in a triangular and hexagonal pattern, with each channel separated by a channel wall 610.

[0211] Figure 7A is an exploded perspective view of a fluid separator including a header 710 containing a partitioning member 711 and a channeling member 712, and a monoblock 720.

[0212] Figure 7B is a detailed view of the fluid separator of Figure 7A. It shows that the partitioning member 711 is connected to the channeling member 712 to form a header 710. The header 710 may be detachably or permanently connected to the monoblock 720. In this exemplary embodiment, the header 710 is detachably connected to the monoblock 720 by clips 730 on the header 710 and recesses 731 for detachably receiving the clips 730, or by other mechanisms or members for detachable connection, as shown in the figure.

[0213] Figure 8 shows a channeling member 810 that routes a fluid stream between a transition point 830 and an associated fluid flow channel 840 of a monoblock 820, consistent with several disclosed embodiments. The face of the channeling member 810 shows the multichannel fluid flow at the transition point 830, including a multichannel process fluid flow 811 and a multichannel discharge fluid flow 812, each of which forms an alternating row. The channeling member 810 routes the multichannel process fluid flow 811 and the multichannel discharge fluid flow 812 between the transition point 830 and the associated fluid flow channel 840 of the monoblock 820. In this exemplary embodiment, the row of multichannel process fluid flow 811 is routed into a first fluid flow channel group 841 (which is a checkerboard arrangement) within the monoblock 820. The row of multichannel discharge fluid flow 812 is routed to exit a second fluid flow channel group 842 (which is also a checkerboard arrangement) within the monoblock 820.

[0214] Figure 9 shows the mechanism of the target fluid flow 900 through a monoblock channel wall 910, consistent with several disclosed embodiments. This figure includes a first fluid flow channel group 920 through which a process fluid stream 921 passes, and a second fluid flow channel group 930 through which a discharge fluid stream 931 passes. The first fluid flow channel group 920 is at a higher pressure compared to the second fluid flow channel group 930.

[0215] The channel wall 910 separates the first fluid flow channel group 920 and the second flow channel group 930. The channel wall 910 has pores 911 on both sides that generate permeability through the channel wall 910. The channel wall 910 is impregnated with a high-boiling liquid, which in this embodiment is an ionic liquid 912. In other embodiments, the high-boiling liquid may only partially impregnate the channel wall, or it may impregnate only the first half of the channel wall, starting from the portion of the channel wall closest to the first fluid flow channel group.

[0216] A process fluid stream 921 containing a mixture of fluid types, including a target fluid type 922, flows into a monoblock within a first fluid flow channel group 920. As the process fluid stream 921 passes through the first fluid flow channel group 920, one or more target fluid types 922 (for example, CO2 in this exemplary embodiment) are attracted to the ionic liquid 912 impregnated in the channel wall 910. The ionic liquid 912 then absorbs at least a portion of the target fluid types 922 through the pores 911 of the channel wall 910.

[0217] The target fluid species—a compound of the ionic liquid—diffuses across the channel walls 910 due to the pressure difference between them. When compound 913 reaches the other side of the channel walls 910, the relatively low pressure causes the target fluid species 922 to desorb from the ionic liquid 912. Once the target fluid species 922 has desorbed, it enters the second fluid flow channel group 930 through the pores 911 of the channel walls 910. The target fluid species 922 then exits the monoblock as an exhaust fluid stream 931 through the second fluid flow channel group 930. In this exemplary embodiment, the process fluid stream 921 and the exhaust fluid stream 931 flow in opposite directions from each other.

[0218] Figure 10 is a two-dimensional front view of a monoblock structure 1000 consistent with several disclosed embodiments. This front view of the monoblock structure 1000 shows a plurality of fluid flow channels 1010 formed within the monoblock 1000. The fluid flow channels 1010 include a first fluid flow channel group 1011 and a second fluid flow channel group 1012, which are separated by a thermally conductive channel wall 1020. The channel wall 1020 is fabricated from substantially the same material as the monoblock structure 1000 but is impregnated with a high-boiling point liquid.

[0219] As shown in Figure 9, the target fluid species 1040 is transferred from the first fluid flow channel group 1011 to the second fluid flow channel group 1012 through the channel wall 1020, which is impregnated with a high-boiling point liquid.

[0220] This embodiment allows for heating or cooling of a process fluid stream contained within a first fluid flow channel group. A tube 1030 is inserted into a second fluid flow channel group 1012. The tube 1030 is made of a thermally conductive material and carries a heating or cooling fluid 1031. The tube 1030 is in physical contact with the channel wall 1020 inside the second fluid flow channel group 1012. When the tube 1030 contains a cooling fluid 1031, heat 1050 flows from the process fluid stream to the channel wall 1020, and then through the thermally conductive channel wall 1020 through the thermally conductive tube 1030 to the cooling fluid 1031.

[0221] Figure 11 is a block diagram of two monoblocks 1110, 1120 arranged in series, consistent with several disclosed embodiments. In this exemplary embodiment, there is a first monoblock 1110 impregnated with a first high-boiling liquid 1113 having an affinity for water vapor, and a second monoblock 1120 impregnated with a second high-boiling liquid 1123 having an affinity for CO2. The first monoblock 1110 receives a first process fluid stream 1111 and separates at least a portion of the water vapor into a first exhaust fluid stream 1114. The first conditioned process fluid stream 1112 exits the first monoblock 1110 and functions as a second process fluid stream 1121. The second monoblock 1120 receives the second process fluid stream 1121 and separates at least a portion of the CO2 into a second exhaust fluid stream 1124. The second conditioned process fluid stream 1122 then exits the second monoblock 1120. In this exemplary embodiment, a vacuum pump 1130 generates negative pressure to extract a first discharge fluid stream 1114 and a second discharge fluid stream 1124 from a first monoblock 1110 and a second monoblock 1120, respectively. In this exemplary embodiment, the first process fluid stream 1111 may be outdoor air, and the second conditioned process fluid stream 1122 may be directed into the building. This arrangement may be preferred if the building's occupants prefer air with low humidity and low CO2 concentration.

[0222] Figure 12A is a block diagram of a fluid adjustment unit 1200 ("FCU"). In applications where continuous adjustment of a process fluid stream is desired, an FCU may be provided with an array of monoblocks 1210 for adjusting the process fluid stream in parallel, in series, or a combination thereof, using pipes or tubes 1250. Adjusting the process fluid stream in parallel allows one or more monoblocks to be switched over during the operation of the adjustment process if one or more monoblocks 1210 fail in operation or require periodic maintenance. If necessary, a housing 1220 may be provided to enclose and seal at least one monoblock 1210 and a header. In this configuration, the combination of monoblock 1210 and housing 1220 constitutes a line-replaceable unit ("LRU") 1225, which can be individually replaced in the event of monoblock 1210 failure or periodic maintenance.

[0223] In this embodiment, each housing 1220 may incorporate a sensor 1260 for monitoring the performance and operation of the monoblock 1210 integrated within the housing 1220. Each sensor in the housing may communicate with a central processing unit (CPU) 1230 and send a warning if the housing 1220 requires replacement. The CPU 1230 is also connected to a central controller 1240, which can reroute the process fluid stream away from the LRU 1225 that requires replacement.

[0224] Figure 12B is a perspective view of a line exchange unit ("LRU") 1225, consistent with several disclosed embodiments. In this exemplary embodiment, the LRU 1225 optionally comprises a housing 1220 that encloses and seals a monoblock 1210 and a header. The housing 1220 may be open to provide access to the monoblock 1210 housed inside. To facilitate opening, the housing may have a clip 1221 and a recess 1222 for receiving the clip 1221, or may have other mechanisms or members for detachable connection. The housing 1220 may have connecting mechanisms such as snaps, clips, latches for detachably connecting one LRU 1225 to one or more adjacent LRU 1225 and / or structural scaffolding.

[0225] The above description, including the dimensions and number of specific elements, is presented for illustrative purposes only. It is not exhaustive and is not limited to the exact shape or embodiment disclosed. Modifications and adaptations of embodiments will become apparent from a review of the details and practices of the disclosed embodiments. While certain components are described as being coupled together, these components may be integrated with each other or dispersed in any suitable manner.

[0226] Furthermore, while illustrative embodiments are described herein, their scope includes all embodiments having equivalent elements, modifications, omissions, combinations (e.g., combinations of aspects across various embodiments), adaptations, and / or variations based on this disclosure. The elements in the claims should be interpreted broadly based on the terminology adopted herein and are not limited to the examples described herein or in the examination process of this application. Such examples should be interpreted non-exclusively. Furthermore, the steps of the disclosed methods can be modified in any way, including changing the order of the steps and / or inserting or deleting steps.

[0227] The features and advantages of this disclosure are evident from this detailed description, and the attached claims are intended to cover all systems and methods that fall within the true spirit and scope of this disclosure. The indefinite articles "a" or "an" used herein mean "one or more." Similarly, the use of the plural form does not necessarily mean plural unless it is clear in the given context. Words such as "and" and "or" mean "and / or" unless specifically indicated. Furthermore, since numerous modifications and variations readily arise from examining this disclosure, it is undesirable to limit this disclosure to the exact configuration and operation illustrated and described, and therefore all suitable modifications and equivalents are available within the scope of this disclosure.

[0228] Throughout this application, various embodiments of the Disclosure may be presented in scope form. It should be understood that scope form is merely for convenience and brevity and should not be interpreted as a strict limitation on the scope of the Disclosure. Therefore, a scope description should be considered to specifically disclose all possible subranges and individual numerical values ​​within that range. For example, a scope description of 1 to 6 should be considered to include subranges such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., and also include individual numerical values ​​within those ranges, such as 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the scope.

[0229] Other embodiments will become apparent from the description and practice of the embodiments disclosed herein. This specification and the examples should be considered merely illustrative, and the true scope and spirit of the disclosed embodiments are shown by the appended claims.

Claims

1. A header configured to split a bulk fluid flow into a multi-channel fluid flow, It comprises at least one inlet, a transition element, multiple routing channels, and at least one outlet, The first inlet is configured to receive the first fluid bulk flow, At least one outlet comprises multiple openings fluidly connected to multiple fluid flow channels on a device mounted on the header, The transition element is configured to split the first bulk fluid flow into a first multi-channel fluid flow. Multiple first routing channels are configured to route the first multi-channel fluid flow to the first outlet. A header having a first outlet with multiple openings fluidly connected to a first fluid flow channel group.

2. Further comprising a second inlet having multiple openings fluidly connected to a second fluid flow channel group on a device mounted on the header, The second inlet is configured to receive the second multi-channel fluid flow from the second fluid flow channel group. Multiple second routing channels are configured to route the second multi-channel fluid flow from the second inlet to the transition element. The transition element is further configured to merge the second multi-channel fluid flow with the second bulk fluid flow. The second outlet is configured to discharge the second bulk fluid flow from the header. The first fluid flow channel group is structurally different from the second fluid flow channel group. The header according to claim 1, wherein the first routing channel is structurally different from the second routing channel and is not in fluid communication with the second routing channel.

3. The header according to claim 1, wherein the header is configured to maintain a pressure difference between a first fluid flow channel group and a second fluid flow channel group.

4. Plenum structure and The device further comprises a second inlet fluid-connected to a second fluid flow channel group on a device mounted on a header, The second inlet is configured to receive the second multi-channel fluid flow from the second fluid flow channel group. The plenum structure is configured to merge the second multi-channel fluid flow to form a second bulk fluid flow. The second outlet is configured to discharge the second bulk fluid flow. The header according to claim 1, wherein the first fluid flow channel group is structurally different from the second fluid flow channel group.

5. The header according to claim 4, wherein the plenum structure is selected from a group consisting of a housing, manifold, ductwork, chamber, air distribution box, and cavity.

6. The header according to claim 1, wherein the header is at least partially made of a material selected from the group consisting of polymers, soluble polymers, composite materials, waxes, and metals.

7. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group are between two fluid flow channels and 1,600 fluid flow channels.

8. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group have a size of approximately 200 channels / square inch to approximately 1200 channels / square inch.

9. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group have a length of approximately 50 mm to approximately 500 mm.

10. The header according to claim 1, wherein the first fluid flow channel group is housed inside a monoblock.

11. Both the first fluid flow channel group and the second fluid flow channel group are housed inside the monoblock. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group are separated by channel walls formed of the material on which the monoblock is formed.

12. The header according to claim 11, wherein the channel wall is porous and selectively permeable.

13. The header according to claim 12, wherein the channel wall is impregnated with one or more high-boiling point liquids selected from the group consisting of ionic liquids, hydrocarbons, and amines.

14. The monoblock comprises multiple fluid flow channels, including a first fluid flow channel group independent of the second fluid flow channel group, The plurality of fluid flow channels are separated by channel walls, The channel wall is formed of a porous, selectively permeable material into which a monoblock is formed. The channel wall is impregnated with one or more high-boiling point liquids. An apparatus in which at least a portion of a first fluid flow channel group is adjacent to at least a portion of a second fluid flow channel group.

15. The apparatus according to claim 14, wherein the first fluid flow channel group is structurally different from the second fluid flow channel group.

16. The apparatus according to claim 14, wherein the monoblock is configured to maintain a pressure difference between a first fluid flow channel group and a second fluid flow channel group.

17. The apparatus according to claim 14, wherein the channel wall is impregnated with a high-boiling point liquid by a process comprising the following steps. (a) The step of selecting a high-boiling point liquid having a boiling point of at least about 100°C. (b) The step of selecting a carrier liquid having a lower boiling point than the selected high-boiling-point liquid. (c) A step of mixing a high-boiling point liquid with a carrier to produce a solution having a concentration of approximately 15% to approximately 20% of the high-boiling point liquid. (d) Impregnating at least a portion of a plurality of fluid flow channels with the solution using a process that performs at least partial pore injection.

18. The apparatus according to claim 14, wherein the one or more high-boiling point liquids are selected from the group consisting of ionic liquids, hydrocarbons, and amines.

19. The apparatus according to claim 14, wherein the one or more high-boiling point liquids are configured to preferentially absorb one or more components of a process fluid stream introduced into the first fluid flow channel group.

20. The apparatus according to claim 14, wherein the one or more high-boiling point liquids are configured to inactivate at least a portion of viruses, dust, mites, bacteria, pathogens, mold spores, or other biological contaminants from a process fluid stream introduced into a first fluid flow channel group.

21. Multiple fluid flow channels are approximately 20 inches in diameter. ２ / inch ３ ~Approximately 200 inches ２ / inch ３ The apparatus according to claim 14, having a surface area to volume ratio within the range.

22. The apparatus according to claim 14, wherein the channel wall has a pore volume in the range of about 0.1 mL / g to about 1.0 mL / g.

23. The apparatus according to claim 14, wherein the first fluid flow channel group is under a higher pressure than the second fluid flow channel group.

24. The apparatus according to claim 14, wherein the first fluid flow channel group is under positive gauge pressure and the second fluid flow channel group is under negative gauge pressure.

25. The apparatus according to claim 14, wherein the second flow channel group is constricted at one end.

26. It further comprises at least one header having at least one inlet, a transition element, multiple routing channels, and at least one outlet, The first inlet is configured to receive the first bulk fluid flow, The at least one outlet comprises multiple openings fluidly connected to multiple fluid flow channels within the monoblock, The transition element is configured to split the first bulk fluid flow into a first multi-channel fluid flow. Multiple first routing channels are configured to route the first multi-channel fluid flow to the first outlet. The first outlet has multiple openings that are fluid-connected to the first fluid flow channel group but not to the second fluid flow channel group. The apparatus according to claim 14, wherein the at least one header is attached to at least one end of the monoblock.

27. The apparatus according to claim 14, wherein the first fluid flow channel group and the second fluid flow channel group are arranged in a repeating pattern.

28. The apparatus according to claim 27, wherein the repeating pattern is selected from the group consisting of checkerboard patterns, offset checkerboard patterns, honeycomb patterns, four-leaf clover patterns, rectangle patterns, diamond patterns, triangle patterns, triangle and diamond patterns, and triangle and rectangle patterns.

29. The one or more high-boiling point liquids mentioned above are CO ２ The apparatus according to claim 14, comprising one or more ionic liquids configured to preferentially absorb one or more fluids selected from the group consisting of oxygen, water vapor, CO, SOx, NOx, helium, and formaldehyde.

30. Further comprising a device configured to isolate the discharge fluid stream, The apparatus according to claim 14, wherein the device is fluidly connected to a second fluid flow channel group.

31. The apparatus according to claim 14, having a separation efficiency of at least about 50%.

32. A method for reducing the concentration of one or more components in a process fluid stream, The process includes the step of introducing a process fluid stream containing a mixture of fluid species into a device having (a) at least one header and (b) a monoblock, (a) The at least one header is Having at least one inlet, a transition element, multiple routing channels, and at least one outlet, The first inlet is configured to receive the first bulk fluid flow, The at least one outlet comprises a plurality of openings fluidly connected to a plurality of fluid flow channels, The transition element is configured to split the first bulk fluid flow into a first multi-channel fluid flow. Multiple first routing channels are configured to route the first multi-channel fluid flow to the first outlet. The first outlet comprises multiple openings fluidly connected to the first fluid flow channel group. (b) The monoblock is It has multiple fluid flow channels, including a first fluid flow channel group and a second fluid flow channel group. The plurality of fluid flow channels are separated by channel walls, The channel wall is formed of a porous, selectively permeable material into which a monoblock is formed. The channel wall is impregnated with one or more high-boiling point liquids. A method wherein at least a portion of a first fluid flow channel group is adjacent to at least a portion of a second fluid flow channel group.

33. The aforementioned header is, It has a second inlet with multiple openings fluid-connected to the second fluid flow channel group, The second inlet is configured to receive the second multi-channel fluid flow from the second fluid flow channel group. Multiple second routing channels are configured to route the second multi-channel fluid flow from the second inlet to the transition element. The transition element is configured to merge the second multi-channel fluid flow with the second bulk fluid flow. The second outlet is configured to discharge the second bulk fluid flow from the header. The first fluid flow channel group is structurally different from the second fluid flow channel group. The method according to claim 32, wherein the first route setting channel is structurally different from the second route setting channel and is not in fluid communication with the second route setting channel.

34. The method according to claim 32, wherein the header is configured to maintain a pressure difference between the first fluid flow channel group and the second fluid flow channel group.

35. The aforementioned header is, Plenum structure and It has a second inlet which is fluid-connected to a second fluid flow channel group on a device attached to a header, The second inlet is configured to receive the second multi-channel fluid flow from the second fluid flow channel group. The plenum structure is configured to merge the second multi-channel fluid flow to form a second bulk fluid flow. The second outlet is configured to discharge the second bulk fluid flow. The method according to claim 32, wherein the first fluid flow channel group is structurally different from the second fluid flow channel group.

36. The method according to claim 35, wherein the plenum structure is selected from the group consisting of a housing, manifold, ductwork, chamber, air distribution box, and cavity.

37. The method according to claim 32, wherein the header is at least partially made of a polymer or composite material.

38. The method according to claim 32, wherein the plurality of fluid flow channels include 2 to 1600 fluid flow channels.

39. The method according to claim 32, wherein the multiple fluid flow channels have a size ranging from approximately 200 channels / square inch to approximately 1200 channels / square inch.

40. The method according to claim 32, wherein the multiple fluid flow channels have a length of about 50 mm to about 500 mm.

41. The method according to claim 32, wherein the first fluid flow channel group is structurally different from the second fluid flow channel group.

42. The method according to claim 32, wherein the monoblock is configured to maintain a pressure difference between a first fluid flow channel group and a second fluid flow channel group.

43. The method according to claim 32, wherein the one or more high-boiling point liquids are selected from the group consisting of ionic liquids, hydrocarbons, and amines.

44. The method according to claim 32, wherein the one or more high-boiling point liquids are configured to preferentially absorb one or more components of a process fluid stream introduced into the first fluid flow channel group.

45. The method according to claim 32, wherein the one or more high-boiling point liquids are configured to inactivate at least a portion of viruses, dust, mites, bacteria, pathogens, mold spores, or other biological contaminants from a process fluid stream introduced into a first fluid flow channel group.

46. The method according to claim 32, wherein multiple fluid flow channels extend through the length of the monoblock.

47. The plurality of fluid flow channels are about 20 inches ２ / inch ３ to about 200 inches ２ / inch ３ The method according to claim 32, having a surface area to volume ratio in the range of.

48. The method according to claim 32, wherein the channel wall has a pore volume in the range of about 0.1 mL / g to about 1.0 mL / g.

49. The method according to claim 32, wherein the first fluid flow channel group is under a higher pressure than the second fluid flow channel group.

50. The method according to claim 32, wherein the first fluid flow channel group is under positive gauge pressure and the second fluid flow channel group is under negative gauge pressure.

51. The method according to claim 32, wherein the second flow channel group is constricted at one end.

52. The method according to claim 32, wherein the first fluid flow channel group and the second fluid flow channel group are arranged in a repeating pattern.

53. The method according to claim 52, wherein the repeating pattern is selected from the group consisting of checkerboard patterns, offset checkerboard patterns, honeycomb patterns, four-leaf clover patterns, rectangle patterns, diamond patterns, triangle patterns, triangle and diamond patterns, and triangle and rectangle patterns.

54. The one or more high-boiling point liquids mentioned above are CO ２ The method according to claim 32, comprising one or more ionic liquids configured to preferentially absorb one or more fluid species selected from the group consisting of oxygen, water vapor, CO, SOx, NOx, helium, and formaldehyde.

55. Further comprising a device configured to isolate the discharge fluid stream, The method according to claim 32, wherein the device is fluidly connected to a second fluid flow channel group.

56. The method according to claim 32, having a separation efficiency of at least about 50%.

57. A method for manufacturing a header, (a) A step of preparing a monoblock made of a porous material, The monoblock has multiple fluid flow channels formed inside, These multiple fluid flow channels are separated by channel walls, The channel wall is porous and selectively permeable, and consists of steps. (b) A step of preparing a negative mold having fingers configured to align with a subset of fluid flow channels, (c) The step of inserting the fingers of the negative mold into a subset of multiple fluid flow channels, (d) The step of introducing a liquid material selected from the group consisting of polymers, soluble polymers, composite materials, waxes, and metals into the negative mold, (e) A step of curing the liquid polymer material, (f) A method comprising the step of removing the negative mold and establishing a header.

58. The method according to claim 57, wherein, in order to facilitate alignment, the negative mold fingers are inserted into a subset of fluid flow channels before the monoblock hardens.

59. The liquid material introduced into the negative mold enters multiple pores within the porous material of the monoblock. The liquid material is at least partially cured. The method according to claim 57, wherein the negative mold is removed and a header attached to the porous monoblock is generated by a liquid material entering multiple pores within the porous material of the monoblock.

Images