Parallel flow channel contactor with active layer

Abstract

The present technology relates generally to parallel flow path contactors having active layers and methods of use thereof. In particular, the present technology relates to parallel flow path contactors having active layers containing sorbents and / or catalysts and methods of use in sorptive gas separations and / or catalytic reactions.

Description

Technical Field

[0001] The embodiments disclosed herein generally relate to parallel flow path contactors, and more specifically, to parallel flow path contactors having an active layer containing an adsorbent and / or a catalyst, and to methods of using the same in adsorptive gas separation and / or catalytic reactions.

Background Art

[0002] Adsorptive gas separation techniques can be used to separate one or more components from a multi-component fluid mixture. Exemplary applications can include the separation of carbon dioxide components from various fluids, such as air streams, combustion gas streams, or process streams, all of which are for reducing the amount of carbon dioxide released into the atmosphere and / or for supplying carbon dioxide for use in further downstream processes or downstream products.

[0003] It can be advantageous to use an adsorptive gas separator with low pressure drop or fluid resistance across the separator as a whole. In some applications, one or more fluid streams, such as a feed gas stream, a regeneration fluid stream, or a conditioning fluid stream, may be available at a low pressure, e.g., up to about 1 bar above ambient pressure. In other examples, the cost associated with any one pressure increase of the fluid stream passing through the separator can be expensive or prohibitively high. In some applications, a short contact time between the fluid and the adsorbent is desirable to agglomerate or remove diluent components from the feed gas stream.

[0004] Adsorptive gas separators having a stationary solid adsorbent are typically composed of a packed adsorbent bed or a parallel flow path contactor. Parallel flow path contactors typically have a lower pressure drop compared to packed adsorbent beds and are thus more suitable for applications where the pressure of the fluid stream supply is limited or the contact time is short (typically less than 1 second).

[0005] A parallel flow contactor may have one or more adsorbents in the form of an active layer or multiple active layers or sheets within and / or on an adsorbent support structure, such as a monolith or layered support.

[0006] Monoliths are typically made from ceramic materials and have a high heat capacity, which can be undesirable for adsorption gas separation processes where rapid temperature fluctuations, such as adsorption-desorption cycles of less than 5 minutes, are desired. Furthermore, monoliths are typically manufactured by extruding slurries through molds with tight tolerances, and the production of large monoliths suitable for handling large volumes of gas can be difficult or expensive.

[0007] Structured adsorbents made from multilayer active layers or multiple active layers or sheets of adsorbent material have been studied as parallel flow contactors in several applications. An early example is provided in U.S. Patent No. 4,234,326, in which the structure of a parallel flow filter consists of alternating layers of charcoal cloth and permeable gaps. Further development of layered structured adsorbents for hydrogen purification using rapid PSA (pressure swing adsorption) is described in several patents, including U.S. Patents No. 5,082,473; 6,451,095; and 6,692,626, which describe equilibrium-controlled PSA processes that can be enhanced by configuring the adsorbent as a layered adsorbent laminate active layer or sheet parallel flow contactor structure, wherein the adsorbent is formed into an adsorbent active layer or multiple active layers, and includes or does not include appropriate reinforcing material incorporated into such active layers or multiple active layers. The specific advantages of the kinetic selectivity of these structures, where a pore adsorbent is used with an adsorbent active layer, active layer, or sheet, are discussed in detail in U.S. Patent No. 7,645,324.

[0008] A contactor may consist of multiple supports stacked or layered on top of each other, separated by spacers to maintain distance and flow paths. In high-speed swing processes where the use of parallel flow path contactors with low heat capacity is desirable, the supports may be manufactured from a material with low heat capacity and a thin active layer or active layer or sheet.

[0009] U.S. Patent No. 6,406,523 discloses a high-surface-area parallel-flow channel adsorbent suitable for high-frequency operation. The adsorbent comprises a lamination of thin active layers or sheets for supporting an adsorbent, together with spacers for establishing flow channels between each of the active layers. The adsorbent active layer comprises an adsorbent bonded to a reinforcing material that can be anodized, such as a mineral fiber matrix (e.g., a glass fiber matrix), a metal wire matrix (e.g., a wire mesh screen), or a metal foil (e.g., aluminum foil). Examples of glass fiber matrices include woven fabrics and nonwoven glass fiber scrims. Spacers are provided by printing or embossing a raised pattern onto each of the adsorbent active sheets, or by placing formed spacers between adjacent pairs of adsorbent active layers.

[0010] U.S. Patent Application Publication 2002 / 0170436 A1 discloses an adsorbent laminate, a method for manufacturing an adsorbent laminate, a spacer, and dimensions of an adsorbent structure. A typical disclosed adsorbent laminate has a flow channel length of about 1 centimeter to about 1 meter, a channel gap height of 50 to 250 microns, and an adsorbent coating thickness of 50 to 300 microns on one or both sides of the active layer. The added thickness of the adsorbent or other material (e.g., desiccant, catalyst, etc.) applied to the substrate is typically in the range of about 10 micrometers to about 500 micrometers.

[0011] U.S. Patent Application Publication 2002 / 0170436A1 also discloses adsorbent sheets with a thickness in the range of about 50 to about 400 micrometers, channel heights between adjacent adsorbent sheets in the range of about 25% to about 200% of the adsorbent sheet thickness, spacers having a thickness or height of about 10 to 250 micrometers, and spacer widths or diameters in the range of millimeters, for example, about 1 to 10 millimeters.

[0012] U.S. Patent Application Publication 2004 / 0118287A1 discloses a parallel flow channel contactor component including an adsorbent sheet, each sheet measuring 200-2500 m 2 / cm 3 It has a sheet surface area to total sheet volume ratio in the range of 50 to 1000 micrometers and a sheet thickness in the range of 50 to 1000 micrometers.

[0013] The use of conventional parallel flow contactors for separating, for example, less than approximately 20% by volume of diluted components from large gas flows has been limited due to costs exceeding the desired capital and operating costs. Spacers used to maintain separation between support structures, sheets, or active layers can increase the mechanical strength of the parallel flow contactor, but they can also increase the pressure drop of the entire contactor. Increasing the thickness of the support structures or active layers can increase the mechanical strength of the parallel flow contactor, but it may unduly increase the heat capacity and volume of the contactor.

[0014] There is a need for a novel parallel flow channel contactor that enables mass production of large-scale contactors while exhibiting low pressure drop, low heat capacity, and high mechanical strength. [Prior art documents] [Patent Documents]

[0015] [Patent Document 1] U.S. Patent No. 4,234,326 [Patent Document 2] U.S. Patent No. 5,082,473 [Patent Document 3] U.S. Patent No. 6,451,095 [Patent Document 4] U.S. Patent No. 6,692,626 [Patent Document 5] U.S. Patent No. 7,645,324 [Patent Document 6] U.S. Patent No. 6,406,523 [Patent Document 7] U.S. Patent Application Publication No. 2002 / 0170436A1 [Patent Document 8] U.S. Patent Application Publication No. 2004 / 0118287A1 [Overview of the project]

[0016] Embodiments of a stacked parallel flow channel contactor structure may comprise multiple active layers stacked on top of each other, each having an adsorbent on top, and each of the multiple active layers being separated by a spacer.

[0017] In a broad embodiment, a parallel flow contactor comprises a plurality of active layers stacked on top of each other, and a plurality of spacers positioned on the surface of each of the plurality of active layers to form channels between two adjacent stacked active layers, thereby forming a plurality of channels for fluid to pass through the contactor. In an embodiment, each channel defines a channel length, a channel width, and a channel height, the ratio of channel length to channel height between each of the plurality of active layers is 100 to 10,000, and the ratio of channel width to channel height between each of the plurality of active layers is 50 to 10,000.

[0018] In other broad embodiments, the stack for use in parallel flow contactors consists of multiple active layers stacked on top of one another; It comprises a plurality of spacers positioned on the surface of each of the plurality of layers to form a channel between two adjacent stacked active layers, and to form a plurality of channels for the fluid to pass through the contactor, Each channel is defined by its channel length, channel width, and channel height. The stack has a permeability value of 2,000 to 40,000 darcies under laminar flow conditions or with an average Reynolds number of less than 1,000, and the flow resistance of the stack caused by the plurality of spacers is 20% or less of the total flow resistance of the stack.

Brief Description of the Drawings

[0019] [Figure 1a] A side perspective view of an embodiment of the present invention, showing an active layer having an arrangement of cylindrical spacers disposed on the upper surface of the active layer. [Figure 1b] A side view of an embodiment of the present invention, showing the alignment of a plurality of active layers according to FIG. 1a and the spacers between each of the plurality of active layers. [Figure 2] A perspective view of an embodiment of the present invention, showing a stack having a plurality of active layers and a plurality of channels. [Figure 3] A perspective view of an embodiment of the present invention, showing a stack of active layers that are separated from each other and define high channels and low channels. [Figure 4a] A top view of an embodiment of the present invention, showing an active layer having rectangular-shaped spacers. [Figure 4b] A top view of a first active layer having rectangular-shaped spacers (according to FIG. 4a) and the spacers of a second active layer superimposed on the spacers of the first active layer. [Figure 4c] A perspective view of an embodiment of the present invention, showing an active layer and spacers according to FIG. 4b. [Figure 5a] A photograph of an embodiment of the present invention, showing an active layer having spacers with circular or dot outlines or shapes printed on an adsorbent sheet. [Figure 5b] A photograph of an embodiment of the present invention, showing a plurality of adsorbent sheets and spacers printed on the adsorbent sheets. [Figure 6a] A photograph of an embodiment of the present invention, showing an active layer having spacers printed on an adsorbent sheet and having a rectangular shape. [Figure 6b]This is a photograph of one embodiment of the present invention, showing multiple adsorbent sheets or active layers, each of which has a rectangular spacer printed on the adsorbent sheet. [Figure 7] This graph shows a plot of pressure drop measured across one embodiment of the present invention, which has a channel length of 1 meter. [Figure 8] This graph shows a plot of the decrease in channel height with respect to compression pressure applied perpendicular to the plane of the active layer of the stack. [Figure 9] This is a process flow diagram of one embodiment of the present invention, illustrating an sorbent gas separation process for separating a first component from a multi-component gas flow using the stack and parallel flow contactor of the embodiment. [Figure 10] This is a process flow diagram of one embodiment of the present invention, illustrating a catalytic sorption process for catalytic action of at least a first component from a fluid flow, using the stack and parallel flow path contactor of the embodiment. [Modes for carrying out the invention]

[0020] Definition: Substrate: A material for supporting one or more active compounds, such as sorbents, adsorbents, absorbents, and catalysts. The substrate may be in the form of a sheet. Active layer or solid layer: A thin slate, layer, sheet, or composite laminate of porous material containing a porous material having a chemical affinity for specific molecules, atoms, or ions. In embodiments, the active layer can be used instead of an adsorbent layer, a heterogeneous catalyst layer, or a combination of adsorbent and heterogeneous catalytic functional layers. Sheet or laminate: An active layer having a thickness of less than 1 mm. In the embodiment, the sheet can be used as an adsorbent sheet, a heterogeneous catalyst sheet, or a combination of adsorption and heterogeneous functional sheets. Active stack: Multiple active layers separated by multiple spacers between each active layer. In embodiments, the spacers may be arranged in at least a portion of the plane of the active layers. In embodiments, the active stack can be used instead of an adsorbent stack, a heterogeneous catalytic stack, or a combination of adsorbent and heterogeneous catalytic stacks. Active contactor: One or more interconnected active stacks that allow a fluid to pass through and come into contact with an active layer. Adsorbent module or module: An active contactor having packing for restricting the flow of process fluid in directions other than inlet to outlet. In embodiments, the adsorbent module allows for the installation of connectors or mounting mechanisms for integration into a reactor or adsorption vessel and optionally provides a mechanical support and pressure-resistant envelope for the contactor. In embodiments, the module may have either or both an adsorbent and / or a catalyst on it. Active elements: Multiple active layers separated by multiple spacers on at least a portion of the plane of the active layer, where the active layers define multiple channels, and the channels may have the same or different channel heights. In embodiments, one or more active elements can be combined to form an active stack. Spacer: A discreet, millimeter-scale solid placed between active layers to provide mechanical support to a stack or contactor. Heat capacity: The ratio of the amount of energy required to raise the temperature of a component, such as a physical part of a contactor, to a specific temperature, before and after energy is added. Channel: A flow path or void within a contactor through which one or more process flows pass. Channel height: The perpendicular distance between active layers, measured from the nearest wet surface of the active layer. Channel length: The distance between the inlet and outlet ends of a channel. Channel width: The distance between the housings of a contactor in a flow barrier, for example, in a direction perpendicular to the intended process flow direction and coplanar with the active layer. To be placed: To be placed on or within a material. Permeability: The ratio of kinematic viscosity to fluid velocity and pressure head loss per unit length (or β).

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[0021] <Overall Geometry> Generally, those skilled in the art often describe adsorption contactors using two descriptors to describe their structure: 1) the ratio of channel length (from feed inlet to product outlet) to channel height; and 2) the ratio of channel width to channel height.

[0022] The definition of channel length in relation to channel height is based on practical considerations, such as enabling high recovery or transformation of target molecules or atoms separated from the fluid source while maximizing the utilization of the active ingredient.

[0023] Furthermore, the geometry of contactors with short channels and large inlet surface areas requires containers with large distributor and collector volumes to connect to standard piping. This is undesirable, especially in rapid cycle separation and adsorption applications.

[0024] Since most physical realizations of multi-channel contactors are formed by corrugation or extrusion, the channel width-to-channel height ratio in contactor designs known in the art is typically significantly smaller than 50.

[0025] Referring to Figures 1a and 1b, in the embodiment, the structure of the adsorbent contactor generally comprises a plurality of active layers 101 stacked on top of each other in parallel. Each of the active layers or adsorbent sheets is separated from each other by a plurality of spacers 102, and the plurality of spacers 102 between each active layer 101 define or form fluid passages or channels between each of the adsorbent sheets 101. Each of the active layers 101 or adsorbent sheets or laminates can be arranged periodically with open spaces between the solid active layers 101 or sheets.

[0026] More specifically, Figures 1a and 1b show examples of active layers 101 having an array or multiple spacers 102 on the upper surface of the active layer 101. As shown in Figure 1b, a set of three active layers 101, 101, 101 can be assembled into an active stack. As shown, in the embodiment, multiple spacers 102 between each of the active layers 101 can be arranged in a specific spatial relationship, resulting in the multiple spacers 102 being oriented perpendicularly to each other. In other embodiments, the multiple spacers 101 may be in a different spatial arrangement than that shown or illustrated in Figure 1b.

[0027] Referring to Figure 2, embodiments of the present invention may have a contactor 200 having a channel length 202 that is at least 100 times greater than the channel height 204, and a channel width 203 that is at least 50 times greater than the channel height 204. This is equivalent to embodiments of the present invention in which the ratio of channel length to channel height is in the range of 100 to 15,000 and the ratio of channel width to channel height is in the range of 50 to 10,000. The applicants note that in preferred embodiments, the ratio of channel length to channel height is in the range of 100 to 10,000 and the ratio of channel width to channel height is in the range of 50 to 7,000.

[0028] More specifically, Figure 2 shows an active element, contactor, or stack 200, in which multiple active layers 201 are stacked or arranged on top of each other. Each active layer 201, together with adjacent active layers 201, defines or forms a flow channel 206 between them. As shown, the multiple flow channels 206 are formed by the multiple active layers 201 in the contactor 200.

[0029] With respect to the flow direction 205 of the process fluid, the channel length 202 can be defined as the distance between the inlet and outlet surfaces of the active layer 201 or the distance between the inlet end and the outlet end. As shown in the figure, the channel length 202 may be the entire length of the active layer.

[0030] The channel width 203 can be defined in a direction substantially perpendicular to the flow direction 205. The channel width may be coplanar with the active layer 201 from end to end. As shown in the figures, and in the embodiments, the channel width 203 is approximately the same as the width of the active layer 201 because fluid movement, diffusion of components of the process fluid flowing through it, or pressure equilibrium are not limited to the vertical direction.

[0031] The channel height 204 can be defined as the distance measured between adjacent wet surfaces of the active layer in the longitudinal direction perpendicular to the plane of the active layer. Using specific ratios of these quantities, a desirable geometry for a stack or contactor with a high surface area and a small pressure drop between the inlet and outlet surfaces can be described.

[0032] The spacers 102 disclosed herein may be inconspicuous, millimeter-scale solid objects separated by a distance of at least 10 channel heights measured from center to center in a direction parallel to the plane of the supporting active layer or sheet, and arranged periodically. In embodiments, the spacer distance between each spacer, measured from center to center, can be in the range of 10 to 90 times the channel height. The contactor 200 may have a coarse periodic spacer distribution arranged in a periodic arrangement with respect to at least some portions of the contactor 200.

[0033] As disclosed above, conventional adsorption contactors comprise parallel active layers with spacers between each of the active layers. Embodiments of the present invention rely on spacers, and as a result, more than 92% of the volume of the channels between each active layer is open and available for the flow and passage of fluid.

[0034] Referring back to Figure 2, in this embodiment, the channel height 204 can be in the range of 0.1 mm to 2.0 mm.

[0035] In the embodiment, the ratio of the channel volume to the entire sorbent stack of the structure is in the range of 15% to 70%.

[0036] In some embodiments, the surface area relative to the volume ratio of the wet active layer or sheet (both sides of each active layer or sheet) is 1000 m². 2 / m 3 ~8000m 2 / m 3 It may also be within that range.

[0037] In the embodiment, the adsorbent active layer or sheet stack length may be in the range of 50 mm to 2000 mm (flow length).

[0038] As shown in Figures 5a and 5b, an adsorbent sheet or active layer may have multiple spacers printed thereon. Referring particularly to Figure 5b, a stack may comprise multiple adsorbent sheets stacked on top of each other, along with multiple spacers that separate each active layer from one another and form channels that allow fluid to flow between adjacent stacked active layers.

[0039] As shown, the multiple spacers shown in Figures 5a and 5b can have a dot shape or contour and can be separated from each other by a spacer distance of approximately 18 mm. The active layer has a thickness of approximately 0.4 mm, as shown in Figures 5a and 5b. Hundreds of adsorbent sheets can be stacked while maintaining vertical indexing, as indicated by the vertical rows of dots visible from the stacking edge.

[0040] In embodiments, the contactor, stack, or active layer can be oriented in any direction with respect to the gravity vector. However, in embodiments, coplanar orientation perpendicular to the active layer or multiple active layers or sheets is desirable to allow for easier removal of liquid condensates in gas separation applications.

[0041] <Characteristics of the adsorbent active layer> In embodiments, each adsorbent active layer may be a composite active layer made of fibers, a binder, and an active adsorbent solid. These active layers may also be made from a porous polymer, with or without any reinforcing binder or fibers. In embodiments, a feature of such embodiments is that they have at least 80% by weight of adsorbent solid components.

[0042] An sorbent contactor used in the context of a thermal swing adsorption process or partial pressure swing adsorption process having a large temperature swing (at least 10°C) during adsorption or desorption may have one or more active components, such as an adsorbent and / or a catalyst, where the heat capacity of one or more active components is greater than the heat capacity of the substrate.

[0043] In some embodiments, the adsorbent of the present invention may have a heat capacity exceeding 75% of the heat capacity associated with the adsorbed active component, or the combined heat capacity of the active component and the substrate. A decrease in the heat capacity of the substrate and / or the overall heat capacity of the contactor in relation to the addition of the active component allows for a rapid thermal response to endothermic or exothermic processes occurring within the contactor.

[0044] In embodiments, the contactor structure of the present invention may have a heat capacity exceeding 75% of the heat capacity associated with the active component, or the combined heat capacity of the active component, substrate, and spacer element. A decrease in the heat capacity of the substrate and / or the overall heat capacity of the contactor in relation to the filling of its active component allows for a rapid thermal response to endothermic or exothermic processes occurring within the contactor.

[0045] In embodiments, the active layer may be strong enough to be manipulated and processed. A porous substrate impregnated with slurry can be heated in an oven, rolled on a receiving roll, transferred to a rotary screen printing tool, printed with spacer dots or lines, cut, and laminated. In one embodiment, the active layer can be produced by impregnating a porous web or sheet with an adsorbent suspended in a liquid or slurry of adsorbent. Excess slurry can be removed by known methods, and the impregnated sheet can be dried using conventional means. Each dried sheet can then have multiple spacers printed, deposited, or otherwise arranged on it. In some embodiments, a stencil can be used to apply a spacer ink, which can be cured by heat or UV treatment, to a dried sheet to form the active layer. After the printed spacers have cured, the active layer is cut to size and then stacked vertically on top of each other and indexed to obtain vertical alignment of the spacers in each active layer. In embodiments, the stencil can provide the shape of the printed spacers, which may be dots or circular shapes, or rectangular or elongated shapes.

[0046] The resulting active layer may have a tensile strength of more than 1 N / mm, more preferably 2 N / mm, and even more preferably 4 N / mm.

[0047] In the embodiment, the thickness of the adsorbent active layer or sheet may vary in the range of 100 micrometers to 1000 micrometers.

[0048] [Flow Resistance Characteristics] In some embodiments, the permeability of the structured adsorbent of the present invention may be in the range of 2,000 to 40,000 darcy for flows corresponding to laminar flow or having a Reynolds number of less than 1,000.

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[0049] The height of the spacer in the structure can be selected after the thickness of the active layer or sheet is fixed, based on the kinetics required for adsorption to achieve the high penetration rates within the specific range described above. In some embodiments, the advantage of a small wetting area of ​​the spacer is that it results in less than 20%, or preferably less than 10%, of the total flow resistance of the contactor, related to the viscous flow resistance of the surface of these spacers.

[0050] <Space-relationship design for spacer printing and stacking for reduced pressure drop and mechanical strength> In embodiments, active layers having an adsorbent solid or liquid component impregnated or placed on top can be assembled into a stack of active layers. The stacking of multiple active layers creates multiple gas flow channels between two adjacent stacked active layers, which can be maintained by arranging or installing a periodic arrangement of multiple spacers between two adjacent stacked active layers. The multiple spacers can be arranged or printed on at least a portion of one side (or top surface) of each active layer. In embodiments, the spacer protrusion area or the area of ​​the top surface of the active layer covered by the spacers may be about 1% to about 20%, or preferably about 1% to about 10%, of the flat surface area of ​​the top surface of the active layer.

[0051] Furthermore, the active layers or sheets can be stacked in such a way that the arrangement of multiple spacers can be substantially aligned from the active layer to adjacently stacked active layers. Such an arrangement allows the contactor to transfer the mechanical load applied perpendicular to the active layer throughout the entire contactor or stack, and can avoid partial collapse of any of the flow channels formed between adjacently stacked active layers when pressure is applied to the stack.

[0052] In one embodiment, the mechanical rigidity of the stack perpendicular to the adsorbent active layer can be obtained by overlapping at least 10%, preferably 30%, and more preferably 50% of the spacer protrusion regions of each active layer when adjacent active layer spacer contours protrude perpendicular to the active layer or sheet.

[0053] In other embodiments, spacers of different sizes and shapes can be used in combination to provide both control over the spacing between active layers and resistance to compressive loads in the stack. Smaller spacers do not need to be precisely aligned from one active layer to another, as long as the proportion of overlap of the larger spacers supporting the compressive load along the axis perpendicular to the active layer or sheet of their protrusions is sufficiently large.

[0054] In other embodiments, adhesive can be applied to the top and / or optionally the bottom of the spacers before stacking to further enhance the mechanical rigidity of the stack and its resistance to deformation in any direction. This further improves the mechanical rigidity of the stack and its resistance to deformation. In further embodiments, adhesive can be applied to more than 20% of the spacers to enhance mechanical rigidity and resistance to deformation.

[0055] In one embodiment, referring to Figures 4a to 4c, the elongated spacers may have overlapping portions that straddle each other, along with non-overlapping portions on both sides of the stress-transmitting surface (overlapping projections tangentially to the active layer or sheet). In such embodiments, the long axes of the elongated spacers may be oriented or directed in different directions so as to be orthogonal between the spacers, preferably through a thin adsorbent active layer or sheet, in mechanical or physical contact.

[0056] Preferably, spacers oriented differently can be arranged, printed, or deposited in a single periodic pattern, and offsets from active layer to active layer or sheet can be used to enable the use of a single pattern for constructing the stack.

[0057] As shown in Figure 4a, the active layer 401 may have elongated or rectangular spacers 402 deposited or printed on it. Referring to Figure 4b, a subsequent active layer 401 having spacers 403 oriented in different directions may be placed on the spacers 401 shown in Figure 4a. The applicant notes that, for ease of understanding and reference, the subsequent active layer 401 has been intentionally omitted to make the overlapping area of ​​spacers 402 and subsequent active layer 403 shown in Figure 4a more visible.

[0058] More specifically, as shown in Figures 4b and 4c, the active layer 401 and the two periodic arrangements of spacers 402 and 403 have significant overlapping regions along with non-overlapping regions spanning each mechanical contact point. Figure 4c provides a perspective view of the active layer 401, spacers 402 and 403 rotated to show the spatial relationship between the spacers in different orientations. The aspect ratio of the rectangular spacers, defined in a plane parallel to the active layer, between their length (or major axis) and width, may preferably be 2 to 6.

[0059] As shown, referring to Figures 6a and 6b, the active layer may have multiple spacers printed on the active layer, which are rectangular or elongated in shape. In such embodiments, the spacers may be made of a thermocurable silica-filled epoxy resin. More specifically, as shown in Figure 6b, the stack may have channels spaced about 1 mm apart after the active layers have been stacked. The applicant notes that spacers having a rectangular shape are more tolerant of positioning errors in stacking the sheets than spacers having a cylindrical shape.

[0060] The advantages of this arrangement include minimizing the possibility of the active layers shifting relative to each other by generating an interlocking function when pressure is applied to the stack in a direction perpendicular to the active layer or sheet plane.

[0061] In the embodiment, a simple stacking of adsorbent active layers using a uniform periodic arrangement of the active layers provides a contactor with a channel height distribution having a coefficient of variation (standard deviation / mean) in the range of 1% to 15%. This distribution affects the fluid flow distribution within the stack and the average adsorbent saturation at the end of the adsorption process, which may be important for high recovery applications. For adsorption separation applications where the capture efficiency target exceeds 90%, this feature may be a design requirement.

[0062] The surface spacer cover density of each of the multiple spacers can be distributed uniformly across various zones or set to be different.

[0063] In embodiments, areas of printed spacers may have different coverage densities compared to other areas of the active layer. In one embodiment, the spacer cover density can be 20% to 200% higher than the coverage density in the middle of the stack near the gas inlet, outlet, or sides of the stack, for example, in the first and last 10% of the layer length in the direction of flow.

[0064] In extreme cases, areas without spacers can be combined with areas with spacers on the same active layer, provided that other methods for maintaining the spacing between adjacent stacked active layers are also adapted. In one embodiment, one such adaptation may be to apply a tensile load or force to the stack (or each active layer) in at least one direction within the plane of the stack, e.g., substantially parallel to the plane of the stack (or each active layer), to prevent bending of the unsupported stack (or each active layer). This strategy can be used for frame plate changers on individual active layers. In embodiments, a combination of spacers for setting the channel geometry near the edges of the active layers, including framing and positioning the stack under tension, is a combination of contactor layers of a structure that is more advantageous than current techniques used in structured adsorbent contactors. For example, a frame or housing made of a material with desired rigidity, e.g., metal or plastic, can be mounted around the active layer or a stack of active layers, while the active layer is subjected to a tensile load substantially along the plane of the active layer.

[0065] Combining framing with placing the stack under tension allows for fine-tuning of the mechanical properties of the adsorption layer in response to stresses in specific regions. The inlets, outlets, and edges of a freestanding or untensioned stack are more prone to cracking than the middle of the active layer due to the non-uniform gas velocity distribution. Framing and tensioning the stack results in a more uniform gas velocity distribution throughout the channel, making it less likely for cracks to develop around or near the edges of each active layer.

[0066] For commercial applications, at least 20 active layers can be stacked together with multiple spacers that are controlledly positioned on adjacent stacked active layers to form a stack. The assembled stacks can be cut and further stacked on top of each other to form modules of various shapes having at least one adsorbent and / or catalyst. In modules with at least one adsorbent and / or catalyst, only a small portion of the channels in the complete assembly exhibits stack irregularity, so it is not necessary to control the relative positioning of the multiple spacers between the stacks.

[0067] <Composite stacking and multi-stack deployment> In embodiments, the simplest lamination of adsorbent active layers is to use a uniform periodic arrangement of an active layer or multiple active layers or sheets using a constant channel height as described above. However, other strategies can be used, taking into account the maintenance of a periodic design along with a predictable distribution of fluid flow through the contactor.

[0068] In the embodiment, two different channel heights are used between adjacent stacked active layers and may be periodically repeated. In such an embodiment, the channel with the larger channel height can drive the majority of the process flow (2 to 50 times the flow in the narrow channel), while the channel with the smaller channel height can be used to improve the uniformity of the sorbent packing and the adsorption / desorption kinetics of the target adsorbate.

[0069] Referring to Figure 3, the stack may have adjacently stacked active layers defining two different channel heights. As shown, the active layers 301 may be arranged in pairs such that alternating pairs result in two different channel heights 302, 303. As shown, in one embodiment, two adjacently stacked active layers can be joined to define a pair of active layers having channel height 303, and two pairs of adjacently stacked active layers can be separated by channel height 302. As shown, channel height 302 can be greater than channel height 303.

[0070] The advantage of this periodic lamination of two different active layers or multiple active layers or sheets is that it always reduces the overall porosity of the layers while maintaining or increasing the permeability at a constant layer porosity. In one embodiment, the low channel height is within the range of 10% to 70% of the high channel height. Table 1 shows the advantages of pressure drop for a constant layer porosity at a face velocity of 2 m / s.

[0071] Table 1 shows calculated estimates and comparisons of relative pressure drops across stacks with repeating elements, each having channels A and B, and configured such that both Example Set 1 and Example Set 2 have the same or constant porosity and the same or varying channel heights. The pressure drop reduction was calculated for a flow rate or face velocity of 2 m / s through the stack and for a stack with an active layer of 0.254 mm thickness. [Table 1]

[0072] The pressure drop characteristics test of the stack shown in Figure 5b was performed after a portion of the stack was enclosed in a case or framed on all four sides to guide the gas flow through the stack along its longitudinal axis. The gas flow rate was recorded by a mass flow meter, converted to empty velocity, and plotted against the measured pressure drop recorded by a pressure transducer. The obtained data is shown as plot 703 in Figure 7. The calculated Darcy permeability for this stack is approximately 10,400.

[0073] Referring to Figure 7, a plot 703 of the pressure drop measured overall or between the inlet and outlet of the stack is shown. The y-axis 701 of the graph measures the pressure drop in kilopascals (kPa), and the x-axis 702 of the graph measures the void velocity of the nitrogen flow passing through the channels of the stack in meters / second. The stack has a channel length of approximately 1 m and a stacked active layer, the active layer having cylindrical spacers protruding in area of ​​approximately 2% along its plane. The pressure drop measurements were performed by flowing nitrogen at ambient temperature and pressurizing it at the void velocity of the nitrogen. The stack further has channels with a height of approximately 0.5 mm and a channel porosity of 60%.

[0074] Referring particularly to Figure 8, a plot of channel height reduction with respect to the compressive pressure applied to the stack is shown. The y-axis 801 of the graph measures the compressive pressure in kilopascals (kPa) applied perpendicular to the plane of the active layer of the stack. The x-axis 802 of the graph measures the percentage of channel height reduction. A stack consisting of 20 active layers and spacers printed on the active layers and aligned perpendicular to the plane of the active layers was used. Forces of 15kPa to 6kPa were applied for 500 cycles to determine the plots. Plots 803 and 804 show the deformation of the channels in the elastic deformation range of up to 3% channel height reduction. The difference between plots 803 and 804 of the displacement-force plots arises from the direction of movement such that some hysteresis (delay or lag) is observed.

[0075] <Mechanical properties of adsorbent stacks> In this embodiment, the channel height of the sorbent in the structure retains 96% or more of its value under a load of 5 kPa applied perpendicularly to the stack.

[0076] In a first broad embodiment, the parallel flow contactor comprises a plurality of active layers stacked on top of each other, and a plurality of spacers positioned or deposited on the surface of each of the plurality of layers to form channels between two adjacent stacked active layers, thereby forming a plurality of channels for fluid to pass through the contactor. Each channel may be defined by channel length, channel width, and channel height, the ratio of the channel length to the channel height of the channel fluid passage between each of the plurality of active layers is 100 to 10,000, the ratio of the channel width to the channel height of each channel fluid passage between the plurality of active layers is 50 to 10,000, and the spacer protrusion region of each active layer in the direction perpendicular to the plane of each active layer is 1% to 20% of the total surface area of ​​each active layer.

[0077] In other embodiments, the contactor of the first embodiment may further have a penetration value of 2,000 to 40,000 darcy under laminar flow conditions or an average Reynolds number of less than 1,000, and the flow resistance of the stack resulting from the plurality of spacers is 20% or less of the total flow resistance of the stack.

[0078] In other embodiments, the contactor of the first embodiment may have a substrate having a heat capacity smaller than the heat capacity of the adsorbent active ingredient impregnated or placed on it.

[0079] In other embodiments, the contactor of the first embodiment may further include a spacer distance in the range of 10 to 90 times the channel height.

[0080] In other embodiments, the multiple spacers of the first embodiment can be configured in a periodic arrangement within a planar region of the active layer.

[0081] In other embodiments, the plurality of spacers of the first embodiment may comprise a first spacer having a first size and a first shape, and a second spacer having a second size and a second shape, wherein at least one of the following is true: the first size is different from the second size, and the first shape is different from the second shape.

[0082] In other embodiments, each of the multiple spacers of the first embodiment may have an elongated shape having an aspect ratio of 2 to 6.

[0083] In other embodiments, the spacer protrusion region of the active layer in the first embodiment may overlap by at least 10% with the spacer protrusion region of another active layer among the multiple active layers.

[0084] In other embodiments, multiple spacers can be arranged or deposited on the surface of each of the multiple spacers having a certain spacer cover density. In one embodiment, the spacer cover density of spacers in one region can be 20% to 200% higher than the spacer cover density of another region.

[0085] In other embodiments, the contactor of the first embodiment may further include means for applying tensile force to the active layer or the plurality of active layers in a direction substantially parallel to the plane of the active layer or the plurality of active layers.

[0086] In other embodiments, each of the multiple spacers of the first embodiment may further comprise an adhesive applied thereon.

[0087] In other embodiments, the plurality of active layers of the first embodiment may further comprise a first active layer adjacent to a second active layer, the first active region having the first plurality of spacers having an elongated shape and forming a first spacer protrusion region perpendicular to the first active layer, the second active region having the second plurality of spacers having an elongated shape and forming a second spacer protrusion region substantially perpendicular to the second active layer, the first spacer protrusion region and the second spacer protrusion region partially overlap, and the long axes of the spacers whose protrusion regions overlap are not collinear.

[0088] In other embodiments, the contactor of the first embodiment comprises at least 20 active layers.

[0089] In other embodiments, the channel of the first embodiment has a channel high coefficient of variation in the range of 1% to 15%.

[0090] In other embodiments, the multiple channels of the first embodiment further comprise two different channel heights, the difference between the channel heights being in the range of 10% to 70%.

[0091] In other embodiments, the contactor of the first embodiment can maintain more than 96% of its channel height when a load of 5 kPa is applied.

[0092] In a second broad embodiment, a stack for use in a parallel flow contactor comprises a plurality of active layers stacked on top of each other, and a plurality of spacers positioned or deposited on the surface of each of the plurality of layers to form channels between two adjacently stacked active layers to allow fluid to flow through the stack. In the embodiment, each channel may be defined by channel length, channel width, and channel height, the stack has a permeability value of 2,000 to 40,000 darcy under laminar flow conditions or an average Reynolds number of less than 1,000, and the flow resistance of the stack resulting from the plurality of spacers is 20% or less of the total flow resistance of the stack.

[0093] In other embodiments, the stack of the second embodiment may have a heat capacity smaller than the heat capacity of the adsorbent active component placed in and / or on the stack.

[0094] In other embodiments, the channel height of the stack in the second embodiment can maintain 96% or more of its channel height when a load of 5 kPa is applied.

[0095] <Acknowledgment gas separation process using a parallel flow contactor with an active layer> In embodiments, the contactor of the present invention can be used in an sorption process for separating a first component from a multi-component gas stream. Embodiments of a contactor or stack can be provided in which at least one sorbent can be placed in and / or on a substrate. In embodiments, the at least one sorbent is, for example, a desiccant, activated carbon, graphite, carbon molecular sieve, activated alumina, molecular sieve, aluminophosphate, silicoaluminophosphate, zeolite adsorbent, ion exchange zeolite, hydrophilic zeolite, hydrophobic zeolite, modified zeolite, natural zeolite, hojasite, clinoptilolite, mordenite, metal exchange silicoaluminophosphate, unipolar resin, dipolar resin, aromatic crosslinked polystyrene matrix, brominated aromatic matrix, methacrylate copolymer, carbon fiber, carbon nanotube, nanomaterial, This may include, but is not limited to, metal salt adsorbents, perchlorates, oxalates, alkaline earth metal particles, ETS, CTS, metal oxides, supported alkali carbonates, alkali-promoted hydrotalcite, chemical adsorbents, amines, organometallic reagents, metal-organic structure (MOF) adsorbents, polyethyleneimine-doped silica (PEIDS) adsorbents, amine-containing porous network polymer adsorbents, amine-doped porous material adsorbents, amine-doped MOF adsorbents, doped activated carbon, doped graphene, and alkali-doped or rare-earth-doped porous inorganic adsorbents.

[0096] Referring to Figure 9, the process embodiment provides an sorbation gas separation process 900 for sorbation gas separation of a multicomponent fluid mixture or flow comprising at least a first component (which may include, for example, carbon dioxide, sulfur oxides, nitrogen, oxygen, and / or heavy metals). In such an embodiment, the sorbation process 900 can separate at least a portion of the first component from the multicomponent fluid mixture or flow.

[0097] In one embodiment, a parallel flow contactor can be utilized, comprising a plurality of active layers stacked on top of each other, and a plurality of spacers positioned on the surface of each of the plurality of active layers to form channels between two adjacent stacked active layers, and a plurality of spacers to form a plurality of channels for the fluid to pass through the contactor. In an embodiment, each channel may have a channel length, a channel width, and a channel height, and the ratio of the channel length to the channel height of the channel between each of the plurality of active layers may be between 100 and 10,000. In a further embodiment, the ratio of the channel width to the channel height of each channel between the plurality of active layers may be between 50 and 10,000, and the plurality of spacers cover the spacer protrusion region of each active layer in a direction perpendicular to the plane of each active layer, and have a spacer cover density of 1% to 20% of the total surface area of ​​each active layer.

[0098] In other embodiments, a parallel flow contactor may be utilized, comprising a plurality of active layers stacked on top of each other, and a plurality of spacers positioned on the surface of each of the plurality of layers to form a plurality of channels to form channels between two adjacent stacked active layers, allowing fluid to flow through the stack, with each channel defined by channel length, channel width, and channel height. In embodiments, the contactor may have a permeability value of 2,000 to 40,000 darcy or an average Reynolds number of less than 1,000 under laminar flow conditions, and the flow resistance of the contactor resulting from the plurality of spacers may be less than 20% of the total flow resistance of the contactor.

[0099] Returning to Figure 9, an embodiment of the sorbation gas separation process 900 can provide a parallel flow contactor disclosed above, having at least one sorbent as an active material. The sorbation step 901 and the subsequent desorbing step 902 can be performed using such a parallel flow contactor, and the sorbation gas separation process 900 can be repeated as desired and optionally include additional steps (not shown in Figure 9).

[0100] As shown, during the sorbition process 901, a multi-component gas stream containing at least a first component, such as carbon dioxide, can be received as a feed stream into a parallel flow contactor or stack, and as the feed stream flows through the contactor, it comes into contact with at least one sorbent. As a result, at least a portion of the first component of the feed stream can be sorbed in and / or on the sorbent. Although not specifically shown, the remaining components that are not sorbed in and / or on the sorbent, such as a second component, such as nitrogen, can substantially pass through the contactor and form a first product stream. In embodiments, the first product stream may be depleted of the first component compared to the feed stream. In embodiments, the first product stream may also be concentrated with the second component compared to the feed stream. In embodiments, the first product stream may be recovered from the parallel flow contactor or stack.

[0101] During the desorption process 902, at least a portion of the first component sorbed in and / or on at least one sorbent can be desorbed by at least one of a temperature swing mechanism, a pressure swing mechanism, and a partial pressure swing mechanism to form a second product flow. In embodiments, the second product flow may be concentrated with the first component compared to the feed flow. The second product flow can be recovered from a parallel flow contactor or stack. Optionally, a vapor flow can be introduced into the parallel flow contactor or stack to desorb the first component. In embodiments, a vapor flow can be recovered from a vapor source and introduced into the contactor or stack to desorb the first component.

[0102] Catalytic process When in use, the contactor embodiment can be used in a catalytic process for catalytic action of at least a first component from a fluid flow.

[0103] In one embodiment, the catalytic process utilizes a parallel flow contactor comprising a plurality of active layers stacked on top of each other, and a plurality of spacers positioned on the surface of each of the plurality of layers to form channels between two adjacent stacked active layers, thereby forming a plurality of channels for the fluid to pass through the contactor. In the embodiment, each channel may be defined by channel length, channel width, and channel height, the channel length and channel height of the channels between each of the plurality of active layers being in a ratio of 100 to 10,000, and the channel width and channel height of each channel between the plurality of active layers being in a ratio of 50 to 10,000. In the embodiment, the plurality of spacers may form spacer protrusion regions of each active layer in a direction perpendicular to the plane of each active layer, and may have a spacer cover density of 1% to 20% of the total surface area of ​​each active layer.

[0104] In other embodiments, a parallel flow contactor can be utilized, comprising a plurality of active layers stacked on top of each other, and a plurality of spacers positioned on the surface of each of the plurality of layers to form channels between two adjacent stacked active layers, and a plurality of spacers to form a plurality of channels for the fluid to pass through the stack, each channel being defined by channel length, channel width and channel height. In embodiments, the contactor can have a permeability value of 2,000 to 40,000 darcy under laminar flow conditions or an average Reynolds number of less than 1,000, and the flow resistance of the contactor resulting from the plurality of spacers is less than 20% of the total flow resistance of the contactor.

[0105] In one embodiment of the catalytic process, the parallel flow channel contactor disclosed above may have at least one catalytic material as an active material.

[0106] In the process embodiment, a fluid flow having a first component flows into a parallel flow contactor or stack as a feed flow, where the feed flow and the first component come into contact with at least one catalytic material that catalyzes a reaction producing a second component. The second component can produce a first production flow, which can then be recovered from the parallel flow contactor or stack.

[0107] Catalyst sorption process In embodiments, the contactor disclosed herein can be used in a catalytic sorption process for catalytic action of at least a first component from a fluid flow. Embodiments of a contactor or stack can be provided in which at least one sorbent can be placed inside and / or on the contactor. In embodiments, the at least one sorbent is, for example, a desiccant, activated carbon, graphite, carbon molecular sieve, activated alumina, molecular sieve, aluminophosphate, silicoaluminophosphate, zeolite adsorbent, ion exchange zeolite, hydrophilic zeolite, hydrophobic zeolite, modified zeolite, natural zeolite, hojasite, clinoptilolite, mordenite, metal exchange silicoaluminophosphate, unipolar resin, dipolar resin, aromatic crosslinked polystyrene matrix, brominated aromatic matrix, methacrylate copolymer, carbon fiber, carbon nanotube, nanomaterial, This may include, but is not limited to, metal salt adsorbents, perchlorates, oxalates, alkaline earth metal particles, ETS, CTS, metal oxides, supported alkali carbonates, alkali-promoted hydrotalcite, chemical adsorbents, amines, organometallic reagents, metal-organic structure (MOF) adsorbents, polyethyleneimine-doped silica (PEIDS) adsorbents, amine-containing porous network polymer adsorbents, amine-doped porous material adsorbents, amine-doped MOF adsorbents, doped activated carbon, doped graphene, and alkali-doped or rare-earth-doped porous inorganic adsorbents.

[0108] Referring to Figure 10, an embodiment of the process provides a catalytic sorption process 1000 for catalytic action of at least a first component from a fluid flow.

[0109] In one such embodiment, the catalyst sorption process 1000 can catalyze a reaction that produces a second component.

[0110] In one embodiment, the catalyst sorption process may utilize a parallel flow contactor comprising a plurality of active layers stacked on top of each other, and a plurality of spacers positioned on the surface of each of the plurality of layers to form channels for fluid to pass through the contactor, with channels between two adjacent stacked active layers, and each channel defined by channel length, channel width, and channel height. In the embodiment, the channel length and channel height of the channels between each of the plurality of active layers may be in a ratio of 100 to 10,000, and the channel width and channel height of each channel between the plurality of active layers may be in a ratio of 50 to 10,000. In the embodiment, the plurality of spacers may form spacer protrusion regions on each active layer in a direction perpendicular to the plane of each active layer, and may have a spacer cover density of 1% to 20% of the total surface area of ​​each active layer.

[0111] In other embodiments, the catalyst sorption process may utilize a parallel flow contactor comprising multiple active layers stacked on top of each other, and multiple spacers positioned on the surface of each of the multiple layers to form channels between two adjacent stacked active layers, thereby forming multiple channels for the fluid to pass through the stack, each channel being defined by channel length, channel width, and channel height. In embodiments, the contactor may have a permeability value of 2,000 to 40,000 darcy under laminar flow conditions or an average Reynolds number of less than 1,000, and the flow resistance of the contactor resulting from the multiple spacers is less than or equal to 20% of the total flow resistance of the contactor.

[0112] In one embodiment of the catalyst sorption process, a parallel flow channel contactor disclosed herein and having at least one sorption material and at least one catalyst material as active materials disposed in and / or on the contactor can be carried out by using such a parallel flow channel contactor. The catalyst sorption process 1000 can be repeated as desired and may optionally include additional steps.

[0113] In one embodiment of the process, during the catalytic step 1001, a fluid flow having the first component can be introduced as a feed flow into a parallel flow contactor or stack and passed through it. In another embodiment, the feed flow and the first component can be in contact with at least one catalyst material capable of catalyzing a reaction that produces at least a second component.

[0114] Referring to Figure 10, during the sorption process 1002, at least one of at least a portion of the first component, at least a portion of the second component, and at least a portion of the third component is sorbed in and / or on at least one sorbent. In the embodiment, the first product flow, which includes the reaction products and / or components not sorbed in and / or on the contactor, can then be recovered from the parallel flow contactor or stack.

[0115] In the embodiment of the process, during the desorption step 1003, at least one of at least a portion of the first component and at least a portion of the third component may be desorbed from at least one sorbent in order to regenerate at least one sorbent. In the embodiment, a second generated flow comprising at least a portion of the first component, at least a portion of the second component, and at least a portion of the third component may be recovered from a parallel flow contactor or stack.

Claims

1. A parallel flow channel contactor, Multiple active layers stacked on top of each other; The device comprises a plurality of spacers arranged on the surface of each of the plurality of layers to form a channel between two adjacent stacked active layers, and to form a plurality of channels for the fluid to pass through the contactor, Each channel is defined by its channel length, channel width, and channel height. In the channels between each of the plurality of active layers, the ratio of the channel length to the channel height is 100 to 10,000. In the channels between the plurality of active layers, the ratio of the channel width to the channel height is 50 to 10,000. The spacer cover density between the area of ​​the spacer cover region on the plane of each active layer covered by the aforementioned plurality of spacers and the total surface area of ​​each active layer is 1% to 20%. The contactor is a parallel flow channel contactor having a permeability value of 2,000 to 40,000 darcy under laminar flow conditions.

2. The contactor according to claim 1, further comprising a penetration rate of 2,000 to 40,000 darcy under laminar flow conditions or an average Reynolds number of less than 1,000, wherein the flow resistance of the contactor generated by the plurality of spacers is 20% or less of the total flow resistance of the contactor.

3. The contactor according to claim 1 or 2, further comprising a base material having a heat capacity smaller than the heat capacity of an adsorbent active component disposed on the base material.

4. The contactor according to claim 1, 2, or 3, wherein the spacer distance between the spacers is within the range of 10 to 90 times the channel height.

5. The contactor according to any one of claims 1 to 4, wherein the plurality of spacers are arranged in a periodic arrangement within a planar region of the active layer.

6. The contactor according to any one of claims 1 to 5, wherein the plurality of spacers are of different sizes or shapes.

7. The contactor according to any one of claims 1 to 6, wherein each of the plurality of spacers has an elongated shape in which the aspect ratio of the length to the width of the spacer defined in a plane parallel to the active layer is 2 to 6.

8. The contactor according to any one of claims 1 to 7, wherein the spacer cover region of each of the plurality of active layers overlaps with the spacer cover region of another active layer of the plurality of active layers by at least 10% along an axis perpendicular to the active layer.

9. The contactor according to any one of claims 1 to 8, wherein the spacer cover density further comprises a plurality of spacer cover densities on the active layer.

10. The contactor according to claim 9, wherein the spacer cover density of a spacer in one region can be made 20% to 200% higher than the spacer cover density of a different region.

11. The contactor according to any one of claims 1 to 10, further comprising means for applying a tensile force to the active layer or the plurality of active layers in a direction parallel to the plane of the active layer or the plurality of active layers.

12. The contactor according to any one of claims 1 to 11, wherein each of the plurality of spacers may further comprise an adhesive applied thereon.

13. The contactor according to any one of claims 1 to 12, wherein the plurality of active layers further comprises a first active layer adjacent to a second active layer, the first active region has a first plurality of spacers having an elongated shape, and a first spacer cover region is formed on the first active layer covered by the first plurality of spacers, the second active region has a second plurality of spacers having an elongated shape, and a second spacer cover region is formed on the second active layer covered by the second plurality of spacers, the first spacer cover region and the second spacer cover region partially overlap along an axis perpendicular to the active layer, and the long axes of the spacers whose cover regions overlap are not on the same straight line.

14. The contactor according to any one of claims 1 to 13, wherein the plurality of active layers comprises at least 20 layers.

15. The contactor according to any one of claims 1 to 14, wherein the plurality of channels have a coefficient of variation of channel height in the range of 1% to 15%, and the coefficient of variation of channel height is based on the value obtained by dividing the standard deviation of the distribution of channel height by the mean.

16. The contactor according to any one of claims 1 to 15, wherein the plurality of channels further include two different channel heights, and the ratio of the lower channel height to the higher channel height is in the range of 10% to 70%.

17. The contactor according to any one of claims 1 to 16, wherein when a load of 5 kPa is applied, the channel height maintains 96% or more of the channel height.

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