High-throughput movable panel direct air recovery system

Abstract

A system and method for direct air capture are described. The system includes a plurality of adsorption panels movable in a linear direction (or circular configuration) and one or more fans configured to move air across the adsorption panels, such adsorption panels being orientable vertically or horizontally with respect to the ground. The system may include a stand-alone regeneration box including a system of headers, ducts, and valves configured to deliver and remove a plurality of gases to and from the regeneration box. The regeneration box includes a plurality of chambers such that steps such as oxygen removal and panel cooling can be performed independently of and simultaneously with the thermal preheating and desorption of CO 2 on the panels. The desorption panels may be configured to achieve countercurrent flow to the hot gas used for thermal preheating and desorption. A multistage heat pump may facilitate the reuse of waste heat and the decarbonization of process heating requirements.

Description

Technical Field

[0001] The subject matter described herein relates to systems and methods for direct air capture.

Background Art

[0002] Direct air capture (DAC), a method of capturing CO2 directly from the atmosphere, is one of several means of reducing anthropogenic greenhouse gas emissions. DAC is advantageous in that it can address emissions from dispersed sources (e.g., cars, airplanes), rather than being attached to a specific emission source such as a particular plant.

[0003] The main challenges of DAC are low cost and high-efficiency air contact. The challenges associated with current DAC processes include providing a system capable of processing air containing a huge volume flow rate of carbon dioxide, and also providing a means of providing energy for regeneration at an acceptable cost.

[0004] Conventional DAC systems relied on the mechanical operation of connected ("train"-shaped) adsorption panels that followed a discontinuous process, orbited an elliptical path, and entered a single-zone regeneration chamber along the same path. This required (i) the need to move a significant amount of mass (discontinuously), (ii) a relatively complex movement system, and (iii) a regeneration box with only a single zone for performing extensive desorption functions internally over a long period. There is a need to provide a DAC system with a sufficiently simplified design that enables carbon dioxide capture in a highly reliable and repeatable manner, and further a cost-effective and scalable DAC system. Additionally, there is a need for a system that minimizes risks associated with the mechanical operation of the panels, and a system that improves the continuity and efficiency of the regeneration process of the above-mentioned monolithic panels.

Brief Description of the Drawings

[0005] [Figure 1] It is a diagram of an exemplary adsorption / desorption and heat recovery cycle. [Figure 2A] An exemplary adsorption / desorption process unit is shown. [Figure 2B] A more detailed diagram of an exemplary adsorption system is provided. [Figure 3] This is an illustrative diagram of an alternative design for an adsorption / desorption process. [Figure 4] This is an illustrative diagram of a larger-scale design consisting of several integrated adsorption / desorption process units. [Figure 5A-5B] This is an illustrative diagram of a playback box having multiple zones. [Figure 6A] This is an illustrative diagram of a continuous steam processing section included within an alternative regeneration box design. [Figure 6B] This is an illustrative diagram of a continuous steam processing section included within an alternative regeneration box design. [Figure 7A] An exemplary panel movement system is shown. [Figure 7B] An exemplary panel movement system is shown. [Figure 7C] An exemplary adsorption / desorption process unit is shown in three dimensions. [Figure 8A] An exemplary process flow diagram is shown, including downstream processes for CO2 and heat recovery. [Figure 8B] An exemplary process flow diagram is shown, including downstream processes for CO2 and heat recovery. [Figure 9] An alternative continuous steam treatment regeneration design is shown. [Figure 10] This shows possible door configurations for achieving continuous panel movement within a vacuum system. [Figure 11] A regeneration box is shown with loading and unloading from both sides to allow panels passing through the steam section to move in a faster stepping motion. [Figure 12A] This diagram illustrates a system where two panels are collected simultaneously and loaded into a regeneration box, and an odd number of panels are held in a steam processing section. [Figure 12B]A system is shown where two panels are collected simultaneously, loaded into a playback box, and odd-numbered panels are held in a steam treatment section. [Figure 13A] Shows a possible alternative layout for a six-adsorption box process with side and horizontal steam treatment boxes. [Figure 13B] Shows a possible alternative layout for a six-adsorption box process with side and horizontal steam treatment boxes. [Figure 14] Shows possible door movements. [Figure 15] Shows an exemplary embodiment of a continuously moving adsorption wall with a batch playback system. [Figure 16] Shows an exemplary embodiment where a panel moves around a curve when moving from one wall to another. [Figure 17A] Shows an exemplary rotation of a panel. [Figure 17B] Shows an exemplary embodiment of a panel. [Figure 17C] Shows an exemplary embodiment of a panel. [Figure 17D] Shows an exemplary embodiment of a panel. [Figure 17E] Shows an exemplary embodiment of a panel. [Figure 18] Shows options for panel preheating and drying / cooling. [Figures 19A-19B] Shows components with which a panel can be constructed. [Figures 20A-20B] Shows a side view of a possible configuration of a double-layer adsorption system with horizontally oriented panels. [Figure 21] Shows a configuration of parallel horizontal panels at the same height. [Figure 22] Shows a side view of a configuration for panel playback in a horizontal orientation. [Figures 23A-23C] Shows an exemplary layout of a single-track horizontal panel adsorption system and possible interactions with their playback steps. [Figure 24A] Shows an exemplary configuration of a dual-track horizontal adsorption system and its interaction with their playback. [Figure 24B] Illustrate exemplary configurations of dual-track horizontal suction systems and their interaction with playback. [Figure 24C] Illustrate exemplary configurations of dual-track horizontal suction systems and their interaction with playback. [Figure 25A] Show further exemplary configurations of the interaction between the suction system and the desorption system of the horizontal panel. [Figure 25B] Show further exemplary configurations of the interaction between the suction system and the desorption system of the horizontal panel. [Figure 25C] Show further exemplary configurations of the interaction between the suction system and the desorption system of the horizontal panel. [Figure 26] Show an exemplary configuration of a single-track horizontal suction system that interacts with a double-chamber vacuum regeneration step. [Figures 27A-27B] Show an exemplary arrangement of fans in a horizontal suction system. [Figures 28A-28B] Show an exemplary arrangement of fans in a horizontal suction system. [Figures 29A-29C] Show an exemplary method for diverting precipitation from a horizontally oriented panel. [Figures 30A-30D] Show an exemplary method for supporting an array of suction cups with a horizontal frame having edge supports. [Figure 31A-31B] Show an exemplary method for supporting an array of suction cups within a horizontal frame using a mesh and wires. [Figure 32] Show an exemplary approach for supporting an array of suction cups within a horizontally oriented frame having a color. [Figure 33] Show the possibility of modifying the edge shape of the suction unit to facilitate support in a horizontally oriented frame. [Figure 34] Show an exemplary method for supporting an array of suction cups within a horizontally oriented frame using a spring clip as an edge support. [Figures 35A-35C]An exemplary method is shown in which an adsorbent array can be supported by a horizontal frame with edge supports. [Figure 36A] An exemplary configuration of a monolithic frame having sealing surfaces between each row of monolithic bricks is shown. [Figure 36B] An exemplary configuration of a monolithic frame having sealing surfaces between each row of monolithic bricks is shown. [Figure 37A] An example of a sealing section used between the panel frame and the chamber is shown. [Figure 37B-1] An example of a sealing section used between the panel frame and the chamber is shown. [Figure 37B-2] An example of a sealing section used between the panel frame and the chamber is shown. [Figure 37B-3] An example of a sealing section used between the panel frame and the chamber is shown. [Figure 37C-1] An example of a sealing section used between the panel frame and the chamber is shown. [Figure 37C-2] An example of a sealing section used between the panel frame and the chamber is shown. [Figure 38] An exemplary single-planar version of the adsorption and regeneration system is shown horizontally. [Figure 39] This shows an exemplary single-plane continuous version of a horizontal orientation system with a parallel regeneration region. [Figure 40A] A plan view of an exemplary portion of the post-cooling gas recovery system is shown. [Figure 40B] Figure 40A is a cross-sectional view along plan AA of an exemplary portion of the post-cooling gas recovery system. [Figure 41] This exhibits an exemplary single-planar, continuous, horizontally oriented system with a single regeneration region. [Figure 42A] A side view of an exemplary mesh support system is shown. [Figure 42B] A side view of an exemplary mesh support system is shown. [Figure 42C] A side view of an exemplary mesh support system is shown. [Figure 42D]A side view of an exemplary mesh support system is shown. [Figure 42E] A side view of an exemplary mesh support system is shown. [Figure 43A] This is a cross-sectional view of an exemplary precipitation mitigation embodiment including a precipitation deflection ring. [Figure 43B] Figure 43A is a perspective view of an exemplary embodiment of precipitation mitigation. [Figure 44A] Exemplary embodiments of possible configurations of a completely continuous ring-shaped system and adsorption blocks are shown. [Figure 44B] Exemplary embodiments of possible configurations of a completely continuous ring-shaped system and adsorption blocks are shown. [Figure 44C] Exemplary embodiments of possible configurations of a completely continuous ring-shaped system and adsorption blocks are shown. [Figure 44D] Exemplary embodiments of possible configurations of a completely continuous ring-shaped system and adsorption blocks are shown. [Overview of the Initiative]

[0006] The primary objective of the present invention is to provide a simplified, scalable direct air recovery (DAC) system for recovering CO2 from air or gas and producing a CO2 product with a purity of over 95%. The system of the present invention results in a reduction in the cost of DAC.

[0007] In many embodiments, we describe advanced DAC processes designed to reduce not only the cost of capturing CO2 from air and gases containing carbon dioxide, but also the energy load associated with the capture process. This process involves the simplified continuous movement of individual adsorption panels (each panel having multiple adsorption units, which may be monolithic or in alternative configurations) in an airflow, in a single plane, or alternatively, in multiple planes, compared to one or more previous generation processes that require the substantially complex movement of connected adsorption panels discontinuously around an elliptical configuration. By using continuously moving individual adsorption panels in an airflow (and, in certain embodiments, also within a regeneration region), the relative complexity required for starting and stopping connected panels is substantially eliminated, resulting in a significant reduction in the overall mechanical and process risks of the plant, as there is no need to move substantial masses with high inertia. Furthermore, the reduced complexity of the mechanical movement of the adsorption panels allows for greater flexibility in the configuration and overall volume of the substrate and adsorbent, significantly improving system throughput. These advantages improve plant reliability, enhance scalability, and reduce capital expenditure per unit throughput. In the following explanation, the phrases “moving continuously” or “continuous movement” may refer to one or more panels moving at a substantially constant speed.

[0008] In many embodiments, mobile systems for capturing carbon dioxide are also described. Therefore, any implementation of a process or method described herein may be carried out by one or more types of apparatus and will be considered to fall within the scope of the invention. The use of the term “process” in this context includes, or is synonymous with, the term “method.”

[0009] This system and process utilizes the simplified movement of individual adsorption panels, thereby moving them individually and continuously in an airflow across a single plane (or alternatively, multiple planes) for the purpose of performing the process and capturing carbon dioxide, instead of mechanically moving connected adsorption panels discontinuously around an ellipse.

[0010] Furthermore, this process separates the movement of panels required for the carbon capture phase from the movement of panels required for the regeneration phase, significantly increasing the flexibility to optimize the size of the regeneration box and the zones within it (without affecting critical carbon capture steps in the airflow). This allows the current design and process to utilize regeneration boxes with multiple separate zones to perform the various steps required for carbon dioxide desorption, compared to one or more previous generations of processes where a regeneration box with a single multi-function zone was used to perform the entire desorption process. Using multiple zones for different steps of the regeneration process offers several advantages, including (i) the ability to more efficiently specialize each zone for a specific function (air removal, preheating, CO2 desorption, adsorbent cooling), and (ii) increased continuity of the gas flow. In addition, regenerating multiple panels at once increases production capacity compared to single-panel, single-zone regeneration box systems. These advantages lead to reduced energy demand, improved scalability, and lower operational and capital expenditures per unit of throughput. [Modes for carrying out the invention]

[0011] Adsorption / desorption cycle As can be seen in Figure 1, dilute concentration ([CO2] in An airflow containing CO2 (e.g., ambient air) can be adsorbed onto a solid sorbent, and as a result, the concentration of CO2 in the airflow after adsorption ([CO2] out ) becomes lower ([CO2] in >[CO2] out ).

[0012] Next, CO2 can be desorbed from the sorbent contained in a solid sorbent support structure, such as a monolith or other form of sorbent unit (in which several such sorbent units are aligned and arranged within a panel), thereby extracting the CO2. Desorption of CO2 can be performed by a temperature swing, which is brought about, for example, by condensing vapor directly onto the panel, or by reducing the partial pressure of CO2 in the desorption chamber, for example, by filling the desorption chamber with another gas such as vapor, or by drawing the desorption chamber into a vacuum, or by a combination of these measures. Alternatively, the temperature swing can be brought about by indirect heating. Before and after this, steps may be taken to maintain the life of the sorbent and achieve high CO2 purity. Figure 1 includes a flow chart of an exemplary regeneration cycle. Arrows indicate the relative movement of the panel within the system. For convenience, the system will be described as a series of steps in which the panel moves stepwise from one zone to the next, but it can also be easily understood that the description can be applied to a system with continuous movement.

[0013] During regeneration, the panel moves through several zones, where it encounters a variety of conditions. In the example shown in Figure 1, panel

[50] enters a first chamber in zone

[10] , and the first chamber can be isolated by closing the doors

[25] and

[26] at both ends of the chamber. The O2 concentration in the surrounding void can then be reduced by vacuuming the first chamber to about 0.025–0.4 bara, or alternatively, about 0.05–0.2 bara, or by introducing steam, nitrogen, or another inert gas to replace the remaining air volume, or a combination of both. In an optional step, steam can be introduced into the first chamber in zone

[10] while maintaining a vacuum to replace the remaining air or other inert gas. One advantage of introducing atmospheric steam into a vacuum environment is that, because the steam is superheated under vacuum conditions, it can replace some of the air before it condenses. Even if some of the steam condenses, the temperature at which the steam can condense limits the degree to which the panel can heat up due to the vacuum environment, minimizing undesirable CO2 emissions during this step.

[0014] In another embodiment, the chamber

[10] may be flushed with an inert gas such as N2 to completely or partially replace the air before the application of vacuum or the use of vapor.

[0015] In a subsequent step, the vacuum may be released from the first chamber in zone

[10] by introducing a gas. This gas may be fresh steam, steam mixed with CO2 from alternative zone

[11] , or an alternative gas such as CO2 or nitrogen. The temperature may rise by steam condensation to about 70 to about 115°C, alternatively about 70 to about 105°C, alternatively about 80 to about 105°C, alternatively about 90 to about 103°C, or alternatively about 95 to about 100°C. When the pressure in the first chamber approaches atmospheric pressure, the door

[26] to the adjacent zone can be opened, and the panel

[50] can be moved into the first steam processing zone

[11] .

[0016] In zone

[11] , the gas flows through the panel

[50] to complete the heating stage and desorb CO2. This desorption may be by steam, a mixture of steam and CO2 from an alternative zone, or a mixture with some other gas. In the example shown in Figure 1, a mixture of CO2 and steam from zone

[12] is used to heat the panel to temperatures of approximately 70°C to approximately 125°C, alternatively approximately 80°C to approximately 115°C, alternatively approximately 80°C to approximately 105°C, alternatively approximately 90°C to approximately 103°C, and alternatively approximately 95°C to approximately 100°C. Vaporized CO2 is recovered, and the steam condenses to boil the refrigerant in the heat pump cycle. The vaporized CO2 may contain approximately 2 to 70 vol% CO2, alternatively approximately 10 to 40 vol% CO2.

[0017] After a given period, the panel

[50] may then move to the next zone (a second steam treatment zone

[12] , as shown in the example in Figure 1). In the second steam treatment zone

[12] , the panel

[50] is kept at a high temperature to facilitate CO2 desorption, for example, by introducing fresh steam into a plenum that promotes a uniform flow profile within the panel. As shown in Figure 1, the steam and desorbed CO2 leaving zone

[12] flow upstream relative to the movement of the panel and may flow back through the panel in zone

[11] . The advantage of this backflow profile is that the adsorption panel in zone

[12] receives a lower partial pressure of CO2 than the panel in zone

[11] , thus facilitating the desorption of CO2 from the panel in zone

[12] .

[0018] The steam and desorbed CO2 leaving Zone

[11] may flow upstream relative to the movement of the panel and may be able to flow back into Zone

[10] via a block valve

[29] (see Figures 5A–5B). The advantage of applying vaporized CO2 from Zone

[11] to the chamber in Zone

[10] is that the overall amount of steam used for regeneration is reduced, as most of the panel heating is done by steam already used to desorb the panel further down the train. In addition, the CO2 content allows the system to reach ambient pressure at a lower temperature (compared to using fresh steam), allowing the transfer door to open earlier in the cycle. As the partial pressure of CO2 increases, some CO2 may be further adsorbed onto the panel

[50] , but that CO2 will be released again in Zones

[11] and

[12] .

[0019] The ratio of CO2 adsorbed on the panel to the concentration of CO2 in the gas phase typically equilibrates over time to a consistent value influenced by factors including the amount of adsorbent in the panel and the system temperature. A set of adsorption isotherms can be derived, representing a set of curves that relate the amount of CO2 per unit mass of adsorbent to the concentration of CO2 in the vapor phase at a given temperature. Typically, as the temperature rises and the vapor concentration of CO2 decreases, the equilibrium charge of CO2 to the panel decreases.

[0020] For example, a "driving force" is set up when the system moves away from equilibrium by heating the panel and flowing steam through the charged panel to reduce the vapor phase CO2 concentration. This driving force represents how far the system is from equilibrium and can be expressed as the difference between the current gas phase CO2 concentration and the gas phase CO2 concentration that would equilibrium with the current amount of CO2 charged to the panel at the current system temperature. The rate at which CO2 migrates from one phase (e.g., adsorption) to the other phase (e.g., vapor phase) is usually proportional to this driving force.

[0021] When a charged panel is desorbed in a simple batch process (a single chamber into which steam is supplied and a mixture of steam and desorbed CO2 is removed), the driving force is high at the start of the desorption process. The concentration of adsorbed CO2 is high, and the steam phase has a relatively low CO2 concentration. In this case, flowing the steam faster increases the driving force because the additional steam dilutes the desorbed CO2, while flowing the steam more slowly decreases the driving force. Assuming a constant steam flow rate into the chamber, the driving force decreases over time. In other words, as CO2 is desorbed, the concentration of adsorbed CO2 continues to decrease. Therefore, to approach complete desorption, the steam must be flowed for a sufficiently long time until the CO2 concentration in the steam phase becomes considerably low.

[0022] Backflow of steam through one or more panels can be characterized as a system in which the freshest steam flows through the most desorbed panels / panel sections (sections with less adsorbed CO2) before the steam flow contacts the less desorbed parts of the panel. One of the key advantages of this system described here is that backflow can be achieved, for example, by stepping through multiple panels in steam, as shown in Figure 9, or by passing steam back and forth through the panel(s), as shown in Figure 6A. In this process, backflow is desirable because it provides a way to "reuse" steam that has already contacted the panels and desorbed some CO2, while maintaining good driving force for CO2 desorption.

[0023] Consider a simple example of two panels (a first panel and a second panel) in a backflow. The first fully charged panel, in the first position closest to the steam inlet, comes into contact with fresh steam that has not yet touched the panel. The second panel, after the first panel, comes into contact with steam that has already passed through the first panel. Therefore, the steam that comes into contact with the second panel contains a small amount of CO2, slightly reducing the driving force to desorb steam from that second panel. However, if the steam flowing into the second panel is 1% CO2 and the equilibrium state is 10% CO2, the loss of driving force is relatively small (10-1=9 instead of 10-0=10), and the "used" steam can still desorb CO2 from the second panel. When that second panel moves to the first position closest to the steam inlet, it is already partially withdrawn. In the first position, the panel is exposed to fresh steam. The panel in position 1 experiences a similar time profile to an equivalent panel with simple batch desorption, but because the panel starts in a partially uncharged state, it reaches a given level faster (and with less encounter to fresh steam) than an equivalent simple batch panel. Therefore, overall, backflow allows the panel to reach an equivalent desorption level with less steam (or the panel to be more completely desorbed with the same amount of steam).

[0024] Although this simple example considers only two panels, it is easy to see how the general principle can be extended to systems with more backflow stages. The advantages embodied by the invention described herein are a set of methods that can achieve this backflow and thus enable more efficient use of steam and / or more effective desorption of CO2 from the adsorption panels. In some embodiments, this backflow can be applied to any other desorption step described herein, including but not limited to air replacement with an inert gas or cooling / drying of the desorbed panels.

[0025] Once the final steam cycle in zone

[12] is complete, a door

[27] to an adjacent chamber in the downstream zone

[13] is opened, and the panel

[50] moves to the next step of the regeneration cycle. In zone

[13] , the panel

[50] may be dried and / or cooled by evaporation of condensed water on the surface of the panel. This drying and / or cooling may be achieved by lowering the partial pressure of water in the chamber of zone

[13] by introducing an inert gas, such as nitrogen, or by drawing a vacuum. The target partial pressure of water in zone

[13] may be between approximately 0.02 and approximately 0.4 bara, alternatively between approximately 0.05 and approximately 0.2 bara, or alternatively between approximately 0.08 and approximately 0.12 bara.

[0026] The phrase “cooling” a panel may mean drying and / or cooling the panel, as will be discussed at length below with respect to “cooling sections” or “cooling zones”

[13] . Thus, the term “cooling zones”

[13] may refer to a drying / cooling zone that may provide drying and / or cooling of the panel.

[0027] Figure 1 shows a four-zone regeneration box, but it is clear that additional zones can be added. For example, a pre-purge zone

[10] may include one or more chambers to further reduce the risk of air entering the hot zone, to reduce the risk of CO2 loss when the next panel is introduced, and / or to increase the number of panels to complete the air-purge / preheating step within a given time. Furthermore, an additional zone can be added to the central steam section (between zone

[11] and the final cooling zone

[13] ) to further expand the backflow steam flow in that section. Furthermore, the steam flow may pass through several “subzones” within a given panel in succession to provide yet another level of backflow steam flow. Finally, the final cooling section, zone

[13] , can be divided into two or more chambers to better isolate the hot panels (coming out of the desorption section) from the ambient air (to reduce the risk of sorbent deactivation), and / or to increase the number of panels cooled within a given time.

[0028] In another embodiment, the loading

[10] or unloading

[13] zone can be made closer to continuous operation by using multiple doors. These doors may be placed closer to each other than the length of one panel in order to reduce the overall size of the unit. One possible embodiment of this approach is shown in Figure 10 as one that may be applied to the initial inert purge step. At time t1, the newly loaded panel

[50] may enter the purge zone

[10] through the open doors [25a-25d]. Door [25a] may then be closed, and the panel

[50] may begin to move slowly forward while the vacuum is being drawn. The speed of the panel movement and the speed of the vacuum can be timed so that, at the desired pressure, the panel

[50] reaches door [26a] and passes through door [25b] (for example, shown at time t2, about 2 seconds after t1). Door [25b] may then be closed, and door [26a] may be opened. In some embodiments, while the vacuum is maintained, steam may be allowed to flow into the chamber formed between doors [25b] and [26b] to remove any remaining oxygen. At time t3 (e.g., about 4 seconds after t1), the steam sweep may be complete and the chamber may be slightly pressurized. Next, door [25c] may be closed and door [26b] may be opened, and the resulting chamber may begin to be repressurized. At time t5 (e.g., about 8 seconds after t1), panel

[50] may be approaching the end of the purge zone

[10] , and may be at the same pressure as the downstream steam box in zone

[11] , and is ready to be discharged through door [26d].

[0029] Other embodiments of this system may have more or fewer doors, and their spacing may vary. Figure 10 shows a “knife” door, but other styles of doors can also be used. In yet another continuously moving embodiment, instead of doors, seals are attached to the panel surface, so that as the panel moves continuously through different zones, the seals come into contact with different parts of the panel frame, creating a sealed space, similar to the opening and closing effect of doors in the alternative embodiments.

[0030] In one embodiment, as shown in Figure 6A, the panels in the desorption zone

[11] move continuously through a steam flow that is forced to pass through the panels multiple times. Figure 6B shows the steam flow section at t1 in more detail. In this embodiment, as seen in Figure 6A, at the start of the cycle, a new panel [50c] may be rapidly moved from the oxygen purge chamber (zone

[10] ) to the steam processing chamber (zone

[11] ) to align with the panels [50a-50b] already in place. The three panels can then move at a constant speed through a steam flow that flows back and forth, with backflow between the panels. The steam flow pattern can generally meander or flow alternately along different sides of the chamber, so that the steam and gas circulate through each panel multiple times. For example, as seen in Figure 6B, a plenum

[22] may be set up, separated by baffles

[24] with a width of about 1 / 4 the length of the panel. The steam may flow from rear to front in the second and fourth quarters of panel

[50] and from front to rear in the first and third quarters of panel

[50] . The three panels [50a-50c] can then move smoothly through this steam flow throughout the entire cycle. In this embodiment, at time t1, referring to Figure 6B, the leading edge of panel [50a] is exposed to fresh steam flowing from the inlet plenum

[21] to the transfer plenum [22a] on the opposite side of the chamber, and the second quarter of the leading panel [50a] is exposed to steam flowing from the transfer plenum [22b] to the transfer plenum [22c] on the opposite side of the chamber, and some CO2 collected from its leading edge, and so on. The steam may then flow from the transfer plenum [22c] to the transfer plenum [22d] on the same side of the chamber. The steam may then flow through the panel from the transfer plenum [22d] to the transfer plenum [22e] on the opposite side of the chamber. Subsequently, the steam may flow from transfer plenum [22e] to transfer plenum [22f] on the same side of the chamber. Then, the steam may flow through the panel from transfer plenum [22f] to transfer plenum [22g] on the opposite side of the chamber. Then, the steam may flow from transfer plenum [22g] to transfer plenum [22h] on the same side of the chamber.Subsequently, the steam may flow through the panel from the transfer plenum [22h] to the transfer plenum [22i] on the opposite side of the chamber. Then, the steam may flow from the transfer plenum [22i] to the transfer plenum [22j] on the same side of the chamber. Then, the steam may flow through the panel from the transfer plenum [22j] to the transfer plenum [22k] on the opposite side of the chamber. Then, the steam may flow from the transfer plenum [22k] to the transfer plenum [22l] on the same side of the chamber. Then, the steam may flow through the panel from the transfer plenum [22l] to the transfer plenum [22m] on the opposite side of the chamber. Then, the steam may flow from the transfer plenum [22m] to the transfer plenum [22n] on the same side of the chamber. At the end of the train of the panel, the rear quarter of panel [50b] is exposed to steam and gas flowing from the transfer plenum [22n] to the discharge plenum

[23] . This steam and gas has already passed through the panel seven times (from

[21] through [22a~22m] to reach [22n]), and therefore has collected a considerable amount of CO2. At time t3 in Figure 6A, half of the preceding panel [50a] may be out of the steam flow, and the third of the quarter of the preceding panel [50a] may be exposed to fresh steam. At t4, panel [50a] is completely out of the active steam flow, and the central panel [50b] has its leading quarter in the fresh steam flow. The cycle is complete with respect to the steam treatment of the preceding panel [50a], with remaining time until panel [50a] moves forward into the cooling chamber and the next panel [50d] moves into place to restart the cycle. One advantage of this form of continuously moving panels is that, compared to batch or stepwise approaches, the steam and CO2 flow is nearly continuous, and all sections of the panel experience very similar time / temperature / CO2 concentration profiles. Another attractive feature is the ability to achieve multi-stage reverse steam flow while maintaining a reasonable number of panels in the steam processing zone.With respect to Figures 6A and 6B, the eight passes of steam and gas through multiple panels have been described. Alternatively, this system may have a plenum system through which the gas passes through a subset of panels at least approximately 3 times, alternatively at least approximately 4 times, alternatively at least approximately 5 times, alternatively at least approximately 6 times, alternatively at least approximately 7 times, alternatively at least approximately 8 times, alternatively at least approximately 9 times, alternatively at least approximately 10 times, alternatively at least approximately 11 times, and alternatively at least approximately 12 times. In some embodiments, this system may have a plenum system through which the gas passes through a single panel at least approximately 2 times, alternatively at least approximately 3 times, alternatively at least approximately 4 times, alternatively at least approximately 5 times, alternatively at least approximately 6 times, alternatively at least approximately 7 times, and alternatively at least approximately 8 times.

[0031] In an alternative embodiment to the meandering steam flow through the panel, the steam may be ducted around the panel so that it always approaches the same face of the panel. Thus, the steam can move consistently in a "corkscrew" manner, from top to bottom or bottom to top (if the panel is horizontal), rather than entering back and forth (from one face to the other). Alternatively, the steam can move consistently from right to left (or always from left to right) in the vertical direction. Maintaining the direction of the gas flow through the panel can improve system performance, especially when the panel's moving speed increases and the gas flow decreases.

[0032] In another alternative embodiment where the gas flow direction is consistent with respect to the panels, this continuous steam flow can be achieved by changing the direction of movement within the steam treatment zone, as shown in Figure 9. In this embodiment, the panels enter the zone

[10] at the bottom of the figure from the left, move to the steam treatment zone

[11] , move upward there, and then exit from right to left through the vacuum cooling zone

[13] . This embodiment is distinguished from other versions in that the steam treatment zone

[12] achieves both lateral movement of the panels and backflow of steam and panels. These panels may be spaced apart (as shown in the figure) or charged at a higher density. They may move continuously or as a series of steps. The steam treatment chamber may be completely filled (as shown in the figure), or the panels may be concentrated in part of the steam treatment zone (e.g., near the steam source or near the steam removal point). In a normal cycle, newly charged panels [50i] may be charged into the O2 purging or vacuum chamber (zone

[10] ) and subjected to vacuum and / or gas sweep to remove oxygen. Next, the vacuum can be broken and the panels can be moved into the steam processing chamber (zone

[11] ), where panels 50b–50h are stacked parallel to each other so that the faces of adjacent panels 50b–50h are parallel to each other, and then gradually moved laterally toward the parallel stacked end near the steam inlet. As the panels move through the steam flow near the cooling chamber (zone

[13] ), they gradually encounter lower concentrations of CO2, which promotes the desorption of CO2 from the panels. Once they reach the end of steam processing zone

[11] , the panels are moved into the cooling chamber (zone

[13] ), where the temperature of the panels is lowered using vacuum and / or sweep gas, and then the panels can be equalized with ambient pressure and removed from the cooling chamber in zone

[13] . The relative movement of the panels within the system is indicated by arrows.

[0033] One advantage of the present invention is that steam can move in a reverse flow relative to the panels within the steam treatment zone. This allows the steam with the lowest CO2 concentration to come into contact with the panel with the lowest residual level of adsorbed CO2, thus reducing the total amount of steam required for desorption of the panels. The degree of improvement is a function of the adsorption isotherm (a curve representing the equilibrium concentration of CO2 in the gas phase compared to the adsorbed phase), but in most cases, increasing the number of reverse flow stages reduces the overall steam usage. A confounding effect is that keeping the panels at high temperatures for extended periods can be counterproductive, as the adsorbent may decompose at high temperatures, especially in the presence of oxygen. Therefore, increasing the number of panels in reverse flow may be limited. Thus, there is a further advantage in limiting the time that panels stay in the steam treatment zone. This can be achieved, for example, by spacing the panels apart (as shown in Figure 9) or by moving the steam back and forth within the panels (as shown in Figure 6).

[0034] In some embodiments, the speed at which a panel can step through the system may be limited by the time required to open a door, the time required to move a panel in and out of different zones, or the time required to complete an oxygen purge or panel cooling activity. Figure 11 shows one possible approach to mitigate such constraints. Specifically, two inlet chambers [10a and 10b] and two outlet chambers [13a, 13b] may be connected to a single steam processing chamber (zone

[11] ). The chambers within zones [10a] and [13a] may be connected to one adsorption box, while zones [10b] and [13b] may be connected to a second adsorption box that operates out of phase with the first adsorption box. Note that the term “adsorption box” may refer to any structure (i.e., “adsorption structure”) on which adsorption takes place on the adsorption panel

[50] . Panel

[50] may be charged alternately from zones [10a] and [10b], resulting in panel

[50] entering the chamber of steam treatment zone

[11] twice as frequently as it can be processed in either zone [10a and 10b]. Similarly, panels may be removed alternately to the cooling chambers in zones [13a] and [13b], resulting in panel

[50] leaving steam treatment zone

[11] twice as frequently as it can be processed in the cooling zones [13a and 13b]. By making the stepping movement frequency in steam treatment zone

[11] higher than the stepping movement frequency in charging / removal zones

[10] and

[13] , more stages of backflow steam / panel contact within the steam treatment box are possible without increasing the average time spent in the steam treatment zone for each panel. The relative movement of the panels within the system is indicated by arrows.

[0035] Figure 11 examines an embodiment that considers both two purge chambers or vacuum chambers in zone

[10] and two cooling chambers in zone

[13] , but alternative configurations can easily be envisioned. For example, one inlet and two outlets, or two inlets and one outlet, are also possible. Furthermore, configurations can easily be devised in which multiple inlet or outlet chambers can be mounted on one or both sides of the streaming box.

[0036] Figure 12A shows another possible modification that allows for a relatively long oxygen purge in zone

[10] or a cooling step in zone

[13] , while also allowing for an increased number of panels in the steam treatment zone

[11] , while maintaining a reasonable residence time for the panels in the steam treatment zone

[11] . In this embodiment, two panels [50a, 50b] may be loaded simultaneously into a chamber in the oxygen purge zone

[10] and their cycles completed together. The two panels [50a, 50b] can then be loaded together into a chamber in the steam treatment zone

[11] and step-by-step through steam until they are removed in the cooling zone

[12] . Arrows indicate the relative movement of the panels and steam within the system.

[0037] In an alternative embodiment, an odd number of panels may be retained within the chamber of the steam treatment zone

[11] . This means that the inlet subsequent panel [50b] has an extra stage in the steam, during which it encounters fresh steam. In embodiments where an even number of panels are present in the chamber of zone

[11] , the subsequent panel [50b] may be consistently exposed to steam with a higher CO2 concentration than the preceding panel [50a], but in such embodiments, the subsequent panel [50b] will not be.

[0038] Figure 12A shows an embodiment in which two panels are loaded at once, but alternative configurations in which more than two panels are loaded at once can be easily envisioned. Similarly, Figure 12A shows an embodiment in which an odd number of panels are held in the steam processing zone, but alternative configurations in which an even number of panels are held can be easily envisioned. When loading two or more panels at once, it can also be envisioned that the number of panels held in the steam processing zone be adjusted to achieve a removal pattern that maximizes the uniformity of panel loading and unloading.

[0039] Figure 12B shows a possible time-series of events that enable a single adsorption wall or panel row

[54] to supply panels [50a-50e] to the double-width panel loading system

[62] shown in Figure 12A. Panel

[50] may move along the adsorption wall

[54] and gradually protrude beyond the end of the adsorption wall

[53] into a waiting area or waiting zone (e.g., shown in Figure 2). Once panel [50a] is completely released from adsorption and leaves the adsorption box

[60] , panel [50a] can be transported onto a lateral transfer device

[62] . The loaded first panel [50a] can then move within the lateral transfer device

[62] so that a second panel [50b] can be loaded into the available space. The two panels can then be loaded together into the oxygen purge zone

[10] of the regeneration box. In this embodiment, the panels move with the lateral transfer device. One can easily conceive of a system in which a lateral transport device remains stationary while a panel moves across its surface.

[0040] Rapidly moving the panels reduces the frequency of stepping within the regeneration chamber, thereby improving both capital efficiency and the number of backflow stages within the steam processing zone for a given residence time. Simultaneously, tall, thin panels (high aspect ratio) can save capital by allowing shorter adsorption walls for the same area. Unfortunately, high aspect ratios can create distortion forces in the panel frame, increasing the risk of panel tipping and making it difficult to accelerate the panels for rapid movement in and out of the regeneration system.

[0041] In an alternative embodiment, as shown in Figure 17A, the panel

[50] exiting the panel track can be loaded into a device that rotates the panel by 90°, thereby allowing the panel to be loaded into the regeneration chamber at a much lower aspect ratio. Advantageously, the door(s) in the regeneration chamber can be made smaller, and therefore sealing of these rotating panels can be made easier.

[0042] In an alternative embodiment, the suction panel

[50] may be made from subunits

[78] . Once the panel is removed from the suction box, it can be segmented and rearranged into a shape more favorable for regeneration. In one embodiment, the panel

[50] in Figure 17B may be separated into subunits [78a-78c] as seen in Figure 17C. These subunits can then be rearranged so that the maximum surface area is aligned to form a block of 1 subunit height, 1 subunit length, and 3 subunit width (as seen in Figure 17D). Alternatively, the subunits may be arranged so that their edges are in contact (as seen in Figure 17E) to form a block of 1 subunit height, 3 subunit length, and 1 subunit width. Any of these configurations may be better suited to higher acceleration forces than the original orientation of the panel.

[0043] Figure 17B shows a panel that can be segmented into three subunits, but in an alternative embodiment, the panel may be segmented into as few as two subunits, or into as many as ten or more subunits. Figure 17B shows the reconfiguration to process all subunits simultaneously, but in an alternative embodiment, the subunits may be processed independently (one at a time), or in other convenient groupings, such as two at a time.

[0044] In further embodiments, the concept of loading multiple panels into the oxygen purge chamber of zone

[10] or the final cooling chamber of zone

[13] can be combined with the concept of uniform panel steam treatment by adding waiting zones between oxygen removal

[10] and steam treatment

[11] , and / or between steam treatment

[11] and cooling

[13] . This allows, for example, two panels to come out of the oxygen purge simultaneously. One panel then enters the steam flow directly, while the other panel waits for half a step before being transferred to the steam flow. Similarly, at the other end of the steam box

[11] , one panel may enter a waiting zone so that it leaves the steam flow in half a step and merges with the second panel in a full step, resulting in both panels entering the cooling zone

[13] together. Extending this example, it is easy to understand how to treat three, four, or more panels together in zones

[10] and / or

[13] while maintaining a uniform time / temperature profile for the panels within the steam treatment zone

[11] .

[0045] One possible advantage of the lateral steam processing system shown in Figure 9 is that it may be possible to maintain the regeneration chambers in relatively close proximity to each other. Figure 13B shows how lateral flow regeneration chambers [61a~61f] can be arranged in a star shape with adsorption boxes [60a~60f] and lateral steam transfer units [62a~62f], maintaining good separation of the adsorption boxes [60a~60f] while keeping the regeneration chambers [61a~61f] close to each other. Maintaining the regeneration chambers [61a~61f] in close proximity minimizes the length of low-pressure gas piping required to enable multiple regeneration units to share common downstream processing equipment.

[0046] The isolation doors

[26] ,

[27] at the entrances and exits of zones

[11] and

[13] are shown as swing doors in Figure 9, but other designs are also conceivable, including “guillotine” or knife doors that slide into place, or “rotating barrels” that rotate on a vertical axis to move into place with a circular chord as the sealing part.

[0047] Figure 14 shows several possible embodiments of the door. A swing door

[70] rotates around a pivot

[71] so that when open it moves out of the path of panel movement, but when closed it seals against the wall. In the case of a knife or guillotine door

[72] , the door moves out of the path of panel movement in the open position, but then slides into place in the closed position to close the chamber. Optionally, the sealing of the door may be improved by a rotating cam

[73] that presses the sliding door

[72] against the frame. A barrel or revolving door

[74] rotates around a pivot

[75] . The door

[75] is connected to the pivot by one or more mounting arms

[76] located outside the panel's movement zone. When open, the barrel door is outside the movement area, and then rotates into place to create a seal. Optionally, the pivot

[75] may be attached to the movement system so that the door can swing into place and then firmly press against the door frame to improve sealing.

[0048] In other embodiments of this process, panels can move continuously between different zones, which can be achieved by forming a seal on the surface of the moving panel, as shown in Figure 36. Figure 36A shows a side view of one possible configuration. A lower support strut

[0111] may be designed to be flush with the entire panel frame

[95] (in the same plane) to provide a continuous, flat surface that forms a lower seal. A sealing strut

[0128] may be added to the top of the panel, such that its upper surface is flush with the upper surface of the outer frame to provide a continuous, flat sealing surface. The sealing strut

[0128] may be a single element that contacts the sealant

[92] located between the panels. In some embodiments, the sealing strut

[0128] may have an extension

[0129] that minimizes gas flow between rows of panels (e.g., [94a] and [94b] or [94b] and [94c]) and provides rigidity to the sealing surface

[0128] .

[0049] Figure 36B shows a plan view of the adsorption unit support and panel configuration. The adsorption units

[90] are supported by a mesh supported by support struts

[0110] . Individual adsorption units

[90] may be arranged in a linear array (6 × 1 in Figure 36B, but more or fewer units may be used) through which the support struts

[0110] pass between the arrays. The space between the array and the support struts

[0110] and frame

[95] may be filled with a deformable sealant

[92] , which prevents airflow around the adsorption units

[90] and provides some buffering to the brittle adsorption units from stress caused by thermal expansion or migration of the panel. The sealant

[92] may also allow for some variation in the size of the individual adsorption units

[90] . The sealant

[92] may also be used between the individual adsorption units

[90] and between the adsorption units

[90] and the support struts

[0110] . As shown in Figure 36A, the support strut

[0110] may be aligned with the lower sealing strut

[0111] and the upper sealing strut

[0128] .

[0050] Several possible embodiments of mechanisms within a panel-enclosing structure that may be used to complete sealing in a continuously moving system are shown in Figures 37A–37C. Figure 37A shows an embodiment in which a sealing block

[0125] is in contact with at least one sealing strut

[0128] . The sealing block

[0125] is intended to prevent the movement of gas from one array of adsorption units in the panel

[94] to an adjacent array by creating a contact point between the sealing block

[0125] and the upper sealing strut

[0128] (an identical sealing is also made between the lower sealing block

[0125] and the lower sealing strut

[0111] of the panel). This contact seal creates a partition between sets of adsorption unit arrays

[94] , allowing a gas, such as air, to flow through one set of arrays without mixing with the gas flowing through another set of arrays. The sealing block

[0125] may be made of a metal, polymer, or other material that provides a smooth surface and allows it to contact the sealing strut

[0128] . To improve contact and sealing between the upper sealing strut

[0128] or lower sealing strut

[0111] and the sealing block

[0125] , light pressure can be applied in a direction perpendicular to the movement of the panel. The sealing block

[0125] material may have a low coefficient of friction with respect to the panel frame

[95] and the sealing strut

[0128] . The width of the sealing block

[0125] may be wide enough to contact at least two sealing struts

[0111] or

[0128] when the panel

[50] is in a given position. This ensures that even if the panel moves, at least one sealing strut

[0111] or

[0128] can always be in contact with the sealing block

[0125] . To improve sealing, the sealing block

[0125] may be made large enough to contact two, three, four, or more sealing struts

[0111] or

[0128] at a time. In some embodiments, the sealing block

[0125] may be static and the panel may be movable.

[0051] Figures 37B-1 to 37B-3 show alternative embodiments in which a static sealing block (

[0125] in Figure 37A) is replaced by one or more sets of roller seals

[0126] . As shown in Figures 37B-2 and 37B-3, multiple roller seals may be grouped together and arranged to conform to the surface of the panel. For example, multiple roller seals

[0126] may contact the surface of the adsorption units

[90] of an adsorption unit array (e.g., [94b] in Figure 36A) and then deform to accommodate the raised sealing struts

[0128] . Alternatively, the roller seals may be arranged to contact a mesh support

[0103] and deform to accommodate the lower support / sealing struts

[0111] , or they may be arranged to contact only the sealing struts (upper

[0128] , lower

[0111] ). Several rollers may be used so that at least one of them contacts the sealing struts within a given section of the panel enclosure. One possible advantage of using rolling seals is that the wear rate and friction associated with seal formation may be lower than when using stationary sealing blocks (such as

[0125] in Figure 37A).

[0052] Figures 37C-1 and 37C-2 ​​show another possible embodiment in which the seal is formed by a continuous belt

[0127] . The belt

[0127] may be long enough to cover at least two sealing struts

[0128] , or it may cover three, four, or more. Similar to the rollers shown in Figures 37B-1 to 37B-3, the belt seal

[0127] may reduce wear and friction. Figures 37C-1 and 37C-2 ​​show one possible embodiment of the belt in both a top view (Figure 37C-1) and a side view (Figure 37C-2). The upper belt [127a] may contact three upper sealing struts

[0128] , and the lower belt [127b] may contact three lower support struts

[0111] .

[0053] The description in Figure 37 is applicable to systems in which the adsorption unit array

[94] is arranged on a horizontal panel. Designs in which the horizontal panel is supported on a mesh (shown in Figure 36), or by other means (as shown in Figures 30 and 32), or in which the panel is arranged vertically can be easily envisioned.

[0054] In yet another embodiment, the horizontal panels may be arranged in a circular shape in the form of a large “disk” or “torus,” as shown in Figure 44A. In this embodiment, there are two suction trains

[54] and two regeneration stations

[61] , but fewer (one of each) or more (three, four, five or more) are also conceivable. One advantage of this configuration compared to Figure 21 is that, because each panel [50a] moves continuously in a circular motion, there is no need for different “tracks” [54a and 54b] or for transfers between tracks, and a transfer station

[62] at the end of a linear suction track [54a] is not required. Furthermore, the forces acting on the panels [50a, 50b, and 50c] remain continuous. The advantage of continuous operation is that the accelerating and decelerating forces when panel [50a] moves from track [50a] to lateral transfer station

[62] , the accelerating and decelerating forces when panel [50b] moves to align with track [54b], and the force that accelerates panel

[50] from lateral transfer station

[62] to suction track [54b] are eliminated. Because accelerating and decelerating forces are eliminated during normal operation, the power requirements of the system may be reduced, and lighter panel frames with lower thermal inertia may be used.

[0055] In the embodiment shown in Figure 44B, each panel

[50] may be in the shape of a “slice” of a disk / ring. In another embodiment shown in Figure 44C, the concept of panels

[50] can even be eliminated, as discontinuous movement is eliminated, allowing the disk to be composed of a wide segment of a single adsorption unit

[90] with an upper sealing strut

[0128] and a lower sealing strut

[0111] . The disk may consist of radial rows

[0133] of adsorption units

[90] having sealing surfaces separating adjacent rows, or spokes (see rows [133a] to [133e] in Figure 44D). Thus, instead of 120 panels with a width of 12 adsorption units

[90] , the circular system may have 1440 spokes with a width of 1 adsorption unit

[90] . Within the regeneration area (

[61] in Figure 44A), air purging, vapor desorption, cooling, and other possible zones may be similarly shaped to suit each segment with respect to sealing and gas exchange.

[0056] Since the adsorption step uses ambient air, the temperature of the air supply can vary depending on the time of day or season. This can lead to uncontrollable disturbances within the system, and heating requirements may be greater at some points in time (e.g., during winter nights) compared to other points in time (e.g., during summer daytime). One method to mitigate this variability is shown in Figure 18, which illustrates an embodiment in which a portion of the air used for adsorption is preheated. Because the air contains oxygen, which can cause degradation due to adsorption, the range in which the panel [50a] is preheated may be limited, for example, to less than 40°C, less than 30°C, or less than 20°C, or about 20°C to about 40°C, alternatively about 20°C to about 30°C, alternatively more than 20°C, alternatively about 25°C, or alternatively about 30°C. In the illustrated embodiment, the air delivered by the fan

[80] to the last panel [50a] in the panel track

[54] may be preheated in a heat exchanger

[81] by hot water diverted from a cooling tower. Using this waste heat flow prevents the air from being heated to a temperature that could damage the adsorbent (the return water in the cooling tower can always be below 45°C), and also reduces the load on the cooling tower (saving energy). In warm weather such as summer, this air preheating is unlikely to cause a significant rise in panel temperature, but in winter, the panels may be preheated to about 2°C to about 25°C or higher. The main advantage of this approach may be that the temperature of the panels entering regeneration[50b] can be more constant throughout the year. It may also reduce the amount of steam required to desorb the panels in the chamber

[11] and the amount of water condensed in the panels in that step. This may be advantageous in terms of mass transfer rates to and from the panels during desorption

[11] , vacuum cooling

[13] , and subsequent adsorption in the adsorption box

[60] . Figure 18 shows that an auxiliary fan

[80] may be required to balance the airflow through the heated panel[50a] with that of the other panels in the panel track

[54] to compensate for the pressure drop across the air preheater

[81] .

[0057] Another possible complementary embodiment of panel heating is shown in Figure 18. Once most of the oxygen has been removed from the panel and its surroundings in the air purge zone

[10] , the panel [50c] can be heated without causing excessive oxidation of the adsorbent. In an optional step, the panel can be preheated in a preheating chamber

[14] using a high-temperature inert gas (such as CO2). The advantage of preheating the panel is that less steam may be required in the steam treatment zone

[11] , less water may be condensed on the panel surface [50d~50g], and the mass transfer step can continue without interruption. In this exemplary embodiment, CO2 may be heated with steam in an exchanger

[83] and recirculated over the panel by a fan

[82] to minimize the overall use of the high-temperature gas and allow the condensing steam to be recovered directly from the heat exchanger

[83] (allowing the return of hotter, uncontaminated water to the boiler). If the panel [50c] is not fully charged when adsorption is complete, some of the CO2 used for preheating may be adsorbed onto the panel, providing additional heating. The CO2 may be rapidly desorbed in the subsequent steam treatment step

[11] . The panel exiting this section may be preheated to about 50–95°C, alternatively about 60–85°C, or alternatively about 70–80°C.

[0058] If residual water on the panel re-introduces into the adsorption [50k], mass transfer may be restricted, and the rising temperature may make the adsorbent more susceptible to oxidation; therefore, optional processing steps for panel cooling may be employed. As shown in Figure 18, an additional cooling chamber

[15] may be used to surround the partially cooled panel [50i] within the vacuum cooling zone

[13] . In this additional cooling chamber

[15] , a gas such as nitrogen or air is recirculated by a fan

[84] through a heat exchanger

[85] and cooled with a cooling fluid such as water or glycol. This cold gas then flows over the warm panel [50i], causing both the evaporation of additional water (by lowering the vapor pressure of water on the panel surface) and direct cooling, thereby lowering both the panel temperature and residual condensate. The water evaporated from the panel [50i] may then be re-condensed in the heat exchanger

[85] , recovered, and returned to the boiler system. The advantages of this optional additional step are both that the panels returned to the adsorption system [50k] are cooler (reducing oxidation by the adsorbent) and that there is less liquid water in the pore structure inside them (minimizing the limitations on mass transfer). The panels leaving this auxiliary cooling station may be around 10–40°C, alternatively around 20–30°C, or alternatively around 25°C.

[0059] Optionally, as shown in Figure 1, internal heat integration can be achieved by condensing steam throughout the system and cooling other heat sources to produce a warm fluid in one or more condensers

[40] . The energy in this fluid can be upgraded via a series of compressors

[44] , so that the fluid can dissipate heat at a higher temperature to form fresh steam in a boiler

[43] . Heat recycling, which can be achieved by using heat pumps, significantly reduces the overall energy consumption of this process. Water recycling from the condensers

[40] to the boiler

[43] is also possible by condensing most of the steam from the process stream, significantly reducing the process water footprint.

[0060] One advantage of using a mixture of steam (or other easily condensable gas) and vacuum to carry out the CO2 recovery step is that it facilitates heat recovery. A significant amount of energy can be recovered by condensing steam from the CO2-producing gas and transferring this energy to a heat pump. For example, vaporized CO2 leaving Zone

[11] can be used to heat water to 60°C to 70°C, condensing most of the water vapor. The 70°C water can then be used to boil liquid butane to form medium-pressure butane gas. The butane gas can then be compressed using electricity to produce high-pressure butane steam, which can be condensed into high-pressure liquid butane at 110°C, and this can then be used to boil hot water at 105°C to produce low-pressure steam. The condensed high-pressure liquid butane can then be flashed down to medium-pressure butane gas, and the cycle can continue. Similarly, a vacuum stream can be used to produce 40°C water from 30°C water by cooling CO2 using a heat exchanger and condensing most of the water vapor. Removing this water vapor not only recovers energy but also significantly reduces the load on the vacuum system. As before, hot water can be cooled and recycled by boiling a low-pressure refrigerant (e.g., ammonia, propane, or butane) to generate steam, which is then compressed and condensed at high temperatures. For example, this system can supply an additional 70°C water to the high-pressure loop.

[0061] The products of this process may be a mixture of CO2, water, and other gases (e.g., inert gases). The concentration of the inert gas can be controlled by the vacuum depth in zone

[10] and the use of sweep vapor in zone

[10] . The concentration of water in the CO2 exiting the recovery condenser can be controlled by the temperature and pressure at which the gas is cooled. The concentration of the product CO2 may be about 90% by weight or more of CO2 product, alternatively about 93% by weight or more of CO2 product, alternatively about 95% by weight or more of CO2 product, alternatively about 97% by weight or more of CO2 product, or alternatively about 99.9% by weight or more. The concentration of water vapor may be about 10% by weight, alternatively about 5% by weight, alternatively about 2% by weight, or alternatively about 0.1% by weight. The concentration of the inert gas may be about 5% by weight, alternatively about 2% by weight, alternatively about 0.5% by weight, or alternatively about 0.1% by weight.

[0062] General plant design concepts Because desorption can be carried out much faster than adsorption, plants are designed to take into account the desorption-to-adsorption time ratio by using multiple adsorption panels

[50] (typically 60 to 100, but sometimes as few as 8 or more than 140) in a single regeneration box, so that the adsorption panels

[50] can continue the required adsorption time over multiple regeneration cycles of individual panels. This has the advantage of increasing the utilization rate of capital associated with CO2 capture equipment, thereby reducing the capital cost per ton of CO2 produced.

[0063] Previous design approaches for these panel-based systems required connecting adsorption panels to be "trained" and physically moved discontinuously in and out of an inline regeneration area. However, because a series of connected panels have considerable mass, the moving system can present certain mechanical challenges, especially in discontinuous processes. Furthermore, previous panel moving designs required movement along elliptical or circular "tracks." This poses a potential risk to the reliability of such systems with relatively high masses over multiple cycles in outdoor conditions where wind loads and other conditions vary, as well as challenges regarding the sealing of flat panels (against loss of airflow) along curved tracks. An early generation batch process is disclosed in U.S. Patent No. 10,512,880, entitled "Rotating multi-monolith bed movement system for removing carbon dioxide from the atmosphere," which is expressly incorporated herein by express reference in its entirety for all purposes.

[0064] Figure 2A shows an exemplary configuration of the adsorption / desorption system, showing an adsorption box

[60] , a regeneration box

[61] , and a transfer station

[62] through which panels

[50] move. The adsorption box has two rows of adsorption panels

[50] arranged side by side, forming two long walls

[54] , and two short solid walls

[53] positioned perpendicular to the two long walls

[54] , which serve to prevent short-circuiting of air to the overhead fan

[51] . In one embodiment, an air filter

[52] may be used to minimize the impact of dust and other small particles on the system. The air filter

[52] may be positioned parallel to and facing the outer surface of the long walls

[54] of the adsorption panels

[50] .

[0065] The panels

[50] are configured to move continuously through at least a portion of the suction box

[60] . For example, the panels

[50] moving within the suction box

[60] may move at a substantially constant speed along a track within the suction box

[60] . In one embodiment, the suction box

[60] may contain a train of one or more continuously moving panels

[50] at a time.

[0066] The horizontal moving panel design presented herein seeks to eliminate the potential problems that arise from indexing the panels through start-stop movements by moving the suction panels

[50] individually (without connection) and continuously in a flat horizontal direction (or, alternatively, across additional dimensions) in an airflow. This offers the significant advantage that when regenerating the panels, far less mass movement is required than in a "train" of connected suction panels. Furthermore, the horizontal moving panel design allows the suction panels

[50] to move continuously, eliminating the start / stop operation required in alternative designs. The regenerating vacuum sealing system is also reliable, utilizing a relatively narrow door that is only slightly wider than the shortest dimension of the panel. This flat door is closed using an actuator (among alternatives, an electric, pneumatic, or hydraulic actuator) against a fixed plane, unlike sealing systems with rounded surfaces or sealing systems that require precise alignment with very large mass movements. In alternative embodiments, the vacuum chamber / door is eliminated, allowing the entire process to move continuously, which further simplifies the movement of the entire system.

[0067] Another very simple advantage of horizontally moving panel systems is the significantly increased flexibility to load larger volumes of substrate and sorbent, resulting in a substantial increase in throughput. Overall, this offers the potential for lower capital expenditure (and overall cost) per ton of CO2 produced.

[0068] Furthermore, compared to past designs where the regeneration box had only a single zone for the purpose of completing the entire range of steps required for detachment, this design provides multiple individual zones, dividing the regeneration cycle into a series of specialized zones. This allows the detachment process to be completed by a single panel moving between zones. The range of steps may be performed in a single zone, multiple zones, or in combination with the next step in a given zone, and includes: (i) removing air (and oxygen, which can be harmful to the adsorbent at high temperatures) from the adsorption panel by vacuuming or sweeping the air with steam or an inert gas (such as nitrogen); (ii) breaking the vacuum (or evacuating nitrogen or another inert gas) with steam, CO2, or other alternative gases; (iii) heating the adsorption panel with steam (or other means such as indirect heat or high-temperature CO2); and (iv) cooling the adsorption panel by vacuum, application of an inert gas (such as nitrogen), or a combination of other direct or indirect cooling methods. Dividing the regeneration box into multiple zones also facilitates the introduction of additional processing steps, such as panel preheating

[14] or panel cooling

[15] , as shown in Figure 18.

[0069] The use of multiple zones for different steps in the regeneration process is intended to bring about several advantages. Firstly, this allows a given zone to be specifically designed to optimize a particular process (such as oxygen purging, steam application, or cooling), thereby increasing the efficiency of that given process step. Secondly, dividing the regeneration process into separate zones / segments significantly improves the continuity of gas flow, reducing / eliminating discontinuous flows that could cause inefficiencies (and / or functional problems) in the operation of auxiliary equipment such as heat pumps, vacuum pumps, and compressors. Regeneration of multiple panels at once increases capacity compared to single-panel, single-zone regeneration box systems. Furthermore, placing multiple panels in the high-temperature / steam treatment sections (zones 11 and 12) enables a reverse flow pattern where panels nearing the end of the steam treatment / desorption section encounter lower CO2 partial pressure (higher steam flow), while "reusing" that steam to apply to heating and desorption of the panels earlier in the regeneration cycle. This reverse steam flow has the advantage of utilizing high-concentration steam to maximize desorption of panels that are nearly CO2-depleted towards the end of the steam treatment process, and then achieving efficiency by reusing that steam to apply to the previous panel in the steam treatment section. This is in contrast to the costly and inefficient practice of using the steam only once, as experienced in single-zone batch regeneration.

[0070] These benefits lead to reduced energy demand, improved scalability, and lower operational and capital expenditures per unit of throughput.

[0071] Another advantage of the proposed embodiment is that it offers an inherently scalable design. The simplified mobile system can be easily adapted to larger units due to its relatively low mechanical risk. Secondly, the system is highly space-efficient, not only emitting a substantial amount of CO2 within a relatively moderate footprint, but also having the potential to further increase CO2 capture per unit area by allowing units to be stacked. Finally, given the modularity of this design, there is a clear opportunity to scale up not only by scaling up but also by scaling out; that is, by leveraging components suitable for mass production, the feasible rate of scaling up can be accelerated and the cost per ton can be reduced over time.

[0072] In one possible plant layout, as shown in Figure 2A, a regeneration box

[61] can be positioned close to each other in the center of two sets of adsorption boxes [60a, 60b]. The advantage of this layout is that larger and more expensive equipment, such as heat pumps and CO2 compressors, can be placed closer to the regeneration box, thus minimizing the required length of low-pressure / vacuum ducts. To achieve this, adsorption panels

[50] can move along two flat “panel walls”

[54] , on one panel wall, the panel moves away from the regeneration box, and on the other panel wall, the panel returns. The panels can be switched from one side to the other at some form of lateral transfer station

[62] . The approach shown in Figure 2A has a transport system that moves the panel at a 90° angle to the direction of motion along the wall. After exiting the adsorber / fan unit

[60] , the panel

[50] moves to a waiting zone until it is completely disengaged from the airflow. It then slides into a support frame supported on a transport trolley. Next, the trolley and support, along with the enclosed panel, move laterally to the opposite side of the adsorber / fan unit, where the panel is lowered into a waiting area and then collected by a moving system that carries it into the airflow. A magnified view of the adsorber / fan unit is shown in Figure 2B. Arrows indicate the relative movement of the panel within the system.

[0073] In another embodiment, Figure 3 shows a version of this process with a regeneration box

[61] and a lateral transfer station

[62] at each end of the adsorber / fan unit

[60] . Arrows indicate the relative movement of the panels within the system. Alternatively, a system could be envisioned with curved tracks for connecting one side to the other so that the panels always move along the same axis.

[0074] In another embodiment, as shown in Figure 16, a curved track

[64] may be used instead of a lateral transfer station. In this case, the panel

[50] moves from left to right along the wall [54a] of the suction cup until it reaches an end. It is then transferred to one side of the regeneration station [60b] to complete the detachment cycle. The panel is then moved onto the transfer rail [64a] and transported to the entrance of the suction wall [54b]. The panel may be supported by rails or tracks below the panel, suspended from rails above the panel, or both.

[0075] In alternative embodiments, the linear moving wall can be combined with a batch regeneration box having a single chamber, two doors (shown in Figure 16) or one door (shown in Figure 15). In a single chamber, the inlet door can be opened and the panel can be loaded into the chamber. The door can then be closed and air can be purged from the chamber, for example by applying a vacuum and / or by using a sweep gas such as steam. Desorption steam can then be initiated, for example by releasing the vacuum with steam and heating the chamber to a temperature at which CO2 can be desorbed from the panel. The desorbed CO2 can be removed from the chamber and recovered, for example by sweeping additional steam through the chamber. Once sufficient desorption is achieved, the panel may be cooled, for example by applying a vacuum or by using an inert sweep gas such as nitrogen. Once the cooling step is complete and (if necessary) the vacuum is released, the inlet door (for a single-door chamber) or the outlet door (for a two-door chamber) can be opened to remove the panel and reset the system for the next cycle. In the case of a two-door chamber, both doors can be opened simultaneously, and the new panel is installed as soon as the old panel is removed.

[0076] In the embodiment shown in Figure 15, the panel

[50] may move along the wall [54a] of the adsorber until it reaches the end of the wall. The loaded panel

[50] may be transported across the lateral transport unit [62a] into the regeneration box [61a]. The door [25a] to the chamber [61a] may then be closed, and the panel may undergo its regeneration cycle. Once regeneration is complete, the panel

[50] may leave the regeneration chamber [61a] and be loaded into the transport station [62a], where it may be moved to align with the adsorbent wall [54b]. The panel may then function along the wall [54b] until it repeats its regeneration cycle in the regeneration box [61b] / transport system [62b]. In the embodiment shown in Figure 16, a two-door regeneration box

[61] is shown. In this case, the panel

[50] may move along the wall [54a] of the adsorber until it reaches the end of the wall. At this point, the panel may be loaded into the regeneration box 61a through the first door [25a], where it is sealed and completes the regeneration cycle. Next, the second door [25b] may be opened to allow the panel

[50] to move along the transport rail [64a] and bond to the suction wall [54b]. The panel

[50] may then move along the suction wall [54b] and reach the end of the wall. Next, it may be loaded into the regeneration chamber [61b] through the door [25b] for regeneration. Next, it exits through the door [28b] and is returned to the suction wall [54a] by the transport rail [64b].

[0077] Figure 19A shows a possible configuration of the panel

[50] and identifies several possible components. The panel

[50] is a larger, structurally integrated element that can be moved as a single unit. It consists of a number of individual adsorption units, such as monolithic bricks

[90] , each adsorption unit may consist of a porous substrate with a high area-to-volume ratio supporting a CO2 adsorbent. The monolithic brick is a substrate material formed so that medium-sized (mm scale) air channels, separated by porous walls, penetrate in one direction. The pores in the walls are coated with an adsorbent that temporarily binds CO2. The array may contain one, two, three, four, or five adsorption units in a row. In some embodiments, the array may be 2 adsorption units × 2 adsorption units, 2 adsorption units × 3 adsorption units, or 2 × 4 adsorption units, and the array may be 3 × 3 adsorption units. The pores may have a very small diameter so that the entire system has a high surface area relative to its overall volume. The substrate may be a ceramic material.

[0078] These individual adsorption units

[90] may be assembled into arrays

[94] to facilitate the assembly and operation of the panel

[50] . In this embodiment, the panel

[50] includes a set of adsorbent arrays

[94] that are in contact with each other or separated by support shelves or support frames

[91] . As shown in Figure 19A, the panel

[50] includes 36 monolith arrays

[94] , each monolith array containing six adsorption units

[90] . The support shelves

[91] provide structural rigidity to the panel frame

[95] and prevent the weight of the upper monolith arrays from crushing the lower monolith arrays. Figure 19B shows a close-up of a single monolith array

[94] . In this embodiment, the highlighted monolith array contains six adsorption units

[90] separated by sealant

[92] . The sealant

[92] evens out the size inconsistencies of the individual adsorption units

[90] , alleviates some of the stress caused by thermal expansion and movement of the frame

[95] and shelves

[91] , and adheres the panels together to fix them in place. The monolithic array

[94] may be held in place and supported by an array frame

[93] . The array frame

[93] may be made of a rigid material such as steel or aluminum, or of a more plastic material such as silicone foam that absorbs deformation of the steel frame

[91] caused by thermal expansion and panel movement.

[0079] Alternative panel orientation: Horizontal (vs. vertical) Many of the embodiments described utilize the panel vertically, so that the plane of the panel surface is perpendicular to the ground, and the gas flows through the panel in a horizontal path. In another embodiment, the panel is oriented horizontally so that the plane of the panel is parallel to the ground, and the gas flows through the panel in a vertical path.

[0080] One major advantage of having horizontal panels (horizontally oriented panels) is that they have high material stability. Panels can be supported at multiple points, and therefore the risk of tilting is greatly reduced (compared to vertical orientation). The weight of the panels is also distributed more widely, and the center of gravity is at a similar level to their support points.

[0081] In one configuration, the panels move together continuously within the same vertical plane, but at different levels, as shown in Figures 20A–20B (side view). In this configuration, the panels can be configured so that air enters the system between the panels from the side (into the page) and exits through the panels in both upward and downward directions (Figure 20A), or exits through two or more layers of panels (Figure 20B). In either case, panel [50a] moves along a track at a certain level, is lifted (Figure 20A) or lowered (Figure 20B) before returning to the airflow on the other track (panel [50c]). In the embodiment shown in Figure 20B, the freshest air first flows through the lower, more charged panels (maximizing the charge to those panels), and then flows through the less charged panels (to capture some of the remaining CO2 in the air and maximize overall potential CO2 capture). In the embodiments shown in Figures 20A-20B, the tracks are shown with only two levels, but in alternative embodiments, there may be three, four, five, or more layers. Air may be pumped through opposite walls by fans facing each other so that air escapes only up or down through the panels. Alternatively, the walls may be open and fans may draw air up through the panels. Alternatively, the direction of airflow may change because the pressure in the volume between or below the panels may be higher than the volume above (and below) the panels. Alternatively, the incoming airflow may be redirected from horizontal to vertical using blades or other means.

[0082] Figure 21 shows an alternative possible configuration in which a panel

[50] moves along parallel suction tracks

[54] at the same height in opposite directions (see arrows). In this embodiment, the panel moves continuously along a panel track [54a] within the suction area, with air blowing vertically through it. When a given panel [50a] reaches the end position of the suction track [54a], it is moved into a lateral transfer station

[62] , as seen in panel [50b]. This panel can move at the same height from one track to the other and then return to the starting position of the second track [54b] as panel [50c]. In this embodiment, two tracks are shown, but in alternative embodiments, there may be only one track, or instead, three, four, five, or more tracks in parallel.

[0083] Figure 22 shows a possible embodiment of a regeneration system within a horizontal orientation system, and provides a side view of the system. Panel [50a] may exit the adsorption system and enter an air purge zone

[10] at the same height as the adsorption track. Panel may then exit the air purge zone

[10] and enter a preheating zone

[14] at the same height as the air purge zone. Panel [50b] is then lowered into the heated gas, and multiple panels (see, e.g., [50c]) may surround this zone, allowing backflow heating to occur. Panel [50d] then moves from the preheating zone

[14] to a steam treatment zone

[11] at a low height, and then may move upward due to the downward flow of steam. As seen in Figure 22, panels within the steam treatment zone

[11] may move in the opposite direction to the steam flowing into the chamber. In one embodiment, multiple panels may surround the steam treatment zone

[11] (such as panels [50e] and [50f] in this figure) and rise until they reach the height of the adsorption system. Next, the upper panel [50f] may be transferred from the steam processing zone

[11] to the cooling zone

[13] at the height of the adsorption system. Once cooling is complete, the panel [50g] may be transferred from the cooling zone

[13] to a panel return system that returns the panel to the adsorption track.

[0084] The main advantage of operating with multiple panels within a preheating box

[14] is that in a system operating at a constant rhythm, more time is available to preheat each panel. That is, if a new panel enters the heating system once every minute and there is only one panel in the heating system, the maximum time available to heat that panel is 1 minute. If there are two panels with a cadence of 1 minute, the maximum heating time is 2 minutes, and so on. Therefore, by increasing the number of panels in the heating zone and fixing the rhythm, it should be possible to increase the amount of energy that can be transferred to a given panel. Also, backflowing the gas into the panels means that the colder gas comes into contact with the coldest panel, and the gas leaving the heating chamber remains colder throughout the entire cycle, maximizing the driving force of the outside air heater.

[0085] Further advantages of horizontally arranged panels are also shown in Figure 22. That is, as in the case of vertical arrangement, the length of the steam zone

[11] does not need to match the spacing of the panel walls. This allows for a smaller steam processing chamber and makes it easier to bring the panel frames closer together or in contact with each other. This makes it easier to seal the gaps between panels and thus minimizes the flow of hot gas / steam bypassing the inside of the frame.

[0086] Figure 22 shows one possible embodiment of the regeneration system. In alternative embodiments, additional operating steps (such as additional panel cooling) may be applied, and / or panel preheating may be performed independently of the height change. In other embodiments, the steam chamber discharge level may be at a different height from the panel track, in which case there is an additional device to change the panel height. Figure 22 also shows a linear design, which may be particularly useful in a “two-adsorber” configuration similar to that shown in Figure 2A. In other embodiments, a lateral transfer device may be used to have part of the regeneration steps performed along a second adsorption track. Figures 23A–23C show several possible embodiments of this approach and provide a top view of the approximate positioning of the equipment.

[0087] In Figure 23A, the panel moves along the panel track [54a] toward the removal zone, then to the air purge zone

[10] , and then to the preheating chamber

[14] . In one embodiment, the panel may move downward within the preheating chamber

[14] , then exit from a lower level track in a direction perpendicular to the direction in which the panel entered the preheating chamber, and move into the steam treatment chamber

[11] . The panel may then be lifted as it moves through the steam treatment chamber

[11] and then move through the door to the cooling chamber

[13] . In this embodiment, the direction of movement out of the steam treatment chamber is perpendicular to the direction of entry in order to minimize the overall space and travel distance required for the panel. After cooling, the panel may move through the staging area and then return to the adsorption system on the track [54b].

[0088] Figure 23B shows an alternative configuration in which the panel moves along its long axis along the adsorption track [54a], then exits into a staging area, and moves laterally in a second axial direction to the air purge chamber

[10] . Exiting the purge chamber, the panel moves through the staging area, where it changes direction and enters the preheating chamber

[14] at the same height as the adsorption track. The panel is then lowered within the preheating chamber

[14] and may then be moved to a steam treatment chamber

[11] , where it can be raised. The panel may then be transferred into a cooling chamber

[13] , and after completing the cooling step, it may enter the staging area and be returned to the discharge adsorption track [54b].

[0089] Figure 23C shows yet another possible embodiment in which the adsorption tracks [54a] and [54b] can be separated from each other by a longer distance. In this configuration, the panel can leave the panel track [54a] and enter the staging area, where it can leave the panel track [54a] and then move orthogonally to the purge zone

[10] . From there, the panel can move through the upper door to the preheating chamber

[14] , where it can be lowered and heated, and then move through the lower door to the steam zone

[11] . The panel can then leave the steam processing chamber

[11] through the upper door and enter the cooling chamber

[13] . From the cooling chamber

[13] , the panel can move to the transfer area to change direction orthogonally and be reloaded onto the delivery adsorption track [54b].

[0090] Figures 24A–24C illustrate several possible embodiments of a multi-track adsorption system. In the embodiment illustrated in Figure 24A, there may be two parallel adsorption tracks [54a] operating adjacent to a parallel staging area. Panels may then be loaded into two separate but parallel air-purging zones

[10] and into independent preheating chambers

[14] . Panels may continue moving in the same direction and then enter a vapor desorption chamber

[11] before finally entering a cooling chamber

[13] . Panels may then be returned to the parallel adsorption track [54b] for collection and delivery to the staging area. The advantage of this configuration is that panels move in the same direction through all regeneration steps and separation doors, and lateral movement is deferred to a single end station; however, this approach may require more space and may require additional travel distance / time to return to the panel track.

[0091] Figure 24B shows an embodiment in which two central tracks [54a] can perform a “return” trip, allowing the panels to pass from the adsorption area through the staging area to the parallel purge zone

[10] . The panels on these parallel tracks may be arranged alternately with respect to their order, so that they can enter and exit the air purge zone

[10] at different times and be transported to a common preheating zone

[14] at different times. If the preheating zone lowers the panels, subsequent panels may be “stacked” vertically so that the panels move within the same vertical plane but occupy different heights at any given time. The panels may or may not be in physical contact with each other. The panels may then exit the preheating chamber

[14] and enter the vapor desorption zone

[11] , where they may rise on a downward flow of hot gas (e.g., vapor or vapor / CO2 mixture). The panels are drawn out in alternating directions from the steam processing zone

[11] and transported to a separate cooling chamber

[13] , which may then be returned to a “delivery” panel track [54b] occupying two outer tracks in this embodiment. One advantage of this configuration is that the size of the doors to the vacuum chambers

[10] and

[13] can be kept relatively small. On the other hand, a common preheating

[14] and / or steam processing chamber

[11] can enclose more panels and bring us closer to continuous backflow without increasing the overall residence time of individual panels in the hot zone.

[0092] Figure 24C shows an alternative configuration of a dual-track adsorption

[54] / air purge

[10] / cooling

[13] system with a common preheating

[14] and desorption

[12] system, where both the discharge[54b] and return[54a] adsorption tracks may be adjacent to each other. The station layout is also configured to minimize the number of places where the panels change direction within a confined space.

[0093] Figures 25A–25C show several embodiments of a dual-track adsorption system combined with separate vacuum zones (

[10] and

[13] ), but with a common preheating

[14] and steam treatment

[11] system. In all of these embodiments, the panels are configured not to change direction in the horizontal plane during the treatment steps, and all lateral movement takes place on tracks outside the treatment zones. In Figure 25A, the adsorption track [54b] is extended, allowing the long transfer zone shown in Figure 24C to be used for additional CO2 capture. In Figure 25B, part of the space may be used to perform secondary cooling

[15] similar to that described in Figure 18. Figure 25C shows multi-chamber cooling in zone

[13] similar to that described in Figure 6B.

[0094] Figure 26 shows yet another embodiment of the process, combining a single-track adsorption system with a separate vacuum step. Panels may move along a return adsorption track [54a] before entering a staging area, where they may move forward to one air purge zone [10b] or laterally to another air purge zone [10a]. The operation of these air purge zones may be staggered in time to move panels continuously within the adsorption track [54a] into a common preheating chamber

[14] . Using additional transfer station space allows time to move panels while rapidly performing the processing steps, thus allowing for longer transfer distances (i.e., transit time, e.g., travel to the air purge zone [10a] rather than [10b]) and keeping them synchronized with panels with shorter transit times. In this embodiment, panels can move from the air purge

[10] to a common preheating

[14] and steam processing zone

[11] , where panels from different air purges can be stacked to improve backflow performance. After passing through the steam processing zone

[11] , the panel may be separated again and pass through a separate cooling chamber

[13] before being returned to the same delivery panel track [54b].

[0095] A plan view of another possible embodiment of the horizontal orientation system is shown in Figure 38. In this configuration, the CO2 preheating [14a-14c] zone and the steam [11a-11f] zone are configured horizontally to avoid the changes in panel height shown in Figure 22. Rather, the gas flow within these zones may be configured to flow back and forth across different planes of the chamber through continuously moving panels (as shown in Figure 6), although the gas flow may also be ducted around the panels between paths, resulting in the gas flow through the panels always being in the same direction.

[0096] In Figure 38, the panel can move continuously across the entire adsorption train [90a], and the last panel in the train can gradually move away from the airflow and fill the transition area [65a]. Once the panel is completely out of the airflow, it can move rapidly into the air purge chamber [10a], where oxygen can be removed by a combination of vacuum, displacement with steam, N2 or other inert gas, and heating. The panel can move rapidly from the air purge chamber [10a] to another transition area [65b], and then the panel can move continuously into an (optional) CO2 preheating zone [14a-14c], where heated CO2 / steam can flow through subsections of the panel to enable backflow of the panel against the hot gas (details shown in Figure 6). For example, the hot gas may rise through zone [14c], then move downward through zone [14b], and then rise again through [14a]. Alternatively, the hot gas may rise through [14c], be ducted around the train, flow through [14b], be ducted around again, and then rise through [14a]. The preheated panels may then proceed directly to the steam treatment zone [11a] (or directly to this zone from the air purge chamber if an optional CO2 preheating zone is not available). Here again, a reverse flow pattern is achieved as steam can pass through the panels in a series of sub-chambers. For example, while steam flows into [11f] and then through [11e], [11d], [11c], [11b], and [11a] in that order, the panels may move from zone [11a] to [11f]. Once the panel leaves the steam processing zone [11f], it enters the transition area [65c], and once completely free of steam, it moves rapidly to the cooling chamber [13a], where it is cooled and dried with a combination of vacuum, nitrogen, air, or other gases, resulting in the evaporation of water and a decrease in the panel's temperature. Once the cooling cycle is complete, the panel may move to the transition zone [65d], where it may join a train of panels in the adsorption system [90b].The embodiment shown in Figure 38 has two adsorption trains [90a and 90b] and two parallel desorption trains, but other configurations similar to those shown in Figures 24-27 (such as having only one desorption train) can be easily envisioned. Similarly, Figure 38 shows a design in which each desorption train has three preheating sub-chambers and six steam sub-chambers. Embodiments with fewer (0-2) or more (4-10) preheating sub-chambers and fewer (1-5) or more (7-14) steam generating sub-chambers can be easily envisioned.

[0097] Figure 41 shows an exemplary single-planar, continuous, horizontal orientation system having a single regeneration region. As shown in Figure 41, the system may include three suction train sections [90a–90c], two lateral transfer units [62a and 62b], and a single regeneration chamber

[61] . A panel may move continuously from the first suction train [90a] through the first lateral transfer unit [62a], the second suction train [90b], the third suction train [90c], and the second lateral transfer unit [62b] to reach the regeneration chamber

[61] . In other embodiments, the movement may be in the reverse direction. The illustrated layout features a single regeneration chamber

[61] along one of two parallel tracks in the DAC system and may be suitable for smaller-scale DAC operations, for example, when the total suction track is relatively short.

[0098] Figure 39 shows another exemplary embodiment of a process in which a panel moves continuously through the system and an inert gas such as nitrogen

[0115] can be used instead of a vacuum to (i) replace air in a purging step

[10] and (ii) provide cooling in a cooling step

[13] . An advantage of the continuous regeneration system is that there is no need to accelerate the panel in and out of the vacuum chamber, and thus the overall cadence of panel movement can be increased. In this embodiment, the panel can move continuously out of the adsorption area

[90] and directly into the reverse air replacement zone

[10] , where an inert gas such as nitrogen can be used to replace air in the void space around and inside the panel. Since the individual adsorption units consist of a series of narrow airflow channels, the air replacement can be expected to be essentially close to a plug flow, i.e., the airflow channels function almost like a series of parallel drinking straws. In this embodiment, the air replacement chamber may be divided into two sub-chambers separated by a gas seal [120b], an upstream region [10a] and a downstream region [10b]. Fresh inert gas [115a] can enter a downstream sub-chamber [10b] and replace the gas in the void space of the panel. The gas flow velocity can be set so that a given amount of gas is introduced into the downstream sub-chamber [10b] within the time required for a point in the panel to travel through the same sub-chamber. The volume of gas introduced may be between 1 and 2 times the void volume of the sealed sub-chamber, thereby replacing all incoming gas in the void space, although the volume of gas may be between 1 / 2 and 1 times the void volume, or 2 to 3 times the void volume, or more.

[0099] Gas introduced into the downstream sub-chamber [10b] of the air purge section replaces the gas in the upstream sub-chamber [10a], thereby potentially replacing the air in the panel with air outside the system. If the gas flow rates are carefully balanced, nitrogen in the downstream sub-chamber [10b] replaces the gas in the panel entering that sub-chamber, resulting in a large proportion of the gas flowing from downstream to upstream sub-chamber [10a] being air with a small amount of nitrogen. The gas flowing into the upstream sub-chamber [10a] can completely replace the incoming air, resulting in very little nitrogen escaping with the replaced air from the upstream sub-chamber [10a], thus reducing nitrogen loss. Figure 39 shows two sub-chambers, but more chambers may be included.

[0100] The panel moves from the air exchange chamber [10a, 10b] to the nitrogen recovery chamber

[0121] via a seal set [120c] as shown in Figures 37A to 37C-2. Optionally, the nitrogen recovery chambers [121a, 121b] may be operated under a low vacuum (0.5 bara, alternatively 0.25–0.75 bara, alternatively 0.05–0.95 bara) to facilitate nitrogen recovery and removal. This reduced pressure can be achieved using a fan or vacuum pump [122a], and as a result, the recovered nitrogen partially replaces the need for fresh N2.

[0101] Nitrogen replacement can be achieved using steam, CO2, or a mixture of steam and CO2, so that it can be recovered from the steam treatment chamber

[11] . The steam treatment chamber

[11] may have a number of sub-chambers [11a] to [11f]. This replacement is similar to that described for air replacement in chamber

[10] , where the replacement gas mixture enters the downstream sub-chamber [121b] at a rate sufficient to replace 1 to 2 void volumes (or, in alternative processes, less than 1 void volume, or 2 to 3 void volumes, or more) per panel transition time. Thus, the panel void space exiting chamber [121b] may mainly contain steam, while the gas exiting chamber [121b] and entering [121a] may mainly contain replaced N2. This N2-heavy mixture then replaces the N2 gas entering the upstream sub-chamber [121a] with the panel that is from sub-chamber [10b].

[0102] The panel entering the N2 recovery chamber

[0121] may be relatively cold and adsorbs ambient air, so a mixture of CO2 and vapor may interact with the panel, potentially adsorbing some of the CO2 and condensing some of the vapor to heat the panel. While the N2 substitution may not be as simple as the substitution observed in the air substitution chamber

[10] , the same basic principle applies, namely, the formation of a “standing wave” where most of the N2 is substituted and only small amounts of CO2 and water vapor escape to the nitrogen recovery fan [122a].

[0103] A potential advantage of operating the N2 recovery chamber

[0121] under a low vacuum is that the temperature at which vapor can condense is more restricted. For example, at 0.5 bara, the condensation temperature of pure water is 81°C, which is the hottest temperature at which the panel can be subjected to vapor condensation. It may be advantageous to maintain the panel temperature below the level at which significant CO2 desorption occurs.

[0104] Short circuits and backmixing of gases between sub-chambers can negatively impact the overall performance of the system, so sealing between the gas spaces of sub-chambers may be necessary. As the differential pressure across different sections increases, the flow rate through the seal gap increases. Therefore, having a larger multi-contact seal around the vacuum section [120a] may be beneficial.

[0105] From the N2 recovery section

[0121] , the panel moves through the seal [120e] to the continuous steam section

[11] , where steam flows from sub-chamber [11f] through sub-chambers [11e], [11d], [11c], and [11b] to sub-chamber [11a], in the opposite direction to the panel's movement (flowing from seal [120f] through [120j] in sequence and from [11a] to [11f]), to efficiently desorb CO2 and minimize the residual level of CO2 on the panel as it leaves the desorption zone. The steam flow through the panel may be "serpentine" (crossing different sides) as shown in Figure 6, or the gas may be ducted in a "corkscrew" shape around the chamber containing the panel so that it always enters the panel from the same side (as shown here).

[0106] After steam treatment, the panel may move continuously into the cooling chamber [13a], sequentially through [13b], [13c], and [13d], where again the panel encounters a backflow of inert gas [115b] flowing from [13d] to [13a]. In this figure, four cooling stages in four sub-chambers [13a] to [13d] are envisioned, but fewer or more stages may be incorporated. The purpose of the cooling chamber

[13] is both to cool and dry the panel by flowing a warm, dry, oxygen-free gas such as nitrogen through the hot, humid panel. As the panel moves from [13a] to [13d], the gas moves in the opposite direction (from [13d] to [13a]). The incoming gas may be low humidity and may be heated by the heater

[0123] to 20-30°C, 15-40°C, or 10-50°C. Because the gas flowing into the cooling chamber [13d] has low humidity, water may evaporate from the panel surface, cooling both the panel and the gas. When the gas flows into the sub-chamber [13c], the gas may come into contact with warmer panel sections, which may heat the gas and cause further water evaporation.

[0107] Optionally, the gas flowing into [13a], [13b], and [13c] may be reheated. This may increase the evaporation rate, and consequently increase the moisture content and temperature of the gas entering the condenser 124. Alternatively, the required gas flow rate may be reduced to achieve the charging of a given amount of residual water into the panel that leaves region 130 and re-enters the adsorption region 90.

[0108] The gas flow and inlet temperature can be carefully controlled so that the gas exiting the inlet panel's sub-chamber [13a] is warm (65–85°C or 55–90°C or 45–100°C) and near saturation, while the panel exiting the sub-chamber [13d] is cold (20–30°C or 15–40°C or 10–50°C) and has a low moisture level. The hot, moist gas discharged from the sub-chamber [13a] is sent to a condenser

[0124] , where it is cooled to a low temperature (5–10°C or 0–25°C or -5–45°C) and condenses some of the water vapor to supply energy to the heat pump. The dry gas can then be recirculated to a gas heater

[0123] via a fan [122b].

[0109] The void space in the panel exiting the final cooling sub-chamber [13d] may be filled with the gas injected into the cooling chamber

[13] . This gas, for example N2, can be partially recovered through a fan [122c] with backflow displacement of air to minimize the overall loss of nitrogen. Figures 40A–40B show one possible embodiment of the gas recovery system.

[0110] Figures 40A and 40B show embodiments of a device intended to recover most of the inert cooling gas

[0115] from the void space entering with the panel

[50] from the upstream cooling zone

[13] and to minimize contamination of the gas by the air used to replace that void space. This separation is achieved by creating a winding path for the replacement air, so that the flow in the replacement area is generally in the opposite direction to the flow in the panel, but locally passes through the panel multiple times. Thus the flow pattern created is similar to that shown in Figure 6A. This flow pattern is created by forming a series of seals on the opposite side of the panel, which are offset from each other in the direction of the panel's movement by at least one airflow channel. The set of seals creates sub-chambers that are separated from each other in the direction of the panel's movement but connected by airflow channels that connect the opposite sides of the adsorption units in the panel

[50] . The entire system is configured such that the velocity of the gas flow through the panel void space (air flow channel) is approximately equal to the velocity at which the void space moves forward due to the movement of the panel.

[0111] Figures 40A to 40B show plan and cross-sectional views of an embodiment in which the panel moves continuously from the cooling zone

[13] through a seal set [120a to 120d] to isolate the mostly airless cooling zone

[13] from the final gas recovery zone. The seal set [120a to 120d] assists in directing airflow in the opposite vertical direction through the panel 50. The seal set [120a to 120d] includes multiple seals. As seen in Figure 40B, the multiple seals may include a full seal [120a] with sealing members on both sides of the panel and multiple half seals [120b to 120d] with sealing members on only one side of the panel. As seen in Figures 40A to 40B, the half seals [120b, 120b] are located on the underside of the panel

[50] and the half seals [120c] are located on the topside of the panel

[50] . The seal set [120a~120d], together with the side walls

[0139] , the chamber floor

[0135] , and the chamber ceiling or roof

[0137] , forms a number of sub-chambers (130, 131, 132) through which air can flow after passing through the panel. For example, as seen in Figure 40B, the sub-chamber

[0130] is bounded by the chamber floor

[0135] , the bottom surface of the panel

[50] , seal [120a], seal [120b], and the surrounding wall

[0139] (not shown in Figure 40B).

[0112] In some embodiments, the half-seal may contact only a single surface of the panel

[50] . In embodiments with two or more half-seals, the first half-seal may contact the first surface of the panel

[50] , and the second half-seal may contact the second surface of the panel (opposite the first surface)

[50] , thereby forcing the incoming gas to displace the gas in the panel's void space. In embodiments with three or more half-seals, one half-seal may contact the first surface of the panel, and the second and third half-seals may contact the second surfaces of the panel (opposite the first surface), resulting in the gas flowing first through the panel in a first direction perpendicular to the plane defined by the panel

[50] , and then across the surfaces of the panel

[50] , so that the entire panel and the gas flow in opposite directions. The gas flow velocity in one direction may substantially coincide with the movement of the panel void space in the opposite direction so that standing waves can be established and the majority of the gas in the panel's void space entering the zone is recovered with minimal mixing of displacement gas.

[0113] Panel 50 continues past the seal [120b] and through the recovery zone, where the seal is shown to be only on the bottom of the panel. The half seal [120b] prevents gas from flowing from sub-chamber

[0132] to sub-chamber

[0130] and allows gas to flow back from sub-chamber

[0132] to sub-chamber

[0131] through panel

[50] . Since there is no seal on the upper surface of the opposite panel [120b], gas can freely flow into sub-chamber

[0131] . Next, panel

[50] can move past the half seal [120c] on the top surface of the panel and finally past the half seal [120d] on the bottom surface of the panel.

[0114] In Figures 40A and 40B, as the panel moves from left to right, the air moves from right to left. As seen in the cross-sectional view of Figure 40B, the system can be configured so that air enters the panel airflow channels between seals [120c] and [120d] and flows down through the panel in a direction perpendicular or perpendicular to the plane defined by panel

[50] , replacing the gas in those channels. The system can be operated so that air pushes the gas in the void space of the panel through panel

[50] into sub-chamber

[0132] , and then the air pushes into sub-chamber

[0131] through another section of the panel in a direction perpendicular to the plane defined by panel

[50] , but opposite to the airflow entering sub-chamber

[0132] . Air is pushed out of sub-chamber

[0131] into sub-chamber

[0130] in a direction perpendicular to the plane defined by panel

[50] , and in the opposite direction to the airflow entering sub-chamber

[0131] , through another part of the panel's void. At an appropriate flow rate, as the gas moves from sub-chamber

[0132] to

[0131] and then to

[0130] , the inert purge gas

[0115] The concentration of increases, and the sub-chamber

[0130] may be filled mainly with the inert cooling gas

[0115] .

[0115] Air flows into the gas flow channels within the adsorption units contained in the panel

[50] in the space in front of the half seal [120c] and flows orthogonally through the panel

[50] . This air moves the gas in the void space of the panel within the gas flow channels into the sub-chamber

[0132] . From the sub-chamber

[0132] , the gas can rise through the flow channels of the panel, pushing the gas in those channels into a further sub-chamber

[0131] . Finally, after the sub-chamber

[0131] , air can move the gas through the gas flow channels into the sub-chamber

[0130] . ​​From the sub-chamber

[0130] , a vacuum pump

[0122] can extract the gas from the sub-chamber

[0130] , allowing at least a portion of the recovered gas to be returned to the cooling zone

[13] .

[0116] The gas moved into the sub-chamber

[0131] may also include gas

[0115] supplied to the sub-volume

[0130] through the gas flow path of the panel

[50] , as shown in Figure 40B. Gas

[0115] may be an inert gas such as N2. In some embodiments, the void space or gas flow channel in the panel that moves beyond the seal [120a] may be filled with N2, and the sub-chamber

[0130] may also be filled with N2. Thus, the gas in the sub-chamber

[0130] may contain N2, which can be recirculated to the cooling zone

[13] to reduce the use of fresh N2

[0115] . In some embodiments, the gas in the sub-chamber

[0130] may be essentially pure N2. If the half seal [120c] leaks slightly, or if there is backmixing of gases moved from sub-chamber

[0132] to sub-chamber

[0131] , the gas in sub-chamber

[0131] may contain gases other than N2, but the overall risk of those gases returning to the cooling zone

[13] can be minimized. Similarly, the gas in sub-chamber

[0132] should be N2, and it should return gases containing the same gas, as is present in sub-chamber

[0131] , back into sub-chamber

[0131] . If the half seal [120d] leaks, if air flows into the channel above sub-chamber

[0132] , or if gases are overmixed in the panel flow channel, the gas in sub-chamber

[0132] may be slightly contaminated. However, any impurities may be present in the moving panel, and if the gas flow is properly controlled, the impurities may move forward with the panel before flowing into sub-chamber

[0131] .

[0117] In the embodiments shown in Figures 40A to 40B, the sub-chambers [130 to 132] are shown in different sizes for illustrative purposes, but of course, the sub-chambers may be the same size or in sizes relatively different from those shown. This system is shown having three sub-chambers, but similar systems with one, two, four, five, or more partitions can be envisioned. The seals [120a to 120d] are shown as being large enough to seal only one sealing strut

[0128] , but as described elsewhere, they may be larger.

[0118] In yet another embodiment of the fully continuous process, the horizontal panels can be arranged in a circular array (as shown in Figures 44A-44C), eliminating the need for transfer stations at the ends of the linear array and allowing a constant force to be applied throughout.

[0119] In different embodiments of the design, it is possible to have fans oriented so that the blades rotate in a vertical or horizontal plane (or actually at some other angle). Several possible embodiments of fan placement for operating a panel in a horizontal plane are shown in Figures 27A–27B. These show four upright panel tracks [54a–54b] supported by a set of structural support elements

[55] . The panel tracks are drawn from end to end so that in this figure air flows into or out of the page. In Figure 27A, the fan [51a] is mounted horizontally beneath the panel tracks [54a and 54b] and pushes air up through the panel tracks [54a and 54b] in forced draft mode. This may provide the advantage of having the mass of the fan motor close to the ground and may allow stress associated with the rotating equipment to be decoupled from the mechanical support of the panel. Figure 27A also shows an alternative embodiment in which the fan [51b] can be mounted on the panel tracks [54c and 54d] on the panel and draw air through the panel in induced draft mode. This allows for a fan installation area nearly equal to the panel area, and this design can accommodate larger fan diameters. One possible advantage of an inductive draft fan is that it can minimize turbulence in the airflow through the panel and increase the exhaust air velocity from the system without additional equipment. A higher vertical exhaust velocity can be advantageous in terms of the system's airflow pattern and can reduce the amount of used air recirculated to the adsorber inlet.

[0120] In yet another embodiment, as shown in Figure 27B, the fan [51c] may be installed vertically within the wall of a building operating in forced draft mode. This may bring the mass of the fan and its rotating equipment closer to the ground. The fan in this embodiment may be away from the panel tracks [54a and 54b] and may be upstream of the rain screen and filter (not shown), so that turbulence in the wake of the fan can be dissipated before the air encounters the panels. In yet another embodiment, as shown in Figure 27B, a fan with a larger diameter [51d] may be installed vertically, but away from the edge of the panel track [54d] with the building's transition section, to redirect the airflow.

[0121] Figures 28A and 28B show several possible embodiments of the arrangement of the air filters. Four panel tracks [54a to 54d] are shown in side views from the edge of the tracks. In this embodiment, the panel tracks [54a to 54d] are erected and supported by structural elements

[55] . In Figure 28A, the filter [52a] may be positioned vertically within the wall of the building, or the filter [52b] may be positioned horizontally below the panel tracks [54c and 54d]. When the filter [52a] is mounted on the wall, it can be positioned relatively far from the panel track [54a] and downstream of a fan [not shown], so the filter [52a] may help dissipate the airflow from the fan. By positioning the filter [52b] below the panel, more area can be made available for the filter, which may reduce the pressure drop that occurs over air filtration.

[0122] Figure 28B shows two possible embodiments that allow for a larger filtration area while maintaining the separation of the filter

[52] from the panel track

[54] . The filter [52c] may be set at an angle, and the filter [52d] may be vertical, but set back from the edge of the panel track [54d]. The fan may be installed upstream of the filter, between the filter and the fan, or downstream of both the filter and the fan, so various combinations of arbitrary selections of the fan and filter can be easily envisioned.

[0123] When panels are horizontal, precipitation is more likely to affect the air transport surface, so some form of rain protection may be necessary. Figures 29A–29C show several possible embodiments of this precipitation protection. In Figure 29A, a chevron set

[96] can be used to capture precipitation and direct it to a rainwater collection chevron / trough

[98] . In this embodiment, the chevron can be positioned between the panel track

[54] and the exhaust fan

[51] to maintain the highest possible vertical velocity of the fan's exhaust port, but systems with the fan positioned below the chevron, or systems using the chevron in combination with vertical or horizontal induced draft fans below the panel, are easily conceivable. One advantage of having the chevrons

[96] and

[98] between the fan

[51] and the panel track

[54] may be that any small components, such as lubricant from the fan or those that fall during maintenance, may be prevented from hitting the panel track

[54] . In embodiments where the fan is below the chevron or in induced draft mode, the chevron may also function as the roof of the building. In some embodiments, the system may replace the upward-facing chevron

[96] with a fan

[51] operating within a cutout in the flat roof. The downward-facing chevron

[98] may be widened to a width greater than the diameter of the fan to capture water droplets. In some embodiments, the downward-facing chevron

[98] may extend along the width of the building. In some embodiments, the trough may have a circular dish or inverted cone shape to cover a diameter somewhat larger than the projected diameter swept by the fan and may be equipped with a drain to remove water accumulated in a storm. In some embodiments, the cross-section of the trough may be generally chevron-shaped (as shown), or generally V-shaped, generally L-shaped, generally U-shaped, generally straight, or irregular in shape. In some embodiments, the cross-section of the trough may include a shallow concave dish shape along its upward-facing surface.In some embodiments, troughs(s) and / or chevrons(s) may be angled with respect to the vertical, spaced apart from one another, and / or overlapping vertically from one another to allow airflow while preventing rainwater from flowing in. Chevrons or troughs may extend across the building (perpendicular to the direction of panel movement) or along the building (parallel to the direction of panel movement). Troughs / chevrons may have different lengths to approach, for example, a circular fan opening (longer troughs aligned with the center of the opening, and shorter troughs closer to the side of the opening). Without departing from the scope of this disclosure, shapes and arrangements other than those shown and described herein may be used for troughs(s).

[0124] Figure 29B shows two alternative configurations in which a chimney or thimble [97a, 97b] is used. Because precipitation tends to fall at an angle and the exhaust of the fan tends to generate some degree of vortex, the sediment may hit the walls of the chimney

[97] and flow downward, collecting in a trough

[98] at the bottom of the chimney. Two possible embodiments of the chimney are shown. Namely, [97a] is shown to operate with an inductive draft fan (although it may operate with a forced draft). The top of the chimney can be tapered inward to reduce the exhaust area, thereby increasing the velocity of the air exiting the system. This increase in velocity (and the elevation of the exhaust point) may help minimize air recirculation (i.e., minimize the drawback of CO2-depleted air exiting the system into the inlet airflow). The chimney [97b] is shown with an inductive draft fan

[51] and without an exhaust taper. The walls of the precipitation collection trough

[98] may be positioned low enough so that any precipitation seeping over the fan may collide with the side walls of the chimney [97b] and flow into the trough

[98] .

[0125] Figure 29B shows an alternative configuration that may be combined with separate panel tracks (for example, as shown in Figure 23C). The chimney

[97] collects air from two separate adsorption tracks [54a and 54b] in a relatively narrow, relatively wide open space. Precipitation falling through the chimney may be picked up in a precipitation collection trough

[98] . A forced draft fan is assumed as shown, but it may also be possible to mount an induced draft fan on top of the panel or in a narrower portion of the chimney

[97] .

[0126] Figures 43A–43B show an alternative embodiment of a precipitation mitigation system with a wide precipitation collection funnel

[98] below the fan

[51] . The precipitation collection funnel

[98] may be circular or rectangular when viewed from above and may have a diameter / width greater than or equal to the diameter of the fan

[51] . Further precipitation protection may be provided by the building roof

[0117] and by a cowling

[0118] around the fan

[51] , the cowling

[0118] also improves the pattern of airflow through the fan

[51] . If rainwater falls at an angle, further protection can be provided by incorporating multiple precipitation deflection rings [99a–99c], which can collect raindrops falling at an angle and drop them directly into the precipitation collection funnel

[98] . The multiple precipitation deflection rings [99a–99c] may be positioned above or below the fan

[51] . The airflow-direction profiles of these precipitation deflection rings can be made very narrow to minimize resistance to airflow. Figures 43A–43B show three precipitation mitigation rings [99a–99c], but more or fewer rings may be included. The rings may be at the same height or different heights (as seen in Figure 43A) to minimize the possibility of precipitation entering the panel train

[54] . In some embodiments, the rings may be concentric. The precipitation mitigation rings are shown above the fan, but the rings may also be located below the fan

[51] , but above the collection funnel

[98] .

[0127] Referring to Figure 19A, the forces acting on the suction units

[90] within the panel

[50] differ depending on whether the panel is horizontal or vertical. In particular, in the horizontal direction, gravity can pull the suction units

[50] downward, potentially causing them to deviate from the plane of the panel

[50] surface. Several different approaches can be applied to address this problem. In Figure 19A, support shelves

[91] may be used in combination with a binder that functions as an array frame

[93] in Figure 19B, effectively bonding the array

[94] in place. As a further measure, physical support can also be added to the adhesive.

[0128] Figures 30A to 30D show several possible embodiments of the physical support structure. Arrays [94a] and [94b] may consist of a single adsorption unit or multiple adsorption units coupled together in groups of, for example, 2×1, 2×2, or 2×3 adsorption units. Since the sizes of these arrays may vary slightly, the support system is designed to accommodate this variation. Figure 30A shows a side view of an embodiment in which a monolithic array [94a] or [94b] is supported from below by a combination of a vertical support

[0100] and an edge support

[0101] . In this embodiment, the size of the edge support may be large enough to accommodate both a larger [94a] and a smaller array [94b]. The edge support

[0101] may be directly connected to the vertical support

[0101] or may be connected by spring clips that accommodate variations in the size of the adsorbent arrays [94a or 94b]. The support may also be a two-part structure having a vertical component 100 and a horizontal component 101.

[0129] Figure 30B shows plan views of three different possible embodiments of the edge support. Support [101a] embodies a shelf that supports the entire length of the array along all four sides. As an additional variation of this system, support of only one, two, or three sides can also be considered (see Figures 35A–35C). Support [101b] shows an embodiment in which only the corners of the array (not shown) may be supported, and support [101c] embodies an embodiment in which the edge support does not extend the entire length of the edges of the array. Figures 35A–35C show additional variations in which only one, two, or three corners may be supported, and only one, two, or three sides may be supported. The advantage of not covering much of the lower surface area of ​​the array is that more surface is exposed to airflow, which may contribute to CO2 adsorption. The advantage of having a larger support area is that the array

[94] is held more securely in place.

[0130] Figure 30C shows a side view of an alternative embodiment in which tapered supports

[0102] are used. In this embodiment, the larger array [94a] may be positioned slightly higher than the smaller array [94b]. The advantage of this approach is that the surface of the airflow is not obstructed. Figure 30D shows a plan view of this configuration. Although Figure 30C shows a continuous taper, a stepped profile can also be envisioned.

[0131] Figure 34 shows an alternative embodiment for supporting the panel. The spring clip

[0108] is attached to a vertical support at a first end and can be used to form a support shelf at a second end to support the bottom of the array

[94] .

[0132] Alternative embodiments for supporting the panel from below are shown in Figures 31A and 31B. In Figure 31A, a mesh of fine elements

[0103] is formed and supported between vertical supports

[0100] to provide rigidity to the mechanism and maintain sufficient tension in the mesh

[0103] to minimize sagging. To minimize interaction between the mesh

[0103] and the array, the mesh can be partially removed near the center of the array

[94] by a notch

[0104] . In some embodiments, the array

[94] may be located above the notch. In this embodiment, the mesh

[0103] extends parallel and perpendicular to the supports

[0100] . In alternative embodiments, the mesh extends obliquely so that each strand is supported by the frame

[0100] . Additional vertical supports

[0100] extending perpendicular to those shown, or a mesh

[0103] with strands omitted that extend parallel to the supports

[0100] , are also conceivable.

[0133] Figure 31B shows another embodiment of this concept, where the support wires

[0105] are more widely spaced and positioned obliquely to the support

[0100] . The advantage of using fewer support wires

[0105] is that there is less occlusion of the array

[94] surface. The advantage of using more support wires

[0105] is that the array can be thinner because each individual strand holds less weight.

[0134] Another approach for supporting the array

[94] is shown in Figure 32. Collars

[0106] , which are coupled to or rest on a support, may be connected to the array

[94] , for example, by tension fitting or by adhesive. Collars

[0106] may rest on a support

[0100] , or collars

[0106] may be bonded to a support, or the support may be inserted into the collar, or the support may have a spring clip (one embodiment is similar to the device shown in Figure 34) to hold the support in place and compensate for size variations. The height of the collar may be part of the height of the array (as shown in the figure), or a larger part of the overall height, or even greater than the height of the array. The width of the collar

[0106] may be sufficient to account for variations in the width of the array

[94] , and the lower surface of the collar may rest on the upper surface of the support

[0100] , or the variation may be absorbed by an elastic or spring connection (e.g., a spring clip shown in Figure 34). Figure 32 shows elements that can be easily assumed in other embodiments described herein. The sealant

[92] can be used to provide cushioning between the arrays

[94] and prevent gas from bypassing the internal gas channels of the arrays

[94] .

[0135] Figure 33 shows another embodiment of a modification for supporting the adsorption unit

[90] . In this embodiment, the manufacturing process may be adapted to include a support surface

[0107] at the edge of the adsorption unit

[90] . In this embodiment, the corners can be enlarged to engage with an edge support [101b] as shown in Figure 30B.

[0136] Several possible embodiments of the connection between the mesh

[0103] and the support strut

[0110] are shown in Figures 42A to 42E. In Figure 42A, the mesh

[0103] may be sandwiched between the support strut

[0110] and a lower strut

[0111] which may be located below the mesh. In this embodiment, the support strut

[0110] may be located above the mesh

[0103] and may be connected to a panel frame (

[95] in Figure 36), although the strut

[0110] may be located below the mesh. The lower support strut

[0111] is free-floating and is shown attached to the upper support strut

[0110] , which may also serve as the main support and may function as the lower sealing surface of the seal shown in Figure 37. The advantage of the design shown in Figure 42A is that the mesh remains flat and the volume of space below the mesh

[0103] and the lower surface of the lower support strut

[0111] are minimized.

[0137] Figures 42B to 42D show three other possible configurations for the interaction between the upper

[0110] and lower

[0111] support struts. In the embodiment illustrated in Figure 42B, the lower support strut [111a] has a triangular shape which can be set into a suitably shaped opening in the upper support strut [110a]. This configuration has the advantage of reducing the void space directly below the mesh, but has the potential disadvantage of requiring deformation of the support mesh

[0103] . Figure 42C shows an alternative configuration in which the lower support strut [111b] takes on a truncated elliptical profile. Figure 42D shows another possible configuration in which a larger support strut [111c] is at the same height as the bottom surface of the adsorption unit

[94] and the mesh

[0103] is deformed around the lower strut. One advantage of this configuration is that when the lower struts [111c] are attached to the panel frame (

[95] in Figure 36), the upper struts [110c] no longer need to support the load and can primarily serve to prevent mesh movement. Therefore, it may be possible to omit the upper struts [110c] to reduce the overall weight of the panel.

[0138] Figure 42E shows yet another embodiment of the mesh support system, in which the support strut

[0110] takes the form of an "n" shaped component that crimps the edges of two sections of the mesh

[0103] .

[0139] Horizontal Moving Panel DAC System In many embodiments, a direct air recovery system is described in which individual adsorption panels are moved continuously and linearly within an airflow, and then each panel is moved out of the airflow into a regeneration box having multiple zones, so that the necessary desorption steps occur.

[0140] In many embodiments, as shown in Figure 2A, each suction panel

[50] of the system moves along a given wall, track, or row of panels [54a], then enters a multizone regeneration box [61a], then enters an adjacent wall, track, or row of panels [54c], and upon exit transport, is transported via a lateral transfer station [62b] to the opposite / adjacent wall, track, or row [54d], returns along its entire surface, then enters a second multizone regeneration box [61b], then enters an adjacent wall, track, or row of panels [54b], and exits via lateral movement by the lateral transfer station [62a], thus repeating the entire process. In some embodiments, as seen in Figure 2A, the panels

[50] may be arranged end-to-end and serviced by fans

[51] on the top (or opposite end). One advantage of this design is that the parallel units in this configuration are more readily fitted into rectangular housings of relatively standard shapes. Another significant advantage is that, because the adsorption panels are quite long (over 250 feet), placing a fan on top of the panel (or at the opposite end) greatly enhances airflow along the entire length of the adsorption panel. The fan draws in air, fresh air flows through the filter, and then into the panel inside the adsorption box. The airflow changes from horizontal (through the filter / panel) to vertical (through the fan) within the adsorption box.

[0141] Figure 2A shows one possible configuration of a combination of multiple fans

[51] and multiple sets of mobile suction panels

[50] / multizone regeneration boxes [61a, 61b], which form two operating units. For example, as seen in Figure 2A, the suction box [60a] may be a rectangle with a width of 10 to 100 feet and a height of 10 feet, alternatively about 20 feet, alternatively about 30 feet, alternatively about 40 feet, alternatively about 50 feet, alternatively about 60 feet, alternatively about 70 feet, alternatively about 70 feet in width, alternatively about 120 to about 640 feet, or alternatively about 240 to 1280 feet. In one embodiment, the suction wall (Figure 2B

[54] ) may be about 240 feet wide × 19 feet high, 180 feet wide × 25 feet high, or alternatively 40 to 640 feet wide and 5 to 50 feet high. Alternatively, the walls of the adsorber may be 240 to 12,800 feet wide and 25 to 100 feet high. Alternative configurations may, as with other configurations, aggregate the walls of the adsorber. The number of fans

[51] may be 5 to 20, or alternatively 1 to 6, or alternatively 15 to 60, or more.

[0142] An alternative embodiment may have regeneration boxes

[61] at both ends of the adsorption box

[60] , as shown in Figure 3. In an alternative embodiment (Figure 4), additional adsorption boxes [60a-60f] may be arranged in parallel so that the adsorption boxes [60a-60f] and the regeneration boxes [61a, 61b] can share a common centralized downstream equipment (vacuum pump, heat pump, compressor). Other alternative embodiments may have a larger number of regeneration boxes (three or more). In some embodiments, multiple adsorption walls (54) may be stacked vertically in any of these configurations with multiple fans. In other embodiments, multiple adsorption boxes may be arranged in parallel (Figure 13A) or in a non-parallel pattern, such as the star configuration shown in Figure 13B.

[0143] Further embodiments include operating the panel track with the panel track oriented horizontally, as shown in Figure 21 (or arranging horizontal panels along a circular track as shown in Figures 44A-44C, and operating the fans shown in Figures 27A and 27B with the fans oriented horizontally above [51b] or below [51a] the panels, or operating the fans with the fans oriented vertically [51c or 51d] below [54a-54d] the panel track).

[0144] In the embodiment shown in Figure 4, it is shown that regeneration boxes [61a, 61b] serve six separate suction boxes [60a-60f] in parallel, with the panels of each suction box [60a-60f] being regenerated simultaneously and the panels within the suction boxes [60a-60f] arranged in a parallel configuration. Arrows indicate the relative movement of the panels within the system. In an alternative embodiment, these suction boxes [60a-60f] may be oriented end-to-end within a longer, thinner regeneration box.

[0145] The number of panels in adsorption mode

[50] is typically significantly greater than the number of panels in desorption or regeneration mode. The ratio of adsorption mode to desorption or regeneration mode panels can be as small as 2:1, or between 2:1 and 12:1, between 12:1 and 36:1, between 36:1 and 144:1, or higher. Using more panels in adsorption mode allows each panel to spend more time adsorbing before desorption, resulting in additional CO2 being desorbed in each regeneration cycle. This can be beneficial in terms of capital efficiency and energy efficiency, as it increases the amount of CO2 produced per unit of renewable energy. This design also allows for efficient heat recovery and transfer throughout the system.

[0146] Having multiple panels simultaneously during regeneration offers advantages in terms of both capital efficiency and energy efficiency. From a capital efficiency standpoint, having a single regeneration box with multiple zones containing more adsorption panels significantly improves throughput and reduces the capital cost per unit of output. Furthermore, applying steam to a specific zone and then applying that same steam to other panels in other zones increases substantial thermal energy efficiency compared to requiring fresh steam for each panel.

[0147] Figure 2A shows how sets of multiple panels

[50] and regeneration boxes [61a, 61b] may be arranged adjacent to one another. In some embodiments, multiple levels of panels may be serviced by overhead fans

[51] (or, instead, by fans at both ends of the building). In alternative embodiments, there may be three, four, five, or more layers of panels, and the fan configuration may also differ. Multiple fans (and / or even more fans) may be present in the horizontal direction. The ratio of panels to fans may vary to optimize airflow, panel load, pressure drop, and / or fan efficiency.

[0148] The suction box

[60] may include a series of fans

[51] for moving air through the suction panel.

[0149] Regeneration chamber In some examples, the regeneration process may be a simple batch operation in which a panel is loaded (as shown in Figures 15 and 16), and then a series of regeneration steps are performed. These steps may include air removal, panel heating, CO2 desorption, and panel cooling. The panel

[50] can be housed in a chamber by being contained between a series of movable wall elements (e.g., a clamshell) or by being placed in a fixed container with a door closed to isolate it from the surroundings, and these steps can be performed.

[0150] In one embodiment, as shown in Figure 5A, multiple panels [50a-50d] may be housed within a fixed structure. The panels [50a-50d] are inserted from narrow ends to minimize the size of the door

[25] and the required sealing area. The regeneration box

[61] may comprise multiple chambers (or zones). In this embodiment, the regeneration box

[61] includes an initial purge zone

[10] , two steam processing zones

[11] and

[12] , and a final cooling zone

[13] . Possible cycles within zone

[10] may include opening the door

[25] and sliding in a newly loaded panel

[50] while the door

[26] to the steam processing zone

[11] is closed. The chamber of the initial purge zone

[10] may then be evacuated by vacuum. Optionally, steam may be allowed to enter the chamber while the vacuum is applied to push out any remaining air. Next, the vacuum valve may be closed and the chamber

[10] may be repressurized with CO2, fresh steam, or by connecting zone

[10] to an exhaust port from zone

[11] . Once the chamber in zone

[10] is repressurized, the door

[26] may be opened and the panel

[50] may be advanced in zone

[11] , and the fresh steam port may be opened to fill the void space created by removing the panel. Next, the door

[26] may be closed and zone

[10] is ready to receive the next panel. Optionally, while the next panel is being loaded, a port to a heat recovery system may be opened to recover steam in the void space of the chamber in zone

[10] as the new panel enters. Alternatively, before loading the new panel

[50] , air may be swept through the chamber in zone

[10] to remove steam (and optionally recover the steam), and then the next panel may be loaded.

[0151] In alternative embodiments, the initial purge segment can be divided into two, three, or more zones to separate the purge step into various components, such as vacuum and subsequent initial vapor break. This offers several advantages, including (i) reduced loss of vapor and CO2 into the atmosphere, (ii) reduced risk of air intrusion into the hot panels of subsequent zones, and (iii) improved panel movement speed per zone, allowing the timing of this step to better match the timing required for multiple panels in the vapor treatment (and other) steps.

[0152] Figure 5B shows a close-up of the two steam treatment zones

[11] and

[12] . In other embodiments, a different number of steam treatment zones may be used. The steam may be distributed to a plenum

[21] separated from the panel by a porous wall made of, for example, sintered metal or textile material, which may help to evenly distribute the steam flow. In this embodiment, the steam enters the second steam treatment zone

[12] and is forced to flow through the adsorption panel

[50] to the opposite plenum

[22] by a baffle

[24] that separates zone

[11] and zone

[12] on one side of the regeneration box. The steam then flows through the plenum

[22] to zone

[11] , through the panel

[50] contained in its chamber, and then out through the plenum

[23] .

[0153] In other configurations, the steam treatment section may be longer (e.g., 3, 4, 5, or 6-10 zones, or longer), and additional baffles may be installed within the plenum to allow steam to pass through individual panels multiple times (e.g., passing through the front half of the panel in one direction and the other half in the opposite direction, or dividing the panel into thirds, quarters, fifths, etc., by the flow). In yet another configuration, part of the steam treatment chamber may be left empty to allow the panels to move continuously (as illustrated in Figure 6). Figure 6 shows an embodiment in which there is a single steam region

[11] surrounding three panels in a chamber that is approximately 4 panels long. Steam is supplied to the two central panels and can pass through each of these panels eight times, with the steam flowing about a quarter of the panel's length each time it passes through. Three panels [50a, 50b, 50c] are charged into the region and they move gradually through the steam over the course of all steps. The five rows in Figure 6 show the positions of the panels at various times (t1 to t5) in the steam treatment process, with the last row showing the steam-treated panel [50a] exiting and a new panel [50d] entering from the left. By moving the panels along a continuous flow of steam in this way, the same (or similar) steam profile can be generated in all parts of the panel with respect to time, temperature, and CO2 charge. In alternative embodiments, different numbers of panels and zones can be used for this continuous panel movement through the steam, with a minimum of one panel and two zones, or two to five panels and three to six zones, or six to ten panels (or more) and seven to eleven zones (or more).

[0154] In some embodiments, the steam processing zone may be designed to accept high pressures of 2 or 3 bara or more to make the steam available at a higher thermal value. In such cases, additional reinforcement and associated mechanisms may be required in both the walls of the regeneration box and the doors between the zones to provide sufficient resistance (and sealing) to cope with the higher positive pressure.

[0155] In Figures 5A and 5B, the steam-treated panel

[50] exits zone

[12] and enters the vacuum cooling zone

[13] through door

[27] . Next, a valve connecting zone

[13] to a vacuum source is opened, and the chamber is evacuated to reduce the pressure. The reduced pressure causes some of the hot condensed water in panel

[50] to evaporate, resulting in the panel

[50] being cooled and dried at the same time. To reduce the load on the vacuum pump, the resulting steam may be condensed in a heat exchanger so that only non-condensable charge flows through the vacuum pump. Also, since most of the non-condensable charge from zone

[13] is rich in CO2, the discharge from the vacuum pump can be recovered as a product. When the panel in zone

[13] reaches a temperature below 60°C, or preferably below 40°C, or below 30°C, a port to ambient air may be opened and the vacuum may be broken. Next, the last door

[28] can be opened and the cold, dehydrated panel

[50] can be removed. Next, the door

[28] is closed in preparation for the next cycle.

[0156] In alternative embodiments, the cooling segment may be divided into two, three, or more zones to separate the cooling of the panel into different components (initial vacuum cooling, continuous vacuum cooling, and vacuum breaking with air). This may offer several advantages, including (i) a reduced risk of any loss of CO2 into the atmosphere, (ii) a reduced risk of air entering the hot panel in the subsequent zone, and (iii) an improved panel movement speed per zone, allowing the timing of this step to better coincide with the timing required for multiple panels in the steam treatment (and other) steps.

[0157] As seen in Figure 5A, both vacuum chambers in zone

[10] and zone

[13] have two doors, as opposed to one. The vacuum chambers with two doors allow for panel "flow-through," so that one panel can enter the zone while a second panel is moving. The overall process production rate is constrained by how quickly CO2 can be removed from the panels, so minimizing the time required to move a panel maximizes the time available for CO2 removal. If there is only one door, one panel must be removed before the next panel can be loaded, and the void in the vacuum chamber

[10] or

[13] must be filled with gas (usually air). Having two doors and a "flow-through" design makes it possible to move one panel while the previous panel is moving, reducing the overall cycle time and minimizing the filling of the void space with unwanted gas.

[0158] Combining this two-door design with a multi-zone regeneration box offers further advantages. These advantages include the opportunity to minimize void space around the panels, which is particularly beneficial in the inlet and outlet zones

[10]

[13] where air intrusion could have significant adverse effects. It also allows for keeping the high-temperature steam processing zone consistently warm (minimizing the stress and cost of thermal cycling), and for widening the steam distribution plenum in the steam processing zone without adding void space to the vacuum zone (which would be required in a single-zone design). Furthermore, having multiple panels within the steam processing zone allows for operation in a mode where steam and panels flow in opposite directions. The closer the system can get to true reverse flow operation, the more efficiently steam can be used, resulting in a higher concentration of CO2 that can be supplied to downstream processes.

[0159] As shown in Figure 5A, in some embodiments of the system, doors

[26] ,

[27] , and

[28] are all opened simultaneously, allowing panels from zones

[10] ,

[11] , and

[12] to be moved to zones

[11] ,

[12] , and

[13] simultaneously, and allowing panels from zone

[13] to be moved out of the system simultaneously. In other embodiments, panels

[50] in zone

[13] may be carried out with door

[27] closed, filling the void space with air. The air can then be evacuated by closing door

[28] and drawing a vacuum and repressurizing with steam or other inert gas, or replaced by simply flushing the void with steam. In other embodiments, panels in zones

[11] and

[12] may be moved while door

[26] is still closed, resulting in their move from zone

[10] occurring later. In yet another embodiment, all four doors can be opened simultaneously, allowing the panel to be inserted into zone

[10] as it moves from

[10] to

[11] , from

[11] to

[12] , from

[12] to

[13] , and from

[13] out of the playback box.

[0160] In other embodiments, the regeneration box may be sized to accommodate more panels in the direction of movement or parallel to the direction of movement. For example, the length of the regeneration box may remain approximately four panels, but the width may accommodate two, three, four, or more panels, with each panel loaded facing each other. In yet another embodiment, the length of the regeneration box may be increased so that multiple panels are placed end to end in each zone, and those panels are advanced together at each step. For example, each zone may accommodate two panels, three to five panels, or five to ten panels (or more), and in any case, the entire panel of each zone may be moved from one zone to the next.

[0161] System Overview The DAC system employs a chemical sorbent process to remove carbon dioxide from the ambient air supplied to the process using an air treatment system integrated within the system's package envelope. The chemical sorbent process is a reversible reaction that is regenerated by utilizing the distribution and recovery of vapor.

[0162] As can be seen in Figures 2A and 2B, a series of adsorption panels

[50] move continuously in the airflow along a linear plane or row to form a “wall” of panels [54a, 54b] (or alternatively, an additional plane). At the end of the adsorption box [60a], each panel

[50] exits the airflow generated by the fan

[51] inside the adsorption box

[60] and enters the multizone regeneration box [61a]. After the panel

[50] exits the regeneration box [61a], the panel

[50] re-enters the adjacent adsorption box [60b] and joins to a “wall” of panel [54c]. At the end of the adsorption box [60b], the panel

[50] exits the airflow and moves to the opposite side of the adsorption box [60b] via the lateral movement system [62b], joins to another “wall” [54d] of panel [60b], and re-enters the airflow inside the adsorption box [60b]. After exiting the airflow within the adsorption box [60b], the panel

[50] enters the next regeneration box [61b].

[0163] Figure 7A shows an exemplary embodiment of the panel moving system. While in the airflow within the suction box

[60] , each panel

[50] can move continuously across the track

[63] . Such movement can be achieved using stepping motors, or alternatively, hydraulic, pneumatic, electric, or other drive mechanisms, and may include chains or alternative mechanisms to facilitate such movement along the entire length of the track.

[0164] At the far end of each adsorption box

[60] , after exiting the airflow, each panel

[50] may enter a lateral transfer unit

[62] , moving the panel

[50] to the wall

[54] opposite the adsorption panel. Figure 7B shows an exemplary embodiment of a lateral transfer station or lateral unit

[62] . Such a lateral unit

[62] may include an A-frame and other mechanisms for securing the panel

[50] for the purpose of such lateral movement. The panel

[50] may remain open to ambient conditions during the adsorption phase, but may be sealed from any ambient conditions during the regeneration phase, thereby ensuring an optimal environment for facilitating the subsequent desorption of the recovered atmospheric CO2.

[0165] Figure 7C shows an exemplary embodiment of the adsorption box

[60] . Airflow may be supplied to the panel

[50] from one or more fans

[51] , which may typically be an inductive draft design, but may be a forced draft alternatively. The diameter of the fans may be as small as 10 feet, or alternatively 10 to 30 feet, alternatively 30 to 50 feet, or alternatively 50 to 70 feet (or more). The fans may be oriented horizontally or vertically. The fans may be arranged in a stacked vertical arrangement, a side-by-side arrangement, or a combination of side-by-side and vertical arrangements. In some embodiments, three or four (or more) fans may be arranged in an overlapping arrangement, in other embodiments three or four (or more) fans may be arranged side-by-side, and in other embodiments they may be arranged in a 2x2, 3x3, or 4x4 (or more) configuration. Fans can be arranged in different numbers for height and width, such as 3x2 (3x2), 4x2, 4x3, 5x3, 6x3, 5x4, etc. Alternatively, the number of fans in the height direction can be combined with a range of 1 to 6 (or more) for the number of fans in the width direction.

[0166] Once the panel's airflow / CO2 adsorption cycle is complete (as in the example in Figure 1), the panel moves along the track to the regeneration box, where the door is closed to seal it from the surrounding air, and the panel is ready to begin the CO2 regeneration and removal steps. As described above, this can be achieved by using a vacuum pump to remove the air, followed by the addition of steam or an inert gas to remove residual oxygen, and finally by adding steam to break the vacuum. The panel then moves to the steam treatment zone

[11] , where further steam is applied, and then the panel moves to one or more additional zones to continue the steam treatment process. Following the steam step, the panel moves to the final zone (or multiple zones

[13] ) where vacuuming may be performed to facilitate the removal of any remaining CO2 and the cooling of the panel. A valve then introduces air to break the vacuum, at which point the panel moves along the track out of the regeneration box and to a position where it re-enters the airflow of the next panel wall in the adsorption box, thus restarting the adsorption cycle.

[0167] At points where air flows and re-enters the panel wall, care can be taken to ensure that each panel is ready to re-enter the airflow immediately behind the next panel it moves to, in order to avoid gaps that could negatively affect the airflow. Similarly, roller seals (or alternative types of seals) can be used at the panel inlets (and outlets) to minimize the risk of air leaks.

[0168] The regeneration box may complete the entire desorption process in a single zone or through several separate zones, thereby allowing a single panel

[50] to move from zone to zone to complete its desorption process. The steps include (i) removing air (and oxygen, which may be harmful to the adsorbent at high temperatures) from the panel

[50] by vacuuming or sweeping the air out with steam or an inert gas (such as nitrogen); (ii) breaking the vacuum with steam, CO2, or other alternative gases; (iii) heating the panel

[50] with steam or CO2 (or other means such as indirect heat); and (iv) cooling the panel

[50] by vacuum, application of an inert gas (such as nitrogen), or a combination of other direct or indirect cooling methods. As seen in Figure 5A, the regeneration box

[61] comprises three sections. Specifically, (i) a pre-vacuum section (zone

[10] ) in which the air surrounding the panel

[50] is removed by vacuum (or other means) and then the vacuum is broken with steam; (ii) a central steam treatment section (zones

[11] and

[12] ) in which steam is supplied to two (or fewer or more) adsorption panels; and (iii) a cooling section (zone

[13] ) in which the panel

[50] is exposed to vacuum (or alternative means) for cooling before being exposed to ambient conditions again. In alternative embodiments, various alternative means may be used to remove air, add heat, and / or cool the panel

[50] . Alternative embodiments may include a different number of panels in each section, or an additional zone in each section, or both. Furthermore, in certain embodiments, there may be less need to remove air or to cool the panel

[50] , in which case the number and nature of the sections and / or zones, and the number of panels in each section, may vary considerably.

[0169] The doors

[25] ,

[26] ,

[27] , and

[28] of the regeneration box

[61] may be driven by electric, hydraulic, or pneumatic means using actuators located outside the regeneration box

[61] itself. The door seals may be single or double seals, and in the case of double seals, a function may be included to fill the space between the seals with steam.

[0170] The gas may be delivered to (or removed from) a regeneration box

[61] via a series of pipes (or ducts) and valves.

[0171] The entire playback process may take a minimum of one minute and a maximum of four minutes (or more), and each panel

[50] may move from section to section or zone to zone within its overall time limit, with each section lasting a minimum of 10-15 seconds, or a maximum of 45-60 seconds, or 15-30 seconds or 30-45 seconds in between.

[0172] In some embodiments, additional steps may be required to further isolate the hot adsorption panel

[50] from exposure to air as the final panel

[50] is discharged. In such cases, additional steps may be added to remove air from the cooling section (zone

[13] ) (either via vacuum or vapor sweep, or both) before advancing the hot panel to zone

[13] . This can be achieved by either allowing additional time to remove air from zone

[13] before advancing the hot panel

[50] , or by adding yet another zone to the regeneration box to facilitate additional buffering against exposure to incoming air.

[0173] The panels

[50] can be rectangular in shape and of any size, with side dimensions ranging from about 2 feet smaller to over 60 feet larger. In embodiments, alternative shapes may be used for the panels and recycled plates, including polygons of various sizes, or circles or ellipses. In one alternative embodiment, the panels are shown in the shape of disks or rings “slice” to accommodate continuous movement along a circular track (Figure 44A) (Figure 44B).

[0174] Furthermore, the entire DAC process unit (adsorption box

[60] and regeneration box

[61] ) may be arranged side by side, which allows the DAC process unit to share downstream processing equipment such as a heat pump and a compressor.

[0175] When DAC units are adjacent to each other (whether stacked or side-by-side), care must be taken to prevent low-CO2 air emitted from one unit from being drawn into the adjacent unit. In some embodiments, ducts (guide vanes or other airflow deflection devices) can be introduced to ensure that CO2-depleted air is properly discharged from the adjacent unit.

[0176] A single unit can capture approximately 40,000–50,000 tons of CO2 per year, alternatively 1,000–5,000 tons per year, alternatively 5,000–40,000 tons per year, or alternatively 50,000–100,000 tons per year, or alternatively 100,000–300,000 tons per year (or more). Multiple units can be arranged adjacent to each other or stacked to achieve a total volume of 1 million tons / year, or 10 million tons / year or more. Increased production volume can lead to further cost reductions by (i) distributing the costs of shared process equipment (costs do not increase proportionally with scale) across the entire production volume, and (ii) transitioning to a "continuous" process from a process flow perspective (by increasing the number of subunits), which improves the operational efficiency of process equipment and reduces associated energy costs.

[0177] The system may also include an accumulator that allows a portion of the process flow to operate in a more continuous manner. The system may also include a mechanism to prevent foreign matter from interfering with the operation of the panels. For example, the system may include a screen to prevent insects from entering the system. The system may also include a filter to reduce the accumulation of soil, dust, and particulate matter. The system may also require periodic cleaning of the adsorption panels.

[0178] The system is designed to ensure that the entire regeneration cycle can be run efficiently without excessive time allocation, excessive steam breakthroughs, or other factors that negatively impact throughput and / or operating costs.

[0179] The main fluid inputs include air, steam, and, in certain embodiments, one or more inert gases such as CO2 or N2, as well as makeup water. The discharges from the plant are CO2-clean air containing water vapor and product CO2 (plus a possible N2 / air mixture containing water vapor).

[0180] In a preferred embodiment, steam is used to provide heat for desorption, the partial pressure of CO2 reduction, and power to remove CO2 from the regeneration chamber. Alternative embodiments can be readily conceivable. For example, heat can be supplied by embedding heating elements within the adsorption panel. These heating elements may be electrically heated wires or tubes containing a high-temperature fluid. Alternatively, steam can be replaced with another high-temperature gas that can be easily condensed and separated from CO2 in a downstream process. Examples of such fluids may include “natural refrigerants” such as butane, pentane, hexane, or other similar hydrocarbons, synthetic refrigerants such as fluorinated hydrocarbons, ammonia, or other similar gases. The partial pressure of CO2 can be reduced by applying a vacuum during the heating cycle. It is clear that the steps required for desorption can be achieved in several different ways by creating an isolated regeneration space for the panel that can withstand vacuum, high temperature, and high pressure.

[0181] fan When approaching the adsorption panel, an airflow velocity of approximately 3 m / s, alternatively approximately 1 to 5 m / s, alternatively approximately 0.2 to 10 m / s, or alternatively exceeding 12 m / s may be required. Individual adsorption units within the panel may contain numerous small channels resembling a honeycomb, and air may need to be injected into these channels. Therefore, the velocity of air passing through the panel may increase, with airflow velocities of 0.2 to 20 m / s, alternatively 3 to 15 m / s, or alternatively 4 to 10 m / s.

[0182] In some embodiments, air circulation may be provided by a single large fan or a series of fans that roughly match the length of the suction box

[60] . For example, for a suction box that is about 18 feet wide and 260 feet long, 15 fans with a diameter of about 16 feet each could be lined up overhead.

[0183] Adsorbent The adsorbent sets the productivity level and regeneration requirements. This system can use adsorbents specifically designed for DACs. Adsorbents for use with DACs are described in US2019 / 0291077, entitled "PCSTRUCTURES INCLUDING SUPPORTED POLYAMINES AND METHODS OF MAKING THE SUPPORTED POLYAMINES," which is expressly incorporated herein by reference in its entirety for all purposes. The adsorbent material may have low molecular weight, highly branched polyethyleneimines (PEIs) incorporated into the panel substrate. This allows for high volume amine charging (i.e., amine moiety / adsorbent volume). Solid amine adsorbents interact with CO2 via a chemisorption mechanism, resulting in high CO2 adsorption capacity at very low CO2 partial pressures and exhibiting higher selectivity for CO2 than other components in the air, such as water in the form of moisture. Polyethyleneimine (PEI) sorbents may have a limited lifespan, estimated to be 0.5 to 3 years (mainly due to oxidation and polymer leaching), at which point the sorbent on the substrate needs to be replaced. Extensive preliminary studies have been conducted to establish lifespan targets.

[0184] In other embodiments, other adsorbents may be used, such as alternative forms of PEI, alternative forms of amine-based adsorbents, zeolites, metal-organic frameworks (MOFs), and other materials that effectively and selectively recover CO2.

[0185] In the embodiments, other forms of substrates containing an sorbent may also be used, including fibers impregnated with the sorbent, fabrics impregnated with the sorbent, flat surfaces of metals or other materials, or alternative structures and materials designed to optimize CO2 adsorption while limiting the pressure drop.

[0186] Downstream processes Figures 8A–8B show exemplary embodiments of downstream processing for the regeneration box. A large vacuum chamber

[46] allows for rapid removal of air from zone

[10] or zone

[13] while operating a vacuum pump

[47] under a relatively uniform load. Hot steam from zone

[11] , which may contain CO2 and water, is sent to a condenser

[40] , where it can be condensed against a boiling refrigerant such as butane or an alternative gas. The condensate of liquid water from

[40] can be reused to generate more steam, while the remaining uncondensed gas can be directed to a second condenser

[41] operating at a lower temperature. This condenser can be cooled by boiling the refrigerant at a lower pressure. Again, the water from the condenser

[41] may be returned to a boiler

[43] , or the remaining gas, here mainly CO2, may be sent to a product compressor

[49] .

[0187] Low-pressure refrigerant from the condenser

[41] may be sent to a low-stage heat pump compressor

[45] , which may then supply to an accumulator vessel

[39] . Steam from the intermediate-pressure accumulator

[39] may be mixed with intermediate-pressure refrigerant steam from the condenser

[40] and supplied to a high-stage compressor

[44] . High-temperature, high-pressure steam from the compressor

[44] is collected in an accumulator

[38] , and the steam is condensed in a boiler

[43] to produce steam for the process.

[0188] The moist, CO2-rich steam from Zone

[13] may be sent to a condenser

[42] where most of the water vapor is removed as liquid and returned to the boiler, but the remaining steam (mainly CO2) may be sent to a vacuum pump

[48] and discharged to a source for the product compressor

[49] .

[0189] In previous designs, steam for desorption was generated by burning fuel to create a high-temperature gas, which was then used to boil water. The fuel was typically obtained from fossil fuels or, at best, renewable resources (such as biomass or anaerobic digestion). Consequently, such systems contributed to the atmospheric CO2 that the DAC systems described herein are designed to recover. The steam and CO2 generated by the desorption process were typically separated by condensing water vapor from the CO2 gas in a condenser cooled by cooling water. The heat transferred to the cooling water was then released into the atmosphere by evaporating some of the water in a cooling tower.

[0190] The process described herein may enable the condensation of vaporized CO2 discharged from the desorption process in two steps: a first step at a relatively high temperature (e.g., above 50°C, alternatively above 60°C, alternatively about 50°C to about 80°C, alternatively about 70°C, alternatively about 75°C, alternatively about 77°C, alternatively about 78°C) and a second step at a lower temperature (e.g., about 25°C to about 40°C, alternatively about 25°C, alternatively about 30°C).

[0191] A possible embodiment of this design is shown in Figure 8B. The first condenser

[40] can recover most of the energy of the steam CO2 at a higher temperature than usual. This higher temperature means that the energy can be efficiently upgraded in a steam generation heat pump

[38] ,

[40] ,

[43] , and

[44] . This heat pump uses electricity in a refrigerant compressor

[44] to increase the pressure (and therefore the condensation temperature) of the refrigerant, creating conditions that allow the refrigerant to condense at a temperature high enough to boil water and produce low-pressure steam

[43] . The main advantage of using a heat pump is that the amount of electricity required to operate the compressor

[44] is significantly less than the amount of energy that can be supplied to produce steam

[43] . Typically, the energy supplied to the steam is 1 part electrocompression energy and 2-5 parts thermal energy recovered in the process condenser

[40] . Furthermore, in certain embodiments, the power to operate this heat pump can be generated without directly releasing CO2 (e.g., hydropower, wind power, solar power), thereby "decarbonizing" the heat supply to the entire process. As an additional benefit, the heat recovered by the heat pump may be reused directly within the process rather than being discharged into a cooling tower, thus significantly reducing the amount of water used in the cooling tower.

[0192] While it may be preferable to use electricity obtained from processes that do not directly emit CO2, the present invention is not limited thereto, and the improvements described herein can also be applied to systems powered by fossil fuels, renewable resources such as biomass and anaerobic digestion, and such systems are also included within the scope and spirit of the present invention as disclosed herein.

[0193] In some embodiments, to further improve overall process efficiency, and with the high-temperature heat pump in place, a second-stage heat pump can be economically added to the system to operate in a lower temperature / pressure range. The second-stage heat pump (

[39] ,

[41] , and

[45] , and (if integrated)

[38] ) can collect energy at lower temperatures not only from the product stream (exchanger 41) but also from other lower-grade heat sources such as dryer / cooler steam from the drying / cooling section

[13] (inside unit 42) and other locations (e.g., CO2 compressor exhaust, refrigeration plant exhaust). While it is inefficient to raise the temperature from the low temperature (e.g., nominal 30°C) of the second condenser

[41] to produce steam, that heat can be used to boil more butane at intermediate pressure (inside the accumulator

[38] ). With this two-stage heat pump, the power required to upgrade the low-temperature energy is significantly less than the energy recovered in the steam (e.g., 1.5 to 3 times the heat recovered for every unit of power). However, it is less efficient than a high-stage heat pump itself (more energy is recovered, but the efficiency is lower). Such a system significantly reduces the amount of water used in the cooling tower.

[0194] The embodiments described above and in Figure 8B only outline one possible configuration of the process. For example, the temperature at which the heat exchangers

[40] and

[41] collect heat can be increased or decreased (allowing for more efficient heat recovery, but reducing the amount of energy that can be collected), the size of the heat exchangers

[40] ,

[41] , and

[43] can be increased or decreased (allowing for a reduction in the temperature difference between the high-temperature and low-temperature sides, but requiring more capital), or the efficiency and cooling of the refrigerant compressors

[44] and

[45] can be changed. In this embodiment, the steam is shown to be generated at 110°C, but the steam temperature can be changed by lowering or raising the discharge pressure of the compressor

[44] , for example, to 90°C or to 140°C.

[0195] The refrigerant shown in Figure 8B is butane, but several other refrigerants or refrigerant mixtures may be used. Possible refrigerants include, but are not limited to, propane, isobutane, pentane, or similar "natural" refrigerants, or "synthetic" refrigerants such as R1336MZZ. Figures 8A and 8B show the refrigerant directly coupled to the process stream, but a heat transfer fluid such as water can also be used to keep the process and refrigerant separated. In other embodiments, additional stages can be added to the heat pump. For example, a three-stage heat pump collects heat at 80°C, 50°C, and 20°C. In yet another embodiment, different refrigerants can be used for different stages. For example, ammonia can be used in the lower stage (rising from 20-40°C or 0-45°C or -30-50°C to 70-80°C or 65-85°C or 60-90°C), and water vapor can be used in the upper stage (rising from 70-80°C or 60-85°C or 55-90°C to 105-110°C or 102-120°C or 100-140°C). Conventional refrigerants can also be used, and such systems fall within the scope and spirit of the present invention.

[0196] In alternative embodiments, steam may be supplied by a conventional boiler or by waste heat from another process. Cooling may be supplied by a conventional cooling tower or by integration with another process. In another alternative embodiment, the condensers

[40] ,

[41] , and

[42] may be water-cooled, and the water releases its heat to a heat pump.

[0197] Adsorption process The adsorption process combines a contactor with a very high surface area-to-volume ratio, an adsorbent with high selectivity for CO2, and an adsorbent with a low pressure drop, all designed to facilitate the movement of large volumes of air to maximize carbon capture. CO2 adsorption is a function of the uptake curve, and as the adsorbent fills up, the rate at which CO2 is adsorbed to the adsorbent decreases. Therefore, optimizing the adsorption cycle time relative to the desorption time can have a significant impact on the overall CO2 capacity and cost per ton.

[0198] The adsorption capacity depends not only on the adsorption time, but also on the dimensions of the panel (height, width, and length), the porosity of the adsorption panel, the type of adsorbent with its associated selectivity for CO2, the loading of an sorbent capable of adsorbing CO2 into the adsorption panel matrix, and the partial pressure of CO2 in contact with the adsorption panel (i.e., a function of the airflow rate and the CO2 concentration in that air). Furthermore, since the incremental adsorption capacity is a function of the amount of CO2 adsorbed on the adsorption panel, successful desorption significantly impacts the adsorption stage. This embodiment is designed to optimize the above characteristics to maximize the CO2 throughput in the system, thereby increasing capacity and reducing the cost per ton of recovered CO2.

[0199] Regeneration process The steps of the playback process performed in a playback box (an example of which is shown in Figure 5) are described in more detail below.

[0200] The sorbent embedded in the panel

[50] is at risk of deactivation if exposed to oxygen at temperatures well above the ambient temperature, i.e., above 35–60°C. Therefore, a partial or deep vacuum can be drawn via a pump-down step before steam is supplied during regeneration. The vacuum may be about 0.20–0.50 bar, alternatively about 0.10–0.20 bar, alternatively about 0.025–0.20 bar, or alternatively about 0.05–0.1 bar.

[0201] To further improve oxygen replacement, an optional additional step may be taken to purge oxygen by applying a sweep gas (to minimize the risk of inactivating the adsorbent, as described above). In certain embodiments, the sweep gas may be vapor. In such cases, the vapor may be applied at a constant temperature, or rate, or for a certain duration, or while the regeneration chamber is still under vacuum, to minimize heating of the adsorbent (otherwise, there is a risk of inactivating the adsorbent).

[0202] The sweep gas may also be nitrogen, which can be produced from a nitrogen generator at a concentration of approximately 96% to 99.9999%. The nitrogen can then be recovered through another process and recycled again through the system.

[0203] In an alternative embodiment, the sweep gas may be exhaust gas from a gas combustion boiler, in which case NO in the emissions may adversely affect the adsorption medium. x and SO x It needs to be kept to a minimum.

[0204] Alternatively, carbon dioxide itself can be used as a sweep gas, making it economically possible to reuse and recover carbon dioxide through multiple cycles.

[0205] In some embodiments, the system may allow the application of different sweep gases so that process adjustments can be made based on performance / analysis. After the sweep gas is delivered to the panel, it may then travel through a recovery system for reuse.

[0206] As long as an inert gas is used for the initial purge, steam can be applied as a secondary purge to remove non-condensable nitrogen and oxygen from any void space. This step is important because high levels of non-condensable nitrogen and oxygen carried into purification along with unpurified CO2 products can make it difficult to efficiently condense and recover CO2. This steam application can be combined with a vacuum, which replaces most of the inert gas and prevents the steam from condensing at temperatures high enough to promote oxidation or desorb CO2.

[0207] In addition to the above, certain next-generation adsorbents may be available that substantially eliminate the risk of adsorbent deactivation in the presence of oxygen and high heat. Using such adsorbents reduces the need for vacuum, sweep gas, and cooling steps, significantly improving process speed and efficiency and substantially lowering system costs.

[0208] After the O2 concentration around the sorbent decreases, heat is applied to the panel for the purpose of desorbing CO2. This may be achieved by applying steam supplied through steam pipes / ducts attached to a regeneration box. In either case, the gas is supplied / removed through a series of pipes and valves. The steam may be applied to the panel at temperatures of approximately 80°C to 90°C, alternatively 90°C to 100°C, alternatively 100°C to 125°C, and alternatively 120°C to 150°C.

[0209] In some embodiments, it is advantageous to use steam to break the vacuum in the initial zone / chamber within the regeneration box. During this step, steam flows into the chamber and condenses on the colder inner surface. This draws in additional steam, warming the panel, which can lead to sufficient heating to initiate CO2 release. Once the internal volume of the regeneration chamber reaches a suitable pressure, e.g., atmospheric pressure, the panel can move to the next zone / chamber. Further steam condenses, providing a temperature-driven force for further CO2 desorption, and the excess steam removes CO2 gas from the volume, maintaining a low partial pressure and thus maintaining an attractive desorption drive.

[0210] In other embodiments, a preheating step may be used, in which a high-temperature gas (approximately 50°C to 100°C) is recirculated within the chamber and reheated in an external heat exchanger. The recirculated high-temperature gas may be CO2 or a mixture of CO2 and water vapor. Preheating the panel with a high-temperature gas may reduce the amount of vapor that condenses on the panel in subsequent steps, and therefore the amount of condensate in the pores of the panel may be reduced.

[0211] After steam is applied to collect CO2, the adsorption panel moves to the next zone / chamber, where it may undergo a cooling step by evaporating condensed water on the panel surface. This cooling step can be achieved by further reducing the vacuum to about 0.20–0.30 bar, alternatively to 0.10–0.20 bar, or alternatively to 0.01–0.1 bar. This vacuum helps to cool the adsorption panel to a level that not only helps to remove all remaining gas from the system and reduce the amount of water remaining in the adsorbent, but also helps to minimize the potential oxidation of the adsorbent. In some embodiments, the adsorption panel may need to be cooled to below about 60°C, alternatively to about 40°C, or alternatively to about 25°C.

[0212] Additionally, or alternatively, nitrogen may be applied to accelerate cooling and remove residual water from the panels. The nitrogen may be moved again through a recovery system to allow for reuse. Alternatively, a gas such as air or nitrogen may be used after the initial vacuum cooling step, and that gas may be recirculated through a cooler / condenser.

[0213] The duration of the cooling step may vary depending on (i) the target temperature level and the percentage of water remaining until it is achieved, and (ii) the size of the vacuum pump and / or blower used to facilitate the cooling step.

[0214] CO2 emitted from the system is mixed with water vapor (or, in other embodiments, another readily condensable gas) and an inert, largely non-condensable gas (such as N2 or O2). This water vapor (or other readily condensable gas) can be condensed by cooling and / or pressurizing the product flow, making it possible to recover the condensable gas as a liquid flow. The heat released by condensing the vapor is recovered in a process fluid that can be used to supply a heat pump. In any case, the condensed water from the product flow is recovered and can be recycled and reused (as well as any excess nitrogen if nitrogen was used as part of the cooling step). The product flow exiting this cooling / compression stage may be 80–99% by weight CO2 and can be recovered directly as a product. Further cooling can increase the CO2 concentration to a further 95–99.9% by weight.

[0215] The recovered and regenerated CO2 may then undergo a liquefaction / purification step, in which the CO2 enters a series of compression and cooling steps to increase its concentration and liquefy it. Compressed CO2 can have a purity of approximately 95% to 99.99% by weight. The recovered CO2 can be immediately used in products (such as chemicals, materials used in plastics and concrete, carbon fibers, food, and beverages) or sequestered underground. Alternatively, the recovered CO2 may be stored in high-pressure, low-temperature tanks and periodically transported to locations where the CO2 is used in products, or sequestered underground instead.

[0216] When the panel temperature drops below the temperature at which rapid inactivation of the adsorbent can occur in the presence of oxygen, and the water level remaining in the pore spaces decreases below a threshold, the panel can be released from the regeneration box and begin moving along the track again, allowing air movement and the adsorption phase to resume.

[0217] Heat pumps, heat recovery, and other downstream processes Conventional methods of operating a DAC system may involve burning fuel to generate steam, powering the process, and sending waste heat to a cooling tower. This is relatively inefficient in terms of energy use and can affect the carbon reduction effectiveness of a DAC plant.

[0218] In some embodiments, the systems described herein may use a heat pump instead of a boiler and cooling tower that burn fuel. A heat pump is a device that recovers low-grade heat from the process and upgrades it for reuse by using an electric motor to power a compressor. In certain embodiments, the electric motor may be powered by renewable energy, which can reduce carbon emissions during the operation of the entire process. The heat pump also eliminates the load on the cooling tower and reduces the water footprint.

[0219] While it may be preferable to use electricity derived from processes that do not directly emit CO2 to operate a heat pump, the present invention is not limited thereto, and the improvements described herein can also be applied to systems powered by fossil fuels, renewable resources such as biomass or anaerobic digestion, and such systems are also within the scope and spirit of the present invention as disclosed herein.

[0220] This process design is configured to recover waste heat at two temperature levels to improve the efficiency of the energy upgrade. In the regeneration system, integrating the heat pump with a lower cooling step than before improves water recovery (less water lost into the atmosphere / less water replenished in the steam system) and lowers the temperature of the panels transitioning from regeneration to adsorption (higher temperature / reduced adsorber degradation due to O2).

[0221] Optionally, this process is designed to allow for optimized heat recovery and reduced energy requirements. A heat pump can be used to supply most of the heat required by the process and to recover and reuse heat throughout the system. This can be achieved by using a heat pump that combines medium and high temperature units based on a suitable refrigerant such as butane, or isobutane, propane, pentane, or hexane, or similar hydrocarbons, or perfluorohydrocarbons such as R1336mzz. A water tank can be used to facilitate heat transfer between the various components of the heat pump and to temporarily store heat, which can facilitate the interaction between the batch CO2 adsorption / desorption process and the continuous heat pump.

[0222] By recovering thermal energy from the entire system (including steam recovery, high-temperature gas from drying / cooling cycles, and excess thermal energy from liquefaction / purification steps), and upgrading this thermal energy to over 100°C, the heat pump could potentially generate almost all of the thermal energy needed to produce the required steam, eliminating the need for a gas-fired boiler (and thus avoiding emissions from gas-based CO2 production).

[0223] The equipment may be enlarged to accommodate the rotation speed increase / decrease to such an extent that the given embodiment cannot supply a continuous gas flow, or an accumulator may be added to smooth the flow. The accumulator may serve to store gas as needed. Alternatively, in the case of a vacuum pump, using a vacuum accumulator may enable more continuous operation of the pump, allowing the vacuum to be continuously available and reducing the time required to achieve a particular level of vacuum in the system. The accumulator may be coupled to a heat pump so that the discontinuous supply of heat from panel regeneration can be coupled to a continuously operating heat pump.

[0224] Regarding heat pump systems, an effective accumulator can be realized through a water tank associated with such a system. Heat recovery also allows for the recovery of water in the form of condensate, which can be returned to the boiler. Therefore, this system not only recovers energy but also reduces the water footprint.

[0225] Operation details This invention will not only significantly advance the level of DAC technology, but will also drastically reduce the cost per ton of carbon dioxide that can be recovered and optionally sequestered.

[0226] The embodiments described herein include, but are not limited to, systems, apparatus, and methods for recovering carbon dioxide from ambient air and gas mixtures. One embodiment of the present invention disclosed herein recovers carbon dioxide from the atmosphere using a continuous moving panel system coupled with a multizone regeneration box system, which is described throughout this specification. In another embodiment, individual units may be specialized in recovering carbon dioxide from air, while other units may be specialized in recovering carbon dioxide from a gas mixture flow of air and exhaust gas, which may contain emissions from the energy source of the direct air recovery unit (particularly using optimized adsorption panels). In yet another embodiment, adsorption panels within all individual units may be specialized in recovering carbon dioxide via a gas mixture flow of air and exhaust gas.

[0227] Various aspects of this subject matter are described below in re-examination of the embodiments described herein and / or in complement to those embodiments, with emphasis on the interrelationships and interchangeability of the embodiments described herein. In other words, emphasis is placed on the fact that, unless explicitly stated otherwise or unless logically impossible, each feature of an embodiment can be combined with all other features. The embodiments described herein are paraphrased and expanded in the following paragraphs without explicit reference to the figures.

[0228] In many embodiments, a system for removing carbon dioxide from ambient air includes a plurality of adsorption panels, each of which has a surface and a substrate configured to recover CO2 from the atmosphere, and each of which is configured to move independently; at least one adsorption structure comprising at least one fan configured to circulate air through a portion of the panels of the plurality of adsorption panels; and at least one regeneration unit comprising at least one oxygen purging section, at least one CO2 desorption section, and at least one drying / cooling section.

[0229] In some embodiments, the multiple adsorption panels are configured to move continuously through at least a portion of at least one adsorption structure and at least a portion of at least one regeneration unit. In some embodiments, the multiple adsorption panels are configured to move continuously through all of at least one adsorption structure and all of at least one regeneration unit.

[0230] In some embodiments, the multiple adsorption panels are configured to move through multiple sections of at least one regeneration unit, and one or more sections of at least one regeneration unit are configured to provide one or more gas backflows in the direction of movement of the multiple adsorption panels within the section.

[0231] In some embodiments, at least one oxygen purge section includes a sealable chamber and a first outlet; at least one CO2 desorption section includes a desorption chamber, a gas inlet, and a gas outlet; and at least one drying / cooling section includes a drying / cooling chamber, a first drying / cooling inlet, and a first drying / cooling outlet.

[0232] In some embodiments, multiple adsorption panels are configured to move through a desorption chamber, and the gas is configured to flow from the gas inlet to the gas outlet such that it first contacts the adsorption panels with a high desorption rate, and then contacts the adsorption panels with a low desorption rate.

[0233] In some embodiments, the adsorption panels are configured to move through multiple sections of at least one regeneration unit in a first direction from at least one oxygen purging section toward at least one drying / cooling section, and in each of the multiple sections of the at least one regeneration unit, the section is configured to facilitate the flow of one or more gases through the section in a second direction opposite to the first direction.

[0234] In some embodiments, multiple adsorption panels are configured to move continuously through each of the multiple chambers within the CO2 desorption section.

[0235] In some embodiments, multiple adsorption panels are configured to move continuously through a sealable chamber of the CO2 desorption section.

[0236] In some embodiments, the adsorption panels are configured to move through multiple sections of at least one regeneration unit in a first direction from at least one oxygen purging section toward at least one drying / cooling section, and one or more gases are configured to flow through each section within the multiple sections of at least one regeneration unit in a second direction opposite to the first direction.

[0237] In some embodiments, multiple adsorption panels are configured to move through a drying / cooling chamber, and the gas is configured to flow from a first drying / cooling inlet to a first drying / cooling outlet, so that it first contacts the adsorption panels with a higher degree of cooling, and then contacts the adsorption panels with a lower degree of cooling.

[0238] In some embodiments, at least one oxygen purge section further includes a first inlet and a first outlet, and the plurality of adsorption panels are configured to move through a sealable chamber, and the gas is configured to flow from the first inlet to the first outlet such that the gas first contacts the adsorption panel with a large amount of oxygen purge and then contacts the adsorption panel with a small amount of oxygen purge.

[0239] In some embodiments, at least one regeneration unit further includes at least one gas recovery section, and the plurality of adsorption panels are configured to move from the oxygen purge section through the gas recovery section to the CO2 desorption section, and the gas is configured to flow from the gas recovery inlet of the gas recovery section closer to the CO2 desorption section to the gas recovery outlet of the gas recovery section closer to the oxygen purge section.

[0240] In some embodiments, the plurality of adsorption panels are configured to move through a desorption chamber, and the gas is configured to flow from the gas inlet to the gas outlet such that the gas first contacts the adsorption panel with a large amount of desorption and then contacts the adsorption panel with a small amount of desorption.

[0241] In some embodiments, the system further includes a first door, a second door, a third door, and a fourth door, the first door is located at a first end of at least one oxygen purge section, the second door is located between at least one oxygen purge section and at least one CO2 desorption section, the third door is located between at least one CO2 desorption section and at least one drying / cooling section, and the fourth door is located at an end of at least one drying / cooling section.

[0242] In some embodiments, the plurality of adsorption panels are configured to move continuously through at least one oxygen purge section, at least one CO2 desorption section, and at least one drying / cooling section, and each panel of the plurality of adsorption panels includes a plurality of arrays held together and a plurality of sealing struts. One pair of the plurality of sealing struts provides a continuous flat sealing surface for engaging one or more seals to prevent gas movement between adjacent arrays.

[0243] In some embodiments, the first outlet of the at least one oxygen purge section is connected to a vacuum source.

[0244] In some embodiments, the plurality of adsorption panels are configured to move periodically through at least a portion of at least one adsorption structure and / or at least a portion of at least one regeneration unit.

[0245] In some embodiments, the at least one oxygen purge section further includes a second inlet connected to a sweep gas source. In some embodiments, the sweep gas is steam, nitrogen, CO2, or a combination thereof.

[0246] In some embodiments, the inlet gas is steam.

[0247] In some embodiments, the first drying / cooling outlet of the at least one drying / cooling section is connected to a vacuum source.

[0248] In some embodiments, the first drying / cooling outlet of the at least one drying / cooling section is connected to a sweep gas source. In some embodiments, the sweep gas is steam, nitrogen, or a combination thereof.

[0249] In some embodiments, the system further includes a plurality of tracks configured to transport a plurality of adsorption panels through and out of at least one adsorption structure and at least one regeneration unit.

[0250] In some embodiments, the system further includes a plurality of tracks configured to transport a plurality of suction panels through and out of at least one regeneration unit. In some embodiments, the plurality of tracks are arranged in a circle, and each track of the plurality of tracks forms a circular section. In some embodiments, a panel among the plurality of suction panels includes two arcs on opposite sides of the panel and two straight edges on opposite sides of the panel. In some embodiments, the system includes a plurality of suction units arranged in a plurality of rows, each row extending radially. In some embodiments, a plurality of rows among the plurality of rows are arranged like spokes of a wheel.

[0251] In some embodiments, at least one CO2 desorption section further includes an additional desorption chamber and a plenum between the desorption chambers, the plenum being configured to allow vapor from the additional desorption chambers to flow into the desorption chambers.

[0252] In some embodiments, a first drying / cooling inlet of at least one drying / cooling section is in communication with an inert gas source.

[0253] In some embodiments, the multiple tracks within at least one adsorption structure include a first track and a second track, each extending longitudinally into, through, and out of the at least one adsorption structure. In some embodiments, the system further includes at least one lateral transfer unit configured to move at least one panel from the first track to the second track. In some embodiments, the first track is substantially parallel to the second track.

[0254] In some embodiments, the system further includes at least one waiting zone between at least one adsorption structure and at least one lateral transfer unit.

[0255] In some embodiments, at least one lateral transfer unit is configured to include at least two panels of a plurality of suction panels.

[0256] In some embodiments, at least one CO2 desorption section is configured to move multiple panels laterally at one time from at least one oxygen purging section to at least one drying / cooling section, and at least one oxygen purging section and at least one drying / cooling section are configured to include two panels from the multiple adsorption panels, and at least one CO2 desorption section is configured to include an odd number of panels from the multiple panels.

[0257] In some embodiments, the sealable chamber of at least one oxygen purge section is configured to include at least two panels of a plurality of adsorption panels.

[0258] In some embodiments, the detachment chamber is configured to include at least two of a plurality of adsorption panels.

[0259] In some embodiments, the detachment chamber is configured to include about 2 to about 10 of the multiple adsorption panels.

[0260] In some embodiments, the drying / cooling chamber is configured to include at least two of a plurality of adsorption panels.

[0261] In some embodiments, the detachment chamber is configured to include 3 to 20 panels out of a plurality of adsorption panels.

[0262] In some embodiments, the sealable chamber is configured to include a plurality of panels, and the detachable chamber is configured to include a number of panels that is not an integer multiple of the number of panels within the sealable chamber. In some embodiments, the sealable chamber is configured to include seven panels, and the detachable chamber is configured to include two panels.

[0263] In some embodiments, at least one fan is configured to move air at a speed of about 0.2 m / s to about 15 m / s through at least a portion of the panels of the plurality of adsorption panels.

[0264] In some embodiments, the system includes two adsorption structures and two regeneration units, and the two regeneration units are located between the two adsorption structures.

[0265] In some embodiments, at least one regeneration unit is located at a first end of at least one adsorption structure, and at least one lateral transfer section is located at a second end of at least one adsorption structure.

[0266] In some embodiments, at least one CO2 desorption section further includes a first plenum associated with a first wall of the detachable chamber and a second plenum associated with a second wall of the detachable chamber, the first wall of the detachable chamber faces the second wall of the detachable chamber, and the first plenum is connected to a steam source. In some embodiments, the second plenum is configured to release steam from the detachable chamber to a recovery system. In some embodiments, at least one CO2 desorption section further includes a first at least one baffle disposed within the first plenum and a second at least one baffle disposed within the second plenum.

[0267] In some embodiments, at least one CO2 desorption section further includes a first plurality of plenums associated with a first wall of the desorption chamber and a second plurality of plenums associated with a second wall of the desorption chamber, the first wall of the desorption chamber facing the second wall of the desorption chamber. In some embodiments, each plenum of the second plurality of plenums is connected to an adjacent plenum within the second plurality of plenums. In some embodiments, the first plurality of plenums comprises a first plenum, a last plenum, and at least one plenum between them, the first plenum of the first plurality of plenums being connected to a gas inlet and the last plenum of the first plurality of plenums being connected to a gas outlet.

[0268] In some embodiments, the gas inlet is connected to a steam source.

[0269] In some embodiments, the second plurality of plenums includes a first plenum, a last plenum, and at least one plenum in between them. In some embodiments, the first plenum of the second plurality of plenums is configured to receive gas from the first plenum of the first plurality of plenums and to transfer the received gas to at least one plenum in between them of the second plurality of plenums. In some embodiments, at least one plenum in between them of the second plurality of plenums is configured to transfer the received gas to at least one plenum in between them of the first plurality of plenums. In some embodiments, at least one plenum in between them of the first plurality of plenums is configured to transfer the received gas to the last plenum of the second plurality of plenums. In some embodiments, the last plenum of the second plurality of plenums is configured to transfer the received gas to the last plenum of the first plurality of plenums.

[0270] In some embodiments, at least one of the second plurality of plenums, between them, includes at least two plenums. In some embodiments, at least one of the second plurality of plenums, between them, includes at least six plenums. In some embodiments, at least one of the first plurality of plenums, between them, includes at least two plenums. In some embodiments, at least one of the first plurality of plenums, between them, includes at least six plenums.

[0271] In some embodiments, the steam treatment chamber further includes a third wall, and at least an adsorption structure and at least one regeneration unit are connected to the steam treatment chamber along the third wall.

[0272] In some embodiments, the steam treatment chamber further includes a third wall and a fourth wall, with at least an adsorption structure connected to the steam treatment chamber along the third wall, and at least one regeneration unit connected to the steam treatment chamber along the fourth wall.

[0273] In some embodiments, the system further includes at least one waiting zone between at least one adsorption structure and at least one regeneration unit.

[0274] In some embodiments, at least one regeneration unit comprises a first end and a second end, the first adsorption structure being coupled to the first end of at least one regeneration unit, and the second adsorption structure being coupled to the second end of at least one regeneration unit.

[0275] In some embodiments, the system further includes a first lateral transfer unit and a second lateral transfer unit, the first lateral transfer unit being coupled to the end of a first adsorption structure, and the second lateral transfer unit being coupled to the end of a second adsorption structure.

[0276] In some embodiments, at least one regeneration unit is located at the end of at least one adsorption structure, and at least one lateral transfer section is located opposite the at least one adsorption structure with at least one regeneration unit in between.

[0277] In some embodiments, the adsorption structure further comprises a preheater configured to heat the air before it is circulated through a portion of the panel by at least one fan.

[0278] In some embodiments, the regeneration unit further comprises a preheating section having a preheating inlet connected to a heating gas source. In some embodiments, the preheating section further includes a preheater outlet, and a plurality of adsorption panels are configured to move through the preheating section, and the gas is configured to flow from the preheating inlet to the preheater outlet such that it first contacts the more heated adsorption panels and then the less heated adsorption panels. In some embodiments, the heating gas includes CO2, nitrogen, or a combination thereof at a temperature of at least 40°C. In some embodiments, the heating gas includes CO2, nitrogen, or a combination thereof at a temperature of at least 100°C or higher. In some embodiments, the preheating section is configured to hold two or more adsorption panels.

[0279] In some embodiments, at least one drying / cooling section of at least one regeneration unit comprises a first drying / cooling section and a second drying / cooling section. In some embodiments, the first drying / cooling section is a vacuum drying / cooling section, and the second drying / cooling section comprises a drying / cooling inlet connected to a cooling gas source.

[0280] In some embodiments, the multiple adsorption panels are oriented vertically within at least one regeneration unit. In some embodiments, the system further includes at least one adsorption structure and at least one regeneration unit, and multiple tracks configured to transport the multiple adsorption panels through them and out of them, with each adsorption panel of the vertically oriented multiple adsorption panels being transported on a single track.

[0281] In some embodiments, the multiple adsorption panels are oriented horizontally within at least one regeneration unit. In some embodiments, the system further includes at least one adsorption structure and at least one regeneration unit, and a plurality of tracks configured to transport the plurality of adsorption panels through them and out of them, wherein each of the horizontally oriented plurality of adsorption panels is transported on a track that includes at least two rails.

[0282] In some embodiments, the multiple tracks include a first section of a first height and a second section of a second height. In some embodiments, at least one fan of at least one suction structure is located above the top surface of at least one panel of the multiple suction panels. In some embodiments, at least one fan of at least one suction structure is located below the bottom surface of at least one panel of the multiple suction panels. In some embodiments, at least one fan of at least one suction structure is positioned perpendicular to the end of at least one suction structure. In some embodiments, at least one suction structure further comprises a filter located below the bottom surface of at least one panel of the multiple suction panels. In some embodiments, at least one suction structure further comprises a filter oriented vertically. In some embodiments, at least one suction structure further comprises a filter oriented at an angle between 0 and 90 degrees with respect to the ground.

[0283] In some embodiments, the adsorption structure further comprises a chimney located on a plurality of adsorption panels.

[0284] In some embodiments, at least one adsorption structure further comprises a plurality of troughs located beneath a plurality of adsorption panels.

[0285] In some embodiments, each panel of a plurality of adsorption panels comprises a plurality of monolithic arrays held together by a support structure. In some embodiments, the system further includes a deformable sealant located between the plurality of monolithic arrays and the support structure. In some embodiments, the sealant is located between the individual monolithic arrays of the plurality of monolithic arrays.

[0286] In some embodiments, the support structure includes a frame and at least one sealing strut, the frame and sealing strut having surfaces in a common plane that can form a movable gas seal with a surface inside the enclosure.

[0287] In some embodiments, the system further includes a plurality of sealing struts, the sealing struts of which are located between adjacent monolithic arrays within a plurality of monolithic arrays.

[0288] In some embodiments, the system further includes a sealing surface which is coupled to a support structure and configured to contact at least one of a plurality of sealing struts.

[0289] In some embodiments, the sealing surface is a static block, and the multiple monolithic arrays are configured to move relative to the sealing block.

[0290] In some embodiments, the sealing surface is configured to move along the length of the support structure. In some embodiments, the sealing surface includes a plurality of rollers. In some embodiments, the sealing surface includes a belt. In some embodiments, the sealing surface is configured to contact at least two of a plurality of sealing struts.

[0291] In some embodiments, the sealing surface includes a first opening at a first end and a second opening at a second end, the openings configured to allow gas to flow over or into a portion of a plurality of monolith arrays contained within a space defined by the sealing surface and at least one sealing strut in contact with the sealing block.

[0292] In some embodiments, the support structure includes a vertical component and a horizontal component, the vertical component being configured to be located between adjacent arrays of a plurality of monolithic arrays, and the horizontal component being configured to be located directly below the bottom surface of one of the arrays of the plurality of monolithic arrays.

[0293] In some embodiments, the sealing surface includes a first portion and a second portion, the first portion being in contact with at least one of a plurality of sealing struts on a first surface of a panel among a plurality of adsorption panels, and the second portion being in contact with at least one of a plurality of sealing struts on a second surface of a panel among a plurality of adsorption panels.

[0294] In some embodiments, the sealing surface includes a plurality of seals, each of which is in contact with a single surface of one of the plurality of adsorption panels. In some embodiments, the plurality of seals includes at least two seals, at least one of the at least two seals being in contact with a first surface of one of the plurality of adsorption panels, and the other of the at least two seals being in contact with a second surface of one of the plurality of adsorption panels, the second surface being opposite to the first surface.

[0295] In some embodiments, the horizontal component is a spring clip. In some embodiments, the vertical and horizontal components are located within a single structure.

[0296] In some embodiments, the support structure includes four sides, each of which is configured to support a side of one of a plurality of monolithic arrays.

[0297] In some embodiments, the support structure includes at least one support located at at least one corner of the quadrilateral configuration, each of which is configured to support a corner of an array among a plurality of monolithic arrays.

[0298] In some embodiments, the support structure includes a plurality of spaced ledges arranged along the perimeter of the quadrilateral configuration, each of which is configured to support the edge of an array among a plurality of monolithic arrays.

[0299] In some embodiments, the support structure includes a plurality of tapered supports having a bottom width, a first side and a second side, and an upper edge, wherein the first and second sides are configured to support the bottom edge of an array among a plurality of monolithic arrays. In some embodiments, the first and second sides of the tapered support have a stepped configuration, wherein the steps of the stepped configuration are configured to support the bottom edge of an array among a plurality of monolithic arrays.

[0300] In some embodiments, the support structure includes a first vertical support and a second vertical support, and a mesh coupled to the first and second vertical supports, wherein the plane of the mesh is perpendicular to the plane of the first or second vertical support, and the mesh further includes openings configured to receive an array of a plurality of monolithic arrays.

[0301] In some embodiments, the support structure comprises multiple sets of upper and lower support struts, and a mesh coupled to the multiple upper and lower support struts. In some embodiments, the mesh is sandwiched between each set of the multiple sets of upper and lower support struts. In some embodiments, the upper support struts of the multiple sets of upper and lower support struts include a female interface, and the lower support struts of the multiple sets of upper and lower support struts include a male interface, and the female interface of the upper support strut is configured to receive the male interface of the lower support strut.

[0302] In some embodiments, the male interface of the lower support strut is triangular. In some embodiments, the male interface of the lower support strut is concave. In some embodiments, the female interface of the upper support strut is U-shaped.

[0303] In some embodiments, the upper side of the lower support struts among the multiple sets of upper and lower support struts is at the same level as the bottom surface of the lowest row of multiple monolithic arrays.

[0304] In some embodiments, the adsorption structure further includes a funnel directly below at least one fan.

[0305] In some embodiments, the system further includes a cowling around at least one fan.

[0306] In some embodiments, the system further includes at least one ring attached to the cowling above at least one fan. In some embodiments, the system further includes at least one ring attached to the cowling below at least one fan.

[0307] In some embodiments, the system further includes a trough directly below at least one fan. In some embodiments, the at least one ring is a plurality of rings, and the plurality of rings includes at least two rings having different diameters. In some embodiments, the at least two rings have different lengths. In some embodiments, the at least two rings have different heights.

[0308] In some embodiments, the support structure includes a first vertical support and a second vertical support, and a plurality of support wires coupled to the first vertical support and the second vertical support, wherein the plurality of support wires include at least one pair of intersecting support wires, and the intersection of the intersecting support wires is configured to be located adjacent to the surface of one of the plurality of monolithic arrays.

[0309] In some embodiments, the support structure includes collars coupled to a plurality of vertical supports, the collars configured to surround one of the arrays.

[0310] In some embodiments, the support structure is incorporated into an array of multiple arrays, and the support structure includes an extended angle that extends beyond the outer surface of the array of the multiple monolithic arrays.

[0311] In many embodiments, a direct air recovery method includes the steps of circulating air through a plurality of adsorption panels having at least one fan, wherein each panel of the plurality of adsorption panels is configured to move independently; housing at least one panel of the plurality of adsorption panels in a first chamber of at least one purge section of at least one regeneration unit; reducing the concentration of oxygen contained in the first chamber of the first purge section of at least one regeneration unit; housing at least one panel in a second chamber of at least one CO2 desorption section of at least one regeneration unit; collecting CO2 from the at least one panel housed in the second chamber; housing at least one panel in a third chamber of at least one drying / cooling section of at least one regeneration unit; and drying and / or cooling the at least one panel housed in the third chamber.

[0312] In some embodiments, at least one panel housed in the CO2 desorption section includes at least a first panel and a second panel, the first panel entering the desorption section before the second panel, and the desorption gas flowing through the desorption section such that it first contacts the first panel and then the second panel.

[0313] In some embodiments, the oxygen concentration in the first chamber is reduced by evacuating the first chamber with a vacuum source. In some embodiments, the oxygen concentration in the first chamber is further reduced by adding steam to the first chamber while it is being evacuated with a vacuum source.

[0314] In some embodiments, CO2 is collected from the second chamber by applying steam to at least one panel within the second chamber. In some embodiments, the at least one panel has a first surface and a second surface, and the applied steam flow flows laterally through the at least one panel from the first surface to the second surface, and returns one or more times in a meandering or corkscrew manner. In some embodiments, the at least one panel has a first surface and a second surface, and while the at least one panel moves through the first chamber, the second chamber, and / or the third chamber, one or more flows of one or more gases flow laterally through the at least one panel from the first surface to the second surface, and returns one or more times in a meandering or corkscrew manner. In some embodiments, the at least one panel has a first surface and a second surface, and the applied steam flow flows in a first direction through the at least one panel, enters the first surface, and exits the second surface within the second chamber. In some embodiments, the applied steam flow flows further in a second direction, enters a second surface, and exits from the first surface of at least one panel in the second chamber.

[0315] In some embodiments, at least one panel has a first surface and a second surface, and while at least one panel is inside a second chamber, the applied steam flow flows back and forth at least once through the first surface and the second surface of at least one panel.

[0316] In some embodiments, at least one panel has a first surface and a second surface, and the applied steam flow flows through at least a first portion of the first surface, a subsequent first portion of the second surface, and a subsequent second portion of the first surface.

[0317] In some embodiments, at least one panel includes a first portion, a second portion, and a third portion, and the applied steam flow flows through the first portion in a first direction, then through the second portion in a second direction, and then through the third portion in a third direction, the second direction being substantially opposite to the first and third directions. In some embodiments, at least one panel further includes a fourth portion, and the applied steam flow flows through the fourth portion in a fourth direction, the fourth direction being substantially opposite to the first and third directions.

[0318] In some embodiments, the method further includes the steps of housing at least one panel in at least one additional chamber of at least one CO2 desorption section of at least one regeneration unit, and collecting CO2 from the at least one panel housed in the at least one additional chamber.

[0319] In some embodiments, CO2 is collected from at least one additional chamber by applying steam to at least one panel in at least one additional chamber. In some embodiments, the steam applied to at least one panel in at least one additional chamber flows through a plenum between a second chamber and at least one additional chamber, and is applied to at least one panel in the second chamber to collect CO2.

[0320] In some embodiments, at least one panel is dried and / or cooled by evacuating a fourth chamber with a vacuum source.

[0321] In some embodiments, at least one panel is moved from a first chamber to a second chamber on a track extending through at least one playback unit.

[0322] In some embodiments, air circulates across the surfaces of multiple adsorption panels, with at least one fan located within the adsorption structure. In some embodiments, the multiple adsorption panels move along multiple tracks within the adsorption structure. In some embodiments, the multiple tracks include a first track and a second track, with the first track being parallel to the second track. In some embodiments, the multiple adsorption panels move from the first track to the second track via a lateral transport section.

[0323] In some embodiments, the method further includes the step of rotating at least one panel by about 90° before housing at least one panel in a second chamber of at least one CO2 desorption section.

[0324] In some embodiments, each panel of a plurality of panels during the circulation step comprises a plurality of subunits configured in a first configuration, and the method further includes the step of rearranging at least one panel of the plurality of panels from the first configuration to a second configuration before housing at least one panel in a first chamber of at least one purge section. In some embodiments, the second configuration has a lower aspect ratio than the first configuration.

[0325] In some embodiments, the at least one panel housed in a second chamber of at least one CO2 desorption section of at least one regeneration unit is two panels, and CO2 is collected from the two panels housed in the second chamber.

[0326] In some embodiments, the method further includes the step of circulating air around a plurality of adsorption panels, and then moving at least one of the plurality of adsorption panels along a track into a first chamber of at least one purge section.

[0327] In some embodiments, the method further includes the step of reducing the oxygen concentration in a first chamber of at least one purge section, and then moving at least one of a plurality of adsorption panels along a track into a second chamber of at least one CO2 desorption section.

[0328] In some embodiments, the method further includes the step of collecting CO2 from at least one panel housed in a second chamber, and then moving at least one of a plurality of adsorption panels along a track into a third chamber.

[0329] In some embodiments, the method further includes the step of heating the air before it is circulated through a plurality of adsorption panels.

[0330] In some embodiments, the method further includes the step of circulating a heated gas through a plurality of adsorption panels in an additional chamber of at least one regeneration unit before housing at least one panel in a second chamber. In some embodiments, the heated gas includes CO2, nitrogen, or a combination thereof at a temperature of at least 40°C. In some embodiments, the heated gas includes CO2, nitrogen, or a combination thereof at a temperature of at least 100°C.

[0331] In some embodiments, the method further includes the steps of housing at least one panel in a fourth chamber of at least one regeneration unit, and cooling and drying the at least one panel in the fourth chamber. In some embodiments, the step of cooling and drying the at least one panel in the fourth chamber includes circulating the cooled gas through the at least one panel in the fourth chamber. In some embodiments, the step of cooling and / or drying the at least one panel in a third chamber includes circulating the gas exiting the fourth chamber into the third chamber. In some embodiments, the method further includes heating the gas exiting the fourth chamber and circulating the heated gas into the third chamber.

[0332] In some embodiments, the multiple adsorption panels are oriented vertically within at least one regeneration unit. In some embodiments, the multiple adsorption panels are oriented horizontally within at least one regeneration unit.

[0333] In some embodiments, each panel of a plurality of adsorption panels comprises a plurality of monolithic arrays held together by a support structure.

[0334] In some embodiments, the support structure includes a vertical component and a horizontal component, the vertical component being configured to be located between adjacent arrays of multiple monolithic arrays, and the horizontal component being configured to be located directly below the bottom surface of one of the arrays of multiple monolithic arrays. In some embodiments, the horizontal component is a spring clip. In some embodiments, the vertical and horizontal components are located within a single structure.

[0335] In some embodiments, the support structure includes a quadrilateral shape, and each side of the quadrilateral shape is configured to support a side of one of the multiple monolithic arrays.

[0336] In some embodiments, the support structure includes at least one support located at at least one corner of the quadrilateral configuration, each of which is configured to support a corner of an array among a plurality of monolithic arrays.

[0337] In some embodiments, the support structure includes a plurality of spaced ledges arranged along the perimeter of the quadrilateral configuration, each of which is configured to support the edge of an array among a plurality of monolithic arrays.

[0338] In some embodiments, the support structure includes a plurality of tapered supports having a bottom width, a first side and a second side, and an upper edge, wherein the first and second sides are configured to support the bottom edge of an array among a plurality of monolithic arrays. In some embodiments, the first and second sides of the tapered support have a stepped configuration, wherein the steps of the stepped configuration are configured to support the bottom edge of an array among a plurality of monolithic arrays.

[0339] In some embodiments, the support structure includes a first vertical support and a second vertical support, and a mesh coupled to the first and second vertical supports, wherein the plane of the mesh is perpendicular to the plane of the first or second vertical support, and the mesh further includes openings configured to support an array of a plurality of monolithic arrays.

[0340] In some embodiments, the support structure includes a first vertical support and a second vertical support, and a plurality of support wires coupled to the first vertical support and the second vertical support, wherein the plurality of support wires include at least one pair of intersecting support wires, and the intersection of the intersecting support wires is configured to be located adjacent to the surface of one of the plurality of monolithic arrays.

[0341] In some embodiments, the support structure includes collars coupled to a plurality of vertical supports, the collars configured to surround one of the arrays.

[0342] In some embodiments, the support structure is incorporated into an array of multiple arrays, and the support structure includes an extended angle that extends beyond the outer surface of the array of the multiple monolithic arrays.

[0343] In many embodiments, the adsorption structure includes a plurality of adsorption panels, each panel of the plurality of adsorption panels having a surface and a substrate configured to recover CO2 from the atmosphere, and each panel of the plurality of adsorption panels being configured to move independently; a plurality of fans configured to circulate air around the plurality of adsorption panels; at least one track configured to transport the plurality of adsorption panels in the vicinity of the plurality of fans; and a first air filter and a second air filter located on either side of the at least one track.

[0344] In some embodiments, at least one track includes a first track and a second track, each extending longitudinally beneath a plurality of fans.

[0345] In some embodiments, at least one track includes a first track and a second track, each extending longitudinally over a plurality of fans. In some embodiments, the first track is substantially parallel to the second track. In some embodiments, the system further includes at least one lateral transport unit configured to move a panel from the first track to the second track.

[0346] In many embodiments, the regeneration unit includes at least one oxygen purge section including a sealable chamber and a first outlet; at least one CO2 desorption section including a desorption chamber, a vapor inlet and a gas outlet; and at least one drying / cooling section including a drying / cooling chamber and a first drying / cooling outlet.

[0347] In some embodiments, the first outlet of at least one oxygen purge section is connected to a vacuum source.

[0348] In some embodiments, at least one oxygen purge section further comprises an inlet connected to a sweep gas source. In some embodiments, the sweep gas is vapor, nitrogen, or a combination thereof.

[0349] In some embodiments, the first drying / cooling outlet of at least one drying / cooling section is connected to a vacuum source.

[0350] In some embodiments, the first dry / cooling outlet of at least one dry / cooling section is connected to a sweep gas source. In some embodiments, the sweep gas is vapor, nitrogen, or a combination thereof.

[0351] In some embodiments, at least one CO2 desorption section further includes an additional desorption chamber and a plenum between the desorption chambers, the plenum being configured to allow steam from the additional steam treatment chamber to flow into the steam treatment chamber.

[0352] In many embodiments, a system for removing carbon dioxide from ambient air includes: a plurality of adsorption panels, each of which has a substrate configured to recover CO2 from the atmosphere, and each of the plurality of adsorption panels is configured to move independently; at least one adsorption structure comprising at least one fan configured to move air through a first portion of one of the plurality of adsorption panels; at least one regeneration unit comprising at least one chamber configured to purge air from a second portion of one of the plurality of panels, desorb CO2 from the second portion of one of the plurality of panels, and dry and / or cool the second portion of one of the plurality of panels; and at least one transfer unit configured to move the second portion of the plurality of panels from at least one adsorption structure to at least one regeneration unit.

[0353] In some embodiments, air is purged from at least one chamber by applying a vacuum to at least one chamber.

[0354] In some embodiments, CO2 is desorbed from a second portion of a panel among a plurality of panels by introducing steam into at least one chamber, and at least one chamber is heated to at least 65°C.

[0355] In some embodiments, the transfer unit comprises a first transfer unit and a second transfer unit configured to move a second portion of a plurality of panels from at least one regeneration unit to at least one adsorption structure.

[0356] In some embodiments, the second part of the panel is a single panel.

[0357] In some embodiments, the first portion of the panel includes a different number of panels than the second portion of the panel.

[0358] In some embodiments, the first portion of the panel includes more panels than the second portion of the panel.

[0359] In some embodiments, at least one chamber of at least one regeneration unit comprises a first chamber, a second chamber, and a third chamber, the first chamber configured to purge air from a second portion of a panel among a plurality of panels, the second chamber configured to desorb CO2 from a second portion of a panel among a plurality of panels, and the third chamber configured to dry and / or cool a second portion of a panel among a plurality of panels.

[0360] In many embodiments, a regeneration unit for desorbing CO2 comprises at least one chamber having a first wall and a second wall, a gas inlet located in the first wall, a gas outlet located in the second wall, and at least one track configured to move at least one panel from the second wall to the first wall in a first direction, wherein the at least one chamber is configured to allow a gas flow to flow in a second direction along the flow path from the gas inlet to the gas outlet, the second direction being opposite to the first direction.

[0361] In some embodiments, the unit includes at least two tracks.

[0362] In some embodiments, at least one panel has a surface that defines a plane, the plane of which is perpendicular to the gas flow from the gas inlet to the gas outlet.

[0363] In some embodiments, the gas is vapor.

[0364] In some embodiments, the system further includes an outlet based on a vacuum source.

[0365] In many embodiments, a method for desorbing CO2 from a plurality of panels, each including a substrate configured to capture CO2 from the atmosphere, wherein the plurality of panels include a first portion of a panel and a second portion of a panel adjacent to the first portion, the method comprising: flowing a gas stream from a gas inlet through the first portion and the second portion of the plurality of panels in a first direction within a first chamber, wherein the first portion of the panel is closer to the gas inlet than the second portion of the panel; removing the first portion of the panel from the first chamber; moving the plurality of panels in a second direction toward the gas inlet within the first chamber, wherein the second direction is different from the first direction; and flowing a gas stream through the second portion of the plurality of panels in a first direction within the first chamber.

[0366] In some embodiments, the gas is vapor.

[0367] In some embodiments, the first direction is the opposite direction to the second direction.

[0368] In some embodiments, the first part of the panel and the second part of the panel each include a single panel.

[0369] In some embodiments, the first part of the panel and the second part of the panel each include at least two panels.

[0370] In some embodiments, the multiple panels include at least two panels.

[0371] In some embodiments, the method further includes the step of purging oxygen from a plurality of panels before flowing a gas stream through a second portion of one of the panels.

[0372] In some embodiments, the step of purging oxygen is performed in a second chamber.

[0373] In some embodiments, the method further includes the step of passing a gas flow through a first portion of a plurality of panels, and then drying and / or cooling the plurality of panels in a third chamber.

[0374] In some embodiments, the plurality of panels further include a third portion of the panel adjacent to a second portion of the panel, and the method further includes the steps of: directing a gas flow from a gas inlet through a first portion of the panel, a second portion of the panel, and a third portion of the panel in a first chamber in a first direction; removing the second portion of the panel from the first chamber; moving the plurality of panels in a second direction toward the gas inlet within the first chamber such that the third portion of the panel is in front of the gas inlet; and directing a gas flow through the third portion of the panel in a first direction within the first chamber.

[0375] In many embodiments, a regeneration unit for desorption of CO2 comprises: at least one chamber having a first wall and a second wall; at least one panel including a substrate configured to recover CO2 from the atmosphere; a gas inlet located in the first wall; at least one plenum located in the second wall, the second wall being opposite to the first wall; a gas outlet; and at least one track oriented substantially parallel to the first wall and configured to move at least one panel in a first direction, wherein the at least one chamber is configured to allow a gas flow from the gas inlet through the face of at least one panel to the at least one plenum located in the second wall in a first flow path; and the at least one chamber is configured to allow a gas flow from the at least one plenum located in the second wall to flow again through the face of the panel or through the opposite face of at least one panel in a second flow path, wherein the first and second flow paths form a meandering or corkscrew-shaped flow path.

[0376] In some embodiments, the gas flows from the gas inlet to the gas outlet in a direction substantially opposite to the first direction, such that the gas first contacts panels with a high desorption rate and then contacts panels with a low desorption rate.

[0377] In some embodiments, the unit further includes at least one plenum located on a first or second wall, the at least one plenum located on the first or second wall being configured to receive a gas flow from a second flow path and to direct the gas flow through the surface of at least one panel in a third flow path to at least one plenum on the second wall.

[0378] In some embodiments, the first direction of at least one track is perpendicular to the direction of the first flow path.

[0379] In some embodiments, at least one plenum located on the second wall includes four plenums.

[0380] In some embodiments, at least one plenum located on the second wall includes eight plenums. In some embodiments, at least one plenum located on the first wall includes four plenums. In some embodiments, at least one plenum located on the first wall includes eight plenums.

[0381] In many embodiments, a method for desorbing CO2 from a plurality of panels, including a substrate configured to recover CO2 from the atmosphere, the method comprising: flowing a gas stream from a gas inlet through the face of at least one panel of the plurality of panels in a first channel; flowing a gas stream through the opposite face of at least one panel of the plurality of panels in a second channel; flowing a gas stream through the face of at least one panel of the plurality of panels in a third channel; and flowing a gas stream through the opposite face of at least one panel of the plurality of panels in a fourth channel, wherein the first and third channels are in a first direction, the second and fourth channels are in a second direction, and the first direction is opposite to the second direction.

[0382] In many embodiments, a method for desorbing CO2 from a plurality of panels, including a substrate configured to recover CO2 from the atmosphere, the method comprising: flowing a gas stream from a gas inlet through the face of at least one panel of the plurality of panels in a first channel; flowing a gas stream through the opposite face of at least one panel of the plurality of panels in a second channel; flowing a gas stream through the face of at least one panel of the plurality of panels in a third channel; and flowing a gas stream through the opposite face of at least one panel of the plurality of panels in a fourth channel, wherein the first and third channels are in a first direction, the second and fourth channels are in a second direction, and the first direction is the same as the second direction.

[0383] In some embodiments, the first flow path carries gas from the gas inlet to the first plenum. In some embodiments, the gas flow carries from the first plenum to the second plenum, and the second flow path carries gas from the second plenum to the third plenum. In some embodiments, the gas flow carries from the third plenum to the fourth plenum, and the third flow path carries gas from the fourth plenum to the fifth plenum. In some embodiments, the gas flow carries from the fifth plenum to the sixth plenum, and the fourth flow path carries gas from the sixth plenum to the seventh plenum. In some embodiments, the first, second, fifth, and sixth plenums are located on the second wall of the chamber, while the third, fourth, and seventh plenums are located on the first wall of the chamber, with the second wall being on the opposite side of the first wall.

[0384] In some embodiments, the first channel flows through a first portion of at least one panel, the second channel flows through a second portion of at least one panel, the third channel flows through a third portion of at least one panel, and the fourth channel flows through a fourth portion of at least one panel.

[0385] In some embodiments, the method further includes the steps of: flowing a gas flow through the face of at least one additional panel of a plurality of panels in a fifth flow path; flowing a gas flow through the opposite face of at least one additional panel of a plurality of panels in a sixth flow path; flowing a gas flow through the face of at least one additional panel of a plurality of panels in a seventh flow path; and flowing a gas flow through the opposite face of at least one additional panel of a plurality of panels in an eighth flow path, wherein the fifth and seventh flow paths are in a first direction, and the sixth and eighth flow paths are in a second direction.

[0386] In some embodiments, the gas flow is from the seventh plenum to the eighth plenum, and the fifth flow path is from the eighth plenum to the ninth plenum.

[0387] In some embodiments, the gas flow flows from the 9th plenum to the 10th plenum, and the 6th flow path flows from the 10th plenum to the 11th plenum. In some embodiments, the gas flow flows from the 11th plenum to the 12th plenum, and the 7th flow path flows from the 12th plenum to the 13th plenum. In some embodiments, the gas flow flows from the 13th plenum to the 14th plenum, and the 8th flow path flows from the 14th plenum to the 15th plenum. In some embodiments, the 9th, 10th, 13th, and 14th plenums are located on the second wall of the chamber, and the 8th, 11th, 12th, and 15th plenums are located on the first wall of the chamber, with the second wall being on the opposite side of the first wall.

[0388] In some embodiments, the fifth channel flows through a first portion of an additional panel, the sixth channel flows through a second portion of an additional panel, the seventh channel flows through a third portion of an additional panel, and the eighth channel flows through a fourth portion of an additional panel.

[0389] In many embodiments, a method for desorbing CO2 from a plurality of panels, including a substrate configured to recover CO2 from the atmosphere, the method comprising: flowing a gas stream through the plurality of panels in a chamber from a gas inlet to a gas outlet; removing a first portion of the plurality of panels closest to the gas inlet from the chamber, leaving the remaining portion of the panel in the chamber; moving the remaining portion of the panel in the chamber toward the gas inlet; and adding a second portion of the panel to the remaining portion of the panel located in the chamber closest to the gas outlet.

[0390] In some embodiments, the rest of the panel moves continuously through the chamber.

[0391] In some embodiments, the rest of the panel moves periodically through the chamber.

[0392] In some embodiments, the gas inlet is located on the first wall of the chamber, the gas outlet is on the second wall of the chamber, the second wall is opposite the first wall, and the rest of the panel moves stepwise from the second wall to the first wall. In some embodiments, the stepwise movement includes about 2 to about 30 steps. In some embodiments, the stepwise movement includes moving two of the rest of the panel together in the stepwise movement.

[0393] In some embodiments, the gas flow continues throughout the steps of moving the rest of the panel within the chamber, during the step of removing the first part of the panel, and during the step of adding the second part of the panel.

[0394] In some embodiments, the gas flow continues throughout the step of removing the first portion of the panel.

[0395] In some embodiments, the gas flow continues throughout the step of adding the second portion of the panel.

[0396] In some embodiments, the first portion of the panel includes approximately 1 to approximately 5 panels.

[0397] In some embodiments, the second portion of the panel includes approximately 1 to 5 panels.

[0398] In some embodiments, the remaining portion of the panel comprises approximately 1 to 40 panels.

[0399] In some embodiments, each panel of a plurality of panels includes a surface, and the gas flow flows through each surface of the plurality of panels in the chamber.

[0400] In some embodiments, the multiple panels within the chamber include a first end panel, a last end panel, and at least one panel between them, wherein the first end panel is closer to the gas inlet than the at least one panel between them, and the last end panel is closer to the gas outlet than the at least one panel between them, and the gas flow flows through the first end panel and then through the at least one panel between them. In some embodiments, the gas flow flows through at least one panel between them and then through the last end panel.

[0401] In some embodiments, the first portion of the panel is removed in a direction perpendicular to the direction from the gas inlet to the gas outlet.

[0402] In some embodiments, the second portion of the panel is moved in a direction perpendicular to the direction from the gas inlet to the gas outlet, so that the second portion of the panel is added to the rest of the panel.

[0403] In many embodiments, a system for removing carbon dioxide from ambient air comprises: a plurality of adsorption panels, each of which includes a substrate configured to recover CO2 from the atmosphere; at least one regeneration unit comprising at least one chamber having a gas inlet and a gas outlet, the at least one regeneration unit configured to desorb CO2 from the plurality of adsorption panels, and the plurality of adsorption panels configured to move continuously through at least one CO2 desorption chamber; and a heat pump coupled between the gas outlet and gas inlet of at least one chamber of at least one regeneration unit.

[0404] In some embodiments, the heat pump comprises: a first condenser coupled to the gas outlet of at least one chamber and configured to receive gas vapor containing steam and CO2 from at least one chamber of at least one regeneration unit and to condense the gas vapor; a boiler coupled to the first condenser and configured to receive liquid water from the first condenser, coupled to the gas inlet and configured to output steam to at least one chamber of at least one regeneration unit; and a first compressor and a first accumulator coupled between the first condenser and the boiler to circulate a refrigerant through the heat pump.

[0405] In some embodiments, a first condenser is configured to condense a gas vapor received from a gas outlet, heat from the first condenser is transferred to a refrigerant, the vapor form of which is supplied to a first compressor at a first refrigerant pressure, the first compressor is configured to compress the vapor form of the refrigerant, a first accumulator is configured to receive the compressed vapor form of the refrigerant and separate the vapor form of the refrigerant from the liquid form of the refrigerant, and a boiler is configured to receive the vapor form of the refrigerant from the first accumulator, boil liquid water to produce a steam output to at least one chamber, condense the refrigerant, and output the liquid form of the refrigerant to the first accumulator.

[0406] In some embodiments, the first condenser is configured to condense gaseous vapors with respect to a boiling refrigerant.

[0407] In some embodiments, the system further includes an evaporator, the first condenser configured to heat the transfer fluid by condensing gas vapors onto the transfer fluid, and the evaporator configured to receive the heat transfer fluid and refrigerant, boil the refrigerant, and cool and reuse the transfer fluid.

[0408] In some embodiments, the system further includes another accumulator and a second compressor, wherein the first condenser is configured to condense gas vapor against the transfer fluid to heat the transfer fluid, the other accumulator is configured to receive the heated transfer fluid, reduce its pressure, and boil at least a portion of the transfer fluid, the vapor of the transfer fluid is compressed by the second compressor, and the remaining transfer fluid is cooled for reuse.

[0409] In some embodiments, a first condenser is configured to condense gas vapor against a transfer fluid, which is used to transfer heat to a refrigerant within the first condenser.

[0410] In some embodiments, the heat pump further includes a second condenser coupled to a first condenser, the first condenser configured to output gas vapor that has not been condensed into liquid water to the second condenser, and the second condenser configured to condense the gas vapor that has not been condensed into liquid water in the first condenser and output the liquid water to a boiler.

[0411] In some embodiments, the heat pump further comprises a third condenser coupled to the drying / cooling section of at least one regeneration unit, wherein output gas vapor flows from the drying / cooling section to the third condenser, which condenses a portion of the gas vapor to output liquid water to a boiler and is configured to transfer heat to the refrigerant at a second refrigerant pressure lower than the first refrigerant pressure.

[0412] In some embodiments, the second condenser is configured to transfer heat to the refrigerant at a second refrigerant pressure lower than the first refrigerant pressure, and to output the refrigerant in vapor form.

[0413] In some embodiments, the liquid water from the second condenser is output at a lower temperature than the liquid water output from the first condenser.

[0414] In some embodiments, other process streams are cooled by transferring heat to a refrigerant at a second pressure, thereby outputting the refrigerant in vapor form.

[0415] In some embodiments, the system comprises at least one regeneration unit having at least one chamber having a gas inlet and a gas outlet, and configured to desorb CO2 from at least one panel including a substrate configured to recover CO2 from the atmosphere; a first condenser configured to condense a gas vapor with respect to a refrigerant at a first pressure, connected to the gas outlet of at least one chamber, configured to receive a gas vapor containing vapor and CO2 from at least one chamber, and configured to output liquid water and a vapor form of the refrigerant at a first refrigerant pressure; and a first compressor configured to compress the vapor form of the refrigerant, receiving the vapor form of the refrigerant at a first refrigerant pressure and compressing it at a third refrigerant pressure. The system comprises: a first compressor configured to output a vaporized form of refrigerant, with a third refrigerant pressure higher than the first refrigerant pressure; a first accumulator configured to separate the vaporized form of refrigerant from the liquid form of refrigerant, configured to receive the vaporized form of refrigerant compressed at the third refrigerant pressure, and configured to output the vaporized form of refrigerant and the liquid form of refrigerant at the third refrigerant pressure; and a boiler configured to boil water to generate steam and condense the refrigerant, configured to receive liquid water from a first condenser and receive the vaporized form of refrigerant at the third refrigerant pressure from the first accumulator, and configured to output steam to at least one chamber of at least one regeneration unit and to output the liquid form of refrigerant to the first accumulator.

[0416] In some embodiments, the first condenser is further configured to output gas vapors that were not condensed into liquid water in the first condenser, and the system includes a second condenser configured to condense the gas vapors that were not condensed into liquid water in the first condenser against a refrigerant at a second pressure, wherein the second pressure is lower than the first pressure of the first condenser. The system further includes a second condenser, which is configured to receive gas vapor that was not condensed into liquid water in the first condenser, and to receive refrigerant in vapor and liquid forms, and to output liquid water to a boiler and refrigerant in vapor form.

[0417] In some embodiments, the liquid water from the second condenser is output at a lower temperature than the liquid water output from the first condenser.

[0418] In some embodiments, the system further includes a second compressor configured to compress the vapor form of a refrigerant from a second condenser, and configured to receive the vapor form of a refrigerant from the second condenser and to output a compressed form of the vapor form of a refrigerant from the second condenser at a pressure higher than the pressure of the vapor form of the refrigerant from the second condenser.

[0419] In some embodiments, the system further includes a second accumulator configured to separate the refrigerant in vapor form from the refrigerant in liquid form, the second accumulator configured to receive a compressed form of the high-pressure refrigerant vapor form from a second compressor, output the refrigerant vapor form to a first compressor, and output the refrigerant liquid form to a second condenser.

[0420] In some embodiments, the refrigerant is butane.

[0421] In many embodiments, a unit for desorbing CO2 from an adsorption panel includes a desorption chamber through which a plurality of adsorption panels are moved, wherein the desorption gas flows such that it first contacts one of the plurality of adsorption panels that desorbs a large amount, and then contacts another of the plurality of adsorption panels that desorbs a small amount.

[0422] In many embodiments, a system for removing carbon dioxide from ambient air comprises a plurality of adsorption panels, each of which has a surface and a substrate configured to recover CO2 from the atmosphere, and each of the plurality of adsorption panels is oriented horizontally with its surface aligned with a horizontal plane; at least one adsorption structure configured for the plurality of panels to move; and at least one regeneration unit including at least one CO2 desorption chamber, wherein the plurality of adsorption panels are configured to move continuously through at least one CO2 desorption chamber.

[0423] In some embodiments, the adsorption panels include a first adsorption panel and a second adsorption panel, which are configured to move simultaneously and continuously within the CO2 desorption chamber while at least a portion of the first adsorption panel or a portion of the second adsorption panel is outside the CO2 desorption chamber.

[0424] In some embodiments, each panel of a plurality of adsorption panels comprises a plurality of arrays and a plurality of sealing struts held together, the sealing struts of which are located between adjacent arrays in the plurality of arrays, and the sealing struts of which are which provide a continuous flat sealing surface for engaging with one or more seals to prevent gas from moving between adjacent arrays.

Claims

1. A system for removing carbon dioxide from the surrounding air, Multiple adsorption panels, wherein each of the multiple adsorption panels absorbs CO from the atmosphere. 2 The plurality of suction panels comprises a surface and a substrate configured to collect, and each panel of the plurality of suction panels is configured to move independently, An adsorption structure comprising at least one fan configured to circulate air through a portion of the multiple adsorption panels, At least one oxygen purge section, at least one CO 2 A regeneration unit comprising a detachable section and at least one drying / cooling section, Includes, The plurality of adsorption panels are configured to move continuously through at least a portion of the at least one adsorption structure and at least a portion of the at least one regeneration unit. The system further comprises a preheater configured to heat the air before it is circulated through a portion of the panel by the at least one adsorption structure.

2. The at least one oxygen purge section includes a sealable chamber, and the at least one CO 2 The system according to claim 1, wherein the detachable section includes a detachable chamber, a gas inlet, and a gas outlet, and the at least one drying / cooling section includes a drying / cooling chamber, a first drying / cooling inlet, and a first drying / cooling outlet.

3. The at least one CO 2 The detachment section further includes an additional detachment chamber and a plenum between the detachment chamber and the additional detachment chamber, the plenum being configured to allow vapor from the additional detachment chamber to flow into the detachment chamber. The first drying / cooling inlet of the at least one drying / cooling section is in communication with an inert gas source, or The system according to claim 2, wherein the gas inlet is connected to a steam source.

4. The system according to claim 2, wherein the plurality of adsorption panels are configured to move through the desorption chamber, and the gas is configured to flow from the gas inlet to the gas outlet such that it first contacts the adsorption panels with a large amount of desorption, and then contacts the adsorption panels with a small amount of desorption.

5. The system according to claim 1, further comprising a heat pump coupled to the regeneration unit and configured to recover a certain amount of energy from one or more gas outlets and to supply at least a portion of the amount of energy in thermal form to one or more gas inlets.

6. The system according to claim 1, wherein the plurality of adsorption panels are configured to move through a plurality of sections of the at least one regeneration unit, and one or more sections of the at least one regeneration unit are configured to provide one or more gas backflows in the direction of movement of the plurality of adsorption panels within the section.

7. The system according to claim 1, further comprising a plurality of substantially parallel tracks configured to transport the plurality of adsorption panels through and out of the at least one adsorption structure or the at least one regeneration unit.

8. The system according to claim 1, wherein the plurality of adsorption panels are oriented horizontally or vertically within the at least one regeneration unit.

9. The system according to claim 1, comprising a plurality of monolithic arrays, each of the plurality of adsorption panels being held together by a support structure, A plurality of sealing struts, wherein one of the sealing struts is located between adjacent monolith arrays in the plurality of monolith arrays, or A deformable sealant located between the plurality of monolith arrays and the support structure, wherein the support structure includes a frame and at least one sealing strut, and the frame and the sealing strut have surfaces in a common plane, The system further comprises the above.

10. It further includes a sealing surface, the sealing surface is It is coupled to the aforementioned support structure, It is configured to contact at least one of the plurality of sealing struts, Includes multiple stickers, Each of the plurality of seals is in contact with a single surface of one of the plurality of adsorption panels. The system according to claim 9, wherein the plurality of seals comprises at least two seals, at least one of the at least two seals in contact with a first surface of the panel of the plurality of adsorption panels, and the other of the at least two seals in contact with a second surface of the panel of the plurality of adsorption panels, the second surface being opposite to the first surface.

11. A direct air recovery method, Circulating air through a plurality of adsorption panels of at least one adsorption structure having at least one fan, wherein each panel of the plurality of adsorption panels is configured to move independently, At least a portion of at least one of the plurality of adsorption panels is housed in a first chamber of at least one purge section of at least one regeneration unit, To reduce the concentration of oxygen contained in the first chamber of the at least one purge section of the at least one regeneration unit, At least one CO of the at least one regeneration unit 2 The second chamber of the detachable section houses at least a portion of at least one panel, CO 2 To collect and To house at least a portion of the at least one panel in a third chamber of at least one drying / cooling section of the at least one regeneration unit, To cool and / or dry the portion of the at least one panel housed in the third chamber, This includes the following steps: The plurality of adsorption panels are configured to move continuously through at least a portion of the at least one adsorption structure and at least a portion of the at least one regeneration unit. The at least one adsorption structure further comprises a preheater configured to heat the air before it is circulated through the plurality of adsorption panels by the at least one fan. The aforementioned method.

12. The aforementioned CO 2 The method according to claim 11, wherein the portion of the at least one panel housed in the detachable section includes at least a first portion and a second portion, the first portion enters the detachable section before the second portion, and the detachable gas flows through the detachable section such that it first contacts the first portion and then the second portion.

13. The aforementioned CO 2 The method according to claim 11, wherein steam is applied to at least one panel in the second chamber, thereby collecting from the second chamber.

14. The method according to claim 11, wherein at least a portion of the at least one panel has a first surface and a second surface, and while at least a portion of the at least one panel moves through the first chamber, the second chamber, and / or the third chamber, one or more flows of one or more gases flow laterally through at least a portion of the at least one panel from the first surface to the second surface, and return one or more times in a meandering or corkscrew-like manner.

15. The method according to claim 11, wherein the plurality of adsorption panels move along a plurality of tracks within the adsorption structure.

16. The method according to claim 15, wherein the plurality of tracks include a first track and a second track, the first track is parallel to the second track, and the plurality of suction panels move from the first track to the second track via a lateral transfer section.

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