Carbon capture system

Abstract

The carbon capture system can include a plurality of CO2 thermal swing adsorption (TSA) beds. The plurality of CO2 TSA beds can include at least a first TSA bed, a second TSA bed, and a third TSA bed configured to capture CO2 within a capture temperature range and regenerate the captured CO2 within a regeneration temperature range above the capture temperature range. The carbon capture system can include a plurality of valves and associated flow paths configured to enable switching between respective operating modes of the first, second, and third TSA beds.

Description

Technical Field

[0001] The present disclosure relates to a carbon capture system (for example, for a semi-closed cycle engine system).

Background Art

[0002] Some existing carbon capture technologies utilize pressure swing adsorption beds to capture carbon dioxide from an exhaust stream. In conventional systems, multiple stages are required to produce carbon dioxide at an appropriate purity, increasing the energy demand to drive the flow through the system and reducing the overall efficiency of the system.

[0003] Such conventional methods and systems are generally considered to be sufficient for their intended purposes. However, there is still a need for improved carbon capture systems in this field. The present disclosure provides a solution for such needs.

Summary of the Invention

[0004] According to at least one aspect of the present disclosure, a carbon capture system can include a plurality of CO2 temperature swing adsorption (TSA) beds. The plurality of CO2 TSA beds can include a first TSA bed, a second TSA bed, and a third TSA bed configured to capture CO2 within a capture temperature range and regenerate the captured CO2 within a regeneration temperature range above the capture temperature range. The carbon capture system can include a plurality of valves and associated flow paths configured to enable switching of the respective operating modes of the first, second, and third TSA beds.

[0005] The carbon capture system may include a control module. The control module is configured to provide continuous operation by controlling a plurality of valves such that at least one of a plurality of TSA beds operates in capture mode to remove CO2 from the exhaust flow and output a nitrogen flow, at the same time at least one of the plurality of TSA beds is used in heating regeneration mode to release CO2 into the production flow, and at the same time at the same time at least one of the plurality of TSA beds operates in cooling mode to be cooled by a cooling flow.

[0006] A carbon capture system may be configured to be connected to a semi-closed-cycle engine system to receive engine exhaust from it. In at least one aspect of this disclosure, the semi-closed-cycle system (e.g., a piston, a turbine, etc.) may include any suitable embodiment of the carbon capture system disclosed herein.

[0007] The carbon capture system may include a generation stream circulator subsystem. This subsystem is selectively connected to each TSA bed and configured to circulate the generation flow through each TSA bed in regeneration mode, thereby regenerating additional CO2 from the TSA beds and increasing the CO2 concentration in the generation flow. The generation stream circulator subsystem may include a heat source configured to add sufficient heat to the generation flow to heat each TSA bed operating in regeneration mode to within the regeneration temperature range. The generation stream circulator subsystem may include a power source configured to move the generation flow within the circulator. The generation stream circulator subsystem may be in fluid communication with a CO2 output subsystem.

[0008] The heat source may be a waste heat exchanger configured to have thermal communication with the exhaust flow located downstream of the engine. The power source may be a compressor connected to a turbine. In certain embodiments, the waste heat exchanger may be in fluid communication with the compressor and the turbine so that the waste heat drives the turbine and supplies power to the compressor.

[0009] In certain embodiments, the carbon capture system may include a flow mover (e.g., a blower, compressor, or fan) configured to provide a powered flow to the exhaust flow for it to flow through the carbon capture system to each TSA bed operating in capture mode. In certain embodiments, the carbon capture system may include a dewatering subsystem located downstream of the flow mover and upstream of at least one of the first, second, and third TSA beds operating in capture mode to remove water located upstream of at least one of the first, second, and third TSA beds.

[0010] In certain embodiments, the dewatering subsystem may include at least two dewatering TSAs and associated valves. The control module may be configured to operate the first dewatering TSA in water capture mode to output dry exhaust to at least one of a plurality of CO2 TSAs, and to operate the second dewatering TSA in water regeneration mode using a nitrogen flow from a plurality of heated CO2 TSAs, for example, or in cooling mode using a nitrogen flow from a plurality of cooled CO2 TSAs. In certain embodiments, the dewatering subsystem may be integrated with each of the first, second, and third TSA beds to remove water and CO2 from the same location.

[0011] In certain embodiments, the nitrogen recirculation system may have a nitrogen flow mover configured to recirculate nitrogen output by each TSA bed in capture mode in order to increase the cooling effect of the first, second, and third TSA beds when operating in cooling mode. In certain embodiments, the system may include a dewatering subsystem located downstream of at least one of the first, second, and third TSA beds when operating in generation mode in order to remove water located downstream of at least one of the first, second, and third TSA beds when operating in generation mode.

[0012] In at least one aspect of this disclosure, the carbon capture system may include a thermal swing adsorption (TSA) bed and a generation stream circulator subsystem. The thermal swing adsorption (TSA) bed is configured to capture CO2 within a capture temperature range and to regenerate the captured CO2 within a regeneration temperature range above the capture temperature range. The generation stream circulator subsystem is selectively connected to the TSA bed and is configured to circulate a heated generation stream through the thermal swing adsorption (TSA) bed to regenerate additional CO2 from the TSA bed and increase the CO2 concentration in the generation stream. The generation stream circulator subsystem may be any suitable embodiment of a generation stream circulator, such as those disclosed above.

[0013] In at least one aspect of this disclosure, the method may include the step of recirculating a heated CO2-rich production flow to a CO2 TSA bed to increase the CO2 concentration in the production mode of the CO2 TSA bed. The method may include the step of using engine waste heat to heat and power the heated CO2-rich production flow. In certain embodiments, the method may include the step of recirculating nitrogen to cool the TSA bed in a cooling mode. The method may include any other suitable method and / or part thereof.

[0014] These and other features of the embodiments of this disclosure will become more readily apparent to those skilled in the art from the following detailed description, which is to be interpreted in conjunction with the drawings.

[0015] Embodiments thereof are described below in detail with reference to specific figures so that those skilled in the art who relate to this disclosure can easily understand how to construct and use the devices and methods of this disclosure without excessive experimentation. [Brief explanation of the drawing]

[0016] [Figure 1]Figure 1 shows typical molecular sieve isotherms for H2O and CO2. [Figure 1A] Figure 1A is a system diagram of an embodiment of a semi-closed cycle engine system having an embodiment of the pressure swing adsorption carbon capture system according to the present disclosure, which is shown utilizing a multi-stage pressure swing adsorption process. [Figure 1B] Figure 1B shows embodiments of the valve timing charts for the adsorption, regeneration / generation, and cooling processes, respectively, including a two-bed dehydration TSA chart and a three-bed CO2 pressure swing adsorption (PSA) chart. [Figure 2] Figure 2 is a system diagram of an embodiment of a semi-closed-cycle engine system having an embodiment of the carbon capture system according to this disclosure, shown utilizing a CO2 thermal swing adsorption (TSA) process and a CO2 recirculation system. [Figure 2A] Figure 2A shows an embodiment of the TSA molar sieve adsorption, regeneration / generation (heating), and cooling processes performed simultaneously in, for example, three TSAs. [Figure 2B] Figure 2B shows embodiments of the valve timing charts for the adsorption, regeneration / generation, and cooling processes shown in Figure 2A, respectively, including a two-bed dehydration TSA chart and a three-CO2 TSA bed chart. [Figure 3] Figure 3 is a system diagram of an embodiment of a semi-closed cycle engine system having an embodiment of the carbon capture system according to the present disclosure, shown utilizing a CO2 TSA bed with multilayer containers for dehydration and CO2 capture. [Figure 4] Figure 4 is a system diagram of an embodiment of a semi-closed-cycle engine system having an embodiment of the carbon capture system according to this disclosure, shown utilizing a CO2 TSA bed with N2 recirculation to enhance cooling. [Figure 5]Figure 5 is a system diagram of an embodiment of a semi-closed-cycle engine system having an embodiment of the carbon capture system according to the present disclosure, shown using a CO2 TSA bed with gas turbo start and CO2 recirculation to the semi-closed-cycle engine system (e.g., to the exhaust). [Figure 6] Figure 6 is a system diagram of an embodiment of a semi-closed-cycle engine system having an embodiment of the carbon capture system according to the present disclosure, shown using a CO2 TSA bed having a mechanical CO2 blower and a supplemental CO2 heater. [Figure 7] Figure 7 is a system diagram of an embodiment of a semi-closed-cycle engine system having an embodiment of the carbon capture system according to the present disclosure, shown using a CO2 TSA bed with air cooling and direct air CO2 capture. [Figure 8] Figure 8 is a system diagram of an embodiment of a semi-closed-cycle engine system having an embodiment of the carbon capture system according to the present disclosure, shown utilizing a CO2 TSA bed and a direct-fired CO2 turbo for a CO2 recirculation system. [Figure 9] Figure 9 is a system diagram of an embodiment of a semi-closed-cycle engine system having an embodiment of the carbon capture system according to the present disclosure, shown utilizing a CO2 TSA bed and a burner-enhanced heat exchanger for a CO2 recirculation system. [Figure 10] Figure 10 shows, for example, an embodiment of the CO2 TSA bed arrangement of a system like the one shown in Figure 2 (for example, for a 1 MW piston engine system). [Figure 11A-C] Figure 11A is a side view of the CO2 TSA bed arrangement of the embodiment in Figure 3, showing an exemplary mechanical arrangement of three separate layered TSA vessels. Figure 11B is a orthogonal side view of the embodiment in Figure 11A. Figure 11C is a perspective view of the embodiment in Figure 11A. [Figure 12] Figure 12 is a partial perspective view of an embodiment of a CO2 TSA container structure having an internal liner and insulation. [Figure 13-A]FIG. 13 is a cross-sectional view of an embodiment of a CO2 TSA with an integrated dehydrated TSA media showing, for example, the vessel, liner, and baffle arrangement for the embodiment of FIG. 3. FIG. 13A shows a perspective cross-sectional view of the embodiment of FIG. 13 shown integrated with the embodiment of FIG. 10. [Figure 13B-C] FIG. 13B shows a partial perspective cross-sectional view of the embodiment of FIG. 13A. FIG. 13C shows a perspective cross-sectional view of the embodiment of FIG. 13B. [Figure 13D-E] FIG. 13D shows a schematic plan view of an embodiment of a variable perforated baffle plate. FIG. 13E shows a schematic view of the embodiment of FIG. 13 shown to illustrate the baffle plate arrangement. [Figure 14-A] FIG. 14 shows a perspective view of an embodiment of a CO2 TSA single vessel structure having separate compartments. FIG. 14A shows a perspective view of the embodiment of FIG. 14 shown with the upper component removed. [Figure 14B] FIG. 14B shows a perspective schematic view of the embodiment of FIG. 14A shown with integrated ductwork. [Figure 14C] FIG. 14C shows a cross-section of the embodiment of FIG. 14B with the upper and lower ducts shown transparently so that the position of the dampers can be seen. [Figure 14D] FIG. 14D shows an end front view of the embodiment of FIG. 14C. [Figure 15A-B] FIG. 15A shows a plan view of an embodiment of a large CO2 TSA vessel having the sizing of a 20MW semi-closed cycle gas turbine (e.g., having dimensions of 28’D x 6.5’). FIG. 15B shows a side view of the embodiment of FIG. 15A. [Figure 16] FIG. 16 shows a perspective view of an embodiment of a large CO2 TSA vessel shown attached to an embodiment of ducts and / or valves for a stacked arrangement. [Figure 17] FIG. 17 shows a perspective view of an embodiment of an arrangement with four of the embodiments of FIG. 16 stacked. [Figure 18A-B]Figure 18A shows a perspective view of an embodiment of a large CO2 TSA container, shown mounted on a duct and / or valve for horizontal placement. Figure 18B shows a side view of the embodiment shown in Figure 18A. [Figure 19-A] Figure 19 shows a perspective view of an embodiment of a CO2 TSA container and modular construction method for horizontal arrangement. Figure 19A shows a perspective view of a modular arrangement embodiment of several embodiments of Figure 19. [Figure 20] Figure 20 shows a perspective view of an embodiment of a CO2 TSA modular structure having one or more vertical ducts between modules. [Figure 20A] Figure 20A schematically shows the flow directions of different modes in the embodiment of Figure 20. [Figure 20B] Figure 20B shows a perspective view of an embodiment in which multiple embodiments of Figure 20 are connected to one another. [Modes for carrying out the invention]

[0017] Here, similar reference numerals refer to drawings that identify similar structural features or embodiments of the present disclosure. For illustrative and illustrative purposes only, rather than limiting, diagrams of typical molar sieve isotherms for water and CO2 are shown in Figure 1. Other embodiments and / or aspects of the present disclosure are shown in Figures 1A–20B.

[0018] The embodiments can enable carbon capture by CO2 turbo thermal swing adsorption (TSA) for semi-closed cycle engine systems. The embodiments include an improved carbon capture method that is generally applicable to distributed power applications in the range of 0.5 to 25 MW, for example. The embodiments can utilize a CO2 recirculation thermal swing adsorption (TSA) process and are useful in semi-closed cycle systems, but are also applicable to any other suitable primary CO2 source. Any suitable application of any embodiment of the present disclosure is contemplated herein.

[0019] This method can utilize exhaust waste heat or capture heat as part of its process, and furthermore, that heat can be used to mechanically drive process-related components. As a result, a significant reduction in carbon capture auxiliary load can be achieved. Several mechanical implementations of CO2TSA containers and arrangements that can significantly reduce construction, installation, and operation costs are also disclosed.

[0020] Embodiments of a semi-closed cycle system can operate the engine over an artificial atmosphere created by a combination of air, recirculation of cooled exhaust gases, and variable levels (including none) of oxygen injection (air enrichment) to increase the raw CO2 level in the engine exhaust. Certain embodiments can use a combination of molecular sieves (e.g., pressure swing adsorption (PSA) and / or TSA) and phase separation to purify CO2 to a level required for storage or other use. In the case of molecular sieve processes, certain systems can employ thermal swing, pressure swing, or vacuum pressure swing processes, or a combination thereof. Embodiments can also use system waste heat and waste heat to power appropriate components and integrate the available waste heat with the requirements of the gas purification process, resulting in higher net power and higher efficiency for the user.

[0021] Whether absorption-based or adsorption-based carbon capture is used, there are electrical and / or mechanical loads for pumps, blowers, fans, and chillers, and a thermal load (often requiring steam) for heating the media or absorbent to release CO2. Since the heat source (e.g., steam, hot oil) may not be suitable for direct contact with the media or absorbent, the thermal load is usually handled through complex heat exchangers. Steam and other phase-change heat sources can be compact, and commercially available products for generating steam (e.g., exhaust steam generators) exist, but such approaches are inefficient because the heat of vaporization of water itself is often not fully recovered.

[0022] Atmospheric CO2 levels are rising, a rise from around 300 ppm in the 1950s to over 400 ppm today, correlating with the rapid development of the 20th century that continues to this day. While conventional carbon capture technologies can be applied to stationary power plants, smaller, distributed power plants, compressor stations, and off-grid power requirements often do not fit conventional solutions. The desire and methods to monetize the reduction of CO2 emissions are somewhat new, but other engine pollutants such as NOx, SOx, CO, and HC (unburned hydrocarbons) should also be reduced. It would be a valuable addition if a single system could reduce not just one or two, but all of these pollutants. Compared to other methods, Molsieve has the advantage of being designed to capture all pollutants and create a virtually emission-free power system, but Molsieve typically have a high auxiliary load because it requires many stages.

[0023] Embodiments of this disclosure utilize molecular sieve adsorption processes. Molecular sieves are ceramic-like media, available in various physical sizes (e.g., from powder to quarter-circle), and their composition and crystalline structure allow them to adsorb or not adsorb specific species, primarily based on molecular size. For example, 3A sieves adsorb water (H2O), ammonia (NH3), and small amounts of other substances. Molecules such as CO2, O2, N2, and argon pass through the sieve. 3A sieves (and alumina) are typically used in dehydration processes. 5A sieves absorb all the species of 3A, but also adsorb CO2 and most contaminants (CO, HC, NOx), and allow most O2, N2, and argon to pass through. 13X sieves capture larger molecules but still allow O2, N2, and argon to pass through. Molecular sieves adsorb desired species when the desired species is cold and / or when the partial pressure of the desired species is high. The mol sieve releases the desired species when the temperature rises and / or the pressure decreases.

[0024] The embodiments can reduce the cost of carbon capture in small, dispersed applications, for example, between approximately 0.5 MW and 25 MW per engine. The embodiments can enable the use of high-performance molecular sieves in a thermal swing adsorption (TSA) process in a manner that does not dilute the purity of CO2 or reduce capture efficiency. The embodiments can substantially reduce the electrical and / or mechanical loads associated with carbon capture. The embodiments can improve upon the prior art level in the structure of the TSA "vessel" to reduce costs and minimize performance issues associated with leaks. The embodiments can also reduce other contaminants such as NOx, SOx, CO, and HC. Furthermore, the embodiments can provide a solution suitable for new structural or modification applications at the lowest cost.

[0025] Embodiments can be implemented, for example, using a diluted CO2 stream (e.g., 3–11 mass% CO2) present in a distributed power source, to include gas turbines, lean-burn piston engines (spark or compression ignition), and rich-burn piston engines. Any other sources are contemplated herein. According to certain embodiments, the CO2 concentration in engine exhaust can be increased using a semi-closed cycle (SCC) system that includes cooled exhaust recirculation with high-level oxygen level control. Using the carbon capture system according to this disclosure, this cooled exhaust can be cooled to help remove water, then dehydrated with CO2, and contaminants captured in a molecular sieve. As the sieve approaches capacity, the sieve is regenerated, using hot CO2 to flush out the captured CO2 and other contaminants. This hot CO2 can be generated via a turbocharger and heat source, for example, exhaust waste heat from an engine. Recirculation and regeneration in the capture process can enable a CO2 concentration sufficient for storage in a single stage. In the embodiments, since the CO2TSA process can be entirely low-pressure, any pressure vessel holding the TSA media only needs to be rated a few pounds per square inch, and as a result does not need to be a heavy structure. The embodiments allow for vessel arrangements that further reduce space, cost, and installation time.

[0026] Figure 1 shows a series of exemplary isotherms for a particular molecular sieve. The Y-axis (vertical) represents the percentage load by mass of water or CO2 within the sieve as a function of partial pressure and temperature. As the pressure increases or the temperature decreases, the media adsorbs more water or more CO2. Conversely, as the pressure decreases or the temperature increases, the media releases water or CO2. Also from Figure 1, it can be seen that this sieve has a significantly different loading capacity for water compared to CO2 at the same partial pressure and temperature combination. The media also has a different affinity for water compared to CO2. As a result of all these factors, it is possible to capture both water and CO2 using the same media and drive away their species at different points in the process. Essentially, at equal partial pressures, the capacity of water exceeds the capacity of CO2 in certain embodiments. For example, at 100 hPa and nominally 95-100°C, the capacity of water exceeds 20%, while the capacity of CO2 is only about 5%. However, the partial pressures of these components differ considerably in exhaust gases. 10% CO2 at 1 bar (1000 hPa) has a partial pressure of 100 hPa, while a typical water vapor load of less than 1% is only about 10 hPa. As the exhaust gas cools, the partial pressure of water falls below 10 hPa due to more water condensation, while the volume of CO2 increases (for example, at 25°C and 100 hPa, the volume of CO2 is about 15%).

[0027] Figure 1A shows a simplified process flow diagram (PFD) of a mole sieve-based carbon capture system 100 applied to a semi-closed cycle engine system 99. The upper half of Figure 1 shows an embodiment of a semi-closed cycle (SCC) 99 consisting of cooled exhaust recirculation and oxygen increase, as applied to a gas turbine engine (however, any suitable engine is intended herein). Generally, the exhaust CO2 concentration can be increased from about 3% to about 6% to 21% (e.g., about 2 to 7 times the concentration) using SCC technology. A portion of the exhaust flow that is not recirculated, e.g., about 20 to 50% in gas turbine applications, can enter the capture process via a stage one screw (e.g., compressor 101), thereby being compressed to about 50 to 100 psig in certain embodiments. The screw exhaust can be cooled (e.g., in a cooler 103), thereby removing water (e.g., for condensation from the gas in a collector / drain pipe). Next, dewatering of the raw CO2 can occur in a dewatering subsystem 107 (e.g., a TSA process using alumina as the medium), shown in this case using two TSA beds, TSA1 and TSA2. Equipment for heating and cooling the beds that are not in the H2O capture process, such as valves and lines shown, is present using vent gas (mainly dry nitrogen) from the next stage. Beds PS1, PS2, and PS3 represent a three-vessel pressure swing adsorption (PSA) process using conventional CO2 capture media such as 5A or 13X (or any other suitable material for CO2 capture). CO2 is released during the depressurization process, and it has been shown that the CO2 purity in this first stage release is not sufficient for most applications, except when the raw CO2 purity is very high (possible via SCC) (e.g., above 25%). As a result, a useful purity can be achieved using a second-stage PSA assembly 109 with beds PS4, PS5 and a second-stage two-screw (second compressor 111). Finally, a third screw compressor (for example, third compressor 113) can be used as the first stage of the CO2 compression system.

[0028] Figure 1A shows embodiments of the carbon capture system 100, including valves (e.g., on / off butterfly valves), lines, line connections, flow movers, and other components. Figure 1B shows a timing chart of the valves shown, arranged in the line connections shown, for operating the carbon capture system 100 (e.g., primary carbon capture subsystem 102, second stage 113) in various modes (e.g., capture, generation / regeneration, and / or cooling) via the lines shown (an embodiment of the timing of the dehydration subsystem 107 shown in Figure 2B).

[0029] System 100 may include a control module 115 configured to operate the valves shown in the timing chart of Figure 1B. Any other suitable valve control or method is contemplated herein. The control module 115 (and any other control modules disclosed herein) may include any suitable hardware (e.g., a programmable logic controller) and / or software modules configured to perform any suitable function disclosed herein.

[0030] Such an embodiment of the system work is well-built, economically viable, and therefore has reasonable CO2 capture costs. However, the power of the screw (or blower) is important (for example, for the high compression required to operate the PSA). Also, the pressurization and depressurization process of this media, which also captures things like N2 (albeit at a much lower rate) in addition to CO2, consequently relies on at least two stages to reach commercial CO2 purity (e.g., about 95% to 99% or higher). Furthermore, in the embodiment shown, the SCC process bears the exhaust cooling requirements entirely, and a large portion of the available waste heat from the engine is often wasted, except for the loads on TSA1 and TSA2 (which are relatively small). Finally, since this process typically operates at 15 psig or higher, all vessels shown in Figure 1A must be ASME Code or equivalent (Pressure Equipment Directive) certified vessels, which can significantly increase costs. Such vessels are heavy due to the high safety factor required by the Code. Due to their weight, they do not support rapid thermal cycling. Therefore, the sizes of the TSA1 and TSA2 containers correspond to the cycle time, which is measured over several hours rather than several minutes in certain embodiments.

[0031] The embodiment utilizing the PSA system in Figure 1A can use a considerable amount of horsepower (e.g., 20% of the engine hp) to drive the capture flow. The embodiment in Figure 1A can be configured to run one TSA in dehydration mode and one TSA in regeneration mode, thereby making the process a continuous process. As shown, T1D and T2D are dry gas outlet valves located upstream of the cooler P2T. This is where the outlet flow from the capture TSA goes (e.g., dehydrated gas). The outlet gas may be about 90% N2 and about 10% CO2. This flow goes to the corresponding PSA (PS1, PS2, or PS3) operating in capture mode (depending on whether P1in, P2in, or P3in is open). The shown configuration allows for CO2 capture, CO2 generation, and purging of NOx from the PSA.

[0032] Embodiments of the TSA purge valve shown deliver N2 to the H2O TSA bed for heating and cooling (depending on the path opened based on T1H, T2H (hot for regeneration) or T1C, T2C (cold for TSA bed cooling)). P2H and P2X valves can be opened to vent hot N2 from the heater line. A heater 117 may be present in part of the N2 line 119. The flow can be restricted to the thermal purging valves (P1H, P2H, P3H) (e.g., with pipes of different sizes) to bypass smaller portions of the flow in thermal purging mode (e.g., to purge NOx) while allowing water to be generated / purged within the regeneration TSA.

[0033] In the embodiment shown in Figure 1A, a bed can be used continuously until it is saturated with CO2 (e.g., PS1 with P1in open), at which point the control module 115 can operate a valve to switch the flow from PS1 to another unsaturated PSA. Switching beds allows the saturated bed to be closed from the dry gas inlet (indicated as P2T) (e.g., by switching P1in to close PS1, if PS1 is the saturated bed). The outlet valve (e.g., P1D) can then be opened, and the adsorbed CO2 is released due to the stored pressure, going to the second stage compressor 111 (e.g., about 1 / 5 hp of the first stage compressor 101) and the second stage 109.

[0034] As shown in the timing chart, the PSA can operate to switch states over a few minutes. The TSA bed can operate to switch states over several hours. Embodiments may include a cooler 121 downstream of the stage-to-screw (compressor 111). The second pressure swing stage can enable, for example, a CO2 purity of about 95% to 98%. As shown, each PSA stage may include a back pressure regulator (BPR) valve (e.g., a 50-60 psi pressure relief valve or control valve) for venting N2.

[0035] Referring here to Figure 2, in at least one aspect of this disclosure, the carbon capture system 200 may include a plurality of CO2 thermal swing adsorption (TSA) beds 223. The plurality of CO2 TSA beds may include at least a first TSA bed (e.g., bed TS3), a second TSA bed (e.g., bed TS4), and a third TSA bed (e.g., TS5), configured to capture CO2 within a capture temperature range and regenerate the captured CO2 within a regeneration temperature range above the capture temperature range. The carbon capture system 200 may include a number of valves (e.g., T3in, T4in, T5in, T3D, T4D, T5D, T3T, T4T, T5T, T3C, T4C, T5C, T3H, T4H, T5H, T3X, T4X, T5X, and BPR) configured to allow switching between the operating modes of the first, second, and third TSA beds, as well as associated flow paths (lines and connections as shown, e.g., jump-over lines represented as curves on intersecting lines).

[0036] Referring further to Figures 2A and 2B, the carbon capture system 200 may include a control module 215. The control module 215 is configured to provide continuous operation by controlling several valves such that at least one of the multiple TSA beds (e.g., TS3 in Figure 2A) operates in capture mode to remove CO2 from the exhaust flow and output a nitrogen flow, while at the same time, at least one of the multiple TSA beds (e.g., TS4 in Figure 2A) is used in heating regeneration mode to release CO2 into the production flow, and at the same time, at least one of the multiple TSA beds (e.g., TS5 in Figure 2A) operates in cooling mode to be cooled by a cooling flow.

[0037] Figure 2B shows embodiments of timing charts for both a dewatering process using two TSA beds and a capture process using at least three TSA beds. The control module 215 may be configured to control multiple valves, as shown in Figure 2B.

[0038] Similar to the embodiment shown in Figure 1A, the carbon capture system 200 may be configured to be connected to a semi-closed cycle engine system 99 to receive engine exhaust from there, as shown in Figure 2. In at least one aspect of this disclosure, the semi-closed cycle system (e.g., piston, turbine, etc.) may include any suitable embodiment of the carbon capture system (e.g., system 200) disclosed herein.

[0039] The carbon capture system 200 may include a generate stream circulator subsystem 225. The generate stream circulator subsystem 225 is selectively connected to each TSA bed (e.g., beds TS3, TS4, and TS5) (via loop line 229 and valves T3H, T4H, T5H, T3D, T4D, T5D) and is configured to circulate the generate stream (CO2-rich stream) through each TSA bed (e.g., TS4 in Figure 2B) in regeneration mode to regenerate additional CO2 from the TSA bed and increase the CO2 concentration in the generate stream. The generate stream circulator subsystem 225 may include a heat source (e.g., a heat exchanger 227 connected to exhaust line 231 of system 99) configured to add enough heat to the generate stream to heat each TSA bed operating in regeneration mode into the regeneration temperature range. The generate stream circulator subsystem 225 may include a power source (e.g., a compressor 233) configured to move the generate stream within the circulator subsystem 225. The generated stream circulator subsystem 225 can be in fluid communication with the CO2 output subsystem 235 (for example, any suitable component configured to output the generated flow to a CO2 compression system).

[0040] As shown in Figure 2, the heat source may be a waste heat exchanger 227 configured to have thermal communication with the exhaust flow located downstream of the engine. The power source may be a compressor 233 connected to a turbine 237. In certain embodiments, the waste heat exchanger 227 can be in fluid communication with the compressor 233 and the turbine 237 so that the waste heat drives the turbine 237 to supply power to the compressor 233.

[0041] In certain embodiments, the carbon capture system 200 may include a flow mover 201 (e.g., a blower, compressor, or fan, screw, or other device, e.g., with lower horsepower compared to the compressor in Figure 1A) configured to provide a powered flow to the exhaust flow for it to flow through the carbon capture system 200 to each TSA bed (e.g., TS3 in Figure 2A) operating in capture mode. In certain embodiments, similar to the embodiment in Figure 1A, the carbon capture system 200 may include a dewatering subsystem 107 located downstream of the flow mover 201 and upstream of at least one of the first, second, and third TSA beds (e.g., TS3) to remove water (e.g., steam and / or vapor) located upstream of at least one of the first, second, and third TSA beds operating in capture mode.

[0042] In certain embodiments, the dewatering subsystem 107 may include at least two dewatering TSAs (e.g., TSA1 and TSA2) and associated valves (e.g., T1in, T2in, T1D, T2D, T1H, T2H, T1C, T2C, T1X, T2X) arranged as shown. The control module 215 may be configured to operate at least two dewatering TSAs so that the first dewatering TSA (e.g., TSA1) can be operated in water-capture mode to output dry exhaust (exhaust gas from which water vapor has been removed) to at least one of a plurality of CO2 TSAs 223 (e.g., via the inlet valve T3in corresponding to the cooler P2T and TS3 bed). The control module 215 may be configured to operate the second dewatering TSA (e.g., TSA2) in water regeneration mode using a nitrogen flow from a plurality of heated CO2 TSAs 223 (e.g., outlets from TS3 in Figure 2A) (e.g., via heater 117), or in cooling mode using a nitrogen flow from a plurality of cooled CO2 TSAs.

[0043] As shown in the embodiment of system 200 in Figure 2, the carbon capture system 200 can utilize a TSA bed instead of a PSA bed and a hot CO2 flow to purge CO2 from the TSA bed. Such embodiments can utilize a blower or fan for the flow mover 201 because the system can operate at a much lower pressure, such as about 3 psi, rather than about 60 psi in certain embodiments that utilize PSA.

[0044] As shown, the TSA configuration for water removal / dewatering can be similar to or identical to that shown in Figure 1A. Waste heat from the engine can heat the generate flow, thereby driving a turbo, which in turn drives a compressor / fan to provide a powered flow to the generate flow. Embodiments utilizing a TSA function differently from a PSA configuration like that shown in Figure 1A. Embodiments of a TSA use heat to release CO2 from the media. The generated CO2 can then be circulated in a circulator system that heats the gas using, for example, engine heat that would be wasted anyway, then ports to the opposite side of each TSA from which the CO2 was released, providing the TSA with hot CO2, further heating the TSA and releasing even more CO2. This recirculation increases the purity of the CO2 in the generate stream. As shown in Figure 2, a second-stage PSA or other capture system is not required.

[0045] In certain embodiments, referring to the carbon capture system 300 in Figure 3, a dehydration subsystem (not specifically shown) can be integrated with each of the first, second, and third TSA beds (TS3, TS4, and TS5, respectively) to remove water and CO2 at the same location. For example, each TSA bed may include H2O molar sieve media sandwiching CO2 molar sieve media so that each TSA bed can capture both water and CO2.

[0046] As shown, the water-capturing TSA is physically integrated with the carbon-capturing TSA. This eliminates the need for a separate water-capturing system stage, as shown in Figure 1. This physical mixing can be carried out in any manner (e.g., uniformly, in layers, or in any suitable geometric shape). Such embodiments allow, for example, the removal of all dewatering TSA valves and lines. Since TSA media can handle moisture in exhaust gases, but PSA cannot handle moisture properly, residual water can be removed during or after carbon removal. If moisture is not removed upstream, the PSA media may not function properly. As shown, one or more coolers 303 and condensers / separators 305 can be placed on the production outlet line. Hereinafter, any suitable components of any suitable embodiment (e.g., those described above) and / or any suitable control of the valves by the control module 315 (e.g., one or more similar to those in the above embodiments) are contemplated.

[0047] Referring further to Figure 4, in certain embodiments, the carbon capture system 400 may include a nitrogen recirculation system 441 which has a nitrogen flow mover 443 (e.g., a blower, fan, screw, etc.) configured to recirculate nitrogen output by each TSA bed (e.g., TS3 in Figure 2A) in capture mode in order to increase the cooling effect of the first, second, and third TSA beds when operating in cooling mode (by increasing the flow velocity of the N2 flow). The nitrogen loop 445 may include a cooler 447 placed on top of it to further cool the flow. Exhaust valves T3X, T4X, and T5X may be in fluid communication with the nitrogen loop to allow nitrogen that would otherwise be vented (e.g., when the TSA cooling stack valve is open) to circulate within the nitrogen loop 445.

[0048] In certain embodiments, the system 400 may include a dewatering subsystem 407 located downstream of at least one of the first, second, and third TSA beds (when operating in the generation mode) to remove water located downstream of at least one of the first, second, and third TSA beds operating in generation mode. For example, a secondary PSA system can be used for dewatering. To help properly time each mode with the H2O / CO2 TSA combination, a fan blowing N2 can move the flow faster and improve cooling. The net flow of N2, if not recirculated, can be vented to a cooling stack valve.

[0049] In the embodiment shown in Figure 4, the CO2 compressor / turbine system may also have a valve 449 and a thermostat (e.g., connected to a control module 415) configured to reduce the need for cooling by preventing the recirculated CO2 gas from becoming unnecessarily hot. In any embodiment disclosed herein, it is intended that this and / or a nitrogen recirculation system 441 may be implemented. Hereinafter, any suitable components of any suitable embodiment (e.g., those described above) and / or any suitable control of the valve by the control module 415 (e.g., one or more similar to those in the embodiments described above) are intended.

[0050] Referring to Figure 5, the carbon capture system 500 may include a CO2 bleed 551 to increase the concentration of CO2 in the exhaust gas, for example, slightly, to improve the concentration at the inlet to system 500, thereby improving the function and timing of the TSA and the final concentration at output. Also, as shown in Figure 5, system 500 may include a start valve 553 (e.g., a check valve or other suitable valve) that opens when the compressor starts to rotate. Certain embodiments may also have a valve 555 to provide a starter power flow to the CO2 compressor. Once the compressor has started to rotate and is generating sufficient flow / pressure, valve 555 may be closed and valve 553 may be opened.

[0051] The embodiment shown in Figure 5 may otherwise be the same as the embodiment in Figure 3, except that it includes initiation by a CO2 recirculation compressor via gas injection and CO2 bleed to exhaust CO2 for further concentration. In this specification, any suitable component of any suitable embodiment (e.g., those described above) and / or any suitable control of the valve by the control module 515 (e.g., one or more similar to the embodiments described above) are contemplated.

[0052] Referring to Figure 6, the system 600 may include an additional heater 657 to ensure that the recirculated CO2 flow is adequately heated for TSA regeneration. This embodiment also shows having a blower 659 (e.g., partially electrically driven or otherwise driven) instead of (or, in certain embodiments, in addition to) an engine-thermally driven turbo. This embodiment also shows including a nitrogen recirculation system similar to that of the embodiment in Figure 4. Any suitable components of any suitable embodiment (e.g., those described above) and / or any suitable control of the valves by the control module 615 (e.g., similar to one or more of the embodiments described above) are contemplated herein.

[0053] Referring to Figure 7, system 700 could have an air fan 761 instead of an N2 recirculation system. This eliminates the need for a large heat exchanger and allows the existing chiller to cool and condense water from the air. Another advantage is that direct air capture of CO2 may also occur. The horsepower required for the air fan can be reduced and the cooler on the cold nitrogen line can be removed. The chiller load as shown is not an additional heat exchanger source but an existing chiller that allows the use of a small heat exchange of air. Water drops out of the gas after the chiller load, and mostly dry air can be output. The air can be mixed with N2 in the system (output by the capture TSA), and the mixture can be essentially a dry N2 stream.

[0054] Embodiments such as those shown in Figure 7 enable direct air cooling and direct air carbon capture, the use of chillers to reduce water adsorption loads, and a counterflow SCC quench system. In this specification, any suitable components of any suitable embodiment (e.g., those described above) and / or any suitable control of the valve by the control module 715 (e.g., one or more similar to the embodiments described above) are contemplated.

[0055] Referring to Figure 8, in this embodiment of system 800, the fuel can be burned using the existing oxygen supply of the SCC to generate hot CO2. By using O2 as the oxidizer, the unnecessary introduction of N2 is avoided. Such an embodiment may be useful, for example, in modifications. This embodiment allows heating of the flow without absorbing heat from the engine as in the previous embodiment or without using an electric heater.

[0056] System 800 utilizes a combustion CO2 turbo, the heat source of which is an oxygen burner 863. The burner 863 can be thermally connected to, for example, only a generated flow recirculation loop, and the combustion products from the burner can be output to the engine or engine exhaust for processing together with the exhaust by System 800. In certain embodiments, the exhaust from the oxygen burner 863 can be fluidly connected to, for example, a recirculation loop (e.g., a turbine). Hereinafter, any suitable similar components of any suitable embodiment (e.g., those described above) and / or any suitable control of the valve by the control module 815 (e.g., one or more similar to those described above) are contemplated.

[0057] Referring to Figure 9, the system 900 may include, for example, a conventional burner 965 which may be added to heat the exhaust heat exchanger 227 in Figure 2. The shown embodiment also allows for direct venting of N2 gas from capture and, optionally, air from cooling (e.g., via valves T3TX, T4TX, T5TX). The embodiment in Figure 9 is shown to not include N2 recirculation as shown in Figure 7.

[0058] Embodiments may utilize a burner-enhanced CO2 turbo heat exchanger. The burner exhaust may be, for example, about 11% CO2 mixed with SCC exhaust. This specification considers any suitable similar components of any suitable embodiment (e.g., those described above) and / or any suitable control of the valve by the control module 915 (e.g., one or more similar to those described above). This specification considers any suitable combination of any suitable parts of any suitable embodiment.

[0059] In at least one aspect of this disclosure, the carbon capture system may include a thermal swing adsorption (TSA) bed and a generation stream circulator subsystem. The thermal swing adsorption (TSA) bed is configured to capture CO2 within a capture temperature range and to regenerate the captured CO2 within a regeneration temperature range above the capture temperature range. The generation stream circulator subsystem is selectively connected to the TSA bed and is configured to circulate a heated generation stream through the thermal swing adsorption (TSA) bed to regenerate additional CO2 from the TSA bed and increase the CO2 concentration in the generation stream. The generation stream circulator subsystem may be any suitable embodiment of a generation stream circulator, such as those disclosed above.

[0060] In at least one aspect of this disclosure, the method may include the step of recirculating a heated CO2-rich production flow to a CO2 TSA bed to increase the CO2 concentration in the production mode of the CO2 TSA bed. The method may include the step of using engine waste heat to heat and power the heated CO2-rich production flow. In certain embodiments, the method may include the step of recirculating nitrogen to cool the TSA bed in a cooling mode. The method may include any other suitable method and / or part thereof.

[0061] Figure 10 shows an embodiment of the CO2 TSA bed arrangement for a system (e.g., for a 1 MW piston engine system) as shown in Figure 2. Figure 11A is a side view of the CO2 TSA bed arrangement of the embodiment in Figure 3, showing an exemplary mechanical arrangement of three separate layered TSA vessels. Figure 11B is an orthogonal side view of the embodiment in Figure 11A. Figure 11C is a perspective view of the embodiment in Figure 11A. Figures 11A-11C show embodiments of the layered TSA vessels. The upper header may be for the thermal CO2 inlet (before regeneration), the dry N2 outlet (after adsorption), and the dry N2 inlet (for cooling). The lower header may be for the exhaust inlet (for adsorption), the CO2 outlet (after regeneration), and the N2 outlet (post-cooling).

[0062] Figure 12 is a partial perspective view of an embodiment of a CO2TSA container structure having an internal liner and insulation. Figure 12 shows a single container with the lid removed. The container may be an internally insulated “pressure vessel” having a thin-walled stainless steel liner, a mol sieve medium, an inner shell, and insulation. The insulation gap can prevent heat exchange with the steel container.

[0063] Figure 13 is a cross-sectional view of an embodiment of a CO2 TSA having integrated dehydrated TSA media, showing, for example, the container, liner, and baffle arrangement for the embodiment shown in Figure 3. In Figure 13, the outer shell, insulation, and inner liner are hidden. As shown, the “sandwich” structure may include an upper flange, perforated baffles, guard / dehydrated media, CO2 capture media, another guard / dehydrated media, media support screen, perforated baffles, and a lower flange.

[0064] Figure 13A shows a perspective cross-sectional view of the embodiment shown in Figure 13, integrated with the embodiment shown in Figure 10. As shown, the sandwich structure embodiment may include, for example, a plate with about 40% open, an H2O adsorbing molecular sieve, a CO2 adsorbing molecular sieve, another H2O adsorbing molecular sieve, a support media and screen, and another area plate with about 40% open, as shown in Figure 13. Any other suitable arrangements and sizes are contemplated herein.

[0065] Figure 13B shows a partial perspective cross-sectional view of the embodiment shown in Figure 13A. As shown, the structure may include high-temperature insulation in the upper cover, high-temperature insulation in the radial gap (to fill the air gap), and insulation in the lower cover. Figure 13C shows a perspective cross-sectional view of the embodiment shown in Figure 13B. CO2 and dry N2 can be supplied from the top. Raw exhaust can be supplied from the bottom.

[0066] Figure 13D shows a schematic plan view of an embodiment of a variable perforation baffle plate. An example of a variable perforation plate is shown having an area plate that is approximately 40% open, an outer ring with an area plate that is 33% open, and an outlet / inlet projection area of ​​an area plate that is approximately 37.5% open, centered around a pipe projection.

[0067] Figure 13E shows a schematic diagram of the embodiment of Figure 13, illustrating an embodiment of the baffle plate arrangement. Figure 13E shows an example of a stacked baffle plate having a plenum space to facilitate diffusion and being reversed to switched inlet and outlet positions.

[0068] Figure 14 shows a perspective view of an embodiment of a single CO2TSA container structure having separate compartments. Figure 14A shows a perspective view of the embodiment of Figure 14 with the upper components removed. Figure 14B shows a schematic perspective view of the embodiment of Figure 14A, showing it with integrated ductwork. Figure 14C shows a cross-section of the embodiment of Figure 14B, with the upper and lower ducts shown transparently to reveal the position of the damper. Figure 14D shows an end front view of the embodiment of Figure 14C.

[0069] As shown, certain embodiments may have one large container with baffles instead of three cylindrical containers. Valves, though not shown, may be located at the flange where the pipes merge. Embodiments may provide multiple compartments within a single container. Embodiments, by using TSA, cannot have significant pressure or pressure differences, and a flat-side design with minimal reinforcement is possible. Small leaks between compartments will not significantly affect the process. Production takes place at a pressure slightly higher than the rest of the process, and no special high temperatures or complex seals are required.

[0070] The embodiments shown in Figures 14B to 14D eliminate the need for complex ducting (for example, to facilitate shipping) and house the entire assembly in an ISO container. Due to the low pressure, the ducting does not need to be completely sealed, and leaks do not significantly affect performance. Less expensive metals and materials can be used.

[0071] The embodiments are very large and may present challenges in manufacturing and transportation. The following embodiments can address these challenges. Figure 15A shows a plan view of an embodiment of a large CO2TSA vessel having the sizing of a 20MW semi-closed cycle gas turbine (e.g., having dimensions of 28'D × 6.5'). Figure 15A shows an exemplary 20MW SCC gas turbine adsorbent, which is very large and requires large components (e.g., ductwork equivalent to about 60"D). Figure 15B shows a side view of the embodiment of Figure 15A. The embodiment can use a total of four vessels: one for adsorption, one for regeneration, and two for cooling. Appropriate dimensions are intended herein.

[0072] Figure 16 shows a perspective view of an embodiment of a large CO2 TSA container, shown mounted on a duct and / or valve embodiment for stacked arrangement. Figure 16 shows a single TSA with three dampers of approximately 84” × 84” at the top and bottom, as well as a transition to a square duct of approximately 60”.

[0073] Figure 17 shows a perspective view of an embodiment of a stacked arrangement of four TSA embodiments of Figure 16. Figure 17 shows a vertically constructed structure for efficient ductwork sandwiching. As shown, six manifolds and 24 valves are used for the bed. In certain embodiments, the entire system can have about 50'D × 50'H and can contain about 300 tons or more of media lifted.

[0074] Figure 18A shows a perspective view of an embodiment of a large CO2TSA container, shown mounted on a duct and / or valve embodiment for horizontal arrangement. Figure 18B shows a side view of the embodiment in Figure 18A. Figures 18A and 18B show alternative horizontal arrangements for upper and lower ducts. In certain embodiments, for example, four containers can fit into a 120' × 30' space in such embodiments.

[0075] Figure 19 shows a perspective view of an embodiment of a CO2TSA container and modular construction method for horizontal arrangement. Figure 19A shows a perspective view of an embodiment of a modular arrangement of multiple embodiments of Figure 19. The embodiment of Figure 19 may include a 28' diameter equivalent in 22' × 30'. Such an embodiment can be shipped in two 11' × 30' modules. The seal between modules is outside the insulation (e.g., cold). Such an embodiment has ducts and valves on both sides of the media.

[0076] Figure 20 shows a perspective view of an embodiment of a CO2TSA modular structure having one or more vertical ducts between modules. Figure 20A schematically shows different modes of flow direction in the embodiment of Figure 20. Figure 20B shows a perspective view of an embodiment in which multiple embodiments of Figure 20 are connected to each other.

[0077] In certain embodiments, the ducts can be arranged on a single (e.g., top) side, as shown in the embodiment of Figure 20. As shown, the six flow paths are on the upper side of a single TSA. Such embodiments provide an improved packaging in which all ducts are on one side. Embodiments may include, for example, a sandwich structure similar to the cylindrical embodiment described above.

[0078] A larger surface area, as shown, allows vertical transfer ducts to reach the bottom and enables all ducts to be on one side. In certain embodiments, vertical ducts may be located between pairs of CO2TSA modules. As shown in Figure 20A, top-down bed flow for cooling and regeneration can provide higher flow rates, while bottom-up bed flow for adsorption can provide lower flow rates.

[0079] Figure 20B shows four module pairs connected to each other. Given the form factor, such embodiments can be built on a foundation and can also be transported in conventional shipping containers. The four containers shown may instead be housed in a single concrete foundation. In such embodiments, access to the underside of the containers is not required.

[0080] Additional non-limiting descriptions of specific embodiments Figure 2 provides an embodiment of a particular embodiment of the present disclosure, namely a CO2TSA for SCC, which is described in detail herein. In any engine, fuel must be burned, and this requires an oxidizer (usually air). Referring to the engine in Figure 2, the illustrated engine (turbine or piston) is in a working fluid from an intake buffer tank having a mixture of air, oxygen, and cooling exhaust. The mixed oxygen concentration in the intake buffer tank is variable, but is typically in the range of 12-22% O2. The engine burns fuel in this artificial atmosphere to produce hot exhaust, which flows directly into an exhaust heat exchanger CO2HX via a catalyst (if present) and auxiliary combustion (if present). This heat exchanger partially cools the exhaust, typically to about 400°F, where it is then quenched by mixing the exhaust with colder water, typically to about 100°F. This condenses most of the water from the combustion products, which is removed by a conventional gas-liquid separator. Unless used or treated in another way, the water accumulates in a storage tank, but this condensed water is typically used as makeup water in the cooling tower, eliminating or mitigating water treatment problems. The now cooled exhaust, with most of the water removed, returns to the intake buffer tank or TSA screw / blower. The flow rate in this TSA screw / blower is typically variable speed driven or involves other flow control methods, indirectly setting the level of exhaust recirculation. Since the engine flow rate is essentially fixed, anything not removed by the capture system is recirculated, and the balance required by the engine is supplemented by air and / or oxygen. Downstream of the screw / blower is the balance of the CO2 TSA capture system. Immediately downstream of the screw is a heat exchanger / chiller, which is typically cooled to 35-50°F. This causes more water to condense, reducing the load on the subsequent molecular sieves.

[0081] The first step of this process is the dewatering of water in adsorption vessels TSA1 and TSA2, typically with a blend of alumina and 3A sieves. This is a batch process, where one vessel is adsorbing water while the other is offline, heated or cooled. Valves T1In and T2In control which vessel receives the cooled exhaust. For illustrative purposes, assuming TSA1 is dewatering, valve T1In is open, and the exhaust flows through TSA1 and out through valve T1D, and through another cooler P2T to one of the three capture vessels TS3, TS4, or TS5. At the inlet of the capture TSA vessel, the exhaust is essentially water-free and typically contains 5-20% CO2, 0-10% O2, and the remainder being inert gases (nitrogen, and small amounts of argon).

[0082] Assuming that TS3 has adsorbed CO2 at this point, valve T3In is open, and valves T4In and T5In are closed. The current exhaust gas, now free of CO2 and water, flows out of TS3 through the open T3T, while T4T and T5T are closed. This relatively cool, dry gas (mostly N2) is manifolded at several points. First, if all downstream valves are closed, or if the back pressure is temporarily high for some reason, the excess gas is vented to the air through the CO2TSA vent, controlled by the back pressure regulator BPR. Normally, the pressure is below the setpoint, and the BPR remains closed. Some of this dry N2 gas is used, depending on the cycle time, to heat TSA1 or TSA2 (the one that has not adsorbed water, TSA2 in this example), or to cool TSA2. For example, if the design point for water adsorption in TSA1 and TSA2 is 8 hours, TSA1 adsorbs for 8 hours, while in parallel, TSA2 is regenerated (heated) for approximately 4 hours using heated dry N2, first by opening T2H and T2X, and then cooled by opening T2C while closing T2H (with T2X open). After 8 hours, this process is reversed, with TSA2 taking over the role of dehydration adsorption, and TSA1 being heated and then cooled by a combination of valve operations at T1H, T1C, and T1X. The cycle time for water adsorption is typically several hours, usually between 3 and 12 hours.

[0083] In most cases, the amount of CO2 in the exhaust is orders of magnitude greater than the amount of water in the exhaust, and the capacity of CO2 per unit weight of the mol sieve is lower than that of water. As a result, the cycle time for the CO2 adsorption function of beds TS3, TS4, and TS5 is measured in minutes, not hours. Assuming that TS3 is adsorbing CO2 as described herein, T3In and T3T are open, and optionally some of the dry N2, further cooled via a chiller, can pass through T4C or T5C to cool these beds and be discharged via T4X or T5X. Note that the amount of gas required for cooling may not be sufficiently met by the flow rate from TS3, and methods for increasing the flow rate by recirculation or decreasing the required flow rate will be described later in this disclosure.

[0084] After the CO2 adsorption cycle is complete, the captured CO2 needs to be released primarily by a heating TSA process. In certain embodiments of the present invention, this heating is provided by a hot gas mixture, mostly CO2, delivered to the bed TS3 via valve T3H in this example. The supply of hot CO2 is generally 600-800°F, with 650°F being the most common design point. The gas flows downward through the media in the container TS3, gradually heating the media to release more CO2. This warm CO2 flows to a cooler via valve T3D. Also, a portion of the gas is separated and flows to a screw compressor via a separator (theoretically not necessary, but this is a dry gas and in practice exists to increase the volume for improved control), and the remaining CO2 flows downstream to a CO2 compression or utilization system. The flow rate in this CO2 screw is also generally variable in rate, indirectly setting the pressure in the container TS3 during the desorption process.

[0085] The required desorption flow rate, both on a mass-based and volume-based basis, is far higher than the original exhaust flow rate. Furthermore, higher temperatures increase the pressure loss across the bed, reaching up to 10 psi compared to 1-2 psi for adsorption, resulting in a high electrical load. In this invention, the CO2 products are recirculated to support these higher flow rates. More importantly, the power used for recirculation is via a "CO2 turbo," where the heat needed to power the turbocharger and heat the bed itself is obtained from the engine exhaust. Referring again to Figure 2, after passing through the T3D and cooler, some of the CO2 products enter the turbocharger compressor, where the pressure typically rises to 15-25 psi and the temperature rises to over 300°F. The CO2 products then enter the CO2HX, where they are heated to a temperature close to the original exhaust temperature, typically 800-900°F. This thermal CO2 then expands on the expander side of the turbocharger, generating the 600+°F CO2 needed for regeneration. The pressure remains high enough to support the flow through the bed, as in a typical turbocharger, because the pressure increase on the compressor side significantly outweighs the pressure decrease on the expander side.

[0086] At the end of the regeneration process, the TS3 bed is virtually free of CO2 and, naturally, very little water. The media is hot, typically with an average temperature of around 500°F. The media needs to be cooled in preparation for the start of the next adsorption cycle, which is achieved by opening valves T3C and T3X and closing T3In, T3T, T3H, and T3D. The cooling process does not need to return the media temperature completely to ambient temperature. Referring again to Figure 1, some initial CO2 adsorption capacity can be obtained at temperatures below 100°C (212°F), but around 50°C (122°F) or below is preferred. Since the original exhaust stream is nominally supplied at 10°C (50°F), the cooling of the bed continues to some extent in parallel with the adsorption process.

[0087] The flow direction and operating sequence of the TSA process are generally shown in Figure 2A. Examples of process timing for TSA dewatering using a two-bed TSA and TSA capture using a three-bed TSA are summarized in Figure 2B. For beds of similar size, the dewatering process is much slower than the capture process, taking several hours per bed. While theoretically it can be run very quickly, in practice it is run with process intervals of 10-30 minutes.

[0088] Herein, we outline variations of specific embodiments of the present disclosure and preferred process embodiments. Depending on the engine specifications and other process requirements, different combinations of these basic process variations are often used, but the embodiments shown in Figures 3–9 can address these variations.

[0089] As illustrated in Figure 1A, current state-of-the-art technology uses a TSA process for dehydration, while multi-stage vacuum pressure swing adsorption (VPSA) or PSA processes are used for capture (VPSA is technically a subset of PSA, but is a commonly used term in the industry). In certain embodiments of this disclosure, as discussed in the descriptions of Figures 2, 2A, and 2B, the same basic process (TSA) is currently used for both dehydration and capture, and in vessels of similar size, the same capture and regeneration temperatures are used, although the cycle timings of these processes differ.

[0090] Referring to Figure 3, in a particular embodiment of the present disclosure, assuming that the TSA process is used for both dehydration and capture, it is possible to combine these functions in a single vessel. As shown in Figure 1, since a particular media has the ability to capture both CO2 and H2O, the vessel may have layers of different media, a blend of media, or a single media to control where the functions occur.

[0091] Specifically, Figure 3 repeats the basic process of Figure 2, but removes the containers TSA1 and TSA2, as well as their associated valves T1In, T2In, T1X, T2X, T1C, T2C, T1H, T2H, T1D, and T2D, and also removes the inter-process cooler P2T.

[0092] Figure 3 retains all processes related to 18 T3-T5 family valves. Currently, shorter capture cycle times are still dominant, so the amount of dewatered media is much less than that of the capture media, and instead, the dewatered layer can be eliminated as the capture media has some dewatering capacity. However, this is not practical in most cases because typical capture media are more expensive than alumina or 3A. Additional tasks would require a slightly larger container or a slightly shorter process time, but the timing of the capture process in Figure 2A would be retained.

[0093] In certain embodiments, the gas flow rates for capture and regeneration are not equal, and this is regulated by the recirculation of CO2 for regeneration. The modification of the invention from Figure 2 to Figure 3 achieves a significant reduction in capital equipment and the number of valves, but the cooling requirements in Figure 3 are, in some cases, inferior to those in Figure 2, as the dewatered media must also be cooled in a faster cycle. This can be addressed by changing the number of containers. Systems with as few as two containers can be designed, as long as the heating and cooling times in one container can be achieved in parallel with the adsorption time in the other container. This is similar to the two-container dewatering timing in Figure 2B. It is also possible to proceed in the other direction with four, five, or six containers, so that the time available for cooling and / or heating is longer than the capture time. These basic options are summarized in Table 1 below.

[0094] [Table 1] Table 1 It is also possible to have uneven cooling and heating times. For example, in a forbed design, the cycle times can be X for adsorption, X for regeneration, 2X for cooling, or vice versa, or any of the in-between, as long as the cycles can eventually be repeated synchronously.

[0095] Figure 3 shows significant savings and simplification compared to state-of-the-art mole sieve capture systems for semi-closed cycle (SCC) applications. While the capture and dewatering portions in Figure 3 function even without exhaust gas recirculation in the SCC, several methods for concentrating CO2 upstream of the mole sieve capture process reduce the number of stages required to achieve commercial or sequestration quality of CO2, ultimately enabling a single-stage capture system for sequestration applications with appropriate well design.

[0096] Referring to Figure 4, all the components in Figure 3 are repeated, along with the relevant processes and timings, several additional components primarily to address cooling issues, and the CO2 specifications required for non-isolated or pipelined applications. A N2 recirculation fan with a cooler can be used in place of or in addition to an additional vessel, allowing sufficient cooling within the available time. A bypass valve around the CO2 is also present, which can reduce both the flow rate and temperature during the regeneration cycle. Once sufficient heat is present in the media vessel and top layer "inside", and the CO2 is released from that media, the flow rate and temperature can be reduced. The heat wave still descends the vessel as the media acts as a heat regenerator, thereby heating the lower level of the media and beginning to cool the upper level of the media.

[0097] Similarly, referring to Figure 4, a new component is added downstream of the CO2 screw, which includes two PSA vessels with associated valves P1In, P2In, P1D, P2D, P1X, and P2X. The operation of this PSA process is conventional, but by using a medium such as alumina or 3A, the final dewatering is performed in much smaller vessels at a much lower total flow rate than that of TSA1 and TSA2. For applications requiring very low dew points (such as interstate CO2 pipelines), this add-on PSA allows certain embodiments of this disclosure to still meet the specifications of those pipelines. As is well known to those familiar with PSAs, when P1IN, P1D, and P2X are open and the other valves are closed, the vessel downstream of P1IN absorbs water and the vessel downstream of P2IN discharges water, and the opposite is true if the valve positions are reversed.

[0098] Figure 5 includes some of the same improvements as Figure 4, including several additional components that assist in system startup and provide an additional method for concentrating CO2 before TSA. Referring to Figure 5, the CO2 turbo, unlike a turbocharger on a typical engine, typically requires starting. The CO2 turbo is physically an electrically driven “compander” with a compressor and expander, typically on a normal bull gear, and when started, the motor power is nearly zero (or even negative, sometimes even functioning like a generator). If the CO2 turbo is like an engine's turbocharger, with the compressor and turbine physically connected on a common shaft and no external input or output, something needs to start that shaft rotating. To achieve starting, higher-pressure CO2 (or whatever gas is initially present in the process at this point) is compressed and sent via a check valve or auto valve to the CO2 turbo expander, which is downstream of the compressor but upstream of the CO2HX, to mechanically start the turbine spool up. When the CO2 turbo expander detects hot gas, it starts immediately, opening the check downstream of the CO2 turbo compressor and closing the other check (if not automated). Figure 5 also includes additional features. Because the flow rate through the regeneration process is typically much higher (typically twice) than the flow rate of the original engine exhaust, and because this flow is high-purity CO2 (>>90%CO2), while the engine exhaust is much lower-purity CO2 (sometimes <10%CO2) even with SCC, very small amounts of bleed flow, as part of the CO2 regeneration flow, have a significant impact on the purity of the original CO2 entering the cycle. This CO2TSA recirculation is another way to concentrate exhaust CO2, similar to SCC, but without the need to return the CO2 to the engine inlet. The latter may require a larger oxygen plant or the modification of other engines that are incompatible with certain engine types, especially in the case of modification projects or new installations using standard engine manufacturer products, ratings, and controls that are not optimized for SCC.

[0099] Figure 6 shows another improvement to the basic invention of Figure 3. In very efficient engines, especially highly efficient lean-burn piston engines, there is insufficient exhaust heat to fully support the operation of the CO2TSA CO2 turbo. In other cases, there is sufficient heat, but the custom has chosen to use that heat for its own process, resulting in less total exhaust heat available. In an extreme example (as shown in Figure 6), there is no total exhaust heat available, and the CO2 turbo has been replaced with an electrically driven blower, and the CO2HX with an electric heater. The rest of the process remains the same. In practice, the CO2HX exists, and the CO2 turbo exists in the form of a compander (electrically assisted), but the additional heat and power are provided by the compander's motor, downstream of the CO2HX in Figure 3, but there is a small heater upstream of the CO2 expander or T#H valve.

[0100] Figure 7 shows some of the improvements already described in Figures 4-6, as well as some new features. Specifically, the recirculating N2 blower in Figure 4 is replaced with an air blower or fan and chiller to remove as much water as possible (dew point approximately 40°F, or <<1% water). In addition to dry N2, air is used in the cooling process. As previously mentioned, N2 flows from the T#T valve to the T#C valve, consistent with Figure 2B, but now this flow rate is increased upstream of the T#C valve with partially dehydrated air. This eliminates the need for the large component, the N2 recirculating cooler, providing an additional benefit. Because the air is at a lower temperature than the recirculating N2, the use of direct air cooling in the CO2TSA cools the bed more effectively and quickly. This also allows the bed to capture a small amount of CO2 from the air. While this small amount of CO2 typically accounts for 1-2% of the total captured CO2, CO2TSA, with proper design, can already capture over 99% of CO2, making it sufficient to make the entire system carbon negative (non-emission).

[0101] Another improvement shown in Figure 7, which is more easily applicable to gas turbines than piston engines, is the use of counterflow direct contact coolers within the SCC. This significantly reduces the flow rate of chilled water required for quenching, but certainly increases the back pressure. Turbine engines are more tolerant of this back pressure than piston engines, otherwise they would require very high water flow rates to achieve quenching.

[0102] The final improvement in Figure 7 is also the use of adsorption chillers and mechanical chillers, which are more easily applicable to gas turbines than piston engines and to support the greater cooling requirements associated with partial dehydration of the air in this cycle and other cooling loads. It should be noted that Figure 7 retains the final dehydrated PSA of Figure 4 or Figure 5. This is because using direct air cooling results in more water being contained in the CO2 product, requiring final dehydration in most applications.

[0103] Figure 8 reflects another variation of a particular embodiment of the present disclosure and is similarly applicable to piston engines with limited exhaust heat, or turbine engines where all or most of the heat is already used by other engines. This figure shows a small combustor located between a CO2 turbocompressor and an expander, which essentially transforms this turbocharger into a small thermal CO2 generator. This mini gas generator is combusted with oxygen because the amount of combustion required to achieve the desired temperature is very small, the resulting mixture is not combustible in air oxidation, and this is already on the product side of the capture process. The products of the combustion are CO2 and water, and the CO2, being hot, eventually flows through the media and is added to the captured CO2. The combustion water is removed by the final PSA, as shown in Figure 7. This approach is practical only in SCC implementations where a high-purity oxygen source is already in use, as the economics of O2 production for this small load is not economically viable in most cases.

[0104] Figure 9 shows a more frequently used practical method for increasing available exhaust waste heat. As with many heat recovery steam generators, auxiliary combustion is generally performed in the gas turbine exhaust to increase available heat. Another way to achieve the same result, although this is compatible with SCC, is to install a burner upstream of the CO2HX, but in parallel with the main exhaust flow rather than in series. This is much more compatible with modified installations and produces an enriched CO2 stream of about 11%. This can be added to the original SCC exhaust, which is downstream of a custom heat exchanger but upstream of the quench system.

[0105] The explanation of Figures 10-20 follows to address the mechanical implementation of a specific embodiment.

[0106] In the invention of CO2TSA, to a lesser extent, the SCC itself undergoes various implementations depending on engine efficiency and custom installation specifications (primarily due to different amounts of usable exhaust waste heat). The invention of CO2TSA also has different mechanical implementations for small systems, typically for piston engines, where individual vessels can form a subset of larger but still transportable / modular systems. Conversely, for much larger systems, and generally for larger gas turbines, for mechanical reasons, the flow must be split into multiple flows, i.e., "dual-exhaust CO2TSA," or the vessel compartment must be divided into multiple modules to be assembled on-site. The reason this is possible is that the three functions of the CO2TSA process—adsorption, regeneration, and cooling—all occur at essentially the same pressure, with regeneration occurring at a slightly higher pressure. Because the pressures are similar and all are low, the structural requirements are minimal. More importantly, because regeneration (CO2 generation) occurs at a slightly higher pressure, all leaks are returned from the product (regeneration) side to the process side (adsorption or cooling), so no CO2 is lost, nor are any product impurities that would lead to leaks. What appears to be pipes / ducts in the process diagram can actually be implemented within a larger structure by baffles or panels, eliminating the need to worry about inter-process sealing in the CO2TSA invention.

[0107] Figure 10 shows a typical general arrangement for a particular embodiment of this disclosure in a small piston engine generator called 1 MW. As is typical, the engine is housed in an enclosure, which in this example includes an SCC recirculation system and an exhaust quench. Three radiators are mounted on the front of the enclosure: one for SCC quench water, one for aftercooling water, and one for jacket water. The CO2HX is located at the top of the enclosure, and the plant balance reflects an electric CO2 blower with an N2 recirculation fan and heat exchanger. CO2TSA vessels TS3, TS4, and TS5 are shown as individual round pressure vessels of lightweight construction (mostly stainless steel).

[0108] Figure 11 shows details of the upper header for the thermal CO2 inlet (before regeneration), dry N2 outlet (after adsorption), and dry N2 inlet (for cooling). Figure 11 also provides details of the lower header for the exhaust inlet (for adsorption), CO2 outlet (after regeneration), and N2 outlet (post-cooling). All of the above is for a stacked container approach, where the dehydration and capture processes are performed in a single container.

[0109] Figure 12 provides key details of a particular embodiment of this disclosure. The media is held within a very thin-walled stainless steel liner insulated on the inside of the container wall and the inside of the lid. Thus, only the media and a very small amount of supporting metal inner liner need to have their temperature changed for the process. This design is made possible by new developments in thin, high-performance aerogel insulation, particularly the development of aspen aerogel.

[0110] Figure 13 and its subparts show different views in cross-section of a single vessel, e.g., TS3. The relative loads of the dewatering (guard) layer (usually using 3A or alumina) above and below the capture media (usually 5A or 13X) are shown. It is important that the media have good flow distribution, and low pressure loss is also important. Both goals are achieved with relatively short aspect ratios. Typically, the media height is much smaller than the vessel diameter. Ductwork is also oversized for low pressure loss and low velocity, using baffle plates used to help distribute flow from the duct to the bed. Computational fluid dynamics (CFD) modeling has shown that typical ceramic balls, often used as flow distributors in mole sieve vessels, can be largely removed, even if not completely removed, through the baffle plates. Guard media are often coarser (larger in size) than the capture media to further facilitate distribution.

[0111] Figures 10–13 all show three independent TSA containers, all of which are cylindrical with flat lids. Other container configurations are available, including semi-elliptical heads, hemispherical heads, and even spherical containers, which are commonly used in pressure vessel designs and can be used in this invention. The nature of the design, which uses very low pressures and similar pressures in three different processes, allows for unconventional designs of “pressure vessels.” Compartments, including planar modules or hexagonal or rectangular / square cross-sections, can be packed into a single, larger “pressure” structure. The maximum load in the container designs of this invention is often caused not by gas pressure, but by the weight of the media and the pressure drop of the media.

[0112] Figure 14 shows one alternative packaging method for TS3, TS4, and TS5. However, this method can be used with fewer or more TSA compartments. Figure 14 shows a single rectangular cross-section container with three compartments, which is equivalent to the three-container design in Figure 11 in terms of media loading and cross-section. Figure 14A shows an internal view with the lid removed, revealing three independent compartments with the same basic internal liner and internal insulation structure as shown for the circular cross-section containers in Figures 12 and 13. Tie rods or internal structures within the media help support the thin walls against the weight of the media. Figure 14B is the same as Figures 14 and 14A in terms of container design, but the upper and lower pipes for N2, CO2, and exhaust are replaced with ducts and internal dampers. These are all inside a larger pressure boundary / structure, but some pressure difference still exists between the three processes during operation. As previously mentioned, some leakage from one process to the others does not significantly impair operation. These ducts can actually be created by placing panels within a larger structure, as shown in Figure 14B. These panels may further include access ports or handholes to allow access to internal mechanisms such as dampers, damper actuators, and linkages.

[0113] Figures 15A–20B address different mechanical implementation approaches for specific embodiments of this disclosure relating to larger systems. The sizes shown in Figures 15–20 correspond to 15–25 MW gas turbine installations. Larger systems present different mechanical challenges and implementation solutions than the smaller systems described in Figures 10–14. Specifically, the following technical issues are dominant in larger systems: electrical load for blowers (larger cross-sectional area minimizes pressure loss and therefore power), CO2 adsorption to water / impact on media (adsorption chillers help remove water before TSA), large diameter / cross-sectional duct sizes, length / volume / pressure loss within ducts, flow distribution in larger cross-sectional vessels (even lower velocities are required in ducts), overall footprint, and size of components for transport.

[0114] Figures 15A and 15B show external views of a single TSA vessel related to the implementation of a nominal 20MW gas turbine in a particular embodiment of the present disclosure. The exemplary 20MW SCC gas turbine TSA is 28' depth x 6.5' height and includes the baffle and all media. The ductwork needs to be approximately 60"D equivalent or greater. Four vessels are required, and in a batch process, one is used for adsorption, one for regeneration, and two for cooling. It is possible to design taller vessels with smaller diameters having the same media load, but a smaller footprint results in a higher bed pressure drop, thereby increasing the N2 / air and TSA screw power requirements.

[0115] Referring to Figure 16, an exemplary mechanical design is shown that transitions from an 84" square damper to a 60" square duct, with three 84"x84" dampers at the top and three 84"x84" dampers at the bottom, in order to keep the velocity as low as possible and to help with even distribution across the large diameter of the vessel. Different dimensions specific to different TSA requirements may exist. All of Figures 15A–20B are intended to provide examples of design embodiments.

[0116] The footprint of four 28'D vessels and all the ducting presents challenges in some installations. The length of the ducting and the associated pressure drop between the vessels and blowers can also be important. Figure 17 shows a solution where a stack of four CO2TSA vessels with six manifolds and 24 valves is used as a bed. The entire system is approximately 50'D x 50'H, with a significantly reduced footprint. However, although the vessels are fairly lightweight for their size, they can lift over 300 tons of media, requiring careful structural design, especially in seismic areas.

[0117] Figure 18 shows a single 28'D TSA container configuration when the selected arrangement of four containers is horizontal rather than vertical. In this example, an 84" square damper is still used, but the rectangular ducts at the top and bottom create a section that is easier to pre-fabricate and ship to site. In this alternative configuration with top and bottom ducts, the container components are still large, but the four containers fit into a 120'x30' space and may require on-site fabrication.

[0118] Figure 19 addresses the issue of the diameter of the larger containers and the ability to ship the larger diameter containers directly to the installation site. Instead of a 28'D TSA, a rectangular 22'x30' equivalent 28' TSA is used. This rectangular container can be shipped in two 11'x30' modules, where the seal between modules is outside the insulation (low temperature), and there is no requirement for special gaskets or seals. It is sufficient to fasten metal and metal bolts with caulking. Figure 19A shows how four of these 28'D equivalent containers, each with two modular compartments, are assembled on site. Similar to the installation of internal insulation, the footprint is preferably still about 30'xabout 100', the weight is essentially the same, but the cost is lower.

[0119] Using two modules to form each TSA container also creates opportunities. Figure 20 shows the use of a central vertical duct, although the vertical duct can be used on one side or both sides so that all valves and ductwork can be located on the sides. As shown in Figure 20, all ducts are at the top, but it can be equally easily achieved that all ducts are at the bottom. A preferred embodiment has a vertical duct between the CO2 TSA module pair.

[0120] Figure 20A is a cross-sectional view of one TSA vessel constructed with two modules and a vertical duct, illustrating how the flow is generated for the three processes of adsorption, regeneration, and cooling.

[0121] Figure 20B shows the assembly of four TSA containers using a modular structure and vertical ducts. The four containers shown do not require access to the underside of the containers and, due to their heavy weight, can instead be housed on a single concrete foundation. This type of structure also helps to eliminate the need for internal reinforcement of the media compartment, making on-site loading of media much easier.

[0122] Variations of specific embodiments of this disclosure, including different numbers of containers, different numbers of compartments, different sizes of ducts, different sizes of valves, and dampers, are carried out based on specific project requirements and installation constraints.

[0123] Embodiments include, for example, a CO2 TSA system for SCC or other suitable applications, TSAs for dehydration and capture, double-layer or multi-layer TSAs, dehydration and capture in the same vessel (e.g., in the same media or in laminated media), multi-layer TSAs with an N2 recirculation fan, final dehydration by a PSA process, CO2 turbo start by gas injection, CO2 bleed for exhaust to further concentrate CO2, an electrically driven CO2 blower, a partially electrically driven CO2 blower (compander), another heat source for CO2, direct air (capture) cooling, use of a chiller to reduce water adsorption load, counterflow SCC quench system, combustion CO2 turbo, burner-enhanced CO2 turbo heat exchanger, burner exhaust CO2 mixed with SCC exhaust, laminated TSA vessel, upper header (for thermal CO2 inlet (before regeneration), dry N2 outlet (after adsorption)), dry N2 inlet (for cooling), Lower header (for exhaust inlet (adsorption), CO2 outlet (after regeneration), N2 outlet (post-cooling)), internally insulated "pressure vessel", thin-walled stainless steel (SS) liner, guard dewatering media upper and / or lower, variable area perforated baffle instead of ceramic balls in TSA for flow distribution, stacked baffle plates in TSA, multiple compartments in a single vessel, no significant pressure or pressure difference, flat side design possible with minimal reinforcement, possibility of planar design with minimal reinforcement, slight leakage between compartments does not significantly affect the process, generation at a pressure slightly higher than the rest of the process to prevent impurities from leaking into the CO2 product, no special high temperature or complex seal required, integrated ductwork / baffles for N2, CO2, etc. within the modular vessel structure, vertically stacked SCC This may include CO2 TSA containers, upper and lower ducts for large containers, large containers formed from smaller modular containers, internal vertical ducts for large modular containers, vertical ducts between modular container components, dampers inside the ducts, ducts formed by baffles inside a single structure, vertical internal ducts that allow all valves to be located at the top, and / or upper duct arrangements having vertical internal ducts that enable a TSA structure "in a ground pool".

[0124] Any suitable control module may include any suitable hardware and / or software modules configured to perform the relevant functions. While specific embodiments relating to valve control have been disclosed above, other suitable control schemes and sequences / timings for controlling valves are considered herein by reference, for example. While embodiments having specific structures have been shown, any other suitable structures having any suitable dimensions and any suitable shapes relative to the embodiments are also considered herein by reference.

[0125] As will be understood by those skilled in the art, aspects of this disclosure may be embodied as systems, methods, or computer program products. Accordingly, aspects of this disclosure may take the form of entirely hardware embodiments, entirely software embodiments (including firmware, resident software, microcode, etc.), or embodiments combining software and hardware embodiments. All such possibilities may be referred to herein as “circuits,” “modules,” or “systems.” A “circuit,” “module,” or “system” may include one or more parts of one or more separate physical hardware and / or software components that can together perform the disclosed functions of the “circuit,” “module,” or “system.” Alternatively, a “circuit,” “module,” or “system” may be a single self-contained unit (e.g., hardware and / or software). Furthermore, aspects of this disclosure may take the form of computer program products embodied in one or more computer-readable media in which computer-readable program code is embodied.

[0126] Any combination of one or more computer-readable media may be used. A computer-readable media may be a computer-readable signal medium or a computer-readable storage medium. A computer-readable storage medium may be, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination thereof. More specific examples (a non-exhaustive list) of computer-readable storage media include electrical connections with one or more wires, portable computer diskettes, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fibers, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In the context of this document, a computer-readable storage medium may be any tangible medium that contains or can store programs for use by, or in connection with, an instruction execution system, apparatus, or device.

[0127] A computer-readable signaling medium may include propagated data signals that incorporate computer-readable program code, for example, in the baseband or as part of a carrier wave. Such propagated signals may take any of a variety of forms, including but not limited to electromagnetic, optical, or any suitable combination thereof. A computer-readable signaling medium may be any computer-readable medium, rather than a computer-readable storage medium, that can communicate, propagate, or transfer programs for use by or in connection with instruction execution systems, apparatus, or devices.

[0128] Program code embodied in a computer-readable medium may be transmitted using any suitable medium, including but not limited to wireless, wired, fiber optic cable, RF, or any suitable combination thereof.

[0129] Computer program code for performing the operations in the aspects of this disclosure may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java, Smalltalk, and C++, and conventional procedural programming languages ​​such as the C programming language or similar programming languages. The program code may run entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter case, the remote computer may be connected to the user's computer via any type of network, including a local area network (LAN) or a wide area network (WAN), or may be connected to an external computer (for example, via the Internet using an Internet service provider).

[0130] Aspects of the present disclosure may be described above with reference to flowcharts and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the present disclosure. It should be understood that each block of any flowchart and / or block diagram, as well as any combination of blocks in any flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions may be provided to the processor of a general-purpose computer, a dedicated computer, or other programmable data processing device for the purpose of manufacturing a machine. Thus, instructions executed via the processor of a computer or other programmable data processing device create means for realizing the functions / operations specified in one or more blocks of any flowchart and / or block diagram.

[0131] These computer program instructions can also be stored in computer-readable media that can instruct a computer, other programmable data processing devices, or other devices to function in a particular manner. This allows instructions stored in computer-readable media to be used to manufacture products containing instructions that perform functions / operations specified in one or more blocks of a flowchart and / or block diagram.

[0132] Computer program instructions can also be loaded into a computer, other programmable data processing device, or other device, causing a series of operational steps to be executed on the computer, other programmable device, or other device to generate a computer implementation process. Thus, instructions executed on a computer or other programmable device provide a process for achieving the functions / operations specified herein.

[0133] Those skilled in the art will understand that any numerical values ​​disclosed herein may be exact values ​​or values ​​within a range. Furthermore, any approximation terms used in this disclosure (e.g., “about,” “around,” “approximately”) may mean values ​​within a range. For example, in certain embodiments, the range may be within 20% (plus or minus), or within 10%, or within 5%, or within 2%, or within any other appropriate percentage or number understood by those skilled in the art (e.g., a known tolerance or error range).

[0134] As used herein and in the appended claims, the articles “a,” “an,” and “the” are used herein to refer to one or more (i.e., at least one) grammatical objects of the article unless the context makes it clear. For example, “an element” means one or more elements.

[0135] As used herein and in the claims, the phrase “and / or” should be understood to mean “either or both” of the elements thus combined, that is, elements that exist as a combination in some cases and as separate in others. Multiple elements enumerated by “and / or” should be interpreted similarly, that is, “one or more” of the elements thus combined. Other elements other than those specifically identified by the phrase “and / or” may exist as optional, whether related to the specifically identified elements or not. Thus, as a non-restrictive example, a reference to “A and / or B” when used in combination with open language such as “including” could, for example, in one embodiment refer to A only (optionally including elements other than B), in another embodiment refer to B only (optionally including elements other than A), and in yet another embodiment refer to both A and B (optionally including other elements).

[0136] As used herein and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” should be interpreted as inclusive, that is, including not just one of several elements or a list of elements, but multiple, and optionally including additional unlisted items. Only terms that are explicitly indicated in the opposite way, such as “one of…”, “any of…”, or, as used in the claims, “consisting of…”, refer to including only one of several elements or a list of elements. In general, the term “or” as used herein should be interpreted only as indicating exclusive substitutes (i.e., “one or the other, but not both”) when preceded by terms of exclusivity such as “either,” “one of…”, “one of…”, or “any of…”.

[0137] Any suitable combination and / or any suitable part thereof of any disclosed embodiment is expected herein to be understood by those skilled in the art in view of this disclosure.

[0138] As described above and shown in the drawings, embodiments of this disclosure are provided for the improvement of the relevant technology. While this disclosure includes references to specific embodiments, it will be readily apparent to those skilled in the art that changes and / or modifications can be made without departing from the spirit and scope of this disclosure. Cross-reference of related applications

[0139] This application claims priority and benefit to U.S. Provisional Application No. 63 / 076,521 filed on September 10, 2020, and U.S. Non-Provisional Application No. 17 / 464,199 filed on September 1, 2021, the entire contents of which are incorporated herein by reference.

Claims

1. A carbon capture system, at least, CO within the capture temperature range 2 The captured CO is captured within a regeneration temperature range that exceeds the capture temperature range. 2 A first TSA bed configured to regenerate CO2 within a capture temperature range. 2 The captured CO is captured within a regeneration temperature range that exceeds the capture temperature range. 2 A second TSA bed configured to regenerate CO2 within the capture temperature range. 2 The captured CO is captured within a regeneration temperature range that exceeds the capture temperature range. 2 Multiple CO2s, including a third TSA bed configured to regenerate CO2s. 2 Thermal Swing Adsorption (TSA) bed and Multiple valves and associated flow paths are configured to enable switching between the respective operating modes of the first, second, and third TSA beds, At least one of the plurality of TSA beds operates in a capture mode to remove CO from the exhaust stream and output a nitrogen stream, and simultaneously, at least one of the plurality of TSA beds is used in a heat regeneration mode to release CO into the product stream, and simultaneously, the plurality of valves are controlled to provide continuous operation such that at least one of the plurality of TSA beds operates in a cooling mode and is cooled by a cooling stream. A control module configured to do so. 2 At least one of the plurality of TSA beds operates in a capture mode to remove CO from the exhaust stream and output a nitrogen stream, and simultaneously, at least one of the plurality of TSA beds is used in a heat regeneration mode to release CO into the product stream, and simultaneously, the plurality of valves are controlled to provide continuous operation such that at least one of the plurality of TSA beds operates in a cooling mode and is cooled by a cooling stream. A control module configured to do so. 2 At least one of the plurality of TSA beds operates in a capture mode to remove CO from the exhaust stream and output a nitrogen stream, and simultaneously, at least one of the plurality of TSA beds is used in a heat regeneration mode to release CO into the product stream, and simultaneously, the plurality of valves are controlled to provide continuous operation such that at least one of the plurality of TSA beds operates in a cooling mode and is cooled by a cooling stream. A control module configured to do so. Connected to each TSA bed via the corresponding valve, the generated stream is circulated through each TSA bed in regeneration mode, and additional CO2 is released from the TSA bed. 2 Regenerates CO in the generated flow 2 A generation stream circulator subsystem configured to increase concentration and Includes, The generated stream circulator subsystem includes a heat source configured to add sufficient heat to the generated stream to heat each TSA bed operating in the regeneration mode to within the regeneration temperature range. The generated stream circulator subsystem includes a power source configured to move the generated flow within the circulator, A carbon capture system comprising a heat source, a waste heat exchanger configured to have thermal communication with the exhaust flow located downstream of the engine, a power source, a compressor connected to a turbine, and a waste heat exchanger in fluid communication with the compressor and the turbine such that the waste heat drives the turbine and supplies power to the compressor.

2. The system according to claim 1, wherein the carbon capture system is configured to be connected to a semi-closed cycle engine system to receive engine exhaust from there.

3. The aforementioned generation stream circulator subsystem is CO 2 The system according to claim 2, wherein it is in fluid communication with an output subsystem.

4. The system according to claim 1, further comprising a flow mover configured to provide a powered flow to the exhaust flow so that it flows through the carbon capture system to each TSA bed operating in the capture mode.

5. The system according to claim 4, further comprising a dewatering subsystem located downstream of the flow mover and upstream of at least one of the first, second, and third TSA beds, for removing water located upstream of at least one of the first, second, and third TSA beds operating in the capture mode.

6. The dewatering subsystem includes at least two dewatering TSAs and associated valves, and the control module controls the dry exhaust to the multiple CO2s. 2 The first dehydration TSA is operated in water capture mode to output to at least one of the TSAs, and the second dehydration TSA is operated to heat the multiple CO2 2 Using the nitrogen stream from the TSA, the water regeneration mode is operated, or the multiple CO2s are cooled. 2 The system according to claim 5, configured to operate the at least two dehydrating TSAs in a cooling mode using the nitrogen stream from the TSAs.

7. Integrated with each of the first, second, and third TSA beds, the same location of water and CO 2 The system according to claim 1, further comprising a dehydration subsystem for removing [a certain substance].

8. The system according to claim 7, further comprising a nitrogen recirculation system having a nitrogen flow mover configured to recirculate nitrogen output by each of the TSA beds in the capture mode in order to increase the cooling effect of the first, second, and third TSA beds when operating in the cooling mode.

9. The system according to claim 8, further comprising a dewatering subsystem located downstream of at least one of the first, second, and third TSA beds when operating in the generation mode, for removing water located downstream of at least one of the first, second, and third TSA beds when operating in the generation mode.

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