Direct air capture filter and processing thereof

Abstract

A direct air carbon capture filter and a method. The direct air carbon capture filter (200a, 200b) includes a porous material (202) that removes solid particulates from the air; and a sorbent (204), attached to the porous material (202), that removes carbon dioxide from the air. The method (400) includes the processing of the direct air carbon capture filter (200a, 200b), where the processing is at least one of releasing of CO2 from the direct air carbon capture filter (200a, 200b), a disposing of the direct air carbon capture filter (200a, 200b), or a repurposing of the direct air carbon capture filter (200a, 200b). The unit includes a heat source to release the CO2 from the direct air carbon capture filter (200a, 200b) and a fan to direct the CO2.

Description

Docket No. 2023PF00465 DIRECT AIR CAPTURE FILTER AND PROCESSING THEREOF BACKGROUND

[0001] While carbon dioxide (CO2) is a naturally occurring chemical compound, which ispresent in the Earth’s atmosphere, the increase of atmospheric CO2over the years plays a significant role in global warming. Efforts have been made to reduce CO2emissions via clean energy. Removing CO2 from the atmosphere is commonly referred to as carbon capture or direct air capture (DAC).

[0002] DAC units are being developed that make use of a fan to draw ambient air over amaterial to capture CO2. Commonly, the material used is sorbent in a liquid or solid. These materials become saturated such that they cannot absorb or adsorb any more CO2. After capturing the CO2, typically heat is applied to the material to release the CO2where the CO2may be sequestered or processed further. The material is then used for further CO2capturing from ambient air. Thus, the typical DAC unit cycles between capturing CO2and releasing the CO2. This cyclical transition is done by having multiple containers with the sorbent where at any time a portion of the containers is exposed to air to capture CO2and another portion is exposed to heat to release the CO2. This cycle occurs with the material in situ, which is while the sorbent is retained in the DAC unit for both the CO2capture and the CO2release. These are large industrial type units which are designed to capture substantial amounts releasing of CO2. For example, over 100 tons per year. As a result, they have a substantial footprint and are costly to build. SUMMARY

[0003] Typically, air conditioning (AC) units use air filters with porous material to removeparticulates to avoid unwanted particles from entering the AC unit, e.g., avoid debris from accumulating on the internal components of the AC unit. An AC unit is defined herein as any residential, commercial, or vehicular cooling system. The AC unit may include more than the cooling system, for example the AC unit may include systems such as heating, ventilation, and air conditioning (HVAC) units.

[0004] It is an object of the invention to leverage the filters in an AC unit to provide direct aircarbon capture filter. AC unit filters need to be changed periodically. The number of filters over time by the number of AC units provides a substantial opportunity for DAC systems. It isDocket No. 2023PF00465 desirable that the direct air carbon capture filter fits in the existing air filter space; thereby, avoiding costly equipment changes.

[0005] It is a further object of the release of the CO2 from the filter, occurs remotely fromwhere the sorption occurred. That is the desorption of the CO2is at a location detached from the AC unit. In an embodiment, remote is not in the same building as the AC unit. In a further embodiment, remote may be a distance greater than 1 mile away from the AC unit. Advantageously, additional equipment does not have to be added to the AC unit to release the CO2. Other or additional processing of the direct air carbon capture filter may occur remotely.

[0006] In an embodiment, a direct air carbon capture filter is provided. The direct air carboncapture filter includes a porous material that removes solid particulates from the air, and a sorbent that removes CO2from the air. Porous material for in AC filters for the removal of solid particulates, such as fiberglass, are known.

[0007] An "adsorbent" has the ability or tendency to surfacely hold and retain a substancesuch as liquids, gas, or energy. That is an adsorbent can adsorb the substance whereby the substance adheres to the adsorbent material. The process of taking in and retaining the substance is known as adsorption.

[0008] An "absorbent" has the ability or tendency to take in and retain a substance such asliquids, gas, or energy. That is an absorbent can absorb the substance. The process of taking in and retaining the substance is known as absorption.

[0009] "Sorbent" refers to a material that through sorption retains a substance. "Sorption"refers to a physical and chemical process by which a substance becomes attached to another. Adsorption and Absorption are both sorption processes. “Desorption” herein refers to a release of the substance that is attached by a sorption process.

[0010] Numerous materials have been identified to capture CO2 and new materials are beingidentified / developed. Examples of CO2capture materials are carbonates, wood fibers, calcium oxide, extruded ceramic, and mycelium-based materials. One skilled in the art would clearly recognize that this is not an exhaustive list but merely an example. It would be understood that any material that could capture CO2 and filter debris would be suitable.

[0011] The sorbent is attached to the porous material. For example, according to anembodiment, the sorbent is on at least one surface of the porous material. According to an embodiment, the sorbent is distributed within the porous material. The above embodiments are combinable where it is possible the sorbent be attached on at least one surface and imbedded inDocket No. 2023PF00465 the porous material. The flexibility on how the sorbent is attached allows for different sorbents or applications of the sorbent. For example, the porous material may be sprayed or painted with the sorbent, the porous material may be constructed with the sorbent or the porous material dipped in a solution with the sorbent.

[0012] The direct air carbon capture filter fits into a filter receptacle of the AC unit. In anembodiment, the direct air carbon capture filter fits into the AC unit without modification to the filter receptacle. Whereby the existing size of the filter receptacle is advantageously leveraged.

[0013] After the direct air carbon capture filter is removed from the AC unit it can bedisposed by the end user or sent by the end user to a processing site to handle the further processing described by a method below. The end user being a person associated with the AC unit such as owner or user. The sending may be directly to the processing site or the sending may be indirectly. For example, the user may directly send one or more direct air carbon capture filter by mail or a package delivery service. Sending indirectly is by putting the direct air carbon capture filter at an intermediate site. For example, the intermediate site may be the same as a garbage or recyclable pickup, in a community drop off box, or at a drop off hub such as a garden center or a hardware / home improvement store.

[0014] The end user may receive a new or refurbished direct air carbon capture filter directly,e.g., by mail or package delivery service or indirectly at a pickup site such as garden center or a hardware / home improvement store.

[0015] The method includes receiving the direct air carbon capture filter with sorbed CO2 andprocessing the direct air direct air carbon capture filter. The processing includes a desorption of the CO2from the direct air carbon capture filter, a disposing of the direct air carbon capture filter, or a repurposing of the direct air carbon capture filter, or combinations thereof. According to an embodiment, the direct air carbon capture filter is received and processed at a location remotely from where the sorption occurred.

[0016] In an embodiment during desorption of the CO2, the method includes heating thetemperature within the filter desorption unit, wherein the CO2is released from the direct air carbon capture filter during the heating. The heat may be a dry heat or steam. The type of heat, dry or steam, may be sorbent dependent. Similarly, the temperature or pressure in the filter desorption unit may be sorbent dependent. It is recognized that high heat reduces the lifespan of the sorbent. A low-pressure steam has been found the be advantageous for the release of CO2and to promote a longer lifespan of the sorbent, low-pressure steam, as defined herein, is less orDocket No. 2023PF00465 equal to 95°C and 1 bar. In an embodiment, the temperature within the filter desorption unit is between 65°C and 90°C and the pressure within the filter desorption unit is between 0.5 bar and 1 bar. In a further embodiment, the temperature within the filter desorption unit is at or below 80°C and the pressure within the filter desorption unit is at or below 0.5 bar. The direct air carbon capture filter may be reused after the release of the CO2.

[0017] The direct air carbon capture filter may be disposed. According to an embodiment, thedirect air carbon capture filter is processed by disposal of the direct air carbon capture filter. For example, the direct air carbon capture filter is buried. Burying the direct air carbon capture filter sequesters the CO2. Prior to the disposing, the direct air carbon capture filter may be enclosed in an airtight container. The enclosure may provide further protection that the CO2is not released back into the atmosphere. The disposal of the direct air carbon capture filter may be with or without the releasing of CO2.

[0018] According to an embodiment, the direct air carbon capture filter is processed byrepurposing the direct air carbon capture filter. For example, the direct air carbon capture filter may be used in building construction, such as insulation, composite materials, or concrete. While the repurposing may be done without the releasing of the CO2, it is possible to perform the releasing of CO2prior to the disposing.

[0019] In the above embodiments, the released CO2 may be sequestered for furtherprocessing. For example, a further processing may include burying the CO2, creating an energy source, producing a carbonation source for carbonated beverages, an additive for materials such as plastic, or as food source for greenhouses. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] To easily identify the discussion of any particular element or act, the most significantdigit or digits in a reference number refer to the figure number in which that element is first introduced.

[0021] FIG. 1 illustrates a schematic of an AC unit.

[0022] FIG that is compatible with the AC unit of FIG. 1. 2A is a schematic illustration ofcross section of a direct air carbon capture filter according to an embodiment.

[0023] FIG that is compatible with the AC unit of FIG. 1. 2B is a schematic illustration ofcross section of a direct air carbon capture filter according to an embodiment.Docket No. 2023PF00465

[0024] FIG. 3 illustrates a schematic of a system that is suitable for removing the direct aircarbon capture filter of FIG. 2A and FIG. 2B.

[0025] FIG. 4 illustrates a method 400 in accordance with an embodiment that is suitable forthe direct air carbon capture filter of FIG. 2A and FIG. 2B and compatible with the system of FIG. 3. DETAILED DESCRIPTION

[0026] Before any embodiments of the invention are explained in detail, it is to be understoodthat the invention is not limited in its application to the details of construction and the arrangement of components set forth in this description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0027] Various technologies that pertain to systems and methods will now be described withreference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0028] Also, it should be understood that the words or phrases used herein should beconstrued broadly, unless expressly limited in some examples. For example, the terms “including,” “having,” and “comprising,” as well as derivatives thereof, mean inclusion without limitation. The singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, the term “and / or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term “or” is inclusive, meaning and / or, unless the context clearly indicates otherwise. The phrases “associated with” and “associated therewith,” as well as derivativesDocket No. 2023PF00465 thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Furthermore, while multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc. described with regard to one embodiment are equally applicable to other embodiments absent a specific statement to the contrary.

[0029] Also, although the terms "first", "second", "third" and so forth may be used herein torefer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

[0030] In addition, the term "adjacent to" may mean that an element is relatively near to butnot in contact with a further element or that the element is in contact with the further portion, unless the context clearly indicates otherwise. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms “about” or “substantially” or like terms are intended to cover variations in a value that are within normal industry manufacturing tolerances for that dimension. If no industry standard is available, a variation of twenty percent would fall within the meaning of these terms unless otherwise stated.

[0031] FIG. 1 illustrates a traditional AC unit 100. Air is received via a return air duct 110. Ablower 104 passes air from the return air duct 110 across an evaporator coil 102 having a refrigerant, whereby the air is cooled by the evaporator coil 102. Condenser unit 106 removes heat from the heated refrigerant. A refrigerant tube 108 circulates refrigerant between the condenser unit 106 and the evaporator coil 102.

[0032] A gap 114 is arranged between the return air duct 110 and the blower 104. A porousfilter 112 is arranged in the gap 114 for removing solid particles from the air that passes through the porous filter 112. A receptacle may be formed by a gap 114 between the return air duct 110 and the blower 104. It would be understood that other arrangements of the gap 114Docket No. 2023PF00465 such that return air passes through the porous filter 112 prior to entering the blower 104 would be acceptable.

[0033] FIG. 2A and FIG. 2B are schematic views of a cross sectional of a direct air carboncapture filter 200a, 200b according to different embodiments. According to the illustrated embodiments of FIG. 2A and FIG. 2B, the direct air carbon capture filter 200a, 200b includes a porous material 202 that filters solid particulates from the air, a sorbent 204 that captures CO2from the air, a front surface 206, and a back surface 208. The front surface 206 is defined as where the air flow 210 enters the direct air carbon capture filter 200a, 200b, and the back surface 208 is defined as where the air flow 210 exits the direct air carbon capture filter 200a, 200b. For simplicity, some of the sorbent 204 is shown without references in the figures.

[0034] In an embodiment, the direct air carbon capture filter 200a, 200b is dimensioned to fitin the gap 114 of the AC unit 100 without modification to the AC unit 100. In another embodiment, a modification is needed to the AC unit 100 to increase the size of the gap 114.

[0035] According to the illustrated embodiment of FIG. 2A, the sorbent 204 is attached toboth the front surface 206 and the back surface 208. The depth of the sorbent 204 on the front surface 206 and / or back surface 208 may vary due to the where the sorbent 204 is attached, e.g., the proximity to a pore, of the porous material 202. It is possible for the sorbent 204 to be attached to only the front surface 206 or only to the back surface 208.

[0036] According to the illustrated embodiment of FIG. 2B, the sorbent 204 is attachedthroughout the porous material 202 including the front surface 206 and the back surface 208. The depth of the sorbent 204 on the front surface 206 and / or back surface 208 may vary due to the where the sorbent 204 is attached, e.g., the proximity to a pore, of the porous material 202. It is possible for the sorbent 204 to be attached to only the front surface 206 or only to the back surface 208.

[0037] FIG. 3 illustrates a system 300 that removes the CO2 from the direct air carbon capturefilter 200a, 200b. The system 300 includes a filter desorption unit 314 and a container 308.

[0038] The filter desorption unit 314 illustrates a casing 302 that includes doors 312a, 312b,312c, each of which can be opened and closed. The first door 312a provides for the placement of the direct air carbon capture filters 200a, 200b into the casing 302 and the second door 312b provides for the removal of the direct air carbon capture filter 200a, 200b. The third door 312c allows for CO2that is released from the direct air carbon capture filters 200a, 200b to enter into container 308. When each of the doors 312a, 312b, 312c are closed, the filter desorption unitDocket No. 2023PF00465 314 may be sealed to avoid ambient air from entering the filter desorption unit 314 as well as avoid released CO2from exiting the filter desorption unit 314. For example, the filter desorption unit 314 may be hermetically sealed. The filter desorption unit 314 includes a conveyor 306 to load the direct air carbon capture filter 200a, 200b into the casing 302 and to unload the direct air carbon capture filter 200a, 200b from the casing 302.

[0039] The casing 302 houses a heat source 304, a fan 310, fluid 322, and a vacuum 320. Theheat source 304 is a resistive electric heating element for providing heat to the fluid 322. The fluid 322 is heated by the heat source 304 in order to create a steam to raise the temperature of the direct air carbon capture filter 200a, 200b contained in the system 300 to at or below 80°C and the vacuum 320 regulates the pressure in the filter desorption unit 314 to at or below .5 bar.

[0040] Container 308 stores the CO2 that is released from the direct air carbon capture filters200a, 200b. The container 308 includes a door 318 that can be opened and closed. When the door 318 is closed the container 308 may be airtight to retain the CO2.

[0041] During operation of the system 300, the container 308 is coupled to the casing 302wherein the third door 312c and the door 318 are at least partially aligned. Coupling may be a stacking of the container 308 on the container 308, a magnetic coupling, chemical coupling, or a mechanical coupling. The first door 312a is opened and the conveyor 306 moves in a direction 316 to place the direct air carbon capture filters 200a, 200b within the container 308. The direct air carbon capture filters 200a, 200b may be stacked horizontally, vertically or arranged haphazardly within the container 308. Prior to emitting heat by the heat source 304, the first door 312a and the second door 312b are closed. The heat source 304 emits a heat causing the fluid 322 to create a steam at a temperature capable of releasing the CO2 from the sorbent 204. The vacuum 320 reduces pressure in the casing 302 during the heating. The fan 310 directs the released CO2 to the container 308, wherein both the third door 312c and the door 318 is opened. After the CO2 is directed into the 308, door 318 is closed. The third door 312c may be closed. The second door 312b is opened and the conveyor 306 moves in a direction 316 to remove the direct air carbon capture filter 200a, 200b from the casing 302. The container 308 may be decoupled from the 302 after the CO2 is stored in the 308.

[0042] It would be understood by those skilled in the art that other configurations may be usedto remove the CO2from the direct air carbon capture filter 200a, 200b. For example, the number of doors 312a, 312b, 312c may be modified to be increased or decreased. The same door 312a may be used to insert and remove the direct air carbon capture filters 200a, 200bDocket No. 2023PF00465 into / from the filter desorption unit 314. It is possible that door 312c be an opening that remains open instead of a door, which would be arranged at a door 318 into the container 308. The door 312c or opening may feed into the ground to sequester the CO2underground bypassing the need for a container 308. Manual, mechanical, or robotic placement and / or removal of the direct air carbon capture filter 200a, 200b may replace the conveyor 306.

[0043] FIG. 4 illustrates a method 400 of processing the direct air carbon capture filter 200a,200b. In block 402, the method 400 receives the direct air carbon capture filter 200a, 200b, the direct air carbon capture filter 200a, 200b comprising sorbed CO2. In block 404, the method 400 processes the direct air carbon capture filter 200a, 200b by a desorption of CO2from the direct air carbon capture filter 200a, 200b, a disposing of the direct air carbon capture filter 200a, 200b, or a repurposing of the direct air carbon capture filter 200a, 200b.

[0044] Although an exemplary embodiment of the present disclosure has been described indetail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form.

[0045] For example, it is possible to have two filters, one for typical debris filtration and onefor DAC. They could be arranged on the AC unit adjacently such that air passing through one filter does not pass through the other. Alternatively, they could be arranged on the AC in a stacked format so air must pass through both filters. In order to handle two filters, it is conceivable that the AC unit could need to be modified to accommodate both filters.

[0046] None of the description in the present application should be read as implying that anyparticular element, step, act, or function is an essential element, which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke a means plus function claim construction unless the exact words "means for" are followed by a participle.

Claims

Docket No. 2023PF00465 CLAIMS What is claimed is:

1. A direct air carbon capture filter (200a, 200b) comprising: a porous material (202) that removes solid particulates from the air; and a sorbent (204) that removes carbon dioxide CO2from the air, wherein the sorbent (204) is attached to the porous material (202).

2. The direct air carbon capture filter (200a, 200b) of claim 1, wherein the sorbent (204) is attached on at least one surface of the porous material (202).

3. The direct air carbon capture filter (200a, 200b) of claim 1 or 2, wherein the sorbent (204) is distributed throughout the porous material (202).

4. The direct air carbon capture filter (200a, 200b) of any one of claims 1 to 3, wherein the direct air carbon capture filter (200a, 200b) is suitable to fit into an AC unit without modification to a receptacle 114.

5. A method (300) of processing the direct air carbon capture filter (200a, 200b) according any one of claims 1 to 4 comprising: receiving (402) the direct air carbon capture filter (200a, 200b), the direct air carbon capture filter (200a, 200b) comprising the sorbed CO2; and processing (404) the direct air direct air carbon capture filter (200a, 200b) comprises a desorption of the CO2from the direct air carbon capture filter (200a, 200b), a disposing of the direct air carbon capture filter (200a, 200b), or a repurposing of the direct air carbon capture filter (200a, 200b), wherein the receiving occurs remotely from the sorption.

6. The method (300) according to claim 5, the desorption comprises the desorption of the CO2comprises inserting the direct air carbon capture filter into (200a, 200b) a filter desorption unit (314), and heating a temperature of the filter desorption unit (314), wherein the CO2is released from the filter desorption unit during the heating.Docket No. 2023PF00465 7. The method (300) according to claim 6 wherein the temperature within the filter desorption unit is between 65°C and 90°C; and wherein a pressure within the filter desorption unit (314) is between 0.5 bar and 1 bar.

8. The method (300) according to claim 7 wherein the temperature within the filter desorption unit (314) is at or below 80°C; and wherein a pressure within the filter desorption unit (314) is at or below 0.5 bar.

9. The method (300) according claim 5 or 6, wherein the direct air carbon capture filter (200a, 200b) is disposed.

10. The method (300) of claim 9, comprising: wherein the processing (402) comprises enclosing the direct air carbon capture filter (200a, 200b) in an airtight container prior to the disposing.

11. The method (300) according claim 9 or 10, wherein the disposing is without a desorption of the CO2.

12. The method (300) of claim 5 or 6, wherein the direct air carbon capture filter (200a, 200b) is repurposed.

13. The method (300) according claim 12, wherein the repurposing is without a desorption of the CO2.

14. The method (300) according to any one of claims 5-6 or 9-13, wherein the receiving (402) and the processing (404) are remote from the AC unit having used the direct air carbon capture filter (200a, 200b) to capture the carbon dioxide.

15. The method (300) according to any one of claims 5-6 or 9-14, wherein a plurality of the direct air carbon capture filters (200a, 200b) is received; and wherein a plurality of the direct air carbon capture filters (200a, 200b) is processed substantially simultaneously.

Images