Internal multi-layered insulation for thermal vacuum swing reactors

Abstract

A sorbent reactor for modular and adaptable carbon dioxide (CO2) capture, separation, and storage having improved thermal efficiency. The sorbent reactor comprises a chamber that encloses a structured sorbent that adsorbs carbon dioxide. The interior walls of the sorbent reactor chamber are covered in a multi-layer insulation panel comprising a bottom layer of conformable and compressible water-resistant material, a middle layer of thermally insulating material, and an optional top layer of abrasion-resistant and dust-resistant material. The insulation panel is rigidly compressed against the interior walls of the sorbent reactor chamber using retaining features. The inclusion of the conformable water-resistant layer effectively removes any gaps between the interior walls and the thermally insulating layer that could otherwise be filled via the ingress of steam; blocking the steam from flowing beneath the thermally insulating layer can minimize parasitic heat loss during a steam-assisted temperature vacuum swing adsorption (S-TVSA) process.

Description

INTERNAL MULTI-LAYERED INSULATION FOR THERMAL VACUUM SWING REACTORSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 558,800, filed on February 28, 2024; the disclosure of which is incorporated herein by reference.TECHNICAL FIELD

[0002] The invention relates to systems for energy-efficient direct capture and separation of carbon dioxide (CO2) from the atmosphere or CO2 point sources, such as flue gases. More specifically, the technology relates to systems for improving the internal thermal efficiency of sorbent reactors that undergo thermal vacuum swing processes for direct CO2capture.BACKGROUND

[0003] Global warming is posing devastating effects on our climate, health, and communities. Coastal flooding due to rising sea levels, extended wildfire seasons, as well as more destructive hurricanes are present and direct impacts of climate change. Moreover, global food and water security are at stake. There is a consensus among scientists that global warming is directly linked to the increase in the level of greenhouse gases in the atmosphere. Carbon dioxide (CO2) is a major greenhouse gas, and its concentration in the atmosphere has sharply increased over the past century due to the burning of fossil fuels. Although efforts are underway to move toward renewable energy sources that do not emit greenhouse gases, shifting our energy supply to completely renewable sources is not possible in the near term and requires further technological advancements and significant global investments.Therefore, there is a growing need for technologies that can efficiently capture carbon dioxide from the flue gas of power plants and other industrial processes and, increasingly, even from ambient air. These processes are commonly referred to as carbon capture processes and carbon capture directly from ambient air is known as direct air capture (DAC).

[0004] Carbon capture processes commonly utilize some type of regenerable sorbent material to capture CO2from a source gas stream and then subsequently release the adsorbed CO2under controlled conditions so that it can be captured and stored. Large-scale gas-liquid processes utilizing caustic solutions or liquid amine materials to capture CO2from high-concentration point-sources such as flue gas have been developed but require high capital expenditures and long lead times to construct, have high energy requirements, and are much less efficient at the relatively low concentrations of CO2present in ambient air (421 ppm). Furthermore, liquid sorbent materials are commonly toxic, corrosive,and / or otherwise hazardous in use, so extreme and expensive precautions must be utilized. Therefore, DAC processes more commonly utilize some type of regenerable solid sorbent material to capture the CO2from a gas or air stream (see, for example, Shi, et al., Angewandte Chemie International Edition, 2019, 59, 6984 (hi , which is incorporated by reference in thisdisclosure in its entirety).

[0005] Solid CO? sorbents include various zeolites or molecular sieves; amine-functionalized silicious, inorganic, activated carbon, graphitic, metal organic framework (MOF) or polymeric supports; amine- functionalized carbon, glass, cellulosic, or polymeric fibers; and basic or weakly-basic ion exchange resins. In some cases, the solid CO2 sorbents are utilized in powder or pellet form in fluidized bed or packed bed configurations. In other cases, the solid CO2sorbents are utilized in fibrous webs, mats, or woven fabrics through which air is passed. In still other cases, the solid CO2 sorbents are formed into structured monoliths or other structured forms such as sheets, films, membranes, or plates through or around which air may be passed. However, limitations in the size and mechanical properties of high- capacity structured sorbents that can be fabricated create significant challenges for scaling such methods to a sufficient scale for practical direct air capture. Considerable research efforts are ongoing to develop new, higher performing solid CO2 DAC sorbents and structured versions thereof and are expected to lead to significant advances in the coming years.

[0006] A DAC process typically involves a first step of moving ambient air through a bed of a solid sorbent that is effective at selectively capturing a significant portion of the CO2 included therein. Due to the low concentrations (currently 421 parts per million) of CO2in ambient air, high volumes of ambient air need to be moved and processed in a DAC process. Once the sorbent reaches a level of significant saturation of CO2, it needs to be regenerated in a second step. During regeneration, the adsorbent bed is treated with, for example, heat, vacuum, moisture, steam, or some combination thereof to cause the CO2 to desorb from the sorbent. The released CO2 is subsequently captured, and the regenerated sorbent can then be returned to the first step and reused to capture more CO2. Significant energy is required to circulate the high volume of air and to regenerate the sorbent, so the systems need to be highly efficient and minimize thermal loss.

[0007] A regeneration method that incorporates cycles of applying heat and vacuum to the adsorbent bed is commonly known as temperature-vacuum swing (TVSA) adsorption and has been researched and reported in the literature (see, for example, Wijesiri, et al., Industrial & Engineering Chemistry Research, 2019, 58, 15606-15618 and Bos, et al., Chemical Engineering Science: X, 2019, 2, 100020, both of which are incorporated in this disclosure in their entirety). There is great interest in being able to heat theadsorbent beds quickly and efficiently to conserve energy and optimize cycle times. Some systems, such as those described in U.S. Patent No. 10,279,306 or by Li, et aL, ChemSusChem, 2010, 3, 899-903, which is incorporated in this disclosure in its entirety, seek to heat adsorbents without external heaters and utilize heat from steam, flowing steam through the adsorbent bed to efficiently transfer heat to the adsorbent. A particular version, known in the art as "steam-assisted TVSA" is often described as having several advantages. Steam is an effective carrier to sweep away gaseous CO? as it is being desorbed, thereby promoting increased desorption by way of reducing the partial pressure of the gas above the sorbent. The gaseous CO? can be conveniently separated by condensing the steam and allowing gravity to physically separate the condensed liquid.

[0008] The general steam-assisted TVSA process is often described in terms of a repetitive cycle, with each cycle comprising the following basic steps:1. CO? Adsorption: Air is circulated over, through, or around the sorbent, which is contained inside a space that can be hermetically sealed. When adsorption is complete, the volume is sealed using valves.2. Evacuation: Most of the residual air surrounding the sorbent (~80% to 99%) is evacuated to increase the purity of the recovered CO? and reduce the risk of potentially damaging the sorbent as a result of oxidation at higher temperatures.3. Heating: The sorbent and surrounding structure are heated to a temperature chosen to promote optimum desorption of the CO?, often > 65°C depending on the molecular structure of the sorbent.4. Steam Purge / Regeneration: When the sorbent reaches the desired temperature, a steady flow of steam is initiated to remove CO? and regenerate the sorbent. The flow is controlled to effectively reduce the partial pressure of gaseous CO? as it is desorbed, which has the effect of increasing the amount removed.5. Cooling: The sorbent and surrounding structure are cooled to near ambient temperature. At the end of cooling, the pressure of the surrounding space is equalized with atmospheric pressure by opening the valves maintaining the hermetic seal, thereby completing one cycle.

[0009] Steam-assisted TVSA cycles generally require appreciable amounts of thermal energy in the form of heat to increase the temperature of the sorbent in a sorbent reactor and to counteract the cooling inherent with the endothermic desorption process (heat of desorption). Thermal energy may also be required to generate the steam that sweeps out CO? from the sorbent reactor. Thermal insulation applied to the interior of the sorbent reactor containing the sorbent can reduce the heattransfer to the surrounding structure and reduce energy usage by minimizing thermal losses, but the interiors of thermal vacuum swing reactors are challenging to adequately insulate because of the vacuum temperature cycling environment, especially when utilizing steam as a heating purge medium. Not only must insulation be selected to survive without degradation through repeated exposure to extreme temperatures, vacuum conditions, and contact with water vapor, steam creates challenges for physical heat transfer during the TVSA process that must be overcome by improvements in the state of the art. If there are any gaps, pores, or distance between the insulation and the interior reactor walls, steam will tend to migrate to said gaps and other porous spaces as driven by the vacuum environment. Once in these spaces, the steam can condense to water, resulting in increased heat transfer to the walls of the sorbent reactor due to the heat of condensation. The result is that heat can flow easily around most insulation that is not sealed or pressed firmly against the interior walls of a TVSA sorbent reactor, increasing parasitic heat loss and energy costs.SUMMARY

[0010] The invention relates to systems for adaptable carbon dioxide (CO2) capture, separation, and storage exhibiting improved thermal efficiency through multilayer insulation. The system in accordance with the invention includes a sorbent reactor that encloses one or more structured sorbents, each comprising a sorbent material capable of adsorbing CO2from the atmosphere and fabricated into a structured form; and one or more support structures containing and constraining one or more of the structured sorbents such that an air stream may readily flow through the sorbent reactor in at least one direction. The sorbent reactor comprises a chamber that comprises a plurality of walls having interior wall surfaces that surround the structured sorbent and a valve door operable to provide access, ingress, and egress to said sorbent.

[0011] The sorbent may be a powder, bead, or other particulate form included within a tubular, disc, sheet, or pleated sheet shaped structure through which air may pass.

[0012] In some example embodiments, the sorbent reactor is thermally insulated by an insulation panel in contact with the metal interior walls and said at least one valve door of the sorbent reactor chamber, said insulation panel comprising a plurality of layers each in contact with at least one other layer. The insulation panel can comprise a conforming layer in surface contact with, and covering, said metal interior walls and said at least one valve door, wherein the conforming layer is a hydrophobic and nonhydrolyzing material such as, but not limited to, silicone rubber. The insulation panel can further comprise an insulating layer in surface contact with, and covering, said conforming layer, wherein the insulating layer is a material with lower thermal conductivity and lower thermal density than the metalinterior walls and the valve door, such as, but not limited to, a polyisocyanurate foam.

[0013] In some example embodiments, the insulation panel has an aggregate thickness of between 0.5 inches and 2 inches or between 0.75 inches and 1.25 inches, i.e. the sum of the thickness of all layers that constitute the insulation panel is between 0.5 and 2 inches, or between 0.75 inches and 1.25 inches.

[0014] In some example embodiments, the insulating layer has a thermal conductivity between 0.01 W / mK and 0.1 W / mK, or between 0.02 and 0.05 W / mK, and a thermal density (defined as the product of the insulating material's specific heat and its density) between 15 kJ / m3K and 150 kJ / m3K , or between 15 kJ / m3K and 100 kJ / m3K , or between 15 kJ / m3K and 60 kJ / m3K .

[0015] In some example embodiments, the conforming layer has a durometer of less than 50A (e.g., less than 40A, less than 30A, less than 20A, or less than 10A). In other embodiments, the conforming layer has a thickness between 1 mm and 10 mm (e.g., between 2 mm and 9 mm, between 3 mm and 8 mm, between 4 mm and 7 mm, or between 5 mm and 6 mm). In other embodiments, the conforming layer is adhered to the interior metal walls with an adhesive.

[0016] In some example embodiments, the insulation panel further comprises a protective layer in surface contact with, and covering, the insulating layer, wherein the protective layer is a dust-resistant material such as a silicone spray.

[0017] In some example embodiments, the sorbent reactor further comprises an array of retaining features in surface contact with, and covering, the protective layer, wherein the array of retaining features hold and compress the insulation panel and pass through overlapping holes formed in the plurality of layers of the insulation panel.

[0018] In some example embodiments, the array of retaining features comprises threaded studs distributed on, and affixed to, the metal interior walls and the at least one valve door. The sorbent reactor may further comprise at least one fastener interfacing with each threaded stud, wherein the fasteners are in physical contact with a topmost layer of the insulation panel and can be tightened to compress the plurality of layers of the insulation panel, particularly the conforming layer. The fasteners may comprise screws or bolts and may further comprise mating nuts, washers, or clips. In some example embodiments the retaining features are welded to the metal interior walls.

[0019] In some example embodiments the overlapping hole formed in the insulating layer of the insulation panel is counterbored to a width at least the diameter of the fasteners, wherein all fastener surfaces are level with, or below the top plane of, a topmost layer of the insulation panel when tightened. Note that a "topmost" layer of the insulation panel is the layer furthest from the sorbentreactor chamber wall after installation that does not have another layer deposited thereon. In some embodiments, the topmost layer of the insulation panel is an insulating layer. In other embodiments, the topmost layer of the insulation panel is a protective layer or a rigid retaining layer.

[0020] In some example embodiments, the threaded studs of the array of retaining features are distributed in a uniform pattern on the surface of the metal interior sorbent reactor chamber walls and adjacent threaded studs are spaced equidistant from each other. In other example embodiments, the threaded studs are distributed in a non-uniform pattern such as a zig-zag pattern or one exhibiting a gradient in the distribution density of threaded studs on the walls. For example, a higher density of threaded studs can be distributed along the perimeter of an interior sorbent reactor chamber wall face and a lower density of thread studs can be disposed towards the center interior of the interior sorbent reactor chamber wall face.

[0021] In some example embodiments, the insulation panel further comprises a rigid retaining layer between the protective layer and the array of retaining features, wherein the rigid retaining layer covers the protective layer and is held against the protective layer by the array of retaining features. In some example embodiments, the rigid retaining layer is a solid single contiguous plane. In other example embodiments, the rigid retaining layer is corrugated, porous, or honeycomb in shape and formed of metal or carbon fiber.

[0022] In some example embodiments, the insulation panel is discretized into a plurality of segments, wherein the segments cover portions of the interior metal walls that form the top, sides, and bottom of the sorbent reactor chamber as well as the valve door of the sorbent reactor chamber, and wherein the segments are disconnected from each other.

[0023] In some example embodiments, insulation panel segments mounted to the bottom floor of the sorbent reactor chamber are separated by a gap that forms a water drainage channel.

[0024] In some example embodiments, the conforming layer is formed along the perimeter of the insulation sheet in a ring or annulus, wherein the conforming layer is a gasket or an O-ring. The conforming layer may or may not be partially recessed within a cavity formed in the insulating layer.

[0025] In one aspect of the invention, a sorbent reactor for removing carbon dioxide (CO2) from the atmosphere is provided, the sorbent reactor including a chamber comprising a plurality of metal interior walls and at least one valve door. The sorbent reactor encloses a structure sorbent capable of adsorbing CO2from the atmosphere or CO2point sources. The sorbent reactor further includes at least one insulation panel in contact with the metal interior walls including a plurality of layers. The plurality of layers includes a conforming layer in surface contact with, and covering, the plurality of metal interiorwalls and the at least one valve door; an insulating layer in surface contact with, and covering, the conforming layer; and an array of retaining features in surface contact with, and covering, the insulating layer. The array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer and the insulating layer of the at least one insulation panel.

[0026] In another aspect of the invention, a sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor including a chamber comprising a plurality of metal interior walls and at least one valve door. The sorbent reactor encloses a structured sorbent capable of adsorbing CO2from the atmosphere or CO2point sources. The sorbent reactor further includes at least one insulation panel in contact with the plurality of metal interior walls of the sorbent reactor chamber and comprising a plurality of layers. The plurality of layers includes a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door, an insulating layer in surface contact with, and covering, the conforming layer, a protective layer in surface contact with, and covering, the insulating layer; and an array of retaining features in surface contact with, and covering, the insulating layer and the protective layer. The array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer, the insulating layer, and the protective layer of the at least one insulation panel.

[0027] In another aspect of the invention, a sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor including a chamber comprising a plurality of metal interior walls and at least one valve door. The sorbent reactor encloses a structured sorbent capable of adsorbing CO2from the atmosphere or CO2point sources. The sorbent reactor further includes at least one insulation panel in contact with the plurality of metal interior walls and comprising a plurality of layers. The plurality of layers includes a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door an insulating layer in surface contact with, and covering, the conforming layer, a protective layer in surface contact with, and covering, the insulating layer, a rigid retaining layer in surface contact with, and covering, the protective layer and, optionally, between the protective layer and an array of retaining features, and an array of retaining features in surface contact with, and covering, the insulating layer and the protective layer. The array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer, the insulating layer, and the protective layer of the at least one insulation panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] These and other objects, features, and advantages of the invention will be more fullyappreciated or become better understood when considered in conjunction with the accompanying drawings, where:

[0029] FIG. 1 shows an exemplary sorbent reactor comprising walls and a valve in accordance with the invention;

[0030] FIG. 2 shows a cross section of a counterbored insulation panel and a retaining feature disposed on the interior walls of a sorbent reactor chamber in accordance with the invention;

[0031] FIG. 3 shows a cross section of a counterbored insulation panel having a protective layer and a retaining feature in accordance with the invention;

[0032] FIG. 4 shows a cross section of a counterbored insulation panel having a protective layer and a rigid retaining layer and a retaining feature in accordance with the invention;

[0033] FIG. 5 shows a cross section of a counterbored insulation panel having a protective layer and a rigid retaining layer and a retaining feature in accordance with the invention;

[0034] FIG. 6 shows a cross section of a flat insulation panel and a retaining feature disposed on the interior walls of a sorbent reactor chamber in accordance with the invention;

[0035] FIG. 7 shows a cross section of a flat insulation panel having a protective layer and a retaining feature in accordance with the invention;

[0036] FIG. 8 shows a cross section of a flat insulation panel having a protective layer and a rigid retaining layer and a retaining feature in accordance with the invention;

[0037] FIG. 9 shows a mounting pattern for studs of an array of retaining features having a uniform distribution in accordance with the invention;

[0038] FIG. 10 shows a mounting pattern for studs of an array of retaining features having a non- uniform zig-zag distribution in accordance with the invention;

[0039] FIG. 11 shows an exemplary sorbent reactor having a plurality of insulation panel segments formed into shapes and covering the interior walls of the sorbent reactor chamber in accordance with the invention;

[0040] FIG. 12 shows an exemplary sorbent reactor having a plurality of insulation panel segments covering the floor of the sorbent reactor chamber and a drainage channel between the floor segments of the insulation panel in accordance with the invention;

[0041] FIG. 13 shows an exemplary sorbent reactor having a plurality of insulation panels disposed on the valve doors of the sorbent reactor chamber in accordance with the invention;

[0042] FIG. 14 shows an exemplary sorbent reactor having a plurality of insulation panels and filled with sorbent material in accordance with the invention; and

[0043] FIG. 15 shows a cross section of an insulation panel having fasteners inserted into the walls of the sorbent reactor chamber in accordance with the invention.DETAILED DESCRIPTION

[0044] The system of the present invention is assembled as a sorbent reactor for removing carbon dioxide (COa) from the atmosphere. The primary makeup of an exemplary sorbent reactor 531 is shown in FIG. 1, with a fan 405 located on the outlet side 577 of the sorbent reactor 531 that pulls ambient air through an air filter 402 on the inlet side 566 of the sorbent reactor 531 and through the sorbent reactor 531 during the adsorption step. The sorbent reactor 531 comprises a chamber. During operation, atmospheric air including an ambient concentration of CO2 is drawn into the sorbent reactor 531 along a path 401, passing through the air filter 402, an air inlet valve 403, over sorbent 551, and through an air outlet valve 404 by way of the motive force of fan 405. In some embodiments of the invention, a fan or blower is located on the inlet side 566 of the sorbent reactor 531 and pushes ambient air through the air filter 402 and into and through the sorbent reactor 531.

[0045] Inside each sorbent reactor is a sorbent material that adsorbs CO2from the air, wherein the sorbent material is regenerated and desorbs and releases the captured CO2. The sorbent reactor also comprises instrumentation and controls and components located within the sorbent reactor that integrate with control functions located external to the sorbent reactor. Sorbent reactors comprise a chamber formed by a plurality of walls having a ceiling and floor and at least one valve, wherein the valves provide access to the sorbent material, facilitate fluid flow through the sorbent reactor, and can be actuated or manually opened or closed.

[0046] Various types of sensors can be incorporated within the sorbent bed. In the case of temperature sensors applied to a sorbent bed for capture of carbon dioxide, evenly distributing them through the bed allows for understanding of evenness and rate of both adsorption of CO2and heating and cooling of the bed as part of temperature swings for desorption and regeneration. In some applications, the temperature measurements may also give information relating to the progress of steam heating, evaporative cooling, water cooling, or any number of fluid flow processes that may affect the temperature of the bed. These sensors need not be temperature sensors but can be sensors for any range of measurement, and need not be probes but can be surface sensors, wire leads, etc.

[0047] In some embodiments of the present invention, the sorbent material is a structured sorbent material which allows a high flow of air through the sorbent modules with a low pressure drop. In some embodiments of the present invention, the structured sorbent material is in the form of a monolithmaterial with the sorbent coated onto, incorporated into, or forming the walls of the supporting monolith material. In some embodiments of the present invention, the structured sorbent material is in the form of a honeycomb material with the sorbent coated onto, incorporated into, or forming the walls of the supporting honeycomb material. In some embodiments of the present invention, the structured sorbent material is in the form of parallel sheets or plates supported within a support structure such as a parallel plate contactor structure. The parallel sheets can comprise sorbents coated onto, impregnated into, or embedded in porous polymeric supports; woven glass, carbon, ceramic, or polymeric fiber fabrics; or glass, carbon, ceramic, or polymeric fiber felts. In some embodiments of the present invention, the structured sorbent material can be in the form of an open-cell foam or other type of reticulated sheet or structure through which air can flow. In some embodiments of the present invention, the sorbent material can be in the form of a powder, bead, or other particulate form included within a tubular, disc, sheet, or pleated sheet shaped structure through which air can be passed.

[0048] In some embodiments of the present invention, the sorbent reactors operate via a temperature swing adsorption (TSA) process. The TSA process generally involves three steps: (i) adsorption; (ii) desorption via heated purge; and (iii) cooling. During adsorption, ambient air is pulled or pushed through the sorbent using a fan or blower, and CO2 is adsorbed. Adsorption variables include air flow rate, sorbent capture efficiency, sorbent capacity, and adsorption time. During desorption, air flow is stopped, and a heated purge gas is passed through the sorbent to effect desorption and to sweep desorbed CO2 out of the sorbent reactor. In some embodiments of the present invention, thermal jackets or surface heaters can be utilized to help heat the sorbent modules during the purge step. Desorption variables include purge gas, purge gas flow rate, temperature, and desorption time. After desorption, the sorbent reactor is purged with a cool stream of air or inert gas, depending upon the oxygen sensitivity of the sorbent, to cool the system back to ambient. For a given sorbent and sorbent reactor system, the adsorption time, air flow rate, purge gas temperature and flow rate, desorption time, and cooling time are typical process parameters that can be monitored and controlled.

[0049] In some embodiments of the present invention, the sorbent reactors operate via a temperature vacuum swing adsorption (TVSA) process. The TVSA process generally involves four steps: (i) adsorption; (ii) evacuation; (iii) desorption; and (iv) cooling. During adsorption, ambient air is pulled or pushed through the sorbent using a fan or blower, and CO2 is adsorbed. Adsorption variables include air flow rate, sorbent capture efficiency, sorbent capacity, and adsorption time. During evacuation, the sorbent reactor is sealed, and air is evacuated using a vacuum pump to remove dead air and non-condensable gas impurities. The sorbent in the sorbent reactor is then heated, which desorbs CO2, which is removedthrough the vacuum system. In some embodiments of the present invention, thermal jackets or surface heaters can be utilized to heat the sorbent modules during the evacuation step. Desorption variables include evacuation level, temperature, and desorption time. After desorption, the sorbent reactor is purged with a cool stream of air or inert gas, depending upon the oxygen sensitivity of the sorbent, to cool the system back to ambient. For a given sorbent and sorbent reactor system, the adsorption time, air flow rate, evacuation level, desorption temperature and time, and cooling time are typical process parameters that can be monitored and controlled.

[0050] In some embodiments of the present invention, the sorbent reactors operate via a steam- assisted temperature vacuum swing adsorption (S-TVSA) process. The S-TVSA process generally involves four steps: (i) adsorption; (ii) evacuation; (iii) steam-assisted desorption; and (iv) evaporative cooling. During adsorption, ambient air is pulled or pushed through the sorbent using a fan or blower, and CO2is adsorbed. Adsorption variables include air flow rate, sorbent capture efficiency, sorbent capacity, and adsorption time. During evacuation, the sorbent reactor is sealed, and air is evacuated using a vacuum pump to remove dead air and non-condensable gas impurities. Desorption occurs in two steps: repressurization and purge. Steam is introduced into the sorbent reactor to raise the pressure to the desired desorption pressure, heating the sorbent in the process. The sorbent reactor outlet is then opened to begin purge, which desorbs CO2and sweeps it into a wet CO2product stream. Steam is an effective carrier to sweep away gaseous CO2as it is being desorbed, thereby promoting increased desorption by way of reducing the partial pressure of the gas above the sorbent. Desorption variables include evacuation level, steam temperature / pressure, and purge time. After desorption, the sorbent reactor is evacuated again using a vacuum pump to desorb water from the sorbent and rapidly cool it. The evaporation of this water removes heat from the sorbent, mitigating the risk of sorbent oxygenation when air is readmitted for the next adsorption cycle. For a given sorbent and sorbent reactor system, the adsorption time, air flow rate, evacuation level, steam temperature / pressure, steam purge rate and time, and evaporative cooling time are typical process parameters that are monitored and controlled.

[0051] In embodiments of the present invention, the sorbent reactor is thermally insulated via a multilayer insulation panel formed inside the sorbent reactor chamber and in contact with the metal interior walls and the valve doors. The insulation panel comprises a plurality of layers each in contact with at least one other layer. A cross section of a preferred configuration of the insulation panel is shown in FIG. 2. The insulation panel 200 comprises a conforming layer 201 in surface contact with, and covering, the metal interior walls 202 of the sorbent reactor chamber and the at least one valve door (not pictured). The insulation panel 200 can further comprise an insulating layer 203 in surface contactwith, and covering, the conforming layer 201. A plurality of holes is formed through both the conforming and insulating layers through which is disposed a plurality of retaining features 204 that are attached to the metal interior wall 202 of the sorbent reactor chamber. Each of the plurality of retaining features 204 may comprise a threaded stud, rod, or nut. The plurality of retaining features 204 may be attached to the metal interior wall by any means known in the art, including welding or an adhesive. Each of the plurality of retaining features 204 interfaces with one of a plurality of corresponding fasteners 205 such as bolts or screws to form a bolted joint. Each fastener 205 may have a head or may be optionally connected to a mating nut or clip. A washer 206 is optionally positioned under each fastener head, mating nut, or clip, wherein the washer 206 makes physical contact with the top layer of the insulation panel 200 and compresses the plurality of layers of the insulation panel 200 when the plurality of fasteners 205 are tightened to form the bolted joints.

[0052] In some example embodiments, the overlapping hole formed in the insulating layer 203 of the insulation panel 200 is counterbored to a width of at least the diameter of the fasteners 205, wherein all fastener surfaces are level with, or below the top plane of, the insulating layer 203 when tightened. An embodiment of the insulation panel 200 having a counterbored fastener hole in the insulating layer 203 is also visible in FIG. 2. This configuration allows for the fasteners 205 to sit flush with the top of the insulating layer 203, or to sit below the top of the insulating layer 203. The counterbore feature allows for a more compact installation by lowering the height of the fasteners 205 relative to the insulation panel 200, which can lower the amount of dead space or volume inside the sorbent reactor not filled by sorbent. Reducing the amount of dead space or dead volume inside a sorbent reactor can increase the output purity of extracted carbon dioxide. Counterbored insulating layers also facilitate the incorporation of additional material on top of the insulating layer and any retaining features and fasteners.

[0053] The conforming layer is preferably water-resistant and non-water absorbing, hence it is preferably both hydrophobic and non-hydrolyzing. Preferred materials for the conforming layer must also be able to withstand the environmental conditions inside the sorbent reactor chamber, including extreme temperatures and rapid temperature swings, exposure to vacuum, and positive pressure. The conforming layer is preferably a silicone-based rubber but can also be selected from a nitrile butadiene rubber, a fluorocarbon-based fluoro-elastomer such as fluorine rubber, an ethylene propylene diene monomer rubber, and others.

[0054] The conforming layer is preferably selected to be sufficiently compliant that it fills all gaps, voids, and pores between the insulating layer and the metal walls of the sorbent reactor chamber whencompressed. The presence of the conforming layer prevents steam, used as a purge gas during the TVSA process, from migrating between the insulating layer and the walls and subsequently condensing into water, which would cause additional physical heat transfer that can contribute to excess parasitic heat losses, impairing the efficiency of the sorbent reactor system. Experimental results suggest that conforming layers exhibiting a durometer (a dimensionless comparative measurement of non-rigid elastomers known in the state of the art) of no more than 60A is preferred, but a comparable material exhibiting a durometer value less than or equal to 60A can be substituted. The ideal thickness of the conforming layer is dependent on its durometer; low durometer materials can be as thin as 0.5 mm, while high durometer materials can be as thick as 10 mm. In some example embodiments, the conforming layer has a durometer of less than 50A (e.g., less than 40A, less than 30A, less than 20A, or less than 10A). In other embodiments, the conforming layer has a thickness between 1 mm and 10 mm (e.g., between 2 mm and 9 mm, between 3 mm and 8 mm, between 4 mm and 7 mm, or between 5 mm and 6 mm). The conforming layer can be mounted to the interior wall via an adhesive, attached to the interior wall via a fixture, fastener, or clamp, or simply held against the wall as part of the insulation panel by the array of retaining features.

[0055] The insulating layer is preferably formed from a material with low thermal conductivity and low thermal density and preferably exhibits lower thermal conductivity and lower thermal density than the metal interior walls and the valve doors. Low thermal conductivity insulation is necessary to prevent heat from flowing from the steam into the sorbent reactor chamber walls, as sorbent reactor chamber heating is a major source of energy loss and efficiency reduction in the carbon separation process. A preferred insulating layer limits the temperature rise measured at the exterior of the sorbent reactor chamber walls to no greater than 10 °C (without any insulation, the temperature rise in the sorbent reactor chamber walls during a steam-assisted thermal vacuum swing adsorption process can be expected to be between 50 °C and 100 °C). Similarly, if the insulating layer has significant thermal density, heat will be wasted heating up the insulation, thereby reducing the efficiency of the process. A preferred insulating layer exhibits a thermal conductivity between 0.01 W / mK and 0.1 W / mK, or between 0.02 and 0.05 W / mK, and exhibits a thermal density (defined as the product of the insulating material's specific heat and its density) between 15 kJ / m3K and 150 kJ / m3K, or between 15 kJ / m3K and 100 kJ / m3K , or between 15 kJ / m3K and 60 kJ / m3K . Preferred materials can include a rigid material having closed-cells such as a polyisocyanurate foam or foamed glass. In an alternative embodiment, the insulating layer can be formed of a non-rigid felt or synthetic porous material such as an aerogel. The thickness of the insulating layer is selected based on the thermal conductivity of its material and theduration of the carbon separation process time. Preferred embodiments exhibit an insulating layer thickness between 25 mm and 35 mm but a layer having a thickness between 15 mm and 150 mm can be substituted. In some example embodiments, the insulation panel has an aggregate thickness of between 0.5 inches and 2 inches, or between 0.75 inches and 1.25 inches, i.e. the sum of the thickness of all layers that constitute the insulation panel is between 0.5 and 2 inches, or between 0.75 inches and 1.25 inches. A preferred embodiment exhibits a total aggregate thickness of the layers comprised in the insulation panel of 1 inch.

[0056] In some example embodiments, the insulation panel further comprises a protective layer. A cross section of this alternative configuration of the insulation panel is shown in FIG. 3. In this embodiment, the insulation panel 200 comprises a protective layer 207 in surface contact with, and covering, the insulating layer 203, wherein the insulating layer 203 is in surface contact with, and covering, the conforming layer 201. A plurality of holes is formed through the conforming, insulating, and protective layers through which is disposed a plurality of retaining features 204 that are attached to the metal interior wall 202 of the sorbent reactor chamber. Each of the plurality of retaining features204 may comprise a threaded stud, rod, or nut. The plurality of retaining features 204 may be attached to the metal interior wall 202 by any means known in the art, including welding or an adhesive. The plurality of retaining features 204 interfaces with one of a plurality of corresponding fasteners 205 to form a bolted joint. Each fastener 205 may comprise a bolt or screw. Each fastener 205 may have a head or may be optionally connected to a mating nut or clip. A washer 206 is optionally positioned under each fastener 205, wherein each washer 206 makes physical contact with the top layer of the insulation panel 200 and compresses the plurality of layers of the insulation panel 200 when the plurality of fasteners205 are tightened to form the bolted joints.

[0057] In some example embodiments, the overlapping holes formed in the insulating layer 203 of the insulation panel 200 are counterbored to a width of at least the diameter of the fasteners 205, wherein all fastener surfaces are level with, or below the top plane of, the insulating layer 203 when tightened. The protective layer 207, when disposed on top of the insulating layer 203, may also be deposited within the counterbored area. An embodiment of the insulation panel 200 having a protective layer 207 and at least one counterbored fastener hole in the insulating layer 203 is also visible in FIG. 3.

[0058] The protective layer is preferably an abrasion-resistant and dust-proof material that protects the underlying plurality of layers of the insulation panel from accumulating dirt and protects said layers from damage. In some example embodiments, the material that forms the insulating layer tends to accumulate dust and particulates, which could present health hazards to personnel working with thesorbent reactor or damage the sorbent. The protective layer is preferably a dust-resistant material such as a polymeric film or coating such as a silicone spray but can also be selected from an epoxy, silicone, rubber or alternative polymer that is sprayed, dipped, painted, molded or brushed onto the insulating layer. The protective layer can be made of a dielectric or electrically insulating material or a nondielectric or conductive material such as an electroless plating. In an alternative embodiment, the protective layer is a solid sheet selected from a plastic, rubber, fiberglass, mylar, Kapton, or similar material, wherein the protective layer is attached or adhered to the insulating layer. The protection layer can be deposited to cover the planar faces of the insulating layer and can also be deposited to cover the orthogonal sides of the insulation panel. In some example embodiments, the protective layer is not a layer at all but the result of heating, melting, cutting, ironing, or scoring the topmost layers of the insulation panel to form a seal over the surfaces and sides of the plurality of layers of the insulation panel.

[0059] In some example embodiments, the insulation panel further comprises a rigid retaining layer. A rigid retaining layer can be beneficial for applying additional stability and compression to the insulation panel, which can further eliminate gaps between the conforming layer and the metal interior walls into which steam can enter during the carbon-separation process. A cross section of this alternative configuration of the insulation panel 200 is shown in FIG. 4. In this embodiment, insulation panel 200 comprises a rigid retaining layer 208 in surface contact with, and covering, the protective layer 207, the protective layer 207 is in surface contact with, and covering, an insulating layer 203, the insulating layer 203 is in surface contact with, and covering, a conforming layer 201, and the conforming layer 201 is in surface contact with, and covering, the metal interior wall 202. A plurality of holes is formed through the conforming, insulating, protective, and rigid retaining layers through which is disposed a plurality of retaining features 204 that are attached to the metal interior wall 202 of the sorbent reactor chamber. Each of the plurality of retaining features 204 may comprise a threaded stud, rod, or nut and may be attached to the metal interior wall 202 by any means known in the art, including welding or an adhesive. The plurality of retaining features 204 interfaces with one of a plurality of corresponding fasteners 205 such as bolts or screws to form a bolted joint. Each of the plurality of fasteners 205 may comprise a head 209. The head 209 may comprise a mating nut or clip that interfaces with each of the plurality of fasteners 205. Alternatively, the head 209 may be a screw head or bolt head made integral with each of the plurality of fasteners 205. A washer 206 is optionally positioned to interface with each fastener 205. Each washer 206 may be disposed under a head 209, wherein each washer 206 makes physical contact with the protective layer 207 and compresses the conforming layer 201 when the plurality of fasteners205 are tightened to form the bolted joints.

[0060] In some example embodiments, the overlapping holes formed in the insulating layer 203 of the insulation panel 200 are counterbored to a width of at least the diameter of the fasteners 205, wherein all fastener surfaces are level with, or below the top plane of, the insulating layer 203 when tightened. The rigid retaining layer 208, when disposed on top of the insulating layer 203 and any protective layers (if present), may abut, or reside next to, the counterbored area. An embodiment of the insulation panel 200 having a protective layer 207, a rigid retaining layer 208, and at least one counterbored fastener hole in the insulating layer is also visible in FIG. 4.

[0061] In some example embodiments, the protective layer 207 does not extend to within the counterbored area of the insulating layer 203. FIG. 5 shows a cross section of an insulation panel 200 that comprises a rigid retaining layer 208 in surface contact with, and covering, a protective layer 207, the protective layer 207 is in surface contract with, and covering, an insulating layer 203, the insulating layer 203 is in surface contact with, and covering, a conforming layer 201, and the conforming layer 201 is in surface contact with, and covering, the metal interior wall 202. The insulating layer 203 is counterbored, and the protective layer 207 and the rigid retaining layer 208 do not extend into or over the counterbored area. A plurality of holes is formed through the conforming, insulating, protective, and rigid retaining layers through which is disposed a plurality of retaining features 204 that are attached to the metal interior wall 202 of the sorbent reactor chamber. Each of the plurality of retaining features 204 may comprise a threaded stud, rod, or nut and may be attached to the metal interior wall 202 by any means known in the art, including welding or via an adhesive. Each of the plurality of retaining features 204 interface with one of a plurality of corresponding fasteners 205 such as a bolt or screw to form a bolted joint. Each fastener 205 may comprise a head 209. The head 209 may comprise a mating nut or clip that interfaces with each of the plurality of fasteners 205. Alternatively, the head 209 may be a screw head or bolt head made integral with each of the plurality of fasteners 205. A washer 206 is optionally positioned to interface with each of the plurality of fasteners 205. Each washer 206 may be disposed under a head 209, wherein the washer 206 makes physical contact with the insulating layer 203 and compresses the conforming layer 201 when the plurality of fasteners 205 are tightened to form the bolted joints. This embodiment would be preferred if the protective layer material, rather than being pourable or sprayable such as silicone epoxy, was a rigid material that could be cut or molded into shapes.

[0062] In some example embodiments, the rigid retaining layer 208 is a solid single contiguous sheet while in other example embodiments it is a corrugated sheet, bent sheet, mesh, honeycomb sheet,series of extrusions, or a planar sheet with holes formed within its surface area. The rigid retaining layer 208 can be formed of a sufficiently dense and hard material such as a metal or carbon fiber.

[0063] It is possible to produce the insulation panels as per the present invention without utilizing a counterbored feature for the sitting of fasteners for retention. These alternative embodiments are visible in FIGS. 6-8.

[0064] FIG. 6 shows a cross section of a multilayer insulation panel 200 having a flat insulating layer 203 in surface contact with a conforming layer 201, wherein the conforming layer is in surface contact with, and covering, the metal interior wall 202. The conforming layer 201 is disposed between the insulating layer 203 and the metal interior walls 202 of the sorbent reactor chamber and is compressed by a plurality of washers 206 that make contact with the insulating layer 203 and a plurality of fasteners 205 that are threaded into a plurality of retaining features 204 and tightened by a plurality of heads 209. Each of the plurality of retaining features 204 corresponds to a washer 206 that makes contact with the insulating layer 203 and a fastener 205 threaded into the retaining feature 204 and tightened by a head 209.

[0065] FIG. 7 shows a cross section of a multilayer insulation panel 200 having a flat insulating layer 203 which is covered by a flat protective layer 207. A conforming layer 201 disposed between the insulating layer 203 and the metal interior walls 202 of the sorbent reactor chamber is compressed by a plurality of washers 206 that make contact with the protective layer 207 and a plurality of fasteners 205 that are threaded into a plurality of retaining features 204 and tightened by a plurality of heads 209. Each of the plurality of retaining features 204 corresponds to a washer 206 that makes contact with the protective layer 207 and a fastener 205 threaded into the retaining feature 204 and tightened by a head 209.

[0066] FIG. 8 shows a cross section of a multilayer insulation panel 200 having a flat insulating layer 203 which is covered by a flat protective layer 207 and a rigid retaining layer 208. A conforming layer 201 disposed between the insulating layer 203 and the metal interior walls 202 of the sorbent reactor chamber is compressed by a plurality of washers 206 that make contact with the rigid retaining layer 208 and a plurality of fasteners 205 that are threaded into a plurality of retaining features 204 and tightened by a plurality of heads 209. Each of the plurality of retaining features 204 corresponds to a washer 206 that makes contact with the rigid retaining layer 208 and a fastener 205 threaded into the retaining feature 204 and tightened by a head 209.

[0067] In some example embodiments the array of retaining features is distributed in a uniform pattern on the surface of the metal interior sorbent reactor chamber walls. FIG. 9 shows an insulation panel 800 having a plurality of holes 801 for engagement with a plurality of threaded studs in a mounting pattern 1mirrored on the metal interior wall of the sorbent reactor chamber. The threaded studs and corresponding holes in this embodiment are spaced equidistant from each other. In another embodiment, the threaded studs and corresponding holes are at least 2 inches apart, at least 4 inches apart, at least 6 inches apart, at least 8 inches apart, or at least 10 inches apart.

[0068] In some example embodiments, the array of retaining features is distributed in a non-uniform pattern on the surface of the metal interior walls such as a zig-zag pattern or one exhibiting a gradient in the distribution density of retaining features on the walls. For example, a higher density of retaining features can be distributed along the perimeter of an interior sorbent reactor chamber wall face and a lower density of retaining features can be disposed towards the center interior of the interior sorbent reactor chamber wall face. FIG. 10 shows an insulation panel 900 having a plurality of holes 902 and 903 for engagement with threaded studs in a mounting pattern mirrored on the metal interior wall of the sorbent reactor chamber. Some of the threaded studs and corresponding holes 902 in this embodiment are spaced equidistant from each other, while other threaded studs and corresponding holes 903 are spaced close together. In another embodiment, some of the threaded studs and corresponding holes are at least 6 inches apart, or at least 8 inches apart, or at least 10 inches apart, while other threaded studs and corresponding holes are less than 6 inches apart, or less than 4 inches apart, or less than 2 inches apart. A benefit of a non-uniform distribution density of retaining features is a reduction in hardware costs.

[0069] FIG. 11 shows a plurality of insulation panels 1000 cut into shapes and disconnected from each other. Insulation panel segments can be sized to cover portions of the interior metal walls that form the top, sides, and bottom of the sorbent reactor chamber as well as any and all valve doors or valves of the sorbent reactor chamber. The shapes of the insulation panels in the example embodiment have portions cut out therefrom, wherein the cut-out portions form gaps that accommodate supplemental fixtures inside the sorbent reactor, such as shelves or platforms, as well as to make space for commanding and measurement instrumentation, such as cables and sensors. Insulation panels can still comprise pass- through holes 1010 for interfacing with retaining features such as threaded studs. Insulation panels can be combined to form shapes that are compatible with sorbent reactors of a variety of shapes and sizes, including rectangular or cylindrical sorbent reactors. In some example embodiments, the insulation panels can be used to form a box, cube, or rectangular three-dimensional structure that surrounds or encloses a sorbent material inside a sorbent reactor.

[0070] In some example embodiments, the sorbent reactor may be built to employ steam as a heating and purge gas in a steam-assisted TVSA carbon separation process, which can result in the condensationof water inside the sorbent reactor. Condensate will therefore pool in the bottom of the sorbent reactor through gravity over time. Condensate is preferably collected in a drainage channel in the bottom of the sorbent reactor chamber floor for easy removal. FIG. 12 shows a view of the bottom interior floor of an exemplary sorbent reactor chamber 1100 having a drainage channel 1110. In the example embodiment, insulation panels 1101 are mounted to, and cover, the sorbent reactor chamber floor on either side of drainage channel 1110.

[0071] Any of the embodiments of the insulation panel disclosed herein may also be used in any combination. For example, at least one insulation panel of FIG. 2 may be used on certain interior metal walls of the sorbent reactor chamber and / or the valve door while at least one insulation panel of FIG. 3 may be used on certain other interior metal walls of the sorbent reactor chamber and / or the valve door.

[0072] An example embodiment of a sorbent reactor in accordance with the invention comprising insulation panels disposed on certain walls and valve doors of the sorbent reactor chamber 1200 is shown in FIG. 13. Sorbent reactor chamber 1200 in FIG. 13 is depicted with valve doors 1250 in an open position. Insulation panels 1000 are mounted to, and cover, the interior walls of the sorbent reactor chamber 1200 as well as the interior-facing planar surfaces of the valve doors 1250. The insulation panels 1000 comprise pass-through holes 1010 for interfacing with retaining features such as threaded studs. The sorbent reactor chamber 1200 additionally comprises floor insulation panels 1101 that are mounted to, and cover, the floor of the sorbent reactor chamber 1200. Floor insulation panels 1101 are disposed to either side of drainage channel 1110, which runs down the center of the sorbent reactor chamber floor and collects condensate, thereby routing any pooled liquid water out of the sorbent reactor chamber 1200 and away from the sorbent material (not shown in FIG. 13). All insulation panels 1000, 1101 depicted in FIG. 13 can be formed as a plurality of segments and can comprise a plurality of layers, including conforming, insulation, protective, and retaining layers in any suitable combination in accordance with another exemplary embodiment of the present invention, such as the insulation panel embodiments shown in FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 12, or FIG. 15.

[0073] Any of the embodiments of the insulating panel disclosed herein may be used in a sorbent reactor that also comprises at least one structured sorbent inside the sorbent reactor that undergoes a carbon capture or TVSA process. An example of a sorbent reactor in accordance with the invention that also comprises structured sorbent is shown in FIG. 14. Here a sorbent reactor chamber 1200 comprising valve doors 1250 (shown in FIG. 14 in an open position) and houses at least one sorbent material 1210 capable of adsorbing carbon dioxide. The sorbent material 1210 may be formed in a freestanding shape such as a sheet or monolith or be contained in a module, package, housing, or some combinationthereof. The sorbent material 1210 is enclosed within the sorbent reactor chamber 1200 and surrounded by the insulation panels 1000. Insulation panels 1000 are mounted to, and cover, the interior walls and floor of the sorbent reactor chamber 1200. The insulation panels 1000 comprise pass- through holes 1010 for interfacing with retaining features such as threaded studs. The insulation panels 1000 depicted in FIG. 14 can be formed as a plurality of segments, and can comprise a plurality of layers, including conforming, insulation, protective, and retaining layers in any suitable combination in accordance with an exemplary embodiment of the present invention, such as the insulation panel embodiments shown in FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 12, or FIG. 15.

[0074] In some example embodiments, the fasteners are not welded or otherwise attached to the planar surfaces of the interior walls of the sorbent reactor chamber and / or the valve doors, but are inserted into or extend into the walls of the sorbent reactor chamber and / or valve doors a predetermined depth via a cutout or hole that is drilled or otherwise machined. An example is shown in FIG. 15, in which a cross section of a metal interior wall 202 with an insulation panel disposed thereon is shown. In this embodiment the insulation panel comprises a protective layer 207 in surface contact with, and covering, an insulating layer 203, wherein the insulating layer 203 is in surface contact with, and covering, a conforming layer 201. A plurality of holes is formed through the conforming, insulating, and protective layers and through at least a portion of the metal interior wall 202 through which is disposed a plurality of retaining features 204 that are attached to the metal interior wall 202 of the sorbent reactor chamber. Each of the plurality of retaining features 204 may comprise a threaded stud, rod, or nut. The plurality of retaining features 204 may be extended into the depth of the metal interior wall 202 and may be attached by any means known in the art, including welding, a press-fit, a threaded mate, or an adhesive. Each of the plurality of retaining features 204 interfaces with one of a plurality of fasteners 205 to form a bolted joint. The plurality of fasteners 205 may comprise bolts or screws. Each fastener 205 may have a head or may be optionally connected to a mating nut or clip. A washer 206 is optionally positioned under each fastener 205, wherein each washer 206 makes physical contact with the top layer of the insulation panel and compresses the plurality of layers of the insulation panel when the plurality of fasteners 205 are tightened to form the bolted joints.

[0075] In some example embodiments, fasteners are not threaded to every threaded stud in the array of retaining features and are only disposed along the perimeter of the insulation panels or the perimeter of the sorbent reactor chamber walls. In some example embodiments, studs are not disposed across the entire interior face of the sorbent reactor chamber walls and are only disposed along the perimeter of the sorbent reactor chamber walls. These configurations have the advantage of reducing the thermaldensity inside the sorbent reactor and lowering the costs of fixtures while offering comparable performance improvements. In examples having threaded studs and / or retaining features disposed only on the perimeter of the sorbent reactor chamber walls or on the perimeter of the insulation panels, the conforming layer can be formed as a hollow sheet with a cutout of the interior plane and having the shape of a rectangular annulus. The conforming layer of this example embodiment makes physical contact with the sorbent reactor chamber walls and the insulating layer only along the perimeter of the insulation sheet or the perimeter of the sorbent reactor chamber walls and the door valve. In this example embodiment the conforming layer may be a gasket or an O-ring.

[0076] The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the invention to the precise embodiments disclosed. The specification describes specific examples of accomplishing a more general goal that also may be accomplished in another way. Those skilled in the art will appreciate that the features described above can be combined in various ways to form multiple variations of the invention. All of the references cited herein are incorporated by reference in their entirety.

[0077] Exemplary Embodiments of the Invention

[0078] El. A sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor comprising: a chamber comprising a plurality of metal interior walls and at least one valve door, wherein the chamber encloses a structured sorbent capable of adsorbing CO2 from the atmosphere or CO2point sources; and at least one insulation panel in contact with the plurality of metal interior walls and the at least one valve door and comprising a plurality of layers, wherein the plurality of layers comprises: a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door; an insulating layer in surface contact with, and covering, the conforming layer; and an array of retaining features in surface contact with, and covering, the insulating layer, wherein the array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer and the insulating layer of the at least one insulation panel.

[0079] E2. The sorbent reactor of El, wherein the overlapping holes formed in the insulating layer of the at least one insulation panel are counterbored to a width of at least a diameter of the array of retaining features.

[0080] E3. The sorbent reactor of El or E2, wherein the array of retaining features comprises at least one threaded stud affixed to the plurality of metal interior walls and the at least one valve door and at least one fastener interfacing with each of the at least one threaded stud, wherein the at least one fastener contacts the insulating layer and is tightened to compress the conforming layer.

[0081] E4. A sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor comprising: a chamber comprising a plurality of metal interior walls and at least one valve door, wherein the chamber encloses a structured sorbent capable of adsorbing CO2 from the atmosphere or CO2 point sources; and at least one insulation panel in contact with the plurality of metal interior walls and the at least one valve door and comprising a plurality of layers, wherein the plurality of layers comprises: a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door; an insulating layer in surface contact with, and covering, the conforming layer; a protective layer in surface contact with, and covering, the insulating layer; and an array of retaining features in surface contact with, and covering, the insulating layer and the protective layer, wherein the array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer, the insulating layer, and the protective layer of the at least one insulation panel.

[0082] E5. The sorbent reactor of E4, wherein the array of retaining features comprises at least one threaded stud affixed to the plurality of metal interior walls and the at least one valve door and at least one fastener interfacing with each of the at least one threaded stud, wherein the at least one fastener contacts the insulating layer and the protective layer and is tightened to compress the conforming layer.

[0083] E6. The sorbent reactor of E5, wherein the overlapping holes formed in the insulating layer of the at least one insulation panel are counterbored to a width of at least a diameter of the array of retaining features.

[0084] E7. The sorbent reactor of E5, wherein the at least one insulation panel is discretized into a plurality of segments, wherein the plurality of segments covers portions of the plurality of interior metal walls and the at least one valve door, and wherein each of the plurality of segments are disconnectedfrom each other.

[0085] E8. The sorbent reactor of any one of E4-E7, wherein the conforming layer comprises a silicone rubber.

[0086] E9. The sorbent reactor of any one of E4-E8, wherein the insulating layer comprises a polyisocyanurate foam.

[0087] E10. The sorbent reactor of any one of E4-E9, wherein the protective layer comprises a silicone spray.

[0088] Ell. A sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor comprising: a chamber comprising a plurality of metal interior walls and at least one valve door, wherein the chamber encloses a structured sorbent capable of adsorbing CO2 from the atmosphere or CO2 point sources; and at least one insulation panel in contact with the plurality of metal interior walls and the at least one valve door and comprising a plurality of layers, wherein the plurality of layers comprises: a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door; an insulating layer in surface contact with, and covering, the conforming layer; a protective layer in surface contact with, and covering, the insulating layer; a rigid retaining layer in surface contact with, and covering, the protective layer and, optionally, between the protective layer and an array of retaining features; and an array of retaining features in surface contact with, and covering, the insulating layer and the protective layer, wherein the array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer, the insulating layer, and the protective layer of the at least one insulation panel.

[0089] E12. The sorbent reactor of Ell, wherein the array of retaining features comprises at least one threaded stud affixed to the plurality of metal interior walls and the at least one valve door and at least one fastener interfacing with each of the at least one threaded studs, wherein the at least one fastener is in physical contact with the insulating layer or the protective layer and, wherein the array of retaining features are tightened to compress the conforming layer.

[0090] E13. The sorbent reactor of Ell, wherein the overlapping holes formed in the insulating layer of the at least one insulation panel are counterbored to a width of at least a diameter of the array of retaining features.

[0091] E14. The sorbent reactor of Ell, wherein the at least one insulation panel is discretized into a plurality of segments, wherein the plurality of segments covers portions of the plurality of interior metal walls and the at least one valve door, and wherein each of the plurality of segments are disconnected from each other.

[0092] E15. The sorbent reactor of any one of E11-E14, wherein the conforming layer comprises a silicone rubber.

[0093] E16. The sorbent reactor of any one of E11-E15, wherein the insulating layer comprises a polyisocyanurate foam.

[0094] E17. The sorbent reactor of any one of E11-E16, wherein the protective layer comprises a silicone spray.

[0095] E18. The sorbent reactor of any one of E11-E17, wherein the rigid retaining layer comprises a metal or carbon fiber.

[0096] E19. The sorbent reactor of E18, wherein the rigid retaining layer comprises a single continuous sheet.

[0097] E20. The sorbent reactor of E18, wherein the rigid retaining layer comprises a honeycomb sheet, a mesh, or a planar sheet having holes formed within its surface area.

Claims

What is claimed is:

1. A sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor comprising: a chamber comprising a plurality of metal interior walls and at least one valve door, wherein the chamber encloses a structured sorbent capable of adsorbing CO2from the atmosphere or CO2point sources; and at least one insulation panel in contact with the plurality of metal interior walls and the at least one valve door and comprising a plurality of layers, wherein the plurality of layers comprises: a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door; an insulating layer in surface contact with, and covering, the conforming layer; and an array of retaining features in surface contact with, and covering, the insulating layer, wherein the array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer and the insulating layer of the at least one insulation panel.

2. The sorbent reactor of claim 1, wherein the overlapping holes formed in the insulating layer of the at least one insulation panel are counterbored to a width of at least a diameter of the array of retaining features.

3. The sorbent reactor of claim 1 or 2, wherein the array of retaining features comprises at least one threaded stud affixed to the plurality of metal interior walls and the at least one valve door and at least one fastener interfacing with each of the at least one threaded stud, wherein the at least one fastener contacts the insulating layer and is tightened to compress the conforming layer.

4. A sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor comprising: a chamber comprising a plurality of metal interior walls and at least one valve door, wherein the chamber encloses a structured sorbent capable of adsorbing CO2from the atmosphere or CO2point sources; and at least one insulation panel in contact with the plurality of metal interior walls and the at leastone valve door and comprising a plurality of layers, wherein the plurality of layers comprises: a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door; an insulating layer in surface contact with, and covering, the conforming layer; a protective layer in surface contact with, and covering, the insulating layer; and an array of retaining features in surface contact with, and covering, the insulating layer and the protective layer, wherein the array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer, the insulating layer, and the protective layer of the at least one insulation panel.

5. The sorbent reactor of claim 4, wherein the array of retaining features comprises at least one threaded stud affixed to the plurality of metal interior walls and the at least one valve door and at least one fastener interfacing with each of the at least one threaded stud, wherein the at least one fastener contacts the insulating layer and the protective layer and is tightened to compress the conforming layer.

6. The sorbent reactor of claim 5, wherein the overlapping holes formed in the insulating layer of the at least one insulation panel are counterbored to a width of at least a diameter of the array of retaining features.

7. The sorbent reactor of claim 5, wherein the at least one insulation panel is discretized into a plurality of segments, wherein the plurality of segments covers portions of the plurality of interior metal walls and the at least one valve door, and wherein each of the plurality of segments are disconnected from each other.

8. The sorbent reactor of any one of claims 4-7, wherein the conforming layer comprises a silicone rubber.

9. The sorbent reactor of any one of claims 4-7, wherein the insulating layer comprises a polyisocyanurate foam.

10. The sorbent reactor of any one of claims 4-7, wherein the protective layer comprises a silicone spray.

11. A sorbent reactor for removing carbon dioxide (CO2) from the atmosphere, the sorbent reactor comprising: a chamber comprising a plurality of metal interior walls and at least one valve door, wherein the chamber encloses a structured sorbent capable of adsorbing CO2from the atmosphere or CO2point sources; and at least one insulation panel in contact with the plurality of metal interior walls and the at least one valve door and comprising a plurality of layers, wherein the plurality of layers comprises: a conforming layer in surface contact with, and covering, the plurality of metal interior walls and the at least one valve door; an insulating layer in surface contact with, and covering, the conforming layer; a protective layer in surface contact with, and covering, the insulating layer; a rigid retaining layer in surface contact with, and covering, the protective layer and, optionally, between the protective layer and an array of retaining features; and the array of retaining features in surface contact with, and covering, the insulating layer and the protective layer, wherein the array of retaining features compresses the conforming layer and passes through overlapping holes formed in the conforming layer, the insulating layer, and the protective layer of the at least one insulation panel.

12. The sorbent reactor of claim 11, wherein the array of retaining features comprises at least one threaded stud affixed to the plurality of metal interior walls and the at least one valve door and at least one fastener interfacing with each of the at least one threaded studs, wherein the at least one fastener is in physical contact with the insulating layer or the protective layer and, wherein the array of retaining features are tightened to compress the conforming layer.

13. The sorbent reactor of claim 11, wherein the overlapping holes formed in the insulating layer of the at least one insulation panel are counterbored to a width of at least a diameter of the array of retaining features.

14. The sorbent reactor of claim 11, wherein the at least one insulation panel is discretized into aplurality of segments, wherein the plurality of segments covers portions of the plurality of interior metal walls and the at least one valve door, and wherein each of the plurality of segments are disconnected from each other.

15. The sorbent reactor of any one of claims 11-14, wherein the conforming layer comprises a silicone rubber.

16. The sorbent reactor of any one of claims 11-14, wherein the insulating layer comprises a polyisocyanurate foam.

17. The sorbent reactor of any one of claims 11-14, wherein the protective layer comprises a silicone spray.

18. The sorbent reactor of any one of claims 11-14, wherein the rigid retaining layer comprises a metal or carbon fiber.

19. The sorbent reactor of claim 18, wherein the rigid retaining layer comprises a single continuous sheet.

20. The sorbent reactor of claim 18, wherein the rigid retaining layer comprises a honeycomb sheet, a mesh, or a planar sheet having holes formed within its surface area.

Images