Flow and heat generator assemblies for carbon dioxide capture systems and methods of use

Abstract

A flow and heat generator (FHG) assembly for a direct air carbon dioxide capture (DACC) system including an air inlet duct in flow communication with a carbon dioxide capture assembly of the DACC system. The air inlet duct receives ambient air to generate an induced air flow. The FHG assembly also includes a compressor for receiving the ambient air to generate a compressed air flow, and a heat exchanger downstream from the compressor form receiving the compressed air flow. Additionally, the FHG assembly includes a nozzle component in flow communication with the heat exchanger. The nozzle component includes an outlet in flow communication with the air inlet duct for injecting the compressed air flow into the air inlet duct to mix with the induced air flow. The heat exchanger of the FHG assembly is also in fluid communication with a carbon capture assembly of the DACC system.

Description

FLOW AND HEAT GENERATOR ASSEMBLIES FOR CARBON DIOXIDE CAPTURESYSTEMS AND METHODS OF USETECHNICAL FIELD

[0001] The disclosure relates generally to direct air carbon dioxide capture (DACC) systems, and more particularly, to flow and heat generator (FHG) assemblies for use by DACC systems and methods use of same.BACKGROUND

[0002] At least some known direct air carbon dioxide capture (DACC) systems include a plurality of components that generate air for the system. For example, at least some conventional DACC systems include a plurality of independent fans (e.g., fan walls) that draw in ambient air to be processed by the DACC system. Such fan walls can sometimes include over 100 individual fans, resulting in increased complexity and potential inefficiencies in the overall operation of the DACC system. For example, each individual fan requires maintenance and up-keep to ensure that an optimum amount of air is being drawn into the DACC system.

[0003] Additionally, even when operating under optimal parameters, the DACC system requires a large number of fans because of the high load demand required by the DACC system. That is, the fans used in these conventional intake systems do not generate a large enough load individually to supply enough air to DACC system for processing. As a result, most conventional intake systems are forced to incorporate a large number of fans, which in turn also exponentially increases the size, the operating cost, and the footprint of the DACC system.

[0004] Furthermore, additional components downstream from the conventional intake system (e.g., fan walls) are sometimes required in the DACC system. For example, where the size of the fan wall is constrained and cannot include a large footprint, the plurality of fans of the constrained fan wall are ty pically not capable of flowing the air through the DACC system at a desired or optimum flow rate. As such, the DACC system may be formed in various stages. Additionally, some conventional DACC systems typically include at least one heat exchanger utilized in the desorption process for captured carbon dioxide (CO2) as the air flows through the DACC. The additional components or parts of the DACC system required to process the intake air downstream of the fans also increasesthe complexity, potential inefficiencies, cost, and size of the DACC system.BRIEF DESCRIPTION

[0005] A first aspect provides an flow and heat generator (FHG) assembly for a direct air carbon dioxide capture (DACC) system. The FHG assembly includes an air inlet duct in flow communication with a carbon dioxide capture assembly of the DACC system. The air inlet duct receives ambient air to generate an induced air flow. The FHG assembly also includes a compressor adjacent to the air inlet duct, wherein the compressor is oriented to receive the ambient air to generate a compressed air flow. Moreover, the FHG assembly includes a heat exchanger downstream from the compressor, wherein the heat exchanger is in flow communication with the compressor to receive the compressed air flow. The FHG assembly also includes a nozzle component in flow communication with the heat exchanger. The nozzle component includes an outlet in flow communication with the air inlet duct for injecting the compressed air flow into the air inlet duct to mix with the induced air flow.

[0006] In a second aspect, a direct air carbon dioxide capture (DACC) system is provided. The DACC system includes a carbon dioxide capture assembly, a compression train in flow communication with the carbon dioxide capture assembly, and a plurality of flow' and heat generator (FHG) assemblies upstream from and in direct flow communication with the carbon dioxide capture assembly. Each of the plurality of FHG assemblies includes an air inlet duct in flow communication with the carbon dioxide capture assembly. The air inlet duct receives ambient air to generate an induced air flow. Each of the plurality of FHG assemblies also include a compressor adjacent to the air inlet duct, wherein the compressor is oriented to the ambient air to generate a compressed air flow. Additionally, each of the plurality of FHG assemblies include a heat exchanger downstream from the compressor, wherein the heat exchanger in flow communication with the compressor to receive the compressed air flow. Moreover, each of the plurality of FHG assemblies include a nozzle component in flow communication with the heat exchanger. The nozzle component includes an outlet in flow communication with the air inlet duct for injecting the compressed air flow into the air inlet duct to mix with the induced air flow.

[0007] In another third aspect, a method of providing air to a carbon dioxide capture assembly of a direct air carbon dioxide capture (DACC) system is provided. The method includes generating compressed air flow in a compressor using ambient air, and extractingheat from the compressed air flow using a heat exchanger in flow communication with the compressor. The method also includes injecting the compressed air flow into an air inlet duct using a nozzle in flow communication with the heat exchanger and the air inlet duct. The air inlet duct is in flow communication with the carbon dioxide capture assembly of the DACC system. Additionally, the method includes mixing the injected, compressed air flow with an induced air flow flowing through the air inlet duct, and flowing the mixture of the compressed air flow and the induced air flow to the carbon dioxide capture assembly of the DACC system using the air inlet duct.

[0008] The illustrative aspects of the present disclosure are designed to solve the problems herein described and / or other problems not discussed.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure, in which:

[0010] FIG. 1 is a schematic illustration of an exemplary direct air carbon dioxide capture (DACC) system including a flow and heat generator (FHG) assembly, a carbon dioxide capture assembly , and a compression train.

[0011] FIG. 2 is a side cross-sectional illustration of the flow and heat generator (FHG) assembly of FIG. 1.

[0012] FIG. 3 is a side cross-sectional illustration of an exemplary FHG assembly of a DACC system.

[0013] FIG. 4 is a side cross-sectional illustration of another exemplary FHG assembly of a DACC system.

[0014] FIG. 5 is a flowchart illustrating an exemplary process for providing air to a carbon dioxide capture assembly of a direct air carbon dioxide capture (DACC) system.

[0015] It is noted that the drawings of the disclosure are not to scale. The drawings are intended to depict only Npical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering represents like elements between the drawings.DETAILED DESCRIPTION

[0016] The embodiments described herein relate to flow and heat generator (FHG) assemblies for use with direct air carbon dioxide capture (DACC) systems that use a compressor to facilitate air flow through the DACC. While a group of fans or a fan wall are ty pically used to move air into and through the DACC system for removing carbon dioxide from the air, the FHG assemblies described herein utilize an air inlet duct, a modified compressor, and a nozzle injector to move air into and through the DACC system more effectively. A single FHG assembly, including a single air inlet duct, modified compressor, and nozzle injector can replace a plurality of conventional fans used to draw air into the DACC system for processing, can thus improve the efficiency of the DACC. Additionally, because the temperature of a portion of the air is increased during compression, the DACC system using the FHG assemblies discussed herein may utilize the heat and / or a heat exchange with the intake air to aid the DACC system in the carbon dioxide (CO2) release or desorption process within the DACC system. Furthermore, the air injected into the air inlet duct at a high flow rate / speed eliminates the need of additional fans or blowers, downstream from the inlet, for moving the air through the DACC system during operation. Moreover, the air injected at the higher flow rate / speed into the air inlet duct also creates an entrainment effect within the air inlet duct, which results in additional air being drawn into the system via the air inlet duct. The heat exchanger can remove or extract a portion of heat from the compressed air and provide that heat to distinct portions of the DACC system for CO2 release and capture, thus eliminating the need for an independent heat source, heat exchanger loop or heating element.

[0017] At least some benefits of the flow and heat generator (FHG) assemblies utilized within a DACC system include: a) less components or parts forming an intake assembly for the DACC system; b) the elimination of additional blowers and / or heaters downstream of the FHG assembly; c) a greater volume of air being drawn into the DACC system as a result of the entrainment effect; and d) a closed loop heat exchanger system that utilizes heat / energy transferred from the compressed air generated in the FHG assembly for use as CChrelease energy required in the DACC system. Additional benefits realized by the FHG assemblies may include reduced maintenance time and demand because of the simplification and / or reduction in components to form the FHG assemblies when compared to conventional intake configurations (e.g., fan walls), as well as a smaller footprint and / or more compact DACC system based on the reduced size of the FHG assemblies.

[0018] Unless otherwise indicated, approximating language, such as “generally,” “substantially,” and “about,” as used herein indicates that the term so modified may apply to only an approximate degree, as would be recognized by one of ordinary skill in the art, rather than to an absolute or perfect degree. Accordingly, a value modified by a term or terms such as “about,” “approximately,” and “substantially” is not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Additionally, unless otherwise indicated, the terms “first.” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, for example, a “second” item does not require or preclude the existence of, for example, a “first” or lower-numbered item or a “third” or higher-numbered item.

[0019] In addition, several descriptive terms may be used regularly herein, and it should prove helpful to define these terms at the onset of this section. These terms and their definitions, unless stated otherwise, are as follows. As used herein, “downstream” and “upstream” are terms that indicate a direction relative to the flow of a fluid, such as the working fluid through the turbine engine or, for example, the flow of air through the combustor or coolant through one of the turbine's component systems. The term “downstream” corresponds to the direction of flow of the fluid, and the term “upstream” refers to the direction opposite to the flow. The terms “forward” and “aft.” without any further specificity, refer to directions, with “forward” referring to the front or compressor end of the engine, and “aft” referring to the rearward or turbine end of the engine. It is often required to describe parts that are at differing radial positions with regard to a center axis. The term “radial” refers to movement or position perpendicular to an axis. In cases such as this, if a first component resides closer to the axis than a second component, it will be stated herein that the first component is “radially inw ard” or “inboard” of the second component. If, on the other hand, the first component resides further from the axis than the second component, it may be stated herein that the first component is “radially outward” or “outboard” of the second component. The term “axial” refers to movement or position parallel to an axis. Finally, the term “circumferential” refers to movement or position around an axis. It will be appreciated that such terms may be applied in relation to the center axis of the turbine.

[0020] FIG. 1 is a schematic illustration of an exemplary direct air car / / bon dioxide capture system 100 (hereafter, “DACC system 100”). In the exemplary embodiment, DACC system 100 includes at least one flow and heat generator assembly 102 (hereafter, ”FHG assembly 102”), at least one carbon dioxide capture assembly 104 (hereafter, "‘CC assembly 104”), and at least one compression train 106. The FHG assembly 102 is upstream from CC assembly 104. Additionally, FHG assembly 102 is fluidly coupled and / or in flow / fluid communication with CC assembly 104. In the example embodiment shown in FIG. 1. and as discussed herein, FHG assembly 102 includes an air inlet duct 108 that is in flow communication with, and / or fluidly coupled to, CC assembly 104 to facilitate providing air directly to CC assembly 104 of DACC system 100. Exemplary embodiments of the various components and / or portions forming FHG assembly 102 are discussed in detail herein with respect to FIGs. 2-4.

[0021] CC assembly 104 is downstream from FHG assembly 102. CC assembly 104 receives air and heat from FHG assembly 102, and subsequently processes the air to remove and / or separate carbon dioxide (CO2) from the received air. CC assembly 104 is formed as any suitable assembly, apparatus, and / or sub-system that facilitates removing and / or separating carbon dioxide (CO2) from the air provided by FHG assembly 102. Additionally, CC assembly 104 of DACC system 100 is formed from any suitable assembly, apparatus, and / or sub-system that utilizes heat to facilitate the removal and / or separation of carbon dioxide (CO2) from the air provided by FHG assembly 102. In exemplary embodiments, CC assembly 104 is formed as a physical or chemical solventbased carbon dioxide capture assembly or as a physical or chemical sorbent-based carbon dioxide capture assembly. In other exemplary embodiments, CC assembly 104 is formed as a cryogenic carbon dioxide capture assembly, a membrane carbon dioxide capture assembly, an electro-chemical carbon dioxide capture assembly, and / or a hybrid carbon dioxide capture assembly. In the exemplary embodiment shown in FIG. 1, and as discussed herein, heat is exchanged between FHG assembly 102 and CC assembly 104, via inlet conduit 110 and outlet conduit 112, respectively, during operation of DACC system 100.

[0022] Compression train 106 is downstream from and is in flow communication with CC assembly 104. In the exemplary embodiment shown in FIG. 1, compression train 106 receives the carbon dioxide (CO2) removed and / or separated from the air that flowed through CC assembly 104 and subsequently compresses the carbon dioxide (CO2). The compression train 106 receives the carbon dioxide (CO2) from the air CC assembly 104 viaa conduit 118. The compressed carbon dioxide (CO2) 119 is then removed from compression train 106 and processed in any suitable manner including, but not limited to, storage and / or transportation. In a non-limiting example, compression train 106 includes a series of compressors and heat exchangers that receive, compress, and / or cool the carbon dioxide (CO2) 119 to perform or facilitate post compression train processing (e.g., storage).

[0023] It is understood that DACC system 100 can include a plurality of flow and heat generator (FHG) assemblies 102. In the exemplary’ embodiment shown in FIG. 1, DACC system 100 includes a plurality’ of FHG assemblies 102. 102A (FHG assembly 102A shown in phantom), that are each upstream from, and in flow communication with, CC assembly 104 for providing air to CC assembly 104, as discussed herein. The number of FHG assemblies 102, 102A included in DACC system 100 is dependent, at least in part, on the size of CC assembly 104, the number of CC assemblies 104, the processing demand of carbon dioxide (CO2) for DACC system 100, the size of FHG assemblies 102, 102A, and / or parameters for components forming the FHG assemblies 102, 102A (e.g., size of air inlet duct 108, load capacity of compressor, etc.).

[0024] FIG. 2 is a cross-sectional side illustration of an exemplary FHG assembly 102 included in DACC system 100. Specifically, FIG. 2 depicts a side cross-sectional view of an upper portion of the various components and / or assemblies forming FHG assembly 102. As discussed herein, air flows from air inlet duct 108 to CC assembly 104 (see, FIG. 1), wherein carbon dioxide (CO2) is separated and / or removed prior to being compressed by compression train 106 and compressed carbon dioxide (CO2) 119 is subsequently- processed (e.g., stored, transported).

[0025] In the exemplary embodiment shown in FIG. 2, air inlet duct 108 includes an opening 120 defined therein. Opening 120 is exposed, open, and / or in flow communication with the ambient air 122 surrounding DACC system 100. As discussed herein, opening 120 receives and / or facilitates ambient air 122 to flow therethrough to generate an induced air flow 124. With reference to FIG. 1, air inlet duct 108 is fluidly coupled to and / or in direct flow communication with CC assembly 104 of DACC system 100. The induced air flow 124 flows downstream from opening 120 toward CC assembly 104 during operation. The air inlet duct 108 can be formed from any component and / or structure that facilitates the receiving, entrainment, and / or the flowing of induced air flow 124 through air inlet duct 108 to CC assembly 104. In an exemplary- embodiment, air inlet ducts 108 can be formed as a substantially annular-conical structure or as an annulus square / rectangular structure.

[0026] In the exemplary embodiment, the FHG assembly 102 of DACC system 100 also includes a compressor 126. Moreover, as shown in FIG. 2, in the exemplary' embodiment compressor 126 is adjacent to air inlet duct 108. More specifically, an opening 128 of compressor 126 is positioned adjacent to opening 120 of air inlet duct 108, and compressor 126 extends within FHG assembly 102 substantially adjacent to air inlet duct 108. Similar to opening 120, opening 128 of compressor 126 is exposed, open, and / or in flow communication with the ambient air 122 surrounding DACC system 100. During operation, and as discussed herein, opening 128 receives and / or facilitates ambient air 122 to flow therethrough to generate a compressed air flow 130.

[0027] Compressor 126 of FHG assembly 102 can include a plurality of compressor stages 132. For example, in the exemplary embodiment, compressor 126 includes three compressor stages 132A. 132B, 132C. Each compressor stage 132A, 132B. 132C includes a plurality of blades 134A, 134B, 134C coupled to a rotor 136 of compressor 126, and a plurality of stator vanes 138A, 138B, 138C adjacent to and upstream each of the plurality of rotating blades 134A, 134B, 134C. Stator vanes 138A, 138B, 138C are coupled and / or secured to a housing 140 of compressor 126 and each extends toward rotor 136. The exemplary embodiment also includes an exit stator vane 141 positioned adjacent to and downstream blade 134C of the final or most-downstream compressor stage of rotating blades 134C. Exit stator vane 141 facilitates floyving and / or guiding compressed air flow 130 out of and / or away from compressor 126. Similar to stator vanes 138A, 138B, 138C, exit stator vane 141 is coupled and / or secured to a housing 140 of compressor 126. Although the exemplary embodiment includes three (3) compressor stages 132A, 132B, 132C, it is understood that compressor 126 can include any suitable number of compressor stages 132 to compress ambient air 122 and generate compressed air flow 130, as discussed herein. For example, compressor 126 can include more or less compressor stages 132 or more compressor stages 132. Additionally, compressor 126 may or may not include exit stator vane 141 doyvnstream the final compressor stage of compressor 126 (see e.g., FIGs. 3 and 4).

[0028] The exemplary embodiment of FHG assembly 102 can also include a heat exchanger 142 downstream from compressor 126. Heat exchanger 142 is fluidly coupled and / or in flow communication with compressor 126 to receive compressed air flow 130. As discussed herein, heat exchanger 142 can remove or extract a portion of the heat from compressed air flow 130 flowing through heat exchanger 142 during operation andfacilitate the transferring the extracted heat to a distinct component of DACC system 100. In the exemplary embodiment, inlet conduit 110 and outlet conduit 112 are fluidly coupled and / or in flow communication with heat exchanger 142. As such, heat exchanger 142 can be provided, transferred, and / or exchanged the portion of heat extracted from compressed air flow 130 with a component of CC assembly 104 that utilizes heat during operation of DACC system 100 (e.g., a heat exchanger, a condenser, etc.).

[0029] FHG assembly 102 of DACC system 100 also includes a nozzle component 144. Nozzle component 144 is downstream from and in flow communication with heat exchanger 142. More specifically, nozzle component 144 is directly downstream from and fluidly coupled / in direct flow communication with heat exchanger 142 for receiving the compressed air flow 130 from heat exchanger 142. Additionally in the exemplary' embodiment, nozzle component 144 is between heat exchanger 142 and a portion of air inlet duct 108. Nozzle component 144 is also fluidly coupled and / or in flow communication with air inlet duct 108. In the non-limiting example shown in FIG. 2, nozzle component 144 includes an outlet 146 that is fluidly coupled and / or in direct flow communication with air inlet duct 108, downstream of opening 120. As discussed herein, outlet 146 injects the compressed air flow 130 directly into air inlet duct 108 to mix with the induced air flow 124. In an exemplary embodiment, nozzle component 144 is formed as a substantially conical structure, and outlet 146 has a predetermined diameter (D) that is smaller than a diameter of an inlet 148 of nozzle component 144 directly adjacent heat exchanger 142. The predetermined diameter (D) of outlet 146 for nozzle component 144 is dependent and / or based on, at least in part, air flow characteristics for the induced air flow 124 flowing through air inlet duct 108, the compressed air flow 130 flowing through nozzle component 144, and / or CC assembly 104 of DACC system 100 and is variably selected to optimize the flow, pressure and / or injection of the compressed air flow 130 into air inlet duct 108, as discussed herein.

[0030] As discussed herein, FHG assembly 102 uses ambient air 122 to generate a flow that is provided to CC assembly 104 for carbon dioxide (CO2) removal / separate, and subsequent processing (e.g., storage) of the removed carbon dioxide (CO2). In the exemplary embodiment, air inlet duct 108 of FHG assembly 102 receives and / or draws in ambient air 122 to generate, create, and / or form an induced air flow 124. That is, the ambient air 122 drawing into air inlet duct 108 forms induced air flow 124 that flows through air inlet duct 108 toward CC assembly 104 of DACC system 100, as discussedherein. Additionally in the exemplary embodiment, and as discussed herein, ambient air 122 / induced air flow 124 is entrained into opening 120 and / or through air inlet duct 108 because of injecting and / or mixing compressed air flow 130 into air inlet duct 108 via nozzle component 144.

[0031] Simultaneous to ambient air 122 flowing through opening 120 of air inlet duct 108, ambient air 122 flows through and / or is drawn into compressor 126 via opening 128. Compressor 126 facilitates the compression of ambient air 122 to form, create, and / or generate compressed air flow 130. In the exemplary embodiment, ambient air 122 flows through the plurality compressor stages 132A, 132B, 132C, and each subsequent stage facilitates the stepped and / or increased compression of ambient air 122 to form compressed air flow7130. Compressed air flow 130 is subsequently ejected downstream of compressor 126, and more specifically, from the final compressor stage 132C of compressor 126. In addition to compressing ambient air 122 to generate compressed air flow 130, the pressure and / or the temperature of ambient air 122 is increased as the ambient air 122 is compressed by compressor 126. That is, and in the exemplary embodiment, compressed air flow 130 generated by compressor 126 has a greater pressure and / or a higher temperature than ambient air 122 flowing through opening 128 and / or supplied to compressor 126 for compression.

[0032] The compressed air flow 130 exiting and / or ejected from compressor 126 flows directly into heat exchanger 142. As discussed herein, compressed air flow 130 flowing through heat exchanger 142 has an increased temperature compared to ambient air 122 / induced air flow 124. Heat exchanger 142 can remove or extract a portion of the heat from compressed air flow7130 flowing through heat exchanger 142 and transfer the extracted portion of heat to a distinct component of D ACC system 100. In the exemplary embodiment, the heat / energy extracted, absorbed, and / or exchanged between heat exchanger 142 and compressed air flow 130 can be transferred from heat exchanger 142 to a distinct component (e.g., CO2 reboiler) of CC assembly 104 via outlet conduit 112 and via a working fluid flowing through outlet conduit 112, inlet conduit 110. and heat exchanger 142. The heat / energy transferred via heat exchanger 142 enables the heat to be used during operation of CC assembly 104 to facilitate removing and / or separating carbon dioxide (CO2) from the air provided by FHG assembly 102, as discussed herein.. In an example, CC assembly 104 is in flow7communication with air inlet duct 108 of FHG assembly 102 to remove the CO2 from the air. Additionally, CC assembly 104is also inflow communication and / or fluidly coupled to heat exchanger 142, via inlet conduit 110 and outlet conduit 112, to provide heat removed from air flow 130 to improve operation of a distinct portion of CC assembly 104 (e.g., CO2 reboiler). Heat exchanger 142 can convectively transfer the heat / energy extracted from compressed air flow 130 to, for example a CO2 reboiler of CC assembly 104, via inlet conduit 110 (and the working fluid flowing therein),. The CO2 reboiler of CC assembly 104 can utilized the transferred heat from heat exchanger 142 to vaporize a liquid, and then can subsequently provide the working fluid back to heat exchanger 142 via outlet conduit 112 for continued heat transfer during operation.

[0033] Although discussed herein as a CO2 reboiler of CC assembly 104, it is understood that heat exchanger 142 of FHG assembly 102 can be in flow communication with any distinct component of CC assembly 104 that can utilize the heat removed from air flow 130 during operation. That is, and dependent on, at least in part, the type of CC assembly (e g., sorbent-based, solvent-based, etc.), heat exchanger 142 is in flow communication with at least one component of CC assembly 104 for providing and / or exchanging the heat removed from air flow 130 during operation.

[0034] Heat exchanger 142 ejects compressed air flow 130 into nozzle component 144. Nozzle component 144 receives compressed air flow 130 and subsequently flows, introduces, and / or injects compressed air flow 130 directly into air inlet duct 108. In the exemplary embodiment, nozzle component 144 is in direct flow communication with air inlet duct 108 and can inject compressed air flow 130 into air inlet duct 108 via outlet 146. Injecting compressed air flow 130 directly into air inlet duct 108 facilitates the mixing of compressed air flow 130 with induced air flow 124 within air inlet duct 108 downstream of nozzle component 144. As such, the air flowing from air inlet duct 108 of FHG assembly 102 to CC assembly 104 includes a mixture of induced air flow 124 and compressed air flow 130.

[0035] As discussed herein, compressed air flow 130 has a temperature and / or a pressure that is higher than a temperature and / or pressure of induced air flow' 124. As a result, w hen compressed air flow 130 is injected into air inlet duct 108 and subsequently mixed with induced air flow 124 a momentum exchange can take place within air inlet duct 108 between induced air flow' 124 and compressed air flow 130. In an exemplary embodiment, the pressure of induced air flow' 124 is increased after the air flow 124 is injected and / or after being mixed with compressed air flow 130, to a pressure level necessary to overcomethe flow resistance of CC System, 104.

[0036] As discussed herein, outlet 146 of nozzle component 144 has a predetermined diameter (D) based on air flow characteristics of induced air flow 124, compressed air flow 130 and / or DACC system 100. For example, the predetermined diameter (D) may be variably sized based a flow rate or flow speed of induced air flow 124 moving through air inlet duct 108, a flow rate or flow speed of compressed air flow 130 exiting heat exchanger 142, and / or flow rate or flow speed requirements for air traveling through air inlet duct 108 to reach and flow through DACC system 100 for carbon dioxide (CO2) separation and / or removal, as discussed herein. Considering these flow characteristics, the predetermined diameter (D) of outlet 146 is sized to enable compressed air flow to be injected 130 into air inlet duct 108 at an increased flow rate or flow speed. In the exemplary embodiment, the predetermined diameter (D) of outlet 146 facilitates increasing the flow rate or speed of compressed air flow 130 as it is injected into air inlet duct 108 via nozzle component 144. As such, compressed air flow 130 is injected into air inlet duct 108 at a flow rate or speed that is higher than the flow rate or speed of the induced air flow 124 traveling through air inlet duct 108. This in turn creates a Coanda effect within air inlet duct 108, wherein the mixing of induced air flow 124 and compressed air flow 130 increases the flow rate or flow speed of induced air flow 124, downstream from nozzle component 144. In addition to increasing the flow rate or flow speed of induced air flow 124 within air inlet duct 108, injecting compressed air flow 130 at the increased flow rate or speed also creates an entrainment effect within air inlet duct 108. For example, injecting compressed air flow 130 into air inlet duct 108 at a flow rate or flow speed greater than induced air flow 124 (and ultimately creating a Coanda effect) entrains additional ambient air 122 to flow through opening 120 and into air inlet duct 108.

[0037] The increased temperature and / or pressure of the mixture of induced air flow 124 and compressed air flow 130 facilitates improving the efficiency of CC assembly 104 when removing carbon dioxide (CO2) from the mixture, as discussed herein. In the exemplary embodiment, and because of the injected flow rate or flow' speed of compressed air flow 130 into air inlet duct 108, CC assembly 104 does not require additional fans and / or blowers to move through CC assembly 104 during processing. Rather, FHG assembly 102 can provide the mixture of induced air flow 124 and compressed air flow 130 to CC assembly 104 at a desired flow rate or flow' speed during operation, as well as provide the needed heat from heat exchanger 142 to facilitate CO2 release in the CC assembly 104(e.g., exchange with CO2 boiler).

[0038] FIGs. 3 and 4 are cross-sectional side view illustrations of additional exemplary embodiments of FHG assembly 102 that may be included in DACC system 100. It is understood that similarly numbered and / or named components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity.

[0039] In the exemplary embodiment shown in FIG. 3, a portion of nozzle component 144 extends into air inlet duct 108. More specifically, outlet 146 of nozzle component 144 extends into, is disposed within, and / or is positioned directly within air inlet duct 108. During operation, induced air flow 124 flows around a portion of nozzle component 144 and / or outlet 146 as induced air flow 124 flows through air inlet duct 108. In the nonlimiting example, outlet 146 extending into air inlet duct 108 allows for compressed air flow 130 to be injected into a central portion of air inlet duct 108 rather than adjacent a sidewall of air inlet duct 108 (see, FIGs. 2 and 4). Injecting compressed air flow 130 into a central portion of air inlet duct 108 may more evenly disrupt and / or mix compressed air flow 130 with induced air flow 124 within air inlet duct 108, prior to the mixture flowing to CC assembly 104.

[0040] In the exemplary embodiment of FIG. 4, a portion of nozzle component 144 extends into air inlet duct 108, directly adjacent a sidewall 150 of air inlet duct 108. As shown, outlet 146 of nozzle component 144 is positioned within air inlet duct 108, directly adjacent sidewall 150. During operation, compressed air flow 130 is injected into air inlet duct 108, via outlet 146, directly adjacent sidewall 150. Distinct from the exemplary embodiment shown and discussed herein with respect to FIG. 3, injecting compressed air flow 130 directly adjacent sidewall 150 of air inlet duct 108 provides a concentration of compressed air flow 130 in the mixture of induced air flow 124 and compressed air flow 130 to flow directly adjacent sidewall 150, prior to flowing to CC assembly 104.

[0041] Additionally in the exemplary embodiment shown in FIG. 4, air inlet duct 108 substantially surrounds compressor 126. Distinct from the non-limiting examples shown in FIGs. 2 and 3, air inlet duct 108 is directly adjacent to and substantially surrounds compressor 126. Air inlet duct 108 also envelops compressor 126. Opening 120 of air inlet duct 108 and opening 128 of compressor 126 are positioned directly adjacent one another and / or at least a portion of air inlet duct 108 near opening 120 is supported by and / or coupled to compressor 126.

[0042] The compressor 126 shown in the exemplary' embodiment also includes four (4) compressor stages 132A. 132B, 132C, 132D. As similarly discussed herein w ith respect to FIG. 2, each compressor stage 132A, 132B, 132C, 132D includes a plurality of rotating blades 134A, 134B, 134C, 134D coupled to rotor 136 of compressor 126, and a plurality of stator vanes 138A, 138B, 138C, 138D adjacent to and upstream of the plurality7of rotating blades 134A, 134B, 134C, 134D. Stator vanes 138A, 138B, 138C, 138D are coupled and / or affixed to housing 140 of compressor 126 and each extend toward rotor 136.

[0043] FIG. 5 illustrates an exemplary process for flowing air through a direct air carbon dioxide capture (DACC) system. Specifically, FIG. 5 illustrates a flowchart depicting an exemplary7process for providing air to a carbon dioxide capture assembly (“CC assembly”) of a DACC system. In some cases, the processes can be performed using DACC system, as discussed above with respect to FIGs. 1-4.

[0044] In process Pl, compressed air flow' is generated. More specifically, compressed air flow' is generated in a compressor of an flow' and heat generator (FHG) assembly included in a direct air carbon dioxide capture (DACC) system using ambient air surrounding the DACC system. Generating the compressed air flow also includes increasing the pressure of the ambient air flowing through the compressor to form the compressed air flow, and increasing the temperature of the ambient air flow ing through the compressor to form the compressed air.

[0045] In process P2, heat is extracted from the compressed air flow. Heat can be removed or extracted from the compressed air flow using a heat exchanger included in the FHG assembly. The heat exchanger can be downstream from and in flow' communication with the compressor to receive the generated compressed air, and subsequently extract and / or exchange heat with the compressed air.

[0046] In process P3, the extracted heat is provided to a distinct component of the DACC system. More specifically, the extracted heat from the compressed air flow is provided and / or transferred to a carbon dioxide capture assembly (‘’CC assembly”) of the DACC system. In an exemplary embodiment, the heat exchanger of the FHG assembly is fluidly coupled and / or in flow communication with CC assembly and / or a component of CC assembly (e.g., CO2 reboiler). CC assembly of DACC system can utilize the provided and / or transferred heat from heat exchanger during operation of the DACC system.

[0047] In process P4, the previously compressed air flow7(e.g., process Pl) is injected into an air inlet duct using a nozzle in flow communication with the heat exchanger and the airinlet duct. In an exemplary embodiment, an outlet of a nozzle is coupled to, extends within, and / or is in flow communication with the air inlet duct to facilitate the injection of the previously compressed air flow directly into the air inlet duct. The air inlet duct is fluidly- coupled to and / or in flow communication with the CC assembly of the DACC system. Additionally, and similar to the compressor, the air inlet duct of the FHG assembly receives ambient air to generate an induced air flow that flows through air inlet duct to the CC assembly. Injecting the previously compressed air flow into the air inlet duct can also include entraining the induced air flow flowing through the air inlet duct. More specifically, the compressed air flow can be injected into the air inlet duct at a predetermined flow rate and / or flow speed to create an entrainment effect within the air inlet duct. The entrainment effect facilitates the (continuous) drawing of induced air flow through the air inlet duct.

[0048] In process P5, the injected, previously compressed air flow is mixed with the induced air flow flowing through the air inlet duct. In the exemplary embodiment, the injecting of the previously compressed air flow into the air inlet duct facilitates the mixing of the injected, compressed air flow and the induced air flow located and flowing within the air inlet duct. Mixing the injected, compressed air flow and the induced air flow within the air inlet duct also may increase the pressure of the induced air flow flowing to the CC assembly (see, process P6). Additionally , mixing the injected, compressed air flow and the induced air flow within the air inlet duct includes increasing the flow rate or the flow speed of the induced air flow flowing through the air inlet duct.

[0049] In process P6, the mixture of the previously compressed air flow and the induced air flow is flowed to the CC assembly. In the exemplary- embodiment, the mixture of the compressed air flow and the induced air flow is flowed to the CC assembly via the air inlet duct. Once supplied to the CC assembly of the DACC system, carbon dioxide (CO2) can be separated from and / or removed from the mixture of the compressed air flow and the induced air flow, and subsequently compressed by a compression train of the DACC system, and processed (e.g., stored, transported, etc.).

[0050] At least some technical effects are to provide FHG assemblies for direct air carbon dioxide capture systems that utilizes a compressor and a nozzle to increase the flow rate of air flowing through the system, while also increasing the amount of air drawn into the system and reducing the number of components utilized to form the FHG assembly and a carbon capture assembly of the DACC system.

[0051] The foregoing drawings show some of the processing associated according to several embodiments of this disclosure. In this regard, each drawing or block within a flowdiagram of the drawings represents a process associated with embodiments of the method described. It should also be noted that in some alternative implementations, the acts noted in the drawings or blocks may occur out of the order noted in the figure or, for example, may in fact be executed substantially concurrently or in the reverse order, depending upon the act involved. Also, one of ordinary skill in the art will recognize that additional blocks that describe the processing may be added.

[0052] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as w ell, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances w here the event occurs and instances where it does not.

[0053] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. “Approximately” and / or “substantially” as applied to a particular value of a range applies to both values, and unless otherwise dependent on the precision of the instrument measuring the value, may indicate + / - 10% of the stated value(s).

[0054] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below' are intended to include any structure, material, or act for performing the function in combination with other claimed elements asspecifically claimed. The description of the present disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

[0055] Exemplary systems and methods that use flow and heat generator (FHG) assemblies for intaking and flowing air to carbon dioxide capture assemblies (“CC assemblies") of direct air carbon dioxide capture systems (“DACC systems'’) are described herein.Moreover, the systems and methods described herein facilitate increasing the overall DACC system efficiency to a level that is higher than possible with traditional air intake assemblies and / or methods for providing air to DACC systems. The exemplary systems and methods as described herein provide several advantages over conventional designs and processes, including increasing the efficiency and performance of providing air to the DACC system, while simultaneously increasing the efficiency and performance of heat exchangers found within the DACC system, downstream of the flow and heat generator (FHG) assembly. Moreover, the above-described systems and methods create an entrainment effect within an air inlet duct of the FHG assembly, facilitating a more effective and efficient intake of a greater volume of air into the FHG assembly.Furthermore, the above-described systems and methods facilitate the FHG assemblies to effectively and efficiently exchange heat with other components of the DACC system using heat extracted from the compressed air, for use in CO2 release in the CC assembly.

[0056] The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Modifications, which fall within the scope of the present invention, will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. The systems described herein are not limited to the specific embodiments described herein, but rather portions of the various systems may be utilized independently and separately from other systems described herein.

[0057] Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. Moreover, references to “one embodiment” in the above description are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. In accordance with the principles of the invention, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0058] Further aspects of the invention are provided by the subject matter of the following clauses:

[0059] A flow and heat generator (FHG) assembly for a direct air carbon dioxide capture (DACC) system, the FHG assembly comprising an air inlet duct in flow' communication with a carbon dioxide capture assembly of the DACC system, the air inlet duct receiving ambient air to generate an induced air flow, a compressor adjacent to the air inlet duct, the compressor oriented to receive the ambient air to generate a compressed air flow, a heat exchanger downstream from the compressor, the heat exchanger in flow' communication with the compressor to receive the compressed air flow, and a nozzle component in flow communication with the heat exchanger, the nozzle component including an outlet in flow communication with the air inlet duct for injecting the compressed air flow into the air inlet duct to mix with the induced air flow.

[0060] The FHG assembly in accordance with any of the preceding clauses, wherein the outlet of the nozzle component includes a predetermined diameter variably sized based on air flow characteristics for at least one of: the induced air flow, the compressed air flow, and the DACC system.

[0061] The FHG assembly in accordance w ith any of the preceding clauses, wherein the outlet of the nozzle component is directly adjacent to a sidewall of the air inlet duct.

[0062] The FHG assembly in accordance with any of the preceding clauses, wherein the outlet of the nozzle component extends into the air inlet duct.

[0063] The FHG assembly in accordance with any of the preceding clauses, w'herein the heat exchanger provides heat extracted from the compressed air flow to the DACC system.

[0064] The FHG assembly in accordance with any of the preceding clauses, wherein the air inlet duct surrounds the compressor.

[0065] The FHG assembly in accordance with any of the preceding clauses, wherein the compressor includes at least tw o compressor stages, wherein each compressor stage includes a plurality of blades coupled to a rotor, and a plurality of stator vanes adjacent toand upstream from the plurality7of blades, each of the plurality of stator vanes coupled to a housing of the compressor and extending towards the rotor.

[0066] A direct air carbon dioxide capture (DACC) system comprising a carbon dioxide capture assembly, a compression train in flow communication with the carbon dioxide capture assembly, and a plurality of flow and heat generator (FHG) assemblies upstream from and in direct flow communication with the carbon dioxide capture assembly, each of the plurality of FHG assemblies including an air inlet duct in flow communication with the carbon dioxide capture assembly, the air inlet duct receiving ambient air to generate an induced air flow, a compressor adjacent to the air inlet duct, the compressor oriented to the ambient air to generate a compressed air flow, a heat exchanger downstream from the compressor, the heat exchanger in flow communication with the compressor to receive the compressed air flow, and a nozzle component in flow communication with the heat exchanger, the nozzle component including an outlet in flow communication with the air inlet duct for injecting the compressed air flow7into the air inlet duct to mix with the induced air flow.

[0067] The DACC system in accordance with any of the preceding clauses, wherein the outlet of the nozzle component includes a predetermined diameter variably sized based on air flow7characteristics for at least one of: the induced air flow, the compressed air flow, and the DACC system.

[0068] The DACC system in accordance with any of the preceding clauses, wherein the outlet of the nozzle component is directly adjacent to a sidewall of the air inlet duct.

[0069] The DACC system in accordance with any of the preceding clauses, wherein the outlet of the nozzle extends into the air inlet duct.

[0070] The DACC system in accordance with any of the preceding clauses, wherein the heat exchanger is in flow communication with the carbon dioxide capture assembly to provide heat extracted from the compressed air flow7to the carbon dioxide capture assembly.

[0071] The DACC system in accordance with any of the preceding clauses, wherein the air inlet duct surrounds the adjacent compressor.

[0072] The DACC system in accordance with any of the preceding clauses, wherein the compressor includes at least two compressor stages, wherein each compressor stage includes a plurality of blades coupled to a rotor, and a plurality of stator vanes adjacent to and upstream from the plurality of blades, each of the plurality of stator vanes coupled to ahousing of the compressor and extending towards the rotor.

[0073] The DACC system in accordance with any of the preceding clauses, wherein the carbon dioxide capture assembly includes one of a physical or chemical solvent-based carbon dioxide capture assembly, a physical or chemical sorbent-based carbon dioxide capture assembly, a cryogenic carbon dioxide capture assembly, a membrane carbon dioxide capture assembly, an electro-chemical carbon dioxide capture assembly, and a hybrid carbon dioxide capture assembly.

[0074] A method of providing air to a carbon dioxide capture assembly of a direct air carbon dioxide capture (DACC) system, the method comprising generating compressed air flow in a compressor using ambient air, extracting heat from the compressed air flow using a heat exchanger in flow communication with the compressor, injecting the compressed air flow into an air inlet duct using a nozzle in flow communication with the heat exchanger and the air inlet duct, the air inlet duct in flow communication with the carbon dioxide capture assembly of the DACC system, mixing the inject, compressed air flow with an induced air flow flowing through the air inlet duct, and flowing the mixture of the compressed air flow and the induced air flow to the carbon dioxide capture assembly of the DACC system using the air inlet duct.

[0075] The method in accordance with any of the preceding clauses, w erein the generating of the compressed air flow further includes increasing a pressure of the ambient air flowing through the compressor, and increasing a temperature of the ambient air flowing through the compressor.

[0076] The method in accordance with any of the preceding clauses, wherein the injecting of the compressed air flow into the air inlet duct further includes entraining the induced air flow flowing through the air inlet duct.

[0077] The method in accordance with any of the preceding clauses, wherein the mixing of the compressed air flow and the induced air flow further includes increasing a pressure of the induced air flow prior to the mixture of the compressed air flow7and the induced air flow7flowing to the carbon dioxide capture assembly.

[0078] The method in accordance with any of the preceding clauses, further comprising providing the extracted heat from the compressed air flow7to the carbon dioxide capture assembly.

Claims

CLAIMSWhat is claimed is:

1. A flow and heat generator (FHG) assembly for a direct air carbon dioxide capture (DACC) system, the FHG assembly comprising: an air inlet duct in flow communication with a carbon dioxide capture assembly of the DACC system, the air inlet duct receiving ambient air to generate an induced air flow; a compressor adjacent to the air inlet duct, the compressor oriented to receive the ambient air to generate a compressed air flow; a heat exchanger dow nstream from the compressor, the heat exchanger in flow communication with the compressor to receive the compressed air flow; and a nozzle component in flow communication with the heat exchanger, the nozzle component including an outlet in flow communication with the air inlet duct for injecting the compressed air flow into the air inlet duct to mix with the induced air flow.

2. The FHG assembly of claim 1. wherein the outlet of the nozzle component includes a predetermined diameter variably sized based on air flow characteristics for at least one of: the induced air flow, the compressed air flow, and the DACC system.

3. The FHG assembly of claim 1, wherein the outlet of the nozzle component is directly adjacent to a sidewall of the air inlet duct.

4. The FHG assembly of claim 1, wherein the outlet of the nozzle component extends into the air inlet duct.

5. The FHG assembly of claim 1, wherein the heat exchanger provides heat extracted from the compressed air flow to the DACC system.

6. The FHG assembly of claim 1. wherein the air inlet duct surrounds the compressor.

7. The FHG assembly of claim 1, wherein the compressor includes at least two compressor stages, wherein each compressor stage includes: a plurality of blades coupled to a rotor; anda plurality of stator vanes adjacent to and upstream from the plurality of blades, each of the plurality' of stator vanes coupled to a housing of the compressor and extending towards the rotor.

8. A direct air carbon dioxide capture (DACC) system comprising: a carbon dioxide capture assembly; a compression train in flow communication with the carbon dioxide capture assembly; and a plurality of flow and heat generator (FHG) assemblies upstream from and in direct flow communication with the carbon dioxide capture assembly, each of the plurality of FHG assemblies including: an air inlet duct in flow communication with the carbon dioxide capture assembly, the air inlet duct receiving ambient air to generate an induced air flow; a compressor adjacent to the air inlet duct, the compressor oriented to the ambient air to generate a compressed air flow; a heat exchanger downstream from the compressor, the heat exchanger in flow communication with the compressor to receive the compressed air flow; and a nozzle component in flow communication with the heat exchanger, the nozzle component including an outlet in flow communication with the air inlet duct for injecting the compressed air flow into the air inlet duct to mix with the induced air flow.

9. The DACC system of claim 8, wherein the outlet of the nozzle component includes a predetermined diameter variably sized based on air flow characteristics for at least one of: the induced air flow, the compressed air flow, and the DACC system.

10. The DACC system of claim 8, wherein the outlet of the nozzle component is directly adjacent to a sidewall of the air inlet duct.

11. The DACC system of claim 8, wherein the outlet of the nozzle extends into the air inlet duct.

12. The DACC system of claim 8, wherein the heat exchanger is in flow communication with the carbon dioxide capture assembly to provide heat extracted fromthe compressed air flow to the carbon dioxide capture assembly.

13. The DACC system of claim 8, wherein the air inlet duct surrounds the adjacent compressor.

14. The DACC system of claim 8, wherein the compressor includes at least two compressor stages, wherein each compressor stage includes: a lurality of blades coupled to a rotor; and a plurality of stator vanes adjacent to and upstream from the plurality of blades, each of the plurality7of stator vanes coupled to a housing of the compressor and extending towards the rotor.

15. The DACC system of claim 8, wherein the carbon dioxide capture assembly includes one of: a physical or chemical solvent-based carbon dioxide capture assembly, a physical or chemical sorbent-based carbon dioxide capture assembly, a cryogenic carbon dioxide capture assembly, a membrane carbon dioxide capture assembly, an electro-chemical carbon dioxide capture assembly, and a hybrid carbon dioxide capture assembly.

16. A method of providing air to a carbon dioxide capture assembly of a direct air carbon dioxide capture (DACC) system, the method comprising: generating compressed air flow in a compressor using ambient air; extracting heat from the compressed air flow using a heat exchanger in flow communication with the compressor; injecting the compressed air flow into an air inlet duct using a nozzle in flow communication with the heat exchanger and the air inlet duct, the air inlet duct in flow communication with the carbon dioxide capture assembly of the DACC system; mixing the inject, compressed air flow with an induced air flow flowing through the air inlet duct; and flow ing the mixture of the compressed air flow' and the induced air flow' to the carbon dioxide capture assembly of the DACC system using the air inlet duct.

17. The method of claim 16, wherein the generating of the compressed air flow further includes: increasing a pressure of the ambient air flowing through the compressor; and increasing a temperature of the ambient air flowing through the compressor.

18. The method of claim 16, wherein the injecting of the compressed air flow into the air inlet duct further includes: entraining the induced air flow flowing through the air inlet duct.

19. The method of claim 16, wherein the mixing of the compressed air flow and the induced air flow further includes: increasing a pressure of the induced air flow prior to the mixture of the compressed air flow and the induced air flow flowing to the carbon dioxide capture assembly.

20. The method of claim 16, further comprising: providing the extracted heat from the compressed air flow to the carbon dioxide capture assembly.

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