System and method for controlling cycles of gas capture system

Abstract

Provided herein is a method for monitoring a sorbent-based gas capture system (20). The method includes monitoring at least one operating parameter of a sorbent-based gas capture system (20) configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system (20) comprises a plurality of stages including an adsorption stage (202), a desorption stage (204), and a cooling stage (206). The method further includes controlling a cycle time (264) of at least one of the plurality of stages based on the at least one operating parameter.

Description

SYSTEM AND METHOD FOR CONTROLLING CYCLES OF GAS CAPTURE SYSTEMBACKGROUND

[0001] The subject matter disclosed herein generally relates to a system and method for controlling cycles for a gas capture system.

[0002] Various undesirable gases pollute the atmosphere. For example, the undesirable gases may include carbon oxides (COx) such as carbon dioxide (CO2) and carbon monoxide (CO), nitrogen oxides (NOx) such as nitrogen dioxide (NO2), and / or sulfur oxides (SOx) such as sulfur dioxide (SO2). CO2 is both an acid gas and a greenhouse gas. Unfortunately, the atmospheric content of CO2 has generally increased over thousands of years, and currently exceeds about 420 parts per million by volume (ppmv) or 643 parts per million by weight (ppmw) in the atmosphere. With various regulations and environmental concerns regarding global warming, it would be desirable to reduce the undesirable gases (e.g.. CO2) in the atmosphere. As such, there is a need for efficient and effective gas capture systems to remove undesirable gases from the atmosphere and / or from exhaust gases discharged into the atmosphere.BRIEF DESCRIPTION

[0003] Certain embodiments commensurate in scope with the originally claimed subject matter are summarized below. These embodiments are not intended to limit the scope of the claimed embodiments, but rather these embodiments are intended only to provide a brief summary of possible forms of the subject matter. Indeed, the presently claimed embodiments may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

[0004] In certain embodiments, a method includes monitoring at least one operating parameter of a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage. The method further includes controlling a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

[0005] In certain embodiments, a system includes a controller having a memory', a processor, and instructions stored on the memory and executable by the processor to monitor at least one operating parameter of a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage. The controller is further configured to control a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

[0006] In certain embodiments, a system includes a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage. The sorbent-based gas capture system includes a first sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage. The sorbent-based gas capture system further includes a second sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage. The sorbent- based gas capture system also includes a third sorbent-based contactor configured to cy cle through the adsorption stage, the desorption stage, and the cooling stage, wherein the first, second, and third sorbent-based contactors cycle through the plurality of stages in a staggered manner. The sorbent-based gas capture system also includes a controller configured to monitor at least one operating parameter of the sorbent-based gas capture system. The controller is further configured to control a cycle time of at least one of the plurality' of stages based on the at least one operating parameter.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other features, aspects, and advantages of the presently disclosed techniques will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0008] FIG. 1 is a block diagram of an embodiment of a combined cycle system having one or more gas capture systems, in accordance with embodiments described herein;

[0009] FIG. 2 is a block diagram of an embodiment of the gas capture system of FIG. 1 , further illustrating an adsorption stage, a desorption stage, and a cooling stage, in accordance with embodiments described herein;

[0010] FIG. 3 is a schematic depiction of sensor feedback inputted into a gas capture optimizer, in accordance with embodiments described herein;

[0011] FIG. 4 is a flow chart of a process for monitoring the gas capture system and adjusting parameters of the gas capture system based on sensor feedback using the gas capture optimizer, in accordance with embodiments described herein; and

[0012] FIG. 5 is a flow chart of a process for training the gas capture optimizer with machine learning, in accordance with embodiments described herein.DETAILED DESCRIPTION

[0013] One or more specific embodiments of the presently disclosed systems and methods are described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementationspecific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary' from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture forthose of ordinary skill having the benefit of this disclosure.

[0014] When introducing elements of various embodiments of the presently disclosed embodiments, the articles “a,” “an,” “the,” and “said” are intended to meanthat there are one or more of the elements. The terms "comprising." “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0015] The present disclosure is generally directed towards systems and methods of gas treatment and gas capture (e.g.. carbon capture). As discussed above, the atmospheric content of CO2 has generally increased over time. Accordingly, it may be desirable to capture undesirable gases from exhaust gases prior to discharge into the atmosphere using post combustion capture (PCC) systems and / or capture the undesirable gases directly from the atmosphere using direct air capture (DAC) systems. Gas capture systems may include sorbent-based gas capture systems, such as carbon capture systems, used to capture undesirable gases (e.g., CO2) for storage and / or various applications. In some embodiments, the sorbent-based gas capture systems progressively transition through a plurality of cycles or stages (e.g., an adsorption stage, a desorption stage, and a cooling stage) using temperature swing adsorption (TSA). The sorbent-based gas capture systems may include one or more sorbent-based carbon capture units operating in parallel in different stages to increase an amount of undesirable gas captured. Further, the sorbent-based carbon capture units may include one or more contactors (e.g., sorbent-based contactors having sorbent material) to enable the adsorption and desorption of the undesirable gases (e.g., CO2).

[0016] To transition between the cycles or stages (e.g., adsorption stage, desorption stage, and cooling stage), a temperature swing or change may be used to sequentially operate the contactors at different temperatures. For example, in the adsorption stage, a sorbent material adsorbs undesirable gases (e.g., CO2) at a first temperature. The adsorption of undesirable gases into the sorbent material is an exothermic process, which causes an increase in temperature of the sorbent material. However, the sorbent material may adsorb the undesirable gases more effectively at a lower temperature range, and thus cooling may be provided to control the temperature of the sorbent material. Subsequently, in the desorption stage, the sorbent material desorbs the undesirable gases (e.g., CO2), for example, by heating the sorbent material from the first temperature to a higher second temperature using a heat source. The heat source may include a heated fluid, such as a heated gas and / or liquid (e.g., steam). In thecooling stage, the adsorber is cooled in preparation for the next adsorption stage. Continuous changes in temperature during transitions between stages within the contactors may be energy demanding. Furthermore, total time for the sorbent material to be saturated during the adsorption stage and desaturated during the desorption stage varies a lot based on different operating conditions, such as properties of the sorbent material, a vacuum condition and vacuum pump capability / capacity for the desorption stage, a contactor temperature of the sorbent material in the various stages, a sweep fluid (e.g., steam or nitrogen (N2)) capability for the desorption stage, and a heat exchange (e.g., cooling) during the adsorption and cooling stages, and a heat exchange (e.g., heating) during the desorption stage. As such, there is a need for control or optimization of contactor cycles and related energetics.

[0017] Accordingly, in certain embodiments of the present disclosure, a gas treatment system may include a gas capture optimizer system to automatically control or optimize contactor cycles and related energetics. The gas capture optimizer may monitor the gas treatment system by measuring and / or receiving sensor feedback (e.g., air flow, capture rate using CO2 sensors, desorption rate, vacuum condition, contactor temperature of each cycle) of various parameters. The sensor feedback may be sent to the gas capture optimizer, wherein based on the sensor feedback, the gas capture optimizer may automatically adjust and / or recommend optimized timing cycles / processes for the adsorption, desorption, and cooling stages. In this way, the gas capture optimizer is able to monitor powder consumption of components within the gas treatment system to prevent and / or predict degradation of components during a period of operation by suggesting preventative maintenance of subcomponents. Thus, the gas capture optimizer may optimize overall power consumption of the gas treatment system. In certain embodiments, the gas capture optimizer may be used for both DAC and PCC systems to help control or optimize contactor cycles of the gas capture system. Accordingly, embodiments of the gas capture optimizer are not limited to gas capture optimizer.

[0018] The gas capture optimizer may monitor the gas treatment system using sensor data. As such, the gas capture optimizer may receive sensor data (e.g., a plurality' of sensor data) that is provided by a plurality of sensors associated with the gas treatment system. For example, the sensors may be positioned within or outside the gas treatmentsystem and coupled to the sorbent-based carbon capture units. Sensor data may be generated by a variety of sensors (e.g.. temperature sensors, pressure sensors, flow rate sensors, gas composition sensors, vacuum sensors, humidity sensors, oxygen sensors, etc.) that measure various aspects associated with the adsorption, desorption, and cooling stages of the sorbent carbon-capture units.

[0019] In an embodiment, the gas capture optimizer may automatically adjust and / or recommend optimized timing cycles / processes for the adsorption, desorption, and cooling stages based on the sensor feedback, wherein the sensor feedback is compared to a threshold value. In the event one or more values deviate from the threshold value, the gas capture optimizer may adjust and / or recommend optimizing timing cycles / processes. For example, the gas capture optimizer may receive a first measurement (e.g. , sensor data) that corresponds to percentage (%) of CChin the untreated gas (e.g., % of inlet CO2) when the sorbent carbon-capture unit is in the adsorption stage. The adsorption stage may adsorb undesirable gases from the untreated gas into a sorbent material and discharge a treated gas, wherein the treated gas exhibits substantially less quantities or amounts of the undesirable gases. Subsequently, the gas capture optimizer may subsequently receive a second measurement that corresponds to percentage (%) of CChin the treated gas (e.g., % of outlet CO2). Accordingly, the gas capture optimizer may determine whether sensor feedback associated with the adsorption stage need to be adjusted based on a comparison of the first measurement and the second measurement over a duration of time. It should be noted that various sensor feedback associated with the adsorption, desorption, and cooling stages, may affect the adsorption process, and the examples provided herein are meant to be non-limiting.

[0020] After receiving the first measurement and second measurement, the gas capture optimizer may compare the values to determine whether one or more processes associated with the adsorption stage need to be adjusted or optimized. In general, the amount of CO2 in the treated gas should be substantially less relative to the untreated gas. As such, the gas capture optimizer may compare (e.g., analyze) the % of outlet CChto the threshold value. The threshold value may correspond to first measurement received by the gas capture optimizer (e.g., % of inlet CO2), or alternatively, it may be a preset value that is considered to be optimal operating conditions associated with the adsorption stage. If the % of outletCCh is not substantially less than % of inlet CO2 (e.g., value of % of inlet CO2 is comparable to value of % of outlet CCh), the gas capture optimizer may adjust and / or recommend optimizing cycle times / processes accordingly. In the preceding example, the value of % of inlet CCh being comparable to the value of % of outlet CCh may indicate that the sorbent material is not effectively adsorbing CO2 (e.g., sorbent material is saturated). Accordingly, the gas capture optimizer may adjust the cycle time / processes by adjusting one or more parameters (e.g.. controlling one or more components), such as by switching to the desorption stage earlier, thereby shortening the time period associated with the adsorption stage cycle, increase / decrease inlet air flow to accommodate the decrease in adsorption of the sorbent material, adjust contactor temperature, switching from a heating source to a cooling source (e.g., adjust temperature swing), decreasing / increasing cycle time, etc. As such, the gas capture optimizer is able to identify inefficient processes within the gas treatment system (e.g., sorbent carbon-capture units) and adjust cycle times / processes, thereby optimizing contactor cycles and reducing overall power consumption.

[0021] In some embodiments, the gas capture optimizer may recommend (e.g., suggest) methods by which a user may employ to optimize contactor cycles and / or reduce associated energy costs. For example, the gas capture optimizer may send and / or generate a notification to an electronic device, wherein the notification may be presented to the user via a display or some other suitable component that may receive inputs. The notification may include interactive icons or objects that cause the electronic device to present information associated with a specific stage (e.g., adsorption, desorption, cooling) indicating that an inefficient process / processes that has been identified. For example, the notification may include information associated with the inefficient process (e.g., value of % of inlet CO2 is comparable to value of % of outlet CO2 during the adsorption stage of a sorbent carbon-capture unit). The notification may also include various suggestions (e.g., methods) by which the inefficient process may be optimized (e.g., adjust the cycle time by switching to the desorption stage earlier, thereby shortening the time period associated with the adsorption stage cycle, reduce inlet air flow to accommodate the decrease in adsorption of the sorbent material, adjust contactor temperature). The gas capture optimizer may receive a selection from the user indicating (e.g., selecting) the method tooptimize the cycle. As such, the gas capture optimizer may adjust the parameters of the of the adsorption stage, desorption stage, and cooling stage accordingly. It should be noted that the gas capture optimizer may continue to monitor the various parameters of the different stages after implementing the adjustment. If the gas capture optimizer does not identify any inefficient processes, the cycles may continue to operate as indicated and the gas capture optimizer may continue to compare a first measurement and a second measurement to identify and predict potential degradation of components. In this way, the gas capture optimizer is able to monitor power consumption of components within the gas treatment system to prevent and / or predict degradation of components during a period of operation by suggesting preventative maintenance of subcomponents.

[0022] In some embodiments, the gas treatment system may be controlled by a controller. Accordingly, the gas capture optimizer system may be communicatively coupled to the controller or integrated into the controller to adjust operational parameters of the gas treatment system. The controller may facilitate in automatically adjusting the parameters of the stages based on the comparison of the sensor feedback and threshold data. For example, the controller may modify one or more operational parameters of the stages to optimize cycle time or reduce energy7consumption. In one example, the controller may adjust parameters of one or more stages (e.g., adsorption stage, desorption stage, cooling stage). In certain embodiments, the controller may receive inputs from the user, thereby allowing the controller to adjust the operational and adjust cycle times / processes based on the selection provided by the user. As such, inefficient processes of the gas treatment system may be optimized to improve energetics of the gas treatment system.

[0023] With the foregoing in mind, FIG. 1 is a block diagram of an embodiment of an industrial plant 10 having a gas turbine system 12, a steam turbine system 14, a heat recovery steam generator (HRSG) 16. a gas treatment system 18 having one or more gas capture systems 20, and a controller 22 coupled to each of the systems 12, 14, 16, and 18. As discussed below, the one or more gas capture systems 20 of the gas treatment system 18 are configured to capture an undesirable gas (e.g., CO2) from exhaust gas and / or air (e.g., direct air capture). As discussed in detail below, the gas treatment system 18 of the industrial plant 10 includes a carbon capture system for usein removing undesirable gases (e.g., CO2) from the exhaust gas of the combustion systems, captured air from the atmosphere, or a combination thereof. It should be noted that the gas capture system 20 (e.g., carbon capture system 100) may not be necessarily coupled to the gas treatment system 18. In certain embodiments, the carbon capture system 100 may be independent or separate from the industrial plant 10, such as a standalone carbon capture system 100 used for direct air capture. Furthermore, the carbon capture system 100 also includes a heating source and a cooling source. Before discussing details of the gas treatment system 18, various aspects of the industrial plant 10 are discussed in further detail. For purposes of orientation in the drawings, reference may be made to an axial direction or axis 40, a radial direction or axis 42 extending radially away from the axial direction or axis 40. and a circumferential direction or axis 44 extending circumferentially around the axial direction or axis 40. The directions or axes 40, 42, and 44 may be in reference to a rotational axis 36 of the gas turbine system 12, for example.

[0024] The gas turbine system 12 includes an air intake 50, a compressor 52 having one or more compressor stages, one or more combustors 54, a turbine 5 having one or more turbine stages, and a load 58 (e.g., electrical generator) driven by the turbine 56. In certain embodiments, the gas turbine system 12 further includes an exhaust gas recirculation (EGR) system 60 configured to recirculate an exhaust gas 62 into the air intake 50. The recirculated exhaust gas 62 helps to reduce the temperature and formation of certain emissions (e.g., nitrogen oxides (NOx)) associated with combustion in the combustors 54. In operation, the compressor 52 receives air (and also exhaust gas 62 if the EGR system 60 is active) from the air intake 50, and compresses the air and / or exhaust gas 62 in one or more compressor stages (e.g., stages of rotating compressor blades). The combustors 54 then combust fuel from a fuel supply system with the compressed air and / or exhaust gas, and generate hot combustion gases. The hot combustion gases expand and drive one or more turbine stages (e.g., stages of rotating turbine blades) in the turbine 56. thereby driving rotation of the compressor 52 and the load 58 via shafts. The turbine 56 then outputs the hot combustion gases as the exhaust gas 62. The gas turbine system 12 may include a variety of piping to support the flow of intake air, compressed air (e.g., bleed air), oneor more fuels (e.g., liquid fuel, gas fuel, etc.), additives for combustion, exhaust gas (e.g., exhaust gas recirculation), or other fluids.

[0025] The HRSG 16 recovers waste heat from the exhaust gas 62 to generate steam for driving the steam turbine system 14. The HRSG 16 includes a high-pressure (HP) steam section 70. an intermediate-steam (IP) section 72, and a low-pressure (LP) steam section 74 configured to generate HP steam 76, IP steam 78, and LP steam 80. The steam turbine system 14 may include an HP steam turbine 82 driven by the HP steam 76, an IP steam turbine 84 driven by the IP steam 78, and a LP steam turbine 86 driven by the LP steam 80. In addition to the steam provided by the HRSG 16, the HP steam turbine 82 provides IP steam to the IP steam turbine 84, and the IP steam turbine 84 provides LP steam to the LP steam turbine 86. The LP steam turbine 86 then outputs any remaining steam / water to a condensate line 88 coupled to the LP steam section 74 of the HRSG 16. The condensate line 88 may include a condenser 90 configured to condense any remaining steam to form a condensate, and a pump 92 configured to pump the condensate back to the LP steam section 74. In operation, the steam turbine system 14 drives a load 94 (e.g., electrical generator) via a shaft. In certain embodiments, the steam turbine system 14 and / or the HRSG 16 may provide heated water and / or steam (e.g., HP steam 76, IP steam 78, and / or LP steam 80) to the gas treatment system 18 to support a desorption mode of the one or more gas capture systems 20. For example, the gas capture systems 20 may receive heated water and / or steam in a temperature range of 100 to 150 degrees Celsius, 110 to 150 degrees Celsius, 120 to 150 degrees Celsius, or 130 to 150 degrees Celsius. The steam turbine system 14 and the HRSG 16 may include a variety of piping to support the flow of exhaust gas, steam, water, or other fluids, thereby facilitating waste heat recovery, steam generation, and steam power.

[0026] After the HRSG 16, the exhaust gas 62 may flow to the EGR system 60 and / or the gas treatment system 18. In the illustrated embodiment, the exhaust gas 62 flows through one or more gas capture systems 20 configured to capture undesirable gases. In some embodiments, the gas capture systems 20 may receive air 64 from an additional source (e.g.. environment, fans, and the like). For example, the air 64 may be atmospheric air when the gas capture system 20 is configured as a direct air capturesystem. The undesirable gases from the exhaust gas 62 and / or the air 64 may include carbon oxides (COx) (e.g., carbon dioxide (CO2) and carbon monoxide (CO)), nitrogen oxides (NOx) (e.g., nitrogen dioxide (NO2)), sulfur oxides (SOx) (e.g., sulfur dioxide (SO2)), or any combination thereof. In the following discussion, CO2 may be used as an example of the undesirable gases; however, the gas capture systems 20 may be designed to capture any of the foregoing undesirable gases. For example, the gas capture systems 20 include one or more carbon capture systems 100 (e.g., CO2 capture systems).

[0027] In some embodiments, the gas capture systems 20 (e.g., carbon capture systems 100) may include sorbent-based gas capture systems, solvent-based gas capture systems, cryogenic gas capture systems, or any combination thereof, configured to remove and capture undesirable gases. The carbon capture system 100 may include components 102, 104, 106, and 108 configured to enable gas capture of undesirable gases (e.g.. CO2) from the exhaust gas 62, thereby outputting a treated gas 110 and a captured gas 1 12 (e.g., CO2). The treated gas 110 may be substantially free of the undesirable gases (e.g., CO2) and may be discharged through an exhaust stack. The captured gas 112 (e.g., CO2) may be compressed by a compression system 114 and stored and / or transported by a storage and / or pipeline system 116. For example, the carbon capture systems 100 may include a post combustion capture (PCC) system that captures undesirable gases from the exhaust gas 62 and / or a direct air capture (DAC) system that captures undesirable gases from the air 64.

[0028] In certain embodiments, the carbon capture system 100 is a sorbent-based carbon capture system, and the components 102, 104, 106, and / or 108 include multiple sorbent-based carbon capture units (e.g., adsorbers having a sorbent material). In certain embodiments, the sorbent material may include porous, solid-phase materials, including mesoporous silicas, zeolites (e.g., aluminosilicates), and metal-organic frameworks (MOFs) and covalent organic frameworks (COFs). In certain embodiments, the carbon capture system 100 is a solvent-based carbon capture system, and the components 102, 104, 106, and / or 108 include one or more absorbers, strippers, and associated equipment. The carbon capture system 100 may include a variety ofsystems to support transitions between cycles of absorption, desorption, cooling, and the like, thereby facilitating carbon capture.

[0029] In the illustrated embodiment, the controller 22 is configured to control all aspects of the industrial plant 10. The controller 22 includes one or more processors 120, memory 122, instructions 124 stored on the memory 122 and executable by the processor 120. and communication circuitry 126 configured to communicate with sensors and various equipment of the industrial plant 10. For example, the controller 22 is configured to receive sensor feedback from one or more sensors 128 coupled to the gas turbine system 12, the steam turbine system 14, the HRSG 16, and the gas treatment system 18 (e.g., gas capture systems 20). and / or additional components of the industrial plant 10 and control the same equipment based on the sensor feedback, operating modes, user input, computer models, or any combination thereof. The sensors 128 may include temperature sensors, pressure sensors, flow rate sensors, gas composition sensors, or any combination thereof.

[0030] In certain embodiments, the controller 22 is configured to control operation of the gas capture systems 20 (e.g., carbon capture systems 100), such by controlling modes of operation (e.g., adsorption mode, desorption mode, and cooling mode), controlling heat sources for supplying heated fluid (e.g., steam) to the gas capture systems 20, controlling cooling sources for supply cooled fluids to the gas capture systems 20, vacuum pumps, or any combination thereof. In one example, the controller 22 may be communicatively coupled with a gas capture optimizer system 66. In certain embodiments, the gas capture optimizer 66 may be integrated into the controller 22 (e.g., processor 120). The gas capture optimizer 66 may include a computer model, a gas capture simulation algorithm, a machine learning algorithm, lookup tables, or any combination thereof, for the adsorption mode, the desorption mode, and the cooling mode of the gas capture system 20. The gas capture optimizer 66 may be stored on and executable by the controller 22 and / or a dedicated computer. In certain embodiments, the gas capture optimizer 66 may include a direct air capture (DAC) optimizer, a post combustion capture (PCC) optimizer, or a combination thereof. In certain embodiments, the controller 22, the gas capture optimizer 66, and / or the one or more sensors 128 of the industrial plant 10 may interface (e.g., input devices) with the carboncapture system 100 as shown in FIG. 2. In some embodiments, the controller 22 and / or the gas capture optimizer 66 may interface with one or more sensors 128 positioned within the gas capture system 20 (e.g.. carbon capture system 100). In some embodiments, the controller 22 and / or the gas capture optimizer 66 may monitor the gas capture system (e.g., carbon capture system 100). Accordingly, the controller 22 and / or the gas capture optimizer 66 may adjust parameters of the carbon of the gas capture system 20 (e.g., carbon capture system 100) by controlling operation automatically in response to sensor feedback and / or operating parameters, in response to user / operator input or selections, or any combination thereof.

[0031] By way of example, FIG. 2 is a schematic of an embodiment of the gas capture system 20 (e.g., carbon capture system 100) of FIG. 1, further illustrating an adsorption stage 202, a desorption stage 204, and a cooling stage 206 of one or more contactors 208, 210, 212 (e.g., adsorbers, sorbent-based adsorbent units). In certain embodiments, the gas capture system 20 is designed as a temperature swing adsorption (TSA) system using temperature swings or changes to transitions between the stages 202, 204, and 206. The contactors 208, 210, 212 may include heat exchangers 214, 216, 218 and sorbent materials 220, 222, 224. The heat exchangers 214, 216, 218 may be controlled to remove or add heat from the contactors 208, 210, 212 during transitions between operational stages of the gas capture system 20. The sorbent material 220, 222. 224 are configured to adsorb or desorb gases in the adsorption and desorption stages 202 and 204, respectively.

[0032] In the illustrated embodiment, the gas capture system 20 has a plurality of contactors (e g., contactors 208, 210, 212) operating in parallel (e.g., simultaneously) with one another in different stages 202, 204, and 206. For example, the contactor 208 is operating in the adsorption stage 202, the contactor 210 is operating in the desorption stage 204, and the contactor 212 is operating in the cooling stage 206. As discussed in detail below, the controller 22 having the gas capture optimizer 66 is configured to control various operating parameters (e.g., temperature, pressure, cycle time, power consumption, etc.) for each of the different stages 202, 204, and 206, including the transition of each contactor in a sequence of the stages: (1) adsorption stage 202, (2) desorption stage 204. and (3) cooling stage 206. Thus, each of the contactors 208, 210.212 progressively operates for a duration of time (or cycle) in each of the stages 202, 204, and 206. In certain embodiments, the gas capture system 20 may include 3, 4, 5, 6. 7, 8, 9. 10, or more contactors operating in parallel (e.g.. simultaneously) with at least one or more of the contactors operating in each of the stages 202, 204, and 206 at all times, such that the contactors are operating in a staggered manner in the stages 202, 204, and 206.

[0033] The gas capture system 20 also may include other equipment upstream, within, and / or downstream from the stages 202, 204, and 206. For example, the gas capture system 20 may include one or more sensors 226 (e.g., sensors 128 of FIG. 1), designated as (S), positioned throughout the gas capture system 20. The one or more sensors 226 (e.g., temperature sensors, pressure sensors, flow rate sensors, gas composition sensors, or any combination thereof) may be measure parameters associated with the gas capture system 20. The sensors 226 may be used for control of the gas capture system 20, and particularly operating parameters (e.g., temperature, pressure, cycle time, power consumption, etc.) of the stages 202, 204, and 206. The gas capture system 20 may also include a vacuum pump 228 that may be disposed downstream from the desorption stage 204. The vacuum pump 228 may create a vacuum in the desorption stage 204 (e.g.. in the contactor 210) to remove water and gases from the desorption stage 204.

[0034] The gas capture system 20 may also include a fluid transfer system 229. The fluid transfer system 229 may be used to provide one or more fluids to the contactors 208, 210, 212 for direct heat transfer (e.g.. directly flowing through contactors 208. 210, 212 in fluid contact with sorbent materials 220, 222, 224) and / or indirect heat transfer (e.g., via heat exchangers 214, 216, 218). The fluid transfer system 229 may include a cooling source 230, 232 and a heating source 234. One or more valves maycontrol a flow of the fluids from the cooling source 230, 232 and the heating source 234 to the contactors 208, 210, 212. The cooling source 230, 232 and the heating source 234 may include one or more fluid tanks, fluid pumps or compressors, valves, conduits, waste heat sources, water sources, steam sources, inert gas sources (e.g., nitrogen), heat exchangers, heaters, coolers, or any combination thereof. For example, the cooling source 230, 232 may include a cooling water, a refrigerant of a refrigerant cycle, acooling gas (e.g., inert gas), or any combination thereof, being supplied from other parts of the industrial plant 10 and / or a cooling system. By further example, the heating source 234 may include a heating water, a steam, a heating gas (e.g., inert gas), or any combination thereof, being supplied from other parts of the industrial plant 10 and / or a heating system. For example, the heating source 234 may include heating water and / or steam from the steam turbine system 14 and / or the HRSG 16 as discussed above.

[0035] The adsorption stage 202 of the gas capture system 20 may be used to capture undesired gases (e.g., CO2). For example, the adsorption stage 202 may receive an untreated gas 236 (e.g., untreated exhaust gas 62 and / or air 64) from an untreated gas supply (e.g., gas turbine system 12, HRSG 16. direct air capture system), adsorb undesirable gases (e.g., CO2) from the untreated gas into a sorbent material, and discharge a treated gas 238 (e.g., treated exhaust gas and / or treated air) with substantially less of the undesirable gases through a treated gas exhaust (e.g., exhaust stack). During the adsorption stage 202, cold fluid from the cooling source 230 of the fluid transfer system 229 may be present in and / or circulated through a contactor 208. For example, the cooling source 230 may supply and / or circulate a cooling fluid directly through the contactor 208 in direct contact with the sorbent material 220 for direct heat transfer (e.g., cooling) of the sorbent material 220 as indicated by arrow 231, or indirectly through the contactor 208 via the heat exchanger 214 for indirect heat transfer (e.g., cooling) of the sorbent material 220 as indicated by arrow 215, or a combination thereof. For direct heat transfer via a fluid flow indicated by arrow 231, the cooling fluid may include a cooled gas (e g., nitrogen). For indirect heat transfer via a fluid flow indicated by arrow 215. the cooling fluid may include a liquid or gas (e.g.. cooled water, refrigerant, gas, etc.). As noted above, the adsorption of undesirable gases into the sorbent material is an exothermic process, which causes an increase in temperature of the sorbent material. Accordingly, the cold fluid present during the adsorption stage 202 may be used to maintain a temperature of the untreated gas 236 and / or the sorbent material 220 below a threshold temperature for adsorption. The sorbent material may generally have reduced adsorption efficiency and / or capacity as the temperature increases, whereas the sorbent material may generally have increased adsorption efficiency and / or capacity as the temperature decreases. In certain embodiments, thecontroller 22 and the gas capture optimizer 66 are configured to adjust and control the cycle time for the adsorption stage 202, the temperature of the sorbent material 220 (e.g.. within upper and lower temperature thresholds), operating parameters (e.g.. temperature, pressure, flow rate, fluid composition, etc.) of the cooling source 230, and heat exchange configuration (e.g., direct and / or indirect heat exchange) to improve the operations of the gas capture system 20 (e.g., efficiency of gas capture, volume of gas capture per duration of time, power usage, etc.).

[0036] In certain embodiments, the temperature of the untreated gas 236 and / or the sorbent material 220 may be controlled to be approximately 30 degrees Celsius or within a range of 20 to 40 degrees Celsius during the adsorption stage 202. However, the temperatures may vary depending on the particular untreated gas 236, sorbent material, undesirable gas, cooling systems, and other aspects of the gas capture system 20. It should be noted, that in some embodiments, the cooling source 230 may be initiated to maintain a certain temperature or temperature range (e.g., between upper and lower temperature thresholds) within the contactor 208 during the adsorption stage 202. Once the sorbent material 220 is saturated with the undesirable gas (e.g., CO2), the gas capture system 20 may change an operating stage from the adsorption stage 202 to the desorption stage 204.

[0037] The desorption stage 204 may be initiated to desorb the undesirable gas from the sorbent material 222. Desorption may be initiated upon heating of the sorbent material 222 within the contactor 210. As such, the gas capture system 20 may flow fluid from the heating source 234 of the fluid transfer system 229 to the contactor 210. For example, the heating source 234 may supply and / or circulate a heating fluid directly through the contactor 210 in direct contact with the sorbent material 222 for direct heat transfer (e.g., heating) of the sorbent material 222 as indicated by arrow 233, or indirectly through the contactor 208 via the heat exchanger 216 for indirect heat transfer (e.g., heating) of the sorbent material 222 as indicated by arrow 217, or a combination thereof. The direct heat transfer and / or indirect heat transfer (e.g., via the heat exchanger 216) may increase the temperature of the contactor 210, thereby heating up the sorbent material 222 to a sufficient temperature range to cause desorption of the undesirable gases (e.g.. CO2) from the sorbent material 222. For direct heat transfer viaa fluid flow indicated by arrow 233, the heating fluid may include steam and / or inert gas (e.g., nitrogen). For indirect heat transfer via a fluid flow indicated by arrow 217, the heating fluid may include a liquid or gas (e.g., heated water, steam, gas, etc.). The sorbent material may generally have increased desorption efficiency as the temperature increases, whereas the sorbent material may generally have decreased desorption efficiency as the temperature decreases. In certain embodiments, the controller 22 and the gas capture optimizer 66 are configured to adjust and control the cycle time for the desorption stage 204, the temperature of the sorbent material 222 (e.g., within upper and lower temperature thresholds), operating parameters (e.g., temperature, pressure, flow7rate, fluid composition, etc.) of the heating source 234, and heat exchange configuration (e.g.. direct and / or indirect heat exchange) to improve the operations of the gas capture system 20 (e.g., efficiency of gas capture, volume of gas capture per duration of time, power usage, etc.).

[0038] In some embodiments, the heating source 234 is controlled to provide heating fluid (e.g., 233, 217) to the contactor 210 within a temperature range of 100 to 150 degrees Celsius, such that the sorbent material 222 heats up to a temperature range of 100 to 150 degrees Celsius. This allows undesirable gases (e.g., CO2) previously adsorbed into the sorbent material 222 to be desorbed from the sorbent material 222 and output from the contactor 210. In some embodiments, the contactor 210 may be in direct fluid communication with the vacuum pump 228. For example, the vacuum pump 228 may be positioned dow nstream from the contactor 210, such that it may draw7out the undesirable gases and any direct heat transfer fluid (e.g., steam and / or inert gas), e.g., collectively extracted fluid. Additionally, the vacuum pump 228 may be in direct communication with both the contactor 210 and the separator 242, wherein the separator 242 may be positioned downstream from the vacuum pump 228. In this way, the separator 242 may separate gases from any moisture (e.g., water (H2O)) in the extracted fluid, thereby outputting undesirable gases as captured gas 248 and the moisture as captured water 246. For example, when using steam as the heating fluid in a direct heat transfer configuration (e g., arrows 233), the steam simultaneously heats the sorbent material 222, causes desorption of the undesirable gases (e.g., CO2) from the sorbent material 222, and combines with the undesirable gases to form the extractedfluid. Thus, the vacuum pump 228 and the separator 242 operate to draw out the extracted fluid and separate the undesirable gases (e.g., CO2) from the steam / water. Once the sorbent material 222 has released the undesirable gases beyond a threshold, the gas capture system 20 may change the operating stage from the desorption stage 204 to the cooling stage 206.

[0039] The cooling stage 206 may be initiated to cool the contactor 212 between the desorption stage 204 and the adsorption stage 202 (e g., an additional adsorption stage), such that the sorbent material 224 is within a desired temperature range (e.g., within upper and lower temperature thresholds). The cooling stage 206 may be initiated by controlling the cooling source 232 of the fluid transfer system 229 to provide cold fluid to the contactor 212. The cold fluid may reduce a temperature of the contactor 212 and sorbent material 224 to meet a desired temperature to initiate an additional adsorption stage. In certain embodiments, the cooling source 232 may supply and / or circulate a cooling fluid directly through the contactor 212 in direct contact with the sorbent material 224 for direct heat transfer (e.g., cooling) of the sorbent material 224 as indicated by arrow 235, or indirectly through the contactor 212 via the heat exchanger 218 for indirect heat transfer (e.g., cooling) of the sorbent material 224 as indicated by arrow 219, or a combination thereof. For direct heat transfer via a fluid flow indicated by arrow 235, the cooling fluid may include a cooled gas (e.g., nitrogen). For indirect heat transfer via a fluid flow indicated by arrow 219, the cooling fluid may include a liquid or gas (e.g., cooled water, refrigerant, gas, etc.). In certain embodiments, the controller 22 and the gas capture optimizer 66 are configured to adjust and control the cycle time for the cooling stage 206, the temperature of the sorbent material 224 (e.g., within upper and lower temperature thresholds), operating parameters (e.g., temperature, pressure, flow rate, fluid composition, etc.) of the cooling source 232 and heat exchange configuration (e.g., direct and / or indirect heat exchange) to improve the operations of the gas capture system 20 (e.g., efficiency of gas capture, volume of gas capture per duration of time, power usage, etc.).

[0040] In certain embodiments, as the gas capture system 20 transitions each of the contactors 208, 210, 212 sequentially between the adsorption stage 202, the desorption stage 204, and the cooling stage 206, the fluid provided by the cooling source 230, 232and / or the heating source 234 may be cycled between the contactors 208, 210, 212 to maintain temperatures of the sorbent material within desired temperature ranges (e.g., within upper and lower temperature thresholds). The heat exchangers 214. 216, 218 may cycle fluid between various contactors 208, 210, 212 to increase and / or decrease a temperature of the contactors 208, 210, 212. Additionally, the cycle times for the adsorption stage 202, the desorption stage 204, and the cooling stage 206 may be controlled based on saturation levels in the sorbent material, undesirable gas content in the exhaust gas 62 and / or air 64, desired emissions levels of the undesirable gas, power consumption limits, or any combination thereof.

[0041] The one or more sensors 226 may be positioned through various parts of the adsorption stage 202, the desorption stage 204, and the cooling stage 206. For example, the one or more sensors 226 may be disposed near and / or within the untreated gas 236 and provide sensor feedback and / or measurements associated with temperature, pressure, flow rate, gas composition (e g., % of inlet CO2. % of inlet H2O), air inlet condition, inlet gas flow, or any combination thereof. The one or more sensors 226 may also monitor temperature fluctuations with respect to the fluid transfer system 239 (e.g., cooling source 230, 232 and heating source 234), thereby providing temperature feedback associated with the fluids. In another example, the one or more sensors 226 may be positioned near and / or within the contactors 208, 210. 212 to provide sensor feedback (e.g., temperature, pressure, flow rate, fluid composition, etc.) relating to the undesirable gas (e.g., CO2) being adsorbed by and desorbed from the sorbent materials 220, 222, 224. In another example, the one or more sensors 226 may be positioned near, within, and / or in contact with the sorbent materials 220, 222, 224, thereby providing sensor feedback (e.g., temperature) relating to the sorbent materials 220, 222, 224. In certain embodiments, the one or more sensors 226 may monitor parameters (e.g., temperature, pressure, flow rate, gas composition, sorbent utilization, contactor vacuum condition, power consumption) of the contactors 208, 210, 212, sorbent material 220, 222, 224. untreated gas, or a combination thereof. The one or more sensors 226 may be disposed near and / or within the treated gas 238 or vacuum pump 228 and provide sensor feedback and / or measurements associated with temperature, pressure, flow rate, gas composition (e.g., % of outlet CO2, % of outlet H2O), air inlet condition, inlet gas flow,contactor vacuum condition, power consumption, or any combination thereof. In some embodiments, additional sensors may be present near and / or within the separator 242, a component receiving captured water 246. and a component receiving captured gas 248. In this way, the gas capture optimizer 66 may utilize the sensor feedback provided by the one or more sensors 226 to adjust parameters of the gas capture system 20 (e.g., carbon capture system 100), thereby improving energetics of the gas treatment system.

[0042] With the foregoing in mind, FIG. 3 is a schematic depiction 260 of parameters that are inputted into a gas capture optimizer 66, in accordance with embodiments described herein. The gas capture optimizer 66 may receive sensor feedback 262 as input from the one or more sensors 226 of FIG. 2. Various sensor feedback 262 may be provided into the gas capture optimizer 66, such that it may improve energetics of the gas capture system 20. Accordingly, the various sensor feedback 262 may include inlet gas flow 262a, air inlet condition 262b, % of inlet CO2 262c. % of outlet CO2 262d, % of CO2 collected 262e, contactor temperature 262f, contactor vacuum condition 262g, sorbent utilization and power consumption 262h, % of inlet oxygen (O2) 262i, and % of outlet O2 262j. In some embodiments, % of inlet H2O and % of outlet H2O may be included as parameters as well. In general, it should be noted that the sensor feedback 262 are meant to be non-limiting, as additional features / parameters may also serve as inputs into the gas capture optimizer 66. In certain embodiments, the gas capture optimizer 66 may receive the sensor feedback 262 in real-time or substantially in real-time (e.g., within 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 seconds) in a continuous or periodic manner (e.g., at preset time intervals). The preset time intervals may be a number of seconds or minutes, such as every 10, 20, 30. 40. 50, or 60 seconds, or every 1, 2, 3, 4, or 5 minutes. In response to the sensor feedback 262, the gas capture optimizer 66 may optimize operating parameters of the gas capture system 20 as discussed in further detail below.

[0043] Accordingly, sensor feedback 262 including inlet gas flow 262a, air inlet condition 262b, % of inlet CO2 262c, of inlet O2 262i, % of inlet H2O, or any combination thereof, may be received as sensor feedback from the one or more sensors 226 positioned near and / or within the untreated gas 236 when the carbon capture system 100 is undergoing the adsorption stage 202. as illustrated in FIG. 2. For example, theone or more sensors 226 positioned near or / within the untreated gas 236 may measure the inlet gas flow 262a, air inlet condition 262b, % of inlet CO2262c (e.g., amount of CO2 in ppm). % of inlet O2 262i (e.g.. amount of % of inlet H2O (e.g., amount of H2O in ppm) within the untreated gas. As discussed above, the untreated gas may include the exhaust gas 62 and / or the air 64 as illustrated in FIG. 1. In certain embodiments, the inlet gas flow 262a may include the exhaust gas 62, a cooling gas (e.g., nitrogen, air, etc.) from the cooling source 230 being used for direct cooling as indicated by arrow 231 in FIG. 1, or any combination thereof, wherein sensor feedback of the inlet gas flow 262a may include a temperature, a pressure, a flow rate, a gas composition, or any combination thereof. The air inlet condition 262b may include the air 64 undergoing a direct air capture (DAC) process in the gas capture system 20, wherein sensor feedback of the air inlet condition 262b may include a temperature, a pressure, a flow rate, a gas composition, or any combination thereof. The % of inlet CO2 262c may include the percent by volume or parts per million (ppm) of CO2 in the untreated gas (e.g., exhaust gas 62 and / or air 64) undergoing the gas capture process in the gas capture system 20. wherein sensor feedback of the % of inlet CO2 262c may include a CO2 measurement and / or analysis. Similarly, the % of inlet O2262i may include the percent by volume or parts per million (ppm) of O2 in the untreated gas (e.g., exhaust gas 62 and / or air 64) undergoing the gas capture process in the gas capture system 20, wherein sensor feedback of the % of inlet O2 262i may include an oxygen measurement and / or analysis.

[0044] Similarly, the one more sensors 226 positioned near and / or within the contactors 208. 210, 212 may measure contactor temperature 262f, contactor vacuum condition 262g, sorbent utilization and power consumption 262h, or any combination thereof. For example, the contactor temperature 262f (e.g., heat exchanger 214, 216, 218) may need to be adjusted to adjust the temperature of sorbent material (e.g., 220, 222, 224) to improve the efficiency of the adsorption stage 202, the desorption stage 204, and the cooling stage 206. In certain embodiments, the contactor temperature 262f may include the temperature of the sorbent material (e.g., 220, 222, 224) on an exterior surface, internally within the sorbent material, on a substrate (e.g., fins, tubes, plates, etc.) supporting the sorbent material, or a combination thereof. The contactor vacuumcondition 262g provides information regarding the vacuum pump 228 and vacuum pressure used to remove undesirable gases during the desorption stage 204. Sorbent utilization and power consumption 262h provides information regarding the adsorptive properties of the sorbent material 220, 222, and 224 and the power consumption when operating the adsorption stage 202, the desorption stage 204, and the cooling stage 206. For example, sorbent utilization may include a saturation level of the undesirable gas (e.g., CO2) in the sorbent material (e.g., 220. 222, 224). By further example, the power consumption may include any power consumption to operate pumps, fans, compressors, cooling for the cooling sources 230, 232, heating for the heating source 234, the vacuum pump 228, the separator 242, or any combination thereof. In general, each of the stages 202, 204, and 206 uses power to operate during each cycle or stage for a particular contactor (e.g., 208, 210, 212), and thus the power consumption is generally a tradeoff with the sorbent utilization of the (e.g., 220, 222, 224).

[0045] As appreciated, a sorbent material has a sorption capacity or saturation point when it is no longer able to adsorb any more undesirable gas (e.g., CO2). During the adsorption stage 202, the sorbent material may gradually adsorb the undesirable gas with an increasing saturation percentage of the saturation point, wherein the adsorption may gradually slow as the saturation percentage approaches the saturation point. Additionally, as the adsorption slows and the power consumption continues to drive the adsorption stage 202, an increasing amount of power consumption is needed for a decreasing percentage of adsorption. Thus, the gas capture optimizer 66 may adjust a target threshold value for the saturation percentage that will trigger an end of the adsorption stage 202 and a transition to the desorption stage 204. thus controlling a cycle time for the adsorption stage 202. Similarly, during the desorption stage 204, the sorbent material may gradually desorb the undesirable gas with a decreasing saturation percentage of the saturation point, wherein the desorption may gradually slow' as the saturation percentage approaches zero. Additionally, as the desorption slows and the power consumption continues to drive the desorption stage 204, an increasing amount of power consumption is needed for a decreasing percentage of desorption. Thus, the gas capture optimizer 66 may adjust a target threshold value for the saturationpercentage that will trigger an end of the desorption stage 204 and a transition to the cooling stage 206, thus controlling a cycle time for the desorption stage 204.

[0046] In another example, the one or more sensors 226 positioned near and / or within treated gas 238 or vacuum pump 228 may measure % of outlet CO2 262d, % of CO2 collected 262e, contactor vacuum condition 262g, % of outlet O2262j, % of outlet H2O. or any combination thereof. For example, the % of outlet CO2 262d, % of outlet O2 262j, % of outlet H2O may be measured downstream of the contactors (e.g., contactor 208, 210, 212) during the adsorption stage 202, such that the measurements are taken in the treated gas after adsorption by the sorbent material (e.g., 220, 222, 224). In certain embodiments, the % of CO2 collected 262e may be measured during the desorption stage 204, after the CO2 is desorbed from the sorbent material (e.g., 220, 222, 224). In general, it should be noted that the one or more sensors 226 may be disposed in various positions with the gas capture system 20 (e.g., carbon capture system 100), thereby providing sensor feedback 262 that may be inputted into the gas capture optimizer 66.

[0047] During the adsorption and desorption stages 202, 204, the gas capture optimizer 66 may use various inlet and outlet measurements to monitor the performance of the contactors (e.g.. 208, 210. 212) and particularly the sorbent materials (e.g., 220. 222, 224) and make adjustments to help balance the efficiency of adsorption and desorption, power consumption, cycle time, and so forth. For example, the gas capture optimizer 66 may monitor and compare the % of inlet CO2262c and the % of outlet CO2 262d to obtain a measurement or calculation of CO2 adsorbed into the sorbent material (e.g., 220, 222, 224) overtime during adsorption stage 202, thereby monitoring a CO2 adsorption rate over time. The CO2 adsorption rate may be an indicator used by the gas capture optimizer 66 to determine when the sorbent material is approaching the saturation point (or an upper threshold saturation percentage of the saturation point). For example, if the CO2 adsorption rate decreases to a threshold CO2 adsorption rate, then the gas capture optimizer 66 may trigger a transition from the adsorption stage 202 to the desorption stage 204 for the particular contactor (e.g., 208, 210, 212). Similarly, the gas capture optimizer 66 may monitor the % of CO2 collected 262e over time during desorption stage 204, thereby monitoring a CO2 desorption rate over time. The CO2desorption rate may be an indicator used by the gas capture optimizer 66 to determine when the sorbent material is approaching a zero saturation (or a lower threshold saturation percentage of the saturation point). For example, if the CO2 desorption rate decreases to a threshold CO2 desorption rate, then the gas capture optimizer 66 may trigger a transition from the desorption stage 204 to the cooling stage 206 for the particular contactor (e.g., 208, 210, 212).

[0048] In certain embodiments, the gas capture optimizer 66 may use the % of inlet O2 262i and the % of outlet O2 262j to monitor possible leakage of the gas capture system 20, particularly, in each of the contactors (e.g., 208, 210, 212) in each of the stages 202. 204, and 206. In general, the gas capture system 20 and the various the contactors (e.g., 208, 210, 212) may be a sealed system, particularly to help reduce contamination by outside fluids (e.g., air). Thus, if the % of inlet O2 262i and the % of outlet O2 262j indicate an increasing percentage of O2, then the gas capture optimizer 66 may generate an alert, alarm, or message to an operator via a computer display and / or control one or more parameters of the gas capture system 20 to help reduce the impact of the possible leakage. In certain embodiments, the % of inlet O2 262i may be used by the gas capture optimizer 66 to control the oxygen content in the untreated gas received by the gas capture system 20, such as by controlling an air-fuel ratio of combustion in the gas turbine system 12.

[0049] In certain embodiments, the gas capture optimizer 66 may monitor and compare the % of inlet H2O and the % of outlet H2O to obtain a measurement or calculation of H2O adsorbed into the sorbent material (e.g., 220. 222, 224) over time during adsorption stage 202, thereby monitoring an H2O adsorption rate over time. The H2O adsorption rate may be an indicator used by the gas capture optimizer 66 to determine when the sorbent material is approaching the saturation point (or an upper threshold saturation percentage of the saturation point). For example, if the H2O and / or CO2 adsorption rates decreases to a threshold adsorption rate, then the gas capture optimizer 66 may trigger a transition from the adsorption stage 202 to the desorption stage 204 for the particular contactor (e.g., 208, 210, 212). Similarly, the gas capture optimizer 66 may monitor the % of H2O collected over time during desorption stage 204, thereby monitoring a H2O desorption rate over time. The H2O desorption rate maybe an indicator used by the gas capture optimizer 66 to determine when the sorbent material is approaching a zero saturation (or a lower threshold saturation percentage of the saturation point). For example, if the H2O and / or CO2 desorption rates decreases to a threshold desorption rate, then the gas capture optimizer 66 may trigger a transition from the desorption stage 204 to the cooling stage 206 for the particular contactor (e.g., 208, 210, 212).

[0050] In certain embodiments, the gas capture optimizer 66 may monitor and compare the contactor temperature 262f against one or more temperature thresholds (e.g., upper and lower thresholds) to enable control of the contactor temperature 262f during the stages 202, 204. and 206. For example, the adsorption may be most efficient below an upper adsorption temperature threshold and / or within upper and lower adsorption temperature thresholds for the adsorption stage 202. Thus, the gas capture optimizer 66 may control the cooling source 230 and / or other operating parameters during the adsorption stage 202 to maintain the contactor temperature 262f within the upper and lower adsorption temperature thresholds. Similarly, the desorption may be most efficient above a lower desorption temperature threshold and / or within upper and lower desorption temperature thresholds for the desorption stage 204. Thus, the gas capture optimizer 66 may control the heating source 234 and / or other operating parameters during the desorption stage 204 to maintain the contactor temperature 262f within the upper and lower desorption temperature thresholds. Finally, the gas capture optimizer 66 may control the contactor temperature 262f within upper and lower cooling temperature thresholds during the cooling stage 206. Each of the foregoing temperature adjustments or optimizations by the gas capture optimizer 66 may account for power consumption, efficiency of the adsorption and desorption of the sorbent material, cycle times, and various other considerations.

[0051] In general, the gas capture optimizer 66 may receive the sensor feedback 262 and determine an inefficient part of the process and / or a component that may be degrading. In certain embodiments, the gas capture optimizer 66 may measure and analyze the contactor temperature 262f during each of the stages 202, 204, 206, the CO2 adsorption rate based on the % of inlet CO2262c and the % of outlet CO2 262d during the adsorption stage 202, the H2O adsorption rate based on the % of inlet H2O and the% of outlet H2O during the adsorption stage 202, the possible O2 leakage based on the % of inlet O2262i and the % of outlet O2 during the adsorption stage 202, the % of CO2 collected 262e during the adsorption stage 204. the contactor vacuum condition 262g during the desorption stage 204, and the sorbent utilization and power consumption 262h during the various stages 202, 204, 206. The gas capture optimizer system 66 may analyze the foregoing measurements and calculations of operating parameters, relationships between the various operating parameters, and tradeoffs between optimizing one parameter versus another parameter. The foregoing analysis may include use of computer models, lookup tables, and machine learning associated with the stages 202, 204, 206 and the entire operation of the gas capture system 20. In an example, the gas capture optimizer 66 may receive sensor feedback indicating that the contactor temperature 262f during the adsorption stage 202 is above an upper absorption temperature threshold or below a lower absorption temperature threshold, and output a control signal and / or alert to control the cooling source 230 to adjust a temperature and / or flow rate of cooling fluid to adjust the contactor temperature 262f between the upper and lower adsorption temperature thresholds. As appreciated, the adsorption stage 202 may consume too much power if the contactor temperature 262f is below the lower desorption temperature threshold, whereas the adsorption stage 202 may be too inefficient at adsorption if the contactor temperature 262f is above the upper adsorption temperature threshold. In another example, the gas capture optimizer 66 may receive sensor feedback indicating that the contactor temperature 262f during the desorption stage 204 is above an upper desorption temperature threshold or below a lower desorption temperature threshold, and output a control signal and / or alert to control the heating source 234 to adjust a temperature and / or flow rate of heating fluid to adjust the contactor temperature 262f between the upper and lower desorption temperature thresholds. As appreciated, the desorption stage 204 may be too inefficient at desorption if the contactor temperature 262f is below the lower desorption temperature threshold, whereas the desorption stage 204 may consume too much power if the contactor temperature 262f is above the upper desorption temperature threshold. Accordingly, the gas capture optimizer 66 may receive sensor feedback 262 and determine one or more inefficient processes of the gas capture system 20 (e.g., carboncapture system 100) and output a control signal and / or alert to control the gas capture system 20 to take corrective action.

[0052] Once the gas capture optimizer 66 determines or identifies one or more inefficient processes of the gas capture system 20 (e.g., carbon capture system 100), the gas capture optimizer 66 may adjust one or more components, cycle times, or processes of the gas capture system 20 (e.g., carbon capture system 100). For example, the gas capture optimizer 66 may adjust cycle times (e.g., delta optimized cycle time 264) for each of the stages 202, 204, 206, reduce degradation of certain components (e.g., component degradation 266), or a combination thereof. The delta optimized cycle time 264 may be a tradeoff between various operating parameters, such as the power consumption, the cost of energy (e.g., cost of electricity), adsorption rate, desorption rate, percentage saturation of saturation point, or any combination thereof. For example, when the current cost of electricity is high, then the gas capture optimizer 66 may reduce the power consumption for cooling and heating during the respective adsorption and desorption stages 202, 204, thereby causing a change in the delta optimized cycle time 264. By further example, when the current cost of electricity is low, then the gas capture optimizer 66 may increase the power consumption for cooling and heating during the respective adsorption and desorption stages 202, 204, thereby causing a change in the delta optimized cycle time 264. The delta optimized cycle time 264 may be achieved by applying a change to the operating conditions of one or more components (e.g., DAC cycle time original + / - delta optimized) or optimizing inlet gas flow 270. For example, if the gas capture optimizer 66 determines that the temperature of the contactor 210 during the desorption stage 204 is greater (e.g., 175 degrees Celsius) than a threshold value (e.g., 100 to 150 degrees Celsius), the gas capture optimizer 66 may adjust the temperature of the contactor 210 by controlling the heating source 234 (e.g. reducing flow rate and / or temperature of heating fluid) to reduce the temperature of the contactor 210. In this way, the gas capture optimizer 66 may apply a "‘negative (-) delta” to adjust (e.g.. reduce) the temperature of the contactor 210 relative to the previous temperature (e.g., 175 degrees Celsius). Alternatively, if the gas capture optimizer 66 determines that the contactor 210 is operating at a temperature lower (e.g., 90 degrees Celsius) than the threshold value (e.g., 100 to 150 degreesCelsius) during the desorption stage 204, the gas capture optimizer 66 may apply a “positive (-) delta” to adjust (e.g., increase) the temperature of the contactor 210 relative to the previous temperature during the desorption stage 204. In some embodiments, the gas capture optimizer 66 may reduce or increase a cycle time based on the energy consumption of one of the stages 202, 204, 206. It should be noted that the gas capture optimizer 66 may compare the sensor feedback data (e.g.. parameters 262) with the threshold value (e.g.. a pre-existing value, such as standard operating values, or a first measurement generated by the one or more sensors 226.

[0053] In some embodiments, the gas capture optimizer 66 may adjust operating conditions to reduce or inhibit component degradation 266. The component degradation 266 may include sorbent degradation of sorbent material (e.g., 220, 222, 224) in the contactors (e.g., 208, 210, 212), component degradation of moving parts (e.g., pumps, compressors, condensers, fans, valves, etc.), corrosion of materials due to water, acid gases, or the like in the fluid flows, mechanical wear, or any combination thereof. Sorbent degradation may be caused by exposure of the sorbent material (e.g., 220, 222, 224) to large temperature changes and various fluids over the stages 202, 204, 206, such as high temperatures, high humidity levels, acid gases, and other detrimental substances in the untreated gas during the adsorption stage 202. For example, if the gas capture optimizer 66 detects a high humidity level in the untreated gas (e.g., above an upper humidity threshold), then the gas capture optimizer 66 may output a control signal and / or alert to take corrective action to reduce the humidity level (e.g., activate a humidity controller or water / gas separator upstream from the adsorption stage 202). In another example, if the gas capture optimizer 66 detects oxygen leakage, then the gas capture optimizer 66 may output a control signal and / or alert to take corrective action to eliminate the oxygen leakage. In another example, the gas capture optimizer 66 may adjust temperature of the contactor 208, 210, 212 to extend the adsorptive properties of sorbent material 220, 222, 224. As such, the gas capture optimizer 66 may adjust one or more components processes, or cycle times to advantageously decrease energetics of the gas capture system 20 (e.g., carbon capture system 100).

[0054] With the preceding in mind, FIG. 4 is a flow chart of a process 300 for monitoring the gas capture system 20 (e.g., carbon capture system 100) and adjustingcycle time, processes, or components of the system based on sensor feedback 262 using the gas capture optimizer 66, in accordance with embodiments described herein. The process 300 may be performed by the gas capture system 20. the control system 22. a computing device, and / or the gas capture optimizer 66 disclosed above with reference to FIG. 1 or any other suitable computing device(s) or controller(s). Furthermore, the blocks of the process 300 may be performed in the order disclosed herein or in any suitable order. For example, certain blocks of the process 300 may be performed concurrently or consecutively. In addition, in certain embodiments, at least one of the blocks of the process 300 may be omitted. Further, it should be noted, that the gas capture system 20 may iteratively perform the blocks outlined in process 300.

[0055] At block 302 of the process 300, the gas capture optimizer 66 may control a gas capture system 20 having one or more adsorbers. The adsorbers may be operating in an adsorption stage 202, desorption stage 204, or cooling stage 206. Each operational stage of the adsorbers may include contactors, which may be used to facilitate a distinct portion of a process to remove undesirable gases from untreated air introduced to the gas capture system 20. To transition between said stages (e.g., adsorption stage, desorption stage, cooling stage) a temperature swing or change may be used to sequentially operate the contactors at different temperatures to increase an efficiency of the gas capture system 20. Accordingly, at block 304 of the process 300, the gas capture optimizer 66 may monitor the one or more sensors 226 coupled to one or more adsorbers to obtain sensor feedback. The sensor feedback 262 may be inputted into the gas capture optimizer 66 to determine whether one or more components of the gas capture system 20 need to be adjusted. As such, at block 306 of the process 300. the gas capture optimizer 66 may be executed to control one or more parameters (e.g., one or more components) of the adsorption, desorption, and cooling stages based on sensor feedback.

[0056] At block 308, the gas capture optimizer 66 may determine if the one or more the stages are in cycle. Based on the stage that is in cycle, the gas capture optimizer 66 may begin its optimization process accordingly. As such, at blocks 310a, 310b, 310c, the gas capture optimizer 66 may initiate optimization of the ongoing cycle (e.g., adsorption, desorption, cooling). At block 312a. 310b, 310c, the gas capture optimizer66 may compare sensor feedback with threshold values (e.g., a preset value or a first measurement) associated with the specific stage in cycle to obtain a comparison. As such, at block 314a, 314b, 314c, the gas capture optimizer 66 may analyze comparisons. For example, the gas capture optimizer 66 may determine that % of outlet CO2 is comparable to % of inlet CO2 while the adsorber is in the adsorption stage, indicating that the sorbent material of the adsorber is saturated and unable to adsorb any more CO2. The gas capture optimizer 66 may also analyze sensor feedback from other sensors 226 when analyzing the comparisons. For example, the gas capture optimizer 66 may also determine that sensor feedback associated with sorbent utilization and power consumption is low relative to a threshold value, which may be the reason for the adsorbers inability to adsorb CO2. In this way. the gas capture optimizer 66 may utilize sensor feedback from a plurality of sensors prior to adjusting a parameter.

[0057] Accordingly, at block 316a, 316b, 316c, the gas capture optimizer 66 mayadjust parameters of the stage or cycle (e g., adsorption stage 202, desorption stage 204, or cooling stage 204). For example, the gas capture optimizer 66 may reduce inlet gas flow to reduce energy costs, reduce the time of the adsorption stage cycle, or reduce the temperature of the contactor to promote adsorption of the CO2 with respect to the preceding example in block 314a, 314b, 314c. As such, at block 318a, 318b, 318c, the gas capture optimizer 66 may control the stage or cycle based on the adjustment. In this way, the gas capture optimizer 66 advantageously is able to identify inefficient aspects of the gas capture system 20 and optimize the processes accordingly.

[0058] By way of example. FIG. 5 is a flow chart of a process 350 for training the gas capture optimizer 66 with machine learning, in accordance with embodiments described herein. The process 350 may be performed by the gas capture system 20, the control system 22, a computing device, and / or the gas capture optimizer 66 disclosed above with reference to FIGS. 1-4 or any other suitable computing device(s) or controller(s). Furthermore, the blocks of the process 350 may be performed in the order disclosed herein or in any suitable order. For example, certain blocks of the process 350 may be performed concurrently or consecutively. In addition, in certain embodiments, at least one of the blocks of the process 350 may be omitted. Further, it should be noted,that the gas capture system 20 may iteratively perform the blocks outlined in process 350.

[0059] At block 352 of the process 350, the gas capture optimizer 66 may receive historical data and computer model data regarding operation of the gas capture system 20 having one or more adsorbers operating in adsorption, desorption, and cooling stages. The historical data may include operating data of the gas capture system 20 over the course of any desired duration of time, including many days, weeks, months, or years. The historical data also may include operating data of a plurality of gas capture systems at different sites, such that operating data may include similar or different operating conditions (e.g., altitude, atmospheric temperature, weather conditions, untreated gases, etc.). In contrast, the computer model data may include simulated data that is modelled based on operating conditions of the gas capture system 20. The historical and simulated data may include any of the operating parameters discussed herein, including, for example, all inputs to and calculations by the gas capture optimizer 66 as discussed in detail above with reference to FIG. 3. For example, the historical and simulated data may include the temperature of the contactor / sorbent material in the stages 202, 204, 206, the temperature, fluid composition, and flow rate of the untreated gas flowing through the adsorption stage 202, the temperature and flow rate of cooling and heating fluids from the cooling sources 230. 232 and the heating source 234, the CO2 adsorption and desorption rates in the adsorption and desorption stages 202, 204, the power consumption during the stages 202, 204, 206, and any other operating parameters affecting the gas capture system 20.

[0060] At block 354, the gas capture optimizer 66 is trained based on the historical data and model data. In this way, the gas capture optimizer 66 may be trained in using a variety7of data covering a wide range of operating conditions, such that it may identify inefficient processes of the gas capture system 20. At block 356, gas capture optimizer 66 may be executed to provide initial settings for parameters of the adsorption, desorption, and cooling stages. For example, the gas capture optimizer 66 may utilize historical data and / or modelled data to generate threshold data or values, such as upper and lower threshold values for the temperature of the contactor / sorbent material in the stages 202. 204, 206. the temperature, fluid composition, and flow rate of the untreatedgas flowing through the adsorption stage 202, the temperature and flow rate of cooling and heating fluids from the cooling sources 230, 232 and the heating source 234, the CO2 adsorption and desorption rates in the adsorption and desorption stages 202, 204. the power consumption during the stages 202, 204, 206, and any other operating parameters affecting the gas capture system 20. In certain embodiments, the upper and lower threshold values may account for a current, average, or forecast price of electricity, demand for electricity, weather conditions, carbon credits, demand for captured gas (e.g., CO2), price for captured gas (e g., CO2), or any combination thereof.

[0061] At block 358, the gas capture optimizer 66 may control the gas capture system 20 based on the initial settings for parameters of the adsorption, desorption, and cooling stages 202, 204, 206. Accordingly, the three stages may be operated using the threshold data generated at block 356. Based on the initial settings, at block 360, the gas capture optimizer 66 may monitor sensors coupled to the one or more adsorbers to obtain sensor feedback associated with the stage 202, 204. 206. Based on the sensor feedback, at block 362, the gas capture optimizer 66 analyzes initial settings (e.g., threshold data) and sensor feedback. For example, the gas capture optimizer 66 may analyze trends or changes (e.g., rates of increase or decrease) of the temperature, fluid composition, and flow rate of the untreated gas flowing through the adsorption stage 202, the temperature and flow rate of cooling and heating fluids from the cooling sources 230, 232 and the heating source 234, the CO2 adsorption and desorption rates in the adsorption and desorption stages 202, 204, the power consumption during the stages 202. 204, 206, and any other operating parameters affecting the gas capture system 20. The gas capture optimizer 66 also may analyze trends or changes (e.g., rates of increase or decrease) of the price of electricity, demand for electricity, weather conditions, carbon credits, demand for captured gas (e.g., CO2), price for captured gas (e.g., CO2), or any combination thereof. The gas capture optimizer 66 also may analyze trends or changes (e.g., rates of increase or decrease) of the component health or degradation, such as the sorbent materials in the contactors.

[0062] At block 364, based on the analysis, the gas capture optimizer 66 may generate adjusted settings for parameters of the adsorption, desorption, and cooling stages 202. 204, 206. As such, at block 366, the gas capture optimizer 66 may controlone or more parameters of the gas capture system 20 (e.g., carbon capture system 100) based on the adjusted settings associated with the adsorption, desorption, and / or cooling stages 202. 204, 206. For example, the gas capture optimizer 66 may maintain and / or adjust the upper and lower threshold values for the temperature of the contactor / s orbent material in the stages 202, 204, 206, the temperature, fluid composition, and flow rate of the untreated gas flowing through the adsorption stage 202, the temperature and flow rate of cooling and heating fluids from the cooling sources 230. 232 and the heating source 234, the CO2 adsorption and desorption rates in the adsorption and desorption stages 202, 204, the power consumption during the stages 202, 204, 206, and any other operating parameters affecting the gas capture system 20.

[0063] Technical effects of the disclosed embodiments enable improved or optimized control of the operating parameters of the gas capture system 20, including operating parameters of the adsorption, desorption, and cooling stages 202, 204, 206. A technical problem with previous gas capture systems 20 is a lack of dynamic control based on a myriad of factors, including both operating parameters of the gas capture system 20 and external factors such as the price of electricity, demand for electricity, weather conditions, carbon credits, demand for captured gas (e.g., CO2), price for captured gas (e g., CO2), or any combination thereof. For example, a technical problem with previous gas capture systems 20 may be in that the gas capture system merely has fixed cycle times and / or fixed operating parameters, which can detrimentally impact the operating costs, efficiency, and component degradation without taking advantage of changes in the external factors. Accordingly, a technical solution to this technical problem dynamically controls the operating parameters of the gas capture system 20 via the gas capture optimizer 66 and controller 22, such as in real-time, taking full consideration of the external factors. Thus, if electricity costs decrease, the gas capture optimizer 66 may prioritize higher gas capture rates over power consumption rates by controlling the gas capture system 20 to consume more power to increase efficiency of the adsorption, desorption, and cooling stages 202. 204, 206, to increase the gas capture rates (e.g., volume of CO2 per time), and so forth. For example, the gas capture optimizer 66 may control the cooling source 230 to cool the sorbent material to a lower temperature during the adsorption stage 202, control the heating source 234 to heat thesorbent material to a higher temperature during the desorption stage 204, and / or control the cooling source 232 to cool the sorbent material to a lower temperature during the cooling stage 206. In turn, the changes in cooling and heating may alter the cycle times for the stages 202, 204, 206. In some embodiments, while the electricity costs are low, the gas capture optimizer 66 may increase the cycle times for the stages 202, 204, 206, even though the adsorption and desorption rates may gradually decrease later in the cycles (thereby gradually costing more for less adsorption and desorption later in the cycles). In contrast, if electricity costs increase, the gas capture optimizer 66 may prioritize lower power consumption over higher gas capture rates by controlling the gas capture system 20 to consume less power with reduced efficiency of the adsorption, desorption, and cooling stages 202, 204, 206. In some embodiments, while the electricity costs are high, the gas capture optimizer 66 may reduce the cycle times for the stages 202, 204, 206, even though the reduced cycle time may not fully adsorb and desorb the undesirable gases (e.g., CO2). In certain embodiments, the gas capture optimizer 66 may prioritize component health (e.g., sorbent material health) over other considerations (e.g., adsorption and desorption efficiency, power consumption, etc.), particularly if the component health is declining and / or past a threshold value, if costs for new sorbent material is increasing and / or high, if time is needed for future service scheduling, and / or for other reasons. Thus, the gas capture optimizer 66 may optimize various operating parameters gas capture system 20 based on operating parameters, external factors, and / or certain priorities.

[0064] The subject matter described in detail above may be defined by one or more clauses, as set forth below.

[0065] In certain embodiments, a method includes monitoring at least one operating parameter of a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage. The method further includes controlling a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

[0066] The method of the preceding clause, wherein the undesirable gas includes carbon dioxide (CO2).

[0067] The method of any preceding clause, wherein the sorbent-based gas capture system comprises a post combustion capture system and the gas flow includes an exhaust gas flow, or the sorbent-based gas capture system comprises a direct air capture system and the gas flow comprises an air flow.

[0068] The method of any preceding clause, wherein the at least one operating parameter includes a sorbent saturation level during the adsorption stage, the desorption stage, or a combination thereof, wherein controlling the cycle time is based on the sorbent saturation level relative to at least one sorbent saturation threshold.

[0069] The method of any preceding clause, wherein the at least one operating parameter includes an amount of the undesirable gas in the gas flow at a first position upstream from a sorbent-based contactor, a second position downstream from the sorbent-based contactor, or a combination thereof, in the adsorption stage.

[0070] The method of any preceding clause, wherein the at least one operating parameter includes an amount of the undesirable gas in an extracted flow downstream from a sorbent-based contactor in the desorption stage.

[0071] The method of any preceding clause, wherein the at least one operating parameter includes an adsorption rate of the undesirable gas adsorbed in the adsorption stage, a desorption rate of the undesirable gas desorbed in the desorption stage, or a combination thereof, wherein controlling the cycle time is based on the adsorption rate relative to an adsorption rate threshold, a desorption rate relative to a desorption rate threshold, or a combination thereof.

[0072] The method of any preceding clause, wherein the at least one operating parameter includes a temperature of a sorbent-based contactor in the adsorption, desorption, and cooling stages, wherein controlling the cycle time comprises controlling the temperature of the sorbent-based contactor in the adsorption, desorption, and cooling stages based on one or more temperature thresholds.

[0073] The method of any preceding clause, wherein the at least one operating parameter includes amounts of water, oxygen, and undesirable gas in the gas flow during the adsorption stage.

[0074] The method of any preceding clause, wherein the at least one operating parameter includes a power consumption during the adsorption, desorption, and cooling stages, wherein controlling the cycle time includes controlling the power consumption in the adsorption, desorption, and cooling stages based on a cost of power, a demand for power, a demand for the undesirable gas, a price of the undesirable gas, or a combination thereof.

[0075] The method of any preceding clause, including increasing the power consumption to reduce the cycle time, decreasing the power consumption to increase the cycle time, or a combination thereof.

[0076] The method of any preceding clause, wherein controlling the cycle time includes controlling a plurality of cycle times including an adsorption cycle time of the adsorption stage, a desorption cycle time of the desorption stage, and a cooling cycle time of the cooling stage, wherein controlling the plurality of cycle times includes dynamically varying each of the plurality of cycle times via a gas capture optimizer to control a power consumption, an efficiency or rate of the sorbent-based gas capture system, and a health or degradation of the sorbent-based gas capture system.

[0077] The method of any preceding clause, wherein controlling the plurality of cycle times includes increasing the power consumption and increasing the efficiency or rate of the sorbent-based gas capture system in response to a decrease in a cost of power or an increase in a demand for power. The method further includes decreasing the power consumption and decreasing the efficiency or rate of the sorbent-based gas capture system in response to an increase in the cost of power or a decrease in the demand for power.

[0078] The method of any preceding clause, wherein the gas capture optimizer includes a computer model, a machine learning system, and historical data relating to the sorbent-based gas capture system.

[0079] The method of any preceding clause, including monitoring, via a processor, a plurality of sensors to obtain the at least one operating parameter, wherein the plurality of sensors is coupled to a plurality of sorbent-based contactors in the sorbent-based gas capture system. The method also includes determining, via the processor, a comparison between a plurality of sensor data and threshold data of the at least one operating parameter. The method further includes analyzing, via the processor, the comparison between the plurality of sensor data and threshold data of the at least one operating parameter. The method includes generating, via the processor, adjusted settings based on the comparison. The method further includes controlling, via the processor, the gas capture system based on the adjusted settings, wherein the adjusted settings comprise the cycle time, cooling settings of a cooling source, heating settings of a heating source, a temperature of the plurality of sorbent-based contactors, adsorption settings, and desorption settings.

[0080] In certain embodiments, a system includes a controller having a memory, a processor, and instructions stored on the memory and executable by the processor to monitor at least one operating parameter of a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage. The controller is also configured to control a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

[0081] The system of the preceding clause, including the sorbent-based gas capture system including a plurality of sorbent-based contactors that cycle through the plurality of stages, wherein the undesirable gas comprises carbon dioxide (CO2), wherein the gas flow comprises an exhaust gas flow or an air flow.

[0082] The system of any preceding clause, wherein the controller includes a gas capture optimizer to control a power consumption, an efficiency or rate of the sorbentbased gas capture system, and a health or degradation of the sorbent-based gas capture system when controlling the cycle time.

[0083] In certain embodiments, a system includes a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbentbased gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage, and the sorbent-based gas capture system includes a first sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage. The sorbent-based gas capture system further includes a second sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage. The sorbent-based gas capture system further includes a third sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage, wherein the first, second, and third sorbent-based contactors cycle through the plurality of stages in a staggered manner. The sorbent-based gas capture system further includes a controller configured to monitor at least one operating parameter of the sorbent-based gas capture system. The controller is further configured to control a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

[0084] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

Claims:

1. A method, comprising: monitoring at least one operating parameter of a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbentbased gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage; and controlling a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

2. The method of claim 1, wherein the undesirable gas comprises carbon dioxide (CO2).

3. The method of claim 2, wherein the sorbent-based gas capture system comprises a post combustion capture system and the gas flow comprises an exhaust gas flow, or the sorbent-based gas capture system comprises a direct air capture system and the gas flow comprises an air flow.

4. The method of claim 1, wherein the at least one operating parameter comprises a sorbent saturation level during the adsorption stage, the desorption stage, or a combination thereof, wherein controlling the cycle time is based on the sorbent saturation level relative to at least one sorbent saturation threshold.

5. The method of claim 1, wherein the at least one operating parameter comprises an amount of the undesirable gas in the gas flow at a first position upstream from a sorbent-based contactor, a second position downstream from the sorbent-based contactor, or a combination thereof, in the adsorption stage.

6. The method of claim 1 , wherein the at least one operating parameter comprises an amount of the undesirable gas in an extracted flow downstream from a sorbent-based contactor in the desorption stage.

7. The method of claim 1. wherein the at least one operating parameter comprises an adsorption rate of the undesirable gas adsorbed in the adsorption stage, a desorption rate of the undesirable gas desorbed in the desorption stage, or a combination thereof, wherein controlling the cycle time is based on the adsorption rate relative to an adsorption rate threshold, a desorption rate relative to a desorption rate threshold, or a combination thereof.

8. The method of claim 1. wherein the at least one operating parameter comprises a temperature of a sorbent-based contactor in the adsorption, desorption, and cooling stages, wherein controlling the cycle time comprises controlling the temperature of the sorbent-based contactor in the adsorption, desorption, and cooling stages based on one or more temperature thresholds.

9. The method of claim 1, wherein the at least one operating parameter comprises amounts of water, oxygen, and undesirable gas in the gas flow during the adsorption stage.

10. The method of claim 1, wherein the at least one operating parameter comprises a power consumption during the adsorption, desorption, and cooling stages, wherein controlling the cycle time comprises controlling the power consumption in the adsorption, desorption, and cooling stages based on a cost of power, a demand for power, a demand for the undesirable gas, a price of the undesirable gas, or a combination thereof.

11. The method of claim 10, comprising increasing the power consumption to reduce the cycle time, decreasing the power consumption to increase the cycle time, or a combination thereof.

12. The method of claim 1 , wherein controlling the cycle time comprises controlling a plurality of cycle times including an adsorption cycle time of the adsorption stage, adesorption cycle time of the desorption stage, and a cooling cycle time of the cooling stage, wherein controlling the plurality of cycle times comprises dynamically varying each of the plurality of cycle times via a gas capture optimizer to control a power consumption, an efficiency or rate of the sorbent-based gas capture system, and a health or degradation of the sorbent-based gas capture system.

13. The method of claim 12. wherein controlling the plurality of cycle times comprises: increasing the power consumption and increasing the efficiency or rate of the sorbent-based gas capture system in response to a decrease in a cost of power or an increase in a demand for power; and decreasing the power consumption and decreasing the efficiency or rate of the sorbent-based gas capture system in response to an increase in the cost of power or a decrease in the demand for power.

14. The method of claim 12, wherein the gas capture optimizer comprises a computer model, a machine learning system, and historical data relating to the sorbentbased gas capture system.

15. The method of claim 1. comprising: monitoring, via a processor, a plurality of sensors to obtain the at least one operating parameter, wherein the plurality of sensors is coupled to a plurality of sorbent-based contactors in the sorbent-based gas capture system; determining, via the processor, a comparison between a plurality’ of sensor data and threshold data of the at least one operating parameter; analyzing, via the processor, the comparison between the plurality of sensor data and threshold data of the at least one operating parameter; generating, via the processor, adjusted settings based on the comparison; and controlling, via the processor, the gas capture system based on the adjusted settings, wherein the adjusted settings comprise the cycle time, cooling settings of a cooling source, heating settings of a heating source, a temperature of the plurality of sorbent-based contactors, adsorption settings, and desorption settings.

16. A system, comprising: a controller having a memory, a processor, and instructions stored on the memory and executable by the processor to: monitor at least one operating parameter of a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage; and control a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

17. The system of claim 16, comprising the sorbent-based gas capture system comprising a plurality of sorbent-based contactors that cycle through the plurality of stages, wherein the undesirable gas comprises carbon dioxide (CO2), wherein the gas flow comprises an exhaust gas flow or an air flow.

18. The system of claim 16, wherein the controller comprises a gas capture optimizer to control a power consumption, an efficiency or rate of the sorbent-based gas capture system, and a health or degradation of the sorbent-based gas capture system when controlling the cycle time.

19. A system, comprising: a sorbent-based gas capture system configured to capture an undesirable gas from a gas flow, wherein the sorbent-based gas capture system comprises a plurality of stages including an adsorption stage, a desorption stage, and a cooling stage, and the sorbent-based gas capture system comprises: a first sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage; a second sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage; a third sorbent-based contactor configured to cycle through the adsorption stage, the desorption stage, and the cooling stage, wherein the first,second, and third sorbent-based contactors cycle through the plurality of stages in a staggered manner; and a controller configured to: monitor at least one operating parameter of the sorbent-based gas capture system; and control a cycle time of at least one of the plurality of stages based on the at least one operating parameter.

20. The system of claim 19, wherein the controller comprises a gas capture optimizer to control a power consumption, an efficiency or rate of the sorbent-based gas capture system, and a health or degradation of the sorbent-based gas capture system when controlling the cycle time.

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