System and method for controlling gas capture system operating parameters

Abstract

A system includes a carbon capture system. The system also includes a controller having a memory, a processor, and instructions stored on the memory and executable by the processor. The controller is configured to monitor sensor feedback associated with a first contactor of the carbon capture system, wherein the first contactor includes a sorbent material. The controller is also configured to analyze the sensor feedback to determine a health of the first contactor. The controller is also configured to adjust one or more operating parameters for the first contactor based on the health of the first contactor.

Description

SYSTEM AND METHOD FOR CONTROLLING GAS CAPTURE SYSTEM OPERATING PARAMETERSBACKGROUND

[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 system includes a carbon capture system. The system also includes a controller having a memory, a processor, and instructions stored on the memory and executable by the processor. The controller is configured to monitor sensor feedback associated with a first contactor of the carbon capture system, wherein the first contactor includes a sorbent material. The controller is also configured to analyze the sensor feedback to determine a health of the first contactor. The controlleris also configured to adjust one or more operating parameters for the first contactor based on the health of the first contactor.

[0005] In certain embodiments, a system includes a carbon capture system. The carbon capture system includes a vessel and a contactor disposed inside the vessel. The contactor includes a sorbent material. The system also includes a controller having a memory, a processor, and instructions stored on the memory and executable by the processor. The controller is configured to monitor sensor feedback associated with the contactor. The controller is also configured to analyze the sensor feedback to determine a health of the contactor. The controller is also configured to adjust one or more operating parameters for the contactor based on the health of the contactor.

[0006] In certain embodiments, a method includes monitoring, via a processor, sensor feedback associated with a contactor of a carbon capture system. The contactor includes a sorbent material. The method also includes analyzing, via the processor, the sensor feedback to determine a health of the contactor. The method also includes adjusting, via the processor, one or more operating parameters for the contactor based on the health of the contactor.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 diagram of an embodiment of the gas capture system of FIG. 1, further illustrating subsystems of the gas capture system, in accordance with embodiments described herein;

[0011] FIG. 4 is a flowchart of an embodiment of a process of operating the gas capture system of FIG. 1, wherein one or more operating parameters for the contactor are adjusted during an adsorption stage, a desorption stage, and / or a cooling stage, in accordance with embodiments described herein; and

[0012] FIG. 5 is a flowchart of an embodiment of a process of operating the gas capture system of FIG. 1, wherein one or more operating parameters for the contactor are adjusted based on a health of the contactor, 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 for those 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 mean that 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] The disclosed embodiments enable increase in efficiency of a gas capture system by responding to increased inefficiency of the contactors and / or the sorbent material over time. A technical problem with previous gas capture systems is that as the contactors and / or the sorbent material degrade over time, they become less responsive to steam (e.g., used to desorb undesirable gases trapped in the sorbent material) having a fixed set of characteristics (e.g., parameters). That is, as the contactors and / or the sorbent material degrades over time, the steam, if left unchanged, becomes less effective at sweeping the entrapped carbon dioxide, thereby resulting in less carbon dioxide being freed from the sorbent material. Accordingly, the embodiments disclosed herein include monitoring a health of the sorbent material and / or the contactor and dynamically controlling operating parameters of the gas capture system based on the health of the sorbent material and / or the contactor. For example, the health of the sorbent material and / or the contactor may be based on a moisture level, a temperature, and / or a level of degradation of the sorbent material. In response to a level of health of the sorbent material and / or the contactor falling belowa threshold level of health, the controller may adjust one or more operating parameters associated with the sorbent material and / or the contactor. For example, the controller may control the pressure control system to adjust a pressure and / or a flowrate of the steam. Additionally or alternatively, the controller may control the steam generator to adjust a temperature of the steam. Additionally or alternatively, the controller may control a duration of time during which the steam is injected into the vessel.

[0017] 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 use in 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 12. 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.

[0018] 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 56 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), one or more fuels (e.g., liquid fuel, gas fuel, etc.), additives for combustion, exhaust gas (e.g., exhaust gas recirculation), or other fluids.

[0019] 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.

[0020] 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 maybe atmospheric air when the gas capture system 20 is configured as a direct air capture system. 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).

[0021] 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 112 (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 andstored 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.

[0022] 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 or contactors having a sorbent material). In certain embodiments, the sorbent material may include porous, solidphase 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 of systems to support transitions between cycles of absorption, desorption, cooling, and the like, thereby facilitating carbon capture.

[0023] 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, health of the carbon capture system 100 (e.g., sorbent material of the absorbers), or any combination thereof. The sensors 128 may include temperature sensors, pressure sensors, flow rate sensors, gas composition sensors, or any combination thereof.

[0024] 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 controllingmodes 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 66 configured to adjust (e.g., control and optimize) operating parameters of the gas capture system 20 in response to changing health conditions in the gas capture system 20 (e.g., degradation or changing health of the sorbent material of the absorbers). 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. Similarly, 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, that provides operating setpoints for the gas capture system 20 based on health conditions (e.g., degradation or changing health of the sorbent material of the absorbers). For example, as the health of the sorbent material degrades over time, the gas capture optimizer 66 may increase cooling (e.g., increase a cooling flow rate, decrease a cooling temperature, increase a cycle time, etc.) during the adsorption mode and / or the cooling mode, and the gas capture optimizer 66 may increase heating (e.g., increase a heating flow rate, increase a heating temperature, increase a cycle time, etc.) during the desorption mode. If steam is used for the desorption mode, then the gas capture optimizer 66 may increase the heating by adjusting steam characteristics, such as by selecting a steam extraction location having a higher steam temperature, a higher steam pressure, or a combination thereof. 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 carbon capture system 100 as shown in FIG. 2. In some embodiments, the controller 22 and / or the gas capture optimizer 66 may interface withone 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.

[0025] 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 213 (e.g., 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.

[0026] 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. Additionally, the gas capture optimizer 66 is configured to adjust operating parameters of the gas capture system 20 based on a health condition of the plurality of contactors (e.g., contactors 208, 210. 212). and particularly a sorbent health condition of sorbent materials 213 (e.g.. sorbent materials 220. 222, 224). The health condition (e.g., sorbent health condition) may be evaluated with a health score over a health range, such as 0 to 10, 0 to 100, A through F, or the like. For example, a minimum health score may be 0 or F whereas a maximum health score may be 10, 100, or A. Depending on the health condition (or health score), the gas capture optimizer 66 may change cycle times, operating conditions during the cycle, or any combination thereof, to address health degradation (e.g., sorbent degradation) to improve operation of the gas capture system 20.

[0027] 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 the one or more sensors 128, designated as (S), positioned throughout the gas capture system 20. The one or more sensors 128 (e.g., temperature sensors, pressure sensors, flow rate sensors, gas composition sensors, or any combination thereol) may be measure parameters associated with the gas capture system 20. The one or more sensors 128 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.

[0028] 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 heattransfer (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 220 may control a flow of the fluids from the cooling source 230. 232 and the heating source 234to 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, a cooling 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.

[0029] 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 62 and / or treated air 64) 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.. cooledwater, 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. Additionally, the adsorption and desorption efficiency of the sorbent material may degrade over time, and thus the sorbent health condition decreases over time. In certain embodiments, the controller 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.) at least partially based on sensor feedback and the health condition (e.g., sorbent health condition) of the sorbent materials 213 (e.g., sorbent materials 220, 222, 224). For example, if the health condition increases, then the controller 22 and the gas capture optimizer 66 may reduce a cycle time and / or reduce cooling (e.g., cooling temperature, flow rate, etc.) during the adsorption stage 202. In contrast, if the health condition decreases, then the controller 22 and the gas capture optimizer 66 may increase a cycle time and / or increase cooling (e.g., cooling temperature, flow rate, etc.) during the adsorption stage 202.

[0030] 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 supply 236. sorbent material, undesirable gas, cooling systems, health of the sorbent materials 213, 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 temperatureor 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.

[0031] The desorption stage 204 may be initiated to desorb the undesirable gas from the sorbent material 210. Desorption may be initiated upon heating of the sorbent material 210 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 via a 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. As noted above, the adsorption and desorption efficiency of the sorbent material may degrade over time, and thus the sorbent health condition decreases over time. 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, flow rate, 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 perduration of time, power usage, etc.) at least partially based on sensor feedback and the health condition (e.g., sorbent health condition) of the sorbent materials 213 (e.g., sorbent materials 220, 222, 224). For example, if the health condition increases, then the controller 22 and the gas capture optimizer 66 may reduce a cycle time and / or reduce heating (e.g., heating temperature, flow rate, etc.) during the desorption stage 204. In contrast, if the health condition decreases, then the controller 22 and the gas capture optimizer 66 may increase a cycle time and / or increase heating (e.g., heating temperature, flow rate, etc.) during the desorption stage 204.

[0032] 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 downstream from the contactor 210, such that it may draw out 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 contractor 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., arrow 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 extracted fluid. Thus, the vacuum pump 228 and the separator 228 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.

[0033] 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.) at least partially based on sensor feedback and the health condition (e.g., sorbent health condition) of the sorbent materials 213 (e.g., sorbent materials 220, 222. 224). For example, if the health condition increases, then the controller 22 and the gas capture optimizer 66 may reduce a cycle time and / or reduce cooling (e.g., cooling temperature, flow' rate, etc.) during the cooling stage 206. In contrast, if the health condition decreases, then the controller 22 and the gas capture optimizer 66 may increase a cycle time and / or increase cooling (e.g., cooling temperature, flow rate, etc.) during the cooling stage 206.

[0034] 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, 232 and / 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, health conditions (e.g., sorbent health conditions of the sorbent materials 213), or any combination thereof.

[0035] The one or more sensors 128 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 128 may be disposed near and / or within the untreated gas supply 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 236 may also monitor temperature fluctuations with respect to the fluid transfer system 234 (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 236 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 236 may be positioned near, within, and / or in contact with the sorbent materials 220, 222, 224, thereby providing sensor feedback (e.g., temperature) and health condition (e.g.. sorbent health condition) relating to the sorbent materials 220, 222, 224. In certain embodiments, the one or more sensors 236 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 128 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 128 to adjust parameters of the gas capture system 20 (e.g., carbon capture system 100), thereby improving energetics of the gas treatment system.

[0036] FIG. 3 is a schematic diagram of an embodiment of the gas capture system 20, further illustrating subsystems 270 of the gas capture system 20 controlled by the controller 22 having the gas capture optimizer 66. In the illustrated embodiment, the gas capture system 20 includes the carbon capture system 100. As shown, the carbon capture system 100 includes a plurality of vessels 272 (e.g., vessels 274, 276, 278). Although the illustrated shows three vessels 272, the gas capture system 20 may include fewer or more vessels 272. For example, the gas capture system 20 may include 1, 2, 4, 5, 6, 7. or more vessels 272.

[0037] In the illustrated embodiment, each vessel 272 is configured to at least partially enclose a contactor 280 (e.g., contactors 208, 210. and 212). The contactors 280 include the sorbent material 213 (e.g., sorbent material 220, 222. and 224). As shown, the gas capture system 20 also includes a pressure control system 288 having one or more pumps 290 and one or more valves 292 (e.g., valves 294, 296, 298, 300, 302, 304).

[0038] In the illustrated embodiment, the gas capture system a includes a steam generator 306 and a water treatment system 308. In certain embodiments, the water treatment system 308 includes a filter 310 and / or a reverse osmosis system 312 having a semi-permeable membrane to separate water molecules from other substances. The gas capture system 20 also includes a tank 314 (e.g., water tank, water storage tank.etc.) fluidly coupled to the steam generator 306 and the water treatment system 308. As shown, the gas capture system 20 also includes the vacuum pump 228.

[0039] In the illustrated embodiment, the water treatment system 308 receives water 316 and outputs filtered water 318 (e.g., purified water) to the steam generator 306. The steam generator 306 heats the filtered water 318 to generate steam 320, and sends the steam 320 to the pressure control system 288. and first condensate 322 to the tank 314. The tank 314 recirculates the first condensate 322 back to the water treatment system 308. In certain embodiments, the tank 314 is configured to receive second condensate 319 from the flow lines 321 coupling the steam generator 306 to the vessels 272 and / or third condensate 325 from the vessels 272.

[0040] In the illustrated embodiment, the pressure control system 288 is fluidly coupled to the vessels 272 and controls one or more parameters associated with the steam 320 (e.g., flowrate, pressure, temperature, etc.). The pressure control system 288, the steam generator 306, and the water treatment system 308 are communicatively coupled to the controller 22.

[0041] As shown, the vacuum pump 228 is fluidly coupled to each of the vessels 272. The gas capture system 20 includes vacuum valves 323 (e.g., vacuum valves 324, 326, 328) disposed between each vessel 272. The vacuum pump 228 is configured to evacuate the steam 320 from the vessels 272 and transfer evacuated steam 330 to a final destination 332 (e.g.. atmosphere, containment structure, etc.). As shown, the vacuum pump 228 is communicatively coupled to the controller 22.

[0042] In the illustrated embodiment, the gas capture system 20 includes the one or more sensors 128. As shown, the one or more sensors 128 may be coupled to the vessels 272 and / or the contactors 280. The one or more sensors 128 (e.g., thermocouples, humidity sensors, optical sensors, etc.) are communicatively coupled to the controller 22. In certain embodiments, the controller 22 may be configured to monitor sensor feedback associated with the contactor 208 (e.g., first contactor) of the carbon capture system 100.

[0043] The controller 22 may also be configured to analyze the sensor feedback to determine a health (e.g., health condition, health score, etc.) of the contactor 208. In certain embodiments, the health of the contactor 208 may include a level of degradation (e.g., sorbent degradation or aging), a temperature, a moisture level, a quantity of dissolved sorbent material, and / or an additional parameter associated with the sorbent material 220. For example, the one or more sensors 128 may include one or more thermocouples configured to provide one or more measurements indicative of a temperature of the sorbent material 220. Additionally or alternatively, the one or more sensors 128 may include a water content sensor configured to generate a signal indicative of a quantity of dissolved sorbent material in the second condensate 319 received from the flow lines 321 and / or the third condensate 325 received from the vessels 272. The controller 22 may also be configured to adjust one or more operating parameters for the contactor 208 based on the health of the contactor 208.

[0044] It may be recognized that the controller 22 may additionally or alternatively be configured to analyze sensor feedback to determine a health of the contactors 210 and / or 212 with sorbent materials 222 and 224, and may be configured to adjust one or more operating parameters for the contactors 210 and / or 212 based on the health of the contactors 210 and / or 212. In certain embodiments, the controller 22 may be configured to analyze sensor feedback and health during the adsorption stage 202. the desorption stage 204, and / or the cooling stage 206 of the sorbent materials 213, as described in FIG. 2.

[0045] In certain embodiments, the one or more operating parameters for the contactors 280 may include a duration of an injection of the steam 320 into the vessels 272, a pressure of the steam 320, a temperature of the steam 320, a flowrate of the steam 320, an inlet pressure of the vacuum pump 228, or a combination thereof, during the desorption stage 204. In certain embodiments, the controller 22 may control the pressure control system 288, the steam generator 306, and / or the vacuum pump 228 to adjust the one or more operating parameters during the desorption stage 204. In certain embodiments, adjusting the duration of the injection of the steam 320 into the vessels 272 may include adjusting a cycle time of the steam injection during the desorptionstage 204. For example, the controller 22 may adjust the duration of the steam injection, a duration of time between steam injections, or both, during the desorption stage 204.

[0046] In certain embodiments, the controller 22 may be configured to adjust the one or more operating parameters for the one or more contactors 280 in response to the health of the one or more contactors 280 falling below a threshold level of health. For example, the controller 22 may adjust one or more operating parameters for the one or more contactors 280 in response to a temperature of the sorbent material 213 exceeding a threshold temperature. Additionally or alternatively, the controller 22 may adjust one or more operating parameters for the one or more contactors 280 in response to a level of degradation of the sorbent material 213 exceeding a threshold level of degradation. In certain embodiments, the level of degradation of the sorbent material 213 may be determined based on the one or more sensors 128 estimating an amount of dissolved sorbent material 213 in the third condensate 325. Additionally or alternatively, the level of degradation of the sorbent material 213 may be based on an amount of time that the gas capture system 20 has been in operation. Additionally or alternatively, the level of degradation of the sorbent material 213 may be based on an adsorption rate and / or a desorption rate determined based on feedback from the one or more sensors 128. Additionally or alternatively, the level of degradation may be determined based on an estimated moisture of the sorbent material 213 falling below a threshold level of moisture.

[0047] In certain embodiments, the controller 22 is configured to control the one or more valves 292 to adjust a flowrate of the steam 320 from the steam generator 306 to the vessels 272. Additionally or alternatively, the controller 22 may be configured to selectively control the one or more valves 292 to inject the steam 320 into the vessel 272 in response to the corresponding contactor 280 undergoing the desorption stage 204 described in FIG. 2. In certain embodiments, the controller 22 may be configured to adjust the one or more operating parameters of the contactor 280 (e.g., contactor 208, 210, and 212) during the adsorption stage 202 of the contactor 280, the desorption stage 204 of the contactor 280, and / or the cooling stage 206 of the contactor 280 as described in FIG. 2.

[0048] As discussed herein, the tank 314 recirculates the first condensate 322 received from the steam generator 306 back to the water treatment system 308. In certain embodiments, the tank 314 is configured to receive the second condensate 319 from the flow lines 321 coupling the steam generator 306 to the vessels 272 and / or the third condensate 325 from the vessels 272. As shown, the gas capture system 20 includes condensate valves 334 (e.g., condensate valves 336, 338, 340, 342, 344, 346, and 348). In the illustrated embodiment, the condensate valves 336, 338. 340, and 342 are configured to control a flowrate of the second condensate 319 from the flow lines 321 to a condenser 350, where leftover steam 320 is condensed and sent to the tank 314. The condensate valves 344, 346, and 348 are configured to control a flowrate of the third condensate 325 from the vessels 272 to the condenser 350. In certain embodiments, the controller 22 may at least partially open the condensate valves 334 during the cooling stage 206 and, in certain embodiments, the adsorption stage 202 of each contactors 280. For example, the controller 22 may at least partially open the condensate valves 336, 340, and / or 344 during the cooling stage 206 of the contactor 208.

[0049] In certain embodiments, the controller 22 and the gas capture optimizer 66 controls the steam generator 306 to control a temperature, a pressure, and a flow rate of steam to the vessels 272 having the contactors 280 based on sensor feedback and health of the contactors 280 (e.g., sorbent health condition of sorbent materials). For example, for a greater health condition, the controller 22 and the gas capture optimizer 66 may reduce a cycle time and / or reduce cooling during the adsorption stage 202 and the cooling stage 206 and reduce a cycle time and reduce heating (e.g., reduce steam temperature, steam pressure, steam flow rate, etc.) during the desorption stage 204. In contrast, for a lesser health condition, the controller 22 and the gas capture optimizer 66 may increase a cycle time and / or increase cooling during the adsorption stage 202 and the cooling stage 206 and increase a cycle time and increase heating (e.g., increase steam temperature, steam pressure, steam flow rate, etc.) during the desorption stage 204. In certain embodiments, the controller 22 and the gas capture optimizer 66 may be configured to control (e.g., increase, decrease, or generally optimize) steam injection into the vessels 272 to control the amount of CO2 desorbed from the sorbent material213 of the contactors 280. The relative pressure of CO2 in the vessels 272 decreases with the steam injection, thereby helping to cause the CO2 to escape from the chemical structure of the sorbent material 213 of the contactors 280. Additionally, in certain embodiments, the controller 22 and the gas capture optimizer 66 may control the purity of water used to generate steam by the steam generator 306 using the water treatment system 308.

[0050] FIG. 4 is a flowchart of an embodiment of a process 370 of operating the gas capture system 20 of FIG. 1, wherein one or more operating parameters for the contactor 280 are adjusted during an adsorption stage 202, a desorption stage 204, and / or a cooling stage 206 of the contactor 280. The process 370 may be performed by a computing device or controller (e.g., controller 22 having gas capture optimizer 66) disclosed above with reference to FIGS. 1-3 or any other suitable computing device(s) or controller(s). Furthermore, the blocks of the process 370 may be performed in the order disclosed herein or in any other suitable order. For example, certain blocks of the process 370 may be performed concurrently. In addition, in certain embodiments, at least one of the blocks of the process 370 may be omitted.

[0051] In block 372 of the process 370, the controller 22 monitors sensor feedback from a contactor 280 of the carbon capture system 100 (e.g.. sorbent-based carbon capture system). As described herein, the carbon capture system 100 may belong to a gas capture system 20 for processing exhaust gas of an industrial plant. Additionally or alternatively, the carbon capture system 100 may be a DAC system. As described herein, the sensor feedback may be provided to the controller 22 from one or more sensors 128. In certain embodiments, the one or more sensors 128 may include feedback indicative of a temperature of the sorbent material 213, a level of degradation of the sorbent material 213, a moisture level (e.g., moisture content) of the sorbent material 213, or a combination thereof. In certain embodiments, the one or more sensors 128 may include a temperature sensor (e.g., thermocouple), a moisture sensor (e.g. water content sensor), and / or a sensorthat measures a quantity of dissolved sorbent material in a liquid.

[0052] In block 374 of the process 370, the controller 22 analyzes the sensor feedback to determine a health of the contactor 280. In certain embodiments, the health of the contactor 280 is based on a level of degradation of the sorbent material 213. a temperature of the sorbent material 213, a moisture level of the sorbent material 213, or a combination thereof. For example, the health of the contactor 280 may be at least partially determined based on the level of degradation of the sorbent material 213 exceeding a threshold level of degradation, the temperature of the sorbent material 213 exceeding a threshold temperature, a moisture level of the sorbent material 213 exceeding a threshold moisture level (e.g., exceeding a high moisture threshold and / or falling below a low moisture threshold), a pH of the third condensate 325 exceeding a pH threshold (e.g., exceeding a high pH threshold and / or falling below a low pH threshold), or a combination thereof. It may be recognized that the sorbent material 213 may experience increased degradation (e.g., increased wear) when the sorbent material 213 is at a higher temperature. Furthermore, it may be recognized that the age and / or efficacy of the sorbent material 213 may be improved when the sorbent material 213 is kept within a range of moisture levels and / or a range of pH values.

[0053] In block 376 of the process 370, the controller 22 adjusts the one or more operating parameters for the contactor 280 in the adsorption stage 202 of the carbon capture system 100 (e.g., sorbent-based carbon capture system) based on the health. For example, the controller 22 may adjust the one or more operating parameters for the contactor 280 in response to the contactor 280 entering the adsorption stage 202. In certain embodiments, the controller 22 may adjust the one or more operating parameters for the contactor 280 intermittently throughout the adsorption stage 202. For example, the controller 22 may control the pressure control system 288 to adjust a pressure and / or a flowrate of the steam. Additionally or alternatively, the controller 22 may control the steam generator 306 to adjust a temperature of the steam. Additionally or alternatively, the controller may control a duration of time during which the steam is injected into the vessel.

[0054] In block 378 of the process 370, the controller 22 adjusts the one or more operating parameters for the contactor 280 in the desorption stage 204 of the carbon capture system 100 (e.g., sorbent-based carbon capture system) based on the health.For example, the controller 22 may adjust the one or more operating parameters for the contactor 280 in response to the contactor 280 entering the desorption stage 204. In certain embodiments, the controller 22 may adjust the one or more operating parameters for the contactor 280 intermittently throughout the desorption stage 204. For example, the controller 22 may control the pressure control system 288 to adjust a pressure and / or a flowrate of the steam. Additionally or alternatively, the controller 22 may control the steam generator 306 to adjust a temperature of the steam. Additionally or alternatively, the controller may control a duration of time during which the steam is injected into the vessel.

[0055] In block 380 of the process 370, the controller 22 adjusts the one or more operating parameters for the contactor 280 in the cooling stage 206 of the carbon capture system 100 (e.g., sorbent-based carbon capture system) based on the health. For example, the controller 22 may adjust the one or more operating parameters for the contactor 280 in response to the contactor 280 entering the cooling stage 206. In certain embodiments, the controller 22 may adjust the one or more operating parameters for the contactor 280 intermittently throughout the cooling stage 206. For example, the controller 22 may control the pressure control system 288 to adjust a pressure and / or a flowrate of the steam. Additionally or alternatively, the controller 22 may control the steam generator 306 to adjust a temperature of the steam. Additionally or alternatively, the controller may control a duration of time during which the steam is injected into the vessel.

[0056] FIG. 5 is a flowchart of an embodiment of a process 400 of operating the gas capture system 20 of FIG. 1 during the desorption mode 204, wherein one or more operating parameters for the contactor 280 are adjusted based on a health of the contactor 280. The process 400 may be performed by a computing device or controller (e.g., controller 22 having gas capture optimizer 66) disclosed above with reference to FIGS. 1-3 or any other suitable computing device(s) or controller(s). Furthermore, the blocks of the process 400 may be performed in the order disclosed herein or in any other suitable order. For example, certain blocks of the process 400 may be performed concurrently. Additionally or alternatively, in certain embodiments, at least one of the blocks of the process 400 may be omitted.

[0057] In block 402 of the process 400, the controller 22 monitors sensor feedback to a contactor 280 of the carbon capture system 100 (e.g., sorbent-based carbon capture system) during the desorption mode 204. As described herein, the carbon capture system 100 may belong to a gas capture system 20 for processing exhaust gas of an industrial plant. Additionally or alternatively, the carbon capture system 100 may be a DAC system. As described herein, the sensor feedback may be provided to the controller 22 from one or more sensors 128. In certain embodiments, the one or more sensors 128 may include feedback indicative of a temperature of the sorbent material 213, a level of degradation of the sorbent material 213, a moisture level (e.g., moisture content) of the sorbent material 213, or a combination thereof. In certain embodiments, the one or more sensors 128 may include a temperature sensor (e.g., thermocouple), a moisture sensor (e.g. water content sensor), and / or a sensor that measures a quantity of dissolved sorbent material in a liquid.

[0058] In block 404 of the process 400, the controller 22 analyzes the sensor feedback to determine a health of the contactor 280 during the desorption mode 204. In certain embodiments, the health of the contactor 280 is based on a level of degradation of the sorbent material 213, a temperature of the sorbent material 213, a moisture level of the sorbent material 213. or a combination thereof. For example, the health of the contactor 280 may be at least partially determined based on the level of degradation of the sorbent material 213 exceeding a threshold level of degradation, the temperature of the sorbent material 213 exceeding a threshold temperature, a moisture level of the sorbent material 213 exceeding a threshold moisture level (e.g., exceeding a high moisture threshold and / or falling below a low moisture threshold), a pH of the third condensate 325 exceeding a pH threshold (e.g., exceeding a high pH threshold and / or falling below a low pH threshold), or a combination thereof. It may be recognized that the sorbent material 213 may experience increased degradation (e.g., increased wear) when the sorbent material 213 is at a higher temperature. Furthermore, it may be recognized that the age and / or efficacy of the sorbent material 213 may be improved when the sorbent material 213 is kept within a range of moisture levels and / or a range of pH values.

[0059] In block 406 of the process 400, the controller 22 adjusts a duration of time for injecting the steam 320 into the vessel 272 having the contactor 280 based on the health of the contactor 280 during the desorption mode 204. For example, in response to the health of the contactor 280 falling below a threshold health, the controller 22 may increase a duration of time during which the steam 320 is injected into the vessel 272, thereby increasing an amount of gas (e.g., carbon dioxide) swept from the sorbent material 213. In certain embodiments, the controller 22 may decrease a duration of a pause (e g., cessation) between one or more injections of the steam 320 into the vessel 272. That is, the controller 22 may adjust a duty cycle associated with the injection of the steam 320 into the vessel 272.

[0060] In block 408 of the process 400, the controller 22 adjusts an inlet pressure of the vacuum pump 228 fluidly coupled to the vessel 272 based on the health of the contactor 280 during the desorption mode 204. For example, in response to the health of the contactor 280 falling below a threshold health, the controller 22 may decrease an inlet pressure of the vacuum pump 228, thereby increasing the amount of the steam 320 and / or carbon dioxide swept from the vessel 272.

[0061] In block 410 of the process 400, the controller 22 adjusts a flowrate of the steam 320 entering the vessel 272. a pressure of the steam 320 entering the vessel 272. a temperature of the steam 320 entering the vessel 272, or a combination thereof based on the health of the contactor 280 during the desorption mode 204. For example, in response to the health of the contactor 280 falling below a threshold health, the controller 22 may increase the flowrate of the steam 320 entering the vessel 272, thereby increasing the amount of steam used to sweep the vessel 272. Additionally or alternatively, in response to the health of the contactor 280 falling below a threshold health, the controller 22 may increase the pressure of the steam 320 entering the vessel 272. Additionally or alternatively, in response to the health of the contactor 280 falling below a threshold health, the controller 22 may decrease a temperature of the steam 320 entering the vessel 272 to help cool the sorbent material 213.

[0062] Technical effects of the disclosed embodiments enable increase an efficiency of the gas capture system by responding to inefficiencies caused by a change in health(e.g., health condition, health score, etc.) of the contactors 280 and / or the sorbent material 213 over time. A technical problem with previous gas capture systems 20 is that as the contactors 280 and / or the sorbent material 213 degrade over time (e.g.. gradually decreasing sorbent health), they become less responsive to steam 320 having a fixed set of characteristics used to sweep carbon dioxide trapped in the sorbent material 213. That is, as the contactors 280 and / or the sorbent material 213 degrades over time, the steam 320 having a fixed set of parameters becomes less effective at sweeping the entrapped carbon dioxide, thereby resulting in less carbon dioxide being freed from the sorbent material 213. Furthermore, as the contactors 280 and / or the sorbent material 213 degrade over time (e.g.. gradually decreasing sorbent health), they become less responsive removing undesirable gases from the air and / or exhaust gas during the adsorption mode. Accordingly, a technical solution to this technical problem includes monitoring a health of the sorbent material 213 and / or the contactor 280 and dynamically controlling operating parameters of the gas capture system 20 based on the health of the sorbent material and / or the contactor 280. For example, the health of the sorbent material 213 and / or the contactor 280 may be based on a moisture level, a temperature, and / or a level of degradation of the sorbent material 213. In response to a level of health of the sorbent material 213 and / or the contactor 280 falling below a threshold level of health, the controller 22 may adjust one or more operating parameters associated with the sorbent material 213 and / or the contactor 280. For example, the controller 22 may control the pressure control system 288 to adjust a pressure and / or a flowrate of the steam 320 during the desorption mode 204. Additionally or alternatively, the controller 22 may control the steam generator 306 to adjust a temperature of the steam 320 during the desorption mode 204. Additionally or alternatively, the controller 22 may control a duration of time dunng which the steam 320 is injected into the vessel 272 during the desorption mode 204.

[0063] The subject matter described in detail above may be defined by one or more clauses, as set forth below.

[0064] According to a first aspect, a system includes a carbon capture system. The system also includes a controller having a memory, a processor, and instructions stored on the memory and executable by the processor. The controller is configured to monitorsensor feedback associated with a first contactor of the carbon capture system, wherein the first contactor includes a sorbent material. The controller is also configured to analyze the sensor feedback to determine a health of the first contactor. The controller is also configured to adjust one or more operating parameters for the first contactor based on the health of the first contactor.

[0065] The system of the preceding clause, wherein the controller is configured to adjust the one or more operating parameters for the first contactor based on the health of the sorbent material, wherein the health of the sorbent material includes a level of degradation of the sorbent material, a moisture level of the sorbent material, a temperature of the sorbent material, or a combination thereof.

[0066] The system of any preceding clause, wherein the controller is configured to adjust the one or more operating parameters based on the temperature of the sorbent material exceeding a threshold temperature.

[0067] The system of any preceding clause, wherein the controller is configured to adjust the one or more operating parameters based on the moisture level of the sorbent material exceeding a threshold moisture level.

[0068] The system of any preceding clause, wherein the controller is configured to adjust the one or more operating parameters based on the level of degradation of the sorbent material exceeding a threshold level of degradation.

[0069] The system of any preceding clause, wherein the carbon capture system includes a vessel, wherein the vessel is configured to at least partially enclose the first contactor.

[0070] The system of any preceding clause, including a sensor configured to generate a signal indicative of a quantity7of dissolved sorbent material in condensate from the vessel, wherein the quantity of the dissolved sorbent material is indicative of the health of the first contactor.

[0071] The system of any preceding clause, wherein the carbon capture system includes a steam generator fluidly coupled to the vessel, the carbon capture systemincludes a vacuum pump fluidly coupled to the vessel, and the controller is configured to control the steam generator to generate a steam to be injected into the vessel.

[0072] The system of any preceding clause, wherein the one or more operating parameters includes: a duration of injection of the steam into the vessel; a pressure of the inj ected steam; a flow rate of the inj ected steam; a temperature of the inj ected steam; an inlet pressure of the vacuum pump; or a combination thereof.

[0073] The system of any preceding clause, wherein the carbon capture system includes a water treatment system configured to purify water, wherein the steam generator is configured to heat the purified water to produce the steam.

[0074] The system of any preceding clause, wherein the water treatment system includes a reverse osmosis system.

[0075] The system of any preceding clause, wherein the carbon capture system includes a tank configured to: receive a first condensate from the steam generator; receive a second condensate from a line coupling the steam generator to the vessel; receive a third condensate from the vessel; or a combination thereof.

[0076] The system of any preceding clause, wherein the controller is configured to adjust the one or more operating parameters for the first contactor during: an adsorption stage associated with the first contactor; a desorption stage associated with the first contactor; a cooling stage associated with the first contactor; or a combination thereof.

[0077] The system of any preceding clause, wherein the carbon capture system includes second and third contactors, wherein the carbon capture system is configured to sequentially operate each of the first, second, and third contactors in an adsorption stage, a desorption stage, and a cooling stage with adjustments to one or more operating parameters based on the health for each of the first, second, and third contactors.

[0078] According to a second aspect, a system includes a carbon capture system. The carbon capture system includes a vessel and a contactor disposed inside the vessel. The contactor includes a sorbent material. The system also includes a controller having a memory, a processor, and instructions stored on the memory and executable by theprocessor. The controller is configured to monitor sensor feedback associated with the contactor. The controller is also configured to analyze the sensor feedback to determine a health of the contactor. The controller is also configured to adjust one or more operating parameters for the contactor based on the health of the contactor.

[0079] The system of the preceding clause, wherein the controller is configured to adjust the one or more operating parameters for the contactor based on the health of the sorbent material, wherein the health of the sorbent material includes a level of degradation of the sorbent material, a moisture level of the sorbent material, a temperature of the sorbent material, or a combination thereof.

[0080] The system of any preceding clause, wherein the controller is configured to adjust the one or more operating parameters based on the temperature of the sorbent material exceeding a threshold temperature.

[0081] The system of any preceding clause, wherein the controller is configured to adjust the one or more operating parameters based on the moisture level of the sorbent material exceeding a threshold moisture level.

[0082] According to a third aspect, a method includes monitoring, via a processor, sensor feedback associated with a contactor of a carbon capture system. The contactor includes a sorbent material. The method also includes analyzing, via the processor, the sensor feedback to determine a health of the contactor. The method also includes adjusting, via the processor, one or more operating parameters for the contactor based on the health of the contactor.

[0083] The method of the preceding clause, wherein adjusting the one or more operating parameters includes controlling, via the processor, a steam generator to inject steam into a vessel configured to house the contactor.

[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 mayinclude 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 system, comprising: a carbon capture system; and a controller comprising a memory7, a processor, and instructions stored on the memory7and executable by the processor, wherein the controller is configured to: monitor sensor feedback associated with a first contactor of the carbon capture system, wherein the first contactor comprises a sorbent material; analyze the sensor feedback to determine a health of the first contactor; and adjust one or more operating parameters for the first contactor based on the health of the first contactor.

2. The system of claim 1, wherein the controller is configured to adjust the one or more operating parameters for the first contactor based on the health of the sorbent material, wherein the health of the sorbent material comprises a level of degradation of the sorbent material, a moisture level of the sorbent material, a temperature of the sorbent material, or a combination thereof.

3. The system of claim 2, wherein the controller is configured to adjust the one or more operating parameters based on the temperature of the sorbent material exceeding a threshold temperature.

4. The system of claim 2, wherein the controller is configured to adjust the one or more operating parameters based on the moisture level of the sorbent material exceeding a threshold moisture level.

5. The system of claim 2, wherein the controller is configured to adjust the one or more operating parameters based on the level of degradation of the sorbent material exceeding a threshold level of degradation.

6. The system of claim 5, wherein the carbon capture system comprises a vessel, wherein the vessel is configured to at least partially enclose the first contactor.

7. The system of claim 6, comprising a sensor configured to generate a signal indicative of a quantity7of dissolved sorbent material in condensate from the vessel, wherein the quantity of the dissolved sorbent material is indicative of the health of the first contactor.

8. The system of claim 6, wherein the carbon capture system comprises a steam generator fluidly coupled to the vessel, the carbon capture system comprises a vacuum pump fluidly coupled to the vessel, and the controller is configured to control the steam generator to generate a steam to be injected into the vessel.

9. The system of claim 8, wherein the one or more operating parameters comprises: a duration of injection of the steam into the vessel; a pressure of the injected steam; a flow rate of the injected steam; a temperature of the injected steam; an inlet pressure of the vacuum pump; or a combination thereof.

10. The system of claim 8, wherein the carbon capture system comprises a water treatment system configured to purify water, wherein the steam generator is configured to heat the purified water to produce the steam.

11. The system of claim 10, wherein the water treatment system comprises a reverse osmosis system.

12. The system of claim 8, wherein the carbon capture system comprises a tank configured to: receive a first condensate from the steam generator;receive a second condensate from a line coupling the steam generator to the vessel; receive a third condensate from the vessel; or a combination thereof.

13. The system of claim 9, wherein the controller is configured to adjust the one or more operating parameters for the first contactor during: an adsorption stage associated with the first contactor; a desorption stage associated with the first contactor; a cooling stage associated with the first contactor; or a combination thereof.

14. The system of claim 1, wherein the carbon capture system comprises second and third contactors, wherein the carbon capture system is configured to sequentially operate each of the first, second, and third contactors in an adsorption stage, a desorption stage, and a cooling stage with adjustments to one or more operating parameters based on the health for each of the first, second, and third contactors.

15. A system, comprising: a carbon capture system, comprising: a vessel; and a contactor disposed inside the vessel, wherein the contactor comprises a sorbent material; and a controller comprising a memory, a processor, and instructions stored on the memory and executable by the processor, wherein the controller is configured to: monitor sensor feedback associated with the contactor; analyze the sensor feedback to determine a health of the contactor; and adjust one or more operating parameters for the contactor based on the health of the contactor.

16. The system of claim 15, wherein the controller is configured to adjust the one or more operating parameters for the contactor based on the health of the sorbentmaterial, wherein the health of the sorbent material comprises a level of degradation of the sorbent material, a moisture level of the sorbent material, a temperature of the sorbent material, or a combination thereof.

17. The system of claim 16, wherein the controller is configured to adjust the one or more operating parameters based on the temperature of the sorbent material exceeding a threshold temperature.

18. The system of claim 16, wherein the controller is configured to adjust the one or more operating parameters based on the moisture level of the sorbent material exceeding a threshold moisture level.

19. A method, comprising: monitoring, via a processor, sensor feedback associated with a contactor of a carbon capture system, wherein the contactor comprises a sorbent material; analyzing, via the processor, the sensor feedback to determine a health of the contactor; and adjusting, via the processor, one or more operating parameters for the contactor based on the health of the contactor.

20. The method of claim 19, wherein adjusting the one or more operating parameters comprises controlling, via the processor, a steam generator to inject steam into a vessel configured to house the contactor.

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