Low-energy air contactor for seawater carbon dioxide removal

Abstract

The present disclosure relates to systems and methods for carbon dioxide removal are provided. A system for carbon dioxide removal comprises a liquid distribution system, a liquid collector system, a fill media. The fill media is disposed between the liquid collector system and the liquid distribution system. The liquid distribution system distributes a first aqueous solution to the fill media. The first aqueous solution comprises solid hydroxide particles. A gas flow system flows a gas through the fill media such that the gas contacts the first aqueous solution. The gas comprises a gaseous source of carbon dioxide.

Description

[0001] UCH-41725

[0002] LOW-ENERGY AIR CONTACTOR FOR SEAWATER CARBON DIOXIDE REMOVAL

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] This application claims the benefit of priority to U.S. Provisional App. No.

[0005] 63 / 715,955, filed on November 4, 2024. The entire contents of which are hereby incorporated by reference.

[0006] BACKGROUND

[0007] Carbon dioxide removal from the atmosphere has become an increasingly important area of research and development. Various approaches have been proposed and studied for capturing and sequestering atmospheric carbon dioxide, including both land-based and oceanbased methods.

[0008] Seawater-based carbon dioxide removal systems have garnered particular interest due to the vast carbon absorption capacity of the world's oceans. These systems typically involve enhancing the natural carbon absorption processes of seawater through chemical or physical means.

[0009] Cooling tower technology has been widely used in industrial applications for heat rejection and gas-liquid contact. The principles and designs developed for cooling towers may offer potential benefits when adapted for carbon dioxide removal applications. However, the specific requirements and constraints of seawater-based carbon dioxide removal systems differ from those of traditional cooling tower applications.

[0010] Energy efficiency is a critical consideration for any large-scale carbon dioxide removal system. Minimizing the energy input required for operation is essential for improving the overall carbon balance and economic viability of such systems. Additionally, issues such as fouling, corrosion, and precipitation of solid materials present ongoing challenges in the design and operation of seawater-based air contactors.

[0011] SUMMARY OF THE INVENTION

[0012] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify UCH-41725 key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0013] The purpose and advantages of the disclosed subject matter will be set forth and apparent from the description that follows, as well as will be learned by practice of the disclosed subject matter. Additional advantages of the disclosed subject matter will be realized and attained by the devices particularly pointed out in the written description and claims hereof, as well as from appended drawings.

[0014] The disclosed subject matter facilitates carbon dioxide removal while addressing the unique challenges posed by seawater-based approaches and maintaining low energy consumption.

[0015] The disclosed subject matter relates to systems and methods for carbon dioxide removal. Particularly, the present disclosed subject matter is directed to a contactor system for the dissolution of hydroxide solid particles in basified seawater and simultaneous dissolution of carbon dioxide gas into the solution.

[0016] To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter includes a system for carbon dioxide removal comprising a liquid distribution system, a liquid collector system, a fill media, and a gas flow system. The fill media is disposed between the liquid collector system and the liquid distribution system. The liquid distribution system distributes a first aqueous solution to the fill media. The first aqueous solution comprises solid hydroxide particles. The gas flow system flows a gas through the fill media such that the gas contacts the first aqueous solution. The gas comprises a gaseous source of carbon dioxide.

[0017] A flow of the gas may be oriented perpendicular to a flow of the first aqueous solution. A flow of the gas may be parallel and in an opposing direction of a flow of the first aqueous solution. The solid hydroxide particles may a plurality of solid hydroxide particles. The first aqueous solution comprising a solid hydroxide particle may be a suspension. The first aqueous solution comprising a solid hydroxide particle may be a slurry. The solid hydroxide may be magnesium hydroxide. The solid hydroxide may be calcium hydroxide. The solid hydroxide comprises calcium hydroxide and magnesium hydroxide. The system may comprise a fill media chamber. The fill media may be housed within the fill media chamber. The fill media chamber may comprise a fill media shuttle and a fill media shuttle sled. The gas contacting the first aqueous solution may produce a solution comprising UCH-41725 dissolved inorganic carbon. The liquid collector system may receive the solution comprising dissolved inorganic carbon. A flow of the gas may have a velocity approximately between 0.1 m / s and 3.0 m / s. The fill media may comprise a plurality of fill media. The plurality of fill media may comprise hybrid fill media, splash fill media, or a combination thereof. The system may comprise a recirculation liquid pathway. The liquid collector system may be in fluid communication with the liquid distribution system. The system may comprise a separator in fluid communication with the liquid distribution system. The separator may perform a solid-liquid separation. The liquid collector system may be in fluid communication with the separator. A supernatant of the solution comprising dissolved inorganic carbon may be flowed from the liquid collector system to the liquid distribution system. A bottom layer of the solution comprising dissolved inorganic carbon may be flowed from the liquid collector system to the liquid distribution system. The system may comprise a gas flow metering system. The first aqueous solution may be a catholyte produced by an electrolyzer. The system may comprise an electrolyzer in fluid communication with the liquid distribution system. The system may comprise a vessel in fluid communication with the liquid collector system.

[0018] The disclosed subject matter includes a method for carbon dioxide removal. An electrolyzer is contacted with a second aqueous solution. The second aqueous solution is divided into an anolyte in contact with an anode of the electrolyzer and a catholyte in contact with a cathode of the electrolyzer. A voltage is applied to the electrolzyer to induce precipitation of solid hydroxide particles in the catholyte, thereby forming a first aqueous solution comprising solid hydroxide particles. The first aqueous solution comprising solid hydroxide particles is flowed through a fill media. The fill media has a top end, a bottom end, and thickness therebetween.

[0019] A gas comprising a gaseous source of carbon dioxide may be flowed through the fill media such that the gas contacts the first aqueous solution comprising solid hydroxide particles. A saturated solution may drain from a bottom end of the fill media, the saturated solution comprising a solution of dissolved inorganic carbon. The saturated solution may be collected. The saturated solution may be flowed to a top end of the fill media. The saturated aqueous solution may be contacted with solid hydroxide particles, thereby forming a third aqueous solution comprising solid hydroxide particles. The third aqueous solution may comprise solid hydroxide particles to a top end of the fill media. A gas comprising a gaseous UCH-41725 source of carbon dioxide may be flowed through the fill media such that the gas contacts the third aqueous solution comprising solid hydroxide particles.

[0020] The disclosed subject matter includes a method for carbon dioxide removal. An electrolyzer is contacted with a second aqueous solution. The second aqueous solution is divided into an anolyte in contact with an anode of the electrolyzer and a catholyte in contact with a cathode of the electrolyzer. A voltage is applied to the electrolzyer to induce precipitation of solid hydroxide particles in the catholyte, thereby forming a first aqueous solution comprising solid hydroxide particles.

[0021] The first aqueous solution comprising solid hydroxide particles may be filtered to remove the solid hydroxide particles, thereby forming a filtered aqueous solution. The filtered aqueous solution may be flowed through a fill media. The fill media has a top end, a bottom end, and thickness therebetween. A gas comprising a gaseous source of carbon dioxide may be flowed through the fill media such that the gas contacts the filtered aqueous solution.

[0022] The accompanying drawings which are incorporated in and constitute part of this specification are included to illustrate and provide a further understanding of the method and system of the disclosed subject matter. Together with the description, the drawings serve to explain the principles of the disclosed subject matter.

[0023] BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings, which are incorporated and constitute a part of this specification, illustrate various exemplary implementations and together with the description, serve to explain the principles of the disclosed implementations. It is to be understood that in some instances various aspect of the described implementations may be shown exaggerated or enlarged to facilitate an understanding of the described implementations. In the drawings, like reference characters generally refer to like features, functionally, and / or structurally similar elements throughout the various drawings. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the teachings. The drawings are not intended to limit the scope of the present teachings in any way.

[0025] Fig. 1A shows a perspective view of an implementation of a contactor system having a single tower.

[0026] Figs. 1B-1D show side views of an implementation of a contactor system shown in Fig.

[0027] 1A UCH-41725

[0028] Fig. 2A shows a perspective view of an implementation of a liquid distribution system.

[0029] Fig. 2B shows a top view of an implementation of a liquid distribution system shown in Fig. 2A.

[0030] Fig.2C shows a side view of an implementation of a liquid distribution system shown in Fig. 2A.

[0031] Fig. 3A shows a perspective view of an implementation of a fill media shuttle sled.

[0032] Fig. 3B shows a front view of an implementation of a fill media shuttle sled shown in

[0033] Fig. 3A

[0034] Fig. 3C shows a side view of an implementation of a fill media shuttle sled shown in

[0035] Fig. 3A

[0036] Fig. 4 shows a perspective view of an implementation of a fill media shuttle.

[0037] Fig. 5A shows a bottom perspective view of an implementation of a first sled bracket of a fill media shuttle sled.

[0038] Fig. 5B shows a top perspective view of an implementation of a first sled bracket of a fill media shuttle sled shown in Fig. 5A.

[0039] Fig. 5C shows a bottom perspective view of an implementation of a second sled bracket of a fill media shuttle sled.

[0040] Fig. 5D shows a top perspective view of an implementation of a second sled bracket of a fill media shuttle sled shown in Fig. 5D

[0041] Fig- 6 shows a perspective view of an implementation of a main frame assembly.

[0042] Fig. 7A shows a perspective view of an implementation of a side panel of a main frame assembly shown in Fig. 6.

[0043] Fig. 7B shows a front view of an implementation of a side panel shown in Fig. 7A.

[0044] Fig. 7C shows a side view of an implementation of a side panel shown in Fig. 7A.

[0045] Fig. 7D shows a perspective view of an implementation of an end panel of a main frame assembly shown in Fig. 6.

[0046] Fig. 7E shows a front view of an implementation of an end panel shown in Fig. 7D.

[0047] Fig. 8A shows a perspective view of an implementation of a door panel.

[0048] Fig. 8B shows a front view of an implementation of a door panel.

[0049] Fig. 9A shows a perspective view of an implementation of a basin.

[0050] Fig. 9B shows an exploded assembly view of an implementation of a basin shown in

[0051] Fig. 9A UCH-41725

[0052] Fig. 10 shows a diagrammatic view of an implementation of a contactor system comprising a single tower with different portions of fill media.

[0053] Figs. 11A and 11B shows a diagrammatic view of an implementation of a contactor system having multiple towers.

[0054] Fig. 12 shows a diagrammatic view of an implementation of a contactor system having a single tower with crossflow and counterflow configurations.

[0055] Figs. 13A-13F show process flow diagrams of implementations of a contactor system.

[0056] Fig. 14 shows a process flow diagram of an implementation of a contactor system.

[0057] Fig. 15 shows a diagrammatic view of a method for carbon dioxide removal.

[0058] Figs. 16A-16C show views of a first portion of a first sled bracket shown in Figs. 5A and 5B.

[0059] Figs. 17A-17C show views of a second portion of a first sled bracket shown in Figs. 5 A and 5B.

[0060] Figs. 18A-18C show views of a first portion of a second sled bracket shown in Figs.

[0061] 5C and 5D.

[0062] Figs. 19A-19C show views of a second portion of a second sled bracket shown in Figs. 5C and 5D.

[0063] Figs. 20A shows a top view of a grating block of a basin shown in Figs. 9A and 9B.

[0064] Figs. 20B shows a perspective view of a grating block shown in Figs. 20A.

[0065] Figs. 21A-22B show views of grating ledges shown in Figs. 9A and 9B.

[0066] Figs. 23A and 23B show views of flat sheet comers of a basin shown in Figs. 9A and 9B

[0067] Figs. 24A-27B show views of rails of a basin shown in Figs. 9A and 9B.

[0068] Fig. 28 shows a top view of a flat bottom sheet of a basin shown in Figs. 9A and 9B.

[0069] Figs. 29A-30B show views of skid beams of a basin shown in Figs. 9A and 9B.

[0070] DETAILED DESCRIPTION OF THE INVENTION

[0071] The various concepts introduced above and discussed in greater detail below may be implemented in a number of ways, as the described concepts are not limited to any particular manner of implementation.

[0072] Reference will now be made in detail to the exemplary implementations of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever UCH-41725 possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0073] References herein to positions of elements (e.g., “top”, “bottom”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other implementations, and that such variations are intended to be encompassed by the present disclosure.

[0074] The term “about” means a range of values inclusive of the specified value that a person of ordinary skill in the art would reasonably consider comparable to the specified value. In some implementations, “about” means within a standard deviation using measurements generally accepted by a person of ordinary skill in the art. In some implementations, “about” means ranging up to ± 10% of the specified value. In some implementations, “about” means ranging up to ± 5% of the specified value. In some implementations, “about” means the specified value.

[0075] The present disclosure relates to contactor systems, and more particularly to a low- energy contactor system for seawater-based carbon dioxide removal. In particular, a contactor system disclosed herein incorporate principles and structural features of cooling towers. Cooling tower technology has been widely used in industrial applications for heat rejection and gas-liquid contact. The principles and designs developed for cooling towers may offer potential benefits when adapted for carbon dioxide removal applications. However, the specific requirements and constraints of seawater-based carbon dioxide removal systems differ from those of conventional cooling towers. For example, the pressure drop across fill media of the tower can affect velocity of the flowing gas and the thickness of the fill media, which depends on the media’s porosity and structure. This may result in a shorter media flow path compared to that found in conventional cooling towers.

[0076] Given a range of velocity of a gas approximately between 0.1 m / s and 3.0 m / s, the fill media thickness may be approximated by rearranging the Ergun equation to solve for the media thickness, assuming typical porosity and particle diameter values. The desired pressure drop may be considered manageable within the operational limits of conventional cooling towers. Pressure drop can be estimated using the simplified Ergun equation for flow through porous media, which balances the pressure loss due to both viscous and inertial effects. The simplified Ergun equation is defined as: UCH-41725

[0077] Equation 1 where AP is pressure drop, p is dynamic viscosity of air (approximately 18.5 pPa-s at 25°C),6is the porosity of the fill media,vis the superficial velocity of air, L is the thickness of the fill media, ^P is the particle diameter of the fill media, and P is the density of air (approximately 1.2 kg / m3at 25°C). For purposes of the calculation, airflow can be assumed laminar and the fill media can be assumed uniform with consistent porosity across its thickness.

[0078] Referring now to Figs. 1A-1D, and in brief overview, views of an implementation of a contactor system having a single tower is shown. A tower 100 may comprise features common to cooling towers which include a gas flow system 101, a liquid distribution system 102, fill media 105, and a liquid collector system 110. The fill media 105 can be disposed between the liquid collector system 110 and the liquid distribution system 102. The liquid distribution system 102 can include multiple interconnected pipes, employing pipe connectors to define a main flow line 201 and multiple lateral flow lines 202 having nozzles 203 (e.g., clamp on nozzles). Pipes and pipes connectors of the liquid distribution system 102 may be formed of chlorinated polyvinyl chloride. Nozzles 203 can be coupled to each of the lateral flow lines 202 and distributed along their longitudinal length. Each lateral flow line 202 can be in fluid communication with the main flow line 201 and can branch off from the main flow line to facilitate the distribution of liquid to the fill media 105. Liquid can flow through an inlet 205 of the liquid distribution system 102 and through the main flow line 201, subsequently flowing through the lateral flow lines 202 and outlets of the liquid distribution system 102 (e.g., openings of the nozzles 203). In some implementations, an expansion joint with a flange defines the inlet 205. One or more liquid pumps (e.g., centrifugal pump, positive displacement pump) can be used to pump liquid through the liquid distribution system 102. Liquid that passes through the nozzles 203 can be atomized upon ejection, which can enable liquid distribution to the fill media 105. Liquid that passes through the fill media 105 can be collected by the liquid collector system 110 as the liquid drains due to gravity. The liquid distribution system 102 can further comprise one or more valves 204 which can regulate the flow of liquid through the main flow line 201. The liquid can be a first aqueous solution comprising solid hydroxide particles. The gas flow system 101 can flow a gas UCH-41725 through the fill media 105 such that the gas contacts the liquid passing through the fill media 105. To maintain proper airflow distribution, enclosure can be installed on the tower, guiding the gas through the packing. In some implementations, contacting gas with the first aqueous solution comprising solid hydroxide particles comprises passing the gas across the surface of the first aqueous solution. As the first aqueous solution passes through the fill media 105 (from a top end to a bottom end of the fill media) the solid hydroxide particles dissolve and carbon dioxide is dissolved into the solution. Maximizing the gas-liquid contact time can enhance removal of carbon dioxide. A longer contact time can allow for more mass transfer between the gas and the liquid. This extended contact time can enhance the diffusion of the carbon dioxide from the gas phase into the liquid phase, leading to a higher absorption rate. Various factors can affect the gas-liquid contact time such as the gas flow rate, the liquid flow rate, the direction / orientation of the gas flow with respect to the liquid flow, and the fill media type.

[0079] In some implementations, contacting gas with the first aqueous solution comprising solid hydroxide particles is performed at atmospheric pressure. In some implementations, contacting gas with the first aqueous solution comprising solid hydroxide particles is performed at above atmospheric pressure. In some implementations, contacting gas with the first aqueous solution comprising solid hydroxide particles is performed between atmospheric pressure and about 60 psig. In some implementations, the gas (e.g., gaseous source of carbon dioxide) is contacted with the liquid and / or flowed at a specific partial pressure of carbon dioxide (e.g., atmospheric pCCh).

[0080] The gas can comprise a gaseous source, including carbon dioxide (e.g., air, partially combusted natural gas effluent, industrial effluent, flue gas, combustion exhaust, cement stack emission). In some implementations, the gaseous source of carbon dioxide comprises about 2.5% to about 10% carbon dioxide. In other implementations, the gaseous source of carbon dioxide comprises about 2.5% to about 5% carbon dioxide. In some implementations, the flow of the gas has a velocity of about 0.1 m / s. In other implementations, the flow of the gas has a velocity of about 0.1 m / s to about 0.3 m / s. In yet other implementations, the flow of the gas has a velocity of about 0.1 m / s to about 3 m / s. Low gas flow rates may be used to optimize energy usage while maintaining effective gas-liquid contact.

[0081] Still referring to Figs. 1A-1D, and in greater detail, the gas flow system 101 can comprise one or more fans 101. The one or more fans 101 can be disposed on a side of the UCH-41725 tower and coupled to the tower through a shroud. In some implementations, the one or more fans 101 are oriented such that the gas flow is perpendicular to the general flow direction of the liquid passing through the fill media 105. The general flow direction of the liquid may be from the outlet of the liquid distribution system 102 to the liquid collector system 110. In such implementations, the flow of the gas and the liquid may be referred to as a crossflow configuration. In some implementations, the one or more fans 101 are oriented such that the gas flow is parallel and in an opposing direction to the general flow direction of the liquid passing through the fill media 105. In such implementations, the flow of the gas and liquid may be referred to as a counterflow configuration. In some implementations, the gas flow system 101 has both crossflow and counterflow configurations. The gas flow system 101 may further comprise a damper 107, a gas inlet screen 108 (e.g., high-temperature reusable galvanized steel panel filters), and a drift eliminator 106. The damper 107 and the gas inlet screen 108 can be disposed on a side of the tower opposite of the one or more fans 101. In some implementations, a drift eliminator 106 is be disposed between the fill media 105 and the one or more fans 101 (e.g., such that gas is pulled or drawn through the system). In some implementations, a drift eliminator 106 is disposed after the fill media 105 (e.g., such that gas is pushed through the system).

[0082] Still referring to Figs. 1A-1D, and in greater detail, the liquid introduced at the inlet 205 of the liquid distribution system 102 can be the first aqueous solution comprising solid hydroxide particles. In some implementations, the first aqueous solution comprising solid hydroxide particles is a suspension. In some implementations, the first aqueous solution comprising solid hydroxide particles is a slurry. The concentration or loading of the solid content in the aqueous solution may vary. In some implementations, the solid hydroxide is magnesium hydroxide. In some implementations, the solid hydroxide is sodium hydroxide. In some implementations, the first aqueous solution comprises solid hydroxide particles and aqueous sodium hydroxide. In some implementations, the solid hydroxide is calcium hydroxide. In some implementations, the solid hydroxide comprises magnesium hydroxide and sodium hydroxide. In some implementations, the solid hydroxide comprises magnesium hydroxide and calcium hydroxide. In some implementations, the first aqueous solution comprising solid hydroxide particles additionally comprises calcium carbonate.

[0083] In some implementations, a contactor system further comprises an electrolyzer in fluid communication with the tower, which can produce the first aqueous solution comprising UCH-41725 solid hydroxide particles. The aqueous solution may be a catholyte produced by the electrolyzer. By contacting a second aqueous solution (e.g., seawater, produced water) with an electrolyzer, the second aqueous solution can be divided into an anolyte and a catholyte. The anolyte can be in contact with an anode of the electrolyzer and the catholyte can be in contact with a cathode of the electrolyzer. A voltage can be applied to the electrolyzer to induce precipitation of solid hydroxide particles in the catholyte, thereby producing the first aqueous solution comprising solid hydroxide particles.

[0084] Fill media 105 can be a plurality of fill media 105 comprising one or more types of fill media (e.g., splash fill, film fill, hybrid fill). Hybrid fill media can be a combination of splash fill and film fill. A portion of the plurality of fill media 105 may be formed of one material while another portion of the plurality of fill media 105 may be formed of a different material. Fill media 105 may be formed of one or more materials (e.g., a combination thereof) resistant to corrosion and / or fouling, including but not limited to polypropylene, polypropylene-UV protected, polyvinyl chloride, and chlorinated polyvinyl chloride. Fill material 105 may be formed of one or more materials resistant to the corrosiveness of seawater and compatible with calcium carbonate formation. Splash fill media or hybrid media may be used to minimize the impact of high particle loading in the first aqueous solution. Fill media 105 proximal to the liquid distribution system 102 may be splash fill media or hybrid media, while fill media 105 proximal to the liquid collector system 110 may be film fill media, which can have a higher surface area to volume ratio compared to the splash fill media or hybrid media. The film fill media may be designed to enhance kinetic performance of the carbonation process, facilitating faster and more efficient carbon dioxide absorption. The film fill media may be formed of Teflon-based components that are resistant to fouling, including interactions with calcium carbonate. Film fill media can be designed to maximize surface of the liquid (e.g., forming a thin film of liquid).

[0085] Fill media 105 can be arranged to create a gradient of different properties. Fig. 10 shows diagram of an implementation of a contactor system comprising a single tower 1000 with different portions of fill media. Tower 1000 may comprise features common to cooling towers which include a gas flow system (e.g., gas flow system 101), a liquid distribution system (e.g., liquid distribution system 102), fill media (e.g., fill media 105), and a liquid collector system 110 (e .g., liquid collector system 110). Tower 1000 can have features of or be implemented as towers described herein (e.g., tower 100). UCH-41725

[0086] The properties of the different portions may depend on the liquid path because the liquid is the limiting factor that carries the solids which dissolve as they travel downward. In some implementations, a single tower can have three portions of fill media. A first portion 1001a of fill media, proximal to the liquid distribution system 1002a, can have a low surface to area ratio and high fouling resistance. A second portion 1001c of the fill media 105, proximal to the liquid collector system 110, can have a high surface area to volume ratio and low fouling resistance (e.g., film fill media). A third portion 1001b of fill media, positioned between the first portion 1001a and the second portion 1001c, can have a surface to area ratio and fouling resistance that are intermediate to those of the first portion 1001a and the second portion 1001c. In some implementations, the gas flow system can flow a gas (e.g., air) 1003 through each of the portions lOOla-c of fill media such that the gas contacts the liquid (e.g., the first aqueous solution comprising solid hydroxide particles) passing through the different portions of fill media. In some implementations, the gas (e.g., gaseous source of carbon dioxide) is contacted with the liquid and / or flowed at a specific partial pressure of carbon dioxide (e.g., atmospheric pCCh). In some implementations, the gas flow system can flow different gases through each of the portions lOOla-c of fill media. By way of example, air can be flowed through the first portion 1001a and the third portion 1001b of the fill media, while a gaseous source containing a higher carbon dioxide concentration can be flowed through the second portion 1001c to accelerate equilibrium. In some implementations, the gaseous source containing a higher carbon dioxide concentration comprises about 2.5% to about 10% carbon dioxide. In other implementations, the gaseous source containing a higher carbon dioxide concentration comprises about 2.5% to about 5% carbon dioxide.

[0087] In some implementations, the first aqueous solution comprising solid hydroxide particles is carbonated with air and subsequently carbonated with concentrated carbon dioxide to achieve about 4.6 g CCh / Kg catholyte.

[0088] In some implementations, a single tower can have two portions of fill media. In other implementations, a single tower can have four or more portions of fill media. The number of portions of fill media in the tower may depend on several factors, including, but not limited to, the desired contact time between the liquid and the gas, the gas flow rate, the properties of the solid hydroxide particles (e.g., particle size and distribution), the desired pressure drop, and operational constraints (e.g., space available for the system). UCH-41725

[0089] The fill media 105 can be enclosed within a first chamber comprising a fill media shuttle 104 and a fill media shuttle sled 103. Referring now to Figs. 3A-3C, with additional reference to Fig. 4, views of an implementation of a fill media shuttle sled and a fill media shuttle are shown. The fill media shuttle sled 103 may be formed of stainless steel. The fill media shuttle 104 may be formed of stainless steel and polycarbonate (e.g., clear Plexiglass sheeting). The fill media shuttle 104 and the fill media shuttle sled 103 may be formed of individual beams or bar members coupled using fastening mechanisms (e.g., welding, screw, nut, bolt, washer, flange) to form a substantially rectangular prism frame structure such that the structures have at least a top open end and a bottom open end. The fill media shuttle sled 103 can define an internal volume shaped and sized to enclose one or more fill media shuttles 104. The top open end can be proximal to the liquid distribution system 102 and the bottom open end can be proximal to the liquid collector system 110, allowing liquid to flow from the liquid distribution system 102, through the fill media 105, and into the liquid collector system 110. Multiple grid panels having a series of horizontal and vertical members that define a grid pattern can be affixed within the fill media shuttle 104. The grid panels can be used to secure the fill media 105 in place within the fill media shuttle 104. In some implementations, seal decking (e.g., SafePlank Decking) is disposed on a top surface of the fill media shuttle sled 103. Multiple sled brackets e.g., a pair of first sled brackets 109a and a pair of second sled brackets 109b), for example, as shown in Figs. 5A-5D, may be used to couple the fill media shuttle sled 103 (containing one more fill media shuttles 104) to a main frame of the tower, enabling lifting and leveling of the first chamber within the main frame of the tower. The sled backet 109a, b may be formed of carbon steel.

[0090] Referring now to Fig. 6, with additional reference to Figs. 7A-7E, views of an implementation of a main frame of a tower are shown. The main frame of the tower may be formed of stainless steel. Individuals beams or bar members may be coupled using fastening mechanisms (e.g., welding, screw, nut, bolt, washer, flange) to form a substantially rectangular prism frame structure. The main frame of the tower can comprise a pair of side panels (e.g., as shown in Fig. 7A-7C) and multiple end panels (e.g., as shown in Fig. 7D-7E) coupled to each of the side panels. Multiple end panels may be dispersed between parallel side panels and along their longitudinal length to form a 3-dimensional frame structure. Figs. 8A and 8B show a perspective view and a front view of an implementation of a door panel of a main frame assembly. One or more panels may be coupled (e.g., hingedly coupled) to the main frame of UCH-41725 the tower. Various elements described herein e.g., fill media shuttle sled 103, fill media shuttle

[0091] 104, drift eliminator 106, damper 107, gas inlet screen 108, shroud of the fan 101, fan 101) can be coupled to the main frame of the tower using fastening mechanisms (e.g., welding, screw, nut, bolt, washer, flange).

[0092] Referring now to Figs. 9A and 9B, and in brief overview, a perspective view and an exploded assembly view of an implementation of a basin of a contactor system are shown. The liquid collector system 110 can be a basin comprising a body 901 having an open top end which can receive liquid from the liquid distribution system 102 and liquid drained from the fill media

[0093] 105. The liquid entering the liquid collector system 110 may be a solution comprising dissolved inorganic carbon. In some implementations, the solution comprising dissolved inorganic carbon is saturated with dissolved inorganic carbon. In some implementations, the solution comprising dissolved inorganic carbon is saturated with carbon dioxide. In some implementations, the solution comprising dissolved inorganic carbon comprises undissolved solid hydroxide particles. In some implementations, the solution comprising dissolved inorganic carbon does not have solid particles. In some implementations, the dissolved inorganic carbon comprises bicarbonate or carbonate. The top end of the body 901 can include a plurality of grating blocks 902. Grating blocks 902 can allow liquid to flow freely while preventing larger debris from entering the basin.

[0094] Still referring to Figs. 9A and 9B, the body 901 can comprise a plurality of sides that extend vertically from a flat surface. Each of the sides may be a separate element from the flat surface and be coupled to the flat surface using a fastening mechanism e.g., welding, screw, nut, bolt, washer, flange). The plurality of sides may be walls or rails. The body 901 can comprise upper end rails 905a (e.g., as shown in Fig. 24A-24C), upper side rails 905b (e.g., as shown in Fig. 25A-25C), lower side rails 905c (e.g., as shown in Fig. 26A-26B), lower end rails 906a (e.g., as shown in Fig. 27A-27B), and a flat bottom sheet 907 (e.g., as shown in Fig. 28). The flat bottom sheet 907 can be coupled to the lower side rails 905c and the lower end rails 906a. The upper side rails 905b can be coupled to the lower side rails 905c and the lower end rails 906a can be coupled to the upper end rails 905a. The lower end rails 906a can have one or more openings extending through a thickness of the lower end rails. The openings can be oriented substantially perpendicular to the top open end of the body 901 of the basin. The one or more openings can serve as outlets of the liquid collector system 110. Blind flanges 906b can be used to seal the openings of the lower end rails 906a. The body 901 can comprise UCH-41725 skid beams 908a, b (e.g., as shown in Figs. 29A-30B). A plurality of skid beams can be coupled to a bottom side of the flat bottom sheet 907 (opposite of the top open end of the body 901). The body 901 can comprise end grating ledges 903a (e.g., as shown in Fig. 21A-21B), side grating ledges 903b (e.g., as shown in Fig. 22A-22B). End grating ledges 903a can be coupled to the upper end rails 905a. Side grating ledges 903b can be coupled to the upper side rails 905b. When coupled to the rails, a portion of the grating ledges 903a, b can define a flat surface to support one or more grating blocks 902. The body 901 can comprise flat sheet corners 904 (e.g., as shown in Fig. 23b), which can be used to secure an end of the upper side rail 905b to an end of the upper end rail 905a. The body 901 may be formed of one or more materials (e.g., a combination thereof), including but not limited to polyethylene with fiberglass-reinforced plastic, and vinyl ester with fiberglass-reinforced plastic.

[0095] In some implementations, a contactor system can comprise a gas flow metering system. The gas flow metering system can include one or more of: a data logger (e.g., 8- channel programmable portable data logger); a gas flow velocity sensor and / or transmitter; a liquid flow velocity sensor and / or transmitter; and / or a temperature and humidity sensor and / or transmitter. In some implementations, a contactor system can comprise one or more sampling points. By way of example, the liquid distribution system 102 may have one or more sampling points (e.g., valve 204 may be a three-way valve). Additionally or alternatively, the liquid collector system 110 may have one or more sampling points. Sampling points may allow for the collection of liquid samples for testing one or more parameters, including but not limited to pH level,_chemical composition, total suspended solids, temperature, and liquid velocity.

[0096] In some implementations, a contactor system can comprise a plurality of towers (e.g., plurality of towers 100, plurality of towers 1000). Referring now to Fig. 11 A, a diagrammatic view of an implementation of a contactor system having multiple towers is shown. Three towers HOla-c may be arranged in a horizontal configuration or in a vertical configuration and in fluid communication with each other. The inlet of the liquid distribution system 1102a of the tower 1101a can receive a first aqueous solution comprising solid hydroxide particles (e.g., a slurry of magnesium hydroxide and calcium carbonate). The outlet of the liquid collector system of the tower 1101a can be in fluid communication with the inlet of the liquid distribution system 1102b of the tower 1101b, while the outlet of the liquid collector system of the tower 1101b can be in fluid communication with the inlet of the liquid distribution UCH-41725 system 1102c of the tower 1101c. As liquid passes through each tower, a gas (e.g., a gaseous source of carbon dioxide) is contacted with the liquid, which increasingly dissolves carbon dioxide into the liquid, thereby producing a solution containing dissolved inorganic carbon, and may, in addition, contain solid carbonates. In some implementations, the gaseous source of carbon dioxide is contacted with the liquid and / or flowed at a specific partial pressure of carbon dioxide (e.g., atmospheric pCCh).

[0097] Referring now to Fig. 11B, a diagrammatic view of another implementation of a contactor system having multiple towers is shown. Various fluidic connections in Fig. 11A remain consistent with those illustrated in Fig. 11B. Any additional or differing fluidic connections, elements, and / or features will be described in the following.

[0098] In some implementations, for example, as shown in Fig. 11 Bian outlet of the liquid collector system of tower 1101c is in fluid communication with a settler 1151, allowing a liquid (e.g., a solution comprising dissolved inorganic carbon and solid particles such as solid carbonates) exiting from the tower 1101c to be introduced into the settler 1151. The settler 1151 can comprise a vessel to separate solid particles (e.g., calcium carbonate, nesquehonite) from the aqueous part of liquid by gravity. Denser solid particles can settle to the bottom of the settler and form a layer, while the aqueous part of the liquid remains on top (i.e., supernatant). The supernatant can be extracted from the settler 1151 (e.g., using a liquid pump). The layer of the settled solids can be transferred from the settler 1151 to a concentrator 1152, which is in fluid communication with the settler 1151. The layer of settled solids can be a carbonated concentrated slurry having a high particle loading. In some implementations, a liquid (e.g., a carbonated concentrated slurry of magnesium hydroxide and calcium carbonate) can be flowed out of the concentrator 1152, mixed with concentrated carbon dioxide, and subsequently re-introduced into the concentrator 1152. In some implementations, the liquid is recirculated a number of times and the liquid is contacted with the gas until the liquid is fully carbonated, after which it can be extracted from the concentrator 1152. In some implementations, the concentrator 1152 is a continuous stirred- tank reactor. In some implementations, the concentrator 1152 is a contactor system having a counter flow configuration.

[0099] Referring now to Fig. 12, a diagrammatic view of an implementation of a contactor system having a single tower 1200 comprising a crossflow and counterflow configuration is shown. Tower 1200 may comprise features common to cooling towers which include a gas UCH-41725 flow system (e.g., gas flow system 101), a liquid distribution system (e.g., liquid distribution system 102), fill media (e.g., fill media 105), and a liquid collector system 110 e.g., liquid collector system 110)._In some implementations, the flow of liquid and gas through a first portion 1201a of fill media and a second portion 1201b of fill media are arranged in a crossflow configuration, while the flow of liquid and gas through a third portion 1201c of fill media are arranged in a counterflow configuration. In some implementations, the gas flowing through the first portion 1201a and second portion 1201b is air. In some implementations, the gas flowing through the third portion 1201c has a higher concentration of carbon dioxide compared to air. This combination of crossflow and counterflow configurations can enhance the mass transfer process by leveraging the enhanced gradient driving forces in the lower portion (the third portion of fill media 1201c), where a concentrated flow facilitates enhanced carbon dioxide absorption. The crossflow configuration can minimize pressure drop, enabling movement of large quantities of air. In the third portion of fill media 1201c (the portion having a crossflow configuration), the liquid may be distributed such that it completely covers and wets the media.

[0100] In any of the implementations disclosed herein one or more liquid pumps can be used to enable the flow of liquid through different parts of a contactor system (e.g., the liquid distribution system). One or more liquid pumps can be used to pump liquid out of the liquid collector system.

[0101] Referring now to Fig. 13A, a process flow diagram of an implementation of a contactor system is shown. Tower 1315 may comprise features common to cooling towers which include a gas flow system (e.g., gas flow system 101), a liquid distribution system (e.g., liquid distribution system 102), fill media (e.g., fill media 105), and a liquid collector system 110 (e.g., liquid collector system 110). Tower 1315 can have features of or be implemented as towers described herein (e.g., tower 100, tower 1000).

[0102] A second aqueous solution 1301 (e.g., seawater, produced water) can be flowed into an electrolyzer 1304 using one or more positive displacement pumps 1303. The electrolyzer 1304 can produce an anolyte and a catholyte comprising solid hydroxide particles. The electrolyzer 1304 can be in fluid communication with a vessel 1308 and a processor 1307, where the anolyte is directed to the vessel 1308 via an anolyte liquid pathway 1306, while the catholyte comprising solid hydroxide particles is flowed into the processor 1307 via a catholyte liquid pathway 1306. In some implementations, the processor 1307 is a solid-liquid separator for UCH-41725 separating the liquid (e.g., first aqueous solution, catholyte) and the solids (e.g., solid hydroxide particles) from each other. In other implementations, the processor 1307 is a mixer (e.g., stirred tank reactor, static mixer, magnetic stirrer) for mixing the liquid e.g., first aqueous solution, catholyte) and solids (e.g., solid hydroxide particles). In still other embodiments, the processor 1307 includes both a solid-liquid separator and a mixer for performing a solid-liquid separation and a mixing operation (e.g., performing simultaneously or in sequence). In still further implementations, the processor 1307 is a filtration system (e.g., filter press) for filtering the liquid (e.g., first aqueous solution, catholyte) and the solids (e.g., solid hydroxide particles) in order to remove the solids (e.g., solid hydroxide particles), thereby forming a filtered aqueous solution. In this way, the liquid exiting the processor 1307 can be a filtered aqueous solution.

[0103] The processor 1307 can be in fluid communication with a tower 1315, allowing the liquid from the processor 1307 to flow into the tower 1315 through the tower’s liquid distribution system 1316, with a liquid pump 1309 (e.g., centrifugal pump) to pump the liquid. As the liquid flows through the fill media of the tower 1315 it is contacted with a gaseous source including carbon dioxide (e.g., using fans to flow gas through the liquid), thereby forming a saturated aqueous solution which is collected in the liquid collector system of the tower 1315. The liquid 1317 collected in the liquid collector system of the tower 1315 can be a solution comprising dissolved inorganic carbon, which can be flowed out of the tower using a liquid pump 1318 (e.g., centrifugal pump). The solution comprising dissolved inorganic carbon may also comprise undissolved solid hydroxide particles. In some implementations, the liquid collector system of the tower 1315 can be in fluid communication with the processor 1307 to define a recirculation liquid pathway 1313. In other implementations, the liquid collector system of the tower 1315 can be in fluid communication with the catholyte liquid pathway 1306. A first volume of the liquid 1317 can be flowed into the processor 1307 and subsequently into the tower 1315, while a second volume of the liquid 1317 can be flowed into the vessel 1308 via a fluidic pathway 1312, which fluidically connects the tower 1315 and vessel 1308. A volume of the liquid 1317 (collected in the liquid collector system) from the tower 1315 can be recirculated for one or more cycles (e.g., until atmospheric pressure is reached). In this way, the gas (flowed via the gas flow system of the tower 1315) is contacted with the liquid with each recirculation cycle and contact time between the gas and liquid is increased, which can allow for more gas to dissolve into the liquid. In some implementations, gas (e.g., gaseous source of carbon dioxide) flowed and / or contact with the liquid at a specific UCH-41725 partial pressure of carbon dioxide (e.g., atmospheric pCCh). Solid hydroxide may be added to the volume of liquid 1317 when it is recirculated (e.g., the volume of liquid 1317 flowed into the processor 1307 can be contacted with solid hydroxide particles contained in the processor 1307). Liquid e.g., anolyte 1305 and carbonated liquid) in the vessel 1308 can be evacuated into a drainage outlet (e.g., ocean).

[0104] In some implementations, the liquid (e.g., solution comprising dissolved inorganic carbon) is recirculated until the pH of the liquid is about 9 to about 10. The pH of the liquid flowing through any part of a contactor system may be measured manually or automatically. In some implementations, an operator may extract a liquid sample via a sampling point and test the sample using a probe or instrument to determine the pH level. In some implementations, a sensor may automatically take pH readings at specified intervals. One or more sensors may be positioned at various points, for example, within the tower 1315 and / or along the recirculation liquid pathway 1313. When the pH of the liquid reaches a specified value, the pump 1318 may activate a switch to direct all liquid from the tower 1315 into the vessel 1308. In some implementations, the liquid (e.g., the solution comprising dissolved inorganic carbon) is recirculated until the liquid does not comprise particles of the solid hydroxide (e.g., until all of the particles of solid hydroxide are fully dissolved). In some implementations, the liquid is recirculated until the liquid is saturated with carbon dioxide. In some implementations, the liquid is recirculated until the liquid is saturated with dissolved inorganic carbon. One or more sensors can be used to monitor and measure total suspended solids and / or dissolved inorganic carbon. Measurements of the total suspended solids and / or dissolved inorganic carbon can be used to determine whether liquid is recirculated. One or more sensors can be disposed along the gas travel path to measure the CO2 concentration in the gas flowing through the fill media. One or more gas velocity sensors can be installed to monitor the gas velocity and distribution within the fill media.

[0105] Referring now to Figs. 13B-13F, process flow diagrams of implementations of a contactor system are shown. Various fluidic connections in Figs. 13B-13F remain consistent with those illustrated in Fig. 13A. Any additional or differing fluidic connections, elements, and / or features will be described in the following. Towers 1315a, b may comprise features common to cooling towers which include a gas flow system (e.g., gas flow system 101), a liquid distribution system (e.g., liquid distribution system 102), fill media (e.g., fill media 105), UCH-41725 and a liquid collector system 110 (e.g., liquid collector system 110). Tower 1315a, b can have features of or be implemented as towers described herein (e.g., tower 100, tower 1000).

[0106] Undissolved solids may accumulate at the bottom of the liquid collector system of the tower forming a layer (e.g., a layer of solid magnesium hydroxide particles and solid calcium carbonate particles). In some implementations, for example, as shown in Fig. 13B, the liquid pump 1318 selectively pumps only the supernatant 1317a (i.e., the top layer) of the liquid from the liquid collector system of the tower 1315 to the vessel 1308 and through the recirculation liquid pathway 1313. This may minimize the direct handling of an abrasive brucite slurry in the fill media. The liquid pump 1318 may be positioned so that it only extracts the supernatant. A filtration system (e.g., one or more as) may be incorporated to prevent solids from flowing out of the tower 1315. In other implementations, for example, as shown in Fig. 13C, the liquid pump 1318 selectively pumps only the settled solids 1317b. In still other implementations, for example, as shown in Fig. 13D, a liquid pump 1318a selectively pumps only the supernatant 1317a while another liquid pump 1318b selectively pumps only the settled solids 1317b. In such implementations, the settled solids 1317b may be recirculated to the tower 1315 via a recirculation liquid pathway 1313 in fluid communication with the catholyte liquid pathway 1306 and the liquid distribution system of the tower 1315.

[0107] In some implementations, for example, as shown in Fig. 13E, a contactor system includes an electrolyzer 1304, a processor 1307, a first tower 1315a, a second tower 1315b, and a vessel 1308. In such implementations, a first volume of the liquid 1317 collected in the first tower 1315a is flowed to the second tower 1315b via a fluidic pathway 1312a, and a second volume of the liquid 1317 is recirculated to the processor 1307 via a fluidic pathway 1313a. In some implementations, the fill media of the first tower 1315a is a first fill media (e.g., splash fill media) and the fill media of the second tower 1315b is a second fill media (e.g., hybrid fill media, film fill media). A first volume of a liquid collected in the second tower 1315b can be flowed to the vessel 1308 using a liquid pump 1318b via a fluidic pathway 1312b, and a second volume of the liquid can be recirculated to the second tower 1315b through a fluidic pathway 1313b, which is in fluid communication with fluidic pathway 1312a.

[0108] In some implementations, for example, as shown in Fig. 13F, a contactor system includes an electrolyzer 1304, a first processor 1307a, a second processor 1307b, a first tower 1315a, a second tower 1315b, and a vessel 1308. In such implementations, a first volume of the liquid 1317 collected in the first tower 1315a is flowed to into the second processor 1307b UCH-41725 via a fluidic pathway 1312a, and a second volume of the liquid 1317 is recirculated to the first processor 1307a via a fluidic pathway 1313a. Liquid in the second processor 1307b can be flowed through the liquid distribution system of the second tower 1315b. A first volume of the liquid collected in the liquid collector system of the second tower 1315b can be recirculated to the second processor 1307b via a fluidic pathway 1313b, and subsequently to the second tower 1315b. A second volume of the liquid in the second tower 1315b can be flowed to the vessel 1308 via a fluidic pathway 1312b.

[0109] In some implementations, a contactor system does not include a mixer. Additional towers may be in fluid communication with the towers, the vessel, and / or a mixer. Additionally or alternatively, additional towers may have fluidic connections that define recirculation liquid pathways. Check valves can be installed between fluidic connections of different elements e.g., recirculation liquid pathway 1313) to prevent backflow. Pipes and pipe connectors (e.g., coupling, elbow, tee, reducer, flange, adapter, union, cap) can be used to fluidically connect different elements to each other and define a fluidic pathway. In some implementations, the outlet and inlet of different elements are directly connected to each other and can define a fluidic pathway. Liquid pumps may be in fluid communication with various elements to facilitate the flow of liquid throughout the system.

[0110] In some implementations, solids (e.g., precipitated solids, solid calcium carbonate particles, solid magnesium hydroxide particles) can be separated using a hydrocyclone, conical separator, cyclone separator, centrifuge, or similar instruments to separate solids from an aqueous solution. Solids can be separated from the aqueous part of a solution before being introduced and / or reintroduced into a tower.

[0111] In some implementations, a slurry comprising solid hydroxide particles is circulated (e.g., continuously, regularly) through a contactor system. Circulation of the slurry can control its viscosity and solid content, which can prevent excessive wear and tear as well as clogging of the system. The circulating slurry can be introduced into the tower or the vessel.

[0112] In some implementations, a contactor system comprises a tank or vessel for solid-liquid separation. In such implementations, the supernatant of the liquid in the tank or vessel can be flowed into a tower.

[0113] Referring now to Fig. 14, a process flow diagrams of another implementation of a contactor system is shown including a separator 1401, a filtration system 1402, a first vessel 1403a and a second vessel 1403b having a fan, and element 1404. The separator 1401 can be UCH-41725 a solid-liquid separator. The filtration system 1402 can filter the aqueous solution comprising solid hydroxide particles to remove the solid hydroxide particles to form a filtered aqueous solution. In some implementations, the element 1404 is a filtration unit (e.g., centrifuge, filter press). Pipes and pipe connectors (e.g., coupling, elbow, tee, reducer, flange, adapter, union, cap) can be used to fluidically connect different elements to each other and define a fluidic pathway. In some implementations, the outlet and inlet of different elements are directly connected to each other and can define a fluidic pathway. A contactor system can further comprise: one or more instruments 1406 (e.g. , flow gage, flow transmitter, flow meter, pressure transmitter, pressure gage, pH sensor) for measuring pH, temperature, total suspended solids, flow rate, pressure; valves 1407 e.g., check valves, ball valves, plug valves); sampling points 1408; liquid pumps (e.g., centrifugal pump) 1409. The instruments 1406 can collect measurements (e.g., pH, velocity, total suspended solids, temperature, pressure). The valves 1407 can be used to control the flow of the liquid through the system. For example, check valves can be installed between fluidic connections of different elements to prevent backflow. Valves can also have an open configuration, where they allow liquid and / or gas flow, and a closed configuration, where the prevent liquid and / or gas flow. Liquid pumps may be in fluid communication with various elements to facilitate the flow of liquid throughout the system.

[0114] A liquid (e.g., first aqueous solution comprising solid hydroxide particles) can be flowed through the separator 1401 which can separate the solid hydroxide particles from the aqueous solution. The first vessel 1403a can be in fluid communication with the separator 1401, the filtration system 1402, and ambient air. Ambient air can be flowed into the first vessel 1403a using a pump (e.g., pump 1409). In some implementations, ambient air is introduced into the first vessel 1403a at a specific partial pressure of carbon dioxide (e.g., atmospheric pCCL). A gas flow system of the first vessel 1403a can include one or more fans and generate an airflow such that the air contacts the liquid in the vessel. The liquid in the first vessel 1403a can be flowed out of the vessel and into the second vessel 1403b in fluid communication with the first vessel 1403a. The liquid exiting the first vessel 1403a can be a solution comprising dissolve inorganic carbon. There may be a sampling point 1408 between the first vessel 1403a and the second vessel 1403b. The second vessel 1403b can be in fluid communication with a gas source 1410 (e.g., air, flue gas, carbon dioxide source, partially combusted natural gas effluent, industrial effluent, combustion exhaust, cement stack emissions). The gas source 1410 can be introduced into the second vessel 1403b at a specific partial pressure of carbon dioxide UCH-41725

[0115] (e.g., atmospheric pCCh). A gas flow system of the second vessel 1403b can include one or more fans and generate a gas flow such that the gas contacts the liquid in the vessel. The liquid exiting the second vessel 1403b can be a solution comprising dissolve inorganic carbon. In some implementations, the liquid is flowed through element 1404 in fluid communication with the filtration system 1402. The element 1404 can separate solids from liquids. For example and without limitation, element 1404 (e.g., filter press) can separate solids from liquid through pressure filtration which can consist of a series of plates and frames that hold a filter medium. A slurry or liquid (e.g., a solution comprising dissolve inorganic carbon) containing solids can be pumped into element 1404, where pressure forces the liquid through the filter, leaving the solid particles behind as cake on the filter medium. In another example and without limitation, element 1404 (e.g. , centrifuge) can separate components of different densities by spinning them at high speeds. The centrifugal force generated can cause denser particles (e.g., solid hydroxide particles) to move outward to the bottom of element 1404, while lighter contents (e.g., liquid, first aqueous solution, solution comprising dissolve inorganic carbon). In other implementations, the liquid can be flowed through a fluidic pathway in fluid communication with the second vessel 1403b and the filtration system 1402. The fluidic pathway may be a series of interconnected pipes or a single pipe. The fluidic pathway may include a sampling point 1406 and / or one or more instruments 1406. Sampling points may allow for the collection of liquid samples for testing one or more parameters, including but not limited to pH level, chemical composition, total suspended solids, temperature, and liquid velocity.

[0116] In some implementations, the gas flow system of the first vessel 1403a and / or the second vessel 1403b include bubblers or spargers. In some implementations, a gas is contacted with the liquid by bubbling the gas into the liquid. This may be in addition to or an alternative to flowing gas into the vessels 1403a, b using one or more fans.

[0117] The present disclosure relates to methods for carbon dioxide removal (e.g., seawater based carbon dioxide removal). Referring now to Fig. 15, a method for carbon dioxide removal is provided. The method described herein may be performed using a contactor system. At 1501, an electrolyzer is contacted with a second aqueous solution (e.g., seawater, produced water). At 1502, the second aqueous solution is divided into an anolyte in contact with an anode of the electrolyzer and a catholyte in contact with a cathode of the electrolyzer. At 1503, a voltage is applied to the electrolzyer to induce precipitation of solid hydroxide particles in the catholyte, which may also contain solid carbonates. A first aqueous solution UCH-41725 comprising solid hydroxide and / or carbonate particles is formed. The first aqueous solution may be the catholyte produced by the electrolyzer. In some implementations, the solid hydroxide is magnesium hydroxide. In some implementations, the solid hydroxide is sodium hydroxide. In some implementations, the solid hydroxide is calcium hydroxide. In some implementations, the solid hydroxide comprises magnesium hydroxide and sodium hydroxide. In some implementations, the solid hydroxide is magnesium hydroxide and calcium hydroxide. In some implementations, the first aqueous solution comprising solid hydroxide particles additionally comprises calcium carbonate. In some implementations, the first aqueous solution comprising solid hydroxide particles is a suspension. In some implementations, the first aqueous solution comprising solid hydroxide particles is a slurry. The concentration or loading of the solid content in the aqueous solution may vary.

[0118] At 1504, the first aqueous solution comprising solid hydroxide particles is flowed from a top end to a bottom end of a fill media (e.g., splash fill media, hybrid fill media). In some implementations, prior to 1504, the first aqueous solution comprising solid hydroxide particles is filtered to remove the solid hydroxide particles, thereby forming a filtered aqueous solution. At 1505, a gas including a gaseous source of carbon dioxide is flowed through the fill media such that the gas contacts the first aqueous solution comprising solid hydroxide particles. Alternatively, at 1505, a gas including a gaseous source of carbon dioxide is flowed through the fill media such that the gas contacts the filtered aqueous solution. Contacting the filtered aqueous solution with a gaseous source including carbon dioxide may be performed until a specified pressure is reached (e.g., about atmospheric pressure), thereby forming a saturated aqueous solution. The saturated aqueous solution may be contacted (e.g., mixed with) with solid hydroxide particles, thereby forming a third aqueous solution comprising solid hydroxide particles. The third aqueous solution comprising solid hydroxide particles can be contacted with a gaseous source including carbon dioxide.

[0119] In some implementations, the gas flow is perpendicular to the general flow direction of the liquid e.g., first aqueous solution comprising solid hydroxide particles) passing through the fill media. In such implementations, the flow of the gas and the liquid may be referred to as a crossflow configuration. In some implementations, the gas flow is parallel and in an opposing direction to the general flow direction of the liquid passing through the fill media. In such implementations, the flow of the gas and liquid may be referred to as a UCH-41725 counterflow configuration. In some implementations, the gas flow system has both crossflow and counterflow configurations.

[0120] The gas can comprise a gaseous source including carbon dioxide (e.g., air, partially combusted natural gas effluent, industrial effluent, flue gas, combustion exhaust, cement stack emissions). The gas and the first aqueous solution comprising solid hydroxide particles may be flowed simultaneously. In some implementations, the flow of the gas has a velocity of about 0.1 m / s. In other implementations, the flow of the gas has a velocity of about 0.1 m / s to about 0.3 m / s. In yet other implementations, the flow of the gas has a velocity of about 0.1 m / s to about 3 m / s. In some implementations, the gaseous source of carbon dioxide comprises about 2.5% to about 10% carbon dioxide. In other implementations, the gaseous source of carbon dioxide comprises about 2.5% to about 5% carbon dioxide.

[0121] By contacting the gas with the liquid (e.g., performing the step of flowing the gas and the first aqueous solution comprising solid hydroxide), a solution comprising dissolved inorganic carbon can be produced. In some implementations, the solution comprising dissolved inorganic carbon is saturated with dissolved inorganic carbon. In some implementations, the solution comprising dissolved inorganic carbon is saturated with carbon dioxide. In some implementations, the solution comprising dissolved inorganic carbon comprises undissolved solid hydroxide particles. In some implementations, the solution comprising dissolved inorganic carbon does not have solid particles. In some implementations, the dissolved inorganic carbon comprises bicarbonate, carbonate, or a combination of both.

[0122] In some implementations, contacting the gas (e.g., gaseous source including carbon dioxide) with the liquid (e.g., first aqueous solution comprising solid hydroxide) comprises passing carbon dioxide across the surface of the first aqueous solution. In some implementations, contacting the first aqueous solution comprising solid hydroxide particles with the gas comprises agitating (e.g., mechanical agitation) the first aqueous solution comprising solid hydroxide particles with the gas. In some implementations, contacting the gas with the first aqueous solution comprising solid hydroxide particles comprises bubbling the gas through the first aqueous solution comprising solid hydroxide particles.

[0123] In some implementations, contacting the gas with the liquid is performed at atmospheric pressure. In some implementations, contacting the gas with the first aqueous solution comprising solid hydroxide particles is performed at above atmospheric pressure. In UCH-41725 some implementations, contacting the gas with the first aqueous solution comprising solid hydroxide particles is performed between atmospheric pressure and about 60 psig.

[0124] In some implementations, the method is performed until the solution comprising dissolved inorganic carbon does not comprise particles of the solid hydroxide. By way of example, the solution comprising dissolved inorganic carbon can be recirculated to the top end of the fill media one or more times to increase the contact time between the liquid and the gas.

[0125] In some implementations, contacting the gas with the liquid is performed until the solution comprising dissolved inorganic carbon does not comprise particles of a hydroxide (e.g., solid hydroxide). In some implementations, contacting the gas with the liquid is performed until the pH of the solution comprising dissolved inorganic carbon is about 9, about 9.1, about 9.2, about 9.3, about 9.4, about 9.5, about 9.6, about 9.7, about 9.8, about 9.9, or about 10. In some implementations, contacting the gas with the liquid is performed until the solution comprising dissolved inorganic carbon is saturated with dissolved inorganic carbon.

[0126] In some implementations, the method further comprises first contacting air with the aqueous solution comprising a hydroxide and then contacting the gaseous source including carbon dioxide with aqueous solution comprising a hydroxide which comprises about 2.5% to about 10% CO2. In some implementations, the method further comprises first contacting air with the aqueous solution comprising a hydroxide and then contacting the gaseous source including carbon dioxide with the aqueous solution comprising a hydroxide which comprises about 2.5% to about 5% CO2.

[0127] In some implementations, the method further comprises adding solid hydroxide after carbonation (e.g., after contacting the liquid and the gas).

[0128] An experiment was conducted to evaluate the enhanced carbon dioxide dissolution and carbonation kinetics using structured packing in a sequential carbonation process. A reaction column was configured with structured packing (film fill media) to maximize the contact area between the catholyte and carbon dioxide.

[0129] A synthetic catholyte was prepared by basifying seawater to pH of about 10 to about 10.5 and filtering magnesium hydroxide from the solution. Then, carbon dioxide was introduced at atmospheric pCCh into the column containing structured packing. UCH-41725

[0130] Reagent grade magnesium hydroxide was sequentially added after carbonation. The decrease in pH and increase in dissolve inorganic carbon, along with changes in magnesium concentration and calcium concentration over time, were recorded to assess carbonate precipitation rates.

[0131] Enhanced mass transfer due to structured packing increased the rate of pH decrease and dissolved inorganic carbon increase, leading to more efficient carbonate precipitation compared to sparged experiments.

[0132] In another experiment, a column with film fill packing was configured in a lab-scale system to assess direct carbonation efficiency using structured packing.

[0133] Air was directly bubbled through the column containing the simulated catholyte. The decrease in pH and increase in dissolved inorganic carbon over time were recorded, along with the changes in magnesium and calcium concentrations to determine the rates of aragonite, nesquehonite, and other magnesium carbonates.

[0134] The structured packing facilitated a more uniform and quicker adsorption of carbon dioxide and lead to a more pronounced and rapid decrease in pH and an increase in dissolved inorganic carbon.

[0135] Having thus described several illustrative implementations, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to form a part of this disclosure, and are intended to be within the spirit and scope of this disclosure. While some examples presented herein involve specific combinations of functions or structural elements, it should be understood that those functions and elements may be combined in other ways according to the present disclosure to accomplish the same or different objectives. In particular, acts, elements, and features discussed in connection with one implementation are not intended to be excluded from similar or other roles in other implementations. Additionally, elements described herein may be further divided into additional elements or joined together to form fewer elements for performing the same functions. Accordingly, the UCH-41725 foregoing description and attached drawings are by way of example only, and are not intended to be limiting.

[0136] Definitions

[0137] Unless otherwise defined herein, scientific and technical terms used in this application shall have the meanings that are commonly understood by those of ordinary skill in the art. Generally, nomenclature used in connection with, and techniques of, chemistry, chemical engineering, electrical engineering and civil engineering described herein, are those well- known and commonly used in the art.

[0138] The methods and techniques of the present disclosure are generally performed, unless otherwise indicated, according to conventional methods well known in the art and as described in various general and more specific references that are cited and discussed throughout this specification.

[0139] Chemistry terms used herein, unless otherwise defined herein, are used according to conventional usage in the art, as exemplified by “The McGraw-Hill Dictionary of Chemical Terms”, Parker S., Ed., McGraw-Hill, San Francisco, C.A. (1985).

[0140] All publications, patents and published patent applications referred to in this application are specifically incorporated by reference herein. In case of conflict, the present specification, including its specific definitions, will control.

[0141] As used herein, the term “particle size” refers to the mean particle size (dso) as determined through, e.g., dynamic light scattering.

[0142] As used herein, the term “production capacity” refers to the upper boundary of the dry mass of pure product equivalents that may be produced per unit of time.

[0143] The term “source” as used herein in connection with chemical elements (e.g., calcium) refers to a composition that comprises the element.

[0144] INCORPORATION BY REFERENCE

[0145] All publications and patents mentioned herein are hereby incorporated by reference in their entirety as if each individual publication or patent was specifically and individually indicated to be incorporated by reference. In case of conflict, the present application, including any definitions herein, will control. UCH-41725

[0146] EQUIVALENTS

[0147] While specific implementations of the subject invention have been discussed, the above specification is illustrative and not restrictive. Many variations of the invention will become apparent to those skilled in the art upon review of this specification, embodiments, and claims below. The full scope of the invention should be determined by reference to the embodiments and claims, along with their full scope of equivalents, and the specification, along with such variations.

[0148] ADDITIONAL EMBODIMENTS

[0149] Additional embodiments of the present disclosure are encompassed by the following numbered paragraphs:

[0150] 1. A system for carbon dioxide removal comprising: a liquid distribution system; a liquid collector system; a fill media disposed between the liquid collector system and the liquid distribution system, the liquid distribution system distributing a first aqueous solution to the fill media, the first aqueous solution comprising solid hydroxide particles; and a gas flow system flowing a gas through the fill media such that the gas contacts the first aqueous solution, the gas comprising a gaseous source of carbon dioxide.

[0151] 2. The system of paragraph 1, wherein a flow of the gas is oriented perpendicular to a flow of the first aqueous solution.

[0152] 3. The system of paragraph 1, wherein a flow of the gas is parallel and in an opposing direction of a flow of the first aqueous solution.

[0153] 4. The system of paragraph 1, wherein the solid hydroxide particles is a plurality of solid hydroxide particles.

[0154] 5. The system of paragraph 1, wherein the first aqueous solution comprising a solid hydroxide particle is a suspension.

[0155] 6. The system of paragraph 1, wherein the solid hydroxide is magnesium hydroxide. UCH-41725

[0156] 7. The system of paragraph 1, wherein the solid hydroxide is calcium hydroxide.

[0157] 8. The system of paragraph 1, wherein the solid hydroxide comprises calcium hydroxide and magnesium hydroxide.

[0158] 9. The system of paragraph 1, further comprising a fill media chamber, wherein the fill media is house within the fill media chamber.

[0159] 10. The system of paragraph 10, the fill media chamber comprising a fill media shuttle and a fill media shuttle sled.

[0160] 11. The system of paragraph 1, wherein the gas contacting the first aqueous solution produces a solution comprising dissolved inorganic carbon.

[0161] 12. The system of paragraph 11, wherein the liquid collector system receives the solution comprising dissolved inorganic carbon.

[0162] 13. The system of paragraph 1, wherein a flow of the gas has a velocity approximately between 0.1 m / s and 3.0 m / s.

[0163] 14. The system of paragraph 1, the fill media comprising a plurality of fill media, the plurality of fill media comprising hybrid fill media, splash fill media, or a combination thereof.

[0164] 15. The system of paragraph 1, further comprising a recirculation liquid pathway.

[0165] 16. The system of paragraph 1, wherein the liquid collector system is in fluid communication with the liquid distribution system.

[0166] 17. The system of paragraph 1, further comprising a separator in fluid communication with the liquid distribution system, the separator performing a solid-liquid separation.

[0167] 18. The system of paragraph 17, wherein the liquid collector system is in fluid communication with the separator.

[0168] 19. The system of paragraph 12, wherein a supernatant of the solution comprising dissolved inorganic carbon is flowed from the liquid collector system to the liquid distribution system. UCH-41725

[0169] 20. The system of paragraph 12, wherein a bottom layer of the solution comprising dissolved inorganic carbon is flowed from the liquid collector system to the liquid distribution system.

[0170] 21. The system of paragraph 1, further comprising a gas flow metering system.

[0171] 22. The system of paragraph 1, wherein the first aqueous solution is a catholyte produced by an electrolyzer.

[0172] 23. The system of paragraph 1, further comprising an electrolyzer in fluid communication with the liquid distribution system.

[0173] 24. The system of paragraph 1, further comprising a vessel in fluid communication with the liquid collector system.

[0174] 25. A method for carbon dioxide removal comprising: contacting an electrolyzer with a second aqueous solution; dividing the second aqueous solution into an anolyte in contact with an anode of the electrolyzer and a catholyte in contact with a cathode of the electrolyzer; applying a voltage to the electrolzyer to induce precipitation of solid hydroxide particles in the catholyte, thereby forming a first aqueous solution comprising solid hydroxide particles; and flowing the first aqueous solution comprising solid hydroxide particles through a fill media.

[0175] 26. The method of paragraph 25, further comprising flowing a gas comprising a gaseous source of carbon dioxide through the fill media such that the gas contacts the first aqueous solution comprising solid hydroxide particles.

[0176] 27. The method of paragraph 25, wherein a saturated solution drains from a bottom end of the fill media, the saturated solution comprising a solution of dissolved inorganic carbon.

[0177] 28. The method of paragraph 27, further comprising collecting the saturated solution.

[0178] 29. The method of paragraph 27, further comprising flowing the saturated solution to a top end of the fill media. UCH-41725

[0179] 30. The method of paragraph 27, further comprising contacting the saturated aqueous solution with solid hydroxide particles, thereby forming a third aqueous solution comprising solid hydroxide particles.

[0180] 31. The method of paragraph 30, further comprising flowing the third aqueous solution comprising solid hydroxide particles to a top end of the fill media.

[0181] 32. The method of paragraph 31, further comprising flowing a gas comprising a gaseous source of carbon dioxide through the fill media such that the gas contacts the third aqueous solution comprising solid hydroxide particles.

[0182] 33. A method for carbon dioxide removal comprising: contacting an electrolyzer with a second aqueous solution; dividing the second aqueous solution into an anolyte in contact with an anode of the electrolyzer and a catholyte in contact with a cathode of the electrolyzer; and applying a voltage to the electrolzyer to induce precipitation of solid hydroxide particles in the catholyte, thereby forming a first aqueous solution comprising solid hydroxide particles.

[0183] 34. The method of paragraph 33, further comprising filtering the first aqueous solution comprising solid hydroxide particles to remove the solid hydroxide particles, thereby forming a filtered aqueous solution.

[0184] 35. The method of paragraph 34, further comprising flowing the filtered aqueous solution through a fill media.

[0185] 36. The method of paragraph 35, further comprising flowing a gas comprising a gaseous source of carbon dioxide through the fill media such that the gas contacts the filtered aqueous solution.

Claims

UCH-41725CLAIMS1. A system for carbon dioxide removal comprising: a liquid distribution system; a liquid collector system; a fill media disposed between the liquid collector system and the liquid distribution system, the liquid distribution system distributing a first aqueous solution to the fill media; and a gas flow system flowing a gas through the fill media, the gas comprising a gaseous source of carbon dioxide.

2. The system of claim 1, wherein a flow of the gas is oriented perpendicular to a flow of the first aqueous solution.

3. The system of claim 1, wherein a flow of the gas is parallel and in an opposing direction of a flow of the first aqueous solution.

4. The system of claim 1, wherein the solid hydroxide particles is a plurality of solid hydroxide particles.

5. The system of claim 1, wherein the first aqueous solution comprises solid hydroxide particles.

6. The system of claim 5, wherein the solid hydroxide is magnesium hydroxide.

7. The system of claim 5, wherein the solid hydroxide is calcium hydroxide.

8. The system of claim 5, wherein the solid hydroxide comprises calcium hydroxide and magnesium hydroxide.

9. The system of claim 1, further comprising a fill media chamber, wherein the fill media is housed within the fill media chamber. fO. The system of claim fO, the fill media chamber comprising a fill media shuttle and a fill media shuttle sled.UCH-4172511. The system of claim 1, wherein the gas contacts the first aqueous solution, producing a solution comprising dissolved inorganic carbon.

12. The system of claim 11, wherein the liquid collector system receives the solution comprising dissolved inorganic carbon.

13. The system of claim 1, wherein a flow of the gas has a velocity approximately between 0.1 m / s and 3.0 m / s.

14. The system of claim 1, the fill media comprising a plurality of fill media, the plurality of fill media comprising hybrid fill media, splash fill media, or a combination thereof.

15. The system of claim 1, further comprising a recirculation liquid pathway.

16. The system of claim 1, wherein the liquid collector system is in fluid communication with the liquid distribution system.

17. The system of claim 1, further comprising a separator in fluid communication with the liquid distribution system, the separator performing a solid-liquid separation.

18. The system of claim 17, wherein the liquid collector system is in fluid communication with the separator.

19. The system of claim 12, wherein a supernatant of the solution comprising dissolved inorganic carbon is flowed from the liquid collector system to the liquid distribution system.

20. The system of claim 12, wherein a bottom layer of the solution comprising dissolved inorganic carbon is flowed from the liquid collector system to the liquid distribution system.

21. The system of claim 1, further comprising a gas flow metering system.

22. The system of claim 1, wherein the first aqueous solution is a catholyte produced by an electrolyzer.

23. The system of claim 1, further comprising an electrolyzer in fluid communication with the liquid distribution system.

24. The system of claim 1, further comprising a vessel in fluid communication with the liquid collector system.UCH-4172525. A method for carbon dioxide removal comprising: contacting an electrolyzer with a second aqueous solution; dividing the second aqueous solution into an anolyte in contact with an anode of the electrolyzer and a catholyte in contact with a cathode of the electrolyzer; applying a voltage to the electrolzyer to induce precipitation of solid hydroxide particles in the catholyte, thereby forming a first aqueous solution comprising solid hydroxide particles; and flowing the first aqueous solution comprising solid hydroxide particles through a fill media.

26. The method of claim 25, further comprising flowing a gas comprising a gaseous source of carbon dioxide through the fill media such that the gas contacts the first aqueous solution comprising solid hydroxide particles.

27. The method of claim 25, wherein a saturated solution drains from a bottom end of the fill media, the saturated solution comprising a solution of dissolved inorganic carbon.

28. The method of claim 27, further comprising collecting the saturated solution.

29. The method of claim 27, further comprising flowing the saturated solution to a top end of the fill media.

30. The method of claim 27, further comprising contacting the saturated aqueous solution with solid hydroxide particles, thereby forming a third aqueous solution comprising solid hydroxide particles.

31. The method of claim 30, further comprising flowing the third aqueous solution comprising solid hydroxide particles to a top end of the fill media.

32. The method of claim 31, further comprising flowing a gas comprising a gaseous source of carbon dioxide through the fill media such that the gas contacts the third aqueous solution comprising solid hydroxide particles.

33. A method for carbon dioxide removal comprising: contacting an electrolyzer with a second aqueous solution;UCH-41725 dividing the second aqueous solution into an anolyte in contact with an anode of the electrolyzer and a catholyte in contact with a cathode of the electrolyzer; and applying a voltage to the electrolzyer to induce precipitation of solid hydroxide particles in the catholyte, thereby forming a first aqueous solution comprising solid hydroxide particles.

34. The method of claim 33, further comprising filtering the first aqueous solution comprising solid hydroxide particles to remove the solid hydroxide particles, thereby forming a filtered aqueous solution.

35. The method of claim 34, further comprising flowing the filtered aqueous solution through a fill media.

36. The method of claim 35, further comprising flowing a gas comprising a gaseous source of carbon dioxide through the fill media such that the gas contacts the filtered aqueous solution.

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