A reactor for a carbon dioxide catcher and a method for detecting a carbon capture material level drop in such a reactor

Abstract

The disclosure relates to a reactor (100) for a carbon dioxide catcher comprising at least one reactor cassette (110a-e) comprising carbon capture material; a process air inlet (120) and outlet (130) configured to allow process air to be conducted through the reactor (100); at least one pressure sensor (140a-c) configured to measure a differential pressure over the reactor (100); and a control unit (160) configured to identify a carbon capture material level drop in the at least one reactor cassette (110a-e) based on the measured differential pressure. The disclosure further relates to a method for detecting a carbon capture material level drop in a reactor (100).

Description

[0001] A reactor for a carbon dioxide catcher and a method for detecting a carbon capture material level drop in such a reactor

[0002] Technical field

[0003] The present disclosure relates to a reactor for a carbon dioxide catcher and a method for detecting a carbon capture material level drop in a reactor. More specifically, the disclosure relates to a reactor for a carbon dioxide catcher and a method for detecting a carbon capture material level drop in a reactor as defined in the introductory parts of the independent claims.

[0004] Background art

[0005] Carbon dioxide (CO2) is a major greenhouse gas contributing to global warming and climate change and various ways of capturing the gas have been developed over the years. By capturing the carbon dioxide for example from industrial sources helps reducing the amount of this gas released to into the atmosphere, mitigating its impact on the environment. Different types of carbon capture material are known, for example covalent organic frameworks, metal-organic frameworks, activated carbon, zeolites and carbon nanotubes. Carbon capture materials are also good at adsorbing water vapor, which can compete with the capturing of carbon dioxide. Carbon dioxide catcher systems therefore often comprises dehumidifiers upstream of the carbon dioxide catcher, such that the carbon capture material can capture the carbon dioxide more efficiently.

[0006] Carbon dioxide catcher systems typically comprises one or more reactors with cassettes containing the carbon capture material. When the level of carbon capture material in the cassettes drops, air or gas may bypass the carbon capture material and the system will underperform and no longer reach accepted output conditions. That is, the air or gas leaving the carbon dioxide catcher reactor will comprise a too high amount of carbon dioxide. It is thus crucial to make sure that the cassette comprises an optimal level of carbon capture material. Today, inspection of the carbon capture material level is typically performed when the system is already underperforming or after a predetermined duration when it is anticipated that the level should have dropped. Inspection is performed by opening the reactor and filling nozzles and look inside the cassettes. This is cumbersome and requires gasket exchange each time, and it is therefore desired to avoid unnecessary inspections. There is thus a need for improved ways of detecting carbon capture material level drop in a reactor.

[0007] An object of the present disclosure is to mitigate, alleviate or eliminate one or more of the above-identified deficiencies and disadvantages in the prior art and solve at least the above-mentioned problems.

[0008] According to a first aspect there is provided a reactor for a carbon dioxide catcher comprising at least one reactor cassette comprising carbon capture material; a process air inlet and outlet configured to allow process air to be conducted through the reactor; at least one pressure sensor configured to measure a differential pressure over the reactor; and a control unit configured to identify a carbon capture material level drop in the at least one reactor cassette based on the measured differential pressure.

[0009] A reactor for a carbon dioxide catcher may comprise one or more reactor cassettes, each comprising the carbon capture material through which the process air is conducted. The carbon dioxide in the process air will this way be adsorbed on the carbon capture material in the cassette and the process air leaving the reactor will comprise a reduced amount of carbon dioxide. The carbon dioxide level in the process air is typically measured in parts per million, ppm. As mentioned above, the level of carbon capture material in the cassette may drop during operation and this have negative impact on the output from the reactor. With too little carbon capture material in the cassette, the process air may bypass the carbon capture material and the process air leaving the reactor will comprise a too high level of carbon dioxide. Checking the level of carbon capture material is a manual process which requires the reactor to be shut down. By measuring the differential pressure over the reactor, it can be determined that the level of carbon capture material has dropped without having to open the reactor. Thus, level drop of carbon capture material can be detected during operation of the reactor. With more carbon capture material in the cassette, the pressure drop will be higher since there is more resistance for the process air to pass through the cassette. Thus, when the level of carbon capture material has dropped, the pressure drop will be lower. Measuring the pressure differential requires two pressure points and determining the difference between the pressure at these pressure points. Measuring the pressure differential will thus indicate if the carbon capture material level has dropped in the reactor. This way, unnecessary inspections requiring cumbersome work and gasket exchanges are avoided. Furthermore, the level of carbon capture material can be filled up before the reactor starts underperforming. The reactor may also be referred to as an adsorbent and / or absorbent unit. Thus, the reactor is a unit configured to adsorb and / or absorb carbon dioxide in process air conducted through the reactor.

[0010] The pressure differential may be measured continuously during operation of the reactor. Alternatively, the pressure differential may be measured at predetermined intervals during operation of the reactor.

[0011] The carbon capture material mentioned herein is preferably zeolites, specifically zeolite pellets, but may be any other carbon capture material with similar characteristics. Carbon dioxide catchers using zeolites as carbon capture material, work by leveraging the unique properties of zeolites, which are microporous, aluminosilicate minerals. The zeolites thus have a high surface area and a network of tiny pores that can trap the carbon dioxide molecules. When air or gas containing carbon dioxide passes through the zeolite material, the carbon dioxide molecules are adsorbed onto the surface of the zeolite due to physical and chemical interactions. Zeolites can be modified with various cations or amines to enhance their selectivity for carbon dioxide over other gases like nitrogen or oxygen. This makes them particularly effective in capturing carbon dioxide from mixed gas streams. Once the zeolite material is saturated with carbon dioxide, it can be regenerated by applying heat or reducing the pressure, which releases the captured carbon dioxide. The zeolite can then be reused for further carbon dioxide capture cycles. The level drop of zeolite material in the at least one reactor cassette may be caused by vibrations inside the reactor cassette which makes the zeolite pellets break into smaller fragments.

[0012] In some examples, the at least one pressure sensor is arranged to measure a differential pressure over the process air inlet and outlet. The reactor comprises a process air inlet allowing the process air into the reactor, and a process air outlet through which the treated process air leaves the reactor. Measuring the differential pressure over the process air inlet and outlet means that the process air inlet and the process air outlet are the two pressure points where the pressure difference is measured. Measuring the difference in pressure at the process air inlet and outlet is a reliable way of detecting a carbon capture material level drop since all process air will pass these two pressure points. Also, this solution enables measurements without having to open or modify the reactor.

[0013] The reactor may comprise two or more reactor cassettes. Having a plurality of reactor cassettes increases the capacity of the reactor and more carbon dioxide can be captured. In some examples the reactor cassettes are arranged inside a common space of the reactor, wherein the process air enters the common space through the process air inlet, flows through the reactor cassettes and leaves the reactor via the process air outlet.

[0014] The reactor may comprise two or more reactor cassettes arranged in parallel. The process air entering the reactor via the process air inlet will thus be divided over the reactor cassettes and subsequently leave the reactor. Measuring the pressure difference at the process air inlet and the process air outlet is advantageous, because the reactor cassettes are considered to act similarly and thus the carbon capture material level in the different reactor cassettes will vary similarly. A lower pressure drop or pressure differential over the reactor will thus indicate that the carbon capture material level has dropped in all reactor cassettes.

[0015] The reactor may comprise a process air manifold configured to conduct process air through each reactor cassette via separate channels. The at least one pressure sensor may then comprise one or more pressure sensors for each reactor cassette and the respective pressure sensors for each reactor cassette are configured to measure respective differential pressures over each of the plurality of reactor cassettes. Each reactor cassette may thus have at least one pressure sensor measuring the pressure differential over said reactor cassette. Each pressure sensor may have a pressure point upstream of the reactor cassette and one pressure point downstream of the reactor cassette. Typically, the two pressure points are positioned in the respective channel for process air leading into the reactor cassette and leading away from the reactor cassette.

[0016] In some examples, the reactor comprises at least one window configured to allow visual inspection of a current amount of stored carbon capture material in the at least one reactor cassette. Additionally or alternatively, the reactor comprises at least one see-through section of the reactor casing, through which an operator can visually see the level of carbon capture material inside the reactor cassette from outside the reactor. Reactor cassettes are typically made of a mesh material or similar, which makes it possible to see the level of carbon capture material in the reactor cassette from outside the reactor cassette. However, today these reactor cassettes are arranged inside the reactor with no possibility to see the reactor cassettes unless you open the reactor cover. By having at least one window or similar in the reactor casing, visual inspection of the carbon capture material is possible. This way, an operator can determine if the carbon capture material level has dropped or not. This may be used as a complement or back-up to the pressure differential measurement. For example, when the pressure differential indicates that there might be a carbon capture material level drop, the operator may first manually inspect the level through the window before shutting down the reactor and refill the reactor cassette. This way, an even more reliable way of detecting carbon capture material level drop is achieved. In the event that the reactor comprises a plurality of reactor cassettes, the reactor may comprise one window or see- through section for each reactor cassette.

[0017] The control unit may be configured to compare the measured differential pressure with a predetermined threshold value indicating a carbon capture material level drop. The control unit may comprise a database or list comprising at least one predetermined threshold value indicating carbon capture material level drop. The control unit is thus configured to compare the measured pressure differential with the predetermined threshold value and when the measured pressure differential is equal to or below the threshold value, the control unit has detected a carbon capture material level drop.

[0018] The control unit may be configured to provide an alert configured to indicate a carbon capture material level drop. In one example, the control unit is configured to provide an alert when the pressure differential is equal to or below the predetermined threshold value. In another example, the control unit is configured to provide a first alert when the pressure differential falls below a first predetermined threshold value, the first alert recommending the operator to manually inspect the level through the at least one window. The control unit may also be configured to provide a second alert when the pressure differential falls below a second predetermined threshold value, the second alert recommending urgent refilling of carbon capture material. In the event that the reactor comprises multiple reactor cassettes and pressure differentials are measured over each reactor cassette individually, the control unit may also indicate which reactor cassette the alert relates to. The alert may be presented visually on display and / or audibly.

[0019] According to a second aspect of the present disclosure, there is provided an air treatment system comprising a dehumidifier and a carbon dioxide catcher arranged downstream of the dehumidifier, wherein the carbon dioxide catcher comprises at least one reactor according to the first aspect. As previously described, carbon capture materials are also very good at adsorbing water vapor which can interfere with the adsorption of carbon dioxide. By having a dehumidifier which dehumidifies the process air before entering the carbon dioxide catcher, the capturing of carbon dioxide will be much more efficient. The dehumidifier may comprise a desiccant rotor.

[0020] According to a third aspect of the present disclosure, there is provided a method for detecting a carbon capture material level drop in a reactor according to the first aspect, the method comprising measuring a differential pressure over the reactor; and identifying a carbon capture material level drop in the at least one reactor cassette based on the measured differential pressure. The at least one pressure sensor thus measures the differential pressure over the reactor and the control unit receives the measured value from the pressure sensor. The control unit subsequently identifies a carbon capture material level drop based on the received pressure differential value. Typically, the step of identifying the carbon capture material level drop comprises comparing the measured differential pressure with a predetermined threshold value indicating a carbon capture material level drop. Thus, when it is determined that the measured differential pressure is equal to or lower than the predetermined threshold value, the control unit concludes that a carbon capture material level drop has been identified.

[0021] Effects and features of the second and third aspects are to a large extent analogous to those described above in connection with the first aspect. Embodiments mentioned in relation to the first aspect are largely compatible with the second and third aspects.

[0022] The step of measuring the differential pressure over the reactor may comprise measuring a differential pressure over the process air inlet and outlet of the reactor. This may be performed if the reactor comprises one or more reactor cassettes under the assumption that all cassettes behave similarly and thus that the carbon capture material level changes similarly in all reactor cassettes. Alternatively, the step of measuring the differential pressure comprises measuring the differential pressure over each reactor cassette individually.

[0023] The method may further comprise generating an alert configured to indicate a carbon capture material level drop. The alert may be generated when the pressure differential is equal to or below the predetermined threshold value. In some examples, a first alert is generated when the pressure differential falls below a first predetermined threshold value, and a second alert is generated when the pressure differential falls below a second predetermined threshold value. The second threshold value being lower than the first threshold value. The alert may also indicate which reactor cassette that needs inspection and / or refilling of carbon capture material.

[0024] The present disclosure will become apparent from the detailed description given below. The detailed description and specific examples disclose preferred embodiments of the disclosure by way of illustration only. Those skilled in the art understand from guidance in the detailed description that changes and modifications may be made within the scope of the disclosure. Hence, it is to be understood that the herein disclosed disclosure is not limited to the particular component parts of the device described or steps of the methods described since such device and method may vary. It is also to be understood that the terminology used herein is for purpose of describing particular embodiments only, and is not intended to be limiting. It should be noted that, as used in the specification and the appended claim, the articles "a", "an", "the", and "said" are intended to mean that there are one or more of the elements unless the context explicitly dictates otherwise. Thus, for example, reference to "a unit" or "the unit" may include several devices, and the like. Furthermore, the words "comprising", "including", "containing" and similar wordings does not exclude other elements or steps.

[0025] Brief of the

[0026] The above objects, as well as additional objects, features and advantages of the present disclosure, will be more fully appreciated by reference to the following illustrative and non-limiting detailed description of example embodiments of the present disclosure, when taken in conjunction with the accompanying drawings.

[0027] Figures la-b schematically show a rector for a carbon dioxide catcher according to examples of the present disclosure.

[0028] Figures lc-d schematically show a reactor cassette according to an example of the present disclosure.

[0029] Figure 2 shows a diagram of a method for detecting a carbon capture material level drop in a reactor of a carbon dioxide catcher according to an example of the present disclosure.

[0030] Figure 3 schematically shows an air treatment system according to an example of the present disclosure.

[0031] Detailed

[0032] The present disclosure will now be described with reference to the accompanying drawings, in which preferred example embodiments of the disclosure are shown. The disclosure may, however, be embodied in other forms and should not be construed as limited to the herein disclosed embodiments. The disclosed embodiments are provided to fully convey the scope of the disclosure to the skilled person.

[0033] Figure la shows a reactor 100 for a carbon dioxide catcher 300 according to an example of the present invention. The reactor 100 comprises at least one reactor cassette llOa-b comprising carbon capture material. The carbon capture material is configured to adsorb the carbon dioxide molecules and thereby remove the carbon dioxide from the air. The air to be treated by the reactor is herein called process air. The process air suitably comes from a dehumidifier arranged upstream of the carbon dioxide catcher (see Figure 3). The reactor 100 further comprises a process air inlet 120 and a process air outlet 130 configured to allow process air to be conducted through the reactor 100. The process air inlet 120 and outlet 130 may be arranged on the same side or on opposite sides of the reactor 100. The reactor 100 also comprises at least one pressure sensor 140a-c configured to measure a differential pressure over the reactor 100, and a control unit 160 configured to identify a carbon capture material level drop in the at least one reactor cassette llOa-e based on the measured differential pressure.

[0034] The reactor 100 may comprise two or more reactor cassettes llOa-b. The reactor may comprise a pressure sensor 140a arranged to measure a differential pressure over the process air inlet 120 and process air outlet 130. Alternatively, the reactor 100 comprises one or more pressure sensors 140b, 140c for each reactor cassette llOa-b and the respective pressure sensor 140b, 140c is configured to measure differential pressures over each reactor cassette llOa-b individually.

[0035] The reactor 100 may also comprise a process air manifold SI configured to conduct process air through each reactor cassette llOa-b via separate channels.

[0036] Figure lb shows a reactor 100 for a carbon dioxide catcher 300 according to an example of the present invention. The reactor 100 may be configured as disclosed in Figure la. The reactor 100 comprises a reactor casing 180 and a cover 184 removably connected to the casing. In this example, the reactor 100 comprises at least one window 150 configured to allow visual inspection of a current amount of stored carbon capture material in the reactor cassettes llOa-d.

[0037] Figures lc-d schematically show a reactor cassette llOc-d according to an example of the present disclosure. The reactor cassette llOc-d may be used in a reactor 100 as disclosed in Figure la-b. Figure lc shows the process air flowing through the reactor cassette 110c according to an example. The process air is illustrated by arrows. Figure Id shows that the reactor cassette llOd comprises at least one filling nozzle 114 for filling the reactor cassette llOd with carbon capture material. The filling nozzle(s) 114 typically comprises a cover which has to be removed when refilling the reactor cassette llOd.

[0038] Figure 2 shows a diagram of a method for detecting a carbon capture material level drop in a reactor 100 of a carbon dioxide catcher 300 according to an example of the present disclosure. The reactor 100 which the method relates to is suitably configured as disclosed in Figure la-b. The method comprises measuring S100 a differential pressure over the reactor 100; and identifying S200 a carbon capture material level drop in the at least one reactor cassette llOa-e based on the measured differential pressure. The differential pressure is suitably measured by means of the at least one pressure sensor 140a-c. The control unit 160 receives the measured value and determines based on that if a carbon capture material level drop is identified or not.

[0039] The step of identifying S200 the carbon capture material level drop may comprise comparing S210 the measured differential pressure with a predetermined threshold value indicating a carbon capture material level drop. The control unit 160 typically compares the measured pressure differential with a predetermined threshold value stored in the control unit 160. When the measured pressure differential is equal to or lower than the predetermined threshold value, the control unit 160 has identified a carbon capture material level drop.

[0040] The step of measuring S100 the differential pressure over the reactor 100 may comprise measuring S110 the differential pressure over the process air inlet 120 and outlet 130. Alternatively, the step of measuring S100 the differential pressure over the reactor 100 comprises measuring the differential pressure over each reactor cassette llOa-b individually, by means of at least one pressure sensor 140b-c associated with each reactor cassette llOa-b.

[0041] The method may further comprise generating S300 an alert configured to indicate a carbon capture material level drop. The alert may be generated when the pressure differential is equal to or below the predetermined threshold value. The alert may also indicate which reactor cassette that needs inspection and / or refilling of carbon capture material. The alert may be presented visually or audibly.

[0042] Figure 3 schematically shows an air treatment system 500 according to an example of the present disclosure. The air treatment system 500 comprises a dehumidifier 400 and a carbon dioxide catcher 300 arranged downstream of the dehumidifier 400. The carbon dioxide catcher 300 comprises at least one reactor 100 as disclosed in Figure la-b. The dehumidifier 400 may comprise a desiccant rotor 420. The air treatment system 500 further comprises a process air circuit (not shown) configured to conduct process air through a process sector of the rotor 420 and subsequently the carbon dioxide catcher 300 downstream of the rotor 420. This way, the process air entering the carbon dioxide catcher 300 will be dehumidified and the carbon dioxide catcher 300 will capture the carbo dioxide more efficiently. The system 500 may also comprise a first regeneration air circuit configured to conduct regeneration air through a regeneration sector of the rotor 420, and a second regeneration air circuit configured to conduct regeneration air through the carbon dioxide catcher.

[0043] The person skilled in the art realizes that the present disclosure is not limited to the preferred embodiments described above. The person skilled in the art further realizes that modifications and variations are possible within the scope of the appended claims. Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed disclosure, from a study of the drawings, the disclosure, and the appended claims.

Claims

CLAIMS1. A reactor (100) for a carbon dioxide catcher (300), comprising:- at least one reactor cassette (llOa-e) comprising carbon capture material;- a process air inlet (120) and outlet (130) configured to allow process air to be conducted through the reactor (100);- at least one pressure sensor (140a-c) configured to measure a differential pressure over the reactor (100); and- a control unit (160) configured to identify a carbon capture material level drop in the at least one reactor cassette (llOa-e) based on the measured differential pressure.

2. The reactor (100) according to claim 1, wherein the at least one pressure sensor (140a) is arranged to measure a differential pressure over the process air inlet (120) and outlet (130).

3. The reactor (100) according to claim 1 or 2, wherein the reactor (100) comprises two or more reactor cassettes (llOa-b) arranged in parallel.

4. The reactor (100) according to claim 3, wherein the reactor (100) comprises a process air manifold (SI) configured to conduct process air through each reactor cassette (llOa-e) via separate channels, wherein the at least one pressure sensor (140a-c) comprises one or more pressure sensors (140b, 140c) for each reactor cassette (llOa-e) and wherein the respective pressure sensors (140b, 140c) for each reactor cassette (llOa-e) are configured to measure respective differential pressures over each of the plurality of reactor cassettes (llOa-e).

5. The reactor (100) according to any of the preceding claims, further comprising:- at least one window (150a-b) configured to allow visual inspection of a current amount of stored carbon capture material in the at least one reactor cassette (llOa-e).

6. The reactor (100) according to any of the preceding claims, wherein the control unit (160) is configured to compare the measured differential pressure with a predetermined threshold value indicating a carbon capture material level drop.

7. An air treatment system (500) comprising a dehumidifier (400) and a carbon dioxide catcher (300) arranged downstream of the dehumidifier (400), wherein the carbon dioxide catcher (300) comprises at least one reactor (100) according to any one of the preceding claims.

8. A method for detecting a carbon capture material level drop in a reactor (100) according to any one of claims 1-6, the method comprising:- measuring (S100) a differential pressure over the reactor (100); and- identifying (S200) a carbon capture material level drop in the at least one reactor cassette (llOa-e) based on the measured differential pressure.

9. The method according to claim 8, wherein the step of identifying (S200) the carbon capture material level drop comprises comparing (S210) the measured differential pressure with a predetermined threshold value indicating a carbon capture material level drop.

10. The method according to claim 8 or 9, wherein measuring (S100) the differential pressure over the reactor (100) comprises measuring (S110) the differential pressure over the process air inlet (120) and outlet (130).

11. The method according to any one of claim 8-10, further comprising:- generating (S300) an alert configured to indicate a carbon capture material level drop.

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