Reticulated, non-metal packing materials and uses thereof in a rotating packed bed apparatus

Abstract

The present disclosure relates generally to packing materials for high gravity devices and, more particularly, to reticulated, non-metal foam packing materials for use in rotating packed bed apparatus.

Description

PATENT APPLICATIONRETICULATED, NON-METAL PACKING MATERIALS AND USES THEREOF IN A ROTATING PACKED BED APPARATUSGOVERNMENT SUPPORT CLAUSE

[0001] This invention was made with government support under DE-AR0001717 awarded by ARPA-E within the Department of Energy. The government has certain rights to this invention.CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 739,531, filed December 28, 2024, entitled “RETICULATED, NON-METAL PACKING MATERIALS AND USES THEREOF IN A ROTATING PACKED BED APPARATUS”, and U.S. Provisional Patent Application Serial No. 63 / 743,782, filed January 10, 2025, entitled “RETICULATED, NON-METAL PACKING MATERIALS AND USES THEREOF IN A ROTATING PACKED BED APPARATUS”. These provisional patent applications are hereby incorporated by reference in their entireties for all purposes.TECHNICAL FIELD

[0003] The present disclosure relates generally to packing materials for high gravity devices and, more particularly, to reticulated non-metal foam packing materials for use in rotating packed bed apparatus.BACKGROUND

[0004] For packing material of a rotating packed bed (RPB) apparatus in a mass transfer application, the material selection and physical characteristics are of utmost importance when it comes to functionality and efficiency. Because of the need to balance dynamic and static loading and forces with their brittle nature, reticulated non-metal foams (e.g., ceramic and carbon foams) are a packing material that is not immediately considered in a high-speed and centrifugal force application, such as industrial RPB apparatus.SUMMARY

[0005] In view of the shortcomings of existing reticulated, non-metal foam packing materials for use in rotating packed bed (RPB) apparatus, the present disclosure provides reticulated, non-metal (e.g., ceramic and carbon) foam packing materials are chemically compatible, resistant to degradation (e.g., rust or patina), and provide a significant reduction in overall mass compared to metal packing materials, which has many tangible benefits including, but not limited to, reduced drive motor size, minimized bearings and support infrastructure, reduced processing equipment needed for lift / manufacturing, and reduced cost to ship or assemble. This reduction in cost and weight permits scaling of rotors to larger sizes with a reduction in complexity, advantageously permitting mass transfer applications on an industrial or commercial scale.

[0006] As such, one aspect of the present disclosure can include a packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated material, wherein the reticulated material is a non-metal foam made from one or a combination of reticulated vitreous carbon (RVC) foam, expanded carbon foam, siliconcarbide, silicon oxide, silicon nitride, alumina and zirconia, and wherein the reticulated material does not include a hydrophobic layer and / or a hydrophilic layer coated thereon. In one example, the packing comprises RVC foam.

[0007] Another aspect of the present disclosure can include a packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated, non-metal material, wherein the reticulated, non-metal material has a pore density of about 20 pores per inch (PPI) to about 65 PPI, and wherein the reticulated, non-metal material does not include a hydrophobic layer and / or a hydrophilic layer coated thereon.

[0008] Another aspect of the present disclosure can include a packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated, non-metal material, wherein the reticulated, non-metal material includes a plurality of pores, wherein one or more of the pores has an average diameter of about 1.25 mm to about 0.5 mm, and wherein the reticulated, non-metal material does not include a hydrophobic layer and / or a hydrophilic layer coated thereon.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The foregoing and other features of the present disclosure will become apparent to those skilled in the art to which the present disclosure relates upon reading the following description with reference to the accompanying drawings, in which:

[0010] Fig. 1 is a process flow diagram showing one example of a CO2 capture system (blue box) for application of a natural gas combined cycle flue gas;

[0011] Fig. 2 is a graph plotting interfacial area (m2 / m3) vs gas flow rate (standard liters per minute, SLPM) for reticulated vitreous carbon (RVC) foam having different PPI (fixed 900 RPM at 4.5% CO2: 4 L / G); and

[0012] Fig. 3 is a graph plotting interfacial area (m2 / m3) vs rotation speed (RPM) for RVC foam having different PPI (varying RPM at 4.5% CO2: 4 L / G).DETAILED DESCRIPTION

[0013] Definitions

[0014] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which the present disclosure pertains.

[0015] Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.

[0016] In the context of the present disclosure, the term “about”, when expressed as from “about” one particular value and / or “about” another particular value, also specifically contemplated and disclosed is the range from the one particular value and / or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of eachof the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these aspects are explicitly disclosed.

[0017] Optionally, in some aspects, when values or characteristics are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.

[0018] As used herein, phrases such as “between X and Y” and “between about X and Y” can be interpreted to include X and Y.

[0019] As used herein, phrases such as “between about X and Y” can mean “between about X and about Y”.

[0020] As used herein, phrases such as “from about X to Y” can mean “from about X to about Y”.

[0021] It will be understood that when an element is referred to as being “physically associated with”, “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly physically associated with, on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example,“directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

[0022] Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms can encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features.

[0023] As used herein, the terms “first,” “second,” etc. should not limit the elements being described by these terms. These terms are only used to distinguish one element from another. Thus, a “first” element discussed below could also be termed a “second” element without departing from the teachings of the present disclosure. The sequence of operations (or acts / steps) is not limited to the order presented in the claims or figures unless specifically indicated otherwise.

[0024] As used herein, the terms “optionally” and “optional” can mean that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.

[0025] As used herein, the term “commercial scale” can refer to a capture scale of about 10 tons per day (TPD) to about 100,000 TPD or greater of a target gas or sorbent by a RPB apparatus. In one example, “commercial scale” can include about 10 TPD to about 100,000 TPD (e.g., about 10 TPD to about 100 TPD), about 100 TPD to about 1 ,000 TPD, about 1 ,000 TPD to about 10,000 TPD, about 10,000 TPD to about 20,000 TPD, about 20,000 TPD to about 30,000 TPD, about 30,000 TPD to about 40,000 TPD, about 40,000 TPD to about 50,000 TPD, about 50,000 TPD to about 60,000 TPD, about 60,000 TPD to about 70,000 TPD, about 70,000 TPD to about 80,000 TPD, about 80,000 TPD to about 90,000 TPD, or about 90,000 TPD to about 100,000 TPD. It will be appreciated that the term does not refer to, or include, small-scale testing (e.g., bench top) and research applications, e.g., operating at a capture scale of less than about 5 TPD, e.g., less than about 1 TPD.

[0026] As used herein, the terms “rotating packed bed apparatus” or “RPB apparatus” can refer to a device capable of generating a high gravity field to affect mass transfer between at least two liquids and / or gases. The high gravity field is the result of a centrifugal force field generated by rotation of packed beds in the RPB apparatus. The phrase “high gravity field” means that liquid and / or gas reactants are introduced into the high gravity field and react while they are moved centrifugally; or the liquid reactant is moved from the center of the RPB apparatus centrifugally and the gas reactant is introduced oppositely with respect to the liquid reactant along the radial direction when the packed bed is rotating. In general, the reaction represented by the phrase “under high gravity” can be carried out in any RPB apparatus or any other similar high gravity field reactor.

[0027] As used herein, the term “additive build platform” can refer to any device (e.g., printer) that creates physical objects from 3D digital models by layering materials on top of each other. Non-limiting types of such devices can include stereolithography (SLA) printers, selective laser sintering (SLS) printers, fused deposition modeling (FDM) printers, digital light process (DLP) printers, multi jet fusion (MJF) printers, PolyJet printers, direct metal laser sintering (DMLS) printers, and electron beam melting (EBM) lasers.

[0028] As used herein the term “reticulated”, when referring to a non-metal foam packing material (e.g., ceramic or carbon foam) of the present disclosure, can mean a structure resembling a network of fibers or having a mesh-like or sponge-like configuration. Reticulated structures are desired, in part, because of their surface-to-volume ratio, porosity, and / or permeability.

[0029] As used herein, the term “reticulated vitreous carbon foam” or “RVC foam” can refer to an open pore foam material composed solely of vitreous carbon. Vitreous carbon is a form of glass-like carbon which combines some of the properties of glass with those of normal industrial carbons. RVC foam has a low relative density (about 3%), high surface area and rigidity, low resistance to fluid flow, and can withstand very high temperatures in non-oxidizing environments. RVC foam is exceptionally inert over a very wide temperature range, and has very low bulk thermal conductivity and high electrical conductivity. Its unusual rigid geometry provides a large surface area and low pressure drop for fluid flow. Additionally, the structure of RVC foam promotes its ability to hold infused materials within controlled porosity ranges.

[0030] As used herein, the term “pore density” can refer to the average number of pores-per-linear-inch (PPI) for a given material (e.g., a ceramic foam of the present disclosure).

[0031] As used herein, the term “porosity” can refer to the overall percentage of void space within a packing material; essentially, the ratio of pore volume to total volume.

[0032] As used herein, the term “non-metal foam” can refer to a porous substrate made of a material that lacks the traditional properties of metals. Non-limiting examples of non-metal foams can include those comprising, consisting essentially of, or consisting of carbon, silicon, sulfur and selenium.

[0033] As used herein, the term “sorbent” can refer to a liquid or gas used to absorb or adsorb a specific substance.

[0034] Reticulated Non-metal Foams and RPB Apparatus Comprising the Same

[0035] Reticulated non-metal foam packing materials (e.g., ceramic and carbon foams) of the present disclosure are advantageous for several reasons over traditional commercial scale packing materials, such as expanded metal sheet, wound wire, metal foams, metal beads and others. For example, ceramic and carbon foam packing materials are chemically compatible and are resistant to degradation (e.g., rust or patina). Significantly, reticulated non-metal foam packing materials of the present disclosure provide possess an increased area-to-volume ratio and a reduced density, thereby providing a reduction in overall mass compared to commercial scale, metal packing materials for RPB apparatus. Reduction in mass of an equivalent size rotor has many tangible benefits when reducing the cost of a RPB system, such as reduced drive motor size, minimized bearings and support infrastructure, reduced processingequipment needed for lift / manufacturing, and reduced cost to ship or assemble. This reduction in cost and weight permits scaling of rotors to larger sizes with a reduction in complexity, advantageously permitting mass transfer applications on an industrial or commercial scale.

[0036] In addition to the foregoing advantages, reticulated non-metal foam packing materials of the present disclosure can be prepared in many varieties of pore shape and sizes, which allows for selection of specific properties to target performance characteristics and improve efficiency; whereas, conventional metal packing materials are limited in what is economically feasible for large-scale or commercial production. As discussed below, there are several varieties of reticulated non-metal foam packing materials that can be created with variable densities and material properties as well for ideally targeting specific process conditions and environments which is not often feasible in traditional metal packing manufacturing. The flexibility of additive manufacturing, for example, allows for customized material and generating the packing design allows for enhanced CFD simulation, which can further improve design cycle efficiencies and reduce the need for iterative testing plans.

[0037] One aspect of the present disclosure can include a packing material adapted for use with a RPB apparatus e.g., on a commercial scale). The packing material can comprise a reticulated non-metal foam material. In one example, the reticulated non-metal material can include a ceramic or carbon foam made from one or a combination of reticulated vitreous carbon (RVC) foam, expanded carbon foam, silicon carbide, silicon oxide, silicon nitride, alumina and zirconia. The reticulated non-metal foam material does not include a hydrophobic layer and / or a hydrophilic layer physicallyassociated therewith, for example, coated thereon (e.g., directly coated thereon, adhered to, or in contact with, e.g., direct contact). Non-limiting examples of materials that can comprise the hydrophobic or hydrophilic layers include cellulose, sodium hydroxide, phosphonates, and polytetrafluoroethylene.

[0038] Another aspect of the present disclosure can include a packing material adapted for use with a RPB apparatus (e.g., on a commercial scale). The packing material can comprise a reticulated non-metal material (e.g., ceramic or carbon foam, such as RVC foam). The reticulated non-metal material can have a pore density of about 20 pores per inch (PPI) to about 65 PPI. Additionally, the reticulated non-metal foam material does not include a hydrophobic layer and / or a hydrophilic layer physically associated therewith, for example, coated thereon (e.g., directly coated thereon, adhered to, or in contact with, e.g., direct contact). Non-limiting examples of materials that can comprise the hydrophobic or hydrophilic layers include cellulose, sodium hydroxide, phosphonates, and polytetrafluoroethylene.

[0039] Another aspect of the present disclosure can include a packing material adapted for use with a RPB apparatus (e.g., on a commercial scale). The packing material can comprise a reticulated non-metal material (e.g., ceramic or carbon foam, such as RVC foam). The reticulated non-metal material can include a plurality of pores, wherein one or more of the pores has an average diameter of about 1.25 mm to about 0.5 mm. Additionally, the reticulated non-metal foam material does not include a hydrophobic layer and / or a hydrophilic layer physically associated therewith, for example, coated thereon (e.g., directly coated thereon, adhered to, or in contact with, e.g., direct contact). Non-limiting examples of materials that can comprise thehydrophobic or hydrophilic layers include cellulose, sodium hydroxide, phosphonates, and polytetrafluoroethylene.

[0040] In one example, a packing material of the present disclosure can comprise a ceramic or carbon foam made from one or a combination of RVC foam, expanded carbon foam, silicon carbide, silicon oxide, silicon nitride, alumina and zirconia.

[0041] In another example, a packing material of the present disclosure can comprise one or a combination of polymers, such as liquid photopolymers. Polymers (e.g., liquid photopolymers) suitable for use as a packing material of the present disclosure can possess one or more of the following properties: chemically inert or non-reactive; tensile strength of at least about 50 MPa, for example, at least about 55 MPa, at least about 60 MPa (e.g., about 60 MPa), or about 65 MPa or greater; and a HDT of at least about 100°C., or at least about 110°C., or at least about 120°C. (e.g., about 120°C.), or at least about 125°C. or greater.

[0042] In one example, polymers suitable for use as a packing material of the present disclosure can comprise one or a combination of Evonik ST 6100L, Evonik Tl 3100, Loctite IND147, Loctite IND 248, and Henkel 3843.

[0043] In one example, a packing material of the present disclosure can have a surface area of from about 500 m2 / m3to about 4,000 m2 / m3. In another example, a packing material of the present disclosure can have a surface area of about 600 m2 / m3or greater. In another example, a packing material of the present disclosure can have a surface area of about 500 m2 / m3to about 1 ,000 m2 / m3, about 1 ,000 m2 / m3to about 1 ,500 m2 / m3, about 1 ,500 m2 / m3to about 2,000 m2 / m3, about 2,000 m2 / m3to about2.500 m2 / m3, about 2,500 m2 / m3to about 3,000 m2 / m3, about 3,000 m2 / m3to about 3.500 m2 / m3, or 3,500 m2 / m3to about 4,000 m2 / m3.

[0044] In another example, a packing material of the present disclosure can have a porosity of at least about 70% to about 90%, or about 70%, or about 75%, or about 80%, or about 85%, or about 90% or greater. In one example, packing material of the present disclosure can have a porosity of about 80%.

[0045] In yet another example, a packing material of the present disclosure can have a pore density of about 10 PPI to about 70 PPI, about 10 PPI to about 20 PPI, about 20 PPI to about 30 PPI, about 30 PPI to about 40 PPI, about 40 PPI to about 50 PPI, about 50 PPI to about 60 PPI, or about 60 PPI to about 70 PPI.

[0046] In yet another example, a packing material of the present disclosure can have a volume density of about 2% to about 5%, e.g., about 2% to about 3 %, about 3% to about 4%, or about 4% to about 5%.

[0047] In one example, a packing material of the present disclosure can comprise RVC foam having a pore density of about 20 PPI to about 65 PPI and a volume density of about 2% to about 5%.

[0048] Yet another aspect of the present disclosure can include a RPB apparatus comprising a packing material of the present disclosure. In one example, the RPB apparatus can comprise a RPB apparatus as disclosed in any one of U.S. Patent No. 7,537,644, U.S. Patent No. 7,326,283, U.S. Patent No. 11 ,612,854, U.S. Patent No. 11,850,547, and U.S. Patent Application Publication No. 2007 / 0034565.

[0049] Yet another aspect of the present disclosure can include a RPB apparatus comprising a packing material of the present disclosure and being sized anddimensioned for use on a commercial scale. In one example, the RPB apparatus can be sized and dimensioned for use on a commercial scale based on the dimensions (e.g., outer diameter or OD, inner diameter or ID, and height or H) of its rotor housing. In such instances, a rotor housing comprising the RPB can have an OD of at least 1 m to about 6 m (e.g., about 3 m to 5 m, or about 3-3.5 m, or about 3.5-4 m, or about 4-4.5 m, or about 4.5-5 m), an ID of at least about 1 m (e.g., about 2 m to about 4 m, or about 2-2.5 m, or about 2.5-3 m, or about 3-3.5 m, or about 3.5-4 m) to about 5 m, and a height (H) of at least about 4 m (e.g., about 4 m to about 6 m, or about 4-4.5 m, or about 4.5-5 m, or about 5-5.5 m, or about 5.5-6 m) to about 7 m. In one example, a rotor housing comprising the RPB can have an OD of about 3-5 m (e.g., about 1.5 m), an ID of about 2-4 m (e.g., about 1 m), and a height (H) of about 4-6 m (e.g., about 2 m).

[0050] Methods of Use

[0051] Another aspect of the present disclosure can include a method of using an RPB apparatus, which comprises a packing material of the present disclosure (e.g., as described in any one or combination of Aspects 1-3 below), to transfer mass between a sorbent and a gas, or to remove one or more acid gases (e.g., CO2, SO2, H2S, NOx), at a commercial scale. The method can include the steps of: receiving, by the RPB apparatus, a flow of gas; receiving, by the RPB apparatus, a flow of sorbent; and providing a cross-flow of the received sorbent and received gas in a region of mass transfer of the RPB apparatus, thereby obtaining a loaded sorbent and a treated gas.

[0052] In one example, the treated gas is free of, or substantially free of, one or more gases selected from the group consisting of carbon dioxide, mercaptans, hydrogen sulphide, and carbonyl sulphide. The term “substantially free of”, as used in thiscontext, can mean having a trivial amount of, such that a treated gas contains about 0 wt % to about 5 wt % of the one or more gases (e.g., carbon dioxide, mercaptans, hydrogen sulphide, and carbonyl sulphide), or about 0 wt % to about 1 wt %, or about 5 wt % or less, or less than, equal to, or greater than about 4.5 wt %, 4, 3.5, 3.2.5, 2, 1.5, 1 , 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1 , 0.01 , or about 0.001 wt % or less, or about 0 wt %.

[0053] In another example, the method can be performed for the purpose of carbon capture. Using a RPB apparatus that includes a packing material of the present disclosure (e.g., as described in any one or combination of Aspects 1-3 below), a liquid sorbent and a gas containing carbon can be mixed. In the RPB, mass transfer occurs in the packing material when rotated. Due to the artificial gravity that is introduced by the rotation, the effective contact area between the gas and sorbent is increased without causing early flooding. Advantageously, the method can reduce the concentration of at least one gas in a mixture of gasses, such as a flue gas, so that the concentration of carbon dioxide in the flue gas is reduced before it is released into the atmosphere. Alternatively, where the gas mixture is a mixture of hydrogen and carbon dioxide (e.g., as may be generated by a reforming process), the method of the present disclosure can reduce the concentration of carbon dioxide in the gas mixture to generate substantially pure hydrogen.

[0054] In yet another example, carbon capture can be accomplished using a RPB apparatus, which includes a packing material of the present disclosure, in combination with the methods described in PCT Pub. No. WO 2019 / 057932.

[0055] In yet another example, carbon capture can be accomplished using one or more RPB apparatus, all or some of which include a packing material of the present disclosure, comprising a system as shown in Fig. 1.

[0056] Another aspect of the present disclosure can include a method of using a RPB apparatus, which includes a packing material of the present disclosure e.g., as described in any one or combination of Aspects 1-3 below), to degass a liquid (e.g., water, malt beverages, alcohol and non-alcohol beverages or liquids, and fruit juices) containing a target gas containing at least one atom selected from the group consisting of O, N, S, H, and C (e.g., air, oxygen, carbon dioxide, nitrogen). The method can comprise the steps of: causing a rotatable element within the RPB apparatus to spin at a tangential velocity; infusing a liquid containing a gas into the RPB apparatus; applying a vacuum to an interior region of the RPB apparatus; and generating a liquid substantially free of the target gas. The term “substantially free of”, as used in this context, can mean having a trivial amount of, such that the treated liquid contains about 0 wt % to about 5 wt % of the target gas, or about 0 wt % to about 1 wt %, or about 5 wt % or less, or less than, equal to, or greater than about 4.5 wt %, 4, 3.5, 3.2.5, 2, 1.5, 1 , 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1 , 0.01 , or about 0.001 wt % or less, or about 0 wt %.

[0057] In one example, the method can be performed using a RPB apparatus ( / .e., comprising a packing material of the present disclosure) as described in U.S. Patent No.7,537,644.

[0058] Methods of Production

[0059] One aspect of the present disclosure can include a process for producing a packing material, as described herein (e.g., as described in any one or combination of Aspects 1-3 below), which is adapted for use in a RPB apparatus at a commercial scale.

[0060] In one example, the process can comprise additive manufacturing. In another example, the process can comprise an additive manufacturing process as described in U.S. Provisional Patent Application Serial No. 63 / 729,026 (filed December 6, 2024) and International Application Serial No. PCT / US2025 / 058419 (filed December 5, 2025).

[0061] In another example, the process can comprise a casting and / or extrusion process as understood by those skilled in the art, e.g., wherein a slurry of ceramic material is mixed with a sacrificial polymer before being cast or extruded into a desired shape, which is then dried and fired at high temperatures to create the porous structure.

[0062] Exemplary Aspects

[0063] In view of the described compositions, devices, and methods and variations thereof, herein below are certain more particularly described aspects of the present disclosure. These particularly recited aspects should not, however, be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[0064] Aspect 1 : A packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated material, wherein the reticulated material is a non-metal foam made from one or a combination of reticulated vitreous carbon (RVC) foam, expanded carbon foam, silicon carbide, silicon oxide, silicon nitride, alumina andzirconia, and wherein the reticulated material does not include a hydrophobic layer and / or a hydrophilic layer coated thereon.

[0065] Aspect 2: A packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated material, wherein the reticulated material has a pore density of about 20 pores per inch (PPI) to about 65 PPI, and wherein the reticulated material does not include a hydrophobic layer and / or a hydrophilic layer coated thereon.

[0066] Aspect 3: A packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated material, wherein the reticulated material includes a plurality of pores, wherein one or more of the pores has an average diameter of about 1.25 mm to about 0.5 mm, and wherein the reticulated material does not include a hydrophobic layer and / or a hydrophilic layer coated thereon.

[0067] Aspect 4: The packing of any one of Aspects 1 -3, having a surface area of from about 500 to about 4,000 m2 / m3.

[0068] Aspect 5: The packing of any one of Aspects 1 -4, having a porosity of at least about 80%.

[0069] Aspect 6: A rotating packed bed (RPB) apparatus comprising a packing according to any one of Aspects 1 -5.

[0070] Aspect 7: A method of using the RPB apparatus of Aspect 6 to transfer mass between a sorbent and a gas, the method comprising: receiving, by the RPB apparatus, a flow of gas; receiving, by the RPB apparatus, a flow of sorbent; and providing a cross-flow of the received sorbent and received gas in a region of mass transfer of the RPB apparatus, thereby obtaining a loaded sorbent and a treated gas.

[0071] Aspect 8: The method of Aspect 7, wherein the treated gas is free of, or substantially free of, one or more gases selected from the group consisting of carbon dioxide, mercaptans, hydrogen sulphide, and carbonyl sulphide.

[0072] Aspect 9: A method of using the RPB apparatus of Aspect 4 to degass a liquid, the method comprising: causing a rotatable element within the RPB apparatus to spin at a tangential velocity; infusing a liquid containing a gas into the RPB apparatus; applying a vacuum to an interior region of the RPB apparatus; and generating a liquid substantially free of the gas.

[0073] Aspect 10: The method of Aspect 9, wherein the liquid includes water.

[0074] Aspect 11 : The method of any one of Aspects 9-10, wherein the gas is selected from the group consisting of air, oxygen, carbon dioxide, and nitrogen.

[0075] Aspect 12: A method for producing the packing of any one of Aspects 1 -5, comprising employing an additive manufacturing process to obtain the packing.

[0076] The following Examples are for the purpose of illustration only and are not intended to limit the scope of the claims, which are appended hereto.Example 1

[0077] To test the ability to generate, manufacture, and evaluate expanded reticulated vitreous carbon (RVC) foam as a packing material for a rotating packed bed (RPB) apparatus, the following procedure was performed. Remarkably, as compared to a conventional metal foam packing, the expanded RVC foam demonstrated: (1) a drastic reduction in weight without reduction in performance; (2) a drastic reduction in weight with significant increase in performance; and (3) a drastic reduction in weight and volume with moderate increase in performance.

[0078] First, a model of the RVC expanded foam packing was created in SolidWorks with respective mounting features. The inner diameter was 3.5 inches and the outer diameter was 11.75 inches. There were six 0.525-inch diameter by 0.52-inch-long slots evenly spaced around the outside diameter of the volume to act as mounting points. This model was used to create the RVC expanded foam packing and then compared with an existing metal (stainless-steel) foam packing.

[0079] The next step in the process was to select five (5) pore densities of foam for evaluation between 5 and 60 pores per inch (PPI). The selected densities of 5, 20,30, 45 and 60 PPI were fabricated to match the model for the test bed RPB. These samples were installed and tested to directly compare with an existing stainless-steel foam of similar size and 8 PPI pore density.

[0080] The largest area of difference between the RVC expanded foam and stainless-steel foams was the reduction in weight. Overall, the mass was reduced by approximately 90% by switching to the RVC expanded foam packing. This reduction is highly advantageous in reducing drive-motor sizes, bearing sizes, shipping weights, and manufacturing costs when scaling to industrial or commercial levels.

[0081] Functionally, the 30 and 45 PPI RVC expanded foam packing outperformed the stainless-steel foam packing at all levels, while the 5 PPI and 20 PPI functioned almost equivalently to the stainless-steel foam (Figs. 2-3).Example 2

[0082] This Example illustrates a packing material of the present application for a RPB sized for a commercial application.

[0083] The RPB has of the following dimensions: ID - 1 m; OD - 1.5 m; and H - 2 m. This equates with a total packing volume of approximately 1 m3. Traditional packing materials such as wire mesh or corrugated structed metal packings have an average density of 330 kg / m3or 230 kg / m3, respectively, relating to a packing mass of approximately 330 kg or 230 kg. Replacing this packing material with a RVC foam, which has a typical density of 50 kg / m3, equates to a weight savings of up to 85%. An equivalent reduction to the moment of inertia of the RPB rotor allows for a motor size reduction of as much as 60% torque rating. The reduction in motor size, bearing sizes, and shipping weight all drastically reduce the overall cost of the final RPB system.Example 3

[0084] This Example illustrates a packing material of the present application for a RPB sized for a commercial scale carbon capture application.

[0085] The RPB has of the following dimensions: ID - 1 m; OD - 1.5 m; and H - 2 m. This equates with a total packing volume of approximately 2m3.

[0086] Traditional packing materials such as wire mesh or corrugated structed metal packings have an average density of 330 kg / m3or 230 kg / m3, respectively, relating to a packing mass of approximately 660 kg or 460 kg. These traditional materials are also limited in the relative pore density, void density, and specific surface area of about 10 PPI, 70%, and 900 m2 / m3respectively.

[0087] Replacing traditional packing materials with a RVC foam, which has a typical density of 50 kg / m3, equates to a weight savings of up to 85%. Another added benefit is a wider selection of pore density, a maximized void density, and increase specific surface area of about 40 PPI, 90%, and 2500 m2 / m3respectively. An equivalent 85%reduction to the moment of inertia of the RPB rotor allows for a motor size reduction of as much as 60% torque rating. The reduction in motor size, support bearing sizes, and shipping weight all contribute to a reduction in the overall cost of the final RPB system. These factors are all critical when designing an RPB system for a commercial scale and application.

[0088] From the above description of the present disclosure, those skilled in the art will perceive improvements, changes, and modifications. Such improvements, changes, and modifications are within the skill of those in the art and are intended to be covered by the appended claims. All patents, patent applications, and publications cited herein are incorporated by reference in their entirety.

Claims

1. CLAIMSThe following is claimed:

1. A packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated material, wherein the reticulated material is a non-metal foam made from one or a combination of reticulated vitreous carbon (RVC) foam, expanded carbon foam, silicon carbide, silicon oxide, silicon nitride, alumina and zirconia, and wherein the reticulated material does not include a hydrophobic layer and / or a hydrophilic layer physically associated therewith.

2. A packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated non-metal material, wherein the reticulated non-metal material has a pore density of about 20 pores per inch (PPI) to about 65 PPI, and wherein the reticulated non-metal material does not include a hydrophobic layer and / or a hydrophilic layer physically associated therewith.

3. A packing adapted for use with a rotating packed bed apparatus, the packing comprising a reticulated non-metal material, wherein the reticulated non-metal material includes a plurality of pores, wherein one or more of the pores has an average diameter of about 1.25 mm to about 0.5 mm, and wherein the reticulated non-metal material does not include a hydrophobic layer and / or a hydrophilic layer physically associated therewith.

4. The packing of any one of claims 1-3, being configured to capture a target gas or sorbent at a commercial scale.

5. The packing of any one of claims 1-4, having a surface area of from about 500 to about 4,000 m2 / m3.

6. The packing of any one of claims 1-5, having a porosity of at least about 80%.

7. The packing of any one of claims 1-5, wherein the hydrophobic layer and / or hydrophilic layer is not coated on the reticulated material.

8. A rotating packed bed (RPB) apparatus comprising a packing according to any one of claims 1-7.

9. A method of using the RPB apparatus of claim 8 to transfer mass between a sorbent and a gas, the method comprising: receiving, by the RPB apparatus, a flow of gas; receiving, by the RPB apparatus, a flow of sorbent; and providing a cross-flow of the received sorbent and received gas in a region of mass transfer of the RPB apparatus, thereby obtaining a loaded sorbent and a treated gas.

10. The method of claim 9, wherein the treated gas is free of, or substantially free of, one or more gases selected from the group consisting of carbon dioxide, mercaptans, hydrogen sulphide, and carbonyl sulphide.

11. A method of using the RPB apparatus of claim 8 to degass a liquid, the method comprising: causing a rotatable element within the RPB apparatus to spin at a tangential velocity; infusing a liquid containing a gas into the RPB apparatus; applying a vacuum to an interior region of the RPB apparatus; and generating a liquid substantially free of the gas.

12. The method of claim 11 , wherein the liquid includes water.

13. The method of any one of claims 11-12, wherein the gas is selected from the group consisting of air, oxygen, carbon dioxide, and nitrogen.

14. A method for producing the packing of any one of claims 1 -7, comprising employing an additive manufacturing process to obtain the packing.

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