3D-Printed Active Packings for Integrated Absorber Intercooling

Solution Overview

Problem

Existing CO2 capture systems face efficiency reductions due to exothermic CO2 absorption reactions increasing solvent temperature, which decreases CO2 absorption capacity and requires external intercooling, increasing capital costs and equipment size.

Innovation Solution

Integration of additively manufactured structures for in-line heat exchange within the gas/liquid exchange column, utilizing Triply Periodic Minimal Surface geometries to maintain continuous fluid flow and internal cooling, reducing temperature bulges and eliminating external cooling loads by recycling waste heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional in-and-out intercooling is used to cool the solvent, then the temperature bulge is reduced and CO2 absorption capacity is improved, but external cooling units and equipment are required which increases capital costs and equipment size

Engineering Contradiction:

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines the heat exchange function with the absorption column structure by integrating cooling channels directly into the column walls. This merging eliminates the need for separate external cooling units while maintaining effective temperature control of the solvent stream, thereby reducing equipment complexity and capital costs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling channels are nested within the absorption column structure itself, with coolant flow paths embedded in the column walls. This nesting approach allows the cooling system to be contained within the existing column footprint, eliminating external cooling equipment while maintaining effective intercooling functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If external intercooling units are used, then CO2 absorption efficiency is maintained, but the column height and equipment footprint increase

Engineering Contradiction:

Core Design Contradiction:

ProductivityVSLength of stationary object

Solution Approach 1:

By merging the cooling function into the column structure itself, the patent eliminates the need for additional external cooling equipment that would increase the overall equipment footprint. The integrated design maintains absorption efficiency while keeping the column height and footprint compact.

Inventive Principle:

Principle #5Merging (Combining)

3Use of energy by moving object

If the solvent temperature increases during CO2 absorption, then the exothermic reaction proceeds, but the CO2 absorption capacity of the solvent decreases

Engineering Contradiction:

Core Design Contradiction:

Use of energy by moving objectVSQuantity of substance

Solution Approach 1:

The patent implements continuous cooling through embedded channels that remove excess heat as it is generated during the exothermic absorption process. This feedback mechanism maintains the solvent temperature within an optimal range, preserving the solvent's CO2 absorption capacity while allowing the exothermic reaction to proceed.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

By continuously adjusting the coolant flow and heat removal rate, the system maintains the solvent temperature at optimal levels for maximum CO2 absorption capacity. This dynamic parameter control ensures that the exothermic reaction proceeds efficiently without exceeding temperature thresholds that would reduce absorption capacity.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces absorber column height by 10-20%, recovers waste heat, and minimizes reboiler heat duty, enhancing energy efficiency and reducing capital equipment needs while maintaining high CO2 capture efficiency.

Implementation Method 1

The second zone forms an active packing zone including a structure which forms an independent second domain in thermal communication with the first domain... heat from at least one of the first fluid and the second fluid is transferred to the third fluid

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a second fluid operates to at least substantially remove the select gaseous component from the first fluid to create a third fluid

Methodology Applied

Scientific EffectGas absorption: Absorption (physical)

Implementation Method 3

the absorption of CO2 into the solvent is strongly exothermic, which increases the temperature of the solvent as it passes through the column

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentUS11590448B2System and method for integrated absorber intercooling via rich solvent stream using 3D-printed active packings

Publication Date: 2023.02.28

AI summary

The present disclosure relates to an absorber column apparatus for removing a selected component of a gas. The apparatus may have a first zone, a second zone and a third zone, wherein the first and third zones form a first domain through which a first fluid laden with a select gaseous component to be removed therefrom flows along concurrently with a second fluid. The second fluid at least substantially removes the select gaseous component from the first fluid to create a third fluid. The first fluid leaves the absorber column as a fourth fluid with the select gaseous component at least substantially removed therefrom. The second zone forms an active packing zone including a structure which forms an independent second domain in thermal communication with the first domain. The second receives a quantity of the third fluid and channels it through the second zone to help cool at least one of the first and second fluids.