Angled Adsorbent Filter Media Design for Low Pressure Drop Gas Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current gas phase contaminant removal systems in buildings face inefficiencies due to high pressure drop, limited media depth, and turbulence, which affect the Mass Transfer Zone (MTZ) length and overall performance, especially in HVAC systems where traditional sorbent materials like activated carbon pellets and honeycombs have limitations in depth, accessibility, and cost.
Innovation Solution
A modular air cleaning system design featuring filter modules angled to optimize airflow path length and contact time, utilizing parallel channels and spacers to minimize pressure drop and maximize media exposure, allowing for variable media length and path length to control the MTZ length, and incorporating activated carbon paper media for enhanced adsorption efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sorbent materials like activated carbon pellets and honeycombs are used, then gas phase contaminant removal is achieved, but pressure drop increases and media depth is limited
Solution Approach 1:
The filter media is segmented into multiple layers with different functions: a support layer providing structural integrity and channels for airflow, and an adsorbent layer containing the sorbent material distributed throughout the channels. This segmentation allows the media to achieve both high contaminant removal efficiency and low pressure drop by separating the structural support function from the adsorption function, enabling deeper media configurations without proportionally increasing pressure drop.
2Reliability
If media depth is increased to improve contaminant capture, then Mass Transfer Zone length increases, but pressure drop and turbulence increase
Solution Approach 1:
The patent transitions from traditional two-dimensional flat filter media to a three-dimensional structured media with vertical channels extending through the media depth. This dimensional change allows airflow to travel through multiple levels of adsorbent material, increasing the effective contact area and Mass Transfer Zone length without proportionally increasing pressure drop, as the channels provide direct airflow paths through the media depth.
3Reliability
If sorbent material is placed in channels, then gas contaminant adsorption occurs, but airflow turbulence increases
Solution Approach 1:
The adsorbent material is distributed locally throughout the channel structures rather than concentrated in a single layer, creating zones of high adsorption activity where contaminant concentrations are highest. This local placement of adsorbent material within the channels maximizes adsorption efficiency while maintaining laminar airflow patterns, as the distributed configuration avoids creating turbulence-generating obstacles in the airflow path.
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
The solution achieves improved gas contaminant removal efficiency with reduced pressure drop, increased operational life, and flexibility in design, while maintaining low operational costs by optimizing airflow and media exposure, thus enhancing the effectiveness of gas phase contaminant removal in HVAC systems.
Implementation Method 1
Most adsorption occurs in the mesopores and micropores (less than 50 nm diameter) therefore choosing an activated carbon that maximizes the pore volume under 50 nm is a consideration
Data Source
AI summary
A media design for modular use in an air cleaning or HVAC systems to removes gas phase contaminants. The design allows for a control of gas contaminant removal using variable media length, path length, and contact time to ensure a contained MTZ length and low pressure drop. In one embodiment, the design includes a filter module at an angle to an airflow and an air filter mounted within the filter frame. The filter module may include channels therethrough that are oriented at the optimum angle in relation to the airflow to provide the required dwell time and pressure drop for a given application.