CO2 Capture Contactor with Integrated Heat Exchange Channels
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Solution Overview
Problem
Current carbon dioxide capture systems using amine-based scrubbing solutions face challenges in efficiently capturing CO2 from flue gas streams due to oxidative degradation caused by oxygen gas, temperature spikes, and the need for flexible operation across different gas compositions and pressures, which affects the scrubbing solution's effectiveness and longevity.
Innovation Solution
A carbon dioxide capture system incorporating a mass transfer contactor unit with heat exchange channels and modular design, allowing for targeted heat exchange and temperature control within the scrubbing vessel, particularly in high mass transfer zones, to manage exothermic heat generation and oxidative degradation, while accommodating varying gas compositions and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If amine-based scrubbing solution is used to capture CO2 from flue gas, then CO2 capture effectiveness is improved, but oxidative degradation occurs due to oxygen gas reducing solution stability
Solution Approach 1:
The patent introduces an inert gas (nitrogen or carbon dioxide) into the scrubbing system to displace oxygen and create an inert atmosphere. This prevents oxidative degradation of the amine-based scrubbing solution while maintaining effective CO2 capture. The inert gas is supplied through spargers or injection points at the bottom of the scrubbing column, creating a protective environment that extends solution life and maintains performance.
2Productivity
If high liquid-to-gas ratio is used to improve CO2 capture, then capture efficiency is improved, but temperature control becomes difficult due to exothermic reaction heat
Solution Approach 1:
The patent extracts heat from the exothermic scrubbing reaction by introducing a cooling medium (cold water or refrigerated brine) through spargers and cooling coils at the bottom of the column. This removes the reaction heat as it is generated, preventing temperature buildup that would otherwise limit the liquid-to-gas ratio and reduce capture efficiency. The cooling system maintains optimal temperature conditions for high-efficiency CO2 absorption.
Solution Approach 2:
The patent utilizes phase transition of the cooling medium (water or brine) to absorb reaction heat. The cooling fluid circulates through heat exchange coils and spargers, absorbing thermal energy from the exothermic reaction and undergoing temperature changes that effectively control the scrubbing zone temperature, enabling sustained high capture efficiency.
3Productivity
If traditional packed column design is used for mass transfer, then CO2 absorption is achieved, but the system lacks flexibility for different gas compositions and pressures
Solution Approach 1:
The patent transforms the static packed column into a dynamic system by introducing movable spargers, adjustable cooling coils, and controllable inert gas injection. These dynamic elements can be adjusted to optimize performance for different gas compositions and operating pressures. The system can adapt its configuration and operating parameters to handle varying flue gas conditions, power plant loads, and CO2 partial pressures.
Solution Approach 2:
The patent creates a multi-functional scrubbing system that can handle both CO2 absorption and temperature control through integrated spargers and cooling coils. The same equipment structure serves multiple purposes: mass transfer enhancement, heat removal, and oxidative protection. This universal design allows the system to effectively treat various gas compositions (natural gas sweetening, flue gas from different power plants, industrial processes) under different pressure conditions.
4Productivity
If counter-current flow operation is used to enhance mass transfer, then CO2 capture is improved, but temperature spikes occur in the lower portion of the vessel
Solution Approach 1:
The patent applies preliminary cooling action by placing cooling spargers and cooling coils at the bottom of the scrubbing column, where the most intense exothermic reaction occurs. This pre-cools the incoming lean scrubbing solution before it contacts the CO2-rich gas, and continuously removes reaction heat as it is generated in the high-mass-transfer zone, preventing temperature spikes that would otherwise occur in the lower portion of the vessel.
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 system effectively captures CO2 by controlling temperature and preventing oxidative degradation, enhancing the stability and efficiency of the scrubbing solution, particularly in low-pressure flue gas scrubbing applications, and demonstrates flexibility for use in both gas sweetening and flue gas scrubbing operations.
Implementation Method 1
The contactor unit may include a plurality of heat exchange channels in the flow diversion barriers to transport heat exchange cooling fluid through the contactor network to cool the process fluids moving through the flow voids during a carbon dioxide scrubbing operation
Implementation Method 2
promote transfer of carbon dioxide from the gas phase into the liquid phase of the absorption liquid to be captured within the absorption liquid
Implementation Method 3
enhance intermixing and contact between the gas and liquid phases moving through the vessel and to promote transfer of carbon dioxide from the gas phase into the liquid phase
Implementation Method 4
A common carbon dioxide capture system includes an exothermic scrubbing operation in which the scrubbing solution is contacted with a carbon dioxide-containing gas mixture
Data Source
AI summary
A carbon dioxide capture system, fluid contactor and method are disclosed. In embodiments, a gas-liquid contactor unit is disposed along a process fluid flow axis and includes a contactor of network flow diversions barriers with flow voids for movement of process fluids therebetween. A plurality of heat exchange channels are provided in the flow diversion barriers to transport a heat exchange fluid through the contactor network. A heat exchange feed channel is provided to deliver feed of the heat exchange fluid to the heat exchange channels at multiple feed locations spaced along the flow axis. At least one heat exchange bypass channel may extend beyond the multiple feed locations to deliver a portion of the feed of the heat exchange fluid to additional heat exchange channels located downstream from the multiple feed locations for the heat exchange channels.