DAC Module Flow Director Layout to Cut Clean Air Recirculation

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Solution Overview

Problem

Hazardous gas direct air capture systems face inefficiencies due to clean air recirculation, which reduces the capture efficiency of DAC modules and necessitates a larger system footprint.

Innovation Solution

The implementation of a flow director, such as a flow guide member or air mover, coupled to the DAC module frame to direct clean air away from the inlet side, combined with gap filler members and exterior walls to prevent re-entry, along with optimized module arrangements to minimize recirculation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If DAC modules are arranged in angular or staggered fashion to capture hazardous gas, then the capture efficiency is improved, but clean air recirculation occurs which reduces overall system efficiency

Engineering Contradiction:

Improvehazardous gas capture efficiencyVSAvoidclean air recirculation loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The flow director extracts and redirects the harmful clean air flow from the recirculation path, directing it away from the inlet side of DAC modules. This separates the clean air flow from the hazardous gas-laden air intake, preventing recirculation while maintaining the angular/staggered module arrangement for effective gas capture.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The flow director acts as an intermediary component between the DAC module outlet and inlet sides, manipulating the clean air flow path. It serves as a mediating structure that redirects airflow without interfering with the hazardous gas capture process, eliminating recirculation while preserving capture efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If more DAC modules are added to compensate for clean air recirculation losses, then the hazardous gas capture capacity is maintained, but the system footprint increases

Engineering Contradiction:

Improvehazardous gas capture capacityVSAvoidsystem footprint

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The flow director converts the potentially harmful recirculating clean air flow into a beneficial directed flow that exits away from inlet sides. By redirecting rather than blocking the clean air, the system maintains capture capacity with existing modules, avoiding the need for additional modules and reduced footprint.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If flow directors are added to prevent clean air recirculation, then system efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvesystem efficiencyVSAvoidmodule structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Instead of trying to block recirculation at the inlet side with complex structures, the flow director inverts the approach by actively directing clean air away from inlet sides at the outlet side. This simpler inversion of the control point reduces complexity while achieving the same recirculation prevention goal.

Inventive Principle:

Principle #13The other way round (Inversion)

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 configuration significantly reduces clean air recirculation to less than 10%, enhancing the efficiency and reducing the overall system footprint while maintaining high capture rates of hazardous gases like CO2.

Implementation Method 1

a first air mover configured to draw air into an inlet side of the frame and over the plurality of hazardous gas capture contactors to remove hazardous gas from the air

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

a flow director operatively coupled to the frame and configured to direct the clean air exiting an outlet side of the frame away from the frame to reduce re-entry of the clean air into the inlet side of the frame

Methodology Applied

Scientific EffectFluid flow direction control:

Data Source

PatentEP4691599A2Hazardous gas direct air capture module and system

Publication Date: 2026.02.11 GENERAL ELECTRIC TECH GMBH

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AI summary

A hazardous gas direct air capture (DAC) module includes a frame enclosing a plurality of hazardous gas capture contactors, and a first air mover configured to draw air into an inlet side of the frame and over the plurality of hazardous gas capture contactors to remove hazardous gas from the air, producing clean air. The DAC module also includes a flow director operatively coupled to the frame and configured to direct the clean air exiting the outlet side of the frame away from the frame to reduce re-entry of the clean air into the inlet side of the frame. A DAC system includes set(s) of DAC modules with each set including a first plurality of DAC modules arranged in a first line, and a second plurality of DAC modules arranged in a second line parallel to the first line. The module/system reduce clean air recirculation and more efficient.