DAC Gas-Liquid Contactor with Segmented Packing
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Solution Overview
Problem
Direct air capture (DAC) systems face inefficiencies in capturing CO2 from the atmosphere due to low concentrations and large air volumes, with existing technologies struggling to maintain operational flexibility and reliability, particularly in preventing plume re-ingestion and contamination of the CO2 capture solution.
Innovation Solution
A gas-liquid contactor system designed for DAC, featuring a housing with structural members, packing sections, and a liquid distribution system, utilizing caustic-compatible materials and configurations that minimize pressure drop, prevent contamination, and optimize CO2 capture solution distribution, including the use of FRP structures, vinyl ester resin, and a geomembrane liner to enhance durability and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cooling tower designs are used for DAC, then large amounts of air can be moved and commercially available equipment can be employed, but the system becomes vulnerable to plume re-ingestion and contamination of the CO2 capture solution
Solution Approach 1:
The system divides the gas-liquid contactor into multiple sections with packed beds separated by distribution and collection systems. This segmentation prevents short-circuiting of the gas stream and ensures complete contact between air and capture solution while preventing re-ingestion of processed gas.
Solution Approach 2:
The patent introduces intermediate distribution manifolds and collection systems that act as mediators between the packed beds. These intermediaries ensure proper flow distribution and prevent direct connection between inlet and outlet, eliminating plume re-ingestion pathways.
2Productivity
If the CO2 capture solution is circulated through the packing sections, then CO2 capture efficiency is improved, but the solution becomes prone to contamination and degradation
Solution Approach 1:
The system employs different materials of construction for different sections of the gas-liquid contactor based on their specific functional requirements. The packed beds use materials resistant to the caustic capture solution, while other components use materials suitable for their specific functions, optimizing both capture efficiency and solution durability.
Solution Approach 2:
The patent utilizes composite material structures, particularly in the packed beds and housing, combining materials with complementary properties to achieve both high CO2 capture performance and resistance to solution degradation and contamination.
3Reliability
If caustic-compatible materials are used throughout the system, then solution durability is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of using caustic-resistant materials throughout the entire system, the patent applies these specialized materials only to the packed beds and other components directly exposed to the caustic capture solution. Other components can use standard materials, reducing overall manufacturing complexity and cost while maintaining necessary durability.
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 improves CO2 capture efficiency, reduces maintenance costs, and prevents contamination and plume re-ingestion, ensuring reliable operation and efficient processing of large air volumes with enhanced material compatibility and structural integrity.
Implementation Method 1
CO2 in the air reacts with the liquid sorbent
Implementation Method 2
a fan is used to draw air across a high surface area packing that is wetted with a solution comprising the liquid sorbent
Data Source
AI summary
A cooling tower system includes a gas-liquid contactor having a housing coupled to a plurality of structural members. The system includes one or more basins positioned within the housing, and the one or more basins include a bottom basin. The system includes one or more packing sections positioned at least partially above the bottom basin, a fan operable to circulate a gas through the one or more packing sections, and a liquid distribution system configured to flow a solution onto the one or more packing sections, wherein the gas-liquid contactor comprises one or more materials of construction (MOCs). The plurality of structural members define a plenum comprising a containment that is at least partially segregated from the bottom basin by one or more walls, the bottom basin positioned at least partially below the packing.