Integrated Horizontal Amine Carbon Capture System
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Solution Overview
Problem
Current carbon capture technologies are costly and inefficient for low-pressure streams, such as those from internal combustion engines, due to the high material and installation costs of traditional vessel designs.
Innovation Solution
A novel carbon capture system that integrates multiple process steps, including direct contact cooling, CO2 absorption, and water wash, into a single vessel with shared walls, reducing the number of vessel walls and material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate vessel designs are used for carbon capture processes, then each process step can be independently optimized, but the number of vessel walls and material requirements increase significantly
Solution Approach 1:
The patent combines multiple process steps (cooling, CO2 absorption, water wash) that were traditionally performed in separate vessels into a single integrated contactor. This merging eliminates the need for multiple separate vessel walls and connections, directly reducing material consumption while maintaining manufacturing simplicity through a unified design approach
Solution Approach 2:
The single contactor vessel is designed to perform multiple functions simultaneously: cooling the exhaust stream, absorbing CO2 through amine contact, and washing to remove entrained liquids. This multi-functional design reduces the total number of vessels needed while maintaining independent optimization capability for each process step through internal zoning
2Reliability
If multiple separate vessels are used for different process steps, then each vessel can be optimized for its specific function, but the number of connections and installation complexity increase
Solution Approach 1:
By merging multiple process functions into a single contactor vessel, the patent eliminates the need for multiple external connections, supports, and alignment requirements between separate vessels. This reduces installation complexity while maintaining process optimization through internal design features such as separate contact zones and flow paths for each process step
3Strength
If thick-walled vessels are used to withstand process pressures, then vessel strength and reliability are improved, but material costs and environmental impact increase
Solution Approach 1:
The patent employs thin-walled construction for the contactor vessel, utilizing the inherent strength-to-weight ratio advantages of thin-shell structures. The vessel maintains sufficient mechanical strength to withstand process pressures while using minimal material, thereby reducing environmental impact associated with material production and disposal
Solution Approach 2:
The contactor is designed with a horizontal orientation rather than vertical stacking, which allows for more efficient stress distribution across the vessel walls. This dimensional change optimizes the structural efficiency of thin walls by distributing pressures more evenly, reducing the need for thick local reinforcements
4Volume of moving object
If vertical stacking of vessels is used, then space utilization is improved, but vessel material requirements and installation costs increase
Solution Approach 1:
The patent transitions from vertical stacking of multiple vessels to a horizontal single-vessel configuration. This dimensional change consolidates multiple process steps into one horizontally-oriented contactor, reducing the total number of vessel walls required while achieving efficient space utilization through the extended horizontal footprint
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 achieves efficient carbon dioxide capture with a pressure drop of less than 6 kPa and vessel walls thinner than 2.7 mm, making it cost-competitive with upcoming carbon taxes and reducing the environmental impact of carbon capture processes.
Implementation Method 1
the engine exhaust can be cooled with a direct counter current contact water spray using mass and heat transfer arrangement in an internal chamber
Implementation Method 2
The cooled exhaust is then directed through an internal channel to a second internal chamber to be contacted by a direct counter current contact chilled lean liquid CO2 absorbent (e.g. amine) spray using mass transfer arrangement to capture carbon dioxide
Implementation Method 3
The internal supports also serve as process baffles
Data Source
AI summary
A series of connected vertical contactors arranged horizontally, that are a compact and lower weight boxed arrangement integrated in multiple processing steps to treat engine exhaust to capture carbon dioxide. A direct contact cooler, optional gas scrubber, liquid CO2 absorbent (e.g., amine) absorption and optional water wash are combined in one overall integrated vessel, separated by internal chambers that is organized horizontally to reduce the weight (and cost) of construction through modular, reduced footprint, lower pump heads, with common internal walls and thinner material of constructions.