Modular Direct Air Capture Platform With Swappable Sorbent Cartridges
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Solution Overview
Problem
Existing carbon capture technologies face challenges in scalability, efficiency, and adaptability due to limitations in sorbent size and mechanical properties, high energy requirements, and the need for flexible and easily upgradable systems to handle low CO2 concentrations in ambient air.
Innovation Solution
A modular open systems architecture (MOSA) with interchangeable sorbent cartridges and modular utilities modules, allowing for mass production, rapid deployment, and easy upgradeability, enabling flexible siting and continuous improvement of carbon dioxide capture systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If large-scale gas-liquid processes utilizing caustic solutions or liquid amine materials are used to capture CO2 from flue gas, then CO2 capture capacity is improved, but capital expenditure and construction time increase significantly
Solution Approach 1:
The system divides the CO2 capture facility into modular units that can be manufactured independently and assembled on-site. Each module contains integrated sorbent beds, heat exchangers, and control systems, allowing parallel manufacturing and rapid deployment without requiring large-scale civil construction
Solution Approach 2:
The invention extracts the CO2 capture function from traditional large-scale chemical plant configurations and implements it using standardized modular units. This separation allows each module to be optimized independently and assembled like building blocks, dramatically reducing construction time and capital expenditure
2Productivity
If liquid sorbent materials are used for CO2 capture, then CO2 absorption efficiency is improved, but safety risks and operational complexity increase due to toxicity and corrosiveness
Solution Approach 1:
The system uses solid sorbent materials that can be replaced periodically rather than requiring complex containment and handling systems for hazardous liquids. The solid sorbents are less hazardous, and when they reach capacity, entire cartridges can be swapped out and regenerated off-site, eliminating the need for expensive safety infrastructure
Solution Approach 2:
The invention employs porous solid sorbent materials with high surface area to volume ratios that provide liquid-like absorption efficiency in a solid format. These materials allow CO2 to diffuse through their porous structures rapidly, achieving high capture rates without the safety risks associated with liquid caustic solutions or amines
3Productivity
If high-capacity structured sorbents are used for DAC, then CO2 capture performance is improved, but mechanical property limitations create scaling challenges
Solution Approach 1:
The system divides large sorbent beds into multiple smaller modular cartridges, each containing structured sorbent elements. This segmentation allows the use of high-capacity structured sorbents in manageable sizes that maintain their mechanical integrity, while achieving large total capture capacity through parallel arrangement of multiple modules
Solution Approach 2:
The invention uses composite structured sorbent materials that combine high CO2 capacity components with mechanically robust support structures. These composites maintain the high performance of the active sorbent material while providing the mechanical strength needed for scaling to industrial applications
4Adaptability or versatility
If modular interchangeable sorbent cartridges are implemented, then system adaptability and upgradeability are improved, but device complexity increases
Solution Approach 1:
The system employs universal cartridge interfaces and standardized connection protocols that allow different sorbent types to be used in the same hardware platform. This universality enables easy swapping of sorbent cartridges to adapt to different CO2 concentrations, temperatures, or performance requirements without redesigning the overall system
Solution Approach 2:
The modular design allows system parameters such as sorbent type, bed volume, and regeneration conditions to be changed by simply swapping cartridges or adjusting operational settings. This parameter flexibility enables the system to adapt to varying climate conditions and CO2 concentrations without increasing fundamental system complexity
Data Source
AI summary
Systems and methods for modular and adaptable carbon dioxide (CO2) capture, separation, and storage in a variety of disparate site locations are provided. The systems and methods include utilizing a plurality of transportable, mass-producible, and stackable CO2 capture modules locally arranged in a cluster serviced by modular or locally fixed utilities modules that are in turn serviced by centralized plant services facilities, which may be dedicated to the CO2 capture system or may alternatively be shared with other co-located operations. The CO2 capture modules comprise a plurality of sorbent reactors, each comprising removable sorbent cartridges which may be easily exchanged for maintenance or upgrade purposes. The CO2 sorbent reactors are alternatively operated in adsorption and desorption modes and synchronized with each other within the sorbent module and the corresponding cluster to achieve continuous operation.