Modular CO2 Separation Layout for Drying and Sorption Balance

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Solution Overview

Problem

Existing carbon dioxide capture systems face inefficiencies due to sorbent degradation, high energy consumption, and the need for laborious and expensive measures to manage ambient air parameters like temperature and humidity, particularly when using physisorbents like zeolites and chemisorbents like amines, and the limitations of renewable energy sources like hydropower, wind, and solar power.

Innovation Solution

A modular system design with a pre-conditioning unit, drying unit, and sorption unit, utilizing physisorbents, where the gas flow is divided among multiple modules to optimize drying and sorption processes, minimizing thermal power losses and installation space, and utilizing renewable energy sources like wind and solar power.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If chemisorbents like amines are used to separate carbon dioxide, then separation efficiency is improved, but the sorbent material degrades when exposed to oxygen at temperatures above 60°C during desorption

Engineering Contradiction:

Improvecarbon dioxide separation efficiencyVSAvoidsorbent material stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent introduces an inert atmosphere (nitrogen or carbon dioxide) in the desorption phase to prevent oxygen exposure to the amine-based sorbent material. This protective measure allows the sorbent to operate reliably at higher temperatures (around 100°C) during desorption without degradation, resolving the contradiction between maintaining separation efficiency and ensuring material stability.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Productivity

If physisorbents like zeolites are used to separate carbon dioxide, then separation capability is improved, but the sorbent has higher affinity for water vapor than for carbon dioxide, requiring prior drying of ambient air

Engineering Contradiction:

Improvecarbon dioxide separation capabilityVSAvoidpre-processing requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements a drying unit with desiccant material that performs preliminary drying of the ambient air before it enters the sorption unit. This pre-action removes water vapor to prevent competition with carbon dioxide for sorption sites, enabling the physisorbent to function effectively without complex pre-processing systems.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If multiple functional modules are used to optimize drying and sorption processes, then separation efficiency is improved, but system complexity and installation space increase

Engineering Contradiction:

Improveseparation efficiencyVSAvoidnumber of functional modules

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the system into distinct functional modules: a drying unit with desiccant material and a sorption unit with sorbent material. Each module performs a specific function, allowing independent optimization and maintenance. This segmentation enables efficient carbon dioxide separation while keeping each module compact and manageable, balancing performance with system complexity.

Inventive Principle:

Principle #1Segmentation

4Use of energy by moving object

If renewable energy sources like hydropower are used to operate carbon dioxide capture plants, then energy sustainability is improved, but the potential for energy generation is limited by geography and already fully utilized watercourses

Engineering Contradiction:

Improveenergy sustainabilityVSAvoidgeographic applicability

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The patent designs the carbon dioxide capture system to be compatible with multiple renewable energy sources including wind power, solar energy, geothermal energy, and hydropower. This universal energy interface allows the system to be deployed anywhere renewable energy is available, overcoming the geographic limitations of hydropower-specific designs and enhancing adaptability across different locations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 separation with reduced energy consumption and minimal thermal power losses, optimizing the use of renewable energy and minimizing installation space, while ensuring continuous operation and efficient adaptation to varying ambient conditions.

Implementation Method 1

Carbon dioxide can be separated from the ambient air using different sorbents. Physisorbents, such as zeolites

Methodology Applied

Scientific EffectPhysisorption: Physisorption

Implementation Method 2

Physisorbents, such as zeolites, have the problem that the affinity of the sorbent material for water (vapor) is higher than for carbon dioxide

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS20250367599A1System For Separating Carbon Dioxide From A Gas Flow

Publication Date: 2025.12.04 VOLKSWAGEN AG

AI summary

The disclosure relates to a system for separating carbon dioxide from a gas flow, in particular from an air flow. The system comprises at least one first functional unit and at least one second functional unit connected downstream of the first functional unit in the flow direction of a main air flow through the system. It is provided that the first functional unit has a first number of functional modules and the second functional unit has a second number of functional modules, wherein the second number is higher than the first number.