Radial-Flow Sorbent Bed Layout for Low-Pressure-Drop DAC
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Solution Overview
Problem
Existing direct air capture (DAC) technologies face inefficiencies in energy consumption, sorbent durability, and maintenance costs, particularly in steam-assisted, temperature-vacuum swing processes, due to high pressure drops and condensation issues within sorbent chambers.
Innovation Solution
A radial flow, steam-assisted, temperature-vacuum swing DAC system with vertically stacked sorbent beds and integrated thermally conductive heating and purging coils, which reduces pressure drop, prevents condensation, and facilitates modular sorbent replacement, enhancing energy and sorbent efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam-assisted temperature-vacuum swing process is used for DAC, then carbon dioxide capture capability is improved, but pressure drop increases and condensation occurs within sorbent chambers
Solution Approach 1:
The sorbent chamber is divided into multiple vertically stacked sorbent beds (first sorbent bed, second sorbent bed, etc.) separated by distribution manifolds. This segmentation allows gas to flow through multiple beds in series, increasing capture capability while maintaining manageable pressure drops across each individual bed. The radial flow configuration further segments the flow path to reduce overall pressure drop.
Solution Approach 2:
The patent transitions from conventional axial flow to radial flow configuration, where gas flows radially outward through the sorbent beds from a central axis. This dimensional change in flow pattern reduces pressure drop by distributing flow across multiple radial paths simultaneously, while vertically stacked beds increase capture capacity in the vertical dimension.
2Productivity
If steam-assisted temperature-vacuum swing process is used for DAC, then carbon dioxide capture capability is improved, but condensation occurs within sorbent chambers
Solution Approach 1:
Thermally conductive heating coils are integrated at specific locations within the sorbent beds to provide localized heating. This ensures that temperature is maintained above condensation points in critical areas where steam is introduced, preventing condensation while maintaining the steam-assisted process for improved capture capability.
Solution Approach 2:
The patent controls temperature and pressure parameters dynamically during the steam-assisted temperature-vacuum swing process. By maintaining temperature above dew point and optimizing pressure differentials, the system prevents condensation while enabling the steam-assisted process to enhance carbon dioxide capture capability.
3Reliability
If conventional DAC systems are used, then operation is maintained, but energy consumption is high and sorbent durability is reduced
Solution Approach 1:
Multiple sorbent beds are operated in a continuous cycle where different beds are at different stages of the capture-regeneration cycle. This allows continuous CO2 capture operation while regenerating sorbents in parallel, improving sorbent durability through reduced thermal cycling stress and maintaining energy efficiency through continuous productive operation.
Solution Approach 2:
Thermally conductive heating coils are pre-installed within the sorbent beds to enable rapid and uniform heating during the regeneration phase. This preliminary preparation of heating infrastructure reduces the energy required for regeneration by eliminating heat transfer limitations, thereby reducing overall energy consumption while maintaining sorbent 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 carbon dioxide removal efficiency and reduces costs by minimizing energy consumption, sorbent degradation, and maintenance through optimized radial flow and integrated heating/purging mechanisms, enabling scalable carbon dioxide capture.
Implementation Method 1
a sorbent chamber (118) configured to house a set of sorbent beds (120)... absorb a portion of the carbon dioxide within the flow of inlet gas via the set of sorbent beds (120)
Implementation Method 2
a conductive heating subsystem (102)... a set of thermally conductive heating coils (104) arranged within the sorbent chamber (118), each thermally conductive heating coil (104) in the set of thermally conductive heating coils (104): arranged within a sorbent bed (120) in the set of sorbent beds (120); and configured to circulate a thermally conductive heating fluid (108) to heat the sorbent bed
Implementation Method 3
a purging subsystem (110)... a set of purging coils (112)... configured to distribute a purging fluid (116) via a set of purging nozzles (114) to a sorbent bed (120) in the set of sorbent beds (120)... desorb carbon dioxide from the set of sorbent beds (120)
Implementation Method 4
a depressurization subsystem (148) configured to reduce the absolute pressure within the sorbent chamber (118) to 80 millibars or less
Data Source
AI summary
A direct air capture (DAC) system includes: a sorbent chamber housing a set of sorbent beds; a conductive heating subsystem; and a purging subsystem. The sorbent beds: arrange vertically within the sorbent chamber; define a set of radial interstices between vertically adjacent sorbent beds; and extend radially about a vertical manifold defining a set of manifold apertures. The conductive heating subsystem includes a set of thermally conductive heating coils arranged within a sorbent bed in the set of sorbent beds; and configured to circulate a thermally conductive heating fluid to heat the sorbent bed. The purging subsystem includes a set of purging coils configured to distribute a purging fluid via a set of purging nozzles to a sorbent bed; and arranged above the sorbent bed.