Self-Supporting Sorption Elements for Faster Direct Air Capture Cycles
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Solution Overview
Problem
Existing methods for extracting carbon dioxide from ambient air face challenges such as inefficient heat and cooling phases, high energy consumption, cumbersome handling of loose granules, and increased system costs due to the use of inorganic sorbent materials and holding structures, which reduce gas flow and surface area utilization.
Innovation Solution
A method involving the use of a carbon dioxide-binding starting material mixed with a binder, shaped into a sorbent medium structure, and heat treated to form a self-supporting sorption element with improved thermal conductivity, allowing for efficient heat distribution and reduced energy demand, and eliminating the need for holding structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic sorbent materials (zeolites) are used for carbon dioxide extraction, then the robustness and suitability as adsorbers is improved, but the heating and cooling phases become longer, resulting in reduced effectiveness and increased energy consumption
Solution Approach 1:
The patent uses composite sorbent materials combining inorganic components (zeolites, alumina) with organic components (amines, polymers) to achieve both robustness and faster thermal response. The composite structure allows the inorganic part to provide mechanical stability while the organic part enables quicker adsorption-desorption cycles with lower energy demand.
Solution Approach 2:
The patent modifies the thermal and chemical parameters of sorbent materials by using chemisorbents with different binding energies and thermal stabilities. This allows optimization of heating/cooling phases to reduce energy consumption while maintaining effectiveness.
2Reliability
If inorganic sorbent materials are used, then the adsorption capability is improved, but the heating and cooling phases increase the cycle time, reducing process productivity
Solution Approach 1:
Composite sorbent materials combine the high adsorption capacity of inorganic zeolites with the faster kinetics of organic chemisorbents, achieving both high capability and reduced cycle time.
Solution Approach 2:
The patent applies different material properties to different functional requirements: inorganic materials for structural stability and capacity, organic materials for rapid response, creating a locally optimized composite structure.
3Stability of the object's composition
If holding structures are used to support sorbent materials, then the mechanical stability is improved, but the gas flow is reduced and surface area utilization decreases
Solution Approach 1:
The patent removes traditional holding structures (grates, nets, support frames) by using self-supporting monolithic sorbent elements that maintain their own mechanical stability through their intrinsic structure, eliminating obstacles to gas flow.
Solution Approach 2:
The patent uses thin-walled monolithic structures with optimized wall thickness that provide sufficient mechanical stability while minimizing obstruction to gas flow and maximizing surface area utilization.
4Adaptability or versatility
If loose granules are used as sorbent material, then the flexibility and ease of replacement is improved, but the handling becomes cumbersome and void formation increases
Solution Approach 1:
The patent merges individual granules into a single integrated monolithic structure that eliminates handling issues while maintaining replaceability at the module level. The monolith acts as one piece that can be easily installed and replaced without the complications of loose granules.
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 method enables simplified assembly, reduced energy consumption, and cost-effective production of sorption elements with enhanced carbon dioxide adsorption and desorption efficiency, minimizing void formation and optimizing gas flow.
Implementation Method 1
heat treating the sorbent medium structure or the coated carrier structure, with a sorbent material contained in the sorbent medium structure or the coated carrier structure being compacted and/or chemically activated
Implementation Method 2
carbon dioxide present in the atmospheric air is bound in a sorption element
Implementation Method 3
utilize so-called chemisorbents as well as composite adsorbents as sorbent materials
Implementation Method 4
The carbon dioxide bound in the sorption element can be released again in a second process step
Data Source
AI summary
Technologies and techniques for producing a sorption element for removing carbon dioxide from ambient air. The method includes providing a carbon dioxide-binding starting material and a binder, mixing them to form a homogeneous mixture, and either molding the mixture into a sorption structure or coating a support structure with the mixture. The sorption structure or coated support structure is then thermally treated to solidify and/or chemically activate the sorbent material. The disclosed method enables the production of highly efficient sorption elements with enhanced thermal and electrical conductivity, which improve adsorption and desorption processes. The disclosure also includes systems and apparatus configured to perform this method, offering reduced material usage, improved energy efficiency, and customizable geometries for diverse applications.