Continuous Sorbent Monolith Loop for Valve-Free Direct Air Capture
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Solution Overview
Problem
Existing direct air capture (DAC) systems face challenges with high costs, mechanical complexity, and reduced reliability due to the need for rapid-cycling and high-cycling valves, which lead to mechanical stress and decreased efficiency.
Innovation Solution
A continuous motion direct air capture system utilizing a continuous loop of sorbent monoliths with multiple process zones, allowing for steady-state operation and reducing the need for mechanical movement, thereby minimizing equipment requirements and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid-cycling and high-cycling valves are used to switch between adsorption and desorption modes, then CO2 capture productivity is improved, but mechanical stress and reliability deteriorate
Solution Approach 1:
The patent implements a continuous motion system where monolith panels move constantly through adsorption and desorption zones without stopping. This eliminates the cyclic valve switching required in batch systems, maintaining continuous CO2 capture productivity while removing the mechanical stress and reliability issues associated with rapid-cycling valves.
Solution Approach 2:
The patent replaces the valve-based mechanical switching system with a continuous conveyor-based transport system. Instead of using high-cycling valves to switch gas flows between adsorption and desorption modes, the system uses a mechanical conveyor to continuously move monolith panels through different process zones, eliminating the need for rapid valve operation and improving reliability.
2Productivity
If multiple monolith panels are physically moved through regeneration area, then adsorption-desorption cycle efficiency is improved, but mechanical complexity and wear increase
Solution Approach 1:
The patent divides the continuous loop into multiple monolith panels that can be independently positioned and controlled. Each panel undergoes adsorption and desorption cycles sequentially as they move through designated zones, allowing efficient cycling while simplifying the overall mechanical control compared to managing a single large batch system with complex valve switching.
Solution Approach 2:
The continuous conveyor system maintains uninterrupted movement of monolith panels through adsorption and desorption zones, eliminating the start-stop-cycling operations required in batch systems. This continuous motion improves cycle efficiency while reducing mechanical complexity by replacing complex valve timing mechanisms with a simple continuous transport system.
3Manufacturing precision
If monolith panels are stopped in regeneration area for sealing, then desorption completeness is improved, but cycle time and productivity are reduced
Solution Approach 1:
The patent maintains continuous motion of monolith panels through the regeneration area while achieving effective sealing and desorption. The sealing mechanism operates during continuous movement rather than requiring panel stopping, thus maintaining both desorption completeness and high productivity through uninterrupted processing.
Solution Approach 2:
The system prepares the monolith panels for desorption by positioning and sealing them in advance as they approach the regeneration zone, while maintaining continuous motion. This preliminary preparation ensures complete desorption occurs during movement, eliminating the need to stop panels and maintaining high productivity throughout the cycle.
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 a 33% reduction in capital expenditure (CAPEX) and operating costs while enhancing reliability by maintaining a continuous CO2 capture process with high purity and efficiency.
Implementation Method 1
Solid amine adsorbents interact with CO2 via a chemical adsorptive mechanism, resulting in high CO2 adsorption capacities at very low CO2 partial pressures and high selectivity to CO2 over other components of air
Implementation Method 2
Desorption can be performed by contacting the CO2 laden monolith with steam, for example, so as to heat it and release the bound CO2
Data Source
AI summary
A system and a method for continuously separating carbon dioxide from gas mixtures, utilizing a continuous loop of porous monoliths which support a sorbent within its pores. Continuously exposing a portion of the continuous loop of monoliths to a flow of gas mixture containing a minor proportion of carbon dioxide, to adsorb carbon dioxide from the flow. The loop passes through a sealed regeneration and carbon dioxide capture assembly located astride a portion of the loop, and which is capable of sealingly containing a monolith in relative movement through the assembly. The assembly chamber comprises a plurality of separately sealed zones, including at least one zone for purging oxygen from the monoliths, —a subsequent zone for heating the monolith to release the adsorbed carbon dioxide, and another cooling zone for cooling the monolith prior to reentering the adsorption portion of the loop where it is exposed to oxygen.