Multi-layered Sorbent Sheets for Natural Gas Storage
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Solution Overview
Problem
Current methods for storing low-density hydrocarbons, such as natural gas, face challenges due to low volumetric energy densities, leading to expensive and inefficient storage and transport, as well as limitations in reducing void volumes in sorbent materials like activated carbon.
Innovation Solution
The development of a low-density hydrocarbon storage device utilizing a multi-layered sorbent sheet product with a void volume of 20% or less, comprising stacked or rolled sorbent sheets with high sorbent material content and specific binders, which are encapsulated within a housing to enhance energy storage density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If activated carbon is used in granular, pellet, monolithic, or powder forms, then natural gas can be adsorbed to achieve high energy densities, but void volume between particles increases to 40-45%, reducing overall storage efficiency
Solution Approach 1:
The patent applies this principle by transforming rigid granular activated carbon into flexible thin film form. The sorbent material is deposited as a continuous thin film on a support structure, eliminating inter-particle voids while maintaining adsorption capacity. This transformation from discrete particles to continuous film directly addresses the void volume problem while preserving the high energy density benefit.
Solution Approach 2:
The patent employs composite materials by combining sorbent material with a support structure to form a integrated film system. The support structure provides mechanical integrity while the sorbent layer provides adsorption function. This composite approach enables the sorbent to be used in a continuous film format rather than discrete particles, thereby eliminating void volume while maintaining high sorbent loading.
2Loss of substance
If ceramic monoliths containing sorbents are used, then void volume is reduced, but manufacturing becomes expensive and time-consuming with limited sorbent options
Solution Approach 1:
The patent replaces the complex mechanical ceramic monolith manufacturing process with a deposition-based film formation process. Instead of forming and sintering ceramic structures with embedded sorbents, the invention uses deposition techniques to create thin films of sorbent material on flexible or rigid supports. This substitution dramatically simplifies manufacturing while achieving the same void volume reduction goal.
Solution Approach 2:
The patent changes the physical state and form of the sorbent material from bulk granular or monolithic forms to thin film form. This parameter change in morphology and dimensionality enables new manufacturing approaches that are simpler and more flexible than traditional ceramic monolith fabrication, while simultaneously reducing void volume through continuous film structure.
3Quantity of substance
If high pressure is used to increase volumetric energy density, then storage capacity improves, but reinforced tanks become heavy, bulky, and expensive
Solution Approach 1:
The patent uses porous sorbent materials that can adsorb large volumes of natural gas within their pore structures. This adsorption mechanism allows the system to achieve high volumetric energy density at much lower pressures compared to compressed gas storage. The porous structure provides high surface area for gas uptake without requiring the high pressures that would necessitate heavy reinforced tanks.
Solution Approach 2:
The patent changes the storage mechanism from physical compression to adsorption on sorbent surfaces. This parameter change in the fundamental storage mechanism allows the system to achieve high energy density at low pressure, thereby eliminating the need for heavy pressure-containing vessels while maintaining high volumetric energy density.
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
This solution achieves a volumetric energy storage density at least 10% greater than traditional activated carbon storage devices, reducing storage costs and improving efficiency by minimizing void volumes and optimizing energy transfer during adsorption and desorption.
Implementation Method 1
One such alternative method increases volumetric energy density by adsorbing low-density hydrocarbons onto a sorbent
Data Source
AI summary
Sorbent sheets containing sorbent and binder may be used for efficient adsorption and desorption of low-density hydrocarbons to the sorbent, such as activated carbon, therein. One or more sheets, optionally arranged in a multi-layered configuration, may be included in a housing for improved storage and transportation of low-density hydrocarbons such as natural gas.