AU2022222824A1 - Atmospheric carbon dioxide extractor assembly - Google Patents

Atmospheric carbon dioxide extractor assembly Download PDF

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Publication number
AU2022222824A1
AU2022222824A1 AU2022222824A AU2022222824A AU2022222824A1 AU 2022222824 A1 AU2022222824 A1 AU 2022222824A1 AU 2022222824 A AU2022222824 A AU 2022222824A AU 2022222824 A AU2022222824 A AU 2022222824A AU 2022222824 A1 AU2022222824 A1 AU 2022222824A1
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composite
mof
carbon dioxide
lattice
air
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AU2022222824A
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Rohan Gillespie
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Southern Green Gas Ltd
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Southern Green Gas Ltd
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Priority claimed from AU2021900383A external-priority patent/AU2021900383A0/en
Application filed by Southern Green Gas Ltd filed Critical Southern Green Gas Ltd
Publication of AU2022222824A1 publication Critical patent/AU2022222824A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0407—Constructional details of adsorbing systems
    • B01D53/0415—Beds in cartridges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0407—Constructional details of adsorbing systems
    • B01D53/0438—Cooling or heating systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0407—Constructional details of adsorbing systems
    • B01D53/0446—Means for feeding or distributing gases
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0462—Temperature swing adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
    • B01J20/223—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material containing metals, e.g. organo-metallic compounds, coordination complexes
    • B01J20/226—Coordination polymers, e.g. metal-organic frameworks [MOF], zeolitic imidazolate frameworks [ZIF]
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    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
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    • B01J20/30—Processes for preparing, regenerating, or reactivating
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    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
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    • B01J20/34—Regenerating or reactivating
    • B01J20/3441—Regeneration or reactivation by electric current, ultrasound or irradiation, e.g. electromagnetic radiation such as X-rays, UV, light, microwaves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
    • B01D2253/10—Inorganic adsorbents
    • B01D2253/112—Metals or metal compounds not provided for in B01D2253/104 or B01D2253/106
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
    • B01D2253/20—Organic adsorbents
    • B01D2253/204—Metal organic frameworks (MOF's)
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/50—Carbon oxides
    • B01D2257/504—Carbon dioxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2259/40083—Regeneration of adsorbents in processes other than pressure or temperature swing adsorption
    • B01D2259/40088—Regeneration of adsorbents in processes other than pressure or temperature swing adsorption by heating
    • B01D2259/40094—Regeneration of adsorbents in processes other than pressure or temperature swing adsorption by heating by applying microwaves
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    • B01J2220/00—Aspects relating to sorbent materials
    • B01J2220/50—Aspects relating to the use of sorbent or filter aid materials
    • B01J2220/62—In a cartridge
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02C—CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]
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Abstract

The present invention in a first aspect is broadly directed to an atmospheric carbon dioxide (CO2) extractor assembly (10) comprising an air flow chamber (12) containing an adsorbent composite metal-organic framework (MOF) (14) and a source of electromagnetic radiation (16) associated with the airflow chamber (12). The composite MOF (14) is produced by additive manufacturing and the source of electromagnetic radiation (16) takes the form of a microwave device associated with the airflow chamber (12). In a second aspect of the invention the source of electromagnetic radiation is replaced with resistive heating means which generates resistive heating via an electrical current passing through a conductive material associated with the composite MOF. The conductive material includes a carbon-based material which on resistive heating is effective in desorption of the adsorbed CO

Description

ATMOSPHERIC CARBON DIOXIDE EXTRACTOR ASSEMBLY Technical Field
[0001] The present invention is directed to an atmospheric carbon dioxide (CO2) extractor assembly. More broadly the invention is directed to a method of extracting CO2 from air. The invention also generally relates to a method of fabricating an atmospheric CO2 extractor.
[0002] The present invention is also directed to an atmospheric CO2 extractor cartridge. The invention is broadly directed to a method of constructing an atmospheric CO2 extractor cartridge, and a method of directly extracting ambient CO2 from air. The invention is particularly, although not exclusively, directed to an atmospheric CO2 extractor assembly including a plurality of the extractor cartridges.
Summary of Invention
[0003] According to a first aspect of the present invention there is provided an atmospheric carbon dioxide extractor assembly comprising: an airflow chamber containing an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing; a source of electromagnetic radiation associated with the airflow chamber whereby in operation the composite MOF adsorbs carbon dioxide (CO2) from air flowing through the airflow chamber and the adsorbed CO2 is, under the influence of electromagnetic radiation generated by the source of electromagnetic radiation, desorbed from the composite MOF for extraction of the desorbed CO2 from the air.
[0004] Preferably the source of electromagnetic radiation is in the form of a microwave device which emits the electromagnetic radiation for desorption of the adsorbed CO2 from the composite MOF. More preferably the microwave device emits the electromagnetic radiation at a wavelength spectrum including infrared radiation, microwave radiation, or a combination of infrared and microwave radiations.
[0005] According to a second aspect of the invention there is provided an atmospheric carbon dioxide extractor assembly comprising: an airflow chamber containing an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing; resistive heating means associated with the airflow chamber whereby in operation the composite MOF adsorbs carbon dioxide (CO2) from air flowing through the airflow chamber and the adsorbed CO2 is, under the influence of resistive heating generated by the resistive heating means desorbed from the composite MOF for extraction of the desorbed CO2 from the air.
[0006] Preferably the resistive heating means generates the resistive heating via an electrical current passing through a conductive material of or associated with the composite MOF. More preferably the conductive material includes a carbon-based material of or associated with the composite MOF for heat transfer and thus desorption of the adsorbed CO2 from the composite MOF.
[0007] According to a third aspect of the invention there is provided a method of extracting carbon dioxide from air, said method comprising steps of: exposing air to an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing, carbon dioxide (CO2) from the air being adsorbed by the composite MOF; exposing the composite MOF and the adsorbed CO2 to electromagnetic radiation which is effective in desorption of the adsorbed CO2 from the composite MOF for extraction of the CO2 from the air.
[0008] According to a fourth aspect of the invention there is provided a method of extracting carbon dioxide from air, said method comprising steps of: exposing air to an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing, carbon dioxide (CO2) from the air being adsorbed by the composite MOF; exposing the composite MOF and the adsorbed CO2 to resistive heating which is effective in desorption of the adsorbed CO2 from the composite MOF for extraction of the CO2 from the air.
[0009] According to a fifth aspect of the invention there is provided a method of fabricating an atmospheric carbon dioxide (CO2) extractor, said method comprising the steps of: producing an adsorbent composite metal-organic framework (MOF) by additive manufacturing; locating the composite MOF within an airflow chamber thereby providing the CO2 extractor.
[0010] Preferably the production of the composite MOF by additive manufacturing involves 3D printing of a composite resin mixture from which the composite MOF is produced. More preferably the composite resin mixture includes a light-sensitive resin, and a metal-organic framework compound. Alternatively the composite resin mixture includes a heat-sensitive resin, and the metal-organic framework compound. In these embodiments the composite resin mixture also includes a binder, a hydrophobicity agent, and a solvent.
[0011] Preferably the 3D printing of the composite resin mixture involves digital light processing (DLP) which is effective in curing the composite resin mixture including the light-sensitive resin and the MOF compound from which the composite MOF is produced. Alternatively the 3D printing involves filament deposition or fused deposition modelling (FDM) which is effective in curing the alternative composite resin mixture including the heat-sensitive resin and the MOF compound from which the composite MOF is produced. In another embodiment the 3D printing involves stereolithography (SL) which is effective in curing the composite resin mixture. In another embodiment the 3D printing involves robocasting using shear thinning to stabilise the mixture.
[0012] Preferably the airflow chamber is formed by a substantially sealed housing including an air inlet and an air outlet. More preferably the composite MOF occupies substantially the entire airflow chamber. Even more preferably the sealed housing includes a cylindrical casing enclosed at its opposing ends with respective of end walls including the air inlet and the air outlet. Still more preferably the sealed housing includes one or more CO2 outlets associated with the cylindrical casing for discharge of desorbed CO2 from the composite MOF.
[0013] Preferably the extractor assembly also comprises a fan/blower operatively coupled to the sealed housing to promote the flow of air through the airflow chamber for adsorption of the CO2 to the composite MOF. More preferably said assembly further comprises an inlet valve associated with the air inlet to control the rate of flow of air through said chamber. Even more preferably said assembly also comprises an outlet valve associated with the air outlet to control the flow of air from the airflow chamber.
[0014] Preferably the carbon dioxide extractor assembly is standalone off-grid comprising solar photovoltaic (PV) cells and battery storage for the provision of electricity for powering said assembly. More preferably the off-grid electricity powers the fan/blower and either the source of electromagnetic radiation or the resistive heating means.
[0015] According to a sixth aspect of the present invention there is provided an atmospheric carbon dioxide extractor assembly comprising: a plurality of carbon dioxide (CO2) extractor cartridges each including:
(a) an airflow chamber including a composite metal-organic framework (MOF) lattice produced by additive manufacturing;
(b) resistive heating means associated with the composite MOF lattice; at least one CO2 adsorption station configured to permit air to flow through the airflow chamber of at least one of the plurality of extractor cartridges whereby its associated composite MOF lattice directly adsorbs CO2 from said air; a CO2 desorption station including an electricity sub-assembly operatively coupled to a solar-derived electricity source, said electricity sub-assembly arranged to contact exposed electrical contacts of the resistive heating means of another of said extractor cartridges for resistive heating of the associated composite MOF lattice whereby directly adsorbed CO2 is desorbed from said lattice for extraction of the desorbed CO2 from the air.
[0016] Preferably said at least one CO2 adsorption station includes forced draft means arranged to promote air flow through the airflow chamber of each of the extractor cartridges. More preferably said forced draft means includes one or more fans or blowers.
[0017] Preferably the CO2 desorption station includes a sealing sub-assembly arranged to seal the airflow chamber and the associated composite MOF lattice to enhance the desorption of the adsorbed CO2 from said lattice under the influence of the resistive heating means. More preferably said CO2 desorption station also includes a vacuum or low pressure sub-assembly arranged to cooperate with said other of the cartridges to remove the desorbed CO2 from the sealed airflow chamber.
[0018] Preferably said carbon dioxide extractor assembly further comprises a plurality of cartridge mounting sub-assemblies being interconnected and dedicated to respective of the plurality of CO2 extractor cartridges for releasable mounting of said cartridges in a bank. More preferably the bank of CO2 extractor cartridges are each arranged to cooperate with (a) the forced draft means at the CO2 adsorption station in a CO2 adsorption cycle, and (b) the sealing sub-assembly and/or vacuum sub- assembly at the CO2 desorption station in a CO2 desorption cycle.
[0019] Preferably said carbon dioxide extractor assembly also comprises a cartridge actuator sub-assembly connected to the plurality of cartridge mounting sub- assemblies and configured for movement of the associated CO2 extractor cartridges between the CO2 adsorption and desorption stations for CO2 adsorption and desorption cycles, respectively. More preferably said actuator assembly includes a rotating shaft about which the cartridge mounting sub-assemblies are mounted for rotation of the extractor cartridges between the adsorption and desorption stations.
[0020] Preferably said carbon dioxide extractor assembly further comprises a utilities mounting sub-assembly arranged for fixed mounting of the CO2 adsorption stations and the CO2 desorption station for staged alignment with the CO2 extractor cartridges during movement of the associated cartridge mounting sub-assemblies between said adsorption and desorption stations. More preferably the forced draft means of the CO2 adsorption station aligns with one of the extractor cartridges during the CO2 adsorption cycle whilst the sealing sub-assembly of the CO2 desorption station aligns with the other of the extractor cartridges during the CO2 desorption cycle.
[0021] According to a seventh aspect of the invention there is provided an atmospheric carbon dioxide extractor cartridge comprising: an airflow chamber including a composite metal-organic framework (MOF) lattice produced by additive manufacturing; resistive heating means associated with the composite MOF lattice and including exposed electrical contacts adapted to contact electrical terminals of a solar- derived electricity source for powering the resistive heating means for resistive heating of the composite MOF lattice whereby in operation (a) in a CO2 adsorption cycle, the composite MOF lattice directly adsorbs carbon dioxide (CO2) from air flowing through the airflow chamber, and (b) in a CO2 desorption cycle, the directly adsorbed CO2 is, under the influence of the resistive heating of the composite MOF lattice, desorbed from said lattice for extraction of the desorbed CO2 from the air.
[0022] Preferably said extractor cartridge includes a cylindrical casing being open- ended whilst otherwise surrounding the composite MOF lattice. More preferably one end of the casing forms an air inlet arranged to cooperate with one or more fans or blowers for promoting the flow of air through the airflow chamber and into contact with the composite MOF lattice, and an opposite end of the casing forms an air outlet for the discharge of air depleted of CO2 from the airflow chamber.
[0023] Preferably the composite MOF lattice is additively printed from a composite resin mixture which includes a resin and a metal-organic framework (MOF) compound. More preferably the composite MOF lattice includes or is associated with a conductive material which in the CO2 desorption cycle transfers electrical current from the electrical terminals of the solar-derived electricity source and the associated contacts of the resistive heating means to the composite MOF lattice for effective resistive heating of said lattice. Even more preferably the conductive material includes a carbon-based material.
[0024] According to an eighth aspect of the invention there is provided a method of extracting carbon dioxide from air, said method comprising the steps of: exposing air to a composite metal-organic framework (MOF) lattice produced by additive manufacturing, carbon dioxide (CO2) from the air being directly adsorbed by the composite MOF lattice; resistively heating the composite MOF lattice by exposing a conductive material of or associated with said MOF lattice to electricity derived from a solar- derived electricity source whereby the directly adsorbed CO2 is desorbed from the composite MOF lattice for extraction of the CO2 from air. [0025] According to a ninth aspect of the invention there is provided a method of constructing an atmospheric carbon dioxide extractor cartridge, said method comprising the steps of: producing a composite metal-organic framework (MOF) lattice by additive manufacturing; forming resistive heating means associated with the composite MOF lattice and including electrical contacts adapted to contact electrical terminals of a solar- derived electricity source; locating the composite MOF lattice within an airflow chamber whereby in operation air flow through the airflow chamber enables direct adsorption of carbon dioxide (CO2) from the air onto the composite MOF lattice, and under the influence of resistive heating of the composite MOF lattice, desorption of the directly adsorbed CO2 from said MOF lattice.
[0026] Preferably the production of the composite MOF lattice by additive manufacturing involves 3D printing of a composite resin mixture from which the composite MOF lattice is produced. More preferably the composite resin mixture includes a light-sensitive resin, and a metal-organic framework compound. Alternatively the composite resin mixture includes a heat-sensitive resin, and the metal-organic framework compound. In these examples the composite resin mixture also includes a binder, a hydrophobicity agent, and a solvent.
[0027] Preferably the 3D printing of the composite resin mixture involves digital light processing (DLP) which is effective in curing the composite resin mixture including the light-sensitive resin and the MOF compound from which the composite MOF lattice is produced. Alternatively the 3D printing involves filament deposition or fused deposition modelling (FDM) which is effective in curing the alternative composite resin mixture including the heat-sensitive resin and the MOF compound from which the composite MOF lattice is produced. In another embodiment the 3D printing involves stereolithography (SL) which is effective in curing the composite resin mixture. In another embodiment the 3D printing involves robocasting using shear thinning to stabilise the mixture. [0028] Preferably the step of forming the resistive heating means involves additive manufacturing of a conductive material to form a conductive lattice associated with the composite MOF lattice. More preferably the conductive lattice is additively manufactured in conjunction with the additive manufacturing of the composite MOF lattice wherein said lattices are integrated. Even more preferably the composite resin mixture from which the conductive lattice is 3D printed includes the conductive material.
Brief Description of Drawings
[0029] In order to achieve a better understanding of the nature of the present invention a preferred embodiment of an atmospheric carbon dioxide extractor assembly together with associated aspects of the technology will now be described, by way of example only, with reference to the accompany drawing in which:
Figure 1 is a schematic illustration shown in part cutaway of an atmospheric carbon dioxide extractor assembly of a preferred embodiment of one aspect of the invention;
Figure 2 is a perspective view of an atmospheric CO2 extractor assembly including CO2 extractor cartridges of a preferred embodiment of other aspects of the technology;
Figure 3 is a side elevational view of the atmospheric CO2 extractor assembly of the preferred embodiment of figure 2;
Figure 4 is a side elevational view shown in cross section of a CO2 adsorption station of the atmospheric CO2 extractor assembly of the preferred embodiment of figures 2 and 3;
Figure 5 is a side elevational view shown in cross section of a CO2 desorption station of the atmospheric CO2 extractor assembly of the preferred embodiment of figures 2 and 3 together with its sealing sub-assembly. Detailed Description
[0030] As seen in figure 1 there is an atmospheric carbon dioxide (CO2) extractor assembly 10 which according to a first aspect of the invention broadly comprises an air flow chamber 12 containing an adsorbent composite metal-organic framework (MOF) 14, and a source of electromagnetic radiation 16 associated with the airflow chamber 12. The composite MOF 14 is produced by additive manufacturing which in the preferred embodiment involves 3D printing of a composite resin mixture from which the composite MOF 14 is produced. The source of electromagnetic radiation 16 in this embodiment takes the form of a microwave device associated with the airflow chamber 12.
[0031] In a second aspect of the invention the source of electromagnetic radiation is replaced with resistive heating means (not shown). In this variation the resistive heating means generates resistive heating via an electrical current passing through a conductive material of or associated with the composite MOF. The conductive material includes a carbon-based material which on resistive heating is effective in desorption of the adsorbed CO2 from the composite MOF.
[0032] In operation, the composite MOF 14 of the atmospheric CO2 extractor assembly 10 adsorbs carbon dioxide (CO2) from incoming air 18 flowing through the airflow chamber 12. The adsorbed CO2 is, under the influence of electromagnetic radiation (not shown) generated by the microwave device 16 of the first aspect, desorbed from the composite MOF 14. The desorbed CO220 is thus extracted from the incoming air 18 and C02-depleted air 22 exits the airflow chamber 12.
[0033] In one embodiment of both aspects of the invention the composite resin mixture from which the composite MOF 14 is produced includes a light-sensitive resin, and a metal-organic framework compound (not shown). The composite resin mixture also includes a binder, a hydrophobicity agent, and a solvent. In this example the MOF compound is in the form of a powder and the solvent is understood to promote suspension and flow of the powdered MOF compound within the composite resin mixture. It is expected that at least the majority of the solvent will evaporate from the composite resin mixture in the course of its blending or curing. The binder of the composite resin mixture is understood to effectively bind the MOF compound with the light-sensitive resin in blending of the composite resin mixture. It is expected that the light-sensitive resin provides the requisite structural support for the composite MOF in the absence of a substrate which would otherwise provide this structural support. In this example the composite resin mixture includes:
1. the light-sensitive resin in the form of thermoplastic (e.g. acrylonitrile butadiene styrene (ABS)) at approximately 1-15 w/w%;
2. the metal-organic framework compound in the form of TIFSIX-Ni or other MOF at approximately 78-95 w/w%;
3. a binder in the form of a polymer at approximately 1 -15 w/w%;
4. a hydrophobicity agent in the form of a polymer at approximately 1 -15 w/w%;
5. the solvent in the form of water or ethanol or methanol at approximately 1 -15 w/w%.
[0034] In another embodiment the light-sensitive resin is replaced with a heat- sensitive resin. The heat-sensitive resin of this variation is understood to be suited to additive manufacturing of the composite MOF adopting either filament deposition or fixed deposition modelling (FDM) 3D printing technology.
[0035] In the first aspect the microwave device 16 of the preferred embodiment emits the electromagnetic radiation for desorption of the adsorbed CO2 from the composite MOF such as 14. The microwave device 16 emits the electromagnetic radiation at a wavelength spectrum of frequencies ranging from 1GFIz to over 100GFIZ. It is understood that the wavelength spectrum includes infrared radiation, microwave radiation, or a combination of infrared and microwave radiations. In any event the electromagnetic radiation is effective in heating the adsorbed CO2 in order to desorb it from the composite MOF 14.
[0036] In both aspects the airflow chamber 12 of the preferred embodiment is formed by a substantially sealed housing 24 including an air inlet 26 and an air outlet 28. The sealed housing 24 of this example includes a cylindrical casing 30 enclosed at its opposing ends with respective of end walls 32 and 34. The air inlet 26 is connected to one of the end walls 32 whereas the air outlet 28 is connected to the other of the end walls 34. The sealed housing 24 of this embodiment includes a CO2 outlet 36 connected to the cylindrical casing 30 for discharge of the desorbed CO220 from the composite MOF 14. The composite MOF 14 occupies substantially the entire airflow chamber 12 and in this example is configured as depicted in the part cutaway portion of figure 1.
[0037] In this embodiment the extractor assembly 10 also comprises a fan or blower 37 coupled to the sealed housing 24 to promote the flow of incoming air 18 through the airflow chamber 12. The composite MOF 14 occupying the airflow chamber 12 adsorbs CO2 from this flow of air through the chamber 12. In this example the extractor assembly 10 further comprises an inlet valve 38 associated with the air inlet 26, and an outlet valve 40 associated with the air outlet 28. The inlet and outlet valves 38 and 40 assist with control of the flow of air through the airflow chamber 12.
[0038] In third and fourth aspects of the invention and in the context of the preferred embodiment, there is a method of extracting carbon dioxide from air. The method broadly comprises the steps of:
1. exposing air 18 to an adsorbent composite metal-organic framework (MOF) at 14 produced by additive manufacturing;
2. this exposure of the air to the composite MOF being effective in the carbon dioxide (CO2) from the air being absorbed by the composite MOF 14;
3. exposing the composite MOF 14 and the adsorbed CO2 to electromagnetic radiation or resistive heating which is effective in desorption of the adsorbed CO2 from the composite MOF 14 for extraction of the CO2 at 20 from the air.
[0039] In one embodiment of the third aspect of the invention the electromagnetic radiation is provided by the microwave 16. The electromagnetic radiation of the microwave device 16 is of a wavelength spectrum which is effective in desorption of the adsorbed CO2 from the composite MOF 14. In one embodiment of the fourth aspect the resistive heating is provided by resistive heating means including a conductive carbon-based material of or associated with the composite MOF. The conductive material is exposed to an electrical current thereby generating resistive heat which is transferred to the composite MOF for desorption of the absorbed CO2. [0040] In a fifth aspect of the invention there is a method of fabricating an atmospheric carbon dioxide (CO2) extractor such as that incorporated in the assembly 10 of figure 1. The method in the context of the illustrated embodiment broadly comprises the steps of:
1. producing the adsorbent composite metal-organic framework (MOF) by additive manufacturing;
2. locating the composite MOF such as 14 within an airflow chamber such as 12 thereby providing the CO2 extractor.
[0041] The composite MOF such as 14 of this and the preceding aspects is in a preferred embodiment produced by 3D printing of a composite resin mixture via digital light processing (DLP). The composite resin mixture includes the light-sensitive resin and the MOF compound of the described embodiment wherein DLP is effective in curing the composite resin mixture. In another embodiment, the 3D printing of the composite MOF involves stereolithography (SL) which is effective in curing the composite resin mixture. In an alternative embodiment the 3D printing involves robocasting. In an alternative embodiment the 3D printing involves filament deposition or fused deposition modelling (FDM). These additive manufacturing technologies are suited to and effective in curing the alternative resin mixture including the heat- sensitive resin. The 3D-printed composite MOF 14 of these embodiments has a relative high surface area for increased CO2 adsorption within the airflow chamber 12. Flaving said that, the composite MOF 14 is of a relatively high permeability wherein the air passing through the airflow chamber 12 undergoes a relatively low pressure drop.
[0042] Although not illustrated, it is to be understood that all unit operations of the extractor assembly 10 of the described embodiments are powered by solar PV. It is expected batteries charged by the solar PV will provide adequate power for 24/7 operation of the system. In this embodiment the unit operations requiring power include but are not limited to the fan/blower 37 and either the source of electromagnetic radiation or the resistive heating means. [0043] As seen in figures 2 and 3 there is a preferred embodiment of an atmospheric carbon dioxide (CO2) extractor assembly 10 which according to a sixth aspect of the invention broadly comprises:
1. a plurality of CO2 extractor cartridges 12a to 12d;
2. a plurality of CO2 adsorption stations 14b to 14d configured to permit air to flow through respective of select of the plurality of extractor cartridges 12b to 12d for direct adsorption of CO2 from said air;
3. a CO2 desorption station 14a arranged to contact a remaining one of the plurality of CO2 extractor cartridges 12a for resistive heating whereby the directly adsorbed CO2 is desorbed for extraction from the air.
[0044] In a seventh aspect of the invention best seen in figures 4 and 5, each of the CO2 extractor cartridges such as 12a and 12c broadly comprises: a) an airflow chamber 16a and 16c including a composite metal-organic framework (MOF) lattice 18a and 18c produced by additive manufacturing; b) resistive heating means designated broadly at 20a and 20c associated with the composite MOF lattice 18a and 18c.
[0045] In operation, the CO2 cartridges 18a/c function in either (i) a CO2 adsorption cycle seen in figure 4 where the composite MOF lattice 18c directly adsorbs CO2 from air flowing through the airflow chamber 16c, or (ii) a CO2 desorption cycle seen in figure 5 where the directly adsorbed CO2 is, under the influence of resistive heating of the composite MOF lattice 18a via the resistive heating means 20a, desorbed for extraction of the desorbed CO2.
[0046] In this embodiment of both the sixth and seventh aspects of the invention the resistive heating means such as 20a of said one of the extractor cartridges 12a includes exposed electrical contacts 22aa and 22ab at its respective ends. The other extractor cartridge such as 12c is of a substantially identical construction to the extractor cartridge 12c including exposed electrical contacts 22ca and 22cb. The electrical contacts 22aa and 22ab of the extractor cartridge 12a are at the CO2 desorption station 14a adapted to contact corresponding electrical terminals 24a and 24b of a solar-derived electricity source (not shown). In the CO2 desorption cycle, the electricity source powers the resistive heating means such as 20a associated with the composite MOF lattice 18a for resistive heating of said lattice 18a. This resistive heating of the composite MOF lattice 18a is effective in desorption of the directly adsorbed CO2 from said lattice 18a.
[0047] Figure 4 illustrates one of the CO2 extractor cartridges 12c including a cylindrical casing 26c being open-ended whilst otherwise surrounding the associated and composite MOF lattice 18c. One of the open ends of the casing 26c forms an air inlet 28ca arranged to cooperate with forced draft means such as a plurality of fans or blowers such as 30ca to 30cc for promoting the flow of air through the airflow chamber 16c. This airflow through said chamber 16c enhances contact of said air with the composite MOF lattice 18c which in the CO2 adsorption cycle directly adsorbs CO2 from said air. An opposite open end of the casing 26c forms an air outlet 28cb arranged for the discharge of air depleted of CO2 from the airflow chamber 16c.
[0048] The composite MOF lattice of the preferred embodiment such as 18a to 18d is additively printed from a composite resin mixture which includes a resin and a metal-organic framework (MOF) compound. The composite resin mixture from which the composite MOF lattice such as 18a is produced includes a light-sensitive resin, and the MOF compound (not shown). The composite MOF lattice 18a also includes or is associated with a conductive material including a carbon-based material which transfers electrical current through said lattice 18a in the desorption cycle for resistive heating of said lattice 18a via the resistive heating means 20a
[0049] The composite resin mixture of this embodiment also includes a binder, a hydrophobicity agent, and a solvent. In this example the MOF compound is in the form of a powder and the solvent is understood to promote suspension and flow of the powdered MOF compound within the composite resin mixture. It is expected that at least the majority of the solvent will evaporate from the composite resin mixture in the course of its blending or curing. The binder of the composite resin mixture is understood to effectively bind the MOF compound with the light-sensitive resin in blending of the composite resin mixture. It is expected that the light-sensitive resin provides the requisite structural support for the composite MOF lattice in the absence of a substrate which would otherwise provide this structural support. In this example the composite resin mixture includes:
1. the light-sensitive resin in the form of thermoplastic (e.g. acrylonitrile butadiene styrene (ABS)) at approximately 1-15 w/w%;
2. the metal-organic framework compound in the form of TIFSIX-Ni or other MOF at approximately 78-95 w/w%;
3. the carbon-based material at approximately 10-20 w/w;
4. a binder in the form of a polymer at approximately 1 -15 w/w%;
5. a hydrophobicity agent in the form of a polymer at approximately 1 -15 w/w%;
6. the solvent in the form of water or ethanol or methanol at approximately 1 -15 w/w%.
[0050] In another embodiment the light-sensitive resin is replaced with a heat- sensitive resin. The heat-sensitive resin of this variation is understood to be suited to additive manufacturing of the composite MOF lattice adopting either filament deposition or fixed deposition modelling (FDM) 3D printing technology.
[0051 ] The composite MOF lattice such as 18a to18d is in a preferred embodiment produced by 3D printing of a composite resin mixture via digital light processing (DLP). The composite resin mixture includes the light-sensitive resin and the MOF compound of the described embodiment wherein DLP is effective in curing the composite resin mixture. In another embodiment, the 3D printing of the composite MOF lattice involves stereolithography (SL) which is effective in curing the composite resin mixture. In an alternative embodiment the 3D printing involves robocasting. In an alternative embodiment the 3D printing involves filament deposition or fused deposition modelling (FDM). These additive manufacturing technologies are suited to and effective in curing the alternative resin mixture including the heat-sensitive resin. The 3D-printed composite MOF lattice of these embodiments has a relative high surface area for increased CO2 adsorption within the airflow chamber. Flaving said that, the composite MOF lattice is of a relatively high permeability wherein the air passing through the airflow chamber undergoes a relatively low pressure drop.
[0052] As seen in figures 2 and 5, the atmospheric carbon dioxide extractor assembly 10 at the CO2 desorption station 14a includes an electricity sub-assembly designated generally at 32 operatively coupled to the solar-derived electricity source (not shown). The electricity sub-assembly 32 includes the electrical terminals 24a and 24b arranged to contact the exposed electrical contacts such as 22aa and 22ab of the resistive heating means 20a of the associated composite MOF lattice 18a.
[0053] The CO2 desorption station 14a of this embodiment also includes a sealing sub-assembly 34 arranged to seal the airflow chamber such as 16a and the associated composite MOF lattice 18a. The sealing sub-assembly 34 is designed to enhance the desorption of the adsorbed CO2 from the composite MOF lattice 18a under the influence of the resistive heating means 20a. The sealing sub-assembly 34 includes a pair of lower and upper lids 35a and 35b arranged in conjunction with corresponding seals (not shown) to seal the MOF lattice 18a within the airflow chamber 16a. The CO2 desorption station 14a of this embodiment also includes a vacuum or low pressure sub-assembly designated broadly at 36 arranged to cooperate with the extractor cartridge 12a to remove the desorbed CO2 from the sealed airflow chamber 16a.
[0054] Returning to figure 2, in this embodiment the carbon dioxide extractor assembly 10 further comprises a plurality of cartridge mounting sub-assemblies such as 38a to 38d. The cartridge mounting sub-assemblies 38a to 38d are interconnected and dedicated to respective of the plurality of CO2 extractor cartridges 12a to 12d for releasable mounting of said cartridges in a bank formation. The bank of extractor cartridges 38a to 38d are as best seen in figures 2 and 3 arranged to cooperate with:
1. the forced draft means such as fans 30ca to 30cc at each of the CO2 adsorption stations such as 14c in the CO2 adsorption cycle; and
2. the sealing sub-assembly 34 and/or the vacuum sub-assembly 36 at the CO2 desorption station 14a in the CO2 desorption cycle.
[0055] The carbon dioxide extractor assembly 10 of this embodiment also comprises a cartridge actuator sub-assembly designated broadly at 40 connected to the plurality of cartridge mounting sub-assemblies 38a to 38d. The actuator sub- assembly 40 is configured for movement of the associated CO2 extractor cartridges 12a to 12d between the CO2 adsorption stations 14b to 14d and the CO2 desorption station 14a for CO2 adsorption and desorption cycles. In this example the actuator assembly 40 includes a rotating shaft 42 about which the cartridge mounting assemblies 38a to 38d are rigidly mounted via radial arms 44a to 44d for rotation of the extractor cartridges 12a to 12d between the desorption station 14a and the adsorption stations 14b to 14d.
[0056] The carbon dioxide extractor assembly 10 of this embodiment further comprises a utilities mounting sub-assembly designated generally at 46 and arranged for fixed mounting of the CO2 desorption station 14a and the CO2 adsorption stations 14b to 14d. The utilities mounting sub-assembly 46 is configured for staged alignment of the CO2 desorption station 14a and the CO2 adsorption stations 14b to 14d for staged alignment with the CO2 extractor cartridges 12a to 12d during movement of the associated cartridge mounting sub-assemblies 38a to 38d between said desorption 14a and adsorption 14b to 14d stations. The forced draft means of the CO2 adsorption stations 14b to 14d align with corresponding of the extractor cartridges 12b to 12d during the adsorption cycle whilst the sealing sub-assembly 34 of the CO2 desorption station 14a aligns with the other of the extractor cartridges 12a during the desorption cycle.
[0057] Although not illustrated, the cartridge actuator sub-assembly 40 and its associated cartridge sub-assemblies 38a to 38d and corresponding CO2 extractor cartridges 12a to 12d are rotated via a motor or other actuator (not shown) about the utilities mounting sub-assembly 46 which is stationary. This rotation sequentially moves the extractor cartridges 12a to 12d between desorption station 14a and adsorption stations 14b to 14d. It will be understood that prior to this movement of the CO2 extractor cartridges 12a to 12d, the sealing sub-assembly 34 is released from the cartridge mounting sub-assembly such 38a to permit this rotational movement.
[0058] In an eighth aspect of the invention and in the context of the preferred embodiment, there is a method of extracting carbon dioxide from air. This method broadly comprises the steps of:
1. exposing air to a composite metal-organic framework (MOF) lattices such as 18b to 18d produced by additive manufacturing at each of adsorption stations 18b to 18d; 2. resistively heating the composite MOF lattice 18a at desorption station 14a by exposing the conductive material 20a of or associated with said MOF lattice 18a to an electrical current to desorb directly adsorbed CO2 from said composite MOF lattice 18a.
[0059] In step 1 , carbon dioxide from the air is directly absorbed by the composite MOF lattice such as 18b. In step 2, the electrical current exposed to the conductive material such as 20a is derived from a solar-derived electricity source such as solar PV. It is expected that batteries charged by the solar PV will provide adequate power for 24/7 operation of the system. In this embodiment this solar-derived electricity may be used to power not only the resistive heating means but also other unit operations associated with the system including but not limited to the fans/blowers.
[0060] In a ninth aspect of the invention there is method of constructing an atmospheric carbon dioxide extractor cartridge such as that incorporated in the assembly 10 of the preferred embodiment. The method of this aspect broadly comprises the steps of:
1. producing the composite metal-organic framework (MOF) lattice such as 18a by additive manufacturing;
2. forming resistive heating means 20a associated with the composite MOF lattice 18a and including electrical contacts 22aa and 22ab adapted to contact electrical terminals of a solar-derived electricity source (not shown);
3. locating the composite MOF lattice such as 18c within an airflow chamber 16c whereby in operation (i) airflow through the air flow chamber 16c enables direct adsorption of carbon dioxide (CO2) from the air onto the composite MOF lattice 18c, and (ii) under the influence of resistive heating of the composite MOF lattice such as 18a, desorption of directly adsorbed CO2 from said lattice 18a.
[0061 ] Now that preferred embodiments of the various aspects of the technology have been described it will be apparent to those skilled in the art that they have at least the following advantages: 1. the composite MOF is additively manufactured with sufficient inherent structural stability and support without requiring a conventional structural substrate;
2. the extractor assembly and associated methodology utilise electromagnetic radiation or resistive heating in effectively desorbing the adsorbed CO2 from the composite MOF;
3. the extractor assembly lends itself to powering solely by renewable energy sources including solar PV;
4. the carbon dioxide extractor cartridges incorporate resistive heating means associated with the composite MOF lattice which permits resistive heating for effective desorption of the adsorbed CO2;
5. the resistive heating means of the carbon dioxide extractor cartridge includes exposed electrical contacts conveniently arranged for contact with electrical terminals of a solar-derived electricity source which permits powering solely by renewable energy sources;
6. the carbon dioxide extractor assembly including CO2 adsorption and desorption stations lends itself to efficient direct adsorption of CO2 on to the composite MOF lattice of the extractor cartridges associated with each of the adsorption stations and thereafter desorption of the adsorbed CO2 at the desorption station;
7. the carbon dioxide extractor assembly is conveniently engineered for removable or retractable mounting of CO2 extractor cartridges within corresponding mounting sub-assemblies which lends itself to efficient maintenance including servicing or replacement of extractor cartridges.
[0062] Those skilled in the art will appreciate that the invention as described herein is susceptible to variations and modifications other than those specifically described. For example, the shape and/or configuration of the airflow chamber may vary provided it contains an adsorbent composite MOF produced by additive manufacturing. The source of electromagnetic radiation is not limited to the microwave device of the preferred embodiment and extends to other sources which produce the requisite electromagnetic radiation for heating of the composite MOF and the adsorbed CO2 for desorption of the CO2. Likewise, the resistive heating means may vary from the described embodiment provide it is effective in generating heat for desorption of the adsorbed CC>2.The “chemistry” of the composite MOF may vary from the preferred embodiment provided it lends itself to additive manufacturing and is effective in adsorption of CO2 from air. The invention is not limited to any specific additive manufacturing technology and extends to robocasting and other extrusion- based 3D printing techniques. It is to be understood that the CO2 extractor assembly may take the form of a standalone unit or be integrated with a renewable methane or renewable methanol plant.
[0063] All such variations and modifications are to be considered within the scope of the present invention the nature of which is to be determined from the foregoing description.

Claims (56)

Claims
1. An atmospheric carbon dioxide extractor assembly comprising: an airflow chamber containing an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing; a source of electromagnetic radiation associated with the airflow chamber whereby in operation the composite MOF adsorbs carbon dioxide (CO2) from air flowing through the airflow chamber and the adsorbed CO2 is, under the influence of electromagnetic radiation generated by the source of electromagnetic radiation, desorbed from the composite MOF for extraction of the desorbed CO2 from the air.
2. An atmospheric carbon dioxide extractor assembly as claimed in claim 1 wherein the source of electromagnetic radiation is in the form of a microwave device which emits the electromagnetic radiation for desorption of the adsorbed CO2 from the composite MOF.
3. An atmospheric carbon dioxide extractor assembly as claimed in claim 2 wherein the microwave device emits the electromagnetic radiation at a wavelength spectrum including infrared radiation, microwave radiation, or a combination of infrared and microwave radiations.
4. An atmospheric carbon dioxide extractor assembly comprising: an airflow chamber containing an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing; resistive heating means associated with the airflow chamber whereby in operation the composite MOF adsorbs carbon dioxide (CO2) from air flowing through the airflow chamber and the adsorbed CO2 is, under the influence of resistive heating generated by the resistive heating means desorbed from the composite MOF for extraction of the desorbed CO2 from the air.
5. An atmospheric carbon dioxide extractor assembly as claimed in claim 4 wherein the resistive heating means generates the resistive heating via an electrical current passing through a conductive material of or associated with the composite MOF.
6. An atmospheric carbon dioxide extractor assembly as claimed in claim 5 wherein the conductive material includes a carbon-based material of or associated with the composite MOF for heat transfer and thus desorption of the adsorbed CO2 from the composite MOF.
7. An atmospheric carbon dioxide extractor assembly as claimed in any one of the preceding claims wherein the airflow chamber is formed by a substantially sealed housing including an air inlet and an air outlet.
8. An atmospheric carbon dioxide extractor assembly as claimed in claim 7 wherein the composite MOF occupies substantially the entire airflow chamber.
9. An atmospheric carbon dioxide extractor assembly as claimed in either of claims 7 or 8 wherein the sealed housing includes a cylindrical casing enclosed at its opposing ends with respective of end walls including the air inlet and the air outlet.
10. An atmospheric carbon dioxide extractor assembly as claimed in claim 9 wherein the sealed housing includes one or more CO2 outlets associated with the cylindrical casing for discharge of desorbed CO2 from the composite MOF.
11. An atmospheric carbon dioxide extractor assembly as claimed in any one of claims 7 to 10 also comprising a fan/blower operatively coupled to the sealed housing to promote the flow of air through the airflow chamber for adsorption of the CO2 to the composite MOF.
12. An atmospheric carbon dioxide extractor assembly as claimed in claim 11 further comprising an inlet valve associated with the air inlet to control the rate of flow of air through said chamber.
13. An atmospheric carbon dioxide extractor assembly as claimed in in either of claims 11 or 12 also comprising an outlet valve associated with the air outlet to control the flow of air from the airflow chamber.
14. An atmospheric carbon dioxide extractor assembly as claimed in in any one of the preceding claims being standalone and off-grid comprising solar photovoltaic (PV) cells and battery storage for the provision of electricity for powering said assembly.
15. An atmospheric carbon dioxide extractor assembly as claimed in claim 14 wherein the off-grid electricity powers the fan/blower and either the source of electromagnetic radiation or the resistive heating means.
16. A method of extracting carbon dioxide from air, said method comprising steps of: exposing air to an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing, carbon dioxide (CO2) from the air being adsorbed by the composite MOF; exposing the composite MOF and the adsorbed CO2 to electromagnetic radiation which is effective in desorption of the adsorbed CO2 from the composite MOF for extraction of the CO2 from the air.
17. A method of extracting carbon dioxide from air, said method comprising steps of: exposing air to an adsorbent composite metal-organic framework (MOF) produced by additive manufacturing, carbon dioxide (CO2) from the air being adsorbed by the composite MOF; exposing the composite MOF and the adsorbed CO2 to resistive heating which is effective in desorption of the adsorbed CO2 from the composite MOF for extraction of the CO2 from the air.
18. A method of fabricating an atmospheric carbon dioxide (CO2) extractor, said method comprising the steps of: producing an adsorbent composite metal-organic framework (MOF) by additive manufacturing; locating the composite MOF within an airflow chamber thereby providing the CO2 extractor.
19. A method as claimed in any one of claims 16 to 18 wherein the production of the composite MOF by additive manufacturing involves 3D printing of a composite resin mixture from which the composite MOF is produced.
20. A method as claimed in claim 19 wherein the composite resin mixture includes a light-sensitive resin, and a metal-organic framework compound.
21. A method as claimed in claim 19 wherein the composite resin mixture includes a heat-sensitive resin, and a metal-organic framework compound.
22. A method as claimed in any one of claims 19 to 22 wherein the composite resin mixture also includes a binder, a hydrophobicity agent, and a solvent.
23. A method as claimed in claim 20 wherein the 3D printing of the composite resin mixture involves digital light processing (DLP) which is effective in curing the composite resin mixture including the light-sensitive resin and the MOF compound from which the composite MOF is produced.
24. A method as claimed in claim 21 wherein the 3D printing involves filament deposition or fused deposition modelling (FDM) which is effective in curing the composite resin mixture including the heat-sensitive resin and the MOF compound from which the composite MOF is produced.
25. A method as claimed in any one of claims 19 to 22 wherein the 3D printing involves stereolithography (SL) which is effective in curing the composite resin mixture.
26. A method as claimed in any one of claims 19 to 22 wherein the 3D printing involves robocasting using shear thinning to stabilise the mixture.
27. An atmospheric carbon dioxide extractor assembly comprising: a plurality of carbon dioxide (CO2) extractor cartridges each including:
(a) an airflow chamber including a composite metal-organic framework (MOF) lattice produced by additive manufacturing;
(b) resistive heating means associated with the composite MOF lattice; at least one CO2 adsorption station configured to permit air to flow through the airflow chamber of at least one of the plurality of extractor cartridges whereby its associated composite MOF lattice directly adsorbs CO2 from said air; a CO2 desorption station including an electricity sub-assembly operatively coupled to a solar-derived electricity source, said electricity sub-assembly arranged to contact exposed electrical contacts of the resistive heating means of another of said extractor cartridges for resistive heating of the associated composite MOF lattice whereby directly adsorbed CO2 is desorbed from said lattice for extraction of the desorbed CO2 from the air.
28. An atmospheric carbon dioxide extractor assembly as claimed in 27 wherein said at least one CO2 adsorption station includes forced draft means arranged to promote air flow through the airflow chamber of each of the extractor cartridges.
29. An atmospheric carbon dioxide extractor assembly as claimed in claim 28 wherein said forced draft means includes one or more fans or blowers.
30. An atmospheric carbon dioxide extractor assembly as claimed in any one of claims 27 to 29 wherein the CO2 desorption station includes a sealing sub-assembly arranged to seal the airflow chamber and the associated composite MOF lattice to enhance the desorption of the adsorbed CO2 from said lattice under the influence of the resistive heating means.
31. An atmospheric carbon dioxide extractor assembly as claimed in claim 30 wherein said CO2 desorption station also includes a vacuum or low pressure sub- assembly arranged to cooperate with said other of the cartridges to remove the desorbed CO2 from the sealed airflow chamber.
32. An atmospheric carbon dioxide extractor assembly as claimed in claim 31 further comprising a plurality of cartridge mounting sub-assemblies being interconnected and dedicated to respective of the plurality of CO2 extractor cartridges for releasable mounting of said cartridges in a bank.
33. An atmospheric carbon dioxide extractor assembly as claimed in claim 32 wherein the bank of CO2 extractor cartridges are each arranged to cooperate with (a) the forced draft means at the CO2 adsorption station in a CO2 adsorption cycle, and (b) the sealing sub-assembly and/or vacuum sub-assembly at the CO2 desorption station in a CO2 desorption cycle.
34. An atmospheric carbon dioxide extractor assembly as claimed in any one of claims 31 to 33 also comprising a cartridge actuator sub-assembly connected to the plurality of cartridge mounting sub-assemblies and configured for movement of the associated CO2 extractor cartridges between the CO2 adsorption and desorption stations for CO2 adsorption and desorption cycles, respectively.
35. An atmospheric carbon dioxide extractor assembly as claimed in claim 34 including a rotating shaft about which the cartridge mounting sub-assemblies are mounted for rotation of the extractor cartridges between the adsorption and desorption stations.
36. An atmospheric carbon dioxide extractor assembly as claimed in any one of claims 31 to 35 further comprising a utilities mounting sub-assembly arranged for fixed mounting of the CO2 adsorption stations and the CO2 desorption station for staged alignment with the CO2 extractor cartridges during movement of the associated cartridge mounting sub-assemblies between said adsorption and desorption stations.
37. An atmospheric carbon dioxide extractor assembly as claimed in claim 36 wherein the forced draft means of the CO2 adsorption station aligns with one of the extractor cartridges during the CO2 adsorption cycle whilst the sealing sub-assembly of the CO2 desorption station aligns with the other of the extractor cartridges during the CO2 desorption cycle.
38. An atmospheric carbon dioxide extractor cartridge comprising: an airflow chamber including a composite metal-organic framework (MOF) lattice produced by additive manufacturing; resistive heating means associated with the composite MOF lattice and including exposed electrical contacts adapted to contact electrical terminals of a solar- derived electricity source for powering the resistive heating means for resistive heating of the composite MOF lattice whereby in operation (a) in a CO2 adsorption cycle, the composite MOF lattice directly adsorbs carbon dioxide (CO2) from air flowing through the airflow chamber, and (b) in a CO2 desorption cycle, the directly adsorbed CO2 is, under the influence of the resistive heating of the composite MOF lattice, desorbed from said lattice for extraction of the desorbed CO2 from the air.
39. An atmospheric carbon dioxide extractor cartridge as claimed in claim 38 wherein said extractor cartridge includes a cylindrical casing being open-ended whilst otherwise surrounding the composite MOF lattice.
40. An atmospheric carbon dioxide extractor cartridge as claimed in claim 39 wherein one end of the casing forms an air inlet arranged to cooperate with one or more fans or blowers for promoting the flow of air through the airflow chamber and into contact with the composite MOF lattice, and an opposite end of the casing forms an air outlet for the discharge of air depleted of CO2 from the airflow chamber.
41. An atmospheric carbon dioxide extractor cartridge as claimed in any one of claims 38 to 40 wherein the composite MOF lattice is additively printed from a composite resin mixture which includes a resin and a metal-organic framework (MOF) compound.
42. An atmospheric carbon dioxide extractor cartridge as claimed in claim 41 wherein the composite MOF lattice includes or is associated with a conductive material which in the CO2 desorption cycle transfers electrical current from the electrical terminals of the solar-derived electricity source and the associated contacts of the resistive heating means to the composite MOF lattice for effective resistive heating of said lattice.
43. An atmospheric carbon dioxide extractor cartridge as claimed in claim 42 wherein the conductive material includes a carbon-based material.
44. A method of extracting carbon dioxide from air, said method comprising the steps of: exposing air to a composite metal-organic framework (MOF) lattice produced by additive manufacturing, carbon dioxide (CO2) from the air being directly adsorbed by the composite MOF lattice; resistively heating the composite MOF lattice by exposing a conductive material of or associated with said MOF lattice to electricity derived from a solar- derived electricity source whereby the directly adsorbed CO2 is desorbed from the composite MOF lattice for extraction of the CO2 from air.
45. A method of constructing an atmospheric carbon dioxide extractor cartridge, said method comprising the steps of: producing a composite metal-organic framework (MOF) lattice by additive manufacturing; forming resistive heating means associated with the composite MOF lattice and including electrical contacts adapted to contact electrical terminals of a solar-derived electricity source; locating the composite MOF lattice within an airflow chamber whereby in operation air flow through the airflow chamber enables direct adsorption of carbon dioxide (CO2) from the air onto the composite MOF lattice, and under the influence of resistive heating of the composite MOF lattice, desorption of the directly adsorbed CO2 from said MOF lattice.
46. A method as claimed in claim 45 wherein the production of the composite MOF lattice by additive manufacturing involves 3D printing of a composite resin mixture from which the composite MOF lattice is produced.
47. A method as claimed in claim 46 wherein the composite resin mixture includes a light-sensitive resin, and a metal-organic framework compound.
48. A method as claimed in claim 46 wherein the composite resin mixture includes a heat-sensitive resin, and the metal-organic framework compound.
49. A method as claimed in any one of claims 46 to 48 wherein the composite resin mixture also includes a binder, a hydrophobicity agent, and a solvent.
50. A method as claimed in claim 47 wherein the 3D printing of the composite resin mixture involves digital light processing (DLP) which is effective in curing the composite resin mixture including the light-sensitive resin and the MOF compound from which the composite MOF lattice is produced.
51. A method as claimed in claim 48 wherein the 3D printing involves filament deposition or fused deposition modelling (FDM) which is effective in curing the composite resin mixture including the heat-sensitive resin and the MOF compound from which the composite MOF lattice is produced.
52. A method as claimed in claim 46 wherein the 3D printing involves stereolithography (SL) which is effective in curing the composite resin mixture.
53. A method as claimed in claim 46 wherein the 3D printing involves robocasting using shear thinning to stabilise the mixture.
54. A method as claimed in any one of claims 46 to 53 wherein the step of forming resistive heating means involves additive manufacturing of a conductive material to form a conductive lattice associated with the composite MOF lattice.
55. A method as claimed in claim 54 wherein the conductive lattice is additively manufactured in conjunction with the additive manufacturing of the composite MOF lattice wherein said lattices are integrated.
56. A method as claimed in either of claims 53 or 54 wherein the composite resin mixture from which the conductive lattice is 3D printed includes the conductive material.
AU2022222824A 2021-02-16 2022-01-17 Atmospheric carbon dioxide extractor assembly Pending AU2022222824A1 (en)

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AU2021900383A AU2021900383A0 (en) 2021-02-16 Atmospheric Carbon Dioxide Extractor Assembly
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AU2021902305A AU2021902305A0 (en) 2021-07-28 An Atmospheric Carbon Dioxide Extractor Cartridge and Associated Assembly
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