WO2024040000A1 - Système d'adsorption à température modulée de co2 à régénération humide et séchage à chaud - Google Patents

Système d'adsorption à température modulée de co2 à régénération humide et séchage à chaud Download PDF

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Publication number
WO2024040000A1
WO2024040000A1 PCT/US2023/072054 US2023072054W WO2024040000A1 WO 2024040000 A1 WO2024040000 A1 WO 2024040000A1 US 2023072054 W US2023072054 W US 2023072054W WO 2024040000 A1 WO2024040000 A1 WO 2024040000A1
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capture
gas
vessel
stage
regeneration
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PCT/US2023/072054
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English (en)
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Paul M. Dunn
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Enhanced Energy Group LLC
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Priority claimed from US18/361,195 external-priority patent/US20240058740A1/en
Application filed by Enhanced Energy Group LLC filed Critical Enhanced Energy Group LLC
Publication of WO2024040000A1 publication Critical patent/WO2024040000A1/fr

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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
    • 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
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/22—Carbon dioxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/012—Diesel engines and lean burn gasoline engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/014—Stoichiometric gasoline engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/018—Natural gas engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/40007—Controlling pressure or temperature swing adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/40011—Methods relating to the process cycle in pressure or temperature swing adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • 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
    • B01D2259/4009—Regeneration of adsorbents in processes other than pressure or temperature swing adsorption by heating using hot gas
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/403—Further details for adsorption processes and devices using three beds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/404—Further details for adsorption processes and devices using four beds

Definitions

  • the present disclosure relates generally to carbon capture and thermal swing adsorption (TSA) processes for carbon capture.
  • TSA thermal swing adsorption
  • Molecular (mole) sieves include synthetic media (e.g., ceramiclike media), available in various physical sizes (powder to % inch round). Based on a composition and crystal structure of the synthetic media, mole sieves are capable of adsorbing, or not adsorbing, particular species of molecule based mostly on a size of the molecule. For example, a 3 A sieve will adsorb water (H2O), ammonia (NH3), and little else. Molecules like CO2, O2, N2, and argon would pass through the 3 A sieve. The 3 A sieve (and alumina) are typically used in dehydration processes.
  • synthetic media e.g., ceramiclike media
  • NH3 ammonia
  • NH3 ammonia
  • Molecules like CO2, O2, N2, and argon would pass through the 3 A sieve.
  • the 3 A sieve (and alumina) are typically used in dehydration processes.
  • a 5 A sieve will adsorb all of the species of the 3 A but will also adsorb CO2 and most pollutants (CO, HC, NOx) while allowing O2, N2, and argon to pass through the 5 A sieve.
  • a 13X sieve captures larger molecules, including many hydrocarbons, but still allows O2, N2, and argon to pass through the 13X sieve.
  • the terms pressure swing, thermal swing, vacuum swing, or combinations of the swing processes are used to describe the capture and release of the desired species by the mole sieve.
  • the swing processes are inefficient in terms of electrical power required to perform the swing processes to sufficiently capture and release CO2, which increases costs.
  • Activated carbon behaves similarly to mole sieves, and can be used in lieu of mole sieves in some cases. However, activated carbon has a different affinity for compounds that is not based on molecule size. Using activated carbon is higher in cost and lower in performance in terms of CO2 capture compared with mole sieves, but has advantages of a lower heat of adsorption for water (e.g., about 1000 BTU/lb for activated carbon vs. about 1800 BTU/lb for mole sieves) and a lower heat of adsorption for CO2.
  • the carbon capture system of the present disclosure solves one or more of the problems set forth above and/or other problems in the field.
  • a carbon capture system for carbon dioxide (CO2)-thermal swing adsorption (TSA) includes an engine configured to produce a hot exhaust; an adsorption inlet arranged downstream from the engine and configured to receive a cold exhaust comprising a mixture of CO2 and nitrogen (N2), wherein the cold exhaust is derived from the hot exhaust using one or more first heat exchangers; a plurality of capture vessels that are configured to be respectively cycled through a plurality of stages of a CO2-TSA process, including a CO2 capture stage, a regeneration stage, a drying stage, and a cooling stage, wherein the plurality of capture vessels are respectively coupled to the adsorption inlet for receiving the cold exhaust during the CO2 capture stage, wherein, while a first capture vessel of the plurality of capture vessels is configured in the drying stage, a second capture vessel of the plurality of capture vessels is configured in the CO2 capture stage, and wherein the second capture vessel is configured to, during the CO2 capture stage, receive the cold exhaust and absorb CO2 from the cold
  • a carbon capture system for CO2-TSA includes an engine configured to produce a hot exhaust; an adoption inlet arranged downstream from the engine and configured to receive a cold exhaust comprising a mixture of CO2 and N2, wherein the cold exhaust is derived from the hot exhaust using one or more first heat exchangers; a plurality of capture vessels that are configured to be respectively cycled through a plurality of stages of a CO2-TSA process, including a CO2 capture stage, a regeneration stage, a drying stage, and a cooling stage, wherein the plurality of capture vessels are coupled to the adoption inlet for receiving the cold exhaust during the CO2 capture stage; and a CO2 evaporative cooler configured to add water vapor to a CO2 stream, wherein the CO2 evaporative cooler is configured to receive the CO2 stream from a capture vessel of the plurality of capture vessels configured in the regeneration stage, add water vapor to the CO2 stream to produce a mixed stream of CO2 and water vapor, and provide the mixed stream of CO2 and water vapor to the
  • Fig. 1 illustrates a carbon capture system according to one or more implementations.
  • Fig. 2 shows an example cycle timing diagram of a CO2-TSA process using three capture vessels and a plurality of valves for a batch sequence.
  • Fig. 3 shows an example diagram showing flow directions of fluid flow and a process sequence in a capture vessel.
  • Fig. 4 illustrates a carbon capture system according to one or more implementations.
  • Fig. 5 shows a cross-section of a capture vessel according to one or more embodiments.
  • Figs. 6A-6E illustrate a carbon capture system according to one or more implementations.
  • Fig. 7 illustrates a carbon capture system according to one or more implementations.
  • Fig. 8 shows a four-stage process flow of a CO2-TSA process in a capture vessel according to one or more implementations.
  • Fig. 9 shows a structure of a CO2 evaporative cooler according to one or more implementations.
  • This disclosure relates to carbon capture, which is applicable to any machine, system, or plant that uses a combustion engine, such as a piston engine or a turbine engine.
  • the disclosure relates to a CO2 thermal swing adsorption (TSA) process with improved performance using CO2 and a CCb-turbocharger to drive the thermal swing adsorption process with reduced or zero electrical power.
  • TSA thermal swing adsorption
  • Carbon capture systems and methods of carbon capture are provided, which are applicable in general to distributed power applications in a 1- 40 megawatt (MW) range, which uses a CO2-TSA process, designed with a semiclosed cycle (SCC), but also applicable to other raw CO2 sources.
  • the carbon capture systems and methods use exhaust waste heat as part of the CO2-TSA process, and use thermal sinks and mixed water vapor and dry gas for improved CO2 capture.
  • the carbon capture systems and methods may provide as least one of the following benefits, including: (1) lower the cost of carbon capture in small distributed applications, generally between 1 and 40 MW per engine, targeting CO2 associated with semi -closed cycle techniques (e.g., a process that uses a combination of cooled exhaust recirculation and oxygen augmentation for reciprocating piston engines and/or gas turbine engines), but also applicable to other sources; (2) enable a use of high performance molecular sieves, in a TSA process, in a manner which does not dilute a purity of or reduce a capture efficiency of the CO2; (3) substantially reduce electrical and/or mechanical loads associated with the carbon capture; (4) improve a construction of TS A vessels to lower the cost of carbon capture and to minimize performance issues associated with leakage; (5) mitigate other pollutants, such as NOx, SOx, CO, HC; and (6) provide a solution suitable for new construction or retrofit application at lower cost.
  • semi -closed cycle techniques e.g., a process that uses a combination of cooled exhaust recirc
  • the carbon capture systems and methods target dilute CO2 streams (3-11% CO2 content) that exist in distributed power to gas turbines, lean burn piston engines (spark or compression ignited), and rich burn piston engines, with or without exhaust concentration of the SCC.
  • the carbon capture systems and methods may improve regeneration performance in CO2-TSA, reducing a time for regeneration and improving a percentage of carbon captured.
  • the improved regeneration performance in CO2-TSA may be accomplished via a use of a water vapor and CO2 mixture to provide both heat and a purge/displacement effect, which are created in a unique way.
  • some implementations, may include an N2-turbo component to improve dehydration.
  • a management of temperatures at a machinery inlet (e.g., at the CCh-turbocharger) may also be improved and new methods to reduce NOx and SOx are disclosed.
  • adsorption performance may be improved via improved cooling.
  • Fig. 1 illustrates a carbon capture system 100 according to one or more implementations.
  • the carbon capture system 100 includes components for a CO2-TSA processes with a semi -closed cycle.
  • the components may be interconnected by a plurality of manifolds that may be configured to carry one or more fluids (e.g., liquids, gases, or gas-liquid mixtures).
  • the carbon capture system 100 may include an O2 source 102 (e.g., an O2 plant) that provides O2, an air inlet and filter box 104 that provides air, an SCC path 106 that is used to provide a portion of cooled exhaust from an exhaust return path 108, an intake buffer tank 110, and an engine 112.
  • O2 source 102 e.g., an O2 plant
  • air inlet and filter box 104 that provides air
  • SCC path 106 that is used to provide a portion of cooled exhaust from an exhaust return path 108
  • an intake buffer tank 110 e.g., an engine 112.
  • the engine 112 e.g., a turbine engine, piston engine
  • the working fluid 114 used as an artificial atmosphere may be a mixture of air, oxygen, and cooled exhaust.
  • a mixed concentration of oxygen in the intake buffer tank is a variable, but generally falls in the range of 12-22% O2.
  • the engine 112 combusts the fuel in the artificial atmosphere to produce a hot exhaust (e.g., a hot flue gas).
  • the hot exhaust may flow through optional catalysts and supplemental combustion (block 116) to an exhaust heat exchanger (e.g., CO2 heat exchanger (CO2 HX) 118 or chiller 615).
  • CO2 heat exchanger CO2 heat exchanger (CO2 HX) 118 or chiller 615).
  • the exhaust heat exchanger partially cools the hot exhaust (e.g., to about 400° F).
  • the partially cooled exhaust is then mixed with colder water by a spray mixer 120, which quenches the partially cooled exhaust down to about 100° F.
  • the condensed water As a result, most of the water from combustion products in the exhaust condenses, and the condensed water is removed in a gas-liquid separator 122 (e.g., a direct contact cooler (DCC)).
  • a gas-liquid separator 122 e.g., a direct contact cooler (DCC)
  • the condensed water accumulates in a water storage tank 124 unless the condensed water is otherwise used or disposed of.
  • the condensed water may be used as make-up water in a cooling tower, eliminating or reducing a problem of water disposal.
  • the cooled exhaust (e.g., cold exhaust), now depleted of most of the water, returns to the intake buffer tank 110 via the SCC path 106 or to a TSA screw/blower 126 (fan) via a TSA path 128.
  • the SCC path 106 is part of an SCC exhaust loop that starts at the intake buffer tank 110, proceeds through the gasliquid separator 122 to the exhaust return path 108, and returns back through the SCC path to the intake buffer tank 110.
  • the SCC is used to increase CO2 concentration for an adsorption bed (e.g., for capture vessels TS3, TS4, and TS5) via exhaust recirculation.
  • a flowrate at the TSA screw/blower 126 which may be a variable speed drive or may include other methods of flow regulation, indirectly sets a level of exhaust recirculation, since an engine flowrate is essentially fixed.
  • CO2 that is not removed by the carbon capture system 100 may be recirculated, and a balance of the artificial atmosphere at the engine will be made up by air and/or oxygen.
  • Downstream of the TSA screw/blower 126 is a network of interconnected components that are responsible for performing the carbon capture via a CO2-TSA process.
  • a heat exchanger/chiller 130 typically cooling the cold exhaust to 35-50°F, which will cause more water present in the cold exhaust to condense, reducing a load on molecular sieves that follow.
  • a tank 131 may be connected immediately downstream from the heat exchanger/chiller 130 to separate the water from the cold exhaust.
  • Valves Tlln, T2In, T1X, T2X, T1D, T2D, TIC, T2C, T1H, T2H, T3In, T4In, T5In, T3D, T4D, T5D, T3X, T4X, T5X, T3T, T4T, T5T, T3C, T4C, T5C, T3H, T4H, T5H, and BPR are used to control a flow of one or more fluids throughout the carbon capture system 100.
  • An open state and a closed state of each of the valves may be controlled by a controller (not illustrated) according to one or more process stages of the CO2-TSA process.
  • three capture vessels TS3, TS4, or TS5 may be arranged in parallel, and the valves may be controlled such that a process stage at each one of the three capture vessels TS3, TS4, or TS5 (e.g., CO2 capture vessels) is controlled based on a batch sequence of the CO2-TSA process.
  • the valves may be controlled such that the capture vessel TS3 is in an adsorption stage (e.g., a capture stage), while the capture vessel TS4 is in a cooling stage and the capture vessel TS5 is a regeneration stage.
  • the valves may further be controlled such that the capture vessel TS4 is in an adsorption stage (e.g., a capture stage), while the capture vessel TS5 is in a cooling stage and the capture vessel TS3 is a regeneration stage.
  • the valves may further be controlled such that the capture vessel TS5 is in an adsorption stage (e.g., a capture stage), while the capture vessel TS3 is in a cooling stage and the capture vessel TS4 is a regeneration stage.
  • the batch sequence may then be repeated.
  • the capture vessels TS3, TS4, or TS5 may be referred to as “beds.”
  • Each capture vessel TS3, TS4, and TS5 may include media (e.g., capture media) that is configured to capture or adsorb CO2.
  • the media may also adsorb water.
  • a first step in the CO2-TSA process is a water dehydration process carried out by a blend of alumina and a 3 A mole sieve in adsorbent vessels TSAI and TSA2.
  • the water dehydration process is a batch type process.
  • Valves Tlln and T2In control which adsorbent vessel TSAI or TSA2 is receiving the cold exhaust from the heat exchanger/chiller 130.
  • valve Tlln is open, and the cold exhaust flows through the adsorbent vessel TSAI and out valve T1D, through another cooler P2T, to one of the capture vessels TS3, TS4, or TS5 for carbon capture.
  • the cold exhaust has essentially zero water, and is typically composed of 5- 20% CO2, 0-10% O2, and a balance inert mixture (e.g., nitrogen, with a little argon).
  • a balance inert mixture e.g., nitrogen, with a little argon.
  • valve T3In will be open, with valves T4In and T5In closed.
  • the exhaust gas now depleted of CO2 via the capture vessel TS3 and water via one of the adsorbent vessels TSAI and TSA2, flows out of the capture vessel TS3 via valve T3T, which is open, while valves T4T and T5T are closed.
  • the exhaust gas flowing out of the capture vessel TS3 is a relatively warm dry gas having a temperature around 80-160° F, and is composed mostly of N2 gas.
  • the exhaust gas flowing out of the capture vessel TS3 flows out of the capture vessel TS3 and through the valve T3T and may be manifolded to several locations.
  • this relatively warm dry gas that flows out of the capture vessel performing CO2 adsorption (e.g., capture vessel TS3) may be referred to as a dry N2 gas or depleted flue gas.
  • any excess dry N2 gas will be discharged to atmosphere via a CO2 TS A vent, controlled by a back pressure regulator of the valve BPR.
  • the backpressure is lower than a setpoint of the back pressure regulator and the valve BPR remains closed.
  • a portion of the dry N2 gas may be used to heat either adsorbent vessel TSAI or TSA2 (e.g., whichever adsorbent vessel is not adsorbing water, in this example adsorbent vessel TSA2), or to cool TSA2, depending on a cycle time.
  • the dry N2 gas may be directed through an N2 heater 134 (e.g., a heat exchanger) by opening one of the valves T1H or T2H and closing both valves TIC and T2C.
  • the dry (warm) N2 gas may be directed from the valve T3T to bypass the N2 heater 134 by opening one of the valves TIC or T2C and closing both valves T1H and T2H.
  • a design point is 8 hours for water adsorption (dehydration) in the adsorbent vessel TSAI and the adsorbent vessel TSA2
  • the adsorbent vessel TSAI would be set for adsorbing water for 8 hours, and, in parallel, the adsorbent vessel TSA2 would be first set for regeneration (heated) by opening valves T2H and T2X, using the heated dry N2 from the N2 heater 134, for about 4 hours, and then would be cooled, for about 4 hours, by opening valve T2C, while closing valve T2H with valve T2X still open.
  • the captured CO2 After the CO2 adsorption cycle is complete (e.g., in capture vessel TS3), the captured CO2 must be released during the regeneration stage. In a TSA process, releasing captured CO2 is done mostly via heating. In the present disclosure, that heating is provided by a hot gas mixture, which is mostly hot CO2 in this example delivered via valve T3H to the capture vessel TS3.
  • the hot CO2 is generally at 600-800° F.
  • the hot CO2 gas flows downward from a CO2- turbocharger 138, through valve T3H, and through the media in the capture vessel TS3, which gradually heats the media, and drives off more CO2.
  • the flowrate at the CO2 screw compressor 144 also generally variable speed, indirectly sets a pressure in the capture vessel TS3 during a desorption process of the regeneration stage.
  • a desorption flowrate required is much higher than a raw exhaust flowrate on both a mass and volume basis.
  • a pressure drop through the capture vessel would also be higher, up to 10 psi, vs. 1-2 psi for adsorption, resulting in high electrical loads.
  • the CO2 gas produced during the desorption process is recirculated to support these higher flowrates, and more importantly, a powering for a recirculation of the CO2 gas is performed by the CCb-turbocharger 138.
  • a turbocharger compressor 148 of the CCh-turbocharger 138 via manifold 149, boosted in pressure (e.g., to 15-25 psi), raising the temperature of the CO2 gas to 300° F or more.
  • the manifold 149 connects capture vessel TS3, TS4, and TS5 to the turbocharger compressor 148 of the CCh-turbocharger 138 to transport a CO2 stream of CO2 gas generated by a capture vessel set in the regeneration stage to the turbocharger compressor 148.
  • the heated CO2 gas from the turbocharger compressor 148 then enters the CO2 heat exchanger (CO2 HX) 118, and is heated to near raw exhaust temperature, typically 800-900° F, by a heat exchange process that uses the exhaust from the engine 112 for further heating the heated CO2 gas to produce hot CO2 gas.
  • This hot CO2 gas is then expanded through an expander 150 (e.g., a decompressor) of the CCh-turbocharger 138 (which causes the temperature of the hot CO2 to drop due to less pressure).
  • the CO2 gas exiting the expander 150 still has a temperature equal to or greater than 600° F that is sufficient for the regeneration process, and still at a pressure high enough to support a flow through the capture vessel TS3, TS4, or TS5 that is performing the regeneration (e.g., capture vessel TS3 in this example).
  • a pressure increase on a compressor side of the CCh-turbocharger 138 significantly exceeds a pressure decrease on an expander side of the CCh- turbocharger 138, such that a pressure of the CO2 gas exiting the expander 150 toward the capture vessel TS3, TS4, or TS5 is high enough to support the flow of the CO2 gas through the capture vessel TS3, TS4, or TS5 that is performing the regeneration.
  • the expander 150 may be respectively coupled to the capture vessels TS3, TS4, TS5 via manifolds 152, 154, and 156 to provide a heated CO2 gas to a capture vessel that is set in the regeneration stage. At an end of the regeneration process, virtually no CO2, and almost no water, remains in the capture vessel TS3, TS4, or TS5 that is performing the regeneration (e.g., the capture vessel TS3).
  • the media (e.g., the mole sieve) of the capture vessel TS3, TS4, or TS5 is hot, typically with an average temperature of about 500° F, and must be cooled to prepare the capture vessel for a next CO2 adsorption cycle.
  • a cooling process for the capture vessel TS3 is accomplished by opening valves T3C and T3X, while closing valves T3In, T3T, T3H, and T3D.
  • the dry (warm) N2 gas that exits the capture vessel set in the adsorbing stage e.g., capture vessel TS5 for cooling of capture vessel TS3 is directed into the capture vessel TS3 for cooling the media of the capture vessel TS3.
  • the cooling process need not return the media temperature fully to ambient temperature. Any temperature under 100° C (212° F) will provide some capacity for initial adsorption of CO2, with temperatures near or below 50° C (122° F) being preferred.
  • the cooling process may continue in parallel with the adsorption process to some extent since a raw exhaust stream from cooler P2T (e.g., a heat exchanger) is provided at nominally 10° C (50° F).
  • the carbon capture system 100 may include a coolant tank 158 or another coolant source or circulator that is configured to circulate coolant through a capture vessel (e.g., capture vessels TS3, TS4, or TS5) that is configured in an adsorption stage.
  • the coolant may be circulated through a coil of an inter-exchanger of the capture vessel, as described further in connection with Fig. 5, while the capture vessel is performing CO2 adsorption.
  • the inter-exchanger may be used to circulate the coolant in the capture vessel during the cooling stage.
  • Fig. 2 shows an example cycle timing diagram 200 of the CO2- TSA process using capture vessels TS3, TS4, and TS5, including a state of each of the valves during each stage, including the adsorption stage, the cooling stage, and the regeneration stage of the batch sequence.
  • Fig. 3 shows an example diagram 300 showing flow directions of fluid flow and a process sequence in a capture vessel (e.g., capture vessel TS3).
  • the directions of fluid flow correspond to directions in Fig. 1, where an upward flow corresponds to a flow from a bottom of the capture vessel to a top of the capture vessel (e.g., away from valves T3X, T4X, and T5X), and downward flow corresponds to a flow from the top of the capture vessel to the bottom of the capture vessel (e.g., toward valves T3X, T4X, and T5X).
  • Fig. 4 illustrates a carbon capture system 400 according to one or more implementations.
  • the carbon capture system 400 is similar to the carbon capture system 100 described in connection with Fig.
  • the capture vessels TS3, TS4, and TS5 are used for both adsorbing water for dehydration and for adsorbing (capturing) CO2.
  • the capture vessels TS3, TS4, and TS5 additionally perform the water dehydration process carried out by the adsorbent vessels TSAI and TSA2 described in connection with Fig. 1.
  • Fig. 5 shows a cross-section of a capture vessel 500 according to one or more embodiments.
  • the capture vessel 500 may be used for CO2 adsorption during a CO2-TSA process.
  • the capture vessel 500 may correspond to any one of the capture vessels TS3, TS4, and TS5 described in connection with Fig. 1.
  • the capture vessel 500 includes an upper flange 502, an upper perforated baffle 504, an upper guard 506 of dehydrating media, an upper capture media 508 (e.g., an upper bed), an inter-exchanger 510, a lower capture media 512 (e.g., a lower bed), a lower guard 514 of dehydrating media, a media support screen 516, a lower perforated baffle 518, and a lower flange 520.
  • the inter-exchanger 510 is arranged between and in thermal contact with the upper capture media 508 and the lower capture media 512.
  • the interexchanger 510 is configured to reduce temperature in the upper capture media 508 and/or the lower capture media 512 during CO2 adsorption and is configured to aid in cooling during CO2 adsorption.
  • the interexchanger 510 may be enabled during the cooling stage.
  • the interexchanger 510 may be used to circulate the coolant in the capture vessel during the cooling stage to aid in cooling of the media.
  • the upper guard 506 and the lower guard 514 include dehydrating media that has an affinity for water.
  • the exhaust gas from the adsorption inlet 132 may flow into the capture vessel 500 via the upper flange 502 or via the lower flange 520.
  • the upper guard 506 or the lower guard 514 that initially receives the exhaust gas from the adsorption inlet 132 removes water from the exhaust gas to dehydrate the exhaust gas going to the upper capture media 508 and/or the lower capture media 512.
  • the lower capture media 512 will start to capture CO2 before the upper capture media 508 starts to capture CO2.
  • the capture vessel 500 Prior to adsorption the capture vessel 500 is cooled during the cooling stage to increase a capture capacity of the upper capture media 508 and the lower capture media 512.
  • adsorption of CO2 causes the capture media 508 and 512 to release heat, causing a temperature of the capture media to rise.
  • the lower capture media 512 will start to capture CO2 first and start to release heat, the heat released as a result of the CO2 adsorption at the lower capture media 512 may flow toward the upper capture media 508 and lower the capture capacity of the upper capture media 508 due to an increase in temperature at the upper capture media 508.
  • This thermal wave associated with a heat of CO2 adsorption can decrease a capture efficiency of a CO2 capture system. For example, higher temperatures cause a capture efficiency of a capture media to decrease. High enough temperatures (e.g., temperatures exceeding a temperature threshold) may render a capture media inert for CO2 capture.
  • the inter-exchanger 510 may include at least one coil 522 or exchanger bundle configured to carry a coolant.
  • the coil 522 may circulate the coolant through the inter-exchanger 510 to absorb or otherwise take away heat generated in the lower capture media 512 and/or the upper capture media 508 during CO2 adsorption.
  • the coolant may be a cool fluid (e.g., a cool gas, liquid, or fluid mixture) that flows from in inlet to an outlet of the interexchanger 510 to carry heat out of the capture vessel 500 during the adsorption stage.
  • the coolant may be injected into the inter-exchanger 510 when it is desired to lower a temperature of the lower capture media 512 and/or the upper capture media 508.
  • the coil 522 is configured to maintain separation of the coolant from the capture media such that the coolant does not physically interact with the capture media or the exhaust gas flowing through the capture vessel 500.
  • the coil 522 is embedded in the capture media such that the lower capture media 512 and the upper capture media 508 are not physically separated from each other. Instead, the capture media may be filled around the coil 522.
  • the inter-exchanger 510 may be arranged to provide contact between individual bed media pellets and a heat transfer surface of the coil 522.
  • the coil 522 of the inter-exchanger 510 may be made of stainless steel or another lightweight alloy construction, consistent with temperature excursions of the regeneration process.
  • the inter-exchanger 510 may maintain temperatures in the lower capture media 512 and/or the upper capture media 508 below 150° F, which may be a temperature at which the capture capacity of the capture media is significantly reduced, made substantially inefficient, and/or made inert or substantially inert.
  • the inter-exchanger 510 distributed internally within the capture vessel 500, is configured to manage the thermal wave associated with the heat of adsorption by lowering the temperature of the lower capture media 512 and/or the upper capture media 508 to increase the capture capacity of the capture vessel 500 during the adsorption stage.
  • the inter-exchanger 510 may assist in significantly reducing a carbon footprint of a gas turbine engine or a piston engine as a result of achieving a high CO2 capture percentage, generally greater than 95%.
  • Greenhouse gases include CO2, NOx, and SOx that make part of acid rain and/or attack the ozone layer, as well as unburnt hydrocarbon HC (e.g., methane and non-methane), and any partial products of combustion, like aldehydes.
  • Carbon monoxide while not commonly considered a greenhouse gas, is a regulated pollutant that converts in the atmosphere quickly to form CO2.
  • Fig. 6A illustrates a carbon capture system 600 according to one or more implementations.
  • Fig. 6B illustrates a fluid flow path used during a CO2 adsorption stage of a CO2-TS A process in the carbon capture system 600 and is similar to the CO2 adsorption stage described in connection with Fig 1.
  • Fig. 6C illustrates a fluid flow path used during a regeneration stage of the CO2-TSA process in the carbon capture system 600.
  • Fig. 6D illustrates a fluid flow path used during a drying stage of the CO2-TSA process in the carbon capture system 600.
  • Fig. 6E illustrates a fluid flow path used during a cooling stage of the CO2- TSA process in the carbon capture system 600.
  • the carbon capture system 600 adds additional components and manifolds to the carbon capture system 400 described in connection with Fig. 4.
  • the carbon capture system 600 includes an N2 heat exchanger (N2 HX) 602, an N2-turbocharger 604 that includes a compressor 606 and an expander 608, a valve HN2, a valve CN2, a valve CO2R, and a CO2 evaporative cooler (CO2 EVC) 610, a direct air capture (DAC) inlet fan 612, and a valve AC.
  • N2 HX N2 heat exchanger
  • N2-turbocharger 604 that includes a compressor 606 and an expander 608, a valve HN2, a valve CN2, a valve CO2R, and a CO2 evaporative cooler (CO2 EVC) 610, a direct air capture (DAC) inlet fan 612, and a valve AC.
  • DAC direct air capture
  • the compressor 606 may be arranged at an inlet of the N2-turbocharger 604 and is coupled to adsorption outlet 614 of the capture vessels TS3, TS4, and TS5 via manifold 616.
  • the expander 608 may be arranged at an output of the N2- turbocharger 604 and is coupled to an inlet 618 of the capture vessels TS3, TS4, and TS5 via manifold 620.
  • an ABS chiller heat exchanger (HX) 615 is provided to chill the exhaust exiting the CO2 heat exchanger (CO2 HX) 118.
  • the CO2 evaporative cooler (CO2 EVC) 610 is arranged between valves T3D, T4D, and T5D and the CCh-turbocharger 138.
  • optional valves Pl in, P2in, P1V, P2V, P1D, P2D are added, as well as optional PSA vessels PSI and PS2.
  • a drying cycle (e.g., a hot drying cycle) is added after the regeneration stage and before the cooling stage of the batch sequence of the CO2-TS A process described in connection with Fig. 1.
  • a capture vessel e.g., TS3, TS4, or TS5
  • water may be used during the regeneration stage (e.g., a wet regeneration).
  • a change in a regeneration flow direction may be reversed, as compared to the flow direction for regeneration shown in Fig. 3.
  • the flow direction for regeneration may be a flow from the top to the bottom of the capture vessel.
  • the flow direction for wet regeneration may be a flow from the bottom to the top of the capture vessel. This may be accomplished by reconfiguring a piping manifold and/or changing a state of one or more valves to achieve a desired flow direction through the capture vessel.
  • a temperature at a bed exit may vary at an inlet of the CCh-turbocharger 138 from about 100° F to greater than 500° F during the regeneration process.
  • a rate of CO2 production may also change from a negative rate (e.g., capture vessel adsorbing CO2 early in the regeneration process) to a very high rate, over 1.5 times an average rate, through much of the regeneration process.
  • about 10% of the captured CO2 may remain in the capture vessel TS3, TS4, or TS5, even after regeneration performed at greater than 600° F.
  • the CO2-TS A process is a batch process. Whether using a three-stage adsorption, regeneration, and cooling process or a four-stage adsorption, regeneration, drying, and cooling process, the production of CO2 will not be constant, but will occur only during the regeneration process, and generally only later in the regeneration process, after the relevant capture vessel TS3, TS4, or TS5 has warmed up. However, a constant flowrate of CO2 is preferred over an uneven flowrate of CO2. Accordingly, valve CO2R may be provided to allow for recycling CO2 during regeneration.
  • the valve CO2R may function as a pressure regulator, opening to prevent the capture vessel TS3, TS4, and TS5 from going into a high vacuum condition during an instant when a capture value switches from adsorption to regeneration, and partial pressure of CO2 in the capture value increases dramatically.
  • Fig. 6A shows a final dehydration via PSA after the capture process
  • CO2 EVC CO2 evaporative cooler
  • vessels PSI and PS2 loaded with a ceramic like alumina, that will serve to both regulate the temperature at the inlet of the CO2 turbo and to dehydrate the product CO2 before returning to the CO2 heat exchanger (CO2 HX) 118 and the capture vessels TS3, TS4, and TS5.
  • CO2 HX CO2 heat exchanger
  • CO2 is lacking in a main regeneration loop (e.g., the CO2 recirculation loop) shown in Fig. 6C and it would take some time for enough CO2 to be present for the C Ch-turbocharger 138 in the main regeneration loop to become effective.
  • the CO2 storage tank 146 may be used in a secondary regeneration loop to provide additional CO2 (e.g., auxiliary CO2) to the CCh -turbocharger 138 during the initial start of the regeneration stage.
  • valve CO2R may be opened to allow CO2 stored in the CO2 storage tank 146 to be injected into a main regeneration loop. After a predetermined duration, valve CO2R may be closed.
  • the replenished CO2 supply may be used for the initial start of a next regeneration stage (e.g., regeneration of the next capture vessel) by opening the CO2R valve.
  • the secondary regeneration loop includes a CO2 source (e.g., the CO2 storage tank 146) that may be configured to inject the auxiliary CO2 into the CO2 stream of the main regeneration loop during an initial time interval of the regeneration stage.
  • the CO2 source may be configured to siphon off a portion of the CO2 stream from the main regeneration loop during a remaining time interval of the regeneration stage to replenish the CO2 supply that may be used for the initial start of a next regeneration stage (e.g., for a next capture vessel that enters into the regeneration stage).
  • valve CO2R and the CO2 storage tank 146 may be used to increase an amount of CO2 in the main regeneration loop that flows into the CO2 evaporative cooler (CO2 EVC) 610 in order to decrease an amount of time until the CCh-turbocharger 138 becomes effective for regeneration of a capture vessel.
  • CO2 EVC CO2 evaporative cooler
  • the CO2 evaporative cooler (CO2 EVC) 610 may be used during the regeneration stage to provide wet regeneration of a respective capture vessel TS3, TS4, or TS5.
  • the CO2 evaporative cooler (CO2 EVC) 610 may introduce water vapor into a CO2 stream in order to improve a CO2 release at the respective capture vessel by displacing adsorbed CO2 with adsorbed water vapor. Heat is created during the adsorption of the water vapor, which raises the bed temperature, and which further accelerates CO2 release from the respective capture vessel.
  • the CO2 evaporative cooler (CO2 EVC) 610 regulates a temperature of the CO2 flowing into the turbocharger compressor 148 by cooling the CO2.
  • CO2 EVC CO2 evaporative cooler
  • a temperature variation at the inlet of the CCh-turbocharger 138 is reduced.
  • temperatures exceeding 400° at the inlet of the CCb-turbocharger 138 may not be acceptable and may cause failure.
  • a maximum temperature of the CO2 flowing into the inlet of the CCb-turbocharger 138 may be reduced to be closer to 100° (e.g., to be less than 300° F).
  • the CO2 evaporative cooler (CO2 EVC) 610 provides temperature control for the inlet of the CCb-turbocharger 138.
  • the CO2 evaporative cooler (CO2 EVC) 610 may be a DCC. As shown in Fig. 6C, a portion of the warm CO2 that exits a capture vessel (e.g., the capture vessel TS3) during regeneration is provided to the CO2 evaporative cooler (CO2 EVC) 610 as an inlet CO2 gas. A saturated gas mixture of CO2 and water vapor exits the CO2 evaporative cooler (CO2 EVC) 610 to the CO2- turbocharger 138 for wet regeneration. The saturated gas mixture of CO2 and water vapor has a reduced temperature relative to the warm CO2 that exits the capture vessel.
  • a capture vessel e.g., the capture vessel TS3
  • CO2 EVC CO2 evaporative cooler
  • a source of water for the CO2 evaporative cooler (CO2 EVC) 610 in cases where water is used for regeneration, can be condensed water from the engine exhaust stored in the water storage tank 124.
  • CO2 evaporative cooler (CO2 EVC) 610 is operated with the water from the water storage tank 124 shut off, a temperature coming out of a capture vessel (e.g., the capture vessel TS3) may vary from 100-500° F and is moderated based on a thermal capacity of a ceramic of the capture vessel.
  • an inlet temperature e.g., less than 300° F
  • the CO2- turbocharger 138 e.g., an inlet temperature of the turbocharger compressor 1448 is acceptable.
  • the CO2 evaporative cooler (CO2 EVC) 610 acts as a very effective counter flow heat exchanger. Given a low temperature out of the CO2 evaporative cooler (CO2 EVC) 610, a percentage of water vapor in the saturated gas mixture of CO2 and water vapor will be low. For example, at 100° F, a water vapor percentage may be under 7% by volume and under 3% by weight. Nevertheless, the water vapor is present as the saturated gas mixture of CO2 and water vapor exits the expander 150 of the CCh-turbocharger 138 and is provided to the capture vessel that is performing the regeneration (e.g., the wet regeneration).
  • the regeneration e.g., the wet regeneration
  • the C Ch-turbocharger 138 is configured to receive the saturated gas mixture of CO2 and water vapor from the evaporative cooler (CO2 EVC) 610, and heat the saturated gas mixture of CO2 and water vapor using the CO2 heat exchanger (CO2 HX) 118 in order to provide a hot mixed stream of CO2 and water vapor to the capture vessel that is configured in regeneration (e.g., a same capture vessel that produces the CO2 stream that is mixed with the water vapor by the evaporative cooler (CO2 EVC) 610).
  • CO2 EVC evaporative cooler
  • CO2 HX CO2 heat exchanger
  • the CO2 evaporative cooler (CO2 EVC) 610 can also be operated with water on only a percentage of a regeneration cycle. If the water is turned on late during regeneration, when a ceramic mass transfer media of the CO2 evaporative cooler (CO2 EVC) 610 is already hot, a large percentage of water vapor can be created, since a partial pressure of water vapor is 14.7 pounds per square inch absolute (PSIA) at 212° F.
  • PSIA pounds per square inch absolute
  • the water vapor acts like a purge gas (e.g., a water vapor purge gas), but without reducing a dry purity of the CO2 gas that exits the capture vessel.
  • a purge gas e.g., a water vapor purge gas
  • the water vapor purge derived from an output of the CO2 evaporative cooler (CO2 EVC) 610 is configured to increase a temperature associated with the wet regeneration stage.
  • the net result is that the percentage of carbon captured during adsorption vs. released/produced during regeneration can be increased from nominally 90% (without the CO2 evaporative cooler (CO2 EVC) 610) to greater than 95% (with the CO2 evaporative cooler (CO2 EVC) 610).
  • the N2 heat exchanger (N2 HX) 602 and the N2-turbocharger 604 are provided for the drying stage (e.g., hot drying) of the CO2-TSA process.
  • the N2-turbocharger 604 is associated with the N2 heat exchanger (N2 HX) 602 and is configured to reduce a power duty.
  • a hot dry gas 622 is created from a gas 624 (e.g., the dry N2 gas) provided after CO2 adsorption, which exits the capture vessel TS3, TS4, or TS5 at valve T3T, T4T, or T5T, respectively.
  • the dry N2 gas 624 is provided to the compressor 606 of the N2-turbocharger 604 by opening valve HN2 and closing valve CN2.
  • the compressor 606 is connected to the adsorption outlet 614 of the capture vessels TS3, TS4, and TS5 and is configured to receive the dry N2 gas 624 from the capture vessel set in the CO2 adsorption stage via manifold 616.
  • the dry N2 gas 624 enters the N2-turbocharger 604, where the compressor 606 compresses the dry N2 gas 624 to produce compressed N2 gas.
  • the N2 heat exchanger (N2 HX) 602 uses the hot exhaust from the engine 112 to heat the compressed N2 gas to produce heated (compressed) N2 gas.
  • the expander 608 of the N2-turbocharger 604 then expands the heated N2 gas, which results in a drop in temperature of the heated N2 gas, but the heated N2 gas remains sufficiently high with sufficient pressure to be used for hot drying of a respective capture vessel.
  • the expander 608 is configured to output the hot dry gas 622 that is provided to the capture vessel that is set in the drying stage (e.g., capture vessel TS5).
  • the hot dry gas 622 may be delivered from the expander 608 to the inlet 618 of the capture vessels TS3, TS4, and TS5 via manifold 620.
  • the hot dry gas 622 is delivered to the capture vessel that is
  • the exhaust temperature from the engine 112 can be near 900° F, and given the characteristics of the N2-turbocharger 604 and the N2 heat exchanger (N2 HX) 602, it is possible to create a hot dry gas 622 that is mostly N2 gas and has a temperature that is greater than 600° F for the drying process.
  • the drying process may be used to dry the media of the capture vessel after wet regeneration. For example, in order for a capture vessel to again be able to sufficiently adsorb CO2, the water adsorbed during wet regeneration should be released from the capture vessel.
  • the drying process may be used to release the water as water vapor via evaporation and moving the water vapor out of the capture vessel.
  • the N2-turbocharger 604 may be driven exclusively or mostly via engine waste heat (e.g., from the hot exhaust from the engine 112). As a result, little or no mechanical or electrical power is needed to sustain the drying process.
  • N2 heat exchanger (N2 HX) 602 and the CO2 heat exchanger (CO2 HX) 118 are shown in series, in some implementations, the exhaust flow from the engine could be split. As result, the N2 heat exchanger (N2 HX) 602 and the CO2 heat exchanger (CO2 HX) 118 could be provided in parallel, resulting in both the N2 heat exchanger (N2 HX) 602 and the CO2 heat exchanger (CO2 HX) 118 providing a respective hot gas (e.g., a CO2 turbo hot gas and an N2 turbo hot gas) at temperatures greater than 600° F.
  • a respective hot gas e.g., a CO2 turbo hot gas and an N2 turbo hot gas
  • a number of capture vessels need not align with a number of stages.
  • three capture vessels TS3, TS4, and TS5 are used for the four-stage adsorption, regeneration, drying, and cooling process.
  • a second capture vessel can perform regeneration (e.g., wet regeneration) during the same process time slot.
  • a third capture vessel can perform both drying and cooling during the same process time slot, with drying being performed during a first portion of the process time slot and cooling performed during a second portion of the process time slot.
  • each capture vessel may be provided, with each capture vessel being allocated one of the four stages during a process time slot.
  • five or six capture vessels may be provided with additional In, T, C, H, D, and X valving and manifolds.
  • two capture vessels may be used simultaneously for a process that takes longer, such as adsorption or cooling, and only a single capture vessel used for a shorter process, such as regeneration or drying.
  • Valves HN2 and CN2 may allow the carbon capture system 600 to deliver either hot dry gas 622 for the drying process (valve HN2 open and valve CN2 closed) or deliver a cool mixture of N2 and air (e.g., cooled N2 gas 630) for the cooling process (valve CN2 open and valve HN2 closed).
  • a cool mixture of N2 and air e.g., cooled N2 gas 630
  • the four stages can be accomplished, for example, by splitting a drying time and a cooling time for a single capture vessel.
  • the cooling stage may be performed according to Fig. 1.
  • the cooling stage may be performed according to Fig. 6E.
  • the dry N2 gas 624 that exits the capture vessel that is set in the adsorbing stage (e.g., capture vessel TS3) is circulated through the valve CN2, through a chiller 626 for further cooling, though a cooler tank 628 by the TSA screw/blower 126 and to one of the capture vessels TS3, TS4, or TS5.
  • valve HN2 is closed and valve CN2 is open to redirect the dry N2 gas 624 for cooling instead of for drying.
  • the DAC inlet fan 612 is used to introduce outside air into the N2 flow.
  • cooled N2 gas 630 that is mixed with outside air, is provided from the cooler tank 628, to the inlet 618, and passed through the capture vessel that is set in the cooling stage (e.g., capture vessel TS5) and exits though an exit valve (e.g., valve T5X).
  • an exit valve e.g., valve T5X
  • Fig. 7 illustrates a carbon capture system 700 according to one or more implementations.
  • the carbon capture system 700 is similar to the carbon capture system 600 described in connection with Figs. 6A-6E, with the exception that a chiller 702 (e.g., a heat exchanger) and a valve N2R (N2 recycle) are provided between the TSA path 128 and the adsorption outlet 614 that is connected to valves T3T, T4T, T5T, HN2, CN2.
  • a chiller 702 e.g., a heat exchanger
  • N2R N2 recycle
  • the SCC exhaust loop may be used to increase CO2 concentration for an adsorption bed (e.g., for capture vessels TS3, TS4, and TS5) via exhaust recirculation.
  • the SCC has the purpose of concentrating the CO2 in the exhaust, to improve capture performance.
  • higher CO2 concentration reduces a size of capture equipment.
  • a combination of heat of adsorption of water and heat of adsorption of CO2 can result in higher than desired temperatures in a bed (e.g., in a capture vessel) during the CO2 adsorption process. In these cases, reducing a bed temperature during adsorption will improve performance.
  • Valve N2R may be provided to divert some of the dry N2 gas 624 (e.g., the depleted flue gas) generated during CO2 adsorption from the capture vessel to the TSA screw/blower 126 in order to dilute the cold exhaust flowing into the TSA screw/blower 126 from the TSA path 128.
  • the dry N2 gas 624 which is substantially depleted of CO2, is added to the cold exhaust, which results in an amount of CO2 by volume to be decreased at the adsorption inlet 132.
  • the dry N2 gas 624 may be used as a diluent gas (e.g., a cold diluent gas).
  • the cold exhaust flowing into the adsorption inlet 132 may be referred to as a diluted exhaust gas or diluted flue gas, where the amount of CO2 has been diluted by a recycling of the dry N2 gas 624 that is created during the adsorption stage.
  • the dry N2 gas may flow from the adsorption outlet 614, to the N2R valve, and may cooled by the chiller 702 to produce the cold diluent gas.
  • the dry N2 gas 624 may be returned to the adsorption inlet 132, artificially reducing a concentration of CO2 to create diluted flue gas in adsorption inlet 132 and lowering a temperature of a capture vessel during CO2 adsorption. Lowering a temperature of a capture vessel during CO2 adsorption aids in the CO2 adsorption.
  • the CO2 concentration may be increased via exhaust gas recirculation in the SCC exhaust loop, or the CO2 concentration may be reduced with N2 recirculation via valve N2R.
  • the carbon capture system 700 has the ability to get to achieve an optimum CO2 concentration for carbon capture.
  • gas turbines may require a CO2 concentration increase, since the gas turbines run on around 3% CO2, while some piston engines or gas turbines with heavy supplemental firing, may require a reduction in the CO2 concentration.
  • the SCC exhaust loop and/or the N2 recirculation loop via value N2R may be used to control the CO2 concentration at the capture vessels TS3, TS4, and TS5.
  • the use of the SCC exhaust loop and/or the N2 recirculation loop is optional.
  • Fig. 8 shows a four-stage process flow 800 of a CO2-TSA process in a capture vessel according to one or more implementations.
  • the four-stage process flow 800 includes a capture stage 805 (e.g., a CO2 adsorption stage), followed by a wet regeneration stage 810, followed by a hot drying stage 815, and followed by a cooling stage 820.
  • the four-stage process flow 800 may be implemented by the carbon capture system 600 or the carbon capture system 700.
  • a direction of flowrate or flow in the capture vessel may be switched from top-down to bottom-up during regeneration.
  • a change in direction flowrate to a bottom-up direction may improve regeneration because most of the water that is adsorbed into the media of the capture vessel will be adsorbed into a bottom portion of the bed, creating a hot zone at the bottom portion of the bed that heats the gas flowing to the rest of the bed. This may also make drying the bed easier.
  • a drying process may be required. For example, drying is needed for designs that provide continuous water use in the CO2 evaporative cooler (CO2 EVC) 610, but may also be used for designs that only use a brief purge of water vapor late in regeneration. While some drying would occur using the warm depleted exhaust gas (mostly N2) (e.g., cooled N2 gas 630), and some drying would even occur using air, the best drying performance will exist with use of the hot dry gas 622, as shown in Fig. 6D. Structure of CO2 Evaporative Cooler (CO2 EVC)
  • Fig. 9 shows a structure of a CO2 evaporative cooler (CO2 EVC) 900 according to one or more implementations.
  • the CO2 evaporative cooler (CO2 EVC) 900 may correspond to the CO2 evaporative cooler (CO2 EVC) 610 described in connection with Figs. 6A-6E.
  • the CO2 evaporative cooler (CO2 EVC) 900 may be a direct contact cooler (DCC).
  • the gas-liquid separator 122 which may also be a DCC, may have a similar structure.
  • the CO2 evaporative cooler (CO2 EVC) 900 may include an inlet 902 for receiving the inlet CO2 gas described in connection with Fig. 6C.
  • the inlet CO2 gas from the CO2 regeneration flows around a skirt 904, into an area 906 where a percentage of cooling water can optionally be sprayed by water from the water storage tank 124, reducing a temperature of the inlet CO2 gas, akin to a desuperheater.
  • the cooler gas then flows through a mass transfer packing 908, where additional water spray above creates a counter flow effect.
  • the mass transfer packing 908 may function as a buffer that is made of stainless steel, plastic, or ceramic (e.g., ceramic mass transfer media of ’A inch ceramic balls).
  • a temperature of the saturated gas mixture of CO2 and water vapor that exits from a top of the CO2 evaporative cooler (CO2 EVC) 900 can be quite low relative to the inlet CO2 gas.
  • CO2 EVC CO2 evaporative cooler
  • a 600° F CO2 that enters the inlet 902 can be cooled to near 100° F by the water spray at the output of the CO2 evaporative cooler (CO2 EVC) 900, where the saturated gas mixture of CO2 and water vapor will leave the CO2 evaporative cooler (CO2 EVC) 900.
  • Fig. 9 is provided as an example. Other examples may differ from what is described with regard to Fig. 9.
  • the described implementations significantly reduce the carbon footprint of gas turbine and piston engine operations as a result of achieving a high CO2 capture percentage, generally greater than 95%, with the combination of techniques disclosed herein.
  • the greenhouse gas problem is not just CO2, it includes gases such as NOx and SOx that make part of acid rain and attack the ozone layer, as well as unburnt hydrocarbon (methane and non-methane) and any partial products of combustion, like aldehydes.
  • Carbon monoxide while not commonly considered a greenhouse gas, is a regulated pollutant that converts in the atmosphere quickly to form CO2, and thus must also be addressed.
  • CO2-TSA processes described herein have a capability to also capture CO, HC, NOx with an appropriate media choice. However, if CO, HC, NOx gases are captured, CO, HC, NOx must be tolerable as contaminants in the CO2. CO and HC are allowed, but frequently NOx and SOx are not allowed at high concentration, since they could combine with other gases and create a corrosive mixture.
  • catalysts in the optional catalysts and supplemental combustion may be optionally used after the engine 112.
  • Catalysts at block 116 and a DCC e.g., gas-liquid separator 122
  • oxidation catalysts which would convert CO to CO2, and HC to CO2 and H2O, are low cost and may be implemented.
  • a selective catalytic reduction (SCR) process may be used for NOx control, usually using urea or ammonia to reduce the NOx.
  • oxidation catalysts are used to convert NO gas (typically 85% of engine NOx output) to NO2 gas.
  • a larger oxidation catalyst would enable a larger conversion percentage of NO gas to NO2 gas, as well as conversion from SO2 to SO3.
  • these conversions are unimportant, unless they are pre-requisites to good SCR operation, but in the instance of this disclosure, and of the SCC in general, the exhaust is water washed in the gas-liquid separator 122 (e.g., DCC), which may have a similar construction to the CO2 evaporative cooler (CO2 EVC) 900, but may use a non-ceramic high void area mass transfer packing (e.g., stainless steel or plastic).
  • the gas-liquid separator 122 e.g., DCC
  • CO2 EVC CO2 evaporative cooler
  • An artifact of the SCC process is exhaust scrubbing, resulting in NOx that would normally be emitted as a gas being scrubbed out into the condensate.
  • the amount of NOx reduction, pre-capture will be a function of the conversion efficiency of NO to NO2 in the catalyst, but conversion efficiencies of over 90% are possible, resulting in about a 10 times reduction in NOx into the capture system, and NOx release into the atmosphere, or into the CO2 product in lieu of release into the atmosphere.
  • the net result of the carbon capture systems and methods described herein to the CO2-TSA process is a reduction in CO2 emissions, which could exceed 95%, not including the CO2 captured from air as part of the cooling process, and reductions in other engine emissions by up to a factor of 10.
  • activated carbon vs. a conventional mole sieve will reduce the heat of adsorption related to water and can also limit the number of pollutants captured in cases where the CO2 purity requirements are not tolerant of the level of pollutants.
  • Activated carbon can be used as a substitute for mole sieve, or as a blend with mole sieve within the present disclosure.
  • activated carbon may be used in the capture vessel TS3, TS4, and TS5, and/or in a vessel of the CO2 evaporative cooler (CO2 EVC) 610.
  • the carbon capture system 600 may be designed without a mole sieve.
  • a,” “an,” and a “set” are intended to include one or more items, and may be used interchangeably with “one or more.”
  • the article “the” is intended to include one or more items referenced in connection with the article “the” and may be used interchangeably with “the one or more.”
  • the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
  • the term “or” is intended to be inclusive when used in a series and may be used interchangeably with “and/or,” unless explicitly stated otherwise (e.g., if used in combination with “either” or “only one of’).
  • spatially relative terms such as “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures.
  • the spatially relative terms are intended to encompass different orientations of the apparatus, device, and/or element in use or operation in addition to the orientation depicted in the figures.
  • the apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

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  • Treating Waste Gases (AREA)

Abstract

Un système de capture de carbone destiné à une adsorption à température modulée (TSA) de dioxyde de carbone (CO2) comprend un moteur conçu pour produire un échappement chaud ; une pluralité de récipients de capture qui sont conçus pour être respectivement cyclisés à travers une pluralité d'étages d'un processus de TSA CO2 ; un échangeur de chaleur à N2 conçu pour recevoir l'échappement chaud ; et un turbocompresseur à N2 raccordé à l'échangeur de chaleur à N2. Le turbocompresseur à N2 est conçu pour recevoir un gaz N2 provenant d'un premier récipient de capture, chauffer le gaz N2 par l'intermédiaire de l'échangeur de chaleur à N2 par échange thermique avec l'échappement chaud pour produire un gaz N2 chauffé, et fournir le gaz N2 chauffé à un second récipient de capture afin de sécher le milieu de capture du second récipient de capture.
PCT/US2023/072054 2022-08-19 2023-08-11 Système d'adsorption à température modulée de co2 à régénération humide et séchage à chaud WO2024040000A1 (fr)

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US202263371899P 2022-08-19 2022-08-19
US63/371,899 2022-08-19
US18/361,195 US20240058740A1 (en) 2022-08-19 2023-07-28 System and method of co2 thermal swing adsorption with wet regeneration and hot drying
US18/361,195 2023-07-28

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1058074A1 (fr) * 1999-06-04 2000-12-06 Air Products And Chemicals, Inc. Procédé de séparation des gaz de l'air comprenant un moteur à combustion interne pour la production de gaz atmosphériques et d'énergie électrique
US20050139072A1 (en) * 2003-12-08 2005-06-30 Landrum J. M. Process to remove nitrogen and/or carbon dioxide from methane-containing streams
US20150007727A1 (en) * 2013-07-08 2015-01-08 Exxonmobil Research And Engineering Company Carbon dioxide separation using adsorption with steam regeneration
US20220072470A1 (en) * 2020-09-10 2022-03-10 Enhanced Energy Group LLC Carbon capture systems

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1058074A1 (fr) * 1999-06-04 2000-12-06 Air Products And Chemicals, Inc. Procédé de séparation des gaz de l'air comprenant un moteur à combustion interne pour la production de gaz atmosphériques et d'énergie électrique
US20050139072A1 (en) * 2003-12-08 2005-06-30 Landrum J. M. Process to remove nitrogen and/or carbon dioxide from methane-containing streams
US20150007727A1 (en) * 2013-07-08 2015-01-08 Exxonmobil Research And Engineering Company Carbon dioxide separation using adsorption with steam regeneration
US20220072470A1 (en) * 2020-09-10 2022-03-10 Enhanced Energy Group LLC Carbon capture systems

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