WO2025136353A1 - System and method for gas capture using multiple adsorption stages - Google Patents

System and method for gas capture using multiple adsorption stages Download PDF

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Publication number
WO2025136353A1
WO2025136353A1 PCT/US2023/084640 US2023084640W WO2025136353A1 WO 2025136353 A1 WO2025136353 A1 WO 2025136353A1 US 2023084640 W US2023084640 W US 2023084640W WO 2025136353 A1 WO2025136353 A1 WO 2025136353A1
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Prior art keywords
gas
adsorption
adsorption stage
stage
mode
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PCT/US2023/084640
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French (fr)
Inventor
Dhinesh THANGANADAR
Jr. Donald Wayne Whisenhunt
Anindya Kanti De
Subrata Pal
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GE Vernova GmbH
GE Vernova Infrastructure Technology LLC
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General Electric Technology GmbH
GE Infrastructure Technology LLC
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Priority to PCT/US2023/084640 priority Critical patent/WO2025136353A1/en
Publication of WO2025136353A1 publication Critical patent/WO2025136353A1/en
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00Carbon; Compounds thereof
    • C01B32/50Carbon dioxide
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation 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
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/46Removing components of defined structure
    • B01D53/62Carbon oxides
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation 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
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/74General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/75Multi-step processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation 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
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/74General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/81Solid phase processes
    • B01D53/82Solid phase processes with stationary reactants
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation 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
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/96Regeneration, reactivation or recycling of reactants
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2257/00Components to be removed
    • B01D2257/50Carbon oxides
    • B01D2257/504Carbon dioxide
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2258/00Sources of waste gases
    • B01D2258/02Other waste gases
    • B01D2258/0283Flue gases
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/40007Controlling pressure or temperature swing adsorption
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/40011Methods relating to the process cycle in pressure or temperature swing adsorption
    • B01D2259/40058Number of sequence steps, including sub-steps, per cycle
    • B01D2259/40062Four
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/40011Methods relating to the process cycle in pressure or temperature swing adsorption
    • B01D2259/40058Number of sequence steps, including sub-steps, per cycle
    • B01D2259/40064Five
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/40011Methods relating to the process cycle in pressure or temperature swing adsorption
    • B01D2259/40058Number of sequence steps, including sub-steps, per cycle
    • B01D2259/40066Six
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/40083Regeneration of adsorbents in processes other than pressure or temperature swing adsorption
    • B01D2259/40088Regeneration of adsorbents in processes other than pressure or temperature swing adsorption by heating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/40083Regeneration of adsorbents in processes other than pressure or temperature swing adsorption
    • B01D2259/40088Regeneration of adsorbents in processes other than pressure or temperature swing adsorption by heating
    • B01D2259/4009Regeneration of adsorbents in processes other than pressure or temperature swing adsorption by heating using hot gas
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/404Further details for adsorption processes and devices using four beds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/406Further details for adsorption processes and devices using more than four beds
    • B01D2259/4061Further details for adsorption processes and devices using more than four beds using five beds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2259/00Type of treatment
    • B01D2259/40Further details for adsorption processes and devices
    • B01D2259/406Further details for adsorption processes and devices using more than four beds
    • B01D2259/4062Further details for adsorption processes and devices using more than four beds using six beds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation 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
    • B01D53/02Separation 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
    • B01D53/04Separation 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
    • B01D53/0462Temperature swing adsorption

Definitions

  • the present application relates generally to a system and method for capturing undesirable gases associated with a combustion system, such as a combustion-driven power plant.
  • An industrial plant such as a combustion-driven power plant, may produce a variety of gases, such as an exhaust gas of a combustion system.
  • the combustion system may include a gas turbine engine, a reciprocating piston-cylinder engine, a furnace, a boiler, or other industrial equipment.
  • These exhaust gases may include one or more undesirable gases, such as acid gases and/or greenhouse gases.
  • the undesirable gases may include carbon oxides (COx) such as carbon dioxide (CO2) and carbon monoxide (CO), nitrogen oxides (NOx) such as nitrogen dioxide (NO2). and/or sulfur oxides (SOx) such as sulfur dioxide (SO2).
  • CO2 is both an acid gas and a greenhouse gas.
  • a system includes a gas capture system having a first adsorber with a first sorbent material.
  • the first adsorber is configured to adsorb an undesirable gas from a gas flow into the first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas, desorb the undesirable gas from the first sorbent material in a desorption mode, and cool the first sorbent material in a cooling mode.
  • the system further includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control the first adsorber in a sequence of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas. the desorption mode, and the cooling mode.
  • a system includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control a first adsorber of a gas capture system to: adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas.
  • the controller is further configured to desorb the undesirable gas from the first sorbent material in a desorption mode.
  • the controller is further configured to cool the first sorbent material in a cooling mode.
  • a method includes controlling, via a controller, a first adsorber of a gas capture system to adsorb an undesirable gas from a gas flow 7 into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas.
  • the method further includes controlling, via the controller, the first adsorber to desorb the undesirable gas from the first sorbent material in a desorption mode.
  • the method further includes controlling, via the controller, the first adsorber to cool the first sorbent material in a cooling mode.
  • FIG. 1 is a block diagram of an embodiment of a combined cycle system having one or more gas capture systems.
  • FIG. 2 is a schematic of an embodiment of a gas capture system of FIG. 1, illustrating a sorbent-based gas capture system having an adsorption mode, a desorption mode, and a cooling mode, wherein the adsorption mode comprises a plurality of adsorption stages.
  • FIG. 3 is a schematic of a first configuration of four sorbent-based gas capture units during a first duration of time of a staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
  • FIG. 4 is a schematic of a second configuration of the four sorbent-based gas capture units during a second duration of time of the staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
  • FIG. 5 is a schematic of a third configuration of the four sorbent-based gas capture units during a third duration of time of the staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
  • FIG. 6 is a schematic of a fourth configuration of the four sorbent-based gas capture units during a fourth duration of time of the staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
  • FIG. 7 is a flow chart of an embodiment of a process for controlling the staggered operating cycle as illustrated in FIGS. 3-6.
  • FIG. 8 is a flow chart of an embodiment of a process for controlling the staggered operating cycle as illustrated in FIGS. 3-6.
  • the disclosed embodiments include systems and methods to reduce the carbon footprint of combustion systems, such as combustion-driven power plants and/or combined cycle power plants, using a gas treatment system having one or more gas capture systems.
  • the gas capture systems are configured to remove undesirable gases (e.g., CO2) from the intake air and/or the exhaust gas of the combustion systems.
  • the gas capture systems may include sorbent-based gas capture systems, solvent-based gas capture systems, cryogenic gas capture systems, or a combination thereof.
  • the gas capture systems (e.g., sorbent-based gas capture systems) may include one or more temperature swing adsorption (TSA) systems, vacuum temperature swing adsorption (VTSA) systems, concentration swing adsorption (CSA) systems, or any combination thereof.
  • TSA temperature swing adsorption
  • VTSA vacuum temperature swing adsorption
  • CSA concentration swing adsorption
  • the gas capture systems may include one or more temperature swing adsorption (TSA) units or adsorbers, which rely on temperature swings to adsorb undesirable gases at a first temperature (e.g., low temperature) and desorb the undesirable gases at a second temperature (e.g.. high temperature).
  • TSA temperature swing adsorption
  • the gas capture systems may include one or more vacuum temperature swing adsorption (VTSA) units or adsorbers, which rely on temperature and pressure swings to adsorb undesirable gases at a first temperature (e.g., low temperature) and a first pressure (e.g., high pressure) and desorb the undesirable gases at a second temperature (e.g.. high temperature) and a second pressure (e.g., low pressure).
  • VTSA vacuum temperature swing adsorption
  • a heat source to facilitate the desorption may include a variety of heated fluids, such as steam, an inert gas (e.g., nitrogen (N2)), or any other suitable sweep gas.
  • the sorbent-based gas capture systems are configured to adsorb the undesirable gases into a sorbent material, and then subsequently desorb the undesirable gases from the sorbent material using a heat source (e.g., a heated fluid).
  • each sorbent-based gas capture system includes a plurality of sorbent-based gas capture assemblies or units that support the multi-stage adsorption mode in a reverse order of (1) the second adsorption stage - undesirable gas-lean adsorption stage, and (2) the first adsorption stage - undesirable gas-rich adsorption stage, such that each sorbent-based gas capture unit starts with the undesirable gas-lean adsorption stage and ends with the undesirable gas-rich adsorption stage.
  • the disclosed embodiments enable the multi-stage adsorption mode with four (4) sorbent-based gas capture units operating in a staggered operational cycle.
  • the compressor section 42 may include a plurality 7 of compressor stages 58, each having a plurality of the compressor vanes 56 spaced circumferentially about the at least one shaft 50 at an axial position, and a plurality of the compressor blades 54 spaced circumferentially about the at least one shaft 50 at a different axial position (i.e., the compressor vanes 56 and the compressor blades 58 are axially spaced apart).
  • the compressor section 42 is configured to receive a flow of an intake gas 60 from the intake section 40 and to progressively compress the intake gas 60 through the plurality of compressor stages 58.
  • the intake gas 60 may include an intake air, an exhaust gas recirculation (EGR) flow or recirculated exhaust gas, or a combination thereof.
  • EGR exhaust gas recirculation
  • the load 126 may include an electrical generator, a machine, a propulsion system for a vehicle, or any other suitable load.
  • the load 126 may be an electrical generator, such that the combined cycle system 10 is a combined cycle power plant.
  • the combustion gas 112 flows from the combustor 62 into the turbine section 46, wherein the combustion gas 1 12 progressively expands and drives rotation of the turbine blades 118 coupled to the at least one shaft 114 in each of the turbine stages 122.
  • the combustion gas 112 drives the turbine section 46, which in turn drives the compressor section 42 and the load 126 via the interconnected shafts 50, 124, 114, and 128.
  • the gas turbine system 12 can be configured with or without the compressor system 106 and an exhaust gas recirculation (EGR) system 150.
  • the EGR system 150 is configured to recirculate an exhaust gas 152 output by the turbine section 46 back into the compressor section 42 (e.g.. via intake section 40) for compression and delivery to the combustor section 44.
  • the gas turbine system 12 may exclude the EGR system 150 and intake only an airflow into the intake section 40 for compression by the compressor section 42.
  • the recirculated exhaust gas helps to reduce the temperature and formation of certain emissions (e.g., nitrogen oxides (NOx)) associated with combustion in the combustor section 44.
  • NOx nitrogen oxides
  • the heat recovery steam generator 16 may route the high- pressure steam 166 to a high-pressure steam turbine 172, the intermediate-pressure steam 168 to an intermediate-pressure steam turbine 174, and the low-pressure steam 170 to a low-pressure steam turbine 176 of the steam turbine system 14.
  • the steam drives rotation of blades within each of the steam turbines 172, 174, 176, thereby driving a shaft 178 coupled to a load 180, such as an electrical generator.
  • the low- pressure steam turbine 176 also may return a condensate 182 through a return line 181 back to the low-pressure section 164 of the HRSG 16 via a pump 183.
  • the HRSG 16 may then output the exhaust gas 152 as a partially cooled exhaust gas 184.
  • the combined cycle system 10 excludes the HRSG 16 and/or the steam turbine system 14.
  • the exhaust gas 152 output by the turbine section 46 and/or the exhaust gas 184 output by the HRSG 16 may pass through the WHR system 22 for transfer of heat from the exhaust gas into a heated fluid 26 to support the one or more gas capture systems 20 of the gas treatment system 18.
  • the heated fluid 26 may include a heated gas or liquid, such as a heated water and/or steam.
  • the temperature of the heated fluid 26 may be 100 to 150 degrees Celsius, 110 to 150 degrees Celsius, 120 to 150 degrees Celsius, or 130 to 150 degrees Celsius. Accordingly, the heated fluid 26 may provide heat in the one or more gas capture systems 20 to enable desorption in a similar temperature range of 100 to 150 degrees Celsius, 110 to 150 degrees Celsius, 120 to 150 degrees Celsius.
  • the heated fluid 26 may be provided to the gas capture systems 20 to support desorption at a temperature of at least equal to or greater than 100, 110, 120. 130, 140. or 150 degrees Celsius, plus or minus 5 degrees Celsius.
  • the gas treatment system 18 includes one or more gas capture systems 20.
  • the gas capture systems 20 may include any one or any combination of gas capture systems 190, 192, and 194, each having a plurality of components (e.g., components 196, 198, 200, and 202).
  • the gas capture systems 20 e.g., 190, 192. and 194 are configured to obtain a captured gas 204 from the intake gas 60 and/or the exhaust gas 152. 184.
  • the gas capture systems 20 e.g., 190, 192, and 194 may capture and output carbon dioxide (CO2) as the captured gas 204, which may further be directed to a compression system 206.
  • the compression system 206 may include one or more compressors configured to compress the captured gas 204 (e.g., CO2) and deliver the captured gas to storage and/or a pipeline 208.
  • the gas capture system 190 is disposed at, in, or upstream of the intake section 40 for capturing undesirable gases from the intake air.
  • the gas capture systems 192 and 194 are disposed downstream of the gas turbine system 12 and/or the HRSG 16 for capturing undesirable gases from the exhaust gas 152, 184.
  • the gas capture systems 20 (e.g., 190, 192, and 194) may include sorbent-based gas capture systems, solvent-based gas capture systems, cryogenic gas capture systems, or any combination thereof, configured to remove and capture undesirable gases.
  • the gas capture systems 20 may be configured to remove and capture undesirable gases, such as carbon oxides (COx) (e.g., carbon dioxide (CO2) and carbon monoxide (CO)), and thus the gas capture systems 20 maybe described as carbon capture systems.
  • COx carbon oxides
  • CO2 carbon dioxide
  • CO2 carbon monoxide
  • the gas capture systems 20 may be configured to remove and capture undesirable gases, such as nitrogen oxides (NOx) (e.g., nitrogen dioxide (NO2)), and thus the gas capture systems 20 may be described as NOx capture systems.
  • NOx nitrogen oxides
  • the gas capture systems 20 may be configured to remove and capture undesirable gases, such as sulfur oxides (SOx) (e.g., sulfur dioxide (SO2)), and thus the gas capture systems 20 may be described as SOx capture systems.
  • SOx sulfur oxides
  • the gas capture systems 20 e.g., 190, 192, and 194 may be described as sorbent-based carbon capture systems using sorbent materials as an example and/or solvent based carbon capture systems using liquid absorbents (e.g., solvents) as an example.
  • the embodiments disclosed herein may use any type or configuration of gas capture systems 20 (e.g., 190, 192, and 194) as noted above.
  • the components 196, 198, 200, and 202 may include sorbent materials disposed on or in ducts (e.g., adsorption duct, desorption duct, and cooling duct), contactors, cartridges, moving beds, rotating wheels, cartridges, or any combination thereof, along a flow path of the intake gas 60 and/or the exhaust gas 152, 184.
  • the sorbent-based gas capture systems 20 are configured to adsorb the undesirable gases (e.g., CO2) into the sorbent materials in an adsorption mode and desorb the undesirable gases from the sorbent materials in a desorption mode.
  • the components 196 are configured to adsorb the undesirable gases (e.g., CO2) into the sorbent materials in an adsorption mode and desorb the undesirable gases from the sorbent materials in a desorption mode.
  • the 198, 200, and 202 may include cooling systems to help control the temperature of the sorbent materials (e.g., maintain sorbent temperatures within upper and lower temperature thresholds) to improve efficiency of the adsorption mode.
  • the cooling systems may include heat exchangers (e.g., fin and tube heat exchangers), heat pipes, and other thermal control systems coupled to the sorbent materials to help control the temperature of the sorbent materials.
  • the components 196, 198, 200, and 202 also may include heating systems, such as heated fluid systems (e.g., steam systems, electrical heaters, waste heat systems, etc.), configured to apply heat to the sorbent materials to desorb the undesirable gases from the sorbent materials during the desorption mode.
  • heated fluid systems e.g., steam systems, electrical heaters, waste heat systems, etc.
  • the stripper is configured to strip the undesirable gases from the gas-rich solvent in a desorption mode, thereby outputting a gas-lean solvent (e.g., CCh-lean solvent) back to the absorber and outputting the captured gas 204.
  • the components 196, 198, 200, and 202 may include cooling systems coupled to the absorber, wherein the cooling systems are configured to extract heat generated by the absorption mode to help control the temperature of the solvent (e.g., maintain solvent temperatures within upper and lower temperature thresholds) to improve efficiency of the absorption mode.
  • the cooling systems may include heat exchangers (e.g... fin and tube heat exchangers), heat pipes, and other thermal control systems coupled to the absorber to help control the temperature of the solvent.
  • the components 196, 198, 200, and 202 also may include heating systems, such as heated fluid systems (e g., steam systems, electrical heaters, waste heat systems, etc.), coupled to the strippers, wherein the heating systems are configured to apply heat to the gas-rich solvent to desorb the undesirable gases from the gas-rich solvent during the desorption mode.
  • heated fluid systems e g., steam systems, electrical heaters, waste heat systems, etc.
  • the WHR system 22 may be configured to provide the heated fluid 26 to the gas-rich solvent during the desorption mode.
  • the components 196, 198, 200, and 202 of the gas capture system 20 and/or the components 210 (e.g.. WHR system 22 and components 212, 214. and 216) upstream from the gas capture systems 192 and 194 may include one or more of a dryer or water removal system (e.g., water gas separator), a particulate removal system (e.g., filter and/or solid gas separator), one or more booster fans configured to boost a flow of the gas being treated, one or more coolers, one or more valves to control a flow of gas to the gas capture system 20, a bypass system configured to bypass the gas capture system 20, or any combination thereof.
  • a dryer or water removal system e.g., water gas separator
  • a particulate removal system e.g., filter and/or solid gas separator
  • booster fans configured to boost a flow of the gas being treated
  • coolers e.g., one or more coolers
  • valves e.g., one or more valves to control a
  • the cooler may include a heat exchanger, a direct contact cooler (DCC), or a combination thereof.
  • the heat exchanger is configured to indirectly cool the exhaust gas 184 via heat exchange between the exhaust gas 184 and a cooling fluid (e.g., cooling water).
  • the direct contact cooler is configured to directly cool the exhaust gas 184 via direct injection of a cooling fluid (e.g., cooling water) into the exhaust gas 184.
  • the separators may include gravity separators, centrifugal separators, or a combination thereof.
  • the gas capture systems 20 (e.g.. 190. 192, and 194) may be described as multiple gas capture stages.
  • the gas treatment system 18 may include only a single stage and/or gas capture system 20.
  • the gas capture systems 20 may include only one, two, or all three of the gas capture systems 190, 192, and/or 194.
  • one or more of the gas capture systems 20 includes multiple adsorption stages (e.g., first adsorption stage - undesirable gas-rich adsorption stage, and second adsorption stage - undesirable gaslean adsorption stage) achieved with a plurality of gas capture units operating in a reversed order (e.g., undesirable gas-lean adsorption stage followed by undesirable gas-rich adsorption stage), such that each gas capture unit starts with adsorption of undesirable gases (e.g., CO2) from an undesirable gas-lean flow (e g., CCh-lean flow) and ends with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow).
  • undesirable gases e.g., CO2
  • undesirable gas-lean flow e.g., CCh-lean flow
  • CCh-rich flow undesirable gas-rich flow
  • the gas capture system 190 may include multiple gas capture units that start with adsorption of undesirable gases (e.g.. CO2) from an undesirable gas-lean flow (e.g.. CCh-lean flow) and end with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow) of the air.
  • undesirable gases e.g.. CO2
  • undesirable gas-lean flow e.g. CCh-lean flow
  • CCh-rich flow undesirable gas-rich flow
  • the gas capture system 192 or 194 may include multiple gas capture units that start with adsorption of undesirable gases (e.g., CO2) from an undesirable gas-lean flow (e.g., CCh-lean flow) and end with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow) of the exhaust gas 152, 184.
  • undesirable gases e.g., CO2
  • CCh-lean flow undesirable gas-rich flow
  • the combined cycle system 10 also includes a controller 220 coupled to the gas turbine system 12, the steam turbine system 14, the HRSG 16, the gas treatment system 18 (e.g., gas capture systems 20), the fuel system 88, the EGR system 150, the compression system 106, and various sensors 222 distributed throughout the combined cycle system 10.
  • the controller 220 includes one or more processors 224, memory 226, instructions 228 stored on the memory 226 and executable by the processor 224, and communication circuitry 230 configured to communicate with the sensors 222 and various equipment throughout the combined cycle system 10.
  • the controller 220 is configured to control the fuel delivery and distribution from the fuel system 88 to the fuel nozzles 82 in the combustor section 44.
  • the sensors 222 may monitor the temperature of the heated fluid 26 provided to the gas capture systems 20, the temperature of the sorbent materials in sorbentbased gas capture systems, the temperature of solvent in solvent-based gas capture systems, or any combination thereof.
  • the sensors 222 may monitor the undesirable gases (e.g., gas composition or content of CO2) during the adsorption mode of the gas capture systems 20 (e.g., 190, 192, and 194), including sensor measurements before, during, and after each adsorption stage of a plurality of adsorption stages.
  • FIG. 2 is a schematic of an embodiment of a gas capture system 20 of the gas treatment system 18 of FIG. 1. illustrating a sorbent-based gas capture system 250 having multiple adsorption stages.
  • the sorbent-based gas capture system 250 includes a plurality of sorbent-based gas capture assemblies or units 252 (e.g., adsorbers or adsorption units) associated with a plurality of respective conduits 254, such as conduits 255, 256, 258, and 260 (e.g., sorbent-containing conduits).
  • the sorbent-based gas capture units 252 may include one or more temperature swing adsorption (TSA) units, vacuum temperature swing adsorption (VTSA) units, concentration swing adsorption (CSA) units, or any combination thereof.
  • TSA temperature swing adsorption
  • VTSA vacuum temperature swing adsorption
  • CSA concentration swing adsorption
  • the sorbent-based gas capture units 252 may include temperature swing adsorption (TSA) units or adsorbers, wherein a temperature swing or change is used to sequentially operate in an adsorption mode (e.g.. multiple adsorption stages), a desorption mode, and a cooling mode at different temperatures.
  • each adsorption stage of the adsorption mode may operate at one or more first temperatures that are lower than a second temperature of the desorption mode.
  • the lower first temperature enables the sorbent-based gas capture units 252 to adsorb the undesirable gas, where lower temperatures generally increase a capacity for adsorbing the undesirable gas.
  • the higher second temperature enables the sorbent-based gas capture units 252 to desorb the undesirable gas, which can then be captured and used in other downstream processes.
  • the gas capture systems may include one or more vacuum temperature swing adsorption (VTSA) units or adsorbers, which rely on temperature and pressure swings to adsorb undesirable gases at a first temperature (e.g., low temperature) and a first pressure (e.g., high pressure) and desorb the undesirable gases at a second temperature (e.g., high temperature) and a second pressure (e.g., low pressure).
  • VTSA vacuum temperature swing adsorption
  • the sorbent-based gas capture system 250 includes multiple adsorption stages (e.g., first adsorption stage - undesirable gas-rich adsorption stage, and second adsorption stage - undesirable gas-lean adsorption stage) achieved with the plurality of sorbent-based gas capture units 252 operating in a reversed order (e.g., undesirable gas-lean adsorption stage followed by undesirable gas-rich adsorption stage), such that each sorbent-based gas capture unit 252 starts with adsorption of undesirable gases (e.g., CO2) from an undesirable gas-lean flow (e.g., CCh-lean flow) and ends with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow).
  • undesirable gases e.g., CO2
  • undesirable gas-lean flow e.g., CCh-lean flow
  • CCh-rich flow undesirable gas-rich flow
  • the sorbent-based gas capture units 252 include sorbent-based gas capture units 252A, 252B, 252C, and 252D associated with the conduits 255. 256, 258, and 260.
  • the conduits 254 e.g., 255, 256, 258, and 260
  • the conduits 254 may be sorbent-lined along interior surfaces, sorbent-packed within interior volumes. or generally filled with at least 10, 20, 30, 40, 50, 60, 70, 80, 90, or more percent by volume of sorbent material.
  • the sorbent-based gas capture unit 252 may include any number of conduits 254, such as 2. 3, 4, 5. 6, 7. 8. 9, 10, or more, which are configured in parallel and/or series.
  • Each of the conduits 254 (e.g., 255, 256, 258, and 260) includes an outer conduit wall 262 disposed circumferentially about a flow path 264 (e g., fluid passage or bore) along a central axis 266 from an inlet 268 to an outlet 270, wherein a sorbent material 272 is disposed along an interior surface 274 of the outer conduit wall 262 and/or along an exterior surface 276 of a plurality of contactors 280 (e.g., contactor plates, panels, or fins).
  • the contactors 280 are arranged parallel to one another and parallel to the central axis 266.
  • Each of the conduits 254 (e.g., 255, 256, 258. and 260) may include a contactor assembly 278 having any number of the contactors 280, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more contactors 280.
  • Each of the contactors 280 has a body 284 with the exterior surface 276 disposed about an interior portion 286.
  • the sorbent material 272 is disposed along the exterior surface 276, while the interior portion 286 includes a material 282 different than the sorbent material 272.
  • the body 284 may be a solid body throughout the interior portion 286, wherein the body 284 is at least substantially or completely made with the sorbent material 272 throughout the interior portion 286 to the exterior surface 276.
  • the body 284 may be a hollow body in the interior portion 286 (e.g., interior chamber or cavity), wherein the body 284 has an outer wall 288 disposed about the interior portion 286.
  • the interior portion 286 may include a heat exchange circuit or flow path extending throughout the body 284 between a fluid inlet and a fluid outlet, which may be coupled to a heat exchange circuit for cooling and/or heating.
  • the interior portion 286 may be configured to circulate a cooling fluid during an adsorption mode, a heating fluid (e.g., heated water, steam, etc.) during a desorption mode, and a cooling fluid during a cooling mode of the sorbent-based gas capture system 250.
  • the gas capture system 20 is configured to sequentially and repeatedly operate each of the sorbent-based gas capture units 252A. 252B, 252C, and 252D in a cycle of: (1) undesirable gas-lean adsorption stage (e.g., CCh-lean adsorption stage) of a multi-stage adsorption mode, (2) undesirable gas-rich adsorption stage (e.g., CCh-rich adsorption stage) of the multi-stage adsorption mode. (3) a desorption mode, and (4) a cooling mode.
  • undesirable gas-lean adsorption stage e.g., CCh-lean adsorption stage
  • undesirable gas-rich adsorption stage e.g., CCh-rich adsorption stage
  • the undesirable gas-lean adsorption stage (e.g., CCh-lean adsorption stage) of the adsorption mode refers to adsorption of the undesirable gas (e.g., CO2) when the undesirable gas is lean in the gas being treated by the gas capture system 20.
  • the undesirable gas-rich adsorption stage (e.g., CCh-rich adsorption stage) of the adsorption mode refers to adsorption of the undesirable gas (e.g., CO2) when the undesirable gas is rich in the gas being treated by the gas capture sy stem 20.
  • the temperature of the sorbent material 272 directly affects the adsorption efficiency of the sorbent material 272 during the adsorption mode (e.g., including each of the gas-lean adsorption stage and the gas-rich adsorption stage).
  • the sorbent material 272 may have an optimal temperature or temperature range for efficient adsorption of the undesirable gases.
  • the adsorption of the undesirable gases into the sorbent material 272 is an exothermic process, which generates heat that generally increases the temperature of the sorbent material 272 and reduces its adsorption efficiency without any cooling of the sorbent material 272.
  • the disclosed embodiments may control the cooling of the sorbent material 272 during the adsorption mode (e.g., including each of the gas-lean adsorption stage and the gas-rich adsorption stage) to improve the adsorption efficiency.
  • the temperature of the sorbent material 272 directly affects the desorption efficiency of the sorbent material 272 during the desorption mode.
  • the sorbent material 272 may have an optimal temperature or temperature range for efficient desorption of the undesirable gases.
  • the disclosed embodiments may control the heating of the sorbent material 272 during the desorption mode to improve the desorption efficiency.
  • the controller 220 may be configured to control the steam turbine system 14, the HRSG 16, and/or the WHR system 22 to supply heated fluids (e.g., heated water, steam, etc.) to each of the sorbent-based gas capture units 252A, 252B. 252C, and 252D during the desorption mode.
  • heated fluids e.g., heated water, steam, etc.
  • the temperatures in the adsorption mode e.g., including each of the gaslean adsorption stage and the gas-rich adsorption stage
  • the desorption mode may vary depending on the particular application.
  • the adsorption mode (e.g., including each of the gas-lean adsorption stage and the gas-rich adsorption stage) may be configured to adsorb undesirable gas from a gas 340 into the sorbent material 272 at one or more first temperatures
  • the desorption mode may be configured to desorb the undesirable gas from the sorbent material 272 using a heat source (e g., heated water, steam, etc.) at a second temperature
  • the cooling mode may be configured to cool the sorbent material 272 using a cooling source (e.g., cooling fluid) at a third temperature, wherein the second temperature is greater than the first and third temperatures, and the third temperature is lesser than the first and third temperatures.
  • the first temperature may be approximately 40 degrees Celsius (e.g., plus or minus 5, 10, 15, or 20 degrees Celsius)
  • the second temperature may be equal to or greater than approximately 100, 110, 120, 130, 140. or 150 degrees Celsius
  • the third temperature may be less than or equal to approximately 0, 5. 10. 15. 20. 25. or 30 degrees Celsius.
  • the gas capture system 20 includes a thermal control system 290 having a fluid circulation system 292.
  • one or more fluid circulation circuits 294 e.g., fluid conduits, manifolds, valves, etc.
  • the heat exchangers 296 may include one or more heat exchange flow paths coupled to and/or extending through each contactor assembly 278.
  • the heat exchangers 296 also may include a plurality of heat pipes 298, wherein each contactor assembly 278 includes one or more heat pipes 298 coupled to and/or extending through each contactor 280 in the contactor assembly 278.
  • the fluid circulation system 292 may include a plurality of components, such as components 300, 302, and 304, such as heat exchangers, pumps, valves, coolant supplies, or any combination thereof.
  • the thermal control system 290 may circulate a thermal fluid (e.g., liquid or gas thermal fluid) from the fluid circulation system 292 through the fluid circulation circuits 294 and the heat exchangers 296 to exchange heat between the thermal fluid and the contactors 280 and the sorbent materials 272 during any one or all of the operating modes (e.g., each stage of the adsorption mode, desorption mode, and/or cooling mode).
  • a thermal fluid e.g., liquid or gas thermal fluid
  • the fluid circulation circuits 294 may include independent fluid circulation circuits for each of the contactor assemblies 278, such that the thermal control system 290 can independently control the temperature for each of the contactor assemblies 278 depending on the operating modes (e.g.. each stage of the adsorption mode, desorption mode, and/or cooling mode) of the sorbent-based gas capture units 252A, 252B, 252C, and 252D.
  • the thermal control system 290 is configured to circulate the thermal fluid (e.g., coolant or cooling fluid at a relatively lower temperature) during the adsorption mode (e.g...
  • the thermal control system 290 is configured to circulate the thermal fluid (e.g., heated or heating fluid at a relatively higher temperature) during the desorption mode, thereby heating the contactors 280 and the sorbent materials 272 to facilitate desorption.
  • the thermal fluid may include the heated fluid 26 from the WHR system 22, heated water and/or steam from the steam turbine system 14 and/or the HRSG 16, or a combination thereof, during the desorption mode.
  • the sorbent material 272 may cover, coat, or generally line at least 50, 60, 70, 80, 90, 95, or 100 percent of the interior surface 274 of the outer conduit wall 262, the exterior surface 276 of the contactors 280. and/or other structures within the conduits 254.
  • the contactors 280 may include rectangular plates, airfoil shaped panels, a parallel arrangement of tubes, a grid arrangement of tubes, a plurality of cartridges, radial projections, baffles, fins, honeycomb structures, a plurality 7 of contactor elements supported in a bundle, or any combination thereof.
  • the plurality of contactor elements may include a plurality 7 of particles, beads, strips, strands, mesh, or other distributed structures, which leave voids for fluid flow. Additionally or alternatively, the sorbent material 272 may at least partially fill or pack an interior volume of the central bore or interior surface 274, such that voids remain to facilitate fluid flow (e.g., a void fraction of less than or equal to 10, 20, 30, 40, or 50 percent).
  • the central axis 266 extending from the inlet 268 to the outlet 270 may define the flow path 264 as a linear flow path, a curved flow path, a winding or serpentine flow path, a spiral or helical flow path, a tortuous flow path, an expanding and contracting flow path, a flow path with splits and/or unions, or any combination thereof.
  • the flow path 264 may be defined as a tortuous flow path and include any number or configuration of the foregoing flow paths.
  • the sorbent material 272 may include one or more sorbent materials configured to adsorb the undesirable gases, such as sorbent materials designed or suitable for adsorption of carbon oxides (COx) such as carbon dioxide (CO2) and carbon monoxide (CO), nitrogen oxides (NOx), sulfur oxides (SOx) such as sulfur dioxide (SO2), methane (CFU), or any other undesirable gases as described herein or subject to regulations and/or considered greenhouse gases.
  • the sorbent materials 272 may include porous, solid-phase materials, including mesoporous silicas, zeolites (e.g., aluminosilicates), and metal-organic frameworks (MOFs) and covalent organic frameworks (COFs).
  • the foregoing sorbent materials 272 may be particularly well-suited for CO2 adsorption in the sorbent-based gas capture unit 252. However, any suitable sorbent materials 272 may be used depending on the desired target for gas capture of undesirable gases. In certain embodiments, a plurality of the sorbent-based gas capture systems 250 may be used in series, wherein each of the sorbent-based gas capture system 250 uses the same or different sorbent materials 272 to remove and capture the same or different undesirable gases in stages.
  • the sorbent-based gas capture system 250 may be configured to alternate each of the sorbent-based gas capture units 252A, 252B, 252C, and 252D associated with the conduits 255, 256, 258, and 260 in a sequence of the following four cycles: (1) the gas-lean adsorption stage of the adsorption mode (e.g., adsorbing the undesirable gases in an undesirable gas-lean flow into the sorbent material 272), (2) the gas-rich adsorption stage of the adsorption mode (e.g., adsorbing the undesirable gases in an undesirable gas-rich flow into the sorbent material 272), (3) the desorption mode (e.g..).
  • the gas-lean adsorption stage of the adsorption mode e.g., adsorbing the undesirable gases in an undesirable gas-lean flow into the sorbent material 272
  • the gas-rich adsorption stage of the adsorption mode e.g., adsorbing
  • each of the sorbent-based gas capture units 252A, 252B, 252C, and 252D is used in the foregoing sequence, the adsorption stages performed on the gas flow are performed in the reverse order of (1) first adsorption stage - gasrich adsorption by a sorbent-based gas capture unit 252, (2) second adsorption stage - gas-lean adsorption by a different sorbent-based gas capture unit 252.
  • the full sequence (including adsorption stages applied to the gas flow, desorption mode, and cooling mode) of the sorbent-based gas capture units 252A, 252B, 252C, and 252D may be performed as illustrated in FIGS. 3-6.
  • each of the sorbent-based gas capture units 252 is used for all adsorption stages.
  • the sorbent-based gas capture system 250 is able to reduce the total number of the sorbent-based gas capture units 252 to four units operating in four cycles, rather than using a total of six units (i.e., three units in a first stage and three units in a second stage, each cycling between adsorption, desorption, and cooling modes).
  • the controller 220 is configured to control the sorbent-based gas capture system 250 to perform a staggered operational cycle of the sorbent-based gas capture units 252A, 252B, 252C, and 252D between the different operating modes (e.g., gas-lean adsorption stage of the adsorption mode, gas-rich adsorption stage of the adsorption mode, desorption mode, and cooling mode).
  • the different operating modes e.g., gas-lean adsorption stage of the adsorption mode, gas-rich adsorption stage of the adsorption mode, desorption mode, and cooling mode.
  • Table 1 illustrates a sequence using the sorbent-based gas capture units 252A, 252B, 252C, and 252D in the staggered operational cycle.
  • the controller 220 may operate the sorbent-based gas capture unit 252A in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252B in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252C in the desorption mode, and the sorbent-based gas capture unit 252D in the cooling mode.
  • the controller 220 may operate the sorbentbased gas capture unit 252D in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252A in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252B in the desorption mode, and the sorbent-based gas capture unit 252C in the cooling mode.
  • the controller 220 may operate the sorbent-based gas capture unit 252C in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252D in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252A in the desorption mode, and the sorbent-based gas capture unit 252B in the cooling mode.
  • the controller 220 may operate the sorbent-based gas capture unit 252B in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252C in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252D in the desorption mode, and the sorbent-based gas capture unit 252A in the cooling mode.
  • the staggered operational cycle repeats starting with the first duration of time.
  • Table 1 illustrates the staggered operational cycle of the sorbent-based gas capture units 252A, 252B, 252C, and 252D, but the adsorption stages performed on the gas flow (e.g., exhaust gas) are in the opposite order (i.e., first adsorption stage - undesirable gas-rich adsorption stage, followed by second adsorption stage - undesirable gas-lean adsorption stage).
  • gas flow e.g., exhaust gas
  • Table 1 illustrates four sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) operating in the four different configurations over four different periods of time
  • the disclosed embodiments may be used with any number of adsorption stages in the same manner.
  • Table 2 illustrates a sequence using five of the sorbent-based gas capture units (e.g., A, B, C, D, and E) in the staggered operational cycle, wherein the number of adsorption stages has been increased from two adsorption stages to three adsorption stages.
  • each of the sorbent-based gas capture units sequentially operates in the third adsorption stage, the second adsorption stage, the first adsorption stage, the desorption mode, and the cooling mode, and then repeats the cycle.
  • the staggered operational cycle includes five periods of time and five different configurations of the sorbent-based gas capture units (e.g.. A. B, C, D. and E).
  • the plurality of adsorption stages are in a reversed order with an increasing concentration of the undesirable gas.
  • the sorbent-based gas capture system 250 generally adsorbs the undesirable gas from the gas flow (e.g., exhaust gas 152, 184) in the order of the first adsorption stage, the second adsorption stage, and the third adsorption stage, wherein the first adsorption stage adsorbs the undesirable gas from the gas flow with a highest concentration (e.g., highest or rich-CCh concentration), the second adsorption stage adsorbs the undesirable gas from the gas flow with an intermediate concentration (e.g., intermediate CO2 concentration), and the third adsorption stage adsorbs the undesirable gas from the gas flow with a lowest concentration (e.g., lowest or lean-CCh concentration).
  • a highest concentration e.g., highest or rich-CCh concentration
  • the second adsorption stage adsorbs the undesirable gas from the gas flow with an intermediate concentration (e.g., intermediate CO2 concentration)
  • the third adsorption stage adsorbs the undesirable gas from the gas
  • each of the sorbent-based gas capture units adsorbs the undesirable gas in the reversed order starting with the third adsorption stage (e.g.. lowest or lean-CCh concentration), followed by the second adsorption stage (e.g., intermediate CO2 concentration), and then ending with the first adsorption stage (e.g., highest or rich-CCh concentration).
  • the reversed order enables each of the sorbent-based gas capture units (e.g.. A, B. C, D, and E) to progressively handle higher concentrations of the undesirable gas, thereby enabling the sorbent-based gas capture units (e.g., A, B, C, D, and E) to be used effectively in the multiple adsorption stages.
  • Table 3 illustrates a sequence using six of the sorbent-based gas capture units (e.g., A, B, C, D, E, and F) in the staggered operational cycle, wherein the number of adsorption stages has been increased from two adsorption stages to four adsorption stages.
  • the sorbent-based gas capture units e.g., A, B, C, D, E, and F
  • each of the sorbent-based gas capture units sequentially operates in the fourth adsorption stage, the third adsorption stage, the second adsorption stage, the first adsorption stage, the desorption mode, and the cooling mode, and then repeats the cycle.
  • the staggered operational cycle includes six periods of time and six different configurations of the sorbent-based gas capture units (e.g., A, B, C. D, E, and F). Similar to Tables 1 and 2, the pl urality of adsorption stages are in a reversed order with an increasing concentration of the undesirable gas.
  • the sorbentbased gas capture system 250 generally adsorbs the undesirable gas from the gas flow (e.g., exhaust gas 152, 184) in the order of the first adsorption stage, the second adsorption stage, the third adsorption stage, and the fourth adsorption stage, wherein the first adsorption stage adsorbs the undesirable gas from the gas flow with a highest concentration (e.g., highest or rich-CCh concentration), the second adsorption stage adsorbs the undesirable gas from the gas flow with an upper intermediate concentration (e.g., upper intermediate CO2 concentration), the third adsorption stage adsorbs the undesirable gas from the gas flow with a lower intermediate concentration (e.g., lower intermediate CO2 concentration), and the fourth adsorption stage adsorbs the undesirable gas from the gas flow with a lowest concentration (e.g., lowest or lean-CCh concentration).
  • a highest concentration e.g., highest or rich-CCh concentration
  • the second adsorption stage
  • each of the sorbent-based gas capture units adsorbs the undesirable gas in the reversed order starting with the fourth adsorption stage (e.g., lowest or lean- CCh concentration), followed by the third adsorption stage (e.g., lower intermediate CO2 concentration), followed by the second adsorption stage (e.g., upper intermediate CO2 concentration), and then ending with the first adsorption stage (e.g.. highest or rich-CCh concentration).
  • each of the sorbent-based gas capture units e.g., A, B, C, D, E, and F
  • each of the sorbent-based gas capture units e.g., A, B, C, D, E, and F
  • the sorbent-based gas capture units e.g., A, B, C, D, E, and F
  • the sorbent-based gas capture system 250 also may be configured to simultaneously operate multiple units (e.g., 2, 3, 4, or more) of the sorbent-based gas capture units 252 in each of the operating modes, such as multiple units 252 in the gas-lean adsorption stage of the adsorption mode, multiple units 252 in the gas-rich adsorption stage of the adsorption mode, multiple units 252 in the desorption mode, and multiple units 252 in the cooling mode.
  • the multiple units 252 may be arranged in series, in parallel, or a combination thereof.
  • the controller 220 is configured to alternate the sorbent-based gas capture units 252 (e g., 252A.
  • the support systems may include the thermal control system 290, an upstream flow distribution system 310. and a downstream flow distribution system 312.
  • the upstream flow distribution system 310 includes a gas supply system 314 (or gas intake system), a heating fluid supply system 316 (e.g., heated gas and/or heated liquid supply system), and a cooling fluid supply system 318, while the downstream flow distribution system 312 includes a post-adsorption processing system 320 (e.g., after the adsorption mode), a post-desorption processing system 322 (e.g., fluid processing system after the desorption mode), and a post-cooling system 324 (e.g., after the cooling mode). Additionally, a lean/rich staggered adsorption system 319 is coupled to, and part of, both the upstream flow distribution system 310 and the downstream flow distribution system 312. The lean/rich staggered adsorption system 319 is configured to facilitate multiple adsorption stages.
  • the gas supply system 314 of the upstream flow distribution system 310 is configured to provide a gas 340 (e.g., intake gas 60 or exhaust gas 152. 184) to enable the adsorption mode (e.g., gas-nch adsorption stage of the adsorption mode) when selectively operating each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) in the adsorption mode (e.g., gas-rich adsorption stage of the adsorption mode) via the controller 220.
  • the gas supply system 314 includes a gas pre-treatment system 330 having one or more gas pre-treatment components 332, 334.
  • the gas pre-treatment component 332 may include a thermal control component (e.g., gas temperature control component), such as a heat exchanger, a heater, a cooler, or any combination thereof, configured to adjust (e.g., increase or decrease) a temperature of the gas 340.
  • the heat exchanger may exchange heat with water, exhaust gas, compressor bleed flow, waste heat, or some other thermal fluid.
  • the gas supply system 314 also may include one or more valves 342 configured to control the distribution of the gas 340 to the plurality of conduits 254 (e.g., 255, 256. 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C. and 252D) via distribution conduits 343. 344. 346, and 348.
  • the valves 342 may include one or more multi-way valves and/or distribution manifolds to independently distribute the gas 340 through the distribution conduits 343, 344, 346, and/or 348 to the respective sorbent-based gas capture units 252 (e.g.. 252A, 252B, 252C, and 252D) when operating in an adsorption mode (e.g., gas-rich adsorption stage of the adsorption mode) in response to control signals from the controller 220.
  • an adsorption mode e.g., gas-rich adsorption stage
  • the lean/rich staggered adsorption system 319 includes one or more valves 341 of the upstream flow distribution system 310, one or more valves 409 of the downstream flow distribution system 312, and a multi-stage adsorption system 460 coupled to the valves 341 and 409.
  • the one or more valves 341 are configured to control the distribution of a partially treated gas (e.g., gas-lean flow, such as CCh-lean flow) to the plurality of conduits 254 (e.g., 255.
  • a partially treated gas e.g., gas-lean flow, such as CCh-lean flow
  • valves 341 may include one or more multi-way valves and/or distribution manifolds to independently distribute the partially treated gas through the distribution conduits 468, 470, 472, and 474 to the respective sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in an adsorption mode (e.g., gas-lean adsorption stage of the adsorption mode) in response to control signals from the controller 220.
  • an adsorption mode e.g., gas-lean adsorption stage of the adsorption mode
  • the multi-stage adsorption system 460 includes a lean stage 462 and a rich stage 464 configured to enable a lean stage of adsorption (e.g., adsorption of CCh-lean flow) and a rich stage of adsorption (e.g., adsorption of CCh-rich flow).
  • the multi-stage adsorption system 460 may be at least partially integrated with the gas pre-treatment system 330, at least partially between the gas pre-treatment system 330 and the valves 341 and 342, coupled to the valves 341, 342, 409, and 410, or any combination thereof.
  • the multi-stage adsorption system 460 may include control logic (e.g., lean stage control code and rich stage control code) disposed on the controller 220 and/or disposed on an embedded controller of the multi-stage adsorption system 460.
  • the lean/rich staggered adsorption system 319 also may include fluid circuits (e.g., fluid conduits) and valves to facilitate the adsorption stages between the various sorbent-based gas capture units 252, including the fluid circuits and valves of the upstream flow distribution system 310 and the downstream flow distribution system 312.
  • the lean/rich staggered adsorption system 319 includes a fluid circuit 466 between the valves 341 and 409, such that the lean/rich staggered adsorption system 319 can return the gas flow (e.g., partially treated gas) to the upstream flow distribution system 310 for another pass or stage of adsorption through one of the sorbent-based gas capture units 252.
  • gas flow e.g., partially treated gas
  • the lean/rich staggered adsorption system 319 directs a partially treated gas 340 (e.g., gas-lean flow, such as CCh-lean gas) through a different one of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in the gas-lean adsorption stage of the adsorption mode.
  • a partially treated gas 340 e.g., gas-lean flow, such as CCh-lean gas
  • the sorbent-based gas capture units 252 e.g., 252A, 252B, 252C, and 252D
  • the rich stage 464 of the multi-stage adsorption system 460 may facilitate the routing of the gas 340 into and through one of the sorbent-based gas capture units 252 (e.g.. 252A, 252B, 252C, and 252D) when operating in the gas-rich adsorption stage of the adsorption mode.
  • the sorbent-based gas capture units 252 e.g. 252A, 252B, 252C, and 252D
  • the lean stage 462 of the multi-stage adsorption system 460 may facilitate the routing of the partially treated gas 340 into and through the different one of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in the gas-lean adsorption stage of the adsorption mode, such as by directing the partially treated gas 340 along the fluid circuit 466 from the one or more valves 409 to the one or more valves 341.
  • the sorbent-based gas capture units 252 e.g., 252A, 252B, 252C, and 252D
  • the multi-stage adsorption system 460 is further configured to operate each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) in the following adsorption stages: (1) the gas-lean adsorption stage of the multi-stage adsorption mode via the lean stage 462. and (2) the gas-rich adsorption stage of the multi-stage adsorption mode via the rich stage 464.
  • the sorbent-based gas capture units 252 e.g., 252A, 252B, 252C, and 252D
  • the multi-stage adsorption system 460 may be controlled by the controller 220 to ensure that the multi-stage adsorption mode of each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) starts with adsorption of a gas-lean flow (e.g., CO2-lean gas) and ends with adsorption of a gas-rich flow (e.g., CCh-rich gas). After multiple adsorption stages are complete, then each of the sorbent-based gas capture units 252 may proceed to the desorption mode followed by the cooling mode.
  • a gas-lean flow e.g., CO2-lean gas
  • a gas-rich flow e.g., CCh-rich gas
  • the heating fluid supply system 316 of the upstream flow distribution system 310 is configured to supply a heating fluid to enable the desorption mode when selectively operating each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) in the desorption mode via the controller 220.
  • the heating fluid supply system 316 also may coordinate with a vacuum system of the post-desorption processor 442.
  • the heating fluid supply system 316 includes one or more heating fluid supplies 350, such as one or more steam supplies, heated water supplies, heated gas supplies, and/or waste heat supplies.
  • the heating fluids also may be described as sweep fluids, such as a sweep gas or a sweep steam.
  • the heating fluid supplies 350 may include the steam turbine system 14, the HRSG 16, a waste heat recovery system (e.g., recovering heat from compressors, pumps, generators, reactors, or other power plant equipment), a steam generator or boiler, or any combination thereof.
  • the WHR system 22 uses waste heat recovered from the exhaust gas 152, 184, and provides the heated fluid 26 for use as the heating fluid 354.
  • the heated fluid 26 (e.g., waste heat recovery fluid) also may be described as an excess heat or waste heat recovered for use in the heating fluid supply system 316 of the sorbent-based gas capture units 252.
  • the heating fluid supplies 350 may be configured to supply a heating fluid 352 (e.g., steam and/or heated water) and/or a heating fluid 354 (e.g., waste heat recovery fluid, such as heated fluid 26) to a heating fluid control 356 of the heating fluid supply system 316.
  • a heating fluid 352 e.g., steam and/or heated water
  • a heating fluid 354 e.g., waste heat recovery fluid, such as heated fluid 26
  • the heating fluid 352 may include a heated liquid and/or a heated gas, such as heated CO2, air, inert gas such as nitrogen, water, oil, or any combination thereof.
  • the heating fluid control 356 includes one or more heating fluid control components 358, 360, and 362, which may be configured to process, adjust, and/or control characteristics of the heating fluid 352 and/or heating fluid 354 upstream from the conduits 254 (e.g., 255, 256. 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D).
  • the heating fluid control component 358 may include a thermal control component (e.g., temperature control component), such as a heat exchanger, a heater, a cooler, or any combination thereof, configured to adjust (e g., increase or decrease) a temperature of the heating fluid 352 and/or the heating fluid 354.
  • the heat exchanger may exchange heat with water, lubricant, coolant, refrigerant, or some other thermal fluid.
  • a waste heat recovery 7 system may be used for heat transfer in the heat exchanger.
  • the heating fluid control component 360 may include a pressure control component, such as a pressure regulator, an expander or expansion chamber, a constrictor or constriction chamber, a fan or pump to add energy, a turbine to extract energy, or another suitable pressure controller.
  • the heating fluid control component 362 may include a pre-treatment component, such as a particulate filter, a cold water drain, and/or other pre-treatment components configured to alter characteristics of the heating fluid 352 and/or the heating fluid 354 or remove contaminants.
  • the heating fluid supply system 316 also may include one or more valves 364 configured to control the distribution of the heating fluid 352 (e.g., steam and/or heated water) and/or the heating fluid 354 (e.g., waste heat recovery fluid) to the plurality of conduits 254 (e.g., 255, 256, 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) via distribution conduits 365, 366, 368. and 370.
  • the heating fluid 352 e.g., steam and/or heated water
  • the heating fluid 354 e.g., waste heat recovery fluid
  • valves 364 may include one or more multi-way valves and/or distribution manifolds to independently distribute the heating fluid 352 and/or the heating fluid 354 through the distribution conduits 365, 366, 368, and 370 to the respective sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in a desorption mode in response to control signals from the controller 220.
  • the valves 364 may include one or more multi-way valves and/or distribution manifolds to independently distribute the heating fluid 352 and/or the heating fluid 354 through the distribution conduits 365, 366, 368, and 370 to the respective sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in a desorption mode in response to control signals from the controller 220.
  • the cooling fluid supply system 318 of the upstream flow distribution system 310 is configured to supply a cooling fluid to enable the cooling mode when selectively operating each of the sorbent-based gas capture units 252 (e g., 252A, 252B, 252C, and 252D) in the cooling mode via the controller 220.
  • the cooling fluid supply system 318 includes one or more cooling fluid supplies 372, such as one or more water supplies, cooled air supplies, cooled inert gas (e.g., nitrogen) supplies, cooled CO2 supplies, or any combination thereof.
  • the cooling fluid supplies 372 may be configured to supply a coolant or cooling fluid 374 (e.g., liquid or gas coolant) to a cooling fluid control 376 of the cooling fluid supply system 318.
  • the cooling fluid control 376 includes one or more cooling fluid control components 378, 380, and 382, which may be configured to process, adjust, and/or control characteristics of the cooling fluid 374 upstream from the conduits 254 (e.g., 255, 256. 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D).
  • the cooling fluid control component 378 may include a thermal control component (e.g., temperature control component), such as a heat exchanger, a heater, a cooler, or any combination thereof, configured to adjust (e.g., increase or decrease) a temperature of the cooling fluid 374.
  • the heat exchanger may exchange heat with water, lubricant, coolant, refrigerant, or some other thermal fluid.
  • the cooling fluid control component 380 may include a pressure control component, such as a pressure regulator, an expander or expansion chamber, a constrictor or constriction chamber, a fan or pump to add energy, a turbine to extract energy, or another suitable pressure controller.
  • the cooling fluid control component 382 may include a pre-treatment component, such as a particulate filter and/or other pretreatment components, configured to alter characteristics of the cooling fluid 374 or remove contaminants.
  • the cooling fluid supply system 318 also may include one or more valves 384 configured to control the distribution of the cooling fluid 374 (e.g., liquid or gas coolant) to the plurality of conduits 254 (e.g.. 255, 256, 258. and 260) of the sorbentbased gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) via distribution conduits 385, 386, 388, and 390.
  • the cooling fluid 374 e.g., liquid or gas coolant
  • conduits 254 e.g. 255, 256, 258. and 260
  • the sorbentbased gas capture units 252 e.g., 252A, 252B, 252C, and 252D
  • valves 384 may include one or more multi-way valves and/or distribution manifolds to independently distribute the cooling fluid 374 through the distribution conduits 385, 386, 388, and 390 to the respective sorbent-based gas capture units 252 (e g., 252A, 252B, 252C, and 252D) when operating in a cooling mode in response to control signals from the controller 220.
  • the respective sorbent-based gas capture units 252 e g., 252A, 252B, 252C, and 252D
  • the controller 220 is configured to control the upstream flow distribution system 310 and the lean/rich staggered adsorption system 319 to altematingly distribute flows of the partially treated gas 340 (e.g., CO2- lean flow) during the gas-lean adsorption stage of the multi-stage adsorption mode, the gas 340 (e.g., CCh-rich flow) during the gas-rich adsorption stage of the multistage adsorption mode, the heating fluid 352 and/or the heating fluid 354 in the desorption mode, and the cooling fluid 374 in the cooling mode to the different sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) having sorbent material 272.
  • the partially treated gas 340 e.g., CO2- lean flow
  • the gas 340 e.g., CCh-rich flow
  • the heating fluid 352 and/or the heating fluid 354 in the desorption mode e.g., the cooling fluid 3
  • the partially treated gas 340 (e.g., intake gas 60 or exhaust gas 152, 184, already treated in the gas-rich adsorption stage) flows through the conduit 254 of the different selected sorbent-based gas capture unit 252 (e.g.. 252A. 252B, 252C, or 252D) and contacts the sorbent material 272 disposed on the interior surface 274 of the outer conduit wall 262 and/or the exterior surface 276 of the contactors 280, such that the sorbent material 272 adsorbs the undesirable gases (e.g., CO2) from the partially treated gas 340.
  • the undesirable gases e.g., CO2
  • the heating fluid 352 and/or the heating fluid 354 flows through the conduit 254 of the selected sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, or 252D) and contacts the sorbent material 272 disposed on the interior surface 274 of the outer conduit wall 262 and/or the exterior surface 276 of the contactors 280. thereby heating the sorbent material 272 to facilitate desorption of the undesirable gases (e.g., CO2) from the sorbent material 272.
  • the desorption mode may be configured to indirectly heat the sorbent material 272 via a heating circuit (e.g., heating conduit) extending through the sorbent-based gas capture unit 252.
  • the cooling fluid 374 flows through the conduit 254 of the selected sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, or 252D) and contacts the sorbent material 272 disposed on the interior surface 274 of the outer conduit wall 262 and/or the exterior surface 276 of the contactors 280, thereby cooling the sorbent material 272 and the contactors 280.
  • the cooling mode may be configured to indirectly cool the sorbent material 272 and the contactors 280 via a cooling circuit (e.g.. cooling conduit) extending through the sorbent-based gas capture unit 252.
  • the controller 220 is configured to control the downstream flow distribution system 312 to altematingly distribute flows from each sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, and 252D) to route the partially treated gas 340 to the lean/rich staggered adsorption system 319 during or between stages of the adsorption mode, the treated gas 400 to the post-adsorption processing system 320 upon completion of the adsorption mode, the fluid flow 402 (e.g., the undesirable gas, the heating fluid 352, and/or the heating fluid 354) to the post-desorption processing system 322 in the desorption mode, and the fluid flow 404 (e.g., cooling fluid 374) to the post-cooling system 324 in the cooling mode.
  • each sorbent-based gas capture unit 252 e.g., 252A, 252B, 252C, and 252D
  • the controller 220 is configured to control the downstream flow distribution system 312 to altematingly distribute flows from each
  • the downstream flow distribution system 312 includes one or more valves 409 fluidly coupled with the sorbent-based gas capture unit 252A, one or more valves 410 fluidly coupled with the sorbent-based gas capture unit 252B, one or more valves 412 fluidly coupled with the sorbent-based gas capture unit 252C, and one or more valves 414 fluidly coupled with the sorbent-based gas capture unit 252D.
  • the valves 409 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 476, 478, 480, and 482, which are coupled to the lean/rich staggered adsorption system 319, the post-adsorption processing system 320, the post-desorption processing system 322. and the postcooling system 324, respectively.
  • the valves 410 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 415, 416, 418, and 420, which are coupled to the lean/rich staggered adsorption system 319, the postadsorption processing system 320. the post-desorption processing system 322, and the post-cooling system 324, respectively.
  • the valves 412 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 421, 422, 424, and 426, which are coupled to the lean/rich staggered adsorption system 319, post-adsorption processing system 320, the post-desorption processing system 322, and the post-cooling system 324. respectively.
  • the valves 414 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 427, 428, 430, and 432. which are coupled to the lean/rich staggered adsorption system 319, the post-adsorption processing system 320. the postdesorption processing system 322, and the post-cooling system 324, respectively.
  • the controller 220 is configured to control the valves 409, 410, 412, and 414 to independently control the flows from the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) to the lean/rich staggered adsorption system 319 during and between stages of the adsorption mode, to the postadsorption processing system 320 after completion of the adsorption mode, to the post-desorption processing system 322 in the desorption mode, and to the postcooling system 324 in the cooling mode.
  • the sorbent-based gas capture units 252 e.g., 252A, 252B, 252C, and 252D
  • the post-adsorption processing system 320 includes a treated gas processing system 440. which may include an exhaust stack, an additional gas treatment system, or any other suitable post processing equipment. In certain embodiments, the post-adsorption processing system 320 may recirculate all or part of the treated gas 400 to the EGR system 150 as discussed above with reference to FIG. 1.
  • the post-desorption processing system 322 may include a post-desorption processor 442 having one or more post-desorption processing components 444, 446, and 448.
  • the fluid flow 402 directed to the post-desorption processor 442 is a result of the desorption mode, wherein the heating fluid 352 (e.g.. steam and/or heated water) and/or heating fluid 354 (e.g., waste heat recover fluid, such as heated fluid 26) is directed through the conduit 254 of the sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, or 252D) to desorb the undesirable gases (e.g., CO2) from the sorbent material 272.
  • the heating fluid 352 e.g. steam and/or heated water
  • heating fluid 354 e.g., waste heat recover fluid, such as heated fluid 26
  • the one or more postdesorption processing components 444, 446, and 448 may be configured to process, adjust, and/or control characteristics of the fluid flow 402 (e.g., steam, heated water, and/or other fluid flow) from the conduits 254 (e.g., 255, 256. 258, and 260) of the sorbentbased gas capture units 252 (e.g.. 252A, 252B. 252C. and 252D).
  • the post-desorption processing component 444 may include a captured gas/heated fluid separator configured to separate the heating fluid 352 (e.g., steam and/or heated water) and/or the heating fluid 354 from the captured gas. thereby outputting a fluid 450 (e.g., water condensate or other separated fluid) and the captured gas 204.
  • a captured gas/heated fluid separator include thermal control components, pressure control components, chemical separation components, or a combination thereof.
  • the captured gas/heated fluid separator may be configured to condense or cool the heating fluid 352 (e.g., steam) using a condenser.
  • the post-desorption processing component 446 may include one or more removal units configured to remove contaminants from the fluid 450 and/or the captured gas 204.
  • the removal units may include particulate filters and/or water treatment units.
  • the removal units may include particulate filters, water removal units or dryers, or further gas treatment units.
  • the postdesorption processing component 448 may include one or more pressure control components and/or flow control components, such as one or more pumps for the fluid 450 and one or more compressors for the captured gas 204.
  • the post-desorption processing components 448 also may include a vacuum system having one or more vacuum pumps configured to suction the captured gas/heated fluid flow from the sorbent-based gas capture units 252. In other words, the vacuum pumps are configured to create a low-pressure environment to help draw the captured gas/heated fluid flow from the sorbent-based gas capture units 252.
  • the post-cooling system 324 may include a cooling fluid recirculation system 452, which is configured to recirculate the fluid flow 404 back to the cooling fluid supply system 318 as the cooling fluid 374.
  • the cooling fluid recirculation system 452 may include components 454, 456, and 458, such as a recirculation pump, compressor, or booster fan, a cooling system, and flow control valves.
  • the cooling system may include a heat exchanger configured to transfer heat away from the fluid flow 404, thereby cooling the fluid flow for additional use as the cooling fluid 374.
  • the heat available from the fluid flow 404 may be recovered in one or more heat exchangers to heat the heating fluid 352 and/or heating fluid 354 of the heating fluid supply system 316, thereby reducing the total heating energy demand. The remaining low grade heat from the fluid flow 404 may then be rejected to ambient.
  • the controller 220 is configured to receive feedback from the sensors 222 to facilitate adjustments of various operating parameters and change operating modes (e.g., gas-lean adsorption stage of the multi-stage adsorption mode, gas-rich adsorption stage of the multi-stage adsorption mode, desorption mode, and cooling mode) of the sorbent-based gas capture units 252 (e g., 252A, 252B, 252C, and 252D).
  • the controller 220 may be configured to alternate flows (e.g., gas 340, partially treated gas 340, heating fluid 352 and/or heating fluid 354, and cooling fluid 374) through the plurality of conduits 254 (e.g., 255, 256.
  • the sorbent-based gas capture units 252 e.g., 252A, 252B, 252C, and 252D
  • the sorbent-based gas capture units 252 can alternate between the gas-lean adsorption stage of the multi-stage adsorption mode, gas-rich adsorption stage of the multi-stage adsorption mode, the desorption mode, and the cooling mode.
  • the conduit 254 receives a flow of the partially treated gas 340 (e.g., after a previous gas-rich adsorption stage), adsorbs the undesirable gases (e.g., CO2) from the partially treated gas 340 into the sorbent material 272, and outputs a treated gas 400 with a reduced content or concentration level of the undesirable gases (e.g., substantially free of the undesirable gases).
  • a flow of the partially treated gas 340 e.g., after a previous gas-rich adsorption stage
  • the undesirable gases e.g., CO2
  • the conduit 254 receives a flow of the gas 340, adsorbs the undesirable gases (e.g., CO2) from the gas 340 into the sorbent material 272, and outputs the partially treated gas 340 (e.g., gas-lean flow, such as CCh-lean flow) for further treatment in the gas-lean adsorption stage of the multi-stage adsorption mode.
  • the adsorption of undesirable gases into the sorbent material 272 is an exothermic process, which generates heat.
  • the thermal control system 290 including the heat exchangers 296 and the heat pipes 298, help to regulate the temperature of the sorbent material 272 during the adsorption mode, thereby maintaining or increasing the adsorption efficiency of the sorbent material 272.
  • the conduit 254 receives a flow 7 of the heating fluid 352 (e.g., steam and/or heated water) and/or heating fluid 354. desorbs the undesirable gases (e.g., CO2) from the sorbent material 272 into the heating fluid 352 and/or heating fluid 354, and outputs the fluid flow 402 with the desorbed undesirable gases (e.g.. heating fluid 352 and/or heating fluid 354 rich in the undesirable gases such as CO2).
  • the heating fluid 352 e.g., steam and/or heated water
  • the undesirable gases e.g., CO2
  • the desorbed undesirable gases e.g. heating fluid 352 and/or heating fluid 354 rich in the undesirable gases such as CO2
  • the desorption of undesirable gases from the sorbent material 272 is an endothermic process, and the heating fluid 352 and/or heating fluid 354 provides sufficient heat (e.g., directly or indirectly) to drive the desorption of the undesirable gases (e.g., CO2) from the sorbent material 272.
  • the conduit 254 receives a flow of the cooling fluid 374 (e.g., gas or liquid coolant), thereby cooling the sorbent material 272 and the contactors 280.
  • the controller 220 is configured to monitor the sensors 222. such as sensors 222 at or upstream from the inlets 266 and sensors 222 at or downstream from the outlets 270, to evaluate rates of adsorption, desorption, and cooling, concentration levels of the undesirable gases, and other characteristics impacting the operating modes of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D).
  • the sensors 222 such as sensors 222 at or upstream from the inlets 266 and sensors 222 at or downstream from the outlets 270, to evaluate rates of adsorption, desorption, and cooling, concentration levels of the undesirable gases, and other characteristics impacting the operating modes of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D).
  • the controller 220 may be configured to control the valves 341, 342, 364, 384, 409, 410, 412, and 414 to change the flows through the conduits 254 to support the desired operating modes.
  • the sensors 222 also may monitor the temperature of the sorbent material 272 and adjust the thermal control system 290 to provide heating or cooling depending on the operating mode (e.g., cooling during the adsorption and cooling modes and heating during the desorption mode).
  • the controller 220 may be configured to control the gas pre-treatment system 330 to control characteristics of the gas 340 (e.g., temperature, pressure, flow rate, etc.).
  • the controller 220 may be configured to control the multi-stage adsorption system 460 to control the flow of the partially treated gas 340 from the downstream flow distribution system 312 to the upstream flow distribution system 310.
  • the controller 220 is configured to control the treated gas processing system 440 to control the processing of the treated gas 400 discharged from one or more of the conduits 254.
  • the controller 220 may be configured to control the HRSG 16, the steam turbine system 14, the WHR system 22, the heating fluid control 356, or any combination thereof, to control characteristics of the heating fluid 352 and/or the heating fluid 354 (e.g.. temperature, pressure, flow rate, steam content, water content, etc.).
  • the controller 220 is configured to control the post-desorption processor 442 to control the processing of the fluid flow 402 (including the undesirable gas desorbed during the desorption mode) discharged from one or more of the conduits 254.
  • the controller 220 may be configured to control the cooling fluid control 376 and/or the cooling fluid recirculation system 452 to control characteristics of the cooling fluid 374 (e.g., temperature, pressure, flow rate, etc.).
  • the controller 220 is configured to control the cooling fluid recirculation system 452 to control the processing of the fluid flow 404 (e.g., cooling fluid 374) discharged from one or more of the conduits 254.
  • FIGS. 3-6 are schematics of an embodiment of a staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250) of FIGS. 1-2, further illustrating a first stage of an adsorption mode 502 (e g., gas-rich or CCh-rich adsorption stage), a second stage of an adsorption mode 504 (e.g., gas-lean or CO2-lean adsorption stage), a desorption mode 506, and a cooling mode 508 over four periods of time of the staggered operational cycle 500. All illustrated aspects and descriptions of FIGS. 1-2 are applicable to the embodiment of FIGS. 3-6. Similarly, any additional aspects and descriptions of FIGS.
  • an adsorption mode 502 e.g., gas-rich or CCh-rich adsorption stage
  • a second stage of an adsorption mode 504 e.g., gas-lean or CO2-lean adsorption stage
  • desorption mode 506
  • the sorbent-based gas capture system 250 includes sorbent-based gas capture units 1, 2. 3, and 4. which may correspond to the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) as discussed above with reference to FIG. 2.
  • the first stage of the adsorption mode 502 directs a rich flow 510 (e.g., C Ch-rich flow) from the gas turbine system 12 through one of the sorbent-based gas capture units 252, adsorbs undesirable gases (e.g., CO2) from the rich flow 510, and outputs a lean flow 512 (e.g., CCh-lean flow).
  • a rich flow 510 e.g., C Ch-rich flow
  • undesirable gases e.g., CO2
  • a lean flow 512 e.g., CCh-lean flow
  • the rich flow 510 and the lean flow 512 include exhaust gas 152, 184 from the gas turbine system 12, the HRSG 16, or any other combustion system of the combined cycle system 10.
  • the first stage of the adsorption mode 502 may remove at least equal to or greater than 70, 75, 80, 85, 90, 95, or greater percent of a total CO2 concentration in the rich flow 510, thereby generating the lean flow 512 with a substantially reduced concentration of the CO2.
  • the sorbent-based gas capture system 250 then routes the lean flow 512 to the second stage of the adsorption mode 504.
  • the second stage of the adsorption mode 504 directs the lean flow 512 (e.g., CO2-lean flow) from the first stage of the adsorption mode 502 through a different one of the sorbent-based gas capture units 252, adsorbs undesirable gases (e.g., CO2) from the lean flow 512, and outputs a treated gas 514 (e.g., treated exhaust gas 152, 184 substantially free of CO2).
  • the second stage of the adsorption mode 504 may remove all or part of the remaining CO2 concentration (e.g., at least equal to or greater than 70, 75, 80, 85, 90, 95, or greater percent of the remaining CO2 concentration) in the lean flow 512 to generate the treated gas 514.
  • the treated gas 514 may have a CO2 content substantially equal to or less than atmospheric content of the CO2.
  • the sorbent-based gas capture unit 252 may then direct the treated gas 514 through a stack 516 (e.g., exhaust stack).
  • the sorbent-based gas capture unit 252 generally proceeds to the desorption mode 506.
  • the desorption mode 506 provides heat or heating 518 (e g., heating fluid) to the sorbent-based gas capture unit 252, thereby facilitating desorption of the undesirable gases (e.g., CO2) from sorbent material in the sorbent-based gas capture unit 252 to output a captured gas 204 (e.g.. captured CO2).
  • the heat 518 may include a variety of heated fluids, such as heated water, steam, or other heated liquids and gases.
  • the heat 518 also may be applied by an electrical heat source, waste heat, or any combination of heat sources.
  • the sorbent-based gas capture unit 252 generally proceeds to the cooling mode 508.
  • the cooling mode 508 provides cooling 520 (e.g., cooling fluid) to the sorbent-based gas capture unit 252. thereby facilitating cooling of the sorbent material in the sorbent-based gas capture unit 252 to regenerate or generally prepare the sorbent-based gas capture unit 252 for another cycle starting with adsorption.
  • the cooling 520 may include a variety of cooling fluids, such as cooled water, air, or other cooled liquids and gases.
  • the sorbent-based gas capture system 250 operates with a different arrangement or configuration of the sorbent-based gas capture units 252 in the first stage of the adsorption mode 502, the second stage of the adsorption mode 504, the desorption mode 506, and the cooling mode 508.
  • each of the sorbent-based gas capture systems 250 progressively cycles through the following sequence: (1) the second stage of the adsorption mode 504, (2) the first stage of the adsorption mode 502, (3) the desorption mode 506, and (4) the cooling mode 508.
  • FIG. 3 is a schematic of a first configuration 530 during a first duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g.. sorbent-based gas capture system 250).
  • the sorbent-based gas capture unit 1 is disposed in the first stage of the adsorption mode 502
  • the sorbent-based gas capture unit 2 is disposed in the second stage of the adsorption mode 504.
  • the sorbent-based gas capture unit 3 is disposed in the desorption mode 506, and the sorbent-based gas capture unit 4 is disposed in the cooling mode 508.
  • FIG. 4 is a schematic of a second configuration 532 during a second duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250).
  • the sorbent-based gas capture unit 2 is disposed in the first stage of the adsorption mode 502
  • the sorbent-based gas capture unit 4 is disposed in the second stage of the adsorption mode 504.
  • the sorbent-based gas capture unit 1 is disposed in the desorption mode 506, and the sorbent-based gas capture unit 3 is disposed in the cooling mode 508.
  • FIG. 5 is a schematic of a third configuration 534 during a third duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250).
  • the sorbent-based gas capture unit 4 is disposed in the first stage of the adsorption mode 502
  • the sorbent-based gas capture unit 3 is disposed in the second stage of the adsorption mode 504
  • the sorbent-based gas capture unit 2 is disposed in the desorption mode 506
  • the sorbent-based gas capture unit 1 is disposed in the cooling mode 508.
  • FIG. 6 is a schematic of a fourth configuration 536 during a fourth duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250).
  • the sorbent-based gas capture unit 3 is disposed in the first stage of the adsorption mode 502
  • the sorbent-based gas capture unit 1 is disposed in the second stage of the adsorption mode 504
  • the sorbent-based gas capture unit 4 is disposed in the desorption mode 506
  • the sorbent-based gas capture unit 2 is disposed in the cooling mode 508.
  • FIG. 7 is a flow chart of an embodiment of a process 550 for controlling the staggered operating cycle 500 as illustrated in FIGS. 3-6, wherein the process 550 is controlled by the instructions 228 stored on the memory 226 and executable by the processor 224 of the controller 220 of FIG. 1.
  • the process 550 controls a staggered operating cycle 500 with a plurality of sorbent-based gas capture units 252 to capture an undesirable gas (e.g., CO2) from a gas flow (block 552).
  • the process 550 cycles each of the plurality of sorbent-based gas capture units 252 through a plurality of operating modes.
  • the process 550 controls the gas flow (e.g., exhaust gas 152, 184) through a sorbent-based gas capture unit 252 during a gas-lean adsorption stage of a multi-stage adsorption mode (e.g., second stage of adsorption mode 504) of the staggered operating cycle 500.
  • the process 550 controls the gas flow (e.g., exhaust gas 152, 184) through the sorbent- based gas capture unit 252 during a gas-rich adsorption stage of the multi-stage adsorption mode (e.g., first stage of adsorption mode 502) of the staggered operating cycle 500.
  • a gas-rich adsorption stage of the multi-stage adsorption mode e.g., first stage of adsorption mode 502
  • the process 550 controls a heating fluid flow through the sorbent-based gas capture unit 252 during a desorption mode 506 of the staggered operating cycle 500.
  • the process 550 controls a cooling fluid flow through the sorbent-based gas capture unit 252 during a cooling mode 508 of the staggered operating cycle 500.
  • the process 550 repeats the steps of the gas-lean adsorption stage (block 554), the gas-rich adsorption stage (block 556), the desorption mode (block 558), and the cooling mode (block 560) for each of the plurality of sorbent-based gas capture units 252 in the staggered operating cycle 500.
  • FIG. 8 is a flow chart of an embodiment of a process 580 for controlling the staggered operating cycle 500 as illustrated in FIGS. 3-6, wherein the process 580 is controlled by the instructions 228 stored on the memory 226 and executable by the processor 224 of the controller 220 of FIG. 1.
  • the process 580 operates each of a plurality' of sorbent-based gas capture units 252 in a staggered operating cycle 500 of a gas-lean adsorption stage, a gas-rich adsorption stage, a desorption mode, and a cooling mode.
  • the process 580 controls gas flow (e.g., exhaust gas 152, 184) through a first sorbent-based gas capture unit 252 as a first adsorption stage using the gas-rich adsorption stage (e.g.. first stage of adsorption mode 502) of the staggered operating cycle 500.
  • the process 580 controls gas flow (e.g., exhaust gas 152, 184) through a second sorbent-based gas capture unit 252 as a second adsorption stage using the gas-lean adsorption stage (e.g., second stage of adsorption mode 504) of the staggered operating cycle 500.
  • the process 580 controls a heating fluid flow through a third sorbent-based gas capture unit 252 during the desorption mode 506 of the staggered operating cycle 500.
  • the process 580 controls a cooling fluid flow through a fourth sorbent-based gas capture unit 252 during the cooling mode 508 of the staggered operating cycle 500.
  • the process 580 repeats the process with each of the plurality of sorbent-based gas capture units 252 operating in a next operating step in the staggered operating cycle 500.
  • each sorbent-based gas capture unit adsorbs undesirable gases (e.g., CO2) starting in a second adsorption stage (e.g., gas-lean adsorption stage) prior to adsorbing the undesirable gases in a first adsorption stage (e.g., gas-rich adsorption stage).
  • gases e.g., CO2
  • first adsorption stage e.g., gas-rich adsorption stage
  • the use of each sorbent-based gas capture unit in multiple adsorption stages rather than using a first set of sorbent-based gas capture units only in a first adsorption stage and a second set of sorbent-based gas capture units only in a second adsorption stage, helps to improve efficiency, reduce space requirements for the sorbent-based gas capture units, and reduce equipment costs.
  • a system includes a gas capture system having a first adsorber with a first sorbent material.
  • the first adsorber is configured to adsorb an undesirable gas from a gas flow into the first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas, desorb the undesirable gas from the first sorbent material in a desorption mode, and cool the first sorbent material in a cooling mode.
  • the system further includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control the first adsorber in a sequence of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode.
  • the gas capture system is configured to adsorb the undesirable gas in a first adsorption stage followed by a second adsorption stage of the plurality of adsorption stages
  • the controller is configured to control the first adsorber in the sequence of the plurality of adsorption stages in the reversed order by operating the first adsorber in the second adsorption stage prior to operating the first adsorber in the first adsorption stage.
  • the first adsorption stage includes a gas-rich adsorption stage and the second adsorption stage includes a gaslean adsorption stage.
  • the undesirable gas includes carbon dioxide (CO2)
  • the gas-rich adsorption stage includes a CCh-rich adsorption stage
  • the gas-lean adsorption stage includes a CCh-lean adsorption stage
  • the gas capture system includes the first adsorber having the first sorbent material, a second adsorber having a second sorbent material, a third adsorber having a third sorbent material, and a fourth adsorber having a fourth sorbent material.
  • the controller is configured to operate the first, second, third, and fourth adsorbers in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas. the desorption mode, and the cooling mode.
  • the staggered operating cycle includes a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively.
  • the staggered operating cycle further includes a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively.
  • the staggered operating cycle further includes a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively.
  • the staggered operating cycle further includes a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.
  • the gas capture system includes a temperature swing adsorption (TSA) system, a vacuum temperature swing adsorption (VTSA) system, a concentration swing adsorption (CSA) system, or any combination thereof.
  • TSA temperature swing adsorption
  • VTSA vacuum temperature swing adsorption
  • CSA concentration swing adsorption
  • a system includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control a first adsorber of a gas capture system to: adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality 7 of adsorption stages in a reversed order with an increasing concentration of the undesirable gas.
  • the controller is further configured to desorb the undesirable gas from the first sorbent material in a desorption mode.
  • the controller is further configured to cool the first sorbent material in a cooling mode.
  • the gas capture system is configured to adsorb the undesirable gas in a first adsorption stage followed by a second adsorption stage of the plurality of adsorption stages
  • the controller is configured to control the first adsorber in the sequence of the plurality of adsorption stages in the reversed order by operating the first adsorber in the second adsorption stage prior to operating the first adsorber in the first adsorption stage.
  • the undesirable gas includes carbon dioxide (CO2)
  • the first adsorption stage includes a CCh-rich adsorption stage
  • the second adsorption stage includes a CCh-lean adsorption stage
  • the first adsorber includes a temperature swing adsorption (TSA) unit, a vacuum temperature swing adsorption (VTSA) unit, a concentration swing adsorption (CSA) unit, or any combination thereof.
  • TSA temperature swing adsorption
  • VTSA vacuum temperature swing adsorption
  • CSA concentration swing adsorption
  • the gas capture system includes the first adsorber having the first sorbent material, a second adsorber having a second sorbent material, a third adsorber having a third sorbent material, and a fourth adsorber having a fourth sorbent material.
  • the controller is configured to operate the first, second, third, and fourth adsorbers in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode.
  • the staggered operating cycle includes a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively.
  • the staggered operating cycle further includes a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively.
  • the staggered operating cycle further includes a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively.
  • the staggered operating cycle further includes a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.
  • a method includes controlling, via a controller, a first adsorber of a gas capture system to adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas.
  • the method further includes controlling, via the controller, the first adsorber to desorb the undesirable gas from the first sorbent material in a desorption mode.
  • the method further includes controlling, via the controller, the first adsorber to cool the first sorbent material in a cooling mode.
  • the method of the preceding clause further including controlling the first adsorber, a second adsorber, a third adsorber, and a fourth adsorber in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode.
  • the staggered operating cycle includes a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively.
  • the staggered operating cycle further includes a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively.
  • the staggered operating cycle further includes a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively.
  • the staggered operating cycle further includes a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.

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Abstract

A system includes a gas capture system having a first adsorber with a first sorbent material. The first adsorber is configured to adsorb an undesirable gas from a gas flow into the first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas, desorb the undesirable gas from the first sorbent material in a desorption mode, and cool the first sorbent material in a cooling mode. The system further includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control the first adsorber in a sequence of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode.

Description

SYSTEM AND METHOD FOR GAS CAPTURE USING MULTIPLE ADSORPTION STAGES
BACKGROUND
[0001] The present application relates generally to a system and method for capturing undesirable gases associated with a combustion system, such as a combustion-driven power plant.
[0002] An industrial plant, such as a combustion-driven power plant, may produce a variety of gases, such as an exhaust gas of a combustion system. The combustion system may include a gas turbine engine, a reciprocating piston-cylinder engine, a furnace, a boiler, or other industrial equipment. These exhaust gases may include one or more undesirable gases, such as acid gases and/or greenhouse gases. For example, the undesirable gases may include carbon oxides (COx) such as carbon dioxide (CO2) and carbon monoxide (CO), nitrogen oxides (NOx) such as nitrogen dioxide (NO2). and/or sulfur oxides (SOx) such as sulfur dioxide (SO2). CO2 is both an acid gas and a greenhouse gas. Unfortunately, the atmospheric content of CO2 has generally increased over thousands of years, and currently exceeds about 420 parts per million by volume (ppmv) or 643 parts per million by weight (ppmw) in the atmosphere. With various regulations and environmental concerns regarding global warming, it would be desirable to reduce the output of undesirable gases (e.g., CO2) into the atmosphere, particularly for hydrocarbon fuel consuming equipment such as combustion systems.
BRIEF DESCRIPTION
[0003] Certain embodiments commensurate in scope with the originally claimed subject matter are summarized below. These embodiments are not intended to limit the scope of the claimed embodiments, but rather these embodiments are intended only to provide a brief summary’ of possible forms of the subject matter. Indeed, the presently claimed embodiments may encompass a variety of forms that may be similar to or different from the embodiments set forth below. [0004] In certain embodiments, a system includes a gas capture system having a first adsorber with a first sorbent material. The first adsorber is configured to adsorb an undesirable gas from a gas flow into the first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas, desorb the undesirable gas from the first sorbent material in a desorption mode, and cool the first sorbent material in a cooling mode. The system further includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control the first adsorber in a sequence of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas. the desorption mode, and the cooling mode.
[0005] In certain embodiments, a system includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control a first adsorber of a gas capture system to: adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas. The controller is further configured to desorb the undesirable gas from the first sorbent material in a desorption mode. The controller is further configured to cool the first sorbent material in a cooling mode.
[0006] In certain embodiments, a method includes controlling, via a controller, a first adsorber of a gas capture system to adsorb an undesirable gas from a gas flow7 into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas. The method further includes controlling, via the controller, the first adsorber to desorb the undesirable gas from the first sorbent material in a desorption mode. The method further includes controlling, via the controller, the first adsorber to cool the first sorbent material in a cooling mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other features, aspects, and advantages of the presently disclosed techniques will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0008] FIG. 1 is a block diagram of an embodiment of a combined cycle system having one or more gas capture systems.
[0009] FIG. 2 is a schematic of an embodiment of a gas capture system of FIG. 1, illustrating a sorbent-based gas capture system having an adsorption mode, a desorption mode, and a cooling mode, wherein the adsorption mode comprises a plurality of adsorption stages.
[0010] FIG. 3 is a schematic of a first configuration of four sorbent-based gas capture units during a first duration of time of a staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
[0011] FIG. 4 is a schematic of a second configuration of the four sorbent-based gas capture units during a second duration of time of the staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
[0012] FIG. 5 is a schematic of a third configuration of the four sorbent-based gas capture units during a third duration of time of the staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
[0013] FIG. 6 is a schematic of a fourth configuration of the four sorbent-based gas capture units during a fourth duration of time of the staggered operational cycle of the sorbent-based gas capture system of FIGS. 1 and 2.
[0014] FIG. 7 is a flow chart of an embodiment of a process for controlling the staggered operating cycle as illustrated in FIGS. 3-6.
[0015] FIG. 8 is a flow chart of an embodiment of a process for controlling the staggered operating cycle as illustrated in FIGS. 3-6. DETAILED DESCRIPTION
[0016] One or more specific embodiments of the presently disclosed systems and methods are described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementationspecific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0017] When introducing elements of various embodiments of the presently disclosed embodiments, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0018] The disclosed embodiments include systems and methods to reduce the carbon footprint of combustion systems, such as combustion-driven power plants and/or combined cycle power plants, using a gas treatment system having one or more gas capture systems. The gas capture systems are configured to remove undesirable gases (e.g., CO2) from the intake air and/or the exhaust gas of the combustion systems. The gas capture systems may include sorbent-based gas capture systems, solvent-based gas capture systems, cryogenic gas capture systems, or a combination thereof. In certain embodiments, the gas capture systems (e.g., sorbent-based gas capture systems) may include one or more temperature swing adsorption (TSA) systems, vacuum temperature swing adsorption (VTSA) systems, concentration swing adsorption (CSA) systems, or any combination thereof. For example, the gas capture systems (e.g., sorbent-based gas capture systems) may include one or more temperature swing adsorption (TSA) units or adsorbers, which rely on temperature swings to adsorb undesirable gases at a first temperature (e.g., low temperature) and desorb the undesirable gases at a second temperature (e.g.. high temperature). By further example, the gas capture systems (e.g., sorbent-based gas capture systems) may include one or more vacuum temperature swing adsorption (VTSA) units or adsorbers, which rely on temperature and pressure swings to adsorb undesirable gases at a first temperature (e.g., low temperature) and a first pressure (e.g., high pressure) and desorb the undesirable gases at a second temperature (e.g.. high temperature) and a second pressure (e.g., low pressure). In certain embodiments, during the desorption, a heat source to facilitate the desorption may include a variety of heated fluids, such as steam, an inert gas (e.g., nitrogen (N2)), or any other suitable sweep gas. The sorbent-based gas capture systems are configured to adsorb the undesirable gases into a sorbent material, and then subsequently desorb the undesirable gases from the sorbent material using a heat source (e.g., a heated fluid).
[0019] In the disclosed embodiments, each sorbent-based gas capture system is configured to adsorb the undesirable gases from a gas flow (e.g., intake air and/or exhaust gas) in a plurality of adsorption stages that progressively reduce the undesirable gas content. For example, as discussed below with reference to FIGS. 3- 6, a multi-stage adsorption mode may include: (1) a first adsorption stage - undesirable gas-rich adsorption stage to adsorb the undesirable gas from an undesirable gas-rich flow (e.g., CCh-rich flow) into sorbent material, and (2) a second adsorption stage - undesirable gas-lean adsorption stage to adsorb the undesirable gas from an undesirable gas-lean flow (e.g., CCh-lean flow) into sorbent material. For example, when treating an exhaust gas. the first adsorption stage (e.g., CCh-rich adsorption stage) may reduce the content of the undesirable gas (e.g., CO2) by removing at least equal to or greater than 70, 75, 80, 85, 90, 95, or greater percent of a total CO2 concentration in the exhaust gas, thereby changing or cleaning the exhaust gas from a gas-rich flow (e.g., CCh-rich flow) to a gas-lean flow (e.g., CCh-lean flow) of the exhaust gas. By further example, when treating the exhaust gas. the second adsorption stage (e.g., CCh-lean adsorption stage) may further reduce the content of the undesirable gas (e.g., CO2) by removing all or part of the remaining CO2 concentration (e.g., at least equal to or greater than 70, 75, 80, 85, 90, 95, or greater percent of the remaining CO2 concentration) in the gas-lean flow (e.g., CCh-lean flow) of the exhaust gas from the first adsorption stage, thereby further changing or cleaning the exhaust gas from the gas-lean flow (e.g., CCh-lean flow) to a treated gas flow substantially free of the undesirable gas (e.g., CO2).
[0020] In certain embodiments, each sorbent-based gas capture system includes a plurality of sorbent-based gas capture assemblies or units that support the multi-stage adsorption mode in a reverse order of (1) the second adsorption stage - undesirable gas-lean adsorption stage, and (2) the first adsorption stage - undesirable gas-rich adsorption stage, such that each sorbent-based gas capture unit starts with the undesirable gas-lean adsorption stage and ends with the undesirable gas-rich adsorption stage. Thus, the disclosed embodiments enable the multi-stage adsorption mode with four (4) sorbent-based gas capture units operating in a staggered operational cycle. For example, the sorbent-based gas capture system may sequentially operate each of the plurality’ of sorbent-based gas capture units (e.g., four units) in the following sequence: (1) undesirable gas-lean adsorption stage to adsorb the undesirable gas from an undesirable gas-lean flow (e.g., CCh-lean flow) into sorbent material during the multi-stage adsorption mode, (2) undesirable gas-rich adsorption stage to adsorb the undesirable gas from an undesirable gas-rich flow (e.g., CCh-rich flow) into the sorbent material during the multi-stage adsorption mode. (3) desorption to desorb the undesirable gas from the sorbent material using a heating source during a desorption mode, and (4) regeneration to cool the sorbent material using a cooling source during a cooling mode. Thus, while each individual sorbentbased gas capture unit operates in the above sequence as illustrated in Table 1, the overall sorbent-based gas capture system operates in a sequence (including adsorption stages applied to the gas flow, desorption mode, and cooling mode) of the sorbentbased gas capture units 252A, 252B, 252C, and 252D as illustrated in FIGS. 3-6.
[0021] FIG. 1 is a block diagram of an embodiment of a combined cycle system 10 having a gas turbine system 12, a steam turbine system 14, a heat recovery steam generator (HRSG) 16, a gas treatment system 18 having one or more gas capture systems 20, and a waste heat recovery (WHR) system 22. The gas turbine system 12 is driven by hot combustion gases, and outputs an exhaust gas 152. The HRSG 16 recovers heat from the exhaust gas 152 to generate steam, which then drives the steam turbine system 14. In certain embodiments, the HRSG 16 and/or the steam turbine system 14 may be included or excluded from the combined cycle system 10. The one or more gas capture systems 20 of the gas treatment system 18 are configured to capture an undesirable gas (e.g., CO2) from a gas, such as the exhaust gas 152 and/or air. The gas capture systems 20 may include sorbent-based gas capture systems, solvent-based gas capture systems, cryogenic gas capture systems, or any combination thereof. As discussed in further detail below, the gas capture systems 20 may include multiple adsorption stages (e.g., first adsorption stage - undesirable gas-rich adsorption stage, and second adsorption stage - undesirable gas-lean adsorption stage) achieved with a plurality of gas capture units operating in a reversed order (e.g., undesirable gas-lean adsorption stage followed by undesirable gas-rich adsorption stage), such that each gas capture unit starts with adsorption of undesirable gases (e.g., CO2) from an undesirable gas-lean flow (e.g., CCh-lean flow) and ends with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow).
[0022] Before discussing details of the gas treatment system 18, various aspects of the combined cycle system 10 are discussed in further detail. For purposes of orientation in the drawings, reference may be made to an axial direction or axis 30. a radial direction or axis 32 extending radially away from the axial direction or axis 30, and a circumferential direction or axis 34 extending circumferentially around the axial direction or axis 30. The directions or axes 30, 32, and 34 may be in reference to a rotational axis 36 of the gas turbine system 12, for example.
[0023] The gas turbine system 12 may include an intake section 40, a compressor or compressor section 42, a combustor section 44, a gas turbine or turbine section 46, and an exhaust section 48. The compressor section 42 may include at least one shaft 50 disposed along the rotational axis 36, a casing 52 (e.g., annular casing) disposed circumferentially about the at least one shaft 50, a plurality of rotating compressor blades 54 extending radially outward from the at least one shaft 50, and a plurality of stationary compressor vanes 56 extending radially inward from the casing 52 toward the at least one shaft 50. In the illustrated embodiment, the compressor section 42 may include a plurality7 of compressor stages 58, each having a plurality of the compressor vanes 56 spaced circumferentially about the at least one shaft 50 at an axial position, and a plurality of the compressor blades 54 spaced circumferentially about the at least one shaft 50 at a different axial position (i.e., the compressor vanes 56 and the compressor blades 58 are axially spaced apart). Accordingly, the compressor section 42 is configured to receive a flow of an intake gas 60 from the intake section 40 and to progressively compress the intake gas 60 through the plurality of compressor stages 58. As discussed in further detail below, the intake gas 60 may include an intake air, an exhaust gas recirculation (EGR) flow or recirculated exhaust gas, or a combination thereof.
[0024] The combustor section 44 may include one or more combustors 62, such as a single annular combustor disposed circumferentially about the rotational axis 36 or a plurality of combustors 62 circumferentially spaced about the rotational axis 36. In the illustrated embodiment, each combustor 62 includes a head end portion 64 coupled to a combustion portion 66. The combustion portion 66 includes a combustion chamber 68, a combustor liner 70 disposed circumferentially about the combustion chamber 68, a flow sleeve 72 disposed circumferentially about the combustor liner 70, and a passage 74 extending betw een the combustor liner 70 and the flow sleeve 72. The passage 74 is configured to route a compressed gas flow in an upstream direction 76 toward a head end chamber 78 disposed in the head end portion 64. The head end chamber 78 and the combustion chamber 68 of the combustor 62 are separated or divided from one another by an intermediate plate 80. In the head end chamber 78, a plurality of fuel nozzles 82 are coupled to the intermediate plate 80 and an end plate 84 of the head end portion 64. In operation, each combustor 62 receives a compressed gas 86 (e.g., air, EGR, etc.) from the compressor section 42, routes the compressed gas 86 along the passage 74 tow ard the head end chamber 78 as indicated by arrow 76, and routes the compressed gas through the fuel nozzles 82 into the combustion chamber 68.
[0025] In certain embodiments, each combustor 62 may receive one or more fuel flows from a fuel system 88 coupled to the fuel nozzles 82, wherein the fuel system 88 includes a fuel supply system 90 coupled to one or more fuel circuits 92. For example, the fuel circuits 92 may include fuel circuits 94, 96, and 98 coupled to different sets of the fuel nozzles 82. The fuel circuits 92 (e.g., 94, 96, and 98) may include fuel conduits, fuel manifolds, fuel valves, pressure regulators, and other flow controls. The fuel system 88 is configured to supply one or more fuels, such as liquid and/or gas fuels, into each of the fuel nozzles 82 for injection into the combustion chamber 68. The fuels may include natural gas, syngas generated from a gasifier, methane, hydrogen, biofuel, fuel oils, or any combination thereof. The fuel supply system 90 may include a plurality of components to control flows of the various fluids to the combustor 62. For example, the fuel supply system 90 may include one or more components 100. In certain embodiments, the components 100 may include one or more fuel tanks, fuel pumps, valves, pressure regulators, flow regulators, filters, water removal units, particulate removal units, manifolds, flow controllers, or any combination thereof.
[0026] The fuel nozzles 82 are configured to inject one or more fuels from the fuel system 88 and the compressed gas 86 from the compressor section 42. In certain embodiments, the fuel nozzles 82 are configured to inject a compressed air 104 from a compressor system 106 having an air compressor 108 coupled to a drive 110, such as an electric motor, a combustion engine, a shaft coupled to the gas turbine system 12, or another suitable drive. The compressor system 106 may be configured to receive air from ambient and/or from the intake section 40. Additionally, the compressor system 106 may be configured to enable multiple modes of operation, such as EGR mode or non-EGR mode. For example, in certain embodiments of the gas turbine system 12 having exhaust gas recirculation (EGR), the compressor section 42 supplies the compressed gas 86 (e.g., compressed exhaust gas) to each combustor 62, while the compressor system 106 supplies the compressed air 104 to each combustor 62.
[0027] By further example, in certain embodiments of the gas turbine system 12 without exhaust gas recirculation (EGR), the compressor section 42 supplies the compressed gas 86 (e.g., compressed air) to each combustor 62 without any need for additional air supplies. Thus, the compressor system 106 may optionally supply the compressed air 104 to each combustor 62. In operation, the fuel may be combusted with the air in the combustion chamber 68 of each combustor 62. thereby generating a hot combustion gas 112 for delivery from the combustion chamber 68 into the turbine section 46.
[0028] The turbine section 46 includes at least one shaft 114 disposed along the rotational axis 36, a casing 116 (e.g., annular casing) disposed circumferentially about the at least one shaft 114, a plurality of rotating turbine blades 118 extending radially outward from the at least one shaft 114, and a plurality of stationary turbine vanes 120 extending radially inward from the casing 116 toward the at least one shaft 114. The turbine section 46 may include a plurality of turbine stages 122, each having a plurality of the turbine vanes 120 spaced circumferentially about the at least one shaft 114 at an axial position, and a plurality of the turbine blades 118 spaced circumferentially about the at least one shaft 114 at a different axial position (i.e. , the turbine vanes 120 and the turbine blades 118 are axially spaced apart). The at least one shaft 114 also may be coupled to the at least one shaft 50 of the compressor section 42 via at least one intermediate shaft 124. Additionally, the at least one shaft 114 may be coupled to a load 126 via a shaft 128. In certain embodiments, the load 126 may include an electrical generator, a machine, a propulsion system for a vehicle, or any other suitable load. In the illustrated embodiment, the load 126 may be an electrical generator, such that the combined cycle system 10 is a combined cycle power plant. In operation, the combustion gas 112 flows from the combustor 62 into the turbine section 46, wherein the combustion gas 1 12 progressively expands and drives rotation of the turbine blades 118 coupled to the at least one shaft 114 in each of the turbine stages 122. Thus, the combustion gas 112 drives the turbine section 46, which in turn drives the compressor section 42 and the load 126 via the interconnected shafts 50, 124, 114, and 128.
[0029] In certain embodiments, the gas turbine system 12 may be configured with a common rotational direction of the shafts 50. 114, 124, and 128 and the connected compressor blades 54 and turbine blades 118. The shafts 50, 114, 124, and 128 may be removably coupled together with shaft connections, such as flanged joints. In some embodiments, some of the shafts may be combined to reduce the number of shafts. For example, all of the illustrated shafts 50, 114 and 124 may represent a common shaft rotating in the common rotational direction, such as a clockwise or counterclockwise rotational direction.
[0030] The gas turbine system 12 can be configured with or without the compressor system 106 and an exhaust gas recirculation (EGR) system 150. The EGR system 150 is configured to recirculate an exhaust gas 152 output by the turbine section 46 back into the compressor section 42 (e.g.. via intake section 40) for compression and delivery to the combustor section 44. However, the gas turbine system 12 may exclude the EGR system 150 and intake only an airflow into the intake section 40 for compression by the compressor section 42.
[0031] In certain embodiments of the gas turbine system 12 having the EGR system 150, the recirculated exhaust gas 152 flows through the intake section 40 and each of the compressor stages 58 of the compressor section 42, thereby compressing the recirculated exhaust gas as the compressed gas 86 for delivery’ into combustor section 44. Additionally, the combustor section 44 may receive compressed air 104 from the air compressor 108 of the compressor system 106 through the fuel nozzles 82. The combustor section 44 also receives the fuel from the fuel system 88, such as through the fuel nozzles 82. The fuel from the fuel system 88 then combusts with the air from the compressor system 106 to generate the combustion gases 112. which then flow through the turbine section 46 to drive rotation of the turbine blades 118 in each of the turbine stages 122. The recirculated exhaust gas helps to reduce the temperature and formation of certain emissions (e.g., nitrogen oxides (NOx)) associated with combustion in the combustor section 44.
[0032] In certain embodiments of the gas turbine system 12 without the EGR system 150, the compressor section 42 receives an airflow from the intake section 40, progressively compresses the airflow via the compressor stages 58. and delivers the compressed airflow as the compressed gas 86 into the combustor section 44. The compressed airflow then facilitates combustion of the fuel from the fuel system 88, thereby generating the hot combustion gases 112 for delivery to the turbine section 46. In such embodiments, the compressor system 106 may be excluded or included to provide additional compressed air 104 to the combustor section 44. Regardless of the configuration, the combustion gas 112 drives rotation of the turbine blades 118 in the turbine stages 122. thereby rotating the at least one shaft 114 coupled to the at least one shaft 50 of the compressor section 42 and the shaft 128 driving the load 126.
[0033] In certain embodiments, the exhaust gas 152 output by the turbine section 46 may then pass through the HRSG 16 for transfer of heat from the exhaust gas into water to generate steam for the steam turbine system 14. For example, the HRSG 16 may include a first pressure section 160 (e.g., high-pressure (HP) section), a second pressure section 162 (e.g., intermediate-pressure (IP) section), and a third pressure section 164 (e.g., low-pressure (LP) section) in a series arrangement, thereby generating a high-pressure steam 166. an intermediate-pressure steam 168 and a low- pressure steam 170. The heat recovery steam generator 16 may route the high- pressure steam 166 to a high-pressure steam turbine 172, the intermediate-pressure steam 168 to an intermediate-pressure steam turbine 174, and the low-pressure steam 170 to a low-pressure steam turbine 176 of the steam turbine system 14. The steam drives rotation of blades within each of the steam turbines 172, 174, 176, thereby driving a shaft 178 coupled to a load 180, such as an electrical generator. The low- pressure steam turbine 176 also may return a condensate 182 through a return line 181 back to the low-pressure section 164 of the HRSG 16 via a pump 183. The HRSG 16 may then output the exhaust gas 152 as a partially cooled exhaust gas 184. However, in certain embodiments, the combined cycle system 10 excludes the HRSG 16 and/or the steam turbine system 14.
[0034] In the illustrated embodiment, the exhaust gas 152 output by the turbine section 46 and/or the exhaust gas 184 output by the HRSG 16 may pass through the WHR system 22 for transfer of heat from the exhaust gas into a heated fluid 26 to support the one or more gas capture systems 20 of the gas treatment system 18. The heated fluid 26 may include a heated gas or liquid, such as a heated water and/or steam. In certain embodiments, the temperature of the heated fluid 26 may be 100 to 150 degrees Celsius, 110 to 150 degrees Celsius, 120 to 150 degrees Celsius, or 130 to 150 degrees Celsius. Accordingly, the heated fluid 26 may provide heat in the one or more gas capture systems 20 to enable desorption in a similar temperature range of 100 to 150 degrees Celsius, 110 to 150 degrees Celsius, 120 to 150 degrees Celsius. 130 to 150 degrees Celsius, or 110 to 130 degrees Celsius. For example, the heated fluid 26 may be provided to the gas capture systems 20 to support desorption at a temperature of at least equal to or greater than 100, 110, 120. 130, 140. or 150 degrees Celsius, plus or minus 5 degrees Celsius.
[0035] As discussed above, the gas treatment system 18 includes one or more gas capture systems 20. For example, the gas capture systems 20 may include any one or any combination of gas capture systems 190, 192, and 194, each having a plurality of components (e.g., components 196, 198, 200, and 202). The gas capture systems 20 (e.g., 190, 192. and 194) are configured to obtain a captured gas 204 from the intake gas 60 and/or the exhaust gas 152. 184. In the illustrated embodiment, the gas capture systems 20 (e.g., 190, 192, and 194) may capture and output carbon dioxide (CO2) as the captured gas 204, which may further be directed to a compression system 206. For example, the compression system 206 may include one or more compressors configured to compress the captured gas 204 (e.g., CO2) and deliver the captured gas to storage and/or a pipeline 208.
[0036] The gas capture system 190 is disposed at, in, or upstream of the intake section 40 for capturing undesirable gases from the intake air. The gas capture systems 192 and 194 are disposed downstream of the gas turbine system 12 and/or the HRSG 16 for capturing undesirable gases from the exhaust gas 152, 184. The gas capture systems 20 (e.g., 190, 192, and 194) may include sorbent-based gas capture systems, solvent-based gas capture systems, cryogenic gas capture systems, or any combination thereof, configured to remove and capture undesirable gases. In certain embodiments, the gas capture systems 20 (e.g., 190, 192, and 194) may be configured to remove and capture undesirable gases, such as carbon oxides (COx) (e.g., carbon dioxide (CO2) and carbon monoxide (CO)), and thus the gas capture systems 20 maybe described as carbon capture systems. In certain embodiments, the gas capture systems 20 (e.g., 190, 192, and 194) may be configured to remove and capture undesirable gases, such as nitrogen oxides (NOx) (e.g., nitrogen dioxide (NO2)), and thus the gas capture systems 20 may be described as NOx capture systems. In certain embodiments, the gas capture systems 20 (e.g., 190, 192, and 194) may be configured to remove and capture undesirable gases, such as sulfur oxides (SOx) (e.g., sulfur dioxide (SO2)), and thus the gas capture systems 20 may be described as SOx capture systems. In the following discussion, the gas capture systems 20 (e.g., 190, 192, and 194) may be described as sorbent-based carbon capture systems using sorbent materials as an example and/or solvent based carbon capture systems using liquid absorbents (e.g., solvents) as an example. However, the embodiments disclosed herein may use any type or configuration of gas capture systems 20 (e.g., 190, 192, and 194) as noted above.
[0037] Each of the gas capture systems 20 (e.g., 190, 192, and 194) may include components 196, 198, 200, and 202. Additionally, one or more components 210 (e.g., WHR system 22 and components 212, 214, and 216) may be disposed upstream from the gas capture systems 192 and 194. For sorbent-based gas capture systems 20 (e.g., 190, 192, and 194), the components 196, 198, 200, and 202 may include sorbent materials disposed on or in ducts (e.g., adsorption duct, desorption duct, and cooling duct), contactors, cartridges, moving beds, rotating wheels, cartridges, or any combination thereof, along a flow path of the intake gas 60 and/or the exhaust gas 152, 184. The sorbent-based gas capture systems 20 are configured to adsorb the undesirable gases (e.g., CO2) into the sorbent materials in an adsorption mode and desorb the undesirable gases from the sorbent materials in a desorption mode. The components 196. 198, 200, and 202 may include cooling systems to help control the temperature of the sorbent materials (e.g., maintain sorbent temperatures within upper and lower temperature thresholds) to improve efficiency of the adsorption mode. The cooling systems may include heat exchangers (e.g., fin and tube heat exchangers), heat pipes, and other thermal control systems coupled to the sorbent materials to help control the temperature of the sorbent materials. The components 196, 198, 200, and 202 also may include heating systems, such as heated fluid systems (e.g., steam systems, electrical heaters, waste heat systems, etc.), configured to apply heat to the sorbent materials to desorb the undesirable gases from the sorbent materials during the desorption mode. For example, the WHR system 22 may be configured to provide the heated fluid 26 to heat the sorbent materials during the desorption mode. By further example, the steam turbine system 14 and/or the HRSG 16 may be configured to provide steam to heat the sorbent materials during the desorption mode. The components 196, 198, 200, and 202 also may include cooling systems, such as cooling fluid systems (e.g., gas cooling systems, liquid cooling systems, etc.), configured to apply a cooling fluid to the sorbent materials during a cooling mode. The sorbent-based gas capture systems 20 also may include other suitable components 196, 198, 200, and 202 in support of the sorbent materials.
[0038] For solvent-based gas capture systems 20 (e.g., 190, 192, and 194), the components 196, 198, 200, and 202 may include one or more absorbers, one or more strippers, and a solvent circuit through the absorbers and strippers. The absorber is configured to absorb the undesirable gases (e g., CO2) into a solvent in an absorption mode, thereby outputting a treated gas (e.g., treated air or treated exhaust gas) and a gas-rich solvent (e.g., CCh-rich solvent). The stripper is configured to strip the undesirable gases from the gas-rich solvent in a desorption mode, thereby outputting a gas-lean solvent (e.g., CCh-lean solvent) back to the absorber and outputting the captured gas 204. The components 196, 198, 200, and 202 may include cooling systems coupled to the absorber, wherein the cooling systems are configured to extract heat generated by the absorption mode to help control the temperature of the solvent (e.g., maintain solvent temperatures within upper and lower temperature thresholds) to improve efficiency of the absorption mode. The cooling systems may include heat exchangers (e.g.. fin and tube heat exchangers), heat pipes, and other thermal control systems coupled to the absorber to help control the temperature of the solvent. The components 196, 198, 200, and 202 also may include heating systems, such as heated fluid systems (e g., steam systems, electrical heaters, waste heat systems, etc.), coupled to the strippers, wherein the heating systems are configured to apply heat to the gas-rich solvent to desorb the undesirable gases from the gas-rich solvent during the desorption mode. For example, the WHR system 22 may be configured to provide the heated fluid 26 to the gas-rich solvent during the desorption mode. By further example, the steam turbine system 14 and/or the HRSG 16 may be configured to provide steam to the gas-rich solvent during the desorption mode The components 196, 198, 200, and 202 also may include a reboiler coupled to the stripper, pumps and valves to control a flow of the solvent through the solvent circuit between the absorber and the stripper, and heat exchangers to cool the gas-lean solvent supplied to the absorber and to heat the gas-rich solvent supplied to the stripper. The solvent-based gas capture systems 20 also may include other suitable components 196. 198, 200, and 202 in support of the absorbers and strippers.
[0039] In certain embodiments, the components 196, 198, 200, and 202 of the gas capture system 20 and/or the components 210 (e.g.. WHR system 22 and components 212, 214. and 216) upstream from the gas capture systems 192 and 194 may include one or more of a dryer or water removal system (e.g., water gas separator), a particulate removal system (e.g., filter and/or solid gas separator), one or more booster fans configured to boost a flow of the gas being treated, one or more coolers, one or more valves to control a flow of gas to the gas capture system 20, a bypass system configured to bypass the gas capture system 20, or any combination thereof. The cooler may include a heat exchanger, a direct contact cooler (DCC), or a combination thereof. The heat exchanger is configured to indirectly cool the exhaust gas 184 via heat exchange between the exhaust gas 184 and a cooling fluid (e.g., cooling water). The direct contact cooler is configured to directly cool the exhaust gas 184 via direct injection of a cooling fluid (e.g., cooling water) into the exhaust gas 184. Thus, the cooler is configured to cool the exhaust gas 184 prior to treatment in the gas treatment system 18. The separators may include gravity separators, centrifugal separators, or a combination thereof. In some embodiments, the gas capture systems 20 (e.g.. 190. 192, and 194) may be described as multiple gas capture stages. However, in some embodiments, the gas treatment system 18 may include only a single stage and/or gas capture system 20. For example, the gas capture systems 20 may include only one, two, or all three of the gas capture systems 190, 192, and/or 194.
[0040] In certain embodiments, one or more of the gas capture systems 20 (e.g., 190, 192, and 194) includes multiple adsorption stages (e.g., first adsorption stage - undesirable gas-rich adsorption stage, and second adsorption stage - undesirable gaslean adsorption stage) achieved with a plurality of gas capture units operating in a reversed order (e.g., undesirable gas-lean adsorption stage followed by undesirable gas-rich adsorption stage), such that each gas capture unit starts with adsorption of undesirable gases (e.g., CO2) from an undesirable gas-lean flow (e g., CCh-lean flow) and ends with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow). For example, if capturing the undesirable gases from air, then the gas capture system 190 may include multiple gas capture units that start with adsorption of undesirable gases (e.g.. CO2) from an undesirable gas-lean flow (e.g.. CCh-lean flow) and end with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow) of the air. By further example, if capturing the undesirable gases from exhaust gas 152, 184, then the gas capture system 192 or 194 may include multiple gas capture units that start with adsorption of undesirable gases (e.g., CO2) from an undesirable gas-lean flow (e.g., CCh-lean flow) and end with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow) of the exhaust gas 152, 184.
[0041] In certain embodiments, the exhaust gas 184 may partially or entirely bypass the gas treatment system 18 and flow to the EGR system 150, and/or the exhaust gas 184 may partially or entirely flow through the gas treatment system 18 before flowing to the EGR system 150. The EGR system 150 may include one or more conduits, valves, flow controls, coolers, blowers, or any combination thereof, configured to provide at least a portion of the exhaust gas 152, 184 (e.g., EGR flow) to the intake section 40 for recirculation through the compressor section 42. The cooler may be configured to cool the exhaust gas 152, 184 to a lower temperature (e.g., approximately ambient temperature) prior to recirculation into the compressor section 42. The blower may be configured to increase a pressure and flow of the exhaust gas 152, 184 to help overcome pressure losses in the EGR system 150.
[0042] In the illustrated embodiment, the combined cycle system 10 also includes a controller 220 coupled to the gas turbine system 12, the steam turbine system 14, the HRSG 16, the gas treatment system 18 (e.g., gas capture systems 20), the fuel system 88, the EGR system 150, the compression system 106, and various sensors 222 distributed throughout the combined cycle system 10. In the illustrated embodiment, the controller 220 includes one or more processors 224, memory 226, instructions 228 stored on the memory 226 and executable by the processor 224, and communication circuitry 230 configured to communicate with the sensors 222 and various equipment throughout the combined cycle system 10. For example, the controller 220 is configured to control the fuel delivery and distribution from the fuel system 88 to the fuel nozzles 82 in the combustor section 44. In certain embodiments, the controller 220 is configured to control operation of the gas capture systems 20 (e.g., 190, 192, and 194), such by controlling modes of operation (e.g., adsorption mode, desorption mode, cooling mode), controlling the WHR system 22 to control the flow and temperature of the heated fluid 26 provided to the gas capture systems 20, controlling flows of various fluids through the gas capture systems 20, or any combination thereof.
[0043] In certain embodiments, the controller 220 is configured to control operation of the gas capture systems 20 (e.g.. 190, 192, and 194) to operate multiple gas capture units that start with adsorption of undesirable gases (e.g.. CO2) from an undesirable gas-lean flow (e.g., CCh-lean flow) and end with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow). For example, the controller 220 is configured to control operation of the gas capture systems 20 (e.g., 190, 192, and 194) to operate each of at least four gas capture units in a sequence: (1) undesirable gas-lean adsorption stage to adsorb the undesirable gas from an undesirable gas-lean flow (e.g., CCh-lean flow) into sorbent material during a multi-stage adsorption mode, (2) undesirable gas-rich adsorption stage to adsorb the undesirable gas from an undesirable gas-rich flow (e.g., CCh-rich flow) into the sorbent material during the multi-stage adsorption mode. (3) desorption to desorb the undesirable gas from the sorbent material using a heating source during a desorption mode, and (4) regeneration to cool the sorbent material using a cooling source during a cooling mode.
[0044] The sensors 222 (designated with an “S”) are configured to monitor various operational parameters of the combined cycle system 10. In certain embodiments, the sensors 222 include temperature sensors, pressure sensors, flow rate sensors, fluid composition sensors (e.g., gas composition sensors), vibration sensors, clearance sensors, speed sensors, humidity and/or moisture sensors, or any combination thereof. The sensors 222 may monitor the parameters (e.g., temperature, pressure, flow rate, and fluid composition) at one or more locations of the compressor section 42, the combustor section 44, the turbine section 46, the gas treatment system 18, the WHR system 22. the heated fluid 26, or any combination thereof. [0045] For example, the sensors 222 may monitor compressor parameters (e.g., pressure ratio between the inlet and outlet of the compressor section 42), combustion gas parameters (e.g., firing temperature and combustion dynamics), turbine parameters (e.g., temperature and pressure at each turbine stage, the turbine inlet, and the turbine exhaust), and exhaust gas emissions. By further example, the exhaust gas emissions monitored by the sensors 222 may include carbon oxides (COx) such as carbon dioxide (CO2) and carbon monoxide (CO), nitrogen oxides (NOx) such as nitrogen dioxide (NO2), sulfur oxides (SOx) such as sulfur dioxide (SO2), unbumt hydrocarbons, particulate matter, and other undesirable exhaust emissions. By further example, the sensors 222 may monitor the temperature of the heated fluid 26 provided to the gas capture systems 20, the temperature of the sorbent materials in sorbentbased gas capture systems, the temperature of solvent in solvent-based gas capture systems, or any combination thereof. By further example, the sensors 222 may monitor the undesirable gases (e.g., gas composition or content of CO2) during the adsorption mode of the gas capture systems 20 (e.g., 190, 192, and 194), including sensor measurements before, during, and after each adsorption stage of a plurality of adsorption stages. In response to the feedback from the sensors 222, the controller 220 may adjust the operating mode, number of adsorption stages, recirculation for multiple adsorption stages, fluid flows between multiple gas capture units, heating, cooling, or any combination thereof, in the gas capture systems 20.
[0046] FIG. 2 is a schematic of an embodiment of a gas capture system 20 of the gas treatment system 18 of FIG. 1. illustrating a sorbent-based gas capture system 250 having multiple adsorption stages. In the illustrated embodiment, the sorbent-based gas capture system 250 includes a plurality of sorbent-based gas capture assemblies or units 252 (e.g., adsorbers or adsorption units) associated with a plurality of respective conduits 254, such as conduits 255, 256, 258, and 260 (e.g., sorbent-containing conduits). The sorbent-based gas capture units 252 may include one or more temperature swing adsorption (TSA) units, vacuum temperature swing adsorption (VTSA) units, concentration swing adsorption (CSA) units, or any combination thereof. [0047] For example, the sorbent-based gas capture units 252 may include temperature swing adsorption (TSA) units or adsorbers, wherein a temperature swing or change is used to sequentially operate in an adsorption mode (e.g.. multiple adsorption stages), a desorption mode, and a cooling mode at different temperatures. For example, each adsorption stage of the adsorption mode may operate at one or more first temperatures that are lower than a second temperature of the desorption mode. The lower first temperature enables the sorbent-based gas capture units 252 to adsorb the undesirable gas, where lower temperatures generally increase a capacity for adsorbing the undesirable gas. The higher second temperature enables the sorbent-based gas capture units 252 to desorb the undesirable gas, which can then be captured and used in other downstream processes. By further example, the gas capture systems (e.g., sorbent-based gas capture systems) may include one or more vacuum temperature swing adsorption (VTSA) units or adsorbers, which rely on temperature and pressure swings to adsorb undesirable gases at a first temperature (e.g., low temperature) and a first pressure (e.g., high pressure) and desorb the undesirable gases at a second temperature (e.g., high temperature) and a second pressure (e.g., low pressure).
[0048] In the illustrated embodiment, the sorbent-based gas capture system 250 includes multiple adsorption stages (e.g., first adsorption stage - undesirable gas-rich adsorption stage, and second adsorption stage - undesirable gas-lean adsorption stage) achieved with the plurality of sorbent-based gas capture units 252 operating in a reversed order (e.g., undesirable gas-lean adsorption stage followed by undesirable gas-rich adsorption stage), such that each sorbent-based gas capture unit 252 starts with adsorption of undesirable gases (e.g., CO2) from an undesirable gas-lean flow (e.g., CCh-lean flow) and ends with adsorption of the undesirable gases from an undesirable gas-rich flow (e.g., CCh-rich flow). The multiple adsorption stages are discussed in further detail below.
[0049] In the illustrated embodiment, the sorbent-based gas capture units 252 include sorbent-based gas capture units 252A, 252B, 252C, and 252D associated with the conduits 255. 256, 258, and 260. The conduits 254 (e.g., 255, 256, 258, and 260) may be sorbent-lined along interior surfaces, sorbent-packed within interior volumes. or generally filled with at least 10, 20, 30, 40, 50, 60, 70, 80, 90, or more percent by volume of sorbent material. However, the sorbent-based gas capture unit 252 may include any number of conduits 254, such as 2. 3, 4, 5. 6, 7. 8. 9, 10, or more, which are configured in parallel and/or series. Each of the conduits 254 (e.g., 255, 256, 258, and 260) includes an outer conduit wall 262 disposed circumferentially about a flow path 264 (e g., fluid passage or bore) along a central axis 266 from an inlet 268 to an outlet 270, wherein a sorbent material 272 is disposed along an interior surface 274 of the outer conduit wall 262 and/or along an exterior surface 276 of a plurality of contactors 280 (e.g., contactor plates, panels, or fins). In the illustrated embodiment, the contactors 280 are arranged parallel to one another and parallel to the central axis 266. Each of the conduits 254 (e.g., 255, 256, 258. and 260) may include a contactor assembly 278 having any number of the contactors 280, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more contactors 280.
[0050] Each of the contactors 280 has a body 284 with the exterior surface 276 disposed about an interior portion 286. In certain embodiments, the sorbent material 272 is disposed along the exterior surface 276, while the interior portion 286 includes a material 282 different than the sorbent material 272. In certain embodiments, the body 284 may be a solid body throughout the interior portion 286, wherein the body 284 is at least substantially or completely made with the sorbent material 272 throughout the interior portion 286 to the exterior surface 276. In some embodiments, the body 284 may be a hollow body in the interior portion 286 (e.g., interior chamber or cavity), wherein the body 284 has an outer wall 288 disposed about the interior portion 286. For example, the interior portion 286 may include a heat exchange circuit or flow path extending throughout the body 284 between a fluid inlet and a fluid outlet, which may be coupled to a heat exchange circuit for cooling and/or heating. In certain embodiments, the interior portion 286 may be configured to circulate a cooling fluid during an adsorption mode, a heating fluid (e.g., heated water, steam, etc.) during a desorption mode, and a cooling fluid during a cooling mode of the sorbent-based gas capture system 250.
[0051] As discussed in detail below, the gas capture system 20 is configured to sequentially and repeatedly operate each of the sorbent-based gas capture units 252A. 252B, 252C, and 252D in a cycle of: (1) undesirable gas-lean adsorption stage (e.g., CCh-lean adsorption stage) of a multi-stage adsorption mode, (2) undesirable gas-rich adsorption stage (e.g., CCh-rich adsorption stage) of the multi-stage adsorption mode. (3) a desorption mode, and (4) a cooling mode. The undesirable gas-lean adsorption stage (e.g., CCh-lean adsorption stage) of the adsorption mode refers to adsorption of the undesirable gas (e.g., CO2) when the undesirable gas is lean in the gas being treated by the gas capture system 20. The undesirable gas-rich adsorption stage (e.g., CCh-rich adsorption stage) of the adsorption mode refers to adsorption of the undesirable gas (e.g., CO2) when the undesirable gas is rich in the gas being treated by the gas capture sy stem 20. The temperature of the sorbent material 272 directly affects the adsorption efficiency of the sorbent material 272 during the adsorption mode (e.g., including each of the gas-lean adsorption stage and the gas-rich adsorption stage). The sorbent material 272 may have an optimal temperature or temperature range for efficient adsorption of the undesirable gases. Unfortunately, the adsorption of the undesirable gases into the sorbent material 272 is an exothermic process, which generates heat that generally increases the temperature of the sorbent material 272 and reduces its adsorption efficiency without any cooling of the sorbent material 272. Thus, the disclosed embodiments may control the cooling of the sorbent material 272 during the adsorption mode (e.g., including each of the gas-lean adsorption stage and the gas-rich adsorption stage) to improve the adsorption efficiency. Similarly, the temperature of the sorbent material 272 directly affects the desorption efficiency of the sorbent material 272 during the desorption mode. The sorbent material 272 may have an optimal temperature or temperature range for efficient desorption of the undesirable gases. Thus, the disclosed embodiments may control the heating of the sorbent material 272 during the desorption mode to improve the desorption efficiency. As discussed in detail below, the controller 220 may be configured to control the steam turbine system 14, the HRSG 16, and/or the WHR system 22 to supply heated fluids (e.g., heated water, steam, etc.) to each of the sorbent-based gas capture units 252A, 252B. 252C, and 252D during the desorption mode. [0052] The temperatures in the adsorption mode (e.g., including each of the gaslean adsorption stage and the gas-rich adsorption stage), the desorption mode, and the cooling mode may vary depending on the particular application. In certain embodiments of carbon capture (e g., CO2 capture), the adsorption mode (e.g., including each of the gas-lean adsorption stage and the gas-rich adsorption stage) may be configured to adsorb undesirable gas from a gas 340 into the sorbent material 272 at one or more first temperatures, the desorption mode may be configured to desorb the undesirable gas from the sorbent material 272 using a heat source (e g., heated water, steam, etc.) at a second temperature, and the cooling mode may be configured to cool the sorbent material 272 using a cooling source (e.g., cooling fluid) at a third temperature, wherein the second temperature is greater than the first and third temperatures, and the third temperature is lesser than the first and third temperatures. For example, the first temperature may be approximately 40 degrees Celsius (e.g., plus or minus 5, 10, 15, or 20 degrees Celsius), the second temperature may be equal to or greater than approximately 100, 110, 120, 130, 140. or 150 degrees Celsius, and the third temperature may be less than or equal to approximately 0, 5. 10. 15. 20. 25. or 30 degrees Celsius.
[0053] In the illustrated embodiment, the gas capture system 20 includes a thermal control system 290 having a fluid circulation system 292. one or more fluid circulation circuits 294 (e.g., fluid conduits, manifolds, valves, etc.), and one or more heat exchangers 296 coupled to each contactor assembly 278 in the sorbent-based gas capture units 252A, 252B, 252C, and 252D. The heat exchangers 296 may include one or more heat exchange flow paths coupled to and/or extending through each contactor assembly 278. The heat exchangers 296 also may include a plurality of heat pipes 298, wherein each contactor assembly 278 includes one or more heat pipes 298 coupled to and/or extending through each contactor 280 in the contactor assembly 278. The fluid circulation system 292 may include a plurality of components, such as components 300, 302, and 304, such as heat exchangers, pumps, valves, coolant supplies, or any combination thereof. The thermal control system 290 may circulate a thermal fluid (e.g., liquid or gas thermal fluid) from the fluid circulation system 292 through the fluid circulation circuits 294 and the heat exchangers 296 to exchange heat between the thermal fluid and the contactors 280 and the sorbent materials 272 during any one or all of the operating modes (e.g., each stage of the adsorption mode, desorption mode, and/or cooling mode). In certain embodiments, the fluid circulation circuits 294 may include independent fluid circulation circuits for each of the contactor assemblies 278, such that the thermal control system 290 can independently control the temperature for each of the contactor assemblies 278 depending on the operating modes (e.g.. each stage of the adsorption mode, desorption mode, and/or cooling mode) of the sorbent-based gas capture units 252A, 252B, 252C, and 252D. For example, the thermal control system 290 is configured to circulate the thermal fluid (e.g., coolant or cooling fluid at a relatively lower temperature) during the adsorption mode (e.g.. including each of the gas-lean adsorption stage and the gasrich adsorption stage) and the cooling mode, thereby cooling the contactors 280 and the sorbent materials 272. By further example, the thermal control system 290 is configured to circulate the thermal fluid (e.g., heated or heating fluid at a relatively higher temperature) during the desorption mode, thereby heating the contactors 280 and the sorbent materials 272 to facilitate desorption. As noted above, the thermal fluid may include the heated fluid 26 from the WHR system 22, heated water and/or steam from the steam turbine system 14 and/or the HRSG 16, or a combination thereof, during the desorption mode.
[0054] The sorbent material 272 (e.g., solid adsorbents) may cover, coat, or generally line at least 50, 60, 70, 80, 90, 95, or 100 percent of the interior surface 274 of the outer conduit wall 262, the exterior surface 276 of the contactors 280. and/or other structures within the conduits 254. In some embodiments, the contactors 280 may include rectangular plates, airfoil shaped panels, a parallel arrangement of tubes, a grid arrangement of tubes, a plurality of cartridges, radial projections, baffles, fins, honeycomb structures, a plurality7 of contactor elements supported in a bundle, or any combination thereof. The plurality of contactor elements may include a plurality7 of particles, beads, strips, strands, mesh, or other distributed structures, which leave voids for fluid flow. Additionally or alternatively, the sorbent material 272 may at least partially fill or pack an interior volume of the central bore or interior surface 274, such that voids remain to facilitate fluid flow (e.g., a void fraction of less than or equal to 10, 20, 30, 40, or 50 percent). Furthermore, in some embodiments, the central axis 266 extending from the inlet 268 to the outlet 270 may define the flow path 264 as a linear flow path, a curved flow path, a winding or serpentine flow path, a spiral or helical flow path, a tortuous flow path, an expanding and contracting flow path, a flow path with splits and/or unions, or any combination thereof. For example, the flow path 264 may be defined as a tortuous flow path and include any number or configuration of the foregoing flow paths.
[0055] The sorbent material 272 may include one or more sorbent materials configured to adsorb the undesirable gases, such as sorbent materials designed or suitable for adsorption of carbon oxides (COx) such as carbon dioxide (CO2) and carbon monoxide (CO), nitrogen oxides (NOx), sulfur oxides (SOx) such as sulfur dioxide (SO2), methane (CFU), or any other undesirable gases as described herein or subject to regulations and/or considered greenhouse gases. For example, the sorbent materials 272 may include porous, solid-phase materials, including mesoporous silicas, zeolites (e.g., aluminosilicates), and metal-organic frameworks (MOFs) and covalent organic frameworks (COFs). The foregoing sorbent materials 272 may be particularly well-suited for CO2 adsorption in the sorbent-based gas capture unit 252. However, any suitable sorbent materials 272 may be used depending on the desired target for gas capture of undesirable gases. In certain embodiments, a plurality of the sorbent-based gas capture systems 250 may be used in series, wherein each of the sorbent-based gas capture system 250 uses the same or different sorbent materials 272 to remove and capture the same or different undesirable gases in stages.
[0056] The sorbent-based gas capture system 250 may be configured to alternate each of the sorbent-based gas capture units 252A, 252B, 252C, and 252D associated with the conduits 255, 256, 258, and 260 in a sequence of the following four cycles: (1) the gas-lean adsorption stage of the adsorption mode (e.g., adsorbing the undesirable gases in an undesirable gas-lean flow into the sorbent material 272), (2) the gas-rich adsorption stage of the adsorption mode (e.g., adsorbing the undesirable gases in an undesirable gas-rich flow into the sorbent material 272), (3) the desorption mode (e.g.. desorbing the undesirable gases from the sorbent material 272), and (4) the cooling mode (e.g., cooling the sorbent material 272) using the controller 220 and the sensors 222. Although each of the sorbent-based gas capture units 252A, 252B, 252C, and 252D is used in the foregoing sequence, the adsorption stages performed on the gas flow are performed in the reverse order of (1) first adsorption stage - gasrich adsorption by a sorbent-based gas capture unit 252, (2) second adsorption stage - gas-lean adsorption by a different sorbent-based gas capture unit 252. For example, as discussed in further detail below, the full sequence (including adsorption stages applied to the gas flow, desorption mode, and cooling mode) of the sorbent-based gas capture units 252A, 252B, 252C, and 252D may be performed as illustrated in FIGS. 3-6. Thus, rather than using separate sets of the sorbent-based gas capture units 252 for the different adsorption stages, each of the sorbent-based gas capture units 252 is used for all adsorption stages. In this manner, the sorbent-based gas capture system 250 is able to reduce the total number of the sorbent-based gas capture units 252 to four units operating in four cycles, rather than using a total of six units (i.e., three units in a first stage and three units in a second stage, each cycling between adsorption, desorption, and cooling modes). The controller 220 is configured to control the sorbent-based gas capture system 250 to perform a staggered operational cycle of the sorbent-based gas capture units 252A, 252B, 252C, and 252D between the different operating modes (e.g., gas-lean adsorption stage of the adsorption mode, gas-rich adsorption stage of the adsorption mode, desorption mode, and cooling mode).
[0057] Table 1 illustrates a sequence using the sorbent-based gas capture units 252A, 252B, 252C, and 252D in the staggered operational cycle.
Figure imgf000028_0001
Table 1 [0058] As indicated in Table 1, for a first duration of time, the controller 220 may operate the sorbent-based gas capture unit 252A in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252B in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252C in the desorption mode, and the sorbent-based gas capture unit 252D in the cooling mode. For a second duration of time, the controller 220 may operate the sorbentbased gas capture unit 252D in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252A in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252B in the desorption mode, and the sorbent-based gas capture unit 252C in the cooling mode. For a third duration of time, the controller 220 may operate the sorbent-based gas capture unit 252C in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252D in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252A in the desorption mode, and the sorbent-based gas capture unit 252B in the cooling mode. For a fourth duration of time, the controller 220 may operate the sorbent-based gas capture unit 252B in the gas-lean adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252C in the gas-rich adsorption stage of the adsorption mode, the sorbent-based gas capture unit 252D in the desorption mode, and the sorbent-based gas capture unit 252A in the cooling mode. For a subsequent duration of time, the staggered operational cycle repeats starting with the first duration of time. Again, Table 1 illustrates the staggered operational cycle of the sorbent-based gas capture units 252A, 252B, 252C, and 252D, but the adsorption stages performed on the gas flow (e.g., exhaust gas) are in the opposite order (i.e., first adsorption stage - undesirable gas-rich adsorption stage, followed by second adsorption stage - undesirable gas-lean adsorption stage).
[0059] Although Table 1 illustrates four sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) operating in the four different configurations over four different periods of time, the disclosed embodiments may be used with any number of adsorption stages in the same manner. Table 2 illustrates a sequence using five of the sorbent-based gas capture units (e.g., A, B, C, D, and E) in the staggered operational cycle, wherein the number of adsorption stages has been increased from two adsorption stages to three adsorption stages.
Figure imgf000030_0001
Table 2
[0060] As illustrated in Table 2. each of the sorbent-based gas capture units (e.g., A, B, C, D, and E) sequentially operates in the third adsorption stage, the second adsorption stage, the first adsorption stage, the desorption mode, and the cooling mode, and then repeats the cycle. Thus, with three adsorption stages, the staggered operational cycle includes five periods of time and five different configurations of the sorbent-based gas capture units (e.g.. A. B, C, D. and E). Similar to Table 1, the plurality of adsorption stages are in a reversed order with an increasing concentration of the undesirable gas. For example, the sorbent-based gas capture system 250 generally adsorbs the undesirable gas from the gas flow (e.g., exhaust gas 152, 184) in the order of the first adsorption stage, the second adsorption stage, and the third adsorption stage, wherein the first adsorption stage adsorbs the undesirable gas from the gas flow with a highest concentration (e.g., highest or rich-CCh concentration), the second adsorption stage adsorbs the undesirable gas from the gas flow with an intermediate concentration (e.g., intermediate CO2 concentration), and the third adsorption stage adsorbs the undesirable gas from the gas flow with a lowest concentration (e.g., lowest or lean-CCh concentration). In contrast to the order of adsorption stages, each of the sorbent-based gas capture units (e.g., A, B, C, D, and E) adsorbs the undesirable gas in the reversed order starting with the third adsorption stage (e.g.. lowest or lean-CCh concentration), followed by the second adsorption stage (e.g., intermediate CO2 concentration), and then ending with the first adsorption stage (e.g., highest or rich-CCh concentration). The reversed order enables each of the sorbent-based gas capture units (e.g.. A, B. C, D, and E) to progressively handle higher concentrations of the undesirable gas, thereby enabling the sorbent-based gas capture units (e.g., A, B, C, D, and E) to be used effectively in the multiple adsorption stages.
[0061] Table 3 illustrates a sequence using six of the sorbent-based gas capture units (e.g., A, B, C, D, E, and F) in the staggered operational cycle, wherein the number of adsorption stages has been increased from two adsorption stages to four adsorption stages.
Figure imgf000031_0001
Table 3
[0062] As illustrated in Table 3. each of the sorbent-based gas capture units (e.g., A, B. C, D, E. and F) sequentially operates in the fourth adsorption stage, the third adsorption stage, the second adsorption stage, the first adsorption stage, the desorption mode, and the cooling mode, and then repeats the cycle. Thus, with four adsorption stages, the staggered operational cycle includes six periods of time and six different configurations of the sorbent-based gas capture units (e.g., A, B, C. D, E, and F). Similar to Tables 1 and 2, the pl urality of adsorption stages are in a reversed order with an increasing concentration of the undesirable gas. For example, the sorbentbased gas capture system 250 generally adsorbs the undesirable gas from the gas flow (e.g., exhaust gas 152, 184) in the order of the first adsorption stage, the second adsorption stage, the third adsorption stage, and the fourth adsorption stage, wherein the first adsorption stage adsorbs the undesirable gas from the gas flow with a highest concentration (e.g., highest or rich-CCh concentration), the second adsorption stage adsorbs the undesirable gas from the gas flow with an upper intermediate concentration (e.g., upper intermediate CO2 concentration), the third adsorption stage adsorbs the undesirable gas from the gas flow with a lower intermediate concentration (e.g., lower intermediate CO2 concentration), and the fourth adsorption stage adsorbs the undesirable gas from the gas flow with a lowest concentration (e.g., lowest or lean-CCh concentration). In contrast to the order of adsorption stages, each of the sorbent-based gas capture units (e.g., A, B, C, D, E. and F) adsorbs the undesirable gas in the reversed order starting with the fourth adsorption stage (e.g., lowest or lean- CCh concentration), followed by the third adsorption stage (e.g., lower intermediate CO2 concentration), followed by the second adsorption stage (e.g., upper intermediate CO2 concentration), and then ending with the first adsorption stage (e.g.. highest or rich-CCh concentration). The reversed order enables each of the sorbent-based gas capture units (e.g., A, B, C, D, E, and F) to progressively handle higher concentrations of the undesirable gas, thereby enabling the sorbent-based gas capture units (e.g., A, B, C, D, E, and F) to be used effectively in the multiple adsorption stages.
[0063] The sorbent-based gas capture system 250 also may be configured to simultaneously operate multiple units (e.g., 2, 3, 4, or more) of the sorbent-based gas capture units 252 in each of the operating modes, such as multiple units 252 in the gas-lean adsorption stage of the adsorption mode, multiple units 252 in the gas-rich adsorption stage of the adsorption mode, multiple units 252 in the desorption mode, and multiple units 252 in the cooling mode. The multiple units 252 may be arranged in series, in parallel, or a combination thereof. The controller 220 is configured to alternate the sorbent-based gas capture units 252 (e g., 252A. 252B, 252C, and 252D) between the gas-lean adsorption stage of the adsorption mode, the gas-rich adsorption stage of the adsorption mode, the desorption mode, and the cooling mode via a plurality of support systems. [0064] The support systems may include the thermal control system 290, an upstream flow distribution system 310. and a downstream flow distribution system 312. The upstream flow distribution system 310 includes a gas supply system 314 (or gas intake system), a heating fluid supply system 316 (e.g., heated gas and/or heated liquid supply system), and a cooling fluid supply system 318, while the downstream flow distribution system 312 includes a post-adsorption processing system 320 (e.g., after the adsorption mode), a post-desorption processing system 322 (e.g., fluid processing system after the desorption mode), and a post-cooling system 324 (e.g., after the cooling mode). Additionally, a lean/rich staggered adsorption system 319 is coupled to, and part of, both the upstream flow distribution system 310 and the downstream flow distribution system 312. The lean/rich staggered adsorption system 319 is configured to facilitate multiple adsorption stages.
[0065] The gas supply system 314 of the upstream flow distribution system 310 is configured to provide a gas 340 (e.g., intake gas 60 or exhaust gas 152. 184) to enable the adsorption mode (e.g., gas-nch adsorption stage of the adsorption mode) when selectively operating each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) in the adsorption mode (e.g., gas-rich adsorption stage of the adsorption mode) via the controller 220. The gas supply system 314 includes a gas pre-treatment system 330 having one or more gas pre-treatment components 332, 334. and 336, which may be configured to process, adjust, and/or control characteristics of the gas 340 upstream from the conduits 254 (e.g., 255, 256, 258, and 260) of the sorbent-based gas capture units 252 (e.g.. units 252A, 252B, 252C, and 252D). For example, the gas pre-treatment component 332 may include a thermal control component (e.g., gas temperature control component), such as a heat exchanger, a heater, a cooler, or any combination thereof, configured to adjust (e.g., increase or decrease) a temperature of the gas 340. The heat exchanger may exchange heat with water, exhaust gas, compressor bleed flow, waste heat, or some other thermal fluid. In some embodiments, a waste heat recovery system may be used for heat transfer in the heat exchanger. The gas pre-treatment component 334 may include a pressure control component, such as a pressure regulator, an expander or expansion chamber, a constrictor or constriction chamber, a fan or pump to add energy , a turbine to extract energy, or another suitable pressure controller. The gas pre-treatment component 336 may include one or more contaminant removal units, such as a particulate filter, a moisture removal unit or dryer, a chemical removal unit, and/or other removal units configured clean the gas 340. For example, the gas pre-treatment component 336 may include a humidity controller configured to maintain a desired relative humidity7 of the gas 340 being received into the sorbent-based gas capture system 250.
[0066] The gas supply system 314 also may include one or more valves 342 configured to control the distribution of the gas 340 to the plurality of conduits 254 (e.g., 255, 256. 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C. and 252D) via distribution conduits 343. 344. 346, and 348. For example, the valves 342 may include one or more multi-way valves and/or distribution manifolds to independently distribute the gas 340 through the distribution conduits 343, 344, 346, and/or 348 to the respective sorbent-based gas capture units 252 (e.g.. 252A, 252B, 252C, and 252D) when operating in an adsorption mode (e.g., gas-rich adsorption stage of the adsorption mode) in response to control signals from the controller 220.
[0067] The lean/rich staggered adsorption system 319 includes one or more valves 341 of the upstream flow distribution system 310, one or more valves 409 of the downstream flow distribution system 312, and a multi-stage adsorption system 460 coupled to the valves 341 and 409. The one or more valves 341 are configured to control the distribution of a partially treated gas (e.g., gas-lean flow, such as CCh-lean flow) to the plurality of conduits 254 (e.g., 255. 256, 258, and 260) of the sorbentbased gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) via distribution conduits 468, 470, 472, and 474. For example, the valves 341 may include one or more multi-way valves and/or distribution manifolds to independently distribute the partially treated gas through the distribution conduits 468, 470, 472, and 474 to the respective sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in an adsorption mode (e.g., gas-lean adsorption stage of the adsorption mode) in response to control signals from the controller 220. [0068] The multi-stage adsorption system 460 includes a lean stage 462 and a rich stage 464 configured to enable a lean stage of adsorption (e.g., adsorption of CCh-lean flow) and a rich stage of adsorption (e.g., adsorption of CCh-rich flow). In certain embodiments, the multi-stage adsorption system 460 may be at least partially integrated with the gas pre-treatment system 330, at least partially between the gas pre-treatment system 330 and the valves 341 and 342, coupled to the valves 341, 342, 409, and 410, or any combination thereof. In certain embodiments, the multi-stage adsorption system 460 may include control logic (e.g., lean stage control code and rich stage control code) disposed on the controller 220 and/or disposed on an embedded controller of the multi-stage adsorption system 460. The lean/rich staggered adsorption system 319 also may include fluid circuits (e.g., fluid conduits) and valves to facilitate the adsorption stages between the various sorbent-based gas capture units 252, including the fluid circuits and valves of the upstream flow distribution system 310 and the downstream flow distribution system 312. As illustrated, the lean/rich staggered adsorption system 319 includes a fluid circuit 466 between the valves 341 and 409, such that the lean/rich staggered adsorption system 319 can return the gas flow (e.g., partially treated gas) to the upstream flow distribution system 310 for another pass or stage of adsorption through one of the sorbent-based gas capture units 252.
[0069] For example, after the gas supply system 314 directs the gas 340 (e.g., gasrich flow, such as CCh-rich flow) through one of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in the gas-rich adsorption stage of the adsorption mode, then the lean/rich staggered adsorption system 319 directs a partially treated gas 340 (e.g., gas-lean flow, such as CCh-lean gas) through a different one of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in the gas-lean adsorption stage of the adsorption mode. The rich stage 464 of the multi-stage adsorption system 460 may facilitate the routing of the gas 340 into and through one of the sorbent-based gas capture units 252 (e.g.. 252A, 252B, 252C, and 252D) when operating in the gas-rich adsorption stage of the adsorption mode. The lean stage 462 of the multi-stage adsorption system 460 may facilitate the routing of the partially treated gas 340 into and through the different one of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in the gas-lean adsorption stage of the adsorption mode, such as by directing the partially treated gas 340 along the fluid circuit 466 from the one or more valves 409 to the one or more valves 341. The multi-stage adsorption system 460 is further configured to operate each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) in the following adsorption stages: (1) the gas-lean adsorption stage of the multi-stage adsorption mode via the lean stage 462. and (2) the gas-rich adsorption stage of the multi-stage adsorption mode via the rich stage 464. Thus, the multi-stage adsorption system 460 may be controlled by the controller 220 to ensure that the multi-stage adsorption mode of each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) starts with adsorption of a gas-lean flow (e.g., CO2-lean gas) and ends with adsorption of a gas-rich flow (e.g., CCh-rich gas). After multiple adsorption stages are complete, then each of the sorbent-based gas capture units 252 may proceed to the desorption mode followed by the cooling mode.
[0070] The heating fluid supply system 316 of the upstream flow distribution system 310 is configured to supply a heating fluid to enable the desorption mode when selectively operating each of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) in the desorption mode via the controller 220. As discussed in further detail below, the heating fluid supply system 316 also may coordinate with a vacuum system of the post-desorption processor 442. The heating fluid supply system 316 includes one or more heating fluid supplies 350, such as one or more steam supplies, heated water supplies, heated gas supplies, and/or waste heat supplies. The heating fluids also may be described as sweep fluids, such as a sweep gas or a sweep steam. For example, the heating fluid supplies 350 may include the steam turbine system 14, the HRSG 16, a waste heat recovery system (e.g., recovering heat from compressors, pumps, generators, reactors, or other power plant equipment), a steam generator or boiler, or any combination thereof. In certain embodiments, the WHR system 22 uses waste heat recovered from the exhaust gas 152, 184, and provides the heated fluid 26 for use as the heating fluid 354. The heated fluid 26 (e.g., waste heat recovery fluid) also may be described as an excess heat or waste heat recovered for use in the heating fluid supply system 316 of the sorbent-based gas capture units 252. The heating fluid supplies 350 may be configured to supply a heating fluid 352 (e.g., steam and/or heated water) and/or a heating fluid 354 (e.g., waste heat recovery fluid, such as heated fluid 26) to a heating fluid control 356 of the heating fluid supply system 316. In certain embodiments, the heating fluid 352 (e.g., heated fluid 26) may include a heated liquid and/or a heated gas, such as heated CO2, air, inert gas such as nitrogen, water, oil, or any combination thereof.
[0071] The heating fluid control 356 includes one or more heating fluid control components 358, 360, and 362, which may be configured to process, adjust, and/or control characteristics of the heating fluid 352 and/or heating fluid 354 upstream from the conduits 254 (e.g., 255, 256. 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D). For example, the heating fluid control component 358 may include a thermal control component (e.g., temperature control component), such as a heat exchanger, a heater, a cooler, or any combination thereof, configured to adjust (e g., increase or decrease) a temperature of the heating fluid 352 and/or the heating fluid 354. The heat exchanger may exchange heat with water, lubricant, coolant, refrigerant, or some other thermal fluid. In some embodiments, a waste heat recovery7 system may be used for heat transfer in the heat exchanger. The heating fluid control component 360 may include a pressure control component, such as a pressure regulator, an expander or expansion chamber, a constrictor or constriction chamber, a fan or pump to add energy, a turbine to extract energy, or another suitable pressure controller. The heating fluid control component 362 may include a pre-treatment component, such as a particulate filter, a cold water drain, and/or other pre-treatment components configured to alter characteristics of the heating fluid 352 and/or the heating fluid 354 or remove contaminants.
[0072] The heating fluid supply system 316 also may include one or more valves 364 configured to control the distribution of the heating fluid 352 (e.g., steam and/or heated water) and/or the heating fluid 354 (e.g., waste heat recovery fluid) to the plurality of conduits 254 (e.g., 255, 256, 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) via distribution conduits 365, 366, 368. and 370. For example, the valves 364 may include one or more multi-way valves and/or distribution manifolds to independently distribute the heating fluid 352 and/or the heating fluid 354 through the distribution conduits 365, 366, 368, and 370 to the respective sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) when operating in a desorption mode in response to control signals from the controller 220.
[0073] The cooling fluid supply system 318 of the upstream flow distribution system 310 is configured to supply a cooling fluid to enable the cooling mode when selectively operating each of the sorbent-based gas capture units 252 (e g., 252A, 252B, 252C, and 252D) in the cooling mode via the controller 220. The cooling fluid supply system 318 includes one or more cooling fluid supplies 372, such as one or more water supplies, cooled air supplies, cooled inert gas (e.g., nitrogen) supplies, cooled CO2 supplies, or any combination thereof. The cooling fluid supplies 372 may be configured to supply a coolant or cooling fluid 374 (e.g., liquid or gas coolant) to a cooling fluid control 376 of the cooling fluid supply system 318.
[0074] The cooling fluid control 376 includes one or more cooling fluid control components 378, 380, and 382, which may be configured to process, adjust, and/or control characteristics of the cooling fluid 374 upstream from the conduits 254 (e.g., 255, 256. 258, and 260) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D). For example, the cooling fluid control component 378 may include a thermal control component (e.g., temperature control component), such as a heat exchanger, a heater, a cooler, or any combination thereof, configured to adjust (e.g., increase or decrease) a temperature of the cooling fluid 374. The heat exchanger may exchange heat with water, lubricant, coolant, refrigerant, or some other thermal fluid. The cooling fluid control component 380 may include a pressure control component, such as a pressure regulator, an expander or expansion chamber, a constrictor or constriction chamber, a fan or pump to add energy, a turbine to extract energy, or another suitable pressure controller. The cooling fluid control component 382 may include a pre-treatment component, such as a particulate filter and/or other pretreatment components, configured to alter characteristics of the cooling fluid 374 or remove contaminants. [0075] The cooling fluid supply system 318 also may include one or more valves 384 configured to control the distribution of the cooling fluid 374 (e.g., liquid or gas coolant) to the plurality of conduits 254 (e.g.. 255, 256, 258. and 260) of the sorbentbased gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) via distribution conduits 385, 386, 388, and 390. For example, the valves 384 may include one or more multi-way valves and/or distribution manifolds to independently distribute the cooling fluid 374 through the distribution conduits 385, 386, 388, and 390 to the respective sorbent-based gas capture units 252 (e g., 252A, 252B, 252C, and 252D) when operating in a cooling mode in response to control signals from the controller 220.
[0076] In the illustrated embodiment, the controller 220 is configured to control the upstream flow distribution system 310 and the lean/rich staggered adsorption system 319 to altematingly distribute flows of the partially treated gas 340 (e.g., CO2- lean flow) during the gas-lean adsorption stage of the multi-stage adsorption mode, the gas 340 (e.g., CCh-rich flow) during the gas-rich adsorption stage of the multistage adsorption mode, the heating fluid 352 and/or the heating fluid 354 in the desorption mode, and the cooling fluid 374 in the cooling mode to the different sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) having sorbent material 272. In the gas-rich adsorption stage of the multi-stage adsorption mode, the gas 340 (e.g., intake gas 60 or exhaust gas 152, 184) flows through the conduit 254 of the selected sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, or 252D) and contacts the sorbent material 272 disposed on the interior surface 274 of the outer conduit wall 262 and/or the exterior surface 276 of the contactors 280, such that the sorbent material 272 adsorbs the undesirable gases (e.g., CO2) from the gas 340. Similarly, in the gas-lean adsorption stage of the multi-stage adsorption mode, the partially treated gas 340 (e.g., intake gas 60 or exhaust gas 152, 184, already treated in the gas-rich adsorption stage) flows through the conduit 254 of the different selected sorbent-based gas capture unit 252 (e.g.. 252A. 252B, 252C, or 252D) and contacts the sorbent material 272 disposed on the interior surface 274 of the outer conduit wall 262 and/or the exterior surface 276 of the contactors 280, such that the sorbent material 272 adsorbs the undesirable gases (e.g., CO2) from the partially treated gas 340. In certain embodiments, the thermal control system 290 may circulate a coolant through the heat exchanger 296 to provide cooling of the contactors 280 and the sorbent material 272 during the adsorption mode (e.g., gaslean adsorption stage and gas-rich adsorption stage). The thermal control system 290 also may facilitate heat transfer to the coolant via a plurality of heat pipes 298 of the heat exchanger 296. If operating in the gas-rich adsorption stage, then the sorbentbased gas capture unit 252 discharges a partially treated gas 340 (e.g., CCh-lean flow) for a subsequent gas-lean adsorption stage by a different sorbent-based gas capture unit 252 via the lean/rich staggered adsorption system 319. Again, each sorbentbased gas capture unit 252 treats the gas 340 starting with the gas-lean adsorption stage and ending with the gas-rich adsorption stage of the adsorption mode. Once the gas-lean adsorption stage is complete, then the sorbent-based gas capture unit 252 discharges a treated gas 400 (e.g., lean or substantially free of the undesirable gases) to the post-adsorption processing system 320.
[0077] In the desorption mode, the heating fluid 352 and/or the heating fluid 354 flows through the conduit 254 of the selected sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, or 252D) and contacts the sorbent material 272 disposed on the interior surface 274 of the outer conduit wall 262 and/or the exterior surface 276 of the contactors 280. thereby heating the sorbent material 272 to facilitate desorption of the undesirable gases (e.g., CO2) from the sorbent material 272. In some embodiments, the desorption mode may be configured to indirectly heat the sorbent material 272 via a heating circuit (e.g., heating conduit) extending through the sorbent-based gas capture unit 252. For example, the thermal control system 290 may circulate a heating fluid (e.g., heating fluid 352 and/or heating fluid 354) through the heat exchanger 296 to provide heating of the contactors 280 and the sorbent material 272. As noted above, the heating fluid 354 may include the heated fluid 26 from the WHR system 22. The thermal control system 290 also may facilitate heat transfer from the heating fluid across the contactors 280 via the plurality of heat pipes 298 of the heat exchanger 296. The sorbent-based gas capture unit 252 then discharges a fluid flow 402 including the undesirable gas, the heating fluid 352, and/or the heating fluid 354 for further processing by the post-desorption processing system 322. [0078] In the cooling mode, the cooling fluid 374 flows through the conduit 254 of the selected sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, or 252D) and contacts the sorbent material 272 disposed on the interior surface 274 of the outer conduit wall 262 and/or the exterior surface 276 of the contactors 280, thereby cooling the sorbent material 272 and the contactors 280. In some embodiments, the cooling mode may be configured to indirectly cool the sorbent material 272 and the contactors 280 via a cooling circuit (e.g.. cooling conduit) extending through the sorbent-based gas capture unit 252. For example, the thermal control system 290 may circulate a cooling fluid through the heat exchanger 296 to provide cooling of the contactors 280 and the sorbent material 272. The thermal control system 290 also may facilitate heat transfer away from the contactors 280 and the sorbent material 272 via the plurality of heat pipes 298 of the heat exchanger 296. The cooling mode is configured to cool and regenerate the sorbent material 272 prior to a subsequent adsorption mode (e.g., gas-lean adsorption stage followed by gas-rich adsorption stage). The sorbent-based gas capture unit 252 then discharges a fluid flow 404 (e.g., cooling fluid 374) for handling by the post-cooling system 324.
[0079] In certain embodiments, the sorbent-based gas capture system 250 includes a movable sorbent system configured to continuously or periodically move the sorbent material 272 between the gas-lean adsorption stage of the multi-stage adsorption mode, the gas-rich adsorption stage of the multi-stage adsorption mode, the desorption mode, and the cooling mode. For example, the sorbent-based gas capture system 250 may include a rotating contactor assembly or wheel (e.g., rotating contactors with sorbent material 272) configured to rotate from gas-lean adsorption, gas-rich adsorption, desorption and cooling, thereby providing a continuous stream of captured undesirable gases. For example, the wheel (e.g., rotating contactors with sorbent material 272) may extend into each of the plurality of conduits 254, and continuously rotate through the conduits 254. During the wheel rotation, one or more of the conduits 254 flow the gas 340 being treated to remove the undesirable gases, while one or more of the conduits 254 simultaneously flow the heating fluid 352 and/or heating fluid 354 to remove and capture the undesirable gas (e.g., CO2) to generate the captured gas 204, and while one or more of the conduits 254 simultaneously flow the cooling fluid 374 to regenerate the sorbent material 272. For the desorption, the heating fluid 352 and/or heating fluid 354 may be routed or generally configured to provide direct heat transfer and/or indirect heat transfer to the sorbent material 272, thereby helping to separate and capture the undesirable gas.
[0080] In the illustrated embodiment, the controller 220 is configured to control the downstream flow distribution system 312 to altematingly distribute flows from each sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, and 252D) to route the partially treated gas 340 to the lean/rich staggered adsorption system 319 during or between stages of the adsorption mode, the treated gas 400 to the post-adsorption processing system 320 upon completion of the adsorption mode, the fluid flow 402 (e.g., the undesirable gas, the heating fluid 352, and/or the heating fluid 354) to the post-desorption processing system 322 in the desorption mode, and the fluid flow 404 (e.g., cooling fluid 374) to the post-cooling system 324 in the cooling mode. In certain embodiments, the downstream flow distribution system 312 includes one or more valves 409 fluidly coupled with the sorbent-based gas capture unit 252A, one or more valves 410 fluidly coupled with the sorbent-based gas capture unit 252B, one or more valves 412 fluidly coupled with the sorbent-based gas capture unit 252C, and one or more valves 414 fluidly coupled with the sorbent-based gas capture unit 252D.
[0081] The valves 409 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 476, 478, 480, and 482, which are coupled to the lean/rich staggered adsorption system 319, the post-adsorption processing system 320, the post-desorption processing system 322. and the postcooling system 324, respectively. The valves 410 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 415, 416, 418, and 420, which are coupled to the lean/rich staggered adsorption system 319, the postadsorption processing system 320. the post-desorption processing system 322, and the post-cooling system 324, respectively. The valves 412 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 421, 422, 424, and 426, which are coupled to the lean/rich staggered adsorption system 319, post-adsorption processing system 320, the post-desorption processing system 322, and the post-cooling system 324. respectively. The valves 414 may include one or more multi-way valves and/or distribution manifolds coupled to distribution conduits 427, 428, 430, and 432. which are coupled to the lean/rich staggered adsorption system 319, the post-adsorption processing system 320. the postdesorption processing system 322, and the post-cooling system 324, respectively.
[0082] In operation, the controller 220 is configured to control the valves 409, 410, 412, and 414 to independently control the flows from the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) to the lean/rich staggered adsorption system 319 during and between stages of the adsorption mode, to the postadsorption processing system 320 after completion of the adsorption mode, to the post-desorption processing system 322 in the desorption mode, and to the postcooling system 324 in the cooling mode.
[0083] The post-adsorption processing system 320 includes a treated gas processing system 440. which may include an exhaust stack, an additional gas treatment system, or any other suitable post processing equipment. In certain embodiments, the post-adsorption processing system 320 may recirculate all or part of the treated gas 400 to the EGR system 150 as discussed above with reference to FIG. 1.
[0084] The post-desorption processing system 322 may include a post-desorption processor 442 having one or more post-desorption processing components 444, 446, and 448. In certain embodiments, the fluid flow 402 directed to the post-desorption processor 442 is a result of the desorption mode, wherein the heating fluid 352 (e.g.. steam and/or heated water) and/or heating fluid 354 (e.g., waste heat recover fluid, such as heated fluid 26) is directed through the conduit 254 of the sorbent-based gas capture unit 252 (e.g., 252A, 252B, 252C, or 252D) to desorb the undesirable gases (e.g., CO2) from the sorbent material 272. Accordingly, the one or more postdesorption processing components 444, 446, and 448 (e.g., steam, heated water, and/or other fluid processing components) may be configured to process, adjust, and/or control characteristics of the fluid flow 402 (e.g., steam, heated water, and/or other fluid flow) from the conduits 254 (e.g., 255, 256. 258, and 260) of the sorbentbased gas capture units 252 (e.g.. 252A, 252B. 252C. and 252D). For example, the post-desorption processing component 444 may include a captured gas/heated fluid separator configured to separate the heating fluid 352 (e.g., steam and/or heated water) and/or the heating fluid 354 from the captured gas. thereby outputting a fluid 450 (e.g., water condensate or other separated fluid) and the captured gas 204. Examples of the captured gas/heated fluid separator include thermal control components, pressure control components, chemical separation components, or a combination thereof. For example, the captured gas/heated fluid separator may be configured to condense or cool the heating fluid 352 (e.g., steam) using a condenser. The post-desorption processing component 446 may include one or more removal units configured to remove contaminants from the fluid 450 and/or the captured gas 204. For the fluid 450, the removal units may include particulate filters and/or water treatment units. For the captured gas 204, the removal units may include particulate filters, water removal units or dryers, or further gas treatment units. The postdesorption processing component 448 may include one or more pressure control components and/or flow control components, such as one or more pumps for the fluid 450 and one or more compressors for the captured gas 204. The post-desorption processing components 448 also may include a vacuum system having one or more vacuum pumps configured to suction the captured gas/heated fluid flow from the sorbent-based gas capture units 252. In other words, the vacuum pumps are configured to create a low-pressure environment to help draw the captured gas/heated fluid flow from the sorbent-based gas capture units 252.
[0085] The post-cooling system 324 may include a cooling fluid recirculation system 452, which is configured to recirculate the fluid flow 404 back to the cooling fluid supply system 318 as the cooling fluid 374. The cooling fluid recirculation system 452 may include components 454, 456, and 458, such as a recirculation pump, compressor, or booster fan, a cooling system, and flow control valves. The cooling system may include a heat exchanger configured to transfer heat away from the fluid flow 404, thereby cooling the fluid flow for additional use as the cooling fluid 374. In certain embodiments, the heat available from the fluid flow 404 may be recovered in one or more heat exchangers to heat the heating fluid 352 and/or heating fluid 354 of the heating fluid supply system 316, thereby reducing the total heating energy demand. The remaining low grade heat from the fluid flow 404 may then be rejected to ambient.
[0086] The controller 220 is configured to receive feedback from the sensors 222 to facilitate adjustments of various operating parameters and change operating modes (e.g., gas-lean adsorption stage of the multi-stage adsorption mode, gas-rich adsorption stage of the multi-stage adsorption mode, desorption mode, and cooling mode) of the sorbent-based gas capture units 252 (e g., 252A, 252B, 252C, and 252D). For example, the controller 220 may be configured to alternate flows (e.g., gas 340, partially treated gas 340, heating fluid 352 and/or heating fluid 354, and cooling fluid 374) through the plurality of conduits 254 (e.g., 255, 256. 258, and 260), such that the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) can alternate between the gas-lean adsorption stage of the multi-stage adsorption mode, gas-rich adsorption stage of the multi-stage adsorption mode, the desorption mode, and the cooling mode. In the gas-lean adsorption stage of the multi-stage adsorption mode, the conduit 254 receives a flow of the partially treated gas 340 (e.g., after a previous gas-rich adsorption stage), adsorbs the undesirable gases (e.g., CO2) from the partially treated gas 340 into the sorbent material 272, and outputs a treated gas 400 with a reduced content or concentration level of the undesirable gases (e.g., substantially free of the undesirable gases). In the gas-rich adsorption stage of the multi-stage adsorption mode, the conduit 254 receives a flow of the gas 340, adsorbs the undesirable gases (e.g., CO2) from the gas 340 into the sorbent material 272, and outputs the partially treated gas 340 (e.g., gas-lean flow, such as CCh-lean flow) for further treatment in the gas-lean adsorption stage of the multi-stage adsorption mode. The adsorption of undesirable gases into the sorbent material 272 is an exothermic process, which generates heat. The thermal control system 290, including the heat exchangers 296 and the heat pipes 298, help to regulate the temperature of the sorbent material 272 during the adsorption mode, thereby maintaining or increasing the adsorption efficiency of the sorbent material 272.
[0087] In the desorption mode, the conduit 254 receives a flow7 of the heating fluid 352 (e.g., steam and/or heated water) and/or heating fluid 354. desorbs the undesirable gases (e.g., CO2) from the sorbent material 272 into the heating fluid 352 and/or heating fluid 354, and outputs the fluid flow 402 with the desorbed undesirable gases (e.g.. heating fluid 352 and/or heating fluid 354 rich in the undesirable gases such as CO2). The desorption of undesirable gases from the sorbent material 272 is an endothermic process, and the heating fluid 352 and/or heating fluid 354 provides sufficient heat (e.g., directly or indirectly) to drive the desorption of the undesirable gases (e.g., CO2) from the sorbent material 272. In the cooling mode, the conduit 254 receives a flow of the cooling fluid 374 (e.g., gas or liquid coolant), thereby cooling the sorbent material 272 and the contactors 280.
[0088] The controller 220 is configured to monitor the sensors 222. such as sensors 222 at or upstream from the inlets 266 and sensors 222 at or downstream from the outlets 270, to evaluate rates of adsorption, desorption, and cooling, concentration levels of the undesirable gases, and other characteristics impacting the operating modes of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D). If the sensors 222 indicate a need to alternate operating modes (e.g., gas-lean adsorption, gas-rich adsorption, desorption, and cooling modes) of the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D), then the controller 220 may be configured to control the valves 341, 342, 364, 384, 409, 410, 412, and 414 to change the flows through the conduits 254 to support the desired operating modes. The sensors 222 also may monitor the temperature of the sorbent material 272 and adjust the thermal control system 290 to provide heating or cooling depending on the operating mode (e.g., cooling during the adsorption and cooling modes and heating during the desorption mode).
[0089] For the gas 340 treated in one of the conduits 254 in the gas-rich adsorption stage of the multi-stage adsorption mode, the controller 220 may be configured to control the gas pre-treatment system 330 to control characteristics of the gas 340 (e.g., temperature, pressure, flow rate, etc.). For the partially treated gas 340 treated in one of the conduits 254 in the gas-lean adsorption stage of the multi-stage adsorption mode, the controller 220 may be configured to control the multi-stage adsorption system 460 to control the flow of the partially treated gas 340 from the downstream flow distribution system 312 to the upstream flow distribution system 310. Additionally, the controller 220 is configured to control the treated gas processing system 440 to control the processing of the treated gas 400 discharged from one or more of the conduits 254. For the heating fluid 352 (e.g., steam and/or heated water) and/or the heating fluid 354 (e.g.. waste heat recovery fluid, such as heated fluid 26) supporting the desorption mode in one of the conduits 254, the controller 220 may be configured to control the HRSG 16, the steam turbine system 14, the WHR system 22, the heating fluid control 356, or any combination thereof, to control characteristics of the heating fluid 352 and/or the heating fluid 354 (e.g.. temperature, pressure, flow rate, steam content, water content, etc.). Similarly, the controller 220 is configured to control the post-desorption processor 442 to control the processing of the fluid flow 402 (including the undesirable gas desorbed during the desorption mode) discharged from one or more of the conduits 254. For the cooling fluid 374 supporting the cooling mode in one of the conduits 254, the controller 220 may be configured to control the cooling fluid control 376 and/or the cooling fluid recirculation system 452 to control characteristics of the cooling fluid 374 (e.g., temperature, pressure, flow rate, etc.). Similarly, the controller 220 is configured to control the cooling fluid recirculation system 452 to control the processing of the fluid flow 404 (e.g., cooling fluid 374) discharged from one or more of the conduits 254.
[0090] FIGS. 3-6 are schematics of an embodiment of a staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250) of FIGS. 1-2, further illustrating a first stage of an adsorption mode 502 (e g., gas-rich or CCh-rich adsorption stage), a second stage of an adsorption mode 504 (e.g., gas-lean or CO2-lean adsorption stage), a desorption mode 506, and a cooling mode 508 over four periods of time of the staggered operational cycle 500. All illustrated aspects and descriptions of FIGS. 1-2 are applicable to the embodiment of FIGS. 3-6. Similarly, any additional aspects and descriptions of FIGS. 3-6 are applicable to the embodiments of FIGS. 1-2. As illustrated, the sorbent-based gas capture system 250 includes sorbent-based gas capture units 1, 2. 3, and 4. which may correspond to the sorbent-based gas capture units 252 (e.g., 252A, 252B, 252C, and 252D) as discussed above with reference to FIG. 2.
[0091] The first stage of the adsorption mode 502 directs a rich flow 510 (e.g., C Ch-rich flow) from the gas turbine system 12 through one of the sorbent-based gas capture units 252, adsorbs undesirable gases (e.g., CO2) from the rich flow 510, and outputs a lean flow 512 (e.g., CCh-lean flow). In certain embodiments, the rich flow 510 and the lean flow 512 include exhaust gas 152, 184 from the gas turbine system 12, the HRSG 16, or any other combustion system of the combined cycle system 10. The first stage of the adsorption mode 502 may remove at least equal to or greater than 70, 75, 80, 85, 90, 95, or greater percent of a total CO2 concentration in the rich flow 510, thereby generating the lean flow 512 with a substantially reduced concentration of the CO2. The sorbent-based gas capture system 250 then routes the lean flow 512 to the second stage of the adsorption mode 504.
[0092] The second stage of the adsorption mode 504 directs the lean flow 512 (e.g., CO2-lean flow) from the first stage of the adsorption mode 502 through a different one of the sorbent-based gas capture units 252, adsorbs undesirable gases (e.g., CO2) from the lean flow 512, and outputs a treated gas 514 (e.g., treated exhaust gas 152, 184 substantially free of CO2). The second stage of the adsorption mode 504 may remove all or part of the remaining CO2 concentration (e.g., at least equal to or greater than 70, 75, 80, 85, 90, 95, or greater percent of the remaining CO2 concentration) in the lean flow 512 to generate the treated gas 514. In certain embodiments, the treated gas 514 may have a CO2 content substantially equal to or less than atmospheric content of the CO2. The sorbent-based gas capture unit 252 may then direct the treated gas 514 through a stack 516 (e.g., exhaust stack).
[0093] After the first and second stages of the adsorption mode 502 and 504, the sorbent-based gas capture unit 252 generally proceeds to the desorption mode 506. As illustrated, the desorption mode 506 provides heat or heating 518 (e g., heating fluid) to the sorbent-based gas capture unit 252, thereby facilitating desorption of the undesirable gases (e.g., CO2) from sorbent material in the sorbent-based gas capture unit 252 to output a captured gas 204 (e.g.. captured CO2). As discussed above, the heat 518 may include a variety of heated fluids, such as heated water, steam, or other heated liquids and gases. The heat 518 also may be applied by an electrical heat source, waste heat, or any combination of heat sources. [0094] After the desorption mode 506, the sorbent-based gas capture unit 252 generally proceeds to the cooling mode 508. As illustrated, the cooling mode 508 provides cooling 520 (e.g., cooling fluid) to the sorbent-based gas capture unit 252. thereby facilitating cooling of the sorbent material in the sorbent-based gas capture unit 252 to regenerate or generally prepare the sorbent-based gas capture unit 252 for another cycle starting with adsorption. As discussed above, the cooling 520 may include a variety of cooling fluids, such as cooled water, air, or other cooled liquids and gases.
[0095] In each of FIGS. 3-6, the sorbent-based gas capture system 250 operates with a different arrangement or configuration of the sorbent-based gas capture units 252 in the first stage of the adsorption mode 502, the second stage of the adsorption mode 504, the desorption mode 506, and the cooling mode 508. In particular, as discussed in detail above, each of the sorbent-based gas capture systems 250 progressively cycles through the following sequence: (1) the second stage of the adsorption mode 504, (2) the first stage of the adsorption mode 502, (3) the desorption mode 506, and (4) the cooling mode 508.
[0096] FIG. 3 is a schematic of a first configuration 530 during a first duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g.. sorbent-based gas capture system 250). In the first configuration 530 illustrated in FIG. 3, the sorbent-based gas capture unit 1 is disposed in the first stage of the adsorption mode 502, the sorbent-based gas capture unit 2 is disposed in the second stage of the adsorption mode 504. the sorbent-based gas capture unit 3 is disposed in the desorption mode 506, and the sorbent-based gas capture unit 4 is disposed in the cooling mode 508.
[0097] FIG. 4 is a schematic of a second configuration 532 during a second duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250). In the second configuration 532 illustrated in FIG. 4, the sorbent-based gas capture unit 2 is disposed in the first stage of the adsorption mode 502, the sorbent-based gas capture unit 4 is disposed in the second stage of the adsorption mode 504. the sorbent-based gas capture unit 1 is disposed in the desorption mode 506, and the sorbent-based gas capture unit 3 is disposed in the cooling mode 508.
[0098] FIG. 5 is a schematic of a third configuration 534 during a third duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250). In the third configuration 534 illustrated in FIG. 5, the sorbent-based gas capture unit 4 is disposed in the first stage of the adsorption mode 502, the sorbent-based gas capture unit 3 is disposed in the second stage of the adsorption mode 504, the sorbent-based gas capture unit 2 is disposed in the desorption mode 506, and the sorbent-based gas capture unit 1 is disposed in the cooling mode 508.
[0099] FIG. 6 is a schematic of a fourth configuration 536 during a fourth duration of time of the staggered operational cycle 500 of the gas capture system 20 (e.g., sorbent-based gas capture system 250). In the fourth configuration 536 illustrated in FIG. 6, the sorbent-based gas capture unit 3 is disposed in the first stage of the adsorption mode 502, the sorbent-based gas capture unit 1 is disposed in the second stage of the adsorption mode 504, the sorbent-based gas capture unit 4 is disposed in the desorption mode 506, and the sorbent-based gas capture unit 2 is disposed in the cooling mode 508.
[00100] FIG. 7 is a flow chart of an embodiment of a process 550 for controlling the staggered operating cycle 500 as illustrated in FIGS. 3-6, wherein the process 550 is controlled by the instructions 228 stored on the memory 226 and executable by the processor 224 of the controller 220 of FIG. 1. In the illustrated embodiment, the process 550 controls a staggered operating cycle 500 with a plurality of sorbent-based gas capture units 252 to capture an undesirable gas (e.g., CO2) from a gas flow (block 552). The process 550 cycles each of the plurality of sorbent-based gas capture units 252 through a plurality of operating modes. At block 554, the process 550 controls the gas flow (e.g., exhaust gas 152, 184) through a sorbent-based gas capture unit 252 during a gas-lean adsorption stage of a multi-stage adsorption mode (e.g., second stage of adsorption mode 504) of the staggered operating cycle 500. At block 556, the process 550 controls the gas flow (e.g., exhaust gas 152, 184) through the sorbent- based gas capture unit 252 during a gas-rich adsorption stage of the multi-stage adsorption mode (e.g., first stage of adsorption mode 502) of the staggered operating cycle 500. At block 558. the process 550 controls a heating fluid flow through the sorbent-based gas capture unit 252 during a desorption mode 506 of the staggered operating cycle 500. At block 560, the process 550 controls a cooling fluid flow through the sorbent-based gas capture unit 252 during a cooling mode 508 of the staggered operating cycle 500. At block 562. the process 550 repeats the steps of the gas-lean adsorption stage (block 554), the gas-rich adsorption stage (block 556), the desorption mode (block 558), and the cooling mode (block 560) for each of the plurality of sorbent-based gas capture units 252 in the staggered operating cycle 500.
[00101] FIG. 8 is a flow chart of an embodiment of a process 580 for controlling the staggered operating cycle 500 as illustrated in FIGS. 3-6, wherein the process 580 is controlled by the instructions 228 stored on the memory 226 and executable by the processor 224 of the controller 220 of FIG. 1. In the illustrated embodiment, at block 582, the process 580 operates each of a plurality' of sorbent-based gas capture units 252 in a staggered operating cycle 500 of a gas-lean adsorption stage, a gas-rich adsorption stage, a desorption mode, and a cooling mode. At block 584, the process 580 controls gas flow (e.g., exhaust gas 152, 184) through a first sorbent-based gas capture unit 252 as a first adsorption stage using the gas-rich adsorption stage (e.g.. first stage of adsorption mode 502) of the staggered operating cycle 500. At block 586, the process 580 controls gas flow (e.g., exhaust gas 152, 184) through a second sorbent-based gas capture unit 252 as a second adsorption stage using the gas-lean adsorption stage (e.g., second stage of adsorption mode 504) of the staggered operating cycle 500. At block 588, the process 580 controls a heating fluid flow through a third sorbent-based gas capture unit 252 during the desorption mode 506 of the staggered operating cycle 500. At block 590, the process 580 controls a cooling fluid flow through a fourth sorbent-based gas capture unit 252 during the cooling mode 508 of the staggered operating cycle 500. At block 592, the process 580 repeats the process with each of the plurality of sorbent-based gas capture units 252 operating in a next operating step in the staggered operating cycle 500. [00102] Technical effects of the disclosed embodiments enable multiple adsorption stages with fewer sorbent-based gas capture units by operating each of the sorbentbased gas capture units in the multiple adsorption stages in a reversed order. In other words, each sorbent-based gas capture unit adsorbs undesirable gases (e.g., CO2) starting in a second adsorption stage (e.g., gas-lean adsorption stage) prior to adsorbing the undesirable gases in a first adsorption stage (e.g., gas-rich adsorption stage). The use of each sorbent-based gas capture unit in multiple adsorption stages, rather than using a first set of sorbent-based gas capture units only in a first adsorption stage and a second set of sorbent-based gas capture units only in a second adsorption stage, helps to improve efficiency, reduce space requirements for the sorbent-based gas capture units, and reduce equipment costs. Although each sorbent-based gas capture unit is described in context of two adsorption stages, any number of adsorption stages (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more) may be used with the sorbent-based gas capture units described with reference to FIGS. 1-8.
[00103] The subject matter described in detail above may be defined by one or more clauses, as set forth below.
[00104] A system includes a gas capture system having a first adsorber with a first sorbent material. The first adsorber is configured to adsorb an undesirable gas from a gas flow into the first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas, desorb the undesirable gas from the first sorbent material in a desorption mode, and cool the first sorbent material in a cooling mode. The system further includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control the first adsorber in a sequence of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode.
[00105] The system of any preceding clause, wherein the gas capture system is configured to adsorb the undesirable gas in a first adsorption stage followed by a second adsorption stage of the plurality of adsorption stages, and the controller is configured to control the first adsorber in the sequence of the plurality of adsorption stages in the reversed order by operating the first adsorber in the second adsorption stage prior to operating the first adsorber in the first adsorption stage.
[00106] The system of any preceding clause, wherein the first adsorption stage includes a gas-rich adsorption stage and the second adsorption stage includes a gaslean adsorption stage.
[00107] The system of any preceding clause, wherein the undesirable gas includes carbon dioxide (CO2), the gas-rich adsorption stage includes a CCh-rich adsorption stage, and the gas-lean adsorption stage includes a CCh-lean adsorption stage.
[00108] The system of any preceding clause, wherein the gas capture system includes the first adsorber having the first sorbent material, a second adsorber having a second sorbent material, a third adsorber having a third sorbent material, and a fourth adsorber having a fourth sorbent material. The controller is configured to operate the first, second, third, and fourth adsorbers in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas. the desorption mode, and the cooling mode.
[00109] The system of any preceding clause, wherein the staggered operating cycle includes a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively. The staggered operating cycle further includes a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively. The staggered operating cycle further includes a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively. The staggered operating cycle further includes a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively. [00110] The system of any preceding clause, wherein the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas includes at least three adsorption stages.
[00111] The system of any preceding clause, wherein the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas includes at least four adsorption stages.
[00112] The system of any preceding clause, wherein the gas flow includes an exhaust gas from a combustion system.
[00113] The system of any preceding clause, further including a gas turbine system having a turbine, a combustor, and a compressor, wherein the gas turbine system generates the exhaust gas.
[00114] The system of any preceding clause, further including an electrical generator driven by the gas turbine system.
[00115] The system of any preceding clause, wherein the gas capture system includes a temperature swing adsorption (TSA) system, a vacuum temperature swing adsorption (VTSA) system, a concentration swing adsorption (CSA) system, or any combination thereof.
[00116] The system of any preceding clause, further including a steam turbine system and/or a heat recovery steam generator (HRSG) configured to supply a heat to the gas capture system via a heated water and/or a steam during the desorption mode.
[00117] The system of any preceding clause, wherein the gas flow includes an air flow.
[00118] A system includes a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control a first adsorber of a gas capture system to: adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality7 of adsorption stages in a reversed order with an increasing concentration of the undesirable gas. The controller is further configured to desorb the undesirable gas from the first sorbent material in a desorption mode. The controller is further configured to cool the first sorbent material in a cooling mode.
[00119] The system of the preceding clause, wherein the gas capture system is configured to adsorb the undesirable gas in a first adsorption stage followed by a second adsorption stage of the plurality of adsorption stages, and the controller is configured to control the first adsorber in the sequence of the plurality of adsorption stages in the reversed order by operating the first adsorber in the second adsorption stage prior to operating the first adsorber in the first adsorption stage.
[00120] The system of any preceding clause, wherein the undesirable gas includes carbon dioxide (CO2), the first adsorption stage includes a CCh-rich adsorption stage, the second adsorption stage includes a CCh-lean adsorption stage, and wherein the first adsorber includes a temperature swing adsorption (TSA) unit, a vacuum temperature swing adsorption (VTSA) unit, a concentration swing adsorption (CSA) unit, or any combination thereof.
[00121] The system of any preceding clause, wherein the gas capture system includes the first adsorber having the first sorbent material, a second adsorber having a second sorbent material, a third adsorber having a third sorbent material, and a fourth adsorber having a fourth sorbent material. The controller is configured to operate the first, second, third, and fourth adsorbers in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode. The staggered operating cycle includes a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively. The staggered operating cycle further includes a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively. The staggered operating cycle further includes a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively. The staggered operating cycle further includes a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.
[00122] A method includes controlling, via a controller, a first adsorber of a gas capture system to adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas. The method further includes controlling, via the controller, the first adsorber to desorb the undesirable gas from the first sorbent material in a desorption mode. The method further includes controlling, via the controller, the first adsorber to cool the first sorbent material in a cooling mode.
[00123] The method of the preceding clause, further including controlling the first adsorber, a second adsorber, a third adsorber, and a fourth adsorber in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode. The staggered operating cycle includes a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively. The staggered operating cycle further includes a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively. The staggered operating cycle further includes a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively. The staggered operating cycle further includes a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.
[00124] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

CLAIMS:
1. A system, comprising: a gas capture system, comprising: a first adsorber having a first sorbent material, wherein the first adsorber is configured to adsorb an undesirable gas from a gas flow into the first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas, desorb the undesirable gas from the first sorbent material in a desorption mode, and cool the first sorbent material in a cooling mode; and a controller having a processor, a memory, and instructions stored on the member and executable by the processor to control the first adsorber in a sequence of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode.
2. The system of claim 1, wherein the gas capture system is configured to adsorb the undesirable gas in a first adsorption stage followed by a second adsorption stage of the plurality of adsorption stages, and the controller is configured to control the first adsorber in the sequence of the plurality of adsorption stages in the reversed order by operating the first adsorber in the second adsorption stage prior to operating the first adsorber in the first adsorption stage.
3. The system of claim 2, wherein the first adsorption stage comprises a gas-rich adsorption stage and the second adsorption stage comprises a gas-lean adsorption stage.
4. The system of claim 3, wherein the undesirable gas comprises carbon dioxide (CO2), the gas-rich adsorption stage comprises a CCh-rich adsorption stage, and the gas-lean adsorption stage comprises a CCh-lean adsorption stage.
5. The system of claim 1, wherein the gas capture system comprises: the first adsorber having the first sorbent material; a second adsorber having a second sorbent material; a third adsorber having a third sorbent material; and a fourth adsorber having a fourth sorbent material, wherein the controller is configured to operate the first, second, third, and fourth adsorbers in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode.
6. The system of claim 5, wherein the staggered operating cycle comprises: a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively; a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively; a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively; and a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.
7. The system of claim 1, wherein the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas comprises at least three adsorption stages.
8. The system of claim 1, wherein the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas comprises at least four adsorption stages.
9. The system of claim 1, wherein the gas flow comprises an exhaust gas from a combustion system.
10. The system of claim 9, comprising a gas turbine system having a turbine, a combustor, and a compressor, wherein the gas turbine system generates the exhaust gas.
11. The system of claim 10, comprising an electrical generator driven by the gas turbine system.
12. The system of claim 1. wherein the gas capture system comprises a temperature swing adsorption (TSA) system, a vacuum temperature swing adsorption (VTSA) system, a concentration swing adsorption (CSA) system, or any combination thereof..
13. The system of claim 12, comprising a steam turbine system and/or a heat recovery steam generator (HRSG) configured to supply a heat to the gas capture system via a heated water and/or a steam during the desorption mode.
14. The system of claim 1, wherein the gas flow comprises an air flow.
15. A system, comprising: a controller having a processor, a memory7, and instructions stored on the member and executable by the processor to control a first adsorber of a gas capture system to: adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas; desorb the undesirable gas from the first sorbent material in a desorption mode; and cool the first sorbent material in a cooling mode.
16. The system of claim 15, wherein the gas capture system is configured to adsorb the undesirable gas in a first adsorption stage followed by a second adsorption stage of the plurality of adsorption stages, and the controller is configured to control the first adsorber in the sequence of the plurality of adsorption stages in the reversed order by operating the first adsorber in the second adsorption stage prior to operating the first adsorber in the first adsorption stage.
17. The system of claim 16, wherein the undesirable gas comprises carbon dioxide (CO2), the first adsorption stage comprises a CCh-rich adsorption stage, the second adsorption stage comprises a CCh-lean adsorption stage, and wherein the first adsorber comprises a temperature swing adsorption (TSA) unit, a vacuum temperature swing adsorption (VTSA) unit, a concentration swing adsorption (CSA) unit, or any combination thereof.
18. The system of claim 15, wherein the gas capture system comprises: the first adsorber having the first sorbent material; a second adsorber having a second sorbent material; a third adsorber having a third sorbent material; and a fourth adsorber having a fourth sorbent material, wherein the controller is configured to operate the first, second, third, and fourth adsorbers in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode, wherein the staggered operating cycle comprises: a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively; a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively; a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively; and a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.
19. A method, comprising: controlling, via a controller, a first adsorber of a gas capture sy stem to adsorb an undesirable gas from a gas flow into a first sorbent material in a plurality of adsorption stages in a reversed order with an increasing concentration of the undesirable gas; controlling, via the controller, the first adsorber to desorb the undesirable gas from the first sorbent material in a desorption mode; and controlling, via the controller, the first adsorber to cool the first sorbent material in a cooling mode.
20. The method of claim 19, further comprising controlling the first adsorber, a second adsorber, a third adsorber, and a fourth adsorber in a staggered operating cycle of the plurality of adsorption stages in the reversed order with the increasing concentration of the undesirable gas, the desorption mode, and the cooling mode, wherein the staggered operating cycle comprises: a first duration of time having a first adsorption stage, a second adsorption stage, the desorption mode, and the cooling mode implemented by the first, second, third, and fourth adsorbers, respectively; a second duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the second, fourth, first, and third adsorbers, respectively; a third duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the fourth, third, second, and first adsorbers, respectively; and a fourth duration of time having the first adsorption stage, the second adsorption stage, the desorption mode, and the cooling mode implemented by the third, first, fourth, and second adsorbers, respectively.
PCT/US2023/084640 2023-12-18 2023-12-18 System and method for gas capture using multiple adsorption stages Pending WO2025136353A1 (en)

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