BR-122026003184-A2 - A gas-liquid contact system

Abstract

The present invention relates to a CO2 capture system from a diluted gas source comprising a gas and liquid contactor, including a housing coupled to a plurality of structural elements; one or more basins positioned within the housing and configured to contain a CO2 capture solution, one or more basins, including a lower basin; one or more packing sections positioned at least partially above the lower basin; an operable fan for circulating a CO2-rich gas through one or more packing sections; and a liquid distribution system configured to flow the CO2 capture solution to one or more packing sections.

Inventors

• David St. Angelo
• TREVOR SEAN FOLLETT
• BENJAMIN IGNACE LAFFERTY
• Kevin Nold
• Briac Medard de Chardon
• Stephen Slen
• DOUGLAS EDWARD OLMSTEAD
• Teerawat Sanpasertparnich
• MEGAN LYNN O'BRIEN
• Geoff Holmes
• KIM MARTIN NIKOLAISEN

Assignees

• CARBON ENGINEERING LTD.

Dates

Publication Date

20260317

Application Date

20211221

Priority Date

20201221

Claims (20)

1. 1. A gas-liquid contact system, characterized in that it comprises: a housing coupled to a plurality of structural elements; one or more basins positioned inside the housing and configured to contain a liquid, the one or more basins comprising a lower basin and an upper basin; one or more filling sections comprising a first filling section and a second filling section positioned at least partially above the lower basin, the first filling section positioned at least partially above the second filling section; an operable fan for circulating a gas through the one or more filling sections; at least one deflector inside the housing for deflecting part of the gas to the one or more filling sections, the at least one deflector comprising: a vertical extension between the lower portion of the second filling section and a liquid level of the lower basin; and a lateral extension between opposite sides of the housing; and a liquid distribution system configured to flow liquid to one or more filling sections, the liquid distribution system comprising a set of nozzles and one or more liquid distribution tubes, wherein the nozzle set is positioned below the one or more liquid distribution tubes.
2. 2. System according to claim 1, characterized in that at least one deflector is positioned adjacent to a liquid redistributor.
3. 3. System according to claim 1 or 2, characterized in that: one or more basins comprise an upper basin disposed above the first filling section; and at least one deflector comprises at least one upper deflector comprising a vertical extension between an upper portion of the first filling section and a base of the upper basin.
4. 4. System according to any one of claims 1 to 3, characterized in that a vertical gap is defined between the first filling section and the second filling section, and the at least one deflector comprises at least one intermediate deflector positioned in the vertical gap between the first filling section and the second filling section.
5. 5. System according to any one of claims 1 to 4, characterized in that at least one deflector comprises a sheet extending vertically.
6. 6. System according to any one of claims 1 to 5, characterized in that a vertical gap is defined between the first filling section and the second filling section, and the at least one deflector comprises at least one intermediate deflector, the system comprising: a liquid redistributor positioned in the vertical gap, wherein the vertical extension of the at least one intermediate deflector extends between a lower portion of the first filling section and a liquid level of the liquid redistributor.
7. 7. System according to claim 6, characterized in that the liquid redistributor comprises a redistribution basin positioned between the first filling section and the second filling section, and a plurality of redistribution nozzles.
8. 8. A gas-liquid contact system, characterized in that it comprises: a housing coupled to a plurality of structural elements; one or more basins positioned inside the housing and configured to contain a liquid, wherein the one or more basins comprise a lower basin and an upper basin; one or more filling sections positioned at least partially above the lower basin; an operable fan to circulate a gas through the one or more filling sections; at least one gas flow diversion device inside the housing, adjacent to the one or more filling sections, to divert part of the gas to the one or more filling sections; and a liquid distribution system configured to strain the liquid to the one or more filling sections, the liquid distribution system comprising a set of nozzles and one or more liquid distribution tubes, wherein the set of nozzles is positioned below the one or more liquid distribution tubes.
9. 9. System according to claim 8, characterized in that one or more filling sections comprise a first filling section positioned at least partially above a second filling section.
10. 10. System according to claim 9, characterized in that at least one filling support is interposed between the first filling section and the second filling section of one or more filling sections.
11. 11. System according to claim 8 or 9, characterized in that the first filling section comprises a first groove angle and the second filling section comprises a second groove angle that is different from the first groove angle.
12. 12. System according to any one of claims 9 to 11, characterized in that it comprises a liquid redistributor positioned between one or more filling sections, the liquid redistributor comprising at least one of: the second filling section or a plurality of redistribution nozzles configured to flow the liquid to the second filling section.
13. 13. System according to any one of claims 1 to 12, characterized in that one or more liquid distribution tubes each have a set of spray orifices.
14. 14. System according to claim 13, characterized in that the set of sprinkler orifices is oriented at least partially towards a lower surface of the upper basin.
15. 15. System according to any one of claims 1 to 14, characterized in that it comprises a weir coupled to a lower surface of the upper basin, the weir being configured to form a first reservoir and a second reservoir of liquid in the upper basin, wherein: the liquid flows from the first reservoir to the second reservoir; the set of spray orifices is at least partially submerged in the first reservoir; and the set of nozzles is fluidly coupled to the second reservoir.
16. 16. System according to any one of claims 1 to 15, characterized in that the lower basin comprises at least one of: an HDPE basin section or a concrete basin section.
17. 17. System according to claim 16, characterized in that a leak detection system is interposed between the lower basin and the geomembrane liner.
18. 18. System according to any one of claims 1 to 17, characterized in that the plurality of structural elements defines a plenum comprising a containment that is at least partially segregated from the lower basin by one or more walls, the lower basin being positioned at least partially below one or more infill sections.
19. 19. System according to claim 18, characterized in that the containment comprises a reservoir fluidly coupled to a drain pipe that is operable to drain a volume of liquid out of the containment.
20. 20. System according to claim 19, characterized in that the containment comprises a reservoir pump positioned within a reservoir, the reservoir pump being operable to drain a volume of liquid into the lower basin.

Description

TECHNICAL FIELD [001] The present invention relates to systems, apparatus and methods for capturing carbon dioxide. BACKGROUND [002] Capturing carbon dioxide (CO2) from the atmosphere is an approach to mitigating greenhouse gas emissions and slowing climate change. However, many technologies designed for capturing CO2 from point sources, such as flue gases from industrial plants, are generally ineffective at capturing CO2 from the atmosphere due to the significantly lower CO2 concentrations and large volumes of air required for processing. In recent years, there has been progress in the search for more suitable technologies to capture CO2 directly from the atmosphere. Some of these direct air capture (DAC) systems utilize a solid absorbent where an active agent is bonded to a substrate. These DAC systems typically employ a cyclic adsorption-desorption process in which, after being saturated with CO2, the solid sorbent releases the CO2 using moisture or thermal balance and is regenerated. [003] Other DAC systems use a liquid sorbent (sometimes called a solvent) to capture CO2 from the atmosphere. An example of such a gas-liquid contact system would be one based on cooling tower models where a fan is used to draw air from a high surface area packing material that is wetted with a solution containing the liquid sorbent. The CO2 in the air reacts with the liquid sorbent. The rich solution is subsequently processed downstream to regenerate a lean solution and release a concentrated carbon stream, e.g., CO, CO2, or other carbon products. DAC systems that are designed based on cooling towers are advantageous because they employ some commercially available equipment and can move large quantities of air. It is desirable that DAC systems be sustainable in a simple and operationally flexible manner. SUMMARY [004] In one example of implementation, a CO2 capture system from a dilute gas source includes a gas and liquid contactor comprising a housing coupled to a plurality of structural elements; one or more basins positioned inside the housing and configured to contain a CO2 capture solution, one or more basins, including a lower basin; one or more packing sections positioned at least partially above the lower basin; an operable fan to circulate a CO2-rich gas through one or more packing sections; and a liquid distribution system configured to flow the CO2 capture solution to one or more packing sections. [005] In an aspect combinable with the implementation example, the gas and liquid contactor includes one or more construction materials (MOCs) that are compatible with the CO2 capture solution. [006] In another aspect combinable with any of the previous aspects, one or more MOCs include at least one of: fiber-reinforced plastic (FRP) or stainless steel. [007] In another aspect combinable with any of the previous aspects, FRP includes vinyl ester and fiberglass. [008] In another aspect combinable with any of the preceding aspects, the housing includes one or more openings and one or more cut ends. [009] In another aspect combinable with any of the previous aspects, one or more openings and one or more cut ends are coated with a layer of sealant. [0010] In another aspect combinable with any of the previous aspects, the sealant layer includes vinyl ester resin. [0011] In another aspect combinable with any of the previous aspects, one or more openings are covered with a protective sleeve. [0012] In another aspect combinable with any of the previous aspects, the protective sleeve includes PVC. [0013] In another aspect combinable with any of the previous aspects, a protective coating applied to at least one of: the plurality of structural elements, the housing or one or more basins. [0014] In another aspect combinable with any of the previous aspects, the protective coating includes at least one of: vinyl ester, polyurethane, stainless steel or epoxy. [0015] In another aspect combinable with any of the previous aspects, the protective coating includes an additive. [0016] In another aspect combinable with any of the previous aspects, the lower basin includes at least one of: an HDPE basin section or a concrete basin section. [0017] In another aspect combinable with any of the previous aspects, the HDPE basin section is coupled to a basin support structure. [0018] In another aspect combinable with any of the previous aspects, the concrete basin section incorporates a sealing profile including at least one of: thermoplastic vulcanized material (TPV), PVC, hydrophilic chloroprene rubber or stainless steel. [0019] In another aspect combinable with any of the preceding aspects, a geomembrane liner encloses at least part of the lower basin, the geomembrane liner including at least one of: HDPE or ethylene propylene diene monomer (EPDM). [0020] In another aspect that can be combined with any of the previous aspects, a leak detection system is interposed between the lower basin and the geomembrane lining. [0021] In another aspect com