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JP-2026514345-A - Fluid separation system, method of manufacturing the same, and method of use

JP2026514345AJP 2026514345 AJP2026514345 AJP 2026514345AJP-2026514345-A

Abstract

A device for separating fluid species is disclosed. The device comprises at least one header connected to a monoblock. The header uses a transition element to transition one or more fluid streams between a bulk flow and a multi-channel flow pattern. The header is mounted on a monoblock and modifies the raw process fluid stream by adjusting the temperature of the raw process fluid stream and/or separating at least a portion of one or more fluid species from it. Fluid separation is achieved by using a high-boiling-point liquid injected into the pore structure of the monoblock, the output of which is a modified process fluid stream and a discharge fluid stream. A method for manufacturing the device and a method for separating at least a portion of fluid species from a process fluid stream using the device are also disclosed.

Inventors

  • イプリー，ダスティン マシュー

Assignees

  • ディカーボン・エア・リミテッド・ライアビリティ・カンパニー

Dates

Publication Date
20260511
Application Date
20240112
Priority Date
20230116

Claims (20)

  1. A header configured to split a bulk fluid flow into a multi-channel fluid flow, It comprises at least one inlet, a transition element, multiple routing channels, and at least one outlet, The first inlet is configured to receive the first fluid bulk flow, At least one outlet comprises multiple openings fluidly connected to multiple fluid flow channels on a device mounted on the header, The transition element is configured to split the first bulk fluid flow into a first multi-channel fluid flow. Multiple first routing channels are configured to route the first multi-channel fluid flow to the first outlet. A header having a first outlet with multiple openings fluidly connected to a first fluid flow channel group.
  2. Further comprising a second inlet having multiple openings fluidly connected to a second fluid flow channel group on a device mounted on the header, The second inlet is configured to receive the second multi-channel fluid flow from the second fluid flow channel group. Multiple second routing channels are configured to route the second multi-channel fluid flow from the second inlet to the transition element. The transition element is further configured to merge the second multi-channel fluid flow with the second bulk fluid flow. The second outlet is configured to discharge the second bulk fluid flow from the header. The first fluid flow channel group is structurally different from the second fluid flow channel group. The header according to claim 1, wherein the first routing channel is structurally different from the second routing channel and is not in fluid communication with the second routing channel.
  3. The header according to claim 1, wherein the header is configured to maintain a pressure difference between a first fluid flow channel group and a second fluid flow channel group.
  4. Plenum structure and The device further comprises a second inlet fluid-connected to a second fluid flow channel group on a device mounted on a header, The second inlet is configured to receive the second multi-channel fluid flow from the second fluid flow channel group. The plenum structure is configured to merge the second multi-channel fluid flow to form a second bulk fluid flow. The second outlet is configured to discharge the second bulk fluid flow. The header according to claim 1, wherein the first fluid flow channel group is structurally different from the second fluid flow channel group.
  5. The header according to claim 4, wherein the plenum structure is selected from a group consisting of a housing, manifold, ductwork, chamber, air distribution box, and cavity.
  6. The header according to claim 1, wherein the header is at least partially made of a material selected from the group consisting of polymers, soluble polymers, composite materials, waxes, and metals.
  7. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group are between two fluid flow channels and 1600 fluid flow channels.
  8. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group have a size of approximately 200 channels/square inch to approximately 1200 channels/square inch.
  9. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group have a length of approximately 50 mm to approximately 500 mm.
  10. The header according to claim 1, wherein the first fluid flow channel group is housed inside a monoblock.
  11. Both the first fluid flow channel group and the second fluid flow channel group are housed inside the monoblock. The header according to claim 1, wherein the first fluid flow channel group and the second fluid flow channel group are separated by channel walls formed of the material on which the monoblock is formed.
  12. The header according to claim 11, wherein the channel wall is porous and selectively permeable.
  13. The header according to claim 12, wherein the channel wall is impregnated with one or more high-boiling point liquids selected from the group consisting of ionic liquids, hydrocarbons, and amines.
  14. The monoblock comprises multiple fluid flow channels, including a first fluid flow channel group independent of the second fluid flow channel group, The plurality of fluid flow channels are separated by channel walls, The channel wall is formed of a porous, selectively permeable material into which a monoblock is formed. The channel wall is impregnated with one or more high-boiling point liquids. An apparatus in which at least a portion of a first fluid flow channel group is adjacent to at least a portion of a second fluid flow channel group.
  15. The apparatus according to claim 14, wherein the first fluid flow channel group is structurally different from the second fluid flow channel group.
  16. The apparatus according to claim 14, wherein the monoblock is configured to maintain a pressure difference between the first fluid flow channel group and the second fluid flow channel group.
  17. The apparatus according to claim 14, wherein the channel wall is impregnated with a high-boiling point liquid by a process comprising the following steps. (a) The step of selecting a high-boiling-point liquid having a boiling point of at least about 100°C. (b) The step of selecting a carrier liquid having a lower boiling point than the selected high-boiling-point liquid. (c) A step of mixing a high-boiling point liquid with a carrier to produce a solution having a concentration of approximately 15% to approximately 20% of the high-boiling point liquid. (d) A step of impregnating at least a portion of a plurality of fluid flow channels with the solution using a process that performs at least partial pore injection.
  18. The apparatus according to claim 14, wherein the one or more high-boiling point liquids are selected from the group consisting of ionic liquids, hydrocarbons, and amines.
  19. The apparatus according to claim 14, wherein the one or more high-boiling point liquids are configured to preferentially absorb one or more components of the process fluid stream introduced into the first fluid flow channel group.
  20. The apparatus according to claim 14, wherein the one or more high-boiling point liquids are configured to inactivate at least a portion of viruses, dust, mites, bacteria, pathogens, mold spores, or other biological contaminants from a process fluid stream introduced into a first fluid flow channel group.

Description

(Cross-reference to related applications) This application claims priority to U.S. Provisional Application No. 63/480093, filed on 16 January 2023, the contents of which are incorporated herein by reference in their entirety. This disclosure generally relates to the field of fluid separation. This disclosure also relates to materials, devices, and apparatus for carrying this out. Furthermore, this disclosure relates to methods of using such devices and apparatus in industrial processes, indoor air purification, heating, ventilation, and air conditioning ("HVAC") systems, and other fields. Indoor air quality (IAQ) can be a crucial factor in maintaining a healthy and comfortable living or working environment under specific circumstances. Various IAQ factors are measured and maintained, often tailored to the specific needs of individual buildings, such as residences, office buildings, or warehouses. Indoor air problems are caused by a wide range of pollutants and, depending on the specific use, may include particulate matter (PM), formaldehyde, volatile organic compounds (VOCs), carbon dioxide ( CO₂ ), semi-volatile organic compounds, house dust mites, mold, bacteria, and associated health effects such as sick building syndrome, asthma, allergies, Legionnaires' disease, lung cancer, and airborne infections like SARS and COVID-19. Traditionally, IAQ has been partially addressed by introducing outside air into buildings. For example, outside air was introduced to reduce PM, VOC, and CO₂ concentrations, or to control indoor humidity levels. This disclosure was partially conceived in response to both the global coronavirus (COVID-19) pandemic and the increasing levels of outdoor pollution, prompting the inventors to question the industry-wide assumption that introducing outdoor air is the best way to control IAQ factors in building air. When used for treating the air in a building, the innovations underlying this disclosure allow for maintaining IAQ factors at comfortable levels and complying with relevant IAQ standards, while minimizing, and in some cases eliminating, the need to introduce outdoor air into the building. In 2022, the American National Standards Institute (ANSI) and the Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) revised their standards for ventilation and acceptable indoor air quality. See ANSI/ASHRAE Standard 62.1-2022: Ventilation and Acceptable Indoor Air Quality, ASHRAE (September 2022) (hereinafter referred to as "the Standard"). ANSI/ASHRAE Standard 62.1 is an accredited standard for the design of ventilation systems and acceptable IAQ (Indoor Air Quality). The Standard specifies minimum ventilation rates and other measures to minimize adverse health effects on occupants. See ASHRAE Standards 62.1 and 62.2 (September 2022) (https://www.ashrae.org/technical-resources/bookstore/standards-62-1-62-2). Standard 62.1, 2022 edition, reflects how IAQs exceed ventilation requirements. The standard specifies procedures for determining the amount of outside air required to ensure that the concentrations of certain compounds and particulate matter ("PM2.5") with a diameter of 2.5 μm or less in an indoor environment comply with the standard's design limits. See sections 15, 25-26 of Standard 62.1-2022. The standard's design limits for various compounds and PM2.5 are listed below, along with references to the relevant regulatory authorities. Some embodiments of this disclosure enable the reduction of the concentrations of these compounds within the design limits of the standard without dilution from outdoor air. Fluid separation technology is crucial in various industries, and details will be discussed later. Gas separation technology contributes to environmental advancements, particularly carbon capture. Furthermore, gas separation helps improve IAQ by selectively removing contaminants and adjusting air composition. Conventional and current fluid separation technologies suffer from considerable drawbacks, including high energy input, complex mechanisms, high costs, and frequent maintenance. Current separation technologies are described below. Physical absorption method. This method involves passing a gas through a liquid medium that acts as a solvent. Targeting specific gases with similar solubility characteristics is difficult, making precise separation challenging. The desorption from the liquid absorbent requires a significant amount of energy, impacting overall efficiency. Chemical reactions. Selective chemical reactions are used to form compounds for gas separation. However, the complexity of the process, along with the complex reaction mechanism, leads to high operating and maintenance costs. Scaling up for industrial applications presents challenges, reducing efficiency and cost-effectiveness. Membrane separation. This method utilizes semipermeable membranes to separate gases based on size, solubility, or diffusion rate. However, membranes face challenges such as degr