WO2025177240A1 - Système et procédé de capture et de stockage de co2 - Google Patents
Système et procédé de capture et de stockage de co2Info
- Publication number
- WO2025177240A1 WO2025177240A1 PCT/IB2025/051900 IB2025051900W WO2025177240A1 WO 2025177240 A1 WO2025177240 A1 WO 2025177240A1 IB 2025051900 W IB2025051900 W IB 2025051900W WO 2025177240 A1 WO2025177240 A1 WO 2025177240A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- gas
- modular
- storage chamber
- flow
- storage container
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/46—Removing components of defined structure
- B01D53/62—Carbon oxides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/40—Alkaline earth metal or magnesium compounds
- B01D2251/402—Alkaline earth metal or magnesium compounds of magnesium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/40—Alkaline earth metal or magnesium compounds
- B01D2251/404—Alkaline earth metal or magnesium compounds of calcium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/60—Inorganic bases or salts
- B01D2251/606—Carbonates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2256/00—Main component in the product gas stream after treatment
- B01D2256/22—Carbon dioxide
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
- B01D2258/02—Other waste gases
- B01D2258/0283—Flue gases
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/81—Solid phase processes
- B01D53/82—Solid phase processes with stationary reactants
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02C—CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]
- Y02C20/00—Capture or disposal of greenhouse gases
- Y02C20/40—Capture or disposal of greenhouse gases of CO2
Definitions
- the present disclosure is generally related to a system and method for capturing and storing carbon dioxide from a gas moving through a modular containerized carbon capture system.
- CO2 carbon dioxide
- Calcium Looping is a CO2 capture technology that uses CaO (and/or Ca(OH)2) as regenerable calcium (Ca) sorbent of CO2.
- CaO and/or Ca(OH)2
- Ca(OH)2 regenerable calcium
- the state of the art of the fundamental properties of the materials, reactor design and process integration of Calcium Looping has greatly progressed in recent years.
- a wide variety of patents and technical publications have been published to apply Calcium Looping to power plants and industries.
- U.S. Patent No. 8,226,917 B2 shows that these materials can carbonate fast (in particular Ca(OH)2) when in small particle form (i.e., particle diameter of less than 3 mm), at temperatures between 600 and 700°C and in a wide range of CO2 concentrations reach a maximum carbonation conversions of between 0.5-0.7.
- Such limit to the carbonation conversion is known to be limited by porosity (CaCOs molecular volume density is 27100 mol/m 3 , Ca(OH)2 is 29900 mol/m 3 while CaO is 59642 mol/m 3 ) and by the formation of a product layer of CaCOs on the internal surface of CaO.
- the thickness of the product layer is known to decrease with temperature (Y.A. Criado et al, Effect of the carbonation temperature on the CO2 carrying capacity of CaO, Ind. Eng. Chem. Res. 2018, 57, 12595-12599).
- Calcium Looping processes making use of such Ca-containing materials typically use fluidized beds, circulating fluidized beds, or entrained bed carbonator reactors, where the Ca-sorbents will typically carbonate in seconds to several minutes while in contact with the gas containing CO2. Once carbonated, the particles containing CaCOs need to be brought to temperatures typically within 900-950°C to produce CaO (that eventually returns to the carbonator reactor or is purged for cement manufacture or other uses), and a gas stream rich in CO2 (suitable for purification and disposal or use).
- 5,509,362 discloses a fuel gas reforming method with steam, using an adiabatic packed bed reactor filled with CaO sorbent, in which the removal of CO2 forming CaCOs shifts the gas reactions towards a higher production of H2.
- a subsequent calcination stage of CaCOs in the same solid bed is carried out using an oxidation/reduction chemical loop and air, so that CO2 is emitted to the atmosphere in diluted form.
- U.S. Publication No. 2012/0164032 Al discloses an adiabatic Calcium Looping system to reduce the carbon content in a syngas using a packed-bed reactor holding a calcium-based sorbent.
- Mortars containing Ca(OH)2 have been extensively used in construction from Roman times, usually mixed up with other materials to enhance mechanical and other properties.
- the porosity of Ca(OH)2 mortars when settled and dry can be high (between to 0.5-0.7) and this allows almost complete carbonation in ambient air.
- the carbonation mechanism of Ca-containing solids at low temperatures is known to be different than at 600-700°C referred above for Calcium Looping applications.
- Beruto et al. Liquid-like H2O adsorption layers to catalyze the Ca(OH)2/CC>2 solid-gas reaction and to form a non-protective solid iroduct layer at 20°C. J. Eur. Ceram. Soc.
- Such carbonator is therefore energy and resource inefficient, because it needs arranging additional heat exchanging steps to preheat the CaO-containing solids, the stack flue gases (usually emitted at temperatures below 150°C) and to recover the energy released in the carbonator or when cooling the carbonated solids exiting the carbonator.
- Such level of thermal integration may be uneconomic for many industrial applications of relatively small scale, served by the decentralized CO2 capture carbonation method.
- a higher level of energy efficiency and compactness would be desirable for such decentralized carbonation method, combined with centralized regeneration to produce CO2.
- a system for capturing carbon dioxide from a gas comprises a modular carbonator comprising a storage container defining an internal storage chamber; a gas inlet manifold configured to direct a flow of the gas into the internal storage chamber; a gas outlet manifold configured to direct the flow of the gas out of the internal storage chamber; and a packed bed reactor disposed within the internal storage chamber, the packed bed reactor including a plurality of Ca/Mg containing solids configured to capture carbon dioxide from the flow of the gas within the internal storage chamber.
- the gas diffuser extends from a first end of the storage container to a second end of the storage container.
- a gas collector is disposed within an upper portion of the storage container and in fluid communication with the gas outlet manifold, such that the gas collector is configured to direct the flow of gas out of the internal storage chamber and into the gas outlet manifold.
- the gas collector includes a baffle plate configured to extend across the gas outlet manifold for restraining, regulating, and/or redirecting the flow of gas.
- the storage container is thermally insulated.
- the Ca/Mg containing solids can comprise CaO, Ca(OH)2, MgO, Mg(0H)2, or two or more combinations thereof, or any mixture thereof.
- the Ca/Mg containing solids optionally can comprise one or more alkali metal compounds such as one or more alkali metal hydroxides, e.g., LiOH, NaOH, KOH, one or more alkali metal carbonates, e.g., Na2COs, NaHCOs, etc.
- the Ca/Mg containing solids can be porous.
- a fan is configured to pull or push the gas through the modular carbonator.
- a filtration device is configured to remove particulate from the gas after the gas has passed through the modular carbonator.
- a method for capturing carbon dioxide from a gas comprises moving the gas through a plurality of modular carbonators connected to each other in a vertically stacked and/or horizontally linked arrangement such that the plurality of modular carbonators are arranged in series and in fluid communication with each other, wherein each modular carbonator comprises a storage container defining an internal storage chamber; a gas inlet manifold configured to direct the flow of the gas into the internal storage chamber; a gas outlet manifold configured to direct the flow of the gas out of the internal storage chamber; and a packed bed reactor disposed within the internal storage chamber, the packed bed reactor including a plurality of Ca/Mg containing solids configured to capture carbon dioxide from the flow of the gas within the internal storage chamber; and capturing the carbon dioxide from the flow of the gas via the Ca/Mg containing solids disposed within each modular carbonator; wherein the gas is moved through each modular storage container sequentially, such that the gas exiting the gas outlet manifold of one of the modular carbonators subsequently enters the gas in
- the Ca/Mg containing solids can comprise CaO, Ca(OH)2, MgO, Mg(OH)2, or two or more combinations thereof, or any mixture thereof.
- the Ca/Mg containing solids optionally can comprise one or more alkali metal compounds such as one or more alkali metal hydroxides, e.g., LiOH, NaOH, KOH, one or more alkali metal carbonates, e.g., Na2COs, NaHCOs, etc.
- the Ca/Mg containing solids can be porous.
- the storage container of each modular carbonator is thermally insulated.
- each modular carbonator comprises an access portion connected the corresponding storage container for providing access to a corresponding gas manifold.
- each gas manifold of the respective access portion includes the corresponding gas inlet manifold and gas outlet manifold.
- each gas manifold further comprises a bypass valve located between the gas inlet manifold and the gas outlet manifold, the bypass valve being configured to allow the flow of gas directly from the gas inlet manifold to the gas outlet manifold of the corresponding carbonator when in an open configuration, thus preventing or minimizing the flow of gas from entering the internal storage chamber.
- the flow of gas is uniformly directed into the internal storage chamber from the corresponding gas inlet manifold.
- flow of gas is pulled or pushed through the series of connected modular carbonators by a fan.
- particulate is removed from the gas via a filtration device after passing the gas through the series of modular carbonators.
- the plurality of modular carbonators connected to each other in a vertically stacked or horizontally linked arrangement includes at least three modular carbonators arranged in series and in fluid communication with each other.
- the gas moved through modular storage containers can be exhaust gas from an internal combustion engine, e.g., from an internal combustion engine of a shipping vessel.
- the gas moved through modular storage containers can be flue gas, e.g., flue gas from a land-based facility such as a factory plant.
- Another implementation of the present disclosure includes a method of regenerating Ca/Mg containing solids disposed within a modular storage container after CO2 is captured from a gas by such solids.
- the Ca/Mg containing solids can have CO2 captured from a gas according to systems and methods disclosed herein.
- the method can include releasing captured carbon dioxide such as by heating the Ca/Mg containing solids to release the CO2.
- the method can further include regenerating the Ca/Mg containing solid sorbents.
- Regeneration can include hydrating and shaping, e.g., pelletizing, the solids to form or reform Ca/Mg containing solids configured to capture carbon dioxide.
- the regenerated Ca/Mg containing solids can then be disposed within a modular storage container of the present disclosure.
- FIG. 2 depicts a rear perspective view of the modular carbonator of FIG. 1.
- FIG. 3 depicts a rear elevation view of the modular carbonator of FIG. 1.
- FIG. 4 depicts an example of a damper valve according to an implementation of the subject technology.
- FIG. 5 depicts an example of an electrical interface according to an implementation of the subject technology.
- FIG. 6 depicts a cross-sectional view of the carbonator taken along lines 6-
- FIG. 7 depicts a cross-sectional view of the carbonator taken along lines 7-
- FIG. 8 depicts an example of a gas diffuser according to an implementation of the subject technology.
- FIG. 9 depicts an example of a gas collector according to an implementation of the subject technology.
- FIG. 11 depicts an example of a gas inlet manifold according to an implementation of the subject technology.
- FIG. 13 depicts an example of a process for capturing CO2 from a flue gas using a series of modular carbonators according to an implementation of the subject technology.
- FIG. 14 depicts the process for capturing CO2 from a flue gas using a series of modular carbonators according to an implementation of the subject technology.
- FIG. 15 depicts the process for capturing CO2 from a flue gas using a series of modular carbonators according to an implementation of the subject technology.
- FIG. 16 depicts the process for capturing CO2 from a flue gas using a series of modular carbonators according to an implementation of the subject technology.
- FIG. 17 depicts a schematic diagram of the carbon capture system according to an implementation of the subject technology.
- Ca/Mg containing solids can include, for example, lime rocks, extruded cylindrical pellets, bricks or plates made with CaO or Ca(OH)2, MgO, Mg(OH)2, or any combination or mixtures thereof, or porous bags containing the Ca/Mg sorbent in powder form, to avoid their entrainment into the gas.
- the Ca/Mg containing solids can have internal porosities connected to the exterior surface of the solids ranging from about 0.45 to about 0.7 and/or internal surface areas higher than about 10 m 2 /g.
- Such properties allow a maximum molar carbonation conversion of CaO and Ca(OH)2 higherthan about 0.5, at temperatures of carbonation of from about 600°C to about 700°C for CaO and from about 400°C to about 600°C for Ca(OH)2, or at ambient temperature as long as there is 80-100% humidity in the air, for example.
- CO2 can be captured from a gas such as a flue gas or exhaust gas, e.g., exhaust gas of an internal combustion engine of a marine vessel such as a cargo ship.
- the method can include moving the gas through a plurality of modular carbonators, such as modular storage containers, which are connected to each other in series and in fluid communication with each other, and each modular storage container including a plurality of Ca/Mg containing solids disposed therein.
- the gas can be moved through each modular storage container sequentially, such that the gas exiting one of the modular storage containers subsequently enters another one of the modular storage containers.
- the modular storage containers can be in a vertically stacked arrangement and/or horizontally linked arrangement.
- CO2 can be captured from the flow of the gas via the Ca/Mg containing solids disposed within each of the connected modular storage containers.
- CO2 is captured from a flue gas such as exhaust gas from an internal combustion engine, or from a flue gas from a factory plant or other land-based applications, among others.
- CO2 may be captured from an exhaust gas from an internal combustion engine of a marine vessel, such as a cargo ship.
- Advantages of the systems and methods of the present disclosure employing modular carbonator reactors are that the capture and subsequent release of carbon dioxide can be decoupled. That is, carbon dioxide capture can occur at the source of the gas and release of the captured carbon dioxide can occur at a different location and facility.
- the packed bed reactor comprises a plurality of Ca/Mg containing solids, such slaked lime (i.e., calcium hydroxide, Ca(0H)2) and/or a bed of pebble lime (i.e., calcium oxide, CaO), among others.
- Ca/Mg containing solids such as slaked lime (i.e., calcium hydroxide, Ca(0H)2) and/or a bed of pebble lime (i.e., calcium oxide, CaO), among others.
- a volume of approximately 18-28 m 3 , or a mass of approximately 19-30 metric tons of Ca/Mg containing solids may be disposed within the internal storage chamber (112).
- porous Ca(OH)2 is also known to carbonate up to calcium molar conversions exceeding 0.9 at temperatures ranging from about 400°C to about 600°C, or in ambient air, in particular when relative humidity is higher than 80%.
- optimum carbonation conditions different embodiments of this method are defined, depending on the CO2 concentration and temperature of the gas to be treated, so that optimum conditions are reached in the carbonator reactor used for efficient CO2 capture by carbonation.
- Embodiments of the system and methods apply to the capture of CO2 from a flue gas, engine exhaust gas, or industrial gas with CO2 concentrations between 2- 25%v, targeting a carbonation temperature between 600°-700°C for CaO and 400°- 600°C for Ca(OH)2 in the core reaction region of the carbonator.
- the Ca/Mg containing solids used in the reactor are lime rocks produced from the calcination of natural limestone rocks or from recycled carbonated materials, or manufactured from powdered CaO or Ca(OH)2 in the form of porous pellets or extruded, brick-type or honeycombs with holes or channels.
- Such channels can be separated by a solid wall of from about 20-30 mm (allowing a depth of the carbonated layer of 10-15 mm in each side of the wall) and a bed porosity (determined in this case by the fraction of free cross-section area occupied by the holes or channels) of between 0. 15-0.35 sufficient to moderate the pressure drop in the reactor when the gas has CO2 concentrations between 2-25%v.
- Pozzolanic additives for mechanical strength can be included with the Ca/Mg containing solids as well as other additives to enhance porosity and mechanical strength.
- the storage container (110) includes a first end (102) defining a first endwall panel connected to the access portion (120), and a second end (104) defining a second endwall panel comprising an access door (105).
- the access door (105) is configured to open and close for providing selective access to the internal storage chamber (112) where the packed bed reactor filled with Ca/Mg containing solids is stored.
- the access portion (120) comprises a gas manifold including a gas inlet manifold (122) and a gas outlet manifold (124).
- the gas inlet manifold (122) is configured to receive a flow of gas containing CO2, such as exhaust gas from a cargo ship or other sources of industrial flue gas.
- the gas inlet manifold (122) is configured to direct the flow of gas containing CO2 into the internal storage chamber (112) of the storage container (110).
- the gas outlet manifold (124) is configured to expel a flow of decarbonized gas from the internal storage chamber (112) of the storage container (110).
- the gas inlet manifold and the gas outlet manifold may be disposed at the opposite ends of the storage container.
- the first end of the storage container may include the gas inlet manifold
- the second end of the storage container may include the gas outlet manifold, or vice versa.
- the storage container (110) includes a thermally insulated storage chamber (112) containing a packed bed reactor filled with Ca/Mg containing solids, as previously discussed above.
- the access portion (120) is attached to the front endwall panel (102) of the storage container (110), and furthermore extends from the front endwall panel of the storage container. Such an extension may be from approximately 0.5 meter (m) to about 2.5 m, such as approximately 1 m.
- the access portion (120) is furthermore configured to serve as an access area for one or more valve and pipe interfaces (126), as well as one or more electrical interfaces (128).
- the gas inlet manifold (122) is in fluid communication with a gas distribution manifold or gas diffuser (130) disposed within the storage container (110).
- the gas diffuser (130) extends from the first end (102) of the storage container (110) to the second end (104) of the storage container, and is configured to uniformly direct a flow of gas into the internal storage chamber (112) from the gas inlet manifold (122).
- a gas collection manifold or gas collector (140) is also disposed within the storage container (110) and extends from the first end (102) of the storage container (110) to the second end (104) of the storage container.
- the gas collector (140) is configured to direct a flow of gas decarbonized gas out of the internal storage chamber (112) of the storage container and into the gas outlet manifold (124).
- the gas inlet manifold (122) is configured to receive a flow of gas containing CO2 and uniformly direct the flow of gas into the internal storage chamber (112) of the storage container (110) via the gas diffuser (130).
- the gas outlet manifold (124) is configured to receive the flow of gas from the gas collector (140) after CO2 has been captured by the Ca/Mg containing solids of the packed bed reactor within the internal storage chamber (112) of the storage container (110).
- the gas inlet manifold is configured to receive flue gas from a sea vessel, such as a cargo ship, and the gas outlet manifold is configured to expel clean exhaust gas to the atmosphere.
- the gas diffuser includes a mesh or perforated plate configured to prevent or minimize the Ca/Mg containing solids within the internal storage chamber from entering the gas inlet manifold.
- the gas collector includes a mesh or perforated plate configured to prevent or minimize the Ca/Mg containing solids within the internal storage chamber from entering the gas outlet manifold.
- FIG. 8 depicts an implementation of the gas diffuser (130).
- the gas diffuser (130) includes a first layer, such as a diffuser plate (132) having spaced apart holes to allow for uniform gas distribution and to keep gas velocity even and relatively constant through the Ca/Mg containing solids disposed within the internal storage chamber (112) of the storage container (110).
- the holes are spaced in a certain way near each end of the diffuser plate.
- the diffuser plate may include different zones, with each zone having a different pattern and/or size of holes.
- the holes located closer to the gas inlet manifold (122) are smaller than the holes located farther away from the gas inlet manifold.
- the gas diffuser may include an initial layer, such as a mesh or perforated plate, to prevent or minimize the Ca/Mg containing solids from falling through the first layer.
- the gas diffuser may also include a second layer having a reduced cross-sectional area to distribute gas evenly and to keep gas velocity even and relatively constant through the Ca/Mg containing solids of the packed bed reactor disposed within the internal storage chamber (112). Accordingly, in some implementations the initial layer, the first layer, and the second layer may be used together as a three-layer system.
- the gas collector includes a plurality of channels (144) for corralling the decarbonized gas into the gas outlet manifold (124).
- the gas collector also includes a baffle plate (145) that extends across the gas outlet manifold (124).
- FIG. 10 depicts an implementation of the baffle plate (145), which includes a plurality of holes (147) configured to restrain, regulate, and/or redirect the flow of decarbonized gas into the gas outlet manifold (124) from the gas collector (140).
- a bypass valve (150) may be provided between the gas inlet manifold (122) and the gas outlet manifold (124).
- the bypass valve (150) is configured to allow gas to flow directly from the gas inlet manifold to the gas outlet manifold when in an open configuration, thus bypassing the internal storage chamber (112) of the storage container (110).
- the bypass valve (150) is in a closed configuration, gas flows from the gas inlet manifold (122) to the internal storage chamber (112) of the storage container via the gas diffuser (130).
- the bypass valve is a butterfly valve, or other type of flow regulating valve, as shown in FIG. 4.
- bypass valve when in an open configuration, may naturally allow a small amount stagnant engine exhaust into the carbonator which is unlikely to result in any large scale reactions with the Ca/Mg containing solids of the packed bed reactor contained in the internal storage chamber (112).
- the bypass valve (150) is manually controllable via the valve interface (126) located in the access portion (120) of the modular carbonator (100).
- Each modular carbonator (100) includes an electrical enclosure (128) with an electrical interface (i.e., to provide an electrical communication to the ship).
- the electrical interface (129) is a heavy duty 6 pin locking connector at the bottom of the electrical enclosure, as shown in FIG. 5.
- a dedicated cable is provided on the ship for each carbonator, with the male end of the cable being plugged into a female connector housing located at the bottom of the electrical panel. Latches on the connector are used for locking the connector in place. When the connectors are not joined, covers are latched into place for further protection.
- the storage container (110) also includes an insulating layer disposed around the perimeter of the internal storage chamber (112) in order to regulate a temperature within the internal storage chamber (112).
- the insulation is located between the internal and external walls of the storage container in order to keep the external walls and structure below 80° C.
- the insulation used in between the internal and external walls is a primary layer of Pyrogel® XTE which is rated for use up to 650° C and Rockwool® which can withstand a service temperature of up to 250° C.
- such a thermally insulated modular storage container can be configured to allow an internal temperature of the container to be from about 400 °C to about 700 °C and exterior temperature of the container to be no more than about 80 °C, for example.
- a plurality of modular carbonators can be configured to be connected in series, such as in a vertically stacked and/or horizontally linked configuration, wherein each respective gas outlet manifold of a first carbonator is connected to a corresponding gas inlet manifold of a vertically stacked or horizontally linked second carbonator.
- Each modular carbonator is fitted with ISO 1161 comer castings on all eight comers which are configured to interface with standard twist locks.
- the carbonators may be secured to the ship as well as each other using standard lashings or within cell guides.
- a maximum assessed stacking height is eight carbonators, which is limited by the maximum gross weight of each carbonator according to ISO 668.
- each carbonator is securable to other carbonators or base locks on the ship.
- each carbonator is connected to other carbonators as well as the corresponding piping system onboard the ship via DN700 flanges.
- a non-standard bolt pattern is used on these flanges to reduce the overall diameter and provide clearance for installation and removal of flange hardware, as shown in FIGS. 11 and 12. This is made possible by the low internal pressure of the piping system, which is max 15 kPa gauge.
- a flange (123) of the gas inlet manifold (122) is recessed by 10 mm from the bottom plane of the container to allow for the carbonator to be placed on uneven ground without damaging the flange.
- a flexible bellow rated for high temperatures i.e., up to 650 °C
- the gas outlet section of a gas manifold of a first carbonator container can direct the flow of gas into the gas inlet section of a gas manifold of a second storage container.
- the access portion may further include a ladder and/or a manhole for workers to access through a stacked and/or linked configuration of carbonators.
- a ladder and/or a manhole for workers to access through a stacked and/or linked configuration of carbonators.
- each storage container further allows for minimal retrofitting of the carbonator to a source of exhaust (e.g., from an exhaust manifold of an internal combustion engine such as in a shipping vessel), since the gas is moved to meet the Ca/Mg containing solids in the packed bed reactor rather than moving the Ca/Mg containing solids towards the gas, as in moving bed systems.
- a plurality of modular carbonators can be connected to each other in a stacked and/or linked arrangement and in fluid communication with each other such that the gas exiting one of the modular carbonators subsequently enters another one of the modular carbonators.
- the modularity of each carbonator (100) advantageously allows two or more carbonators to be connected in series. For instance, FIG.
- FIG. 13 depicts six storage containers (i.e., 110a, 110b, 110c, HOd, I lOe, I lOf) connected in series in a stacked and/or linked configuration.
- a first gas inlet manifold connected to a first storage container (110a) receives a flow of gas containing CO2, such as exhaust gas from an internal combustion engine having CO2 concentrations between 2-25%v.
- the flow of gas containing CO2 enters a first internal storage chamber (112a) of the first storage container (110a), where the gas is preheated by contacting with a stationary first packed bed reactor including high-temperature Ca/Mg containing solids (200) as the gas moves through the first internal storage chamber.
- An initial carbonation stage of the Ca/Mg containing solids occurs as the flow of gas moves through the bed of solids in the first internal storage chamber (112a).
- the preheated flow of gas then exits the first internal storage chamber (112a) through a first gas outlet manifold connected to the first storage container.
- a second gas inlet manifold connected to a second storage container (110b) then receives the preheated flow of gas, which enters a second internal storage chamber (112b) of the second storage container (110b), where a core reaction stage occurs to achieve effective capture of the CO2 in the moving gas flow by the carbonation of the high temperature Ca/Mg containing solids (200) of the second packed bed reactor within the second internal storage chamber (112b).
- the Ca/Mg containing solids are heated to a carbonation temperature from about 600° to about 700°C for CaO and from about 400° to about 600°C for Ca(OH)2.
- the CO2 diluted flow of gas then exits the second internal storage chamber (112b) through a second gas outlet manifold connected to the second storage container.
- a third gas inlet manifold connected to a third storage container (110c) then receives the CO2 diluted flow of gas, which enters a third internal storage chamber (112c) of the third storage container (110c), where the Ca/Mg containing solids (200) of a third packed bed reactor are preheated.
- a final carbonation stage of the Ca/Mg containing solids occurs as the CO2 diluted flow of gas moves through the packed bed of Ca/Mg containing solids in the third internal storage chamber (112c), thus resulting in a flow of decarbonized gas that exits the third internal storage chamber (112c) through a third gas outlet manifold connected to the third storage container.
- each carbonator 100 further allows individual storage containers to be connected or disconnected during the carbonation process. For instance, with reference to FIG. 14, once CO2 is captured by the Ca/Mg containing solids (200) within the first internal storage chamber (112a) via carbonation, the first storage container (110a) may be disconnected from the second storage container (110b), and the carbonated solids of the first packed bed reactor are able to cool down so that they can be disposed or transported via the first storage container to a secondary location, such as a centralized regeneration plant to obtain pure CO2 from decomposition of CaCOs.
- a secondary location such as a centralized regeneration plant to obtain pure CO2 from decomposition of CaCOs.
- the second gas inlet manifold connected to the second storage container (110b) now receives the flow of gas containing CO2, such as cargo ship exhaust gas having CO2 concentrations between 2-25%v.
- the flow of gas containing CO2 enters the second internal storage chamber (112b) of the second storage container (110b), where the gas is preheated by contacting with stationary high- temperature Ca/Mg containing solids (200) of the second packed be reactor as the gas moves through the second internal storage chamber.
- the initial carbonation stage of the Ca/Mg containing solids thus occurs as the flow of gas moves through the packed bed of Ca/Mg containing solids in the second internal storage chamber (112b).
- the preheated flow of gas then exits the second internal storage chamber (112b) through a second gas outlet manifold connected to the second storage container.
- a third gas inlet manifold of the third storage container (110c) then receives the preheated flow of gas, which enters a third internal storage chamber (112c) connected to the third storage container (110c), where the core reaction stage occurs to achieve effective capture of the CO2 in the moving gas flow by the carbonation of the high temperature Ca/Mg containing solids (200) of the third packed bed reactor within the third internal storage chamber (112c).
- the Ca/Mg containing solids are heated to an optimum target carbonation temperature between 600°-700°C for CaO and between 400°-600°C for Ca(OH)2.
- the CO2 diluted flow of gas then exits the third internal storage chamber (112c) through a third gas outlet manifold connected to the third storage container.
- a fourth gas inlet manifold connected to a fourth storage container (1 lOd) then receives the CO2 diluted flow of gas, which enters a fourth internal storage chamber (112d) of the fourth storage container (HOd), where the Ca/Mg containing solids (200) of the fourth packed bed reactor are preheated.
- a final carbonation stage of the Ca/Mg containing solids occurs as the CO2 diluted flow of gas moves through the bed of solids in the fourth internal storage chamber (112d), thus resulting in a flow of clean gas that exits the fourth internal storage chamber (112d) through a fourth gas outlet manifold connected to the fourth storage container.
- the second storage container (110b) may be disconnected from the third storage container (110c), and the carbonated solids are able to cool down so that they can be disposed or transported via the second storage container to the secondary location, such as a centralized regeneration plant to obtain pure CO2 from decomposition of CaCOs.
- FIG. 15 depicts the flow of gas containing CO2 as entering the third storage container (110c), moving through the fourth storage container (1 lOd), and finally exiting from a fifth storage container (1 lOe) as clean exhaust gas resulting from the sequential carbonation processes occurring within each consecutive packed bed reactor of the corresponding storage container.
- FIG. 16 depicts the flow of gas containing CO2 as entering the fourth storage container (1 lOd), moving through the fifth storage container (1 lOe), and finally exiting from a sixth storage container (11 Of) as clean exhaust gas devoid of CO2, which results from the sequence of carbonation processes occurring within each consecutive packed bed reactor of the corresponding storage container.
- a set of three modular carbonators are active at any given time, wherein the third modular carbonator is stacked on top of the second modular carbonator, which is stacked on top of the first modular packed be reactor.
- the first, or bottommost, modular carbonator is the first to react with the exhaust gas to remove CO2. This reaction is an exothermic reaction. Further, this reaction is thermally insulated.
- the Ca/Mg containing solids which have a high thermal mass, are able to transfer heat to the gas, which is cooler because it comes from the ship’s exhaust. This gas is then heated up through the heat transfer in the gas preheating carbonator.
- the Ca/Mg containing solids have not been fully reacted yet, and so they interact with high temperature gas with CO2. These solids in the second modular carbonator are still predominantly non-limestone at this point, but rather are predominantly calcium, and thus they react more efficiently.
- the Ca/Mg containing solids are much cooler than the gas that has little or no CO2 in it, which is conducive for heat transfer that enables the solid pellets to heat up and cool down the gas.
- the control system senses that the reaction is complete, i.e., by sensing the outlet temperature at the first carbonator is the same as the inlet temperature, then this means there is no real heat transfer or the Ca/Mg containing solids in the bottom container are no longer able to benefit by preheating the gas.
- the first carbonator is shut off and a fourth carbonator that is stacked on top of the third carbonator can be activated. .
- the modularity of the carbonators allows each respective carbonator to be turned on and off so that certain carbonators can be isolated during the carbon capture process.
- the molar conversion of CaO to CaCOs is assumed to be 0.6 in the external layer of carbonated Ca/Mg containing solids, when the carbonation temperature is between 600-700°C (i.e., consistent with maximum carbonation conversion of lime resulting from a first calcination of limestone).
- the molar conversion is assumed to be 0.7-0.9 when the solids are Ca(OH)2 and the temperature of operation is either between 400°-600°C or below 100°C and the relative humidity above 80%.
- a bypass line (304) is also provided that would prevent the flow of gas from being blocked in the event of any sort of failure in the decarbonization process.
- a first measurement system (310) such as a continuous emission monitoring system (CEMS), includes various sensors to measure properties of the exhaust gas, such as CO2, SO2, and H2O.
- the exhaust gas then goes through an isolation valve of the system, such as a butterfly valve, where a first pressure sensor and temperatures sensor obtain the respective pressure and temperature values of the exhaust gas.
- the exhaust gas may then go through a section of pipe (312) that is heated in order to maintain the exhaust temperature. This depends on the ship's specific engine, as it might have an exhaust temperature that's high enough that the pipe does not need to be heated further.
- the exhaust gas then reaches the stack of modular carbonators.
- each respective carbonator When the bypass valve (150a, 150b, 150c, 150d) of each respective carbonator is closed, the exhaust gas is directed in and out of each adjacent carbonator as previously discussed above.
- the exhaust gas reacts with the calcium hydroxide pellets to capture CO2, which is stored or locked in the calcium carbonate.
- Each carbonator is capable of capturing up to a total of 20 metric tonnes of CO2 at a time.
- sorbent such as Ca/Mg containing solids.
- the sorbent used inside the container for carbon capture is pelletized calcium hydroxide (Ca(0H)2).
- the volume capacity of the container is approximately 20.58 m 3 and with a bulk density of approximately 886 kg/m 3 the payload capacity is approximately 18,234 kg.
- the sorbent reacts to form calcium carbonate it increases in weight by up to 4,395 kg for a total payload weight of approximately 22,719 kg.
- the engine exhaust flows through the calcium hydroxide, it reacts with the CO2 to form calcium carbonate, CaCOs, according to the following equation:
- the stacked and/or linked modular arrangement of the plurality of carbonators allows the flow of gas to move through multiple carbonators.
- an exothermic reaction is created within the carbonator, so each subsequent carbonator will increase the temperature of the gas flowing through it, which is advantageous because the ship’s exhaust temperature is generally a little lower than the ideal temperature for the reaction.
- additional sensors such as pressure and temperature, are provided with each successive carbonator in order to monitor a corresponding parameter of the exhaust gas as it travels through each successive carbonator.
- the gas may enter a filtration system (330), such as a cyclone filter, to filter out and remove dust or other fine particles that were swept out of the carbonators and entrained in the flow of gas.
- a fan (340) may be provided to pull or push the gas through the entire stacked and/or linked arrangement of carbonators.
- a venturi tube or other flow measurement instrument (350) may be provided to measure the flow rate of the gas prior to, or as it passes through, an outlet (370), such as an exhaust stack.
- the amount of CO2 captured can be determined by subtracting the flow rate of CO2 at the outlet (370) from the flow rate of CO2 at the inlet (300).
- each carbonator can either be bypassed by opening each corresponding valve (150a, 150b, 150c, 150d), or activated by closing each corresponding valve.
- a maximum of three carbonators are active which limit fan power draw. Reaction progress in each carbonator is monitored by corresponding temperature sensors. For instance, two thermocouples inside the sorbent compartment of each carbonator monitor the progression of the heat front and/or reaction front.
- thermocouples When the temperature of these thermocouples exceeds a certain threshold, the control system, which is installed on the ship and separate from the container, will activate the subsequent stacked and/or linked carbonator by closing its damper valve. If these thermocouples or the valve fails, the container will remain active, which will result in less carbon dioxide captured but no other negative or dangerous consequences. [0100] When the reaction is complete in a particular carbonator (100a, 100b, 100c, lOOd), the control system bypasses the container by opening the corresponding valve (150a, 150b, 150c, 150d). After the passing through the stack of modular carbonators, the exhaust gas flows through the filtration device (330), such as a cyclone filter, to remove any dust that may have accumulated in the exhaust gas while inside the containers.
- the filtration device such as a cyclone filter
- the filtration device removes any calcium -based particulates that escape from the modular carbonators.
- the filtration device is a passive device that uses inertial separation to extract dust particulate from the gas.
- a collection barrel may be provided underneath the filter which can be unloaded from the ship and emptied if it is full.
- the exhaust gas then reaches the fan (340), which causes the pressure differential that draws the exhaust gas into the carbon capture system.
- a centrifugal fan is used to draw the ship’s exhaust through the carbon capture system.
- the exhaust gas flows through the venturi tube (350) which measures its flow rate.
- the venturi tube is a passive device that measures exhaust gas flow rate using Bernoulli’s principle. When flow rate and CO2 concentration at the inlet and outlet of the system are known, the CO2 capture rate can be determined. Fan speed is controlled via a variable frequency drive which receives as feedback the flow rate as measured by the venturi tube as well as the pressure measurements at POO and P05. P05 is placed at the outlet of the exhaust and measures atmospheric pressure.
- the second measurement system (360) measures the CO2 and SO2 content at the outlet, and the third isolation valve (306) allows the decarbonized gas to return back into the exhaust line (370) in the engine casing to be released into the atmosphere.
- a control system comprising an industrial PLC, an industrial PC, networking equipment, field IO devices and an HMI are used to monitor and control the carbon capture system.
- the industrial PLC runs a set of control routines that monitor temperatures, pressures, flow rates and gas concentrations of the process equipment, and controls the heating system, damper valves and centrifugal fan in order to maintain safe and efficient operation of the carbon capture system.
- the control routine monitors the progress of the reaction by measuring the temperature inside the sorbent compartment of the container of each carbonator and automatically activates and deactivates segments of the respective packed bed reactor by opening and closing the corresponding damper valves of each carbonator.
- the control system allows for observation of the process variables, safety information and general status of the system via an HMI station, and also provides for the manual control of the controlled components of the system by a system operator. Further, the control system monitors for any process conditions or equipment failures that would impede the safe or normal operation of the system and raises visual and audible alarms accordingly. The context for such alarms is made available on the HMI, and alarms can be dismissed via the HMI. Additionally, any alarms and the events that triggered them are logged by a logging system.
- the subject technology advantageously, allows a large margin to adapt the design of the reactor to the specific characteristic of the ppmv CO2 in the flue gas.
- the processes of (1) capture and (2) subsequent release of carbon dioxide can be decoupled. That is, carbon dioxide capture can occur at the source of the gas and release of the captured carbon dioxide can occur at a different location and facility.
- the subject technology includes methods of regenerating Ca/Mg containing solids disposed within a modular storage container after CO2 is captured from a gas by such solids.
- FIG. 18 depicts a flow chart illustrating a method of releasing captured carbon dioxide from Ca/Mg containing solids.
- a system of the present technology can be connected to a gas stream and used to capture carbon dioxide (steps 1802, 1804).
- each carbonator module can be removed from the vessel and transported to one or more facilities to release the captured carbon dioxide (1808) and regenerate the sorbent (1810).
- the Ca/Mg containing solids can be removed from a carbonator and put in an oven or kiln and heated to release the CO2 captured by the Ca/Mg containing solids to form desorbed solids.
- Such an oven or kiln can further be equipped to store the released CO2.
- the released CO2 can then be permanently stored or used as a reagent, such as for material preparations, etc.
- the sorbents can be regenerated (1810) by rehydrating the desorbed solids and shaped into particles such as pellets with appropriate sizes and porosities to form regenerated Ca/Mg containing solids.
- the regenerated Ca/Mg containing solids can then be disposed within a modular storage container of the present disclosure (1812).
- Carbonator modules with regenerated Ca/Mg containing solids can then be employed again in the systems and method of the present technology so that the process can be repeated and cycled multiple times.
- the subject technology advantageously allows a large margin to adapt the design of the Ca/Mg containing solids to the specific characteristic of the ppmv CO2 in the flue gas.
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Abstract
Un système et un procédé de capture de dioxyde de carbone à partir d'un gaz comprennent une pluralité de carbonateurs modulaires connectés en série de telle sorte que les carbonateurs modulaires sont en communication fluidique les uns avec les autres. Chaque carbonateur comprend un récipient de stockage ayant une chambre de stockage interne. Une partie d'accès est fixée à chaque récipient de stockage pour fournir un accès à un collecteur de gaz et des vannes, des tuyaux et des connexions électriques associés de chaque carbonateur lorsque les carbonateurs sont empilés verticalement et/ou reliés horizontalement. La partie d'accès comprend un collecteur d'entrée de gaz qui dirige un écoulement du gaz dans la chambre de stockage interne correspondante. La partie d'accès comprend également un collecteur de sortie de gaz qui dirige l'écoulement du gaz hors de la chambre de stockage interne. Un réacteur à lit fixe rempli d'une pluralité de solides contenant du Ca/Mg est disposé à l'intérieur de la chambre de stockage interne pour capturer le dioxyde de carbone à partir de l'écoulement du gaz à l'intérieur de la chambre de stockage interne.
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