Direct capture of carbon dioxide

Patent metadata

Field	Value
Publication number	US-12172127-B2
Application number	US-202017781943-A
Country	US
Kind code	B2
Filing date	Dec 3, 2020
Priority date	Dec 3, 2019
Publication date	Dec 24, 2024
Grant date	Dec 24, 2024

Abstract

Systems and methods for direct air capture of carbon dioxide or other gases utilize a calcium sorbent in a manner that allows for wide scale, relatively low cost implementation. In particular, a calcium sorbent may be provided as a substantially thin coating on one or more substrates and utilized for direct air capture of carbon dioxide through chemisorption. The carbonated sorbent may be disposed of for sequestration of the carbon dioxide or regenerated with capture of carbon dioxide released from the carbonated sorbent during the regeneration process.

First claim

The invention claimed is:

1. A method for direct air capture of carbon dioxide, the method comprising:
preparing a continuous coating layer of a calcium sorbent material at a density of less than 10 kilograms per square meter on one or more substrates, the continuous coating layer of the calcium sorbent material has an average thickness on the one or more substrates of about 0.01 mm to about 2 cm;
subjecting the one or more substrates with the continuous coating layer of the calcium sorbent material to contact with air including carbon dioxide for a time sufficient for the calcium sorbent to react with the carbon dioxide and thereby capture at least a portion of the carbon dioxide from the air and convert at least a portion of the calcium sorbent to a carbonated form;
removing at least a portion of the calcium sorbent in the carbonated form from the one or more substrates; and
processing the calcium sorbent in the carbonated form such that the carbon dioxide captured from the air is ready for sequestration or other use.

2. The method of claim 1 , wherein the one or more substrates is configured substantially as a sheet.

3. The method of claim 1 , wherein one or both of the following conditions is met:
the continuous coating layer of the calcium sorbent material is configured to exhibit a carbonation rate such that at least 25% by weight of the calcium sorbent material is carbonated within a time of 96 hours or less;
the continuous coating layer of the calcium sorbent material is configured to exhibit a carbonation rate such that at least 50% by weight of the calcium sorbent material is carbonated within a time of about 1 day to about 14 days.

4. The method of claim 1 , wherein subjecting the one or more substrates with the continuous coating layer of the calcium sorbent material to contact with air including carbon dioxide comprises hanging the one or more substrates with the continuous coating layer of the calcium sorbent material in a location where the continuous coating layer of the calcium sorbent material is in contact with the air.

5. The method of claim 1 , wherein removing at least a portion of the calcium sorbent in the carbonated form from the one or more substrates comprises subjecting the one or more substrates to a force sufficient to break the continuous coating layer of the calcium sorbent material and loosen the continuous coating layer of the calcium sorbent material from the one or more substrates.

6. The method of claim 1 , wherein processing the calcium sorbent in the carbonated form comprises particularizing the calcium sorbent in the carbonated form for sequestration of the calcium sorbent in the carbonated form.

7. The method of claim 1 , wherein processing the calcium sorbent in the carbonated form comprises further subjecting the calcium sorbent in the carbonated form to ambient air for a time sufficient to increase carbonation percentage.

8. The method of claim 1 , wherein processing the calcium sorbent in the carbonated form comprises:
calcining the calcium sorbent in the carbonated form to release carbon dioxide therefrom and form calcium oxide; and
capturing the carbon dioxide released from the calcium sorbent.

9. The method of claim 8 , further comprising slaking the calcium oxide to form the calcium sorbent material used in preparing the continuous coating layer.

10. The method of claim 8 , further comprising removing a portion of the calcium sorbent in the carbonated form prior to calcining and adding makeup limestone during calcining.

11. The method of claim 1 , wherein one or both of the following conditions are met:
preparing the continuous coating layer of the calcium sorbent material comprises dipping the one or more substrates in a reservoir of the calcium sorbent material;
preparing the continuous coating layer of the calcium sorbent material comprises dripping, pouring, or spraying the calcium sorbent material onto the one or more substrates.

12. The method of claim 1 , wherein the one or more substrates is flexible and non-porous.

13. The method of claim 1 , wherein the continuous coating layer has an average thickness of about 0.01 mm to about 5 mm and a density of about 0.1 kilograms per square meter to about 5 kilograms per square meter.

14. The method of claim 1 , wherein removing at least a portion of the calcium sorbent in the carbonated form from the one or more substrates comprises subjecting the one or more substrates to a force effective to cause the one or more substrates to one or both of bend and flex.

15. A method for direct air capture of carbon dioxide, the method comprising:
applying a calcium sorbent material on a substrate that is flexible and non-porous to define a layer of the calcium sorbent material on a surface of the substrate, the layer of the calcium sorbent material defining a continuous coating along the surface of the substrate with an average thickness of about 0.01 mm to about 5 mm and a density of about 0.1 kilograms per square meter to about 5 kilograms per square meter;
subjecting the substrate with the continuous coating of the calcium sorbent material to contact with air including carbon dioxide for a time sufficient for the calcium sorbent to react with the carbon dioxide and thereby capture at least a portion of the carbon dioxide from the air and convert at least a portion of the calcium sorbent to a carbonated form;
removing at least a portion of the calcium sorbent in the carbonated form from the substrate by subjecting the substrate to a force effective to cause the substrate to one or both of bend and flex such that the continuous coating of the calcium sorbent breaks and loosens from the substrate; and
processing the calcium sorbent in the carbonated form such that the carbon dioxide captured from the air is ready for sequestration or other use.

16. A method for direct air capture of carbon dioxide, the method comprising:
preparing a continuous coating layer of a calcium sorbent material at a density of less than 10 kilograms per square meter on one or more substrates;
subjecting the one or more substrates with the continuous coating layer of the calcium sorbent material to contact with air including carbon dioxide for a time sufficient for the calcium sorbent to react with the carbon dioxide and thereby capture at least a portion of the carbon dioxide from the air and convert at least a portion of the calcium sorbent to a carbonated form;
removing at least a portion of the calcium sorbent in the carbonated form from the one or more substrates;
processing the calcium sorbent in the carbonated form such that the carbon dioxide captured from the air is ready for sequestration or other use, said processing comprising calcining the calcium sorbent in the carbonated form to release carbon dioxide therefrom and form calcium oxide, and capturing the carbon dioxide released from the calcium sorbent;
removing a portion of the calcium sorbent in the carbonated form prior to calcining; and
adding makeup limestone during calcining.

17. A method for direct air capture of carbon dioxide, the method comprising:
preparing a continuous coating layer of a calcium sorbent material on one or more substrates, the continuous coating layer having an average thickness of about 0.01 mm to about 5 mm and a density of about 0.1 kilograms per square meter to about 5 kilograms per square meter;
subjecting the one or more substrates with the continuous coating layer of the calcium sorbent material to contact with air including carbon dioxide for a time sufficient for the calcium sorbent to react with the

Assignees

• 8 Rivers Capital Llc

Inventors

• Goff Adam
• Beauchamp Damian
• Fetvedt Jeremy Eron
• Palmer Miles R
• Lu Xijia
• Rathbone Daniel

Classifications

• B01J20/3483

  by thermal treatment not covered by groups B01J20/3441 - B01J20/3475, e.g. by heating or cooling · CPC title

• B01J20/3433

  of sorbents or filter aids other than those covered by B01J20/3408 - B01J20/3425 · CPC title

• B01J20/3297

  Coatings in the shape of a sheet · CPC title

• B01J20/3236

  containing metal, other than zeolites, e.g. oxides, hydroxides, sulphides or salts · CPC title

• B01J20/28033

  Membrane, sheet, cloth, pad, lamellar or mat · CPC title