Direct capture of carbon dioxide

Patent metadata

Field	Value
Publication number	US-12465889-B2
Application number	US-202519011889-A
Country	US
Kind code	B2
Filing date	Jan 7, 2025
Priority date	Dec 3, 2019
Publication date	Nov 11, 2025
Grant date	Nov 11, 2025

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 (DAC) of carbon dioxide, the method comprising:
preparing a layer of a calcium sorbent material at a density of less than 10 kilograms per square meter on a substrate; subjecting the substrate with the layer of the calcium sorbent material to contact with air including carbon dioxide within a storage unit or facility such that at least a portion of the carbon dioxide from the air converts at least a portion of the calcium sorbent to a carbonated form; and controlling a carbonation condition within the storage unit or facility while the substrate with the layer of the calcium sorbent material contacts the air including carbon dioxide.

2 . The method of claim 1 , where the carbonation condition is a relative humidity percentage (RH %) in the storage unit or facility.

3 . The method of claim 2 , where the RH % in the storage unit or facility is maintained at a value greater than about 40 RH %.

4 . The method of claim 2 , where the RH % in the storage unit or facility is maintained in a range of from about 45 to about 90 RH %.

5 . The method of claim 1 , further comprising removing at least a portion of the calcium that has been converted to the carbonated form from the substrate by subjecting the substrate to a force effective to cause at least a portion of the calcium that has been converted to the carbonated form to break and loosen from the substrate.

6 . The method of claim 5 , further comprising processing the calcium that has been converted to the carbonated form such that the carbon dioxide captured from the air is ready for sequestration or other use.

7 . The method of claim 1 , where the carbonation condition is a carbon dioxide concentration in the air proximate to the calcium sorbent material.

8 . The method of claim 7 , where the carbon dioxide concentration in the air proximate to the calcium sorbent material is controlled to be no more than 5% less than a carbon dioxide concentration of an average ambient air entering the storage unit facility.

9 . The method of claim 1 , where the carbonation condition is an air circulation of the air proximate to the calcium sorbent material.

10 . The method of claim 1 , where the carbonation condition is a temperature of the air proximate to the calcium sorbent material.

11 . A method for direct air capture (DAC) of carbon dioxide, the method comprising:
applying a calcium sorbent material on a substrate to define a layer of the calcium sorbent material on the substrate at a density of about 0.1 kilograms per square meter to about 5 kilograms per square meter; subjecting the substrate with the layer of the calcium sorbent material to contact with air including carbon dioxide within a storage unit or facility such that at least a portion of the carbon dioxide from the air converts at least a portion of the calcium sorbent to a carbonated calcium; and controlling a carbonation condition within the storage unit or facility while the substrate with the layer of the calcium sorbent material contacts the air including carbon dioxide.

12 . The method of claim 11 , where the carbonation condition is a relative humidity percentage (RH %) in the storage unit or facility.

13 . The method of claim 12 , where the RH % in the storage unit or facility is maintained at a value greater than about 40 RH %.

14 . The method of claim 12 , where the RH % in the storage unit or facility is maintained in a range of from about 45 to about 90 RH %.

15 . The method of claim 11 , further comprising removing at least a portion of the carbonated calcium from the substrate by subjecting the substrate to a force effective to cause at least a portion of the carbonated calcium to break and loosen from the substrate.

16 . The method of claim 15 , further comprising processing the carbonated calcium such that the carbon dioxide captured from the air is ready for sequestration or other use.

17 . The method of claim 11 , where the carbonation condition is a carbon dioxide concentration in the air proximate to the calcium sorbent material.

18 . The method of claim 17 , where the carbon dioxide concentration in the air proximate to the calcium sorbent material is controlled to be no more than 5% less than a carbon dioxide concentration of an average ambient air entering the storage unit facility.

19 . The method of claim 11 , where the carbonation condition is an air circulation of the air proximate to the calcium sorbent material.

20 . The method of claim 11 , where the carbonation condition is a temperature of the air proximate to the calcium sorbent material.

21 . A method for direct air capture (DAC) of carbon dioxide, the method comprising:
subjecting a layer of a calcium sorbent material to contact with air including carbon dioxide within a storage unit or facility such that at least a portion of calcium sorbent material undergoes carbonation by reacting with the carbon dioxide from the air and converts to a carbonated calcium, the layer of the calcium sorbent material being present on one or more substrates at a density of about 0.1 kilograms per square meter to about 5 kilograms per square meter; and controlling the carbonation of the calcium sorbent material by controlling one or more properties of the air including carbon dioxide within the storage unit or facility.

22 . The method of claim 21 , where the one or more properties of the air including carbon dioxide is a relative humidity percentage (RH %) of the air in the storage unit or facility.

23 . The method of claim 22 , where the RH % in the storage unit or facility is maintained at a value greater than about 40 RH %.

24 . The method of claim 22 , where the RH % in the storage unit or facility is maintained in a range of from about 45 to about 90 RH %.

25 . The method of claim 21 , where the one or more properties of the air including carbon dioxide is a concentration of the carbon dioxide in the air proximate to the calcium sorbent material.

26 . The method of claim 25 , where the concentration of the carbon dioxide in the air proximate to the calcium sorbent material is controlled to be no more than 5% less than a carbon dioxide concentration of an average ambient air entering the storage unit facility.

27 . The method of claim 21 , further comprising removing at least a portion of the carbonated calcium from the substrate by subjecting the substrate to a force effective to cause at least a portion of the carbonated calcium to break and loosen from the substrate.

28 . The method of claim 27 , further comprising processing the carbonated calcium such that the carbon dioxide captured from the air is ready for sequestration or other use.

29 . The method of claim 21 , where the one or more properties of the air including carbon dioxide is a circulation of the air proximate to the calcium sorbent material.

30 . The method of claim 21 , where the one or more properties of the air including carbon dioxide is a temperature of the air proximate to the calcium sorbent material.

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