Systems and Methods for Processing CO2

• US 20100230830A1
• Filed: 03/10/2010
• Published: 09/16/2010
• Est. Priority Date: 03/10/2009
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Seeker, William Randall, Farsad, Kasra, Self, Kyle, Wall, Justin, O'Connor, Richard P., Elliott, Robert W.
• Granted Patent: US 8,137,444 B2
• Time in Patent Office: Days
• US Class Current: 261/20
• CPC Class Codes: B01D 2257/302 Sulfur oxides
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/602 Mercury or mercury compounds
• CPC Class Codes: B01D 53/1456 Removing acid components
• CPC Class Codes: B01D 53/18 Absorbing units; Liquid distributors therefor B01D3/16, B01D3/26, B01D3/30 take precedence; packing elements B01J19/30, B01J19/32
• CPC Class Codes: B01D 53/60 Simultaneously removing sulfur oxides and nitrogen oxides
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: B01D 53/64 Heavy metals or compounds thereof, e.g. mercury
• CPC Class Codes: B01D 53/78 with gas-liquid contact
• CPC Class Codes: Y02C 20/40 of CO2

Abstract

Systems and methods for lowering levels of carbon dioxide and other atmospheric pollutants are provided. Economically viable systems and processes capable of removing vast quantities of carbon dioxide and other atmospheric pollutants from gaseous waste streams and sequestering them in storage-stable forms are also discussed.

Claims

1. An apparatus comprising:

an absorber comprising a bubble column;

an inlet for an industrial gas, wherein the industrial gas comprises CO₂, SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash in an amount equal to a time-averaged original composition, operably connected to the absorber;

an inlet for an absorbing solution, wherein the absorbing solution comprises an alkaline solution comprising a salt water, particulate material, or both in an absorbing slurry;

an outlet for an effluent gas, said gas characterized by being depleted in CO₂ and at least one of SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash relative to said original composition of said industrial gas, wherein the outlet is operably connected to said absorber;

an outlet for absorbing solution that has contacted the industrial gas operably connected to the absorber; and

a processing station operably connected to the output, wherein the processing station is configured to obtain at least one of the following saleable products;

a building material comprising a CO₂ sequestering component, a desalinated water, a potable water, a slurry comprising a CO₂ sequestering component, or a solution comprising a CO₂ sequestering component,

wherein the bubble column is configured to produce bubbles of the industrial gas within the absorbing solution such that at least 10% by weight of the carbon dioxide in the industrial gas is transferred to the absorbing solution.

7. The apparatus of any of claims 1-6, wherein the inlet for an industrial gas is configured to accept industrial waste gas, combustion flue gas, cement kiln flue gas, compressed carbon dioxide, super critical carbon dioxide, or any combination thereof.

8. The apparatus of any of claim 7, wherein the absorbing solution is contacted with the industrial gas such that the absorbing solution is present as droplets, rivulets, columns of liquid, jet sprays, liquid sheets, neutrally buoyant clouds of solution, or any combination thereof.

9. The apparatus of claim 8, further comprising atomizing components, comprising:

pressure atomizers (nozzles), rotary atomizers, air-assisted atomizers, airblast atomizers, ultrasonic atomizers, ink jet atomizers, MEMS atomizers, electrostatic spray atomizers, dual fluid atomizers, eduction nozzles, or any combination thereof within the contacting chamber.

10. The apparatus of claim 7, wherein the salt water in absorbing solution comprises sea water, an alkaline brine, a cation rich brine, a synthetic brine, an industrial waste water, an industrial waste brine, or any combination thereof.

11. The apparatus of any of claims 1-10;

further comprising a recirculation system.

12. The apparatus of claim 11, wherein the recirculation system comprises conduits and pumps to move absorbing solution that has contacted the industrial gas from the outlet for absorbing solution that has contacted the industrial gas, the processing station or both to the inlet for absorbing solution, the atomizing components, or any combination thereof.

13. The apparatus of claim 12, wherein the recirculation system comprises conduits and pumps to move gas reduced in CO₂ from the outlet for effluent gas to the inlet for industrial gas, the bubble columns, sparging vessel, or any combination thereof.

2. An apparatus comprising:

an absorber comprising a sparging vessel;

an inlet for an industrial gas, wherein the industrial gas comprises CO₂, SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash in an amount equal to a time-averaged original composition, operably connected to the absorber;

an inlet for an absorbing solution, wherein the absorbing solution comprises an alkaline solution comprising a salt water, particulate material, or both in an absorbing slurry;

an outlet for an effluent gas, said gas characterized by being depleted in CO₂ and at least one of SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash relative to said original composition of said industrial gas, wherein the outlet is operably connected to said absorber;

an outlet for absorbing solution that has contacted the industrial gas operably connected to the absorber; and

a processing station operably connected to the output, wherein the processing station is configured to obtain at least one of the following saleable products;

a building material comprising a CO₂ sequestering component, a desalinated water, a potable water, a slurry comprising a CO₂ sequestering component, or a solution comprising a CO₂ sequestering component,

wherein the sparging vessel is configured to produce bubbles of the industrial gas within the absorbing solution such that at least 10% by weight of the carbon dioxide in the industrial gas is transferred to the absorbing solution.

3. An apparatus comprising:

an absorber comprising a spray tower;

an inlet for an industrial gas, wherein the industrial gas comprises CO₂, SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash in an amount equal to a time-averaged original composition, operably connected to the absorber;

an inlet for an absorbing solution, wherein the absorbing solution comprises an alkaline solution, particulate material, or both in an absorbing slurry;

an outlet for an effluent gas, said gas characterized by being depleted in CO₂ and at least one of SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash relative to said original composition of said industrial gas, wherein the outlet is operably connected to said absorber;

an outlet for absorbing solution that has contacted the industrial gas operably connected to the absorber; and

a processing station operably connected to the output, wherein the processing station is configured to obtain at least one of the following saleable products;

a building material comprising a CO₂ sequestering component, a desalinated water, a potable water, a slurry comprising a CO₂ sequestering component, or a solution comprising a CO₂ sequestering component,

wherein the spray tower is configured to produce streams, droplets, or a combination thereof of the absorbing solution in the industrial gas such that at least 10% by weight of the carbon dioxide in the industrial gas is transferred to the absorbing solution, further wherein the spray tower is configured to operate at a liquid flow rate to gas flow rate ratio (L/G ratio) of between 50 and 5,000 gallons per minute/1000 actual cubic feet.

4. An apparatus comprising:

an absorber comprising a at least one of a spray tower, packing material, a packed bed, trays, shed rows, or a microporous membrane;

an inlet for an industrial gas, wherein the industrial gas comprises CO₂, SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash in an amount equal to a time-averaged original composition, operably connected to the absorber;

an inlet for an absorbing solution, wherein the absorbing solution comprises an alkaline solution, particulate material, or both in an absorbing slurry;

an outlet for an effluent gas, said gas characterized by being depleted in CO₂ and at least one of SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash relative to said original composition of said industrial gas, wherein the outlet is operably connected to said absorber;

an outlet for absorbing solution that has contacted the industrial gas operably connected to the absorber; and

a processing station operably connected to the output, wherein the processing station is configured to obtain at least one of the following saleable products;

a building material comprising a CO₂ sequestering component, a desalinated water, a potable water, a slurry comprising a CO₂ sequestering component, or a solution comprising a CO₂ sequestering component,

wherein the absorber is configured to produce streams, droplets, or a combination thereof of the absorbing solution in the industrial gas such that at least 10% by weight of the carbon dioxide in the industrial gas is transferred to the absorbing solution, and further wherein the absorber is configured to operate at a liquid flow rate to gas flow rate ratio (L/G ratio) of between 50 and 5,000 gallons per minute/1000 actual cubic feet.

5. An apparatus comprising:

an absorber comprising a at least one of a spray tower, packing material, a packed bed, trays, shed rows, or a microporous membrane;

an inlet for an industrial gas, wherein the industrial gas comprises CO₂, SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash in an amount equal to a time-averaged original composition, operably connected to the absorber;

an inlet for an absorbing solution, wherein the absorbing solution comprises an alkaline solution, particulate material, or both in an absorbing slurry, wherein said alkaline solution comprises a salt water, a clear solution, or any combination thereof;

an outlet for an effluent gas, said gas characterized by being depleted in CO₂ and at least one of SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash relative to said original composition of said industrial gas, wherein the outlet is operably connected to said absorber;

an outlet for absorbing solution that has contacted the industrial gas operably connected to the absorber; and

a processing station operably connected to the output, wherein the processing station is configured to obtain at least one of the following saleable products;

a building material comprising a CO₂ sequestering component, a desalinated water, a potable water, a slurry comprising a CO₂ sequestering component, or a solution comprising a CO₂ sequestering component,

wherein the absorber is configured to produce streams, droplets, or a combination thereof of the absorbing solution in the industrial gas such that at least 10% by weight of the carbon dioxide in the industrial gas is transferred to the absorbing solution.

6. An apparatus comprising:

an absorber comprising a at least one of a spray tower, packing material, a packed bed, trays, shed rows, or a microporous membrane;

an inlet for an industrial gas, wherein the industrial gas comprises CO₂, SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash in an amount equal to a time-averaged original composition, operably connected to the absorber;

an inlet for an absorbing solution, wherein the absorbing solution comprises an alkaline solution, particulate material, or both in an absorbing slurry, wherein said alkaline solution comprises a salt water;

an outlet for an effluent gas, said gas characterized by being depleted in CO₂ and at least one of SOx, NOx, heavy metal, non-CO₂ acid gas, and/or fly ash relative to said original composition of said industrial gas, wherein the outlet is operably connected to said absorber;

an outlet for absorbing solution that has contacted the industrial gas operably connected to the absorber; and

a processing station operably connected to the output, wherein the processing station is configured to obtain a saleable product,

wherein the absorber is configured to produce streams, droplets, or a combination thereof of the absorbing solution in the industrial gas such that at least 10% by weight of the carbon dioxide in the industrial gas is transferred to the absorbing solution.