Systems and methods for processing CO 2

• US 8,137,444 B2
• Filed: 03/10/2010
• Issued: 03/20/2012
• Est. Priority Date: 03/10/2009
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Farsad, Kasra, Elliott, Robert W., O'Connor, Richard P., Seeker, William Randall, Self, Kyle, Wall, Justin
• Primary Examiner(s): Smith, Duane
• Application Number:
  US12/721,545
• Publication Number:
  US 20100230830A1
• Time in Patent Office: 741 Days
• Field of Search: 952/36, 952/35, 951/52, 962/34, 962/35, 962/36
• US Class Current: 96/235
• 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 sparging vessel, wherein the sparging vessel is configured to produce bubbles of an industrial gas within an absorbing solution such that at least 10% by weight of CO₂ in the industrial gas is transferred to the absorbing solution forming a charged solution comprising carbonates, bicarbonates, or any combination thereof;

a first inlet for an original composition of the industrial gas, wherein the original composition comprises CO₂, SOx, NOx, heavy metals, non-CO₂ acid gases, and/or fly ash, and wherein the first inlet is operably connected to the absorber;

a second inlet for the absorbing solution, wherein the absorbing solution comprises an alkaline solution, and wherein the second inlet is operably connected to the absorber;

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

a second outlet for the charged solution that has contacted the industrial gas, wherein the second outlet is operably connected to the absorber; and

a processing station operably connected to the second outlet, wherein the processing station comprises a third inlet operably connected to a source of divalent cations and a third outlet operably connected to a separation station, configured to separate solids from liquids, and wherein the processing station is configured to contact the charged solution with the divalent cations.

7. The apparatus of any one of claims 1-5, wherein water in the absorbing solution comprises sea water, alkaline brine, cation-rich brine, synthetic brine, industrial waste water, industrial waste brine, or any combination thereof.

8. The apparatus of any one of claims 1-5, further comprising a recirculation system.

9. The apparatus of claim 8, wherein the recirculation system comprises conduits and pumps to move the absorbing solution that has contacted the industrial gas from the third outlet of the processing station to the second inlet for absorbing solution.

10. The apparatus of claim 9, wherein the recirculation system further comprises conduits and pumps to move gas reduced in CO₂ from the first outlet for effluent gas to the first inlet for industrial gas.

2. An apparatus comprising:

an absorber comprising a spray tower wherein the spray tower is configured to produce streams, droplets, or a combination thereof of an absorbing solution in an industrial gas such that at least 10% by weight of CO₂ in the industrial gas is transferred to the absorbing solution forming a charged solution comprising carbonates, bicarbonates, or any combination thereof, 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;

a first inlet for an original composition of the industrial gas, wherein the original composition comprises CO₂, SOx, NOx, heavy metals, non-CO₂ acid gases, and/or fly ash, and wherein the first inlet is operably connected to the absorber;

a second inlet for the absorbing solution, wherein the absorbing solution comprises an alkaline solution, and wherein the second inlet is operably connected to the absorber;

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

a second outlet for the charged solution that has contacted the industrial gas, wherein the second outlet is operably connected to the absorber; and

a processing station operably connected to the second outlet, wherein the processing station comprises a third inlet operably connected to a source of divalent cations and a third operably connected to a separation station, configured to separate solids from liquids, and wherein the processing station is configured to contact the charged solution with the divalent cations.

6. The apparatus of any one of claims 2-5, 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.

3. An apparatus comprising:

an absorber comprising at least one of a spray tower, packing material, a packed bed, trays, shed rows, or a microporous membrane, wherein the absorber is configured to produce streams, droplets, or a combination thereof of an absorbing solution in an industrial gas such that at least 10% by weight of CO₂ in the industrial gas is transferred to the absorbing solution forming a charged solution that comprises carbonates, bicarbonates, or any combination thereof, 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;

a first inlet for an original composition of the industrial gas, wherein the original composition comprises CO₂, SOx, NOx, heavy metals, non-CO₂ acid gases, and/or fly ash, and wherein the first inlet is operably connected to the absorber;

a second inlet for the absorbing solution, wherein the absorbing solution comprises an alkaline solution, and wherein the second inlet is operably connected to the absorber;

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

a second outlet for the charged solution that has contacted the industrial gas, wherein the second outlet is operably connected to the absorber; and

a processing station operably connected to the second outlet, wherein the processing station comprises a third inlet operably connected to a source of divalent cations and a third outlet operably connected to a separation station, configured to separate solids from liquids, and wherein the processing station is configured to contact the charged solution with the divalent cations.

4. An apparatus comprising:

an absorber comprising at least one of a spray tower, packing material, a packed bed, trays, shed rows, or a microporous membrane, wherein the absorber is configured to produce streams, droplets, or a combination thereof of an absorbing solution in an industrial gas such that at least 10% by weight of CO₂ in the industrial gas is transferred to the absorbing solution forming a charged solution that comprises carbonates, bicarbonates, or any combination thereof;

a first inlet for an original composition of the industrial gas, wherein the original composition comprises CO₂, SOx, NOx, heavy metals, non-CO₂ acid gases, and/or fly ash, and wherein the first inlet is operably connected to the absorber;

a second inlet for the absorbing solution, wherein the absorbing solution comprises an alkaline solution, and wherein the second inlet is operably connected to the absorber;

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

a second outlet for the charged solution that has contacted the industrial gas, wherein the second outlet is operably connected to the absorber; and

a processing station operably connected to the second outlet, wherein the processing station comprises a third inlet operably connected to a source of divalent cations and a third outlet operably connected to a separation station, wherein the processing station is configured to contact the charged solution with the divalent cations.

5. An apparatus comprising:

an absorber comprising at least one of a spray tower, packing material, a packed bed, trays, shed rows, or a microporous membrane, wherein the absorber is configured to produce streams, droplets, rivulets, columns of liquid, jet sprays, liquid sheets, neutrally buoyant clouds of solution or a combination thereof of an absorbing solution in an industrial gas wherein the industrial gas comprises combustion flue gas, cement kiln flue gas, compressed carbon dioxide, or any combination thereof such that at least 10% by weight of CO₂ in the industrial gas is transferred to the absorbing solution forming a charged solution that comprises carbonates, bicarbonates, or any combination thereof;

a first inlet for an original composition of the industrial gas, wherein the original composition comprises CO₂, SOx, NOx, heavy metals, non-CO₂ acid gases, and/or fly ash, and wherein the first inlet is operably connected to the absorber;

a second inlet for the absorbing solution, wherein the absorbing solution comprises an alkaline solution, and wherein the second inlet is operably connected to the absorber;

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

a second outlet for the charged solution that has contacted the industrial gas, wherein the second outlet is operably connected to the absorber; and

a processing station operably connected to the second output, wherein the processing station comprises a third inlet operably connected to a source of divalent cations and a third outlet operably connected to a separation station, and wherein the processing station is configured to contact the charged solution with the divalent cations.