Hybrid indirect/direct contactor for thermal management of counter-current processes

1. A hybrid indirect/direct contactor for thermal management of counter-current processes, the contactor comprising:

a vertical reactor column comprising a top end and a bottom end and comprising a wall defining a stream path between the top and bottom ends of the reactor column;

an array of interconnected heat transfer tubes within the reactor column, each of the tubes crossing the stream path, and the array forming a continuous heat transfer fluid flow path sealed by the tubes from the stream path;

a gas flowing up the stream path, around the tubes and exiting the top end of the reactor column;

a solid sorbent comprising adsorbed water and flowing down the stream path, counter-current to the gas flow, cascading around the tubes, and exiting the bottom end of the reactor column;

a heat transfer fluid contained within and flowing through the tubes;

the contactor configured so that as the solid sorbent enters the top of the column, it is heated by contact with both the gas and the tubes, causing evaporation of the water off the sorbent to produce steam, wherein the gas exiting the top end of the column comprises the steam, wherein the evaporation is maintained by continuous heat transfer from the tubes, maintaining the temperature of both the gas and the solid sorbent, and wherein the cascading solid sorbent impinges on the tubes, preventing establishment of a gas boundary that would otherwise restrict heat transfer between the gas and the tubes.

2. The contactor of claim 1 , wherein the column comprises a top contactor comprising heat transfer tubes containing a hot heat transfer fluid and a bottom contactor comprising heat transfer tubes containing a cold heat transfer fluid, configured so that as the sorbent exits the top contactor and enters the bottom contactor, the counter flow of cold air from the bottom contactor sweeps away remaining moisture, cooling the solid sorbent by contact with both the cold gas and the heat transfer tubes containing the cold heat transfer fluid.

3. The contactor of claim 1 , wherein a plurality of stream path diverters are attached to the wall.

4. The contactor of claim 1 , wherein the solid sorbent is uniformly distributed within the contactor.

5. The contactor of claim 1 , wherein the gas is uniformly distributed within the contactor.

6. The contactor of claim 1 , wherein there are no straight-line flow paths from the top to bottom ends of the reactor column.

7. The contactor of to claim 1 , wherein the heat transfer tubes are arranged in vertically spaced-apart rows, and wherein each row is offset from an adjacent row.

8. The contactor of 1 , wherein the heat transfer tubes are interconnected in parallel, each of the heat transfer tubes being connecting to a common inlet manifold and a common outlet manifold.

9. The contactor of claim 1 , wherein the heat transfer tubes are interconnected in series, wherein one of the heat transfer tubes in the array is connected to an inlet port and one of the heat transfer tubes in the array is connected to an outlet port.

10. The contactor of claim 1 , wherein the contactor comprises a plurality of arrays of interconnected heat transfer tubes within the reactor column, each array crossing the stream path and forming a continuous heat transfer fluid flow path.

11. The contactor of claim 1 , configured so that the steam is recycled to provide heat for the processes.

12. The contactor of claim 1 , wherein a plurality of stream path diverters are attached to the wall, and

the tubes and diverters are configured to block all straight-line paths from the top to bottom ends of the reactor column.

13. The contactor of claim 1 , wherein the solid sorbent is uniformly distributed within the contactor,

the gas is uniformly distributed within the contactor,

a plurality of stream path diverters are attached to the wall,

the tubes and diverters are configured to block all straight-line paths from the top to bottom ends of the reactor column, and

the column comprises a top contactor comprising heat transfer tubes containing a hot heat transfer fluid and a bottom contactor comprising heat transfer tubes containing a cold heat transfer fluid, configured so that as the sorbent exits the top contactor and enters the bottom contactor, the counter flow of cold air from the bottom contactor sweeps away remaining moisture, cooling the solid sorbent by contact with both the cold gas and the heat transfer tubes containing the cold heat transfer fluid.

14. The contactor of claim 1 , wherein the heat transfer tubes are arranged in vertically spaced-apart rows, and wherein each row is offset from an adjacent row, and the heat transfer tubes are interconnected in parallel, each of the heat transfer tubes being connecting to a common inlet manifold and a common outlet manifold.

15. A contactor according to claim 1 , wherein the heat transfer tubes are arranged in vertically spaced-apart rows, and wherein each row is offset from an adjacent row, and

the heat transfer tubes are interconnected in series, wherein one of the heat transfer tubes in the array is connected to an inlet port and one of the heat transfer tubes in the array is connected to an outlet port.

16. The contactor of claim 1 , wherein the heat transfer tubes are arranged in vertically spaced-apart rows, and wherein each row is offset from an adjacent row, and the contactor comprises a plurality of arrays of interconnected heat transfer tubes within the reactor column, each array crossing the stream path and forming a continuous heat transfer fluid flow path.

17. The contactor of claim 1 , wherein the contactor comprises a plurality of arrays of interconnected heat transfer tubes within the reactor column, each array crossing the stream path and forming a continuous heat transfer fluid flow path, and in at least one array of the plurality of arrays the heat transfer tubes are interconnected in parallel, each of the heat transfer tubes being connecting to a common inlet manifold and a common outlet manifold.

18. The contactor of claim 1 , wherein the contactor comprises a plurality of arrays of interconnected heat transfer tubes within the reactor column, each array crossing the stream path and forming a continuous heat transfer fluid flow path, and at least one array of the plurality of arrays the heat transfer tubes are interconnected in series, wherein one of the heat transfer tubes in the array is connected to an inlet port and one of the heat transfer tubes in the array is connected to an outlet port.

19. First and second contactors, each according to claim 1 , arranged vertically to define a combined stream path from the top end of the top contactor to the bottom end of the bottom contactor, wherein a hot heat transfer fluid is contained within and flowing through the tubes of the top contactor, and a cold heat transfer fluid is contained within and flowing through the tubes of the bottom contactor.

20. A method of using the contactor of claim 1 comprising steps:

supplying a solid material contained and uniformly distributed within the contactor and cascading down around the tubes;

supplying a gas material contained and uniformly distributed within the contactor and flowing up around the tubes; and

supplying a heat transfer fluid contained within and flowing through the tubes.