IP Library › Granted Patent US 12,239,936
Granted Patent B2
US 12,239,936 · App. 17/048,504 · Granted Mar 4, 2025

Hydration of gas streams

Inventors: Kenton Robert Heidel (Squamish, CA); David St. Angelo (Squamish, CA); Jane Anne Ritchie (Calgary, CA)
Assignee: Carbon Engineering ULC
B01D53/1475B01D53/78B01D2251/304B01D2251/306B01D2251/606B01D2252/103B01D2257/504B01D2258/0283
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Quick Facts
Patent No.
US 12,239,936
App. No.
17/048,504
Granted
Mar 4, 2025
Kind
B2
Abstract

Techniques for humidifying a gas stream using a hydration system includes directing a gas stream through a contact zone of at least one hydration system; directing a hydration solution into the contact zone using a pump; contacting the gas stream with the hydration solution; evaporating water from the hydration solution into the gas stream to form a humidified gas stream, transporting the humidified gas stream out of the at least one hydration system; and collecting the remaining hydration solution in a hydration solution collection basin below the contact zone. The at least one hydration system is fluidly coupled to at least one downstream process and the humidified gas stream from the at least one hydration system is transported as a feed stream to the at least one downstream process.

Claims (60)

1. An apparatus for humidifying a gas stream, comprising:

inlet ports arranged to receive at least one feed stream into a hydration housing vessel;

a gas inlet section configured to receive at least one gas feed stream into the hydration housing vessel, the inlet ports and the gas inlet section coupled to the hydration housing vessel;

a hydration solution having a capacity for hydrating the at least one gas feed stream;

a contact zone coupled to the hydration housing vessel and configured for gas-liquid contact;

a solution distribution system coupled to the hydration housing vessel and comprising a pump configured for flowing the hydration solution over at least a portion of the contact zone;

a hydration solution collection basin coupled to the hydration housing vessel and configured to receive the hydration solution leaving the contact zone;

a drift elimination section coupled to the hydration housing vessel and configured to prevent hydration solution from leaving with a humidified gas stream;

at least one outlet coupled to the hydration housing vessel and configured to dispense the humidified gas stream;

at least one outlet port coupled to the hydration housing vessel and configured to discharge at least a portion of the hydration solution;

a CO 2 capture packing section;

a capture solution drift elimination section; and

an open plenum at least partially delimited by the capture solution drift elimination section, the at least one gas feed stream configured to flow sequentially through the gas inlet section, the contact zone, the drift elimination section, the CO 2 capture packing section, the capture solution drift elimination section and into the open plenum.

2. The apparatus of claim 1 , wherein the contact zone comprises packing material comprising at least one of loose fill or structured fill.

3. The apparatus of claim 1 , wherein the apparatus is coupled to a downstream process, and at least a portion of a humidified gas stream exiting the apparatus is fluidly connected to the downstream process.

4. The apparatus of claim 3 , wherein the drift elimination section is configured to isolate the hydration solution from the downstream process, and comprises one or more of drift eliminators, inlet louvers, demisters, or a combination thereof.

5. The apparatus of claim 3 , wherein the downstream process comprises at least one of a fan or blower configured to move at least a portion of the humidified gas stream through the apparatus, and into the downstream process.

6. The apparatus of claim 5 , wherein the fan or blower comprises a fan cowling defining a fan cowling outlet, the fan cowling outlet positioned vertically above the solution distribution system.

7. The apparatus of claim 3 , wherein the downstream process comprises a process solution, a process solution evaporator unit, and a condenser and collection unit configured to evaporate and collect water from at least a portion of the process solution.

8. The apparatus of claim 3 , wherein one or more of the apparatus and the downstream process are fluidly connected to a water treatment and filtration system.

9. The apparatus of claim 3 , comprising a temperature control system configured to control the temperature of the hydration solution, wherein the temperature control system comprises at least one of a heat exchanger and a gas analysis unit.

10. The apparatus of claim 3 , comprising:

a control system coupled to the apparatus and the downstream process; and

at least one process solution level measurement device coupled to the apparatus and the downstream process, the control system being configured to perform operations comprising:

receiving an output from the at least one process solution level measurement device; and

controlling, based on the received output, a water content of the downstream process.

11. The apparatus of claim 1 , wherein the hydration solution collection basin comprises:

at least one or more solid collection zones; and

a solids transfer system coupled to the hydration solution collection basin and configured to remove solid material from the at least one or more solid collection zones.

12. The apparatus of claim 11 , wherein the solids transfer system comprises at least one of an auger, screw conveyor, progressive cavity pump, screw pump, high density solids pump, or reciprocating pump.

13. The apparatus of claim 11 , wherein the hydration solution collection basin comprises an inclined bottom basin area and a liquid level, wherein the inclined bottom basin area is sloped down towards the at least one or more solid collection zones.

14. The apparatus of claim 1 , wherein the drift elimination section further comprises:

a pre-fabricated mechanical frame; and

a drift eliminator material coupled to the pre-fabricated mechanical frame.

15. The apparatus of claim 14 , comprising a flexible sealant pressed against the drift eliminator material configured for sealing the hydration housing vessel and the drift eliminator material.

16. The apparatus of claim 1 , wherein the hydration solution comprises non-potable water, off-spec water, brackish water, saline water, sea water, waste water, gray water, rain water, storm water, non-process water, or a combination thereof.

17. The apparatus of claim 1 , comprising a CO 2 capture solution collection basin configured to receive CO 2 capture solution from the CO 2 capture packing section, the hydration solution collection basin being positioned adjacent to the CO 2 capture solution collection basin and fluidly separated therefrom;

the hydration solution collection basin being fluidly coupled to the pump; and

the CO 2 capture solution collection basin being fluidly coupled to a capture solution pump.

18. The apparatus of claim 17 , wherein:

the pump is configured to flow the hydration solution from the hydration solution collection basin to the contact zone; and

the capture solution pump is configured to flow the CO 2 capture solution from the CO 2 capture solution collection basin to the CO 2 capture packing section.

19. The apparatus of claim 17 , comprising:

a hydration solution makeup in fluid communication with the hydration solution collection basin; and

a CO 2 capture solution makeup in fluid communication with the CO 2 capture solution collection basin.

20. The apparatus of claim 17 , wherein the CO 2 capture solution comprises a hydroxide or an amine.

21. The apparatus of claim 17 , wherein the CO 2 capture solution collection basin is at least partially positioned beneath the CO 2 capture packing section.

22. The apparatus of claim 21 , wherein the CO 2 capture solution collection basin is positioned beneath the open plenum.

23. The apparatus of claim 1 , comprising a dual-cell, cross-flow gas-liquid contactor, the gas-liquid contactor comprising the open plenum and an induced-draft fan disposed above the open plenum.

24. The apparatus of claim 23 , wherein:

the contact zone comprises a first contact zone and a second contact zone;

a first hydration solution collection basin is positioned below the first contact zone; and

a second hydration solution collection basin is positioned below the second contact zone.

25. The apparatus of claim 1 , wherein the CO 2 capture packing section is configured for capturing CO 2 from air.

26. The apparatus of claim 1 , wherein the CO 2 capture packing is adjacent to the hydration housing vessel and downstream of the hydration housing vessel relative to a direction of flow of the at least one gas feed stream.

27. The apparatus of claim 1 , wherein the solution distribution system is positioned above the hydration housing vessel.

28. The apparatus of claim 1 , comprising a CO 2 capture solution distribution unit positioned above the CO 2 capture packing section.

29. The apparatus of claim 28 , wherein the CO 2 capture solution distribution unit abuts a top portion of the CO 2 capture packing section.

30. The apparatus of claim 1 , comprising at least one seal positioned between the capture solution drift elimination section and a structural housing of the apparatus.

31. The apparatus of claim 30 , wherein the at least one seal abuts the capture solution drift elimination section and is positioned downstream thereof relative to a direction of flow of the at least one gas feed stream.

Assignments (2)
CHANGE OF NAME Recorded Feb 28, 2024
From: CARBON ENGINEERING LTD.
To: CARBON ENGINEERING ULC
Reel/Frame 066593/0551 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 20, 2021
From: HEIDEL, KENTON ROBERT; RITCHIE, JANE ANNE; ANGELO, DAVID ST.
To: CARBON ENGINEERING LTD.
Reel/Frame 054962/0225 →
Continuity (2)
Provisional Application 62658679 · Apr 17, 2018
Related Publication 20210101107A1 · Apr 8, 2021
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