IP Library › Granted Patent US 11,813,562
Granted Patent B2
US 11,813,562 · App. 17/590,248 · Granted Nov 14, 2023

Systems and methods for capturing carbon dioxide in exhaust gas

Inventors: Philip D. Nguyen (Houston, TX); Ronald Glen Dusterhoft (Houston, TX); Stanley Vernon Stephenson (Duncan, OK); Timothy Holiman Hunter (Duncan, OK); Andrew Silas Clyburn (Duncan, OK); Adam Lynn Marks (Duncan, OK)
Assignee: Halliburton Energy Services, Inc.
B01D53/0438B01D53/0446B01D53/0462B01D53/0476B01D53/62B01D2257/504B01D2258/0283B01D2259/402
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Quick Facts
Patent No.
US 11,813,562
App. No.
17/590,248
Granted
Nov 14, 2023
Kind
B2
Abstract

The disclosure provides a method and system for extracting carbon dioxide from an exhaust gas. The method includes lowering a temperature of an exhaust gas using a heat exchanger, lowering a concentration of a particulate matter within the lowered temperature exhaust gas, and passing the lowered particulate concentration and lowered temperature exhaust gas through one or more membrane modules to produce a membrane module permeate flow that contains a higher concentration of carbon dioxide compared to a concentration of carbon dioxide in the lowered particulate concentration and lowered temperature exhaust gas. Further, the system includes a heat exchanger fluidly coupled to a particulate filter that is configured to lower a concentration of the particulate matter within the exhaust gas, and one or more membrane modules fluidly coupled to the particulate filter and configured to produce the membrane module permeate flow.

Claims (73)

1. A method comprising:

lowering a temperature of an exhaust gas using a heat exchanger;

lowering a concentration of a particulate matter within the lowered temperature exhaust gas;

passing the lowered particulate concentration and lowered temperature exhaust gas through one or more membrane modules to produce a membrane module permeate flow that contains a higher concentration of carbon dioxide compared to a concentration of carbon dioxide in the lowered particulate concentration and lowered temperature exhaust gas; and

producing a substantially pure carbon dioxide from the membrane module permeate flow using one or more adsorbent packed beds,

wherein producing the substantially pure carbon dioxide from the membrane module permeate flow using one or more adsorbent packed beds comprises:

injecting the membrane module permeate flow into the one or more adsorbent packed beds;

extracting the substantially pure carbon dioxide from the membrane module permeate flow using a sorbent disposed within the one or more adsorbent packed beds;

releasing the membrane module permeate flow after the substantially pure carbon dioxide has been extracted; and

applying one of a pressure swing by reducing a pressure within the one or more adsorbent packed beds or a temperature swing by raising a temperature of the one or more adsorbent packed beds.

2. The method of claim 1 , wherein:

lowering the temperature of the exhaust gas using a heat exchanger comprises:

passing the exhaust gas through the heat exchanger; and

flowing a heat exchanger fluid through the heat exchanger, wherein flowing the heat exchanger fluid through the heat exchanger raises a temperature of the heat exchanger fluid; and

applying the temperature swing by raising the temperature of the one or more adsorbent packed beds comprises:

injecting the raised temperature heat exchanger fluid flowed through the heat exchanger into the one or more adsorbent packed beds by way of a heated fluid flow line.

3. The method of claim 1 , wherein:

the pressure swing is applied to the one or more adsorbent beds by a vacuum.

4. The method of claim 1 , wherein:

the one or more adsorbent packed beds includes a first adsorbent packed bed and a second adsorbent packed bed coupled in parallel; and

at least one of the first adsorbent packed bed and the second adsorbent packed bed are used to produce the substantially pure carbon dioxide from the membrane module permeate flow.

5. The method of claim 4 , wherein:

the substantially pure carbon dioxide is extracted from the membrane module permeate flow using one of the first adsorbent packed bed or the second adsorbent packed bed; and

one of the pressure swing or the temperature swing is applied using the other of the first adsorbent packed bed or the second adsorbent packed bed, simultaneously.

6. The method of claim 1 , wherein:

lowering the temperature of the exhaust gas using a heat exchanger comprises:

pumping the exhaust gas through the heat exchanger using a first pump;

passing the lowered particulate concentration and lowered temperature exhaust gas through the one or more membrane modules comprises:

pumping the lowered particulate concentration and lowered temperature exhaust gas through the one or more membrane modules using a second pump; and

injecting the membrane module permeate flow into the one or more adsorbent packed beds comprises:

pumping the membrane module permeate flow into the one or more adsorbent packed beds using a third pump.

7. The method of claim 1 further comprising:

storing the produced substantially pure carbon dioxide in a storage container as one of a compressed gas or a liquid.

8. The method of claim 1 further comprising:

capturing the exhaust gas produced by an exhaust gas source.

9. The method of claim 1 wherein the temperature of the exhaust gas is lowered to less than or equal to 200 degrees Fahrenheit.

10. The method of claim 1 , wherein:

lowering the concentration of the particulate matter within the lowered temperature exhaust gas comprises:

passing the lowered temperature exhaust gas through a particulate filter; and

the particulate filter removes the particulate matter from the lowered temperature exhaust gas by one of a cyclonic separation process, an electrostatic process, a tortuous path filtration process, or a process of passing the lowered temperature exhaust gas through a media filter, a venturi scrubber, a liquid bath filter, a catalytic converter, or a diesel particulate filter to lower the concentration of the particulate matter within the lowered temperature exhaust gas.

11. The method of claim 1 , wherein:

passing the lowered particulate concentration and lowered temperature exhaust gas through one or more membrane modules further produces a membrane module retentate flow that contains a lower concentration of carbon dioxide compared to the concentration of carbon dioxide in the lowered particulate concentration and lowered temperature exhaust gas; and

the method further comprises:

recirculating the membrane module retentate flow through the one or more membrane modules.

12. The method of claim 1 , wherein:

the one or more membrane modules includes a first membrane module and a second membrane module; and

passing the lowered particulate concentration and lowered temperature exhaust gas through the one more membrane modules includes passing the lowered particulate concentration and lowered temperature exhaust gas through the first membrane module and the second membrane module in series.

13. The method of claim 1 , further comprising:

storing the produced membrane module permeate flow in a storage container.

14. The method of claim 1 , wherein the temperature of the exhaust gas is lowered to less than or equal to 100 degrees Fahrenheit.

15. A system for extracting carbon dioxide from an exhaust gas, comprising:

a heat exchanger, wherein the heat exchanger is configured to lower a temperature of the exhaust gas;

a particulate filter fluidly coupled to the heat exchanger, wherein the particulate filter is configured to lower a concentration of a particulate matter within the exhaust gas;

one or more membrane modules fluidly coupled to the particulate filter, wherein the one or more membrane modules is configured to produce a membrane module permeate flow from the exhaust gas that contains a higher concentration of carbon dioxide compared to a concentration of carbon dioxide in the exhaust gas; and

one or more adsorbent packed beds fluidly coupled to the one or more membrane modules, wherein the one or more adsorbent packed beds is configured to produce a substantially pure carbon dioxide from the membrane module permeate flow,

wherein the one or more adsorbent packed beds comprises:

a sorbent configured to extract carbon dioxide from the membrane module permeate flow.

16. The system of claim 15 , wherein:

the one or more adsorbent packed beds includes a first adsorbent packed bed and a second adsorbent packed bed coupled in parallel;

the first adsorbent packed bed is fluidly coupled to the one or more membrane modules; and

the second adsorbent packed bed is fluidly coupled to the one or more membrane modules.

17. The system of claim 15 , wherein:

the one or more membrane modules includes a first membrane module and a second membrane module fluidly coupled in series;

the first membrane module is fluidly coupled to the particulate filter; and

the second membrane module is fluidly coupled to the one or more adsorbent packed beds.

18. The system of claim 15 , further comprising:

a first pump fluidly coupled to the heat exchanger;

a second pump fluidly coupled between the particulate filter and the one or more membrane modules; and

a third pump fluidly coupled between the one or more membrane modules and the one or more adsorbent packed beds.

19. The system of claim 15 , further comprising:

a heated fluid flow line fluidly coupled between the heat exchanger and the one or more adsorbent packed beds, wherein the heated fluid flow line is configured to inject a heated heat exchanger fluid from the heat exchanger into the one or more adsorbent packed beds.

20. The system of claim 15 , further comprising:

one or more mobile units, wherein the heat exchanger, the particulate filter, the one or more membrane modules, and the one or more adsorbent packed beds are disposed on the one or more mobile units.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 1, 2022
From: NGUYEN, PHILIP D.; DUSTERHOFT, RONALD GLEN; STEPHENSON, STANLEY VERNON; HUNTER, TIMOTHY HOLIMAN; CLYBURN, ANDREW SILAS; MARKS, ADAM LYNN
To: HALLIBURTON ENERGY SERVICES, INC.
Reel/Frame 058846/0883 →
Continuity (1)
Related Publication 20230241543A1 · Aug 3, 2023