Patent ID: 12214308

DESCRIPTION OF EXEMPLARY EMBODIMENTS

As described below, the various embodiments combine valve and sorbent material, such as amine beds, into one component, dramatically reducing size and mass of scrubber. In embodiments, the continuously regenerable scrubber may also use diamond coated ceramic face seals (flat on flat seal) such as used in pumps (no O-rings or gaskets) for reduced friction, long life, and contaminant insensitivity. The sorbent material beds rotate continuously past breathing gas vent loop ports for scrubbing CO2/H2O and then past vacuum ports for regenerating the sorbent material.

Referring generally toFIGS.1and2, in a first embodiment continuously regenerable scrubber1comprises upper header10, upper header spacer21, lower header40, lower header spacer29, rotatable bed assembly20disposed intermediate the upper header and the lower header, and one or more fasteners60adapted to fasten upper header10to lower header40.

Upper header10typically comprises outer surface11, inner surface12, upper header fluid inlet13disposed through outer surface11and providing a fluid pathway to and through inner surface12, upper header pressure inlet14disposed through outer surface11to and through inner surface12, and upper header gasket19typically disposed intermediate outer surface11and upper header spacer21.

Upper header spacer21is typically disposed about a lower surface of upper header10, typically disposed after outer surface11.

Lower header40is connected to upper header10and typically comprises outer surface41, inner surface42, one or more partitioning walls45disposed within inner surface42, lower header fluid outlet43disposed through outer surface41to and through inner surface42; lower header pressure outlet44disposed through outer surface41to and through inner surface42; and lower header gasket49typically disposed intermediate outer surface41and upper header spacer29. Each partitioning wall45typically defines one or more desorption areas, e.g.42a, and one or more separate adsorption areas, e.g.42b. Lower header spacer29is typically disposed about outer surface41of the lower header40.

Rotatable bed assembly20, which is typically disposed intermediate upper header10and lower header40, typically comprises one or more material containers25, bottom gasket27disposed proximate a lower surface of material container25, bottom bed screen26disposed intermediate bottom gasket27and the lower surface of material container25; bottom disk28connected to bottom bed screen26where lower space29is further disposed intermediate bottom disk28and lower header40; upper gasket23disposed proximate an upper surface of material container25; upper bed screen24disposed intermediate upper gasket23and the upper surface of material container25; upper disk22connected to the upper bed surface; and header spacer22disposed intermediate upper header10and upper gasket23. As used herein, “upper” means towards upper header10and “lower” means towards lower header40.

Rotator51is typically present and disposed through upper header10and/or lower header40and cooperatively mates with rotatable bed assembly20to effect turning of rotatable bed assembly20, such as via motor70(not shown in the figures). One or more washers52may be present as well, such that rotator51is disposed through such washers52.

In addition, skirt65may be disposed about an outer surface of the rotatable bed assembly20.

Upper header spacer21and lower header spacer29typically comprise a ceramic. In embodiments, header spacer22and/or bottom disk28comprise a diamond coating.

In embodiments, upper header gasket19comprises a plurality of openings and upper header spacer21comprises a corresponding plurality of openings. Further, in embodiments lower header gasket49also comprises a plurality of openings and lower header spacer29comprises a plurality of openings corresponding to the openings in lower header gasket49. These openings in upper header gasket19and upper header spacer21do not necessarily have to be the same in number or shape as the openings in lower header gasket49and lower header spacer29, respectively.

Material container25comprises a shape that is rotatable within upper header10and lower header40and further comprises one or more material receivers25atherethrough, each with a predetermined sorbent material100(FIG.4A) disposed therein. Bottom bed screen26and upper bed screen24each typically comprises a shape sufficient to conform to the plurality of material receivers25a. In these embodiments, bottom gasket27comprises a plurality of openings.

In addition, bottom disk28comprises a plurality of openings as does upper gasket23. Moreover, upper disk22and header spacer22may also comprise a plurality of openings.

Fastener60may comprise a plurality of bolts, e.g. bolts disposed through eyelet lugs disposed towards an outer diameter of upper header10and lower headers40. Belleville or wave springs under the bolt heads can provide consistent seal compression and compensation for temperature extremes.

Referring additionally toFIG.3A, header central axis50is defined by an axis extending through a center of upper header10to a center of lower header40.

Referring now toFIG.3B, in a second embodiment, continuously regenerable media purifier2comprises upper header10, lower header40, and substantially circular bed assembly120disposed intermediate upper header10and lower header40.

Referring additional toFIGS.4A-4B, substantially circular bed assembly120, which is similar to rotatable bed assembly20, typically comprises substantially circular upper disc121which comprises a plurality of upper surface voids and substantially circular lower disc122which also comprises a plurality of lower surface voids. Each of substantially circular lower disc122and substantially circular upper disc121typically has the same circumference as substantially circular bed assembly120. Substantially circular bed assembly120further typically comprises substantially circular material container123which has the same circumference as substantially circular upper disc121and substantially circular lower disc122and which is disposed intermediate substantially circular upper disc121and substantially circular lower disc122. Substantially circular material container123is connected to substantially circular upper disc121at an upper side of substantially circular material container123and to substantially circular lower disc122at a lower side of substantially circular material container123.

Substantially circular lower surface material container123typically comprises one or more interior voids125. A disc central axis is defined by axis50(FIG.1) extending through a center of upper disc121, a center of lower disc122, and a center of substantially circular bed assembly120, where the disc central axis is substantially coaxial with respect to axis50. The plurality of the upper surface voids and the plurality of the lower surface voids extend axially from a point proximate axis50to a point proximate an outer boundary of substantially circular bed assembly120.

Substantially circular bed assembly120further typically comprises sorbent material100disposed in one or more of the substantially circular bed assembly interior voids where first constraining filtering member126ais disposed intermediate upper disc121and the interior voids and second constraining filtering member126bis disposed intermediate lower disc122and the interior voids.

Referring back toFIG.3A, in each configuration, upper header10typically comprises fluid input port13and fluid output port14and lower header40typically comprise fluid input port43, which is fluidly isolated from upper header fluid input13and upper header fluid output14, and fluid output port44, which is fluidly isolated from upper header fluid input13and upper header fluid output14. However, in embodiments, only fluid output port44, which is fluidly isolated from upper header fluid input13and upper header fluid output14, may be present.

In any of these embodiments, substantially circular upper disc21,121typically comprises a smooth surface in communication with upper header10and, similarly, substantially circular lower disc122typically comprises a smooth surface in communication with lower header40. Further, substantially circular material container25,123is typically connected to substantially circular upper disc121at the upper side of substantially circular material container25,123and to substantially circular lower disc122at a lower side of substantially circular material container25,123. This connection typically uses one or more fasteners60to connect substantially circular upper disc121to substantially circular lower disc122.

Referring additionally toFIG.3A, in certain alternative embodiments, one or more seals (such as23,27, and127) may be present and disposed intermediate substantially circular upper disc121and upper header10as well as one or more seals127disposed intermediate substantially circular lower disc122and lower header40.

Referring now toFIGS.5A-5E, in alternative embodiments, upper header10further comprises upper header interior void17b,17cand upper header interior wall17adisposed within upper header interior void17, where upper header interior wall17adefines a plurality of upper header fluid chambers. In these embodiments, lower header40further typically comprises one or more lower header interior voids such defined by desorption areas42aand adsorption areas42b, and lower header interior wall disposed45within the lower header interior void where lower header interior wall42defines a plurality of lower header fluid chambers defined by desorption areas42aand adsorption areas42b. These walls and voids may be contiguous. In certain of these alternative embodiments, the plurality of upper header fluid chambers further comprises at least two upper header fluid chambers separated by a fluid blocking portion18and the plurality of lower header fluid chambers further comprises two or more lower header fluid chambers separated by fluid blocking portion45.

Referring now toFIG.6, in embodiments, skirt65may be present, comprising an exterior surface, a substantially arcuate interior65awhose geometry is congruent with an outer boundary of substantially circular bed assembly120, and one or more seals66adapted to isolate substantially circular bed assembly120from the exterior surface of skirt65. Seals66may comprises an O-ring disposed intermediate skirt65and upper header10to allow skirt65to slide axially along the header central axis while maintaining the enclosure.

Fastener60, which may comprise a thread or a clamp, may be present as well and adapted to fix seals66on upper header10and/or lower header40.

Referring still toFIG.6, disc rotation system200comprises a continuously regenerable media purifier in any of the above embodiments as described above; a shaft such as rotator51which is operatively connected to rotatable bed assembly20(or substantially circular bed assembly120); motor70operatively in communication with the shaft; one or more gears71operatively in communication with motor70; one or more sensors72(not shown in the figures) operatively in communication with the shaft; one or more first fluid sources80in fluid communication with fluid input port13; one or more second fluid sources81, which can provide a vacuum, in fluid communication with fluid ports43,44; and control system90operatively in communication with sensors72and motor70, where control system90is operative to control the rotation speed of motor70. In typical embodiments, the rotation speed comprises a fixed rotation speed, a manually changeable rotation speed, a feedback/feedforward-controlled rotation speed, or the like, or a combination thereof.

In any of these embodiments, upper header fluid input port13and lower header fluid input port43may be adapted for use with an input fluid and upper header fluid output port14and lower header fluid output port44may be adapted for use with an output fluid comprising a lower pressure than a pressure of the input fluid, where the output fluid functions as a sweeping fluid.

In any of these embodiments, sorbent material100(FIG.4A) typically comprises amine, and typically comprises beads having a diameter of around 0.36 mm to get a greater surface area/mass than an average bead diameter of 0.48 mm. Selecting for small beads by filtering may increase adsorption significantly because smaller beads have more surface area/mass.

In any of these embodiments, the plurality of upper surface voids and the plurality of lower surface voids may comprise one or more circular or fan-shaped holes and substantially circular material container25,123may comprise one or more walls disposed intermediate the plurality of holes. These holes and wall may define an angled, twisted, or torturous path.

In addition, cutouts on material container25may have one or more shoulders to place filtering materials. Material container25may comprise a tapered shape and rotary interfacing members such as upper disk22and bottom disk28may comprise the same or different sizes.

In the operation of exemplary embodiments, referring generally toFIGS.1,3A, and6, the embodiments of a continuously regenerable media purifier1,2may operate dry, i.e. without lubrication, and operate with a continuous rotational motion, combining valve and bed functions into one component. Typically, beds of sorbent material as used in this invention do not require thermal integration of adsorption and desorption beds because exposure of materials such amine to adsorption and desorption beds switches back and forth faster than material can change temperature.

Fluid may be continuously scrubbed and regenerating using any of the embodiments above by connecting first fluid source80to upper header fluid input13which is selectively fluidly in communication with lower header fluid output43and by connecting upper header pressure inlet14, which is selectively in fluid communication with lower header pressure inlet44, to second fluid source81, typically comprising and/or supplying a fluid under positive or negative pressure such as a vacuum source or other source of sweeping fluid.

Motor70is energized to spin rotatable bed assembly20(or substantially circular bed assembly120) at a predetermined speed which allows absorption or adsorption of materials in the fluids flowing through sorbent material100present such as in material receivers25aand to also allow desorption of materials flowing through sorbent material100. A relatively infinitely tunable CO2output allows power to be minimized and controlling the speed of rotating bed20(or substantially circular bed assembly120) changes the amount of CO2coming out of continuously regenerable scrubber1,2. Speed can be minimized so CO2output level is always at the required level and not better than required. Minimum speed equals minimum power. Faster RPM may be used to shorten adsorption and desorption time.

It has been found that around a 3 millisecond residence time of vent gas flowing through the sorbent material was sufficient to scrub CO2. Testing has also shown that continuously regenerable scrubber1,2can get an effective ceramic seal with low leakage and low torque.

Isolation area between adsorption and desorption sides may be decreased to get more available bead volume. Adsorption to desorption cell ratio may also be changed since desorption happens quickly, giving a lower pressure differential for an adsorption side, but a ratio is assumed to be 1:1. If a 4:3 ratio is used, and an isolation area reduced, flow can be reduced and pressure dropped through each material container25, e.g. by 25%, and the mass of amine beads goes up, e.g. 33%. Desorption time and adsorption time are variable and optimizable by varying the geometry of single or plural of desorption chamber42aand adsorption chamber42b.

An air save feature may be used to save a portion the fluid in material containers25by sending it to a regenerated and evacuated material container25that is about to enter a vent stream, set to occur as material container25rotates. In addition, skirt65, if present, is typically disposed over an outside of ceramic seal65awhich is pressurized to nearly match the pressure inside seal125, thereby nearly eliminating the pressure driving force that causes leakage and pressure driven torque to rotate the bed120.

Moreover, use of one or more pressure balanced seals127, which may be ceramic seals, helps to reduce leakage. This can include skirt65disposed over an outside of seal127which is pressurized to nearly match the pressure inside seal125, thereby nearly eliminating the pressure driving force that causes leakage. Further, use of a pressure balanced bed such as material container25may also reduce required seal squeeze, which, in turn, reduces friction, which, in turn, helps reduce the size, weight, and power of motor70required to spin rotatable bed assembly20.

As is discussed above, in its various embodiments continuously regenerable media purifier1,2may be enclosed in a vessel and pressurized with vent loop pressure. This eliminates the pressure differential from inside rotatable bed assembly20to outside that is forcing the seal apart (sealing faces separating), which otherwise would have to be counteracted by squeezing the seals together harder, which increases friction.

In embodiments sealing interfaces121,122,124a,124bare rotated by motor70, via gear71, and controlled by controller90to form a combination of fluid-diverting valve and sorbent-containing sealed bed120together, minimizing plumbing and ullage volume in the system. This combination of valve functions and rotatable bed assembly20,120inherently achieve fluid-diverting function, obviating a need for additional valves or their control system.

In addition, the temperature of the sorbent material100is inherently prevented from performance decreasing temperature variations by rotatable bed assembly20,120alternately exposed to fluid, e.g. from first fluid source80, and fluid from second fluid source, e.g. regeneration source81, within a short period.

Output fluid flowing through output port14may achieve unvarying concentration of constituents by continuous regeneration. In addition, fluid immediately surrounding sorbent material100typically serves as a sweep fluid when desorbed to lower pressure environment with said sweep fluid preventing back-contamination from the environment.

The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or an illustrative method may be made without departing from the spirit of the invention.