U.S. patent application number 14/208628 was filed with the patent office on 2014-10-16 for adsorbent system for removal of gaseous contaminants.
This patent application is currently assigned to Micropore, Inc.. The applicant listed for this patent is Micropore, Inc.. Invention is credited to Thomas Daley, J. Anthony DelNegro, Douglas B. McKenna.
Application Number | 20140305309 14/208628 |
Document ID | / |
Family ID | 44319741 |
Filed Date | 2014-10-16 |
United States Patent
Application |
20140305309 |
Kind Code |
A1 |
McKenna; Douglas B. ; et
al. |
October 16, 2014 |
Adsorbent System for Removal of Gaseous Contaminants
Abstract
This invention relates to an adsorbent system, adsorbent
cartridge, and external canister for removing gaseous contaminants
from air or another gas.
Inventors: |
McKenna; Douglas B.;
(Avondale, PA) ; DelNegro; J. Anthony;
(Wilmington, DE) ; Daley; Thomas; (Broomall,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Micropore, Inc. |
Elkton |
MD |
US |
|
|
Assignee: |
Micropore, Inc.
Elkton
MD
|
Family ID: |
44319741 |
Appl. No.: |
14/208628 |
Filed: |
March 13, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13014259 |
Jan 26, 2011 |
8685153 |
|
|
14208628 |
|
|
|
|
61298426 |
Jan 26, 2010 |
|
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Current U.S.
Class: |
96/147 ;
96/108 |
Current CPC
Class: |
B01D 2257/2064 20130101;
B01D 53/86 20130101; B01D 2257/302 20130101; Y02C 10/08 20130101;
Y02C 20/40 20200801; B01D 2257/504 20130101; B01D 2257/80 20130101;
B01D 2251/604 20130101; B01D 2257/304 20130101; B01D 2253/34
20130101; B01D 2257/502 20130101; B01D 2257/708 20130101; B01D
2255/2073 20130101; B01D 53/0415 20130101; B01D 2253/108 20130101;
B01D 53/0407 20130101; B01D 2255/20761 20130101; B01D 2253/102
20130101 |
Class at
Publication: |
96/147 ;
96/108 |
International
Class: |
B01D 53/04 20060101
B01D053/04 |
Claims
1. A removable adsorbent cartridge for removal of gaseous
contaminants comprising: a plurality of parallel, non-wound
adsorbent surfaces, mechanically spaced so as to allow gas flow
between each surface in the plurality; and one or more fasteners,
wherein the one or more fasteners secures the plurality of said
surfaces together; wherein the cartridge does not further comprise
a rigid shell encasing the cartridge.
2. The adsorbent cartridge of claim 1, wherein the non-wound
adsorbent surfaces are planar.
3. The adsorbent cartridge of claim 1, wherein the one or more
fasteners are disposed within the adsorbent cartridge.
4. The adsorbent cartridge of claim 1, wherein the one or more
fasteners comprise one or more fasteners independently selected
from stakes, staples, wires, rods, cords, plastic bands, elastic
bands, and rivets.
5. The adsorbent cartridge of claim 1, wherein the one or more
fasteners comprise one or more rigid stakes disposed within the
cartridge, entering the cartridge from the top or bottom sheet.
6. The adsorbent cartridge of claim 5, wherein the rigid stakes are
arranged perpendicular to the gas flow.
7. The adsorbent cartridge of claim 5, wherein the rigid stakes are
arranged at an angle to the gas flow.
8. The adsorbent cartridge of claim 5, wherein the one or more
fasteners comprise a plurality of rigid stakes arranged within the
adsorbent cartridge to fasten the adsorbent surfaces such that no
additional external mechanical support is required during use when
the adsorbent cartridge is subjected to a gas flow.
9. The absorbent cartridge of claim 1, wherein the fasteners secure
the absorbent surfaces together for transport, but additional
mechanical support is required during use when the absorbent
cartridge is subjected to gas flow.
10. The adsorbent cartridge of claim 1, wherein the adsorbent
surfaces are spaced by ribs disposed on the adsorbent surfaces.
11. The adsorbent cartridge of claim 1, wherein the adsorbent
surfaces are spaced by separating screens between the adsorbent
surfaces.
12. The adsorbent cartridge of claim 1, further comprising a
polymer foam that seals the outer surface of the cartridge along
the sides that are not in the inlet or outlet flow stream.
13. The adsorbent cartridge of claim 1, further comprising a
polymer sleeve surrounding the outer surface of the cartridge along
the sides that are not in the inlet or outlet flow stream.
14. The adsorbent cartridge of claim 1, wherein the cartridge
comprises square adsorbent sheets arranged into a cube.
15. The adsorbent cartridge of claim 1, wherein the cartridge
comprises rectangular adsorbent sheets arranged into a rectangular
stack.
16. The adsorbent cartridge of claim 1, wherein the cartridge
comprises round or oval adsorbent sheets arranged into a
cylinder.
17. The adsorbent cartridge of claim 1, wherein the cartridge
comprises triangular or trapezoidal sheets.
18. The adsorbent cartridge of claim 1, wherein said gaseous
contaminant is carbon dioxide.
19. The adsorbent cartridge of claim 1, wherein said gaseous
contaminant is carbon monoxide, chemical or biological toxins,
volatile organic carbons, moisture, acid gases or other impurities
in the feed gas stream.
20. The adsorbent cartridge of claim 1, wherein the adsorbent is
selected from the group consisting of calcium hydroxide and lithium
hydroxide.
21. The adsorbent cartridge of claim 1, wherein the adsorbent is
molecular sieves, activated carbon, or an oxidation catalyst.
22. The absorbent cartridge of claim 1, comprising: a plurality of
parallel, non-wound adsorbent surfaces, mechanically spaced by ribs
along the absorbent surfaces so as to allow gas flow between each
surface in the plurality; and one or more rigid stakes disposed
within the cartridge to secure the plurality of said surfaces
together; wherein the stakes enter the plurality of absorbent
surfaces from the top or bottom sheet; wherein said cartridge does
not further comprise a rigid shell encasing the cartridge.
23. A gaseous contaminant removal system comprising: (1) a
removable adsorbent cartridge comprising: a plurality of parallel,
non-wound adsorbent surfaces, mechanically spaced so as to allow
gas flow between each surface in the plurality; and one or more
fasteners, wherein the one or more fasteners secures the plurality
of said surfaces together; wherein the cartridge does not further
comprise a rigid shell encasing the cartridge; and (2) a canister
comprising: an inlet through which gas can flow to contact the
adsorbent cartridge; an outlet for gas flow; and a plurality of
support structures disposed on the interior walls of the canister,
which provide mechanical stability to the adsorbent cartridge by
restricting movement of the cartridge within the canister during
use; wherein the cartridge is placed in the canister such that the
gas flow from the inlet of the canister can flow between the
adsorbent surfaces in said cartridge.
24. A removable adsorbent cartridge for removal of gaseous
contaminants comprising: a plurality of parallel, non-wound
adsorbent surfaces, mechanically spaced so as to allow gas flow
between each surface in the plurality; and an adhesive used to
secure the plurality of said surfaces together; wherein the
cartridge does not further comprise a rigid shell encasing the
cartridge.
Description
[0001] This application is a continuation of U.S. Ser. No.
13/014,259, filed Jan. 26, 2011, which claims the benefit of
priority of U.S. Provisional Appl. No. 61/298,426, filed Jan. 26,
2010, which is incorporated herein by reference in its
entirety.
TECHNICAL FIELD
[0002] This invention relates to an adsorbent system, an adsorbent
cartridge, and canister, for removing gaseous contaminants from the
air or other gases.
BACKGROUND
[0003] A carbon dioxide removal system maintains carbon dioxide
(CO.sub.2) concentration at a safe level. Maintaining CO.sub.2 at
safe levels can be accomplished by passing exhaled gases through a
chemical adsorbent, such as soda lime or anhydrous lithium
hydroxide (LiOH). The cartridge is composed of fine adsorbent
powder formed into a microporous sheet by thermally induced phase
separation of polyethylene. The process to produce sheets of
microporous lithium hydroxide/calcium hydroxide is defined in U.S.
Pat. No. 5,964,221. This technology of forming fine powders into
pliable sheets replaced the older technology of forming adsorbent
powders into granular adsorbents. Both microporous lithium
hydroxide and calcium hydroxide adsorbents can be produced under
the original patent. The wound cartridge product corrects may of
the problems associated with granular adsorbents, such as dusting,
settling, flow channeling and high pressure drop.
[0004] The microporous technology has been deployed in rebreather
systems, mine shelters, and unpowered emergency carbon dioxide
control in submarines. Submarines use pre-filled cartridges of
granular adsorbents for routine, non-emergency, carbon dioxide
control. Pre-packed containers of adsorbent are installed into an
electric powered canister system for scrubbing CO.sub.2. These
pre-packed granules rely on a relatively large container (or
exoskeleton) to hold the granules. The plastic exoskeleton
containers add material cost to the adsorbent manufacture. They
also may pose safety hazards by increasing the amount of available
fuel in the event of a fire. Plastic containers also have an
environmental impact associated with their disposal. As an
alternative, reusable, pre-packed metal containers are easy to
handle, safe in a fire and do not contribute to landfills; however
in submarine applications for example, they are more expensive
initially, and there is a larger logistics cost for handling and
off-hull refilling of spent cartridges of adsorbent. The system of
stacking adsorbent sheets into a rectangular pack (as described in
U.S. Pat. No. 5,964,221) is both costly and inefficient. The bulky
external frame required to support the sheets occupies volume and
adds manufacturing cost. In applications such as space craft and
submarines volume is a primary design driver.
[0005] An alternative to adsorbent cartridges with rigid frames is
the ExtendAir.RTM. adsorbent cartridge manufactured by Micropore
Inc. For many applications, an adsorbent sheet is wound on a
cylindrical core. The adsorbent is prevented from unwinding, using
an inexpensive polymer film wrapped around the outside of the
cartridge. This wound cartridge does not require an expensive, and
bulky external housing (exoskeleton) to maintain its shape. The
parallel adsorbent surfaces are held in contact with each other by
the tension applied during the winding process and maintained by
the outer polymer film wrap. This cartridge has the ease of
handling advantages but the cylindrical geometry is inefficient for
storage volume and scrubber installation.
[0006] This invention addresses these needs and others.
SUMMARY
[0007] Cylindrical cartridges such as a round Extend Air.RTM.
cartridge do not efficiently utilize storage space. Rectangular
adsorbent is the most efficient shape for storage. Until now
adsorbent stacked into a rectangle required a bulky external frame,
exoskeleton, to support the sheets and provide uniform air flow
passages (U.S. Pat. No. 5,964,221). The standard external frame or
exoskeleton required to hold these sheets together, reduces
volumetric efficiency (the volume occupied by an external frame is
volume not available for the adsorbent chemical), and also costs
additional money to fabricate and assemble This invention allows
for the construction of stacked sheets of adsorbent with minimal
internal support and no external support. This application details
a revolutionary technique, where a stack of adsorbent sheets can be
held together internally, hereby defined as an endoskeleton (by use
of fasteners for example), which solves the problems associated
with external containment of the adsorbent material. The material
cost for this cartridge is reduced because the endoskeleton can be
fabricated from inexpensive materials such as metal or plastic bars
or staples. Unlike the wound cylindrical ExtendAir.RTM. cartridge,
the endoskeleton cartridge can be assembled from stacks of sheets
and formed into various shapes (e.g., cylinders (from oval or
circular sheets), cubes, etc.). The cartridge of stacked sheets may
be held together with sufficient endoskeleton structure (multiple
stakes) to be self-supporting. Gluing or fusing multiple sheets
together using a variety of techniques will also form a stable
stack of adsorbent sheets, but has the disadvantage of added
manufacturing complexity. In both the multiple stake and glued
stacks, the sheets of adsorbent remain in contact with each other
without external support. In this self-supporting configuration,
the endoskeleton cartridge may be installed into a canister wherein
the canister is not required to provide any structural support to
the cartridge.
[0008] The endoskeleton adsorbent may also be loosely held together
(very few stakes is one way to achieve this). The sheets are held
in place to permit packaging and handling of the consumable
cartridge, however, the sheets are not held together with
sufficient force to maintain uniform gas flow between the sheets
during use. Instead, this cartridge, with a limited endoskeleton,
is installed into a specially designed canister, wherein the
scrubber canister provides the additional support needed to
maintain the optimal sheet spacing and adsorbent performance. In
this embodiment, where the adsorbent sheets are loosely held by an
endoskeleton, the canister provides the force to maintain contact
between sheets (with internal spacing). The proper contacting of
the sheets maintains the air passages required for consistent and
efficient adsorption. This loosely held cartridge with a minimal
endoskeleton offers the lowest cost of manufacture, while still
allowing for optimal utilization in the scrubber canister.
[0009] Accordingly, the present invention provides, inter alia, an
adsorbent cartridge for removal of gaseous contaminants
comprising:
[0010] a plurality of parallel, non-wound adsorbent surfaces,
mechanically spaced so as to allow gas flow between each surface in
the plurality; and
[0011] one or more fasteners, wherein the one or more fasteners
secures the plurality of said surfaces together. In some
embodiments, the cartridge does not further comprise a rigid shell
encasing the cartridge. In some embodiments, the non-wound
adsorbent surfaces are planar.
[0012] In some embodiments, the one or more fasteners are disposed
within the adsorbent cartridge. In some embodiments, the one or
more fasteners comprise one or more fasteners independently
selected from stakes, staples, wires, rods, cords, plastic bands,
elastic bands, and rivets. In some embodiments, the one or more
fasteners comprise one or more rigid stakes. In some embodiments,
the fasteners comprise rigid or elastic bands disposed around the
outside of the cartridge, not blocking the direction of gas flow
through the cartridge layers.
[0013] In some embodiments, the one or more fasteners comprise a
plurality of rigid stakes arranged within the adsorbent cartridge
to fasten the adsorbent surfaces such that no additional external
mechanical support is required during use when the adsorbent
cartridge is subjected to a gas flow. In some embodiments, the one
or more fasteners comprise at least one rigid stake arranged to
provide structural support to the cartridge. In some embodiments,
the rigid stakes are arranged perpendicular to the gas flow. In
some embodiments, the rigid stakes are arranged at an angle to the
gas flow.
[0014] In some embodiments, the adsorbent surfaces are spaced by
ribs disposed on the adsorbent surfaces. In some embodiments, the
adsorbent surfaces are spaced by separating screens between the
adsorbent surfaces.
[0015] In some embodiments, the cartridge further comprises a
polymer foam that seals the outer surface of the cartridge, but
does not block the inlet and outlet passages. In some embodiments,
the cartridge further comprises a polymer sleeve surrounding the
outer surface of the cartridge, but does not block the inlet and
outlet passages.
[0016] In some embodiments, the cartridge comprises square
adsorbent sheets arranged into a cube. In some embodiments, the
cartridge comprises round or oval adsorbent sheets arranged into a
cylinder. In some embodiments, the cartridge comprises triangular
or trapezoidal sheets arranged into a solid block of adsorbent. In
some embodiments, the cartridge comprises rectangular adsorbent
sheets arranged into a rectangular stack.
[0017] In some embodiments, the drop of pressure between a flow of
gas into and out of the cartridge is less than 200 Pascals for a
flow rate of gas between 50 to 400 standard liters per minute
(slpm).
[0018] In some embodiments, the gaseous contaminant includes, but
is not limited to, carbon dioxide (CO.sub.2). In some embodiments,
gaseous contaminant includes, but is not limited to, carbon
monoxide, chemical or biological toxins, volatile organic carbons,
moisture, acid gases or other impurities in the feed gas stream. In
some embodiments, the gaseous contaminant includes, but is not
limited to, carbon dioxide (CO.sub.2), carbon monoxide, chemical or
biological toxins, volatile organic hydrocarbons, or moisture.
[0019] In some embodiments, the adsorbent includes, but is not
limited to, calcium hydroxide (Ca(OH).sub.2) and/or lithium
hydroxide (LiOH). In some embodiments, the adsorbent includes, but
is not limited to, molecular sieve, activated carbon, oxidation
catalyst.
[0020] The present invention further provides a canister for use
with an adsorbent cartridge to remove gaseous contaminants
comprising:
[0021] an inlet through which gas can flow to contact the adsorbent
cartridge;
[0022] an outlet for gas flow; and
[0023] a plurality of support structures disposed on the interior
walls of the canister, which provide mechanical stability to the
adsorbent cartridge by restricting movement of the cartridge within
the canister during use.
[0024] In some embodiments, the plurality of support structures
allows the exertion of mechanical pressure on the outer surface of
the cartridge not directly exposed to gas flow (e.g., along the
sides that are not in the inlet or outlet flow stream).
[0025] In some embodiments, the plurality of support structures
comprises a plurality independently selected from springs, bars,
and plates.
[0026] In some embodiments, the plurality of support structures
comprises rigid rods arranged perpendicular to the gas flow.
[0027] In some embodiments, the plurality of support structures
comprises elastic springs which allow exertion of a variable amount
of mechanical force to the sides of the adsorbent cartridge. In
some embodiments, the canister further comprises rails disposed on
up to four walls of the canister to prevent or reduce gas from
flowing around the cartridge.
[0028] In some embodiments, the canister further comprises a
diffusion panel, which allows uniform gas flow across a
cross-sectional surface of the adsorbent cartridge.
[0029] In certain embodiments, the canister is used together with
the adsorbent cartridge.
[0030] In some embodiments, the cartridge comprises:
[0031] a plurality of parallel, non-wound adsorbent surfaces,
mechanically spaced by ribs along the absorbent surfaces so as to
allow gas flow between each surface in the plurality; and
[0032] one or more rigid stakes disposed within the cartridge to
secure the plurality of said surfaces together; wherein the stakes
enter the plurality of absorbent surfaces from the top or bottom
sheet;
[0033] wherein said cartridge does not further comprise a rigid
shell encasing the cartridge.
[0034] The present invention also provides a gaseous contaminant
removal system comprising:
[0035] (1) an adsorbent cartridge comprising:
[0036] a plurality of parallel, non-wound adsorbent surfaces,
mechanically spaced so as to allow gas flow between each surface in
the plurality; and
[0037] one or more fasteners, wherein the one or more fasteners
secures the plurality of said surfaces together; wherein the
cartridge does not further comprise a rigid shell encasing the
cartridge; and
[0038] (2) a canister comprising:
[0039] an inlet through which gas can flow to contact the adsorbent
cartridge;
[0040] an outlet for gas flow; and
[0041] a plurality of support structures disposed on the interior
walls of the canister, which provide mechanical stability to the
adsorbent cartridge by restricting movement of the cartridge within
the canister during use;
[0042] wherein the cartridge is placed in the canister such that
the gas flow from the inlet of the canister can flow between the
adsorbent surfaces in said cartridge.
[0043] In some embodiments, the plurality of support structures
allows the exertion of mechanical pressure on the outer surface of
the cartridge not directly exposed to gas flow.
[0044] In some embodiments, the gaseous contaminant removal system
contaminant eliminates a contaminant which includes, but is not
limited to, carbon dioxide (CO.sub.2), carbon monoxide, chemical or
biological toxins, volatile organic hydrocarbons, or moisture.
[0045] In some embodiments, the gaseous contaminant removal system
includes a cartridge described in one of the above embodiments. In
some embodiments, the gaseous contaminant removal system includes a
canister described in one of the above embodiments.
[0046] In some embodiments, the gaseous contaminant removal system
includes a cartridge featuring a plurality of adsorbent
surfaces.
[0047] The present invention further provides a method of using the
adsorbent cartridge as a backup emergency gaseous contaminant
removal system in an enclosed space by directly inserting the
cartridge into a chute in a scrubbing or ventilation system.
[0048] In some embodiments, an adsorbent cartridge for removal of
gaseous contaminants includes a plurality of parallel, non-wound
adsorbent surfaces, mechanically spaced so as to allow gas flow
between each surface in the plurality; and adhesives that are used
to secure the plurality of said surfaces together; wherein the
cartridge does not further comprise a rigid shell encasing the
cartridge.
[0049] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
[0050] It is appreciated that certain features of the invention,
which are, for clarity, described in the context of separate
embodiments, can also be provided in combination in a single
embodiment.
DESCRIPTION OF DRAWINGS
[0051] FIGS. 1(a)-(e) show different views of a canister of the
present invention.
[0052] FIG. 2 is a cross-section view of parallel aligned sheets
taken along line C-C' of FIG. 1(c).
[0053] FIG. 3 is an enlargement of a portion of the cross-section
shown in FIG. 2.
[0054] FIG. 4 is a cross-section view of a canister of the present
invention having a pleated sheet.
[0055] FIG. 5 is a cross-section view of an adsorption sheet of the
present invention where the sheet is formed of expanded
polytetrafluoroethylene with adsorbent particles encapsulated
within.
[0056] FIG. 6 is a cross-section view of an adsorption sheet of the
present invention where the sheet of FIG. 5 is surrounded by an
outer membrane.
[0057] FIG. 7 is a cross-section view of an adsorption sheet of the
present invention where adsorbent material is attached to an
internal screen and outer membranes are attached to the adsorbent
particles.
[0058] FIG. 8 is a cross-section view of an adsorption sheet of the
present invention where outer membranes are attached to an internal
screen and the interstices in the screen contain adsorbent
material.
[0059] FIGS. 9 through 12 are three-quarter elevation views of a
method for forming the sheet of FIG. 8.
[0060] FIG. 13 is a scanning electron micrograph of adsorbent
powder in a microporous sheet as defined in U.S. Pat. Nos.
5,964,221 and 7,326,280.
[0061] FIG. 14(a) is a three-quarter top elevation view of an
adsorbent sheet for use in the present invention, in which
separating ribs have been molded on one side of the sheet out of
the adsorbent itself.
[0062] FIG. 14(b) is a cross-section view of the adsorbent sheet
shown in FIG. 14(a).
[0063] FIG. 14(c) is a three-quarter top elevation view of another
embodiment of an adsorbent sheet for use in the present invention,
in which separating ribs have been molded in an angular fashion on
one side of the adsorbent sheet.
[0064] FIG. 14(d) is a three-quarter side elevation view of still
another embodiment of an adsorbent sheet for use in the present
invention, in which separating ribs have been molded in an angular
fashion on both sides of the adsorbent sheet.
[0065] FIG. 14(e) is a detailed view of the adsorbent sheet
illustrated in FIG. 14(d).
[0066] FIG. 15 is a self-supported adsorbent cartridge in which
part of the adsorbent volume has been removed (for illustration
purposes) to expose the stakes securely fastening the adsorbent
sheets.
[0067] FIG. 16 is a schematic diagram of a CO.sub.2 removal system,
either a primary or a backup CO.sub.2 removal system, that uses
self-supported adsorbent cartridges shown in FIG. 15.
[0068] FIG. 17 (a)-(d) shows a more detailed view of an embodiment
of the canister of the present invention.
[0069] FIG. 18 shows another embodiment of the canister with
flexible mechanical supports.
[0070] FIG. 19 shows a graph of flow distribution through the
cartridge using different flow distributors for uniform flow.
[0071] FIG. 20 summarizes the results shown in FIG. 19 using mean
velocities and their standard deviations from different runs.
[0072] FIG. 21 shows results obtained from modeling adsorbent
system performance in a submarine.
[0073] FIG. 22 compares the capacity of CO.sub.2 removed by
different adsorbent systems as a function of time.
[0074] FIG. 23 shows the performance of the present invention in
terms of the concentrations of CO.sub.2 at the outlet of the
removal system as a function of time.
[0075] FIG. 24 depicts two non-limiting embodiments of "parallel"
surfaces (A shows two curved parallel surfaces, while B shows two
"planar" parallel surfaces). The spacers (e.g., mechanical spacers
or ribs on the surface) are not shown.
[0076] FIG. 25 depicts one non-limiting embodiment of a cartridge
wherein the fasteners are plastic or elastic bands securing the
surfaces into a shape.
[0077] Certain of the drawings illustrate the invention of a
loosely held stack of sheets installed in a canister that provides
support to these loosely held sheets. Drawings are also included to
illustrate a self-supporting stack of sheets held together with an
inexpensive endoskeleton. Like reference symbols in the various
drawings indicate like elements.
DETAILED DESCRIPTION
[0078] Existing rectangular adsorbent cartridges use rigid external
frames to hold the adsorbent together. These rigid frames add cost
and occupy valuable volume. The volume occupied by an external
frame is not available to hold adsorbent. This unique invention
eliminates the requirement for an external frame. This invention
provides a means of inexpensively and volumetrically efficiently
assembling a stack of adsorbent sheets into a cartridge. In one
embodiment the sheets are loosely secured and are placed into a
canister for operation. In a second embodiment the sheets are
firmly secured with an endoskeleton and operated in a canister or
placed directly in an airstream. The present invention provides a
gas adsorbent system that is designed to provide efficient
adsorption, uniform depletion of adsorbent material, and a minimum
pressure drop for gases passing through. A method of mechanically
securing chemically reactive adsorbent sheets to form adsorbent
cartridges that achieve optimal performance at low cost to
manufacture is also disclosed. As the mechanism for removing
gaseous contaminants from a gas is dependent on the particular
material chosen, the use of the word "adsorption" in this
specification is meant to include adsorption, absorption,
chemisorption, physisorption, catalysis, etc.
[0079] The disclosed apparatus and the method of securing chemical
reactive adsorbent sheets are well suited for operations where
power is available for generating an air stream, including, but not
limited to, enclosed spaces. Existing markets that can benefit from
the disclosed apparatus and method include, but are not limited to,
diesel-electric powered submarines, nuclear submarines, safety
shelters (CBRN--chemical, biological, radiological, and nuclear),
hyperbaric chambers, powered mine shelters, industrial gas
separation and purification processes, and other industrial gas
adsorbent systems. The disclosed apparatus and the method of
securing chemical reactive adsorbent sheets are also advantageous
in rebreather systems such as SCUBA rebreathers, personnel
protection systems and firefighter rebreathers.
[0080] Accordingly, disclosed herein, inter alia, is a gaseous
contaminant removal system, comprising:
[0081] (1) an adsorbent cartridge comprising:
[0082] a plurality of parallel, non-wound adsorbent surfaces,
mechanically spaced so as to allow gas flow between each surface in
the plurality; and
[0083] one or more fasteners, wherein the one or more fasteners
secures the plurality of said surfaces together without a rigid
shell encasing the cartridge; and
[0084] (2) a canister comprising:
[0085] an inlet through which gas can flow to contact the adsorbent
cartridge;
[0086] an outlet for gas flow; and
[0087] a plurality of support structures disposed on the interior
walls of the canister, which provide mechanical stability to the
adsorbent cartridge by restricting movement of the cartridge within
the canister during use wherein the cartridge is placed in the
canister such that the gas flow from the inlet of the canister can
flow between the adsorbent surfaces in said cartridge.
[0088] The system described utilizes a cartridge with adsorbent
surfaces for adsorbing gaseous contaminants, as well as a canister
which, in some embodiments, can provide support for the cartridge.
The cartridge and canister are described in more detail below.
[0089] 1. Adsorbent Cartridge
[0090] The present invention further provides an adsorbent
cartridge for removal of gaseous contaminants comprising:
[0091] a plurality of parallel, non-wound adsorbent surfaces,
mechanically spaced so as to allow gas flow between each surface in
the plurality; and one or more fasteners, wherein the one or more
fasteners secures the plurality of said surfaces together.
[0092] In some embodiments, the cartridge does not further comprise
a rigid shell encasing the outer surfaces of the cartridge
(exoskeleton). The term "non-wound" means that the plurality of
surfaces are not wound into a roll.
[0093] Generally, the adsorbent sheets are positioned parallel to
each other. The term "parallel" as used to describe parallel
surfaces means that each surface is substantially equidistant from
the adjacent surface. The term is not meant to limit the
embodiments to surfaces having common perpendiculars across the
whole surface, although these embodiments are included within the
phrase "parallel surfaces". FIG. 24 depicts two non-limiting
possible arrangements of surfaces within the meaning of "parallel"
surfaces. FIG. 24A shows two curved parallel surfaces, while FIG.
24B shows two planar parallel surfaces.
[0094] In some embodiments, the non-wound adsorbent surfaces are
planar. The term "planar" used to describe surfaces means that the
adsorbent surfaces are substantially without curvature (e.g., the
surfaces are not rolled). These planar adsorbent surfaces may be
flat, or pleated, or contain ribs therein. In some embodiments, the
sheets are stacked into a cube (90 degree corners on all sides but
length, width and depth may or may not be identical). The sheets
may also be stacked into cylinders or other geometries. A fixture
may be used to square up the cube. The cubic shape of the adsorbent
cartridges is optimized for storage volume efficiency. The packaged
sheet adsorbent provides approximately 33% more adsorbent mass than
granular product of similar dimensions.
[0095] Generally, the surfaces are mechanically spaced (e.g., by
ribs or other spacers, screens, etc.) where the spacers are in
contact with the next adjacent sheet. In some embodiments, the
spacers are parallel to the direction of air flow.
[0096] In some embodiments, each adsorbent surface comprises the
same type of adsorbent. In other embodiments, each adsorbent
surface is independently selected from various adsorbents.
[0097] The parallel, planar adsorbent surfaces are then
mechanically secured using one or more fasteners. The adsorbent
cartridges can be mechanically secured under two broad categories:
The fasteners may be rigid stakes disposed within the cartridge. In
some embodiments, the rigid stakes are driven into the surfaces
layers in a direction perpendicular to the top and/or bottom
absorbent sheet. In some embodiments, the fasteners comprise one or
more elastic or rigid plastic bands wrapped around the outside of
the cartridge, but not blocking the direction of gas flows (see
FIG. 25).
[0098] Self-Supported Adsorbent Cartridge
[0099] FIG. 15 shows an embodiment of a self-supported adsorbent
cartridge 141 containing adsorbent sheets 30 in which multiple
stakes 142 and 143 (8 in the embodiment depicted in FIG. 15) are
driven into the adsorbent cartridge to securely hold the chemically
reactive adsorbent sheets together. A volume 145 demarcated by
dashed lines is removed from adsorbent cartridge 141 in FIG. 15 to
expose stakes 142 and 143. These stakes enable the cartridge to
maintain its correct external dimensions while simultaneously
holding each sheet against the adjacent sheets. Alternatively, the
adsorbent sheets can be staked with a staple or staples, a wire,
rod(s), a cord, rivet(s), or elastic materials. The rigid staked
cartridge may be further wrapped with a thin polymer sleeve such
that the sleeve does not cover air inlet and outlet faces 146, 147
of the adsorbent cartridge. This thin sleeve prevents the end user
from contacting the adsorbent chemical. The sleeve provides little
or no clamping forces to hold the adsorbent cartridge together.
[0100] In some embodiments no polymer sheet is wrapped around the
cartridge. The stakes rigidly hold the sheets in place such that
sheet to sheet contact is maintained. As shown in FIG. 15, stakes
142 are inserted perpendicular to flow path 144 and additional
cartridge stability can be achieved by inserting a stake or
multiple stakes 143 at angles up to at 90 degrees with respect to
flow path 144, which reduce or eliminate flexing of the cartridge.
Air inlet face 146 and air outlet face 147 of cartridge 141 can be
reversed should the direction of flow 144 be reversed. Cartridge
141 functions similarly for airflow from both directions.
[0101] Cartridge 141 can further include a wrap of polymer foam on
four sides of the cartridge to allow for sealing when cartridge 141
is installed into a canister. The polymer foam could be installed
by itself or over or under a polymer wrap.
[0102] In another embodiment, a heavy shrink wrap (in the range of
0.020 to 0.063 inches thick, as compared to a thin wrap of a few
thousands of an inch) around the staked cartridge effects a larger
degree of clamping force. The combination of the stakes and outer
wrap enables the self-supported cartridge to maintain sheet to
sheet contact without the need for any additional external
structural support.
[0103] Loosely Secured Staked Adsorbent Cartridge
[0104] In some embodiments, the surfaces of the cartridge may be
only loosely secured together. In this case, the canister provides
mechanical stability to the cartridge during use. Accordingly, in
some embodiments, a few (e.g., 2 or 3) stakes are driven into the
adsorbent cartridge to provide structural integrity for handling
and packaging. Alternatively, the adsorbent sheets can be staked
with a staple or staples, a wire, rod(s), a cord, rivet(s), or
elastic materials. The loosely secured staked cartridge may be
wrapped in a thin polymer sleeve such that the sleeve does not
cover the air inlet and outlet faces of the cartridge. This outer
sleeve prevents the end user from contacting the adsorbent chemical
when loading the cartridge into the canister. The outer sleeve
provides minimal clamping forces to hold the cartridge together.
The stakes provide sufficient structural support to keep the
cartridge intact for installation into the canister. In some
embodiments, the stakes are placed near the center of the cartridge
surface.
[0105] Alternatively, in some embodiments, the cartridge is not
wrapped with a polymer sheet. The sheets are loosely held by stakes
inserted into the sheets.
[0106] In some embodiments, the cartridges can include a wrap of
polymer foam on four sides of the cartridge to allow for sealing
when the cartridge is installed into a canister. The foam may be
installed by itself or over/under a polymer wrap. Stakes installed
in the direction parallel to the flow stream may also be used to
join 2 or more cartridges together. Stakes can also have multiple
possible cross sections. Once the stakes are installed, the
cartridge can then be removed from the forms or tooling and be
subjected to further handling. Cartridges may be placed in
appropriate barriers/containers for their intended shelf lives to
protect the cartridges from water vapor loss or gain, and CO.sub.2
ingress from the air.
[0107] In some embodiments, the adsorbent cartridges may be
installed into a specialized canister that maintains the proper
geometry of the adsorbent. In some embodiments, high shock
mountings or shock isolators can be incorporated into the canister
for operation in hostile environments.
[0108] In some embodiments, the cartridges are deployed in the
system described herein by placement into a canister. Particular
embodiments describing the deployment of the self-supported and
loosely secured cartridge are detailed below.
[0109] 2. The Manufacture of Adsorbent Surfaces
[0110] In some embodiments, the gaseous contaminant includes, but
is not limited to, carbon dioxide. In some embodiments, the
adsorbent material used in the adsorbent surfaces includes, but is
not limited to, calcium hydroxide or lithium hydroxide.
[0111] Activated carbon can be incorporated into adsorbent surfaces
to remove volatile organic compounds (VOCs), chemical or biological
toxicants and other contaminants. Similarly, the use of lithium
hydroxide and calcium hydroxide is not limited only to the removal
of CO.sub.2, they can also remove other acidic gases such as sulfur
dioxide, hydrogen sulfide and chlorine compounds. Furthermore, the
use of desiccants such as molecular sieves in cartridges enables
the removal of moisture. Other types of molecular sieves are able
to remove CO.sub.2 and other contaminant gases.
[0112] Besides the removal of gaseous contaminants, catalysts such
as hopcalite, manganese oxide, copper oxide and precious metals can
be used to accelerate oxidation reactions of gaseous contaminants.
For example, carbon monoxide can be oxidized into carbon dioxide
which can then be removed using an adsorbent cartridge containing,
for example, LiOH or Ca(OH).sub.2.
[0113] In some embodiments, the gaseous contaminant includes, but
is not limited to, carbon dioxide (CO.sub.2), carbon monoxide (CO),
volatile organic compounds (VOCs), chemical or biological
toxicants, sulfur dioxide, hydrogen sulfide, chlorinated compounds
or water vapor.
[0114] Further description of LiOH adsorbent sheets can be found
in, for example, Hrycak et al. in U.S. Pat. No. 7,329,307 and U.S.
Pat. No. 7,326,280, each of which is incorporated herein by
reference in its entirety. Further description of Ca(OH).sub.2
adsorbent sheets and other types of adsorbent sheets can be found
in, for example, in McKenna, U.S. Pat. No. 5,964,221, which is
incorporated herein by reference in its entirety.
[0115] As illustrated in FIGS. 2 and 3, in some embodiments, the
inside hollow portion of canister 10 contains porous, liquid-water
resistant, air permeable sheets 30 that contain an adsorbent
material, which form the adsorbent cartridge. Sheets 30 are aligned
parallel to the direction of gas flow and run substantially the
length of the canister body. Gases from which contaminants (e.g.
CO.sub.2) are to be removed pass through inlet 14 of canister 10 in
FIG. 1(a), through space 34 between sheets 30, and out through
outlet 16. As gases flow past these adsorbent sheets, certain gases
will diffuse into said sheets and react with or be adsorbed by
adsorbents contained therein. Since the sheet surfaces are aligned
parallel to the gas flow, a controlled and lower pressure drop is
maintained, as well as uniform flow past all sheets, allowing for
efficient adsorption and a uniform depletion of the adsorbent
contained in sheets 30.
[0116] As shown in FIG. 2, canister 10 may contain a plurality of
porous hydrophobic, gas-permeable adsorbent sheets 30 that are
aligned so that the gas flows substantially parallel to surfaces of
sheet 30. In this embodiment, canister body 13 of FIG. 1(c) has a
rectangular cross-section. Sheets 30 are spaced apart from each
other by separating screens 32. FIG. 3 shows a detailed sectional
view of adsorbent sheets 30 and separating screens 32 where
separating screens 32 are positioned between sheets 30. The
separating screen 32 and sheets 30 are held in position parallel to
the gas flow through the canister.
[0117] FIG. 4 shows another embodiment taken along line C-C' of
FIG. 1(c) where a rectangular canister body 13 contains a sheet 30
that is "pleated" and portions of the pleated sheet are spaced
apart by separating screens 32. The separating screens 32 need not
be attached to the canister body 12 (FIG. 1(c)) or to the sheet 30.
In one embodiment shown in FIG. 5, sheet 30 is formed of an
adsorbent filled expanded porous PTFE sheet having a microstructure
of nodes 40 interconnected with fibrils 41 wherein adsorbent
material 39 is present in the voids of the PTFE structure as taught
by U.S. Pat. No. 4,985,296 issued to Mortimer, Jr., incorporated
herein by reference in its entirety. This sheet is water repellent,
but air-permeable. Ideally, particles 39 are packed in a
multi-modal (e.g., bi-modal or tri-modal) manner, with particles of
different sizes interspersed around one another to fill as much of
the available void space between particles as is possible so as to
maximize the amount of active material contained in the sheet. This
technique also allows more than one type of adsorbent particle to
be filled into a single sheet.
[0118] By using filled porous expanded polytetrafluoroethylene
(PTFE) as sheet 30, a number of additional advantages are further
imparted. Expanded PTFE is a non-limiting, non-out-gassing inert
material that effectively reduces dusting of adsorbent material
during manufacturing and during the life of the filter.
Additionally, processing advantages of this material include the
ability to make a relatively thin material that can be produced in
a wide sheet and then cut (or cut and pleated) into desired
configurations.
[0119] The properties of CO.sub.2 adsorbent filled PTFE sheet are
such that no other supporting fabric or material is needed to
maintain structural integrity. In fact, not only can this filled
PTFE sheet withstand flexing, pleating and mechanical vibration
under dry conditions, the hydrophobicity of the PTFE offers this
structural durability even while subjected to direct liquid water
contact, without water ever mixing with the CO.sub.2 adsorbent.
[0120] Another embodiment of sheet 30 is shown in FIG. 6, where
filled PTFE sheet 30 is encapsulated between two hydrophobic
gas-permeable membranes 42. These outer membranes 42 add extra
protection to ensure that adsorption material 40 is contained
within sheet 30 while preventing water from reaching the adsorbent
contained in the sheet. Membranes 42 must have a high degree of
filtration efficiency to prevent adsorbent particles from escaping
into the breathing atmosphere. These membranes 42 preferably
comprise porous expanded polytetrafluoroethylene (PTFE), because it
is hydrophobic and offers high particulate filtration
efficiency.
[0121] A third embodiment of the sheet is shown in cut-away FIG. 7
where an internal screen 43 is encapsulated by adsorbent material
39 that is surrounded by two hydrophobic gas-permeable membranes
42.
[0122] A fourth embodiment of the sheet 30 is shown in FIG. 8 where
an internal screen 44 is attached to two hydrophobic gas-permeable
membranes 42 and adsorbent material 39 is positioned in the voids
between screen members 44.
[0123] FIGS. 9 thorough 12 illustrate a method for making sheet 30
of FIG. 8 having an internal screen 44, adsorbent material 40, and
outer membranes 42. FIG. 9 depicts internal screen 44. Next, in
FIG. 10, internal screen 44 is attached to a membrane 42 by a
lamination process. Subsequently, in FIG. 11, adsorbent material 39
is added into the open cells of internal screen 44. Afterwards, in
FIG. 12, a second membrane 42 is laminated to the top of the
internal screen 44, thereby encapsulating adsorbent material 40
within.
[0124] FIG. 13 is a scanning electron micrograph of another
embodiment of sheet 30 used in the cartridges described herein.
This structure is produced by way of thermally induced phase
separation, such as in the following manner.
[0125] A water repellent polymer, such as ultra high molecular
weight polyethylene, is combined with a gas adsorbent material,
such as calcium hydroxide powder. This combination may be
accomplished by combining the two materials together in an
extruder. By conveying this mixture through the extruder and mixing
with a lubricant, such as mineral oil, the polymer dissolves in the
lubricant and become uniformly mixed with the adsorbent and
lubricant. This mixture can then be extruded into a composite sheet
or other shape.
[0126] The composite sheet may be calendared to further flatten the
sheet if desired. The lubricant may then be extracted out of the
resulting sheet using a solvent, such as hexane. The solvent may
then be removed, such as through use of a dry nitrogen purge.
[0127] The resulting structure is highly micro-porous, allowing for
the diffusion of CO.sub.2 or other gases, and yet is able to be
produced with very high adsorbent powder loadings per unit volume.
Additionally, if a very strong polymer, such as Ultra High
Molecular Weight Polyethylene is used, a very small amount of
polymer is required to make the sheet structurally stable, which
allows for even higher adsorbent loadings per unit volume. While
typical powder loadings for this type of manufacturing process are
on the order of 50 to 60% filler powder after process oil
extraction, loadings well above 60% may be possible. In some
embodiments, adsorbent loading is greater or equal to about 90% by
weight. In some embodiments, adsorbent loading is greater or equal
to about 97%. Additionally, in some embodiments, the material is
molded into any desired shape, and thus, the separating means may
be accomplished by molding separating ribs onto the surface of the
sheet.
[0128] Various embodiments of this molded structure are illustrated
in FIGS. 14(a) through 14(e). By molding the separating elements 33
(or "ribs") directly out of adsorbent material, not only is the
adsorbent cartridge easier to produce, but, because of its
self-separating properties, the total amount of adsorbent in the
filter can be increased by 10 to 30 percent. It is contemplated
that any gas adsorbent powder could be integrated for any adsorbent
application and take advantage of the invention disclosed herein
(e.g., the embodiments of the cartridge and/or system).
[0129] 3. Canister
[0130] The disclosed gas adsorbent system includes a canister that
holds the adsorbent cartridge to provide support for the structural
integrity of the cartridge during use, thereby minimizing
structural integrity requirements of the cartridge. Since a
cartridge is replaced when its active adsorbents are consumed, the
less stringent structural integrity requirements lead to lower
associated manufacturing costs. Further, because the fasteners hold
the parallel layers together without need for a rigid outer casing,
the removable cartridge provides more adsorbent in the same volume
and at a lower cost.
[0131] FIGS. 1(a)-(d) show different views of one embodiment of the
gas adsorbent canister device, indicated generally as 10. Canister
10 comprises a wall 12 defining a hollow canister body 13 that has
a gas inlet 14 and outlet 16. In addition, canister 10 has a
front/loading door 17 with a closing/locking mechanism 18. Canister
10 can be of any shape, but is preferably rectangular. FIG. 1(a)
shows the view of the canister from the side of gas inlet 14. FIG.
1(b) shows a perspective view of canister 10. Canister 10 can be
composed of a rigid material, such as stainless steel or glass
fiber reinforced plastic.
[0132] An alternative seal design uses flexible seals in the
canister to prevent or reduce air bypass. In some embodiments,
these flexible seals can be soft round polymer O-rings that line
the inner perimeter of the canister (with a necessary split for
door opening). In other embodiments, these flexible seals can
resemble wiper blades. One edge of the wiper blade is fixed to a
canister wall while a free edge can be bent upwards or downwards
such that the cartridge can form a tight fit upon contact with the
seal when inserted into the canister. Flexible seals are very
useful for cartridges that expand (for example, LiOH) or contract
during operation. These flexible seals can be used alone or in
conjunction with side rails such that the force exerted by the
canister rails and/or seals hold the adsorbent sheets in the
cartridge together.
[0133] To conform to existing (in-place) systems, the canister
could be redesigned to change the pressure drop. The addition of
orifice plates at the inlet, at the outlet or at the inlet and
outlet will increase system pressure drop and match the installed
fan performance. Sintered metal sheets or stacks of fine screens
may be used to increase pressure drop in place of orifice
plates.
[0134] In another embodiment shown in FIG. 18, canister 170
includes elastic mechanisms for securing an adsorbent cartridge.
Only components relevant to the elastic mechanisms are illustrated
in FIG. 18, hence the figure does not show, for example, an inlet
or outlet ports for gases. Canister 170 can employ spring-loaded
rails (171) to clamp the adsorbent, as depicted in the schematic
shown in FIG. 18. One end of springs 172 is attached to a side wall
174 of canister 170, and the other end to rails 171. In some
embodiments, the cartridge can be redesigned to expand into the
canister supports. LiOH cartridges can expand in volume by up to
10% during use. Canisters with elastic mechanisms are thus ideal
for providing variable amounts of mechanical force to secure the
expandable cartridge and to maintain its optimal alignment with the
gas flow during use.
[0135] Instead of the symmetric gas flow design described for the
embodiments above, in some embodiments, the canister can be
designed to allow flow in only one direction.
[0136] Multiple cartridges can be installed into another embodiment
of the canister for concurrent removal of different gases. The
multiple cartridges in the canister can be arranged to have either
parallel or serial flow. For parallel flow, 2 separate cartridges
may be installed side by side to control different contaminants.
One example is a small cartridge to covert carbon monoxide
(typically 10 ppm) to carbon dioxide and a second, much larger
cartridge to remove carbon dioxide (typically in the range of 5,000
ppm). For serial flow, cartridges of two different materials may be
installed in series. This would be useful where higher levels of
carbon monoxide (100 to 2000 ppm) are present along with carbon
dioxide. The first stage (inlet side) can convert carbon monoxide
to carbon dioxide and the second stage can remove the carbon
dioxide.
[0137] The dimensions of the adsorbent cartridge can be tailored
for a specific capacity, rate of flow or pressure drop.
[0138] Canisters may be resized to drawer dimensions for retrofit
into adsorbent systems that use granular drawers, thereby lowering
the cost of an adsorbent system upgrade.
[0139] 4. Deployment of Cartridges
[0140] Deployment of a Self-Supported Cartridge
[0141] In some embodiments, the rigidly staked cartridge is removed
from its protective packaging for installation and operation. The
cartridge may be placed into an intermediate holder to guide the
insertion of the cartridge into a canister where airflow is
directed onto the inlet face of the cartridge. This intermediate
holder may incorporate seals on the holder walls to prevent air
bypass around the cartridge. The seal does not need to provide
additional mechanical force to hold the sheets together, since
either the stakes or the combination of stakes and an outer wrap
supplies the required force. Front/loading door 17 of canister 10
is opened. The cartridge of adsorbent (with or without an
intermediate holder) is inserted into canister 10. The adsorbent
cartridge has air inlet and outlet faces 146, 147 of FIG. 15
positioned toward canister inlet 14 and outlet 16. Canister 10 may
contain sealing rails on up to four sides to prevent or reduce air
from flowing around the cartridge (by-passing).
[0142] In an alternative embodiment, the self-supported cartridge
can be inserted onto a seal installed directly in a ventilation
system for sealed environments. Examples of such sealed
environments are submarines, chemical, biological, radiological,
and nuclear (CBRN) shelters, and spacecraft. A flexible polymer
seal (such as silicone rubber) seals the cartridge at the inlet
edge, or outlet edge or along the side walls. Since the rigidly
staked cartridge is self-supporting, it can be installed directly
into the chamber and seal mechanism and be fully functional. This
application can be used, for example, as a nuclear submarine back
up CO.sub.2 control, by supplementing or replacing a malfunctioning
CO.sub.2 removal machine. The rigid adsorbent cartridge can be
directly fitted into the ventilation system to remove CO.sub.2 from
the compartment air. FIG. 16 schematically shows a CO.sub.2 removal
machine 150 having an inlet 151 that is connected to an emergency
ventilation chute 153, which has the capacity to house at least one
self-supported cartridge. Emergency ventilation chute 153 is
connected to gas outlet 152. Seals 154 are shown in FIG. 16 along
the inlet and outlet edges of the chute. During an emergency, a
self-supported adsorbent cartridge can be inserted directly into
the ventilation chute 153 to function as a backup CO.sub.2 removal
system.
[0143] Deployment of Loosely Secured Staked Cartridge
[0144] In some embodiments, the loosely secured staked cartridge is
removed from its protective packaging (for protection from water
and CO.sub.2 in the air) for installation and operation.
Front/loading door 17 of canister 10 (FIG. 17(a)-(d)) is opened.
The adsorbent cartridge is pushed into canister 10. In one
embodiment, air flows into either the top 166 or bottom 167 of
canister 10 and exits on the opposite end of canister 10. The
adsorbent cartridge has air inlet face outlet faces positioned
toward canister inlet 14 and outlet 16, respectively. As the
loosely staked cartridge is pushed into canister 10 it contacts
side rails 161, 162 and 163, these side rails push the individual
sheets of the adsorbent canister together so that each sheet
contacts the adjacent sheets for optimal performance. To ensure the
air stream passes through individual channels 131 of FIG. 14
(formed between ribs 33 and adjoining sheet as shown FIG. 14) and
does not bypass the adsorbent, in addition to side rails 161-163 of
FIG. 17(d) holding the cartridge in shape, canister 10 contains
sealing rails on four sides to prevent air from flowing around the
cartridge (by-passing). In one embodiment, metal rods are used to
form the seals.
[0145] The internal design of canister 10 provides a means of
applying proper pressure to the stack of adsorbent sheets so that
the reactant gas stream properly contacts the adsorbent sheets. By
allowing the canister to act as the mechanism for securely holding
the adsorbent sheets, the maximum amount of adsorbent can be
packaged or stored in a given volume. This high storage density is
important in applications with limited space such as submarines and
mine shelters. Another advantage of a canister that properly
supports the adsorbent is that the adsorbent stack can then be
assembled with less costly techniques. Low strength fasteners
occupying low volume within the adsorbent can be used to hold the
stacked sheets of adsorbent for handling and packaging. Stakes can
be used to hold the cartridge of adsorbent sheets providing a
practical/cost effective method of stabilizing the stack of
adsorbent. When used in combination with the canisters that
provides internal structure to support the cartridge, the
performance of the adsorbent system is optimized. The combination
of staked sheets and structural canister also produces minimal
interference with the air flowing in intimate contact with the
sheets. When specially designed adsorbent sheet or sheets like
those described above (e.g., as sold under the brand name
ExtendAir.RTM.) are used, problems such as channeling, settling and
by-passing are also eliminated. The environmental issue of disposal
of the used container is also minimized in the staked cartridge and
canister combination.
[0146] As shown in FIG. 17(a-d), canister 10 is configured to
provide mechanical stability to the adsorbent cartridge by using
springs, rods, bars or plates that restrict movement of the
adsorbent sheets. The canister's stabilizing elements (161, 162,
163) may be round, triangular or rectangular in cross section and
constructed of rigid or flexible material. The canister securely
holds the adsorbent sheet(s) so that the process air stream will
flow in a uniform fashion through the block of adsorbent. Staking
blocks of adsorbent takes very little space inside the adsorbent.
This is in contrast to conventional methods of retaining granules
inside a container, which require part of the available volume to
accommodate said container.
[0147] For canister and adsorbent sheet applications, the adsorbent
sheets may be adsorbent sheets or granule or powder enclosed in
porous sheets. Sheets may also be chemicals/catalyst/adsorbents
embedded into fibers and woven into sheets.
[0148] The invention will be described in greater detail by way of
specific examples. The following examples are offered for
illustrative purposes, and are not intended to limit the invention
in any manner. Those of skill in the art will readily recognize a
variety of non-critical parameters which can be changed or modified
to yield essentially the same results.
EXAMPLES
Example 1
Manufacture of a Loosely-Secured Cartridge
[0149] A non self-supported cartridge was manufactured using
individual sheets of adsorbent cut from a large roll of the
adsorbent material. The cartridge was 7.67 inches high by 7.70
inches deep by 5.15 inches wide and included 62 sheets; each sheet
is 7.67.+-.0.05 inches by 7.70.+-.0.05 inches by 0.082 inches thick
(including sheet and rib height)--the rib is 0.027 inches high and
0.054 inches wide with ribs spaced at 0.116 inches. The sheets were
stacked into the cube and a fixture was used to square up the cube.
The approximately 62 sheets in the cartridge were loosely secured
together by 2 4.75 inch staples driven into the cube 1/2 inch above
the center line (the staples were driven into the top sheet of the
cartridge, perpendicular to the gas flow). The 2 staples driven
into the adsorbent cartridge provide structural integrity for
handling and packaging. The loosely secured staked cartridge of
sheets was wrapped in a thin polymer sleeve such that the sleeve
did not cover the air inlet and outlet faces of the cartridge. The
outer sleeve provided minimal clamping forces to hold the cartridge
together.
Example 2
Manufacture of a Canister
[0150] FIG. 1(e) shows the dimensions of an embodiment of the
canister. The canister has a cross-sectional area of 5.23 inch by
7.75 inches and a height of 12.3 inches. The canister is fabricated
using 300 series stainless steel. The canister walls were
fabricated from a 1/8 inch plate and welded to form a box. Grooves
were cut in 2 places on 2 sides to mount the side bars (FIGS. 17(d)
161 and 163). On the front, both sides and rear walls, a groove was
cut at the center line to mount the seal bars (FIG. 17(d) 162). The
front frame was machined from an approximately 1/2 inch plate and
welded to the side walls. The door was machined from a thick
(approximately 3/4inch) plate and attached with a hinge to the
front frame. A groove was machined into the door to accommodate an
o-ring seal. This o-ring sat against the machined surface of the
door frame. The top and bottom transition pieces were made from 20
gauge stainless steel and were welded onto the side walls, front
frame and rear wall. A series of fine mesh screens (FIG. 17(d) 164)
were installed into the inlet and outlet plenums inside the
canister. The screens were identical to allow flow in either
direction. A flat disc 1.25 inches in diameter (hovering plate) was
mounted in the center of the inlet and outlet flow passages. The
combination of the flat disc (floating disc) and the screens
produced uniform flow across the adsorbent. Because the screens and
discs were the same at both ends, flow direction may be reversed
with no performance change.
[0151] The canister and adsorbent cartridge combination provides
33% more material in a volume equal to the existing granule
containers used in conventional systems. The canister and adsorbent
cartridge combination has 79% less pressure drop than 8 to 12 mesh
granules when operated at 200 liters per minute airflow. The
reduced pressure drop enables improved performance either through
increased airflow or reduced power or both. TABLE 1 shows the
change in gas pressure at different gas flow rates for both the
adsorbent cartridge system (using the 62 sheet cartridge that
occupies the same storage volume as the 8-12 mesh granule
container) and the conventional granular adsorbent systems.
TABLE-US-00001 TABLE 1 Drop in pressure as a function of different
flow rates for a system using the disclosed adsorbent cartridge and
a conventional granular adsorbent system. Flow rate (slpm) 100 150
200 250 300 Cube-shaped adsorbent cartridge dP 56 77 115 138 174
(Pascals) Granule dP (Pascals) 461 563
[0152] The adsorbent cartridge was a loosely staked 62 sheet
cartridge described in Example (1) installed in a canister
described in Example (2). The granules were 8-12 mesh tested in the
plastic container supplied for submarine applications.
[0153] The fluid (e.g. gas) flow of the adsorbent system has been
modeled in order to design an optimal flow distribution system. The
flow distribution system includes a stainless steel plate (referred
to as a hovering plate) that limits the gas flow through the center
region of the cartridge, and instead forces the airflow to be
uniformly distributed across the entire cross-sectional area of the
cartridge. The flow distribution system also includes a woven
screen placed upstream from the stainless steel plate. FIG. 19
shows a graph of flow distribution through the cartridge using
different flow distributors/diffusion panels for uniform flow. The
flow velocity in cm/s is plotted against the amount of flow in the
system (i.e. 1.0 is equivalent to 100%). The results shown for Run
2a is obtained from a flow distribution system with a hovering
plate, a screen offset of 0.5 inch and an adsorbent cartridge
mounted 0.25 inches above the screen yielded the best result from
the flow model. The curve 181 depicts the result obtained from Run
2a. Small rails on the flow distribution screen keep the cartridge
1/4inch above the screen. The hovering disc is welded in place and
the screens are fixed into the canister thus keeping the disc to
screen separation at 0.5 inches. In this case, 90% of the flow has
a flow velocity between 10 and 12 cm/s.
[0154] FIG. 20 uses the information presented in the graphs shown
in FIG. 19 and displays the data as average velocities (solid
squares) and their associated standard deviations (vertical lines
through the solid squares). The length of the vertical lines is
proportional to the magnitude of the standard deviation. Run 2a has
the smallest standard deviation, which provides another indication
of uniform airflow.
[0155] FIGS. 21-23 show results from adsorbent modeling and
testing. FIG. 21 shows the results obtained from modeling the
adsorbent system performance in a submarine. The disclosed
adsorbent system (shown by curve 2020) outperforms the conventional
granular adsorbent system by maintaining the CO.sub.2 concentration
in air to less than 1.0% for a duration of 6 hours at a flow rate
of 250 standard liters per minute (slpm), whereas the conventional
system (denoted by curve 2010) cannot maintain that level of
CO.sub.2 for more than 2.5 hours at a lower flow rate of 200 slpm.
FIG. 22 compares the capacity (in liters, L) of CO.sub.2 removed by
the adsorbent systems as a function of time. Curves 2110 and 2120
show the volume of CO.sub.2 removed by the disclosed system
operating at a flow rate of 250 slpm and 200 slpm respectively,
outperforming the conventional system operating at a flow rate of
200 slpm, represented by curve 2130. FIG. 23 shows the performance
of the disclosed system in terms of the concentration of CO.sub.2
as a function of time. Curves 2220 and 2230 show the disclosed
system operating at a flow rate of 250 slpm and 200 slpm
respectively, outperforming the conventional system (represented by
curve 2210) operating at a flow rate of 200 slpm. The disclosed
system is able to keep the CO.sub.2 level below a set level for a
longer period of time than the conventional system.
[0156] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. Accordingly, other embodiments are within
the scope of the following claims.
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