Two stage adsorbent and process cycle for fluid separations

Abstract

In various aspects, apparatuses, systems, and methods are provided for performing two stage separation of CO2 from a gaseous stream. The first stage adsorbent can be comprised of a plurality of cylindrical or substantially cylindrical rings. The first stage adsorbent can be comprised of a metal organic framework. The second stage adsorbent can be subject to a displacement desorption process. The second stage adsorbent can be comprised of a support and a metal compound selected from the group consisting of alkali or alkaline earth. The first and second stage adsorbent can be arranged concentrically for space and efficiency considerations.

Claims

1. A method for separation of CO.sub.2 from a gaseous stream, comprising contacting the gaseous stream with a first stage steam sensitive adsorbent such that CO.sub.2 is adsorbed into the first stage adsorbent and a first CO.sub.2-lean stream is formed; desorbing CO.sub.2 from the first stage adsorbent thereby forming a first CO.sub.2-rich stream; contacting the first CO.sub.2-rich stream with a second stage steam insensitive adsorbent such that CO.sub.2 is adsorbed in the second stage adsorbent and a second CO.sub.2-lean stream is formed; and desorbing CO.sub.2 from the second stage adsorbent thereby forming a second CO.sub.2-rich stream; wherein the second CO.sub.2-rich stream has a higher CO.sub.2 concentration by mol. % than the first CO.sub.2-rich stream.

2. The method of claim 1, wherein the first stage adsorbent consists of a metal organic framework.

3. The method of claim 1, wherein the second stage adsorbent comprises a support and a metal compound selected from the group consisting of alkali or alkaline earth.

4. The method of claim 1, wherein the contacting the gaseous stream and the desorbing CO.sub.2 from the first stage adsorbent steps are performed using a temperature swing process.

5. The method of claim 1, wherein the contacting the first CO.sub.2-rich stream and the desorbing CO.sub.2 from the second stage adsorbent steps are performed using a displacement process.

6. The method of claim 1, wherein the pressure of the gaseous stream is less than 2 bar.

7. The method of claim 1, wherein the temperature of the gaseous stream is between about 60 C. and 90 C.

8. The method of claim 4, wherein the temperature swing process comprises, contacting the gaseous stream with the first stage adsorbent at a first temperature, said first temperature being less than an adsorption temperature of CO.sub.2 for the first stage adsorbent, heating the first stage adsorbent with a hot purge gas, wherein the hot purge gas is at a second temperature, said second temperature being greater than a desorption temperature of CO.sub.2 for the first stage adsorbent.

9. The method of claim 8, wherein the hot purge gas comprises N.sub.2.

10. The method of claim 8, wherein the hot purge gas comprises N.sub.2 and CO.sub.2.

11. The method of claim 8, wherein the hot purge gas comprises flare gas.

12. The method of claim 8, wherein the first stage adsorbent is heated by the hot purge gas by indirect heat exchange.

13. The method of claim 8, wherein the temperature differential between the first temperature and the second temperature is less than 90 C.

14. The method of claim 8, wherein the temperature differential between the first temperature and the second temperature is less than 70 C.

15. The method of claim 8, wherein the temperature differential between the first temperature and the second temperature is less than 50 C.

16. The method of claim 8, wherein the temperature differential between the first temperature and the second temperature is less than 30 C.

17. The method of claim 5, wherein the displacement process comprises, contacting the first CO.sub.2-rich stream with the second stage adsorbent such that CO.sub.2 is adsorbed into the second stage adsorbent; and contacting the second stage adsorbent with steam such that CO.sub.2 is desorbed from the second stage adsorbent.

18. The method of claim 17, wherein CO.sub.2 is desorbed from the second stage adsorbent via one or both of concentration swing and displacement desorption.

19. The method of claim 17, wherein the displacement process is conducted at an initial temperature; wherein the initial temperature does not vary more than 10 C. during the contacting the first CO.sub.2-rich stream with the second stage adsorbent and the contacting the second stage adsorbent with steam steps.

20. The method of claim 5, wherein the contacting the first CO.sub.2-rich stream and the desorbing CO.sub.2 from the second stage adsorbent steps are performed using a displacement process; wherein the displacement process comprises, contacting the first CO.sub.2-rich stream with the second stage adsorbent such that CO.sub.2 is adsorbed into the second stage adsorbent; contacting the second stage adsorbent with steam such that CO.sub.2 is desorbed from the second stage adsorbent.

21. The method of claim 20, wherein the steam usage in moles to CO.sub.2 desorbed in moles ratios is less than 3.

22. The method of claim 1, wherein the first the first stage adsorbent is disposed radially about a central axis; wherein the first stage adsorbent has an interior surface that is a distance x from the central axis and an exterior surface that is a distance y from the central axis, wherein y is greater than x, thereby forming a void space between the central axis and the interior surface of the first stage adsorbent.

23. The method of claim 22, wherein the second stage adsorbent is disposed within the void space of the second stage adsorbent.

24. The method of claim 20, wherein the heat of condensation from the CO.sub.2 that is desorbed from the second stage adsorbent is used to heat the gaseous stream.

25. The method of claim 1, wherein the CO.sub.2 content in the gaseous stream is about 3-10 mol. %.

26. The method of claim 1, wherein the CO.sub.2 content in the first CO.sub.2-rich stream is about 20-35 mol. %.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 shows an isometric view of an apparatus embodying aspects of the current disclosure.

(2) FIG. 2 shows a flow chart for a system embodying aspects of the current disclosure.

(3) FIG. 3 shows a graph of steam usage in moles as a function of CO.sub.2 concentration.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(4) Overview

(5) As discussed above, both TSA and DD processes have shortcomings in terms of steam usage required to achieve the level of CO.sub.2 separation that is required from gaseous streams. The term steam usage is a term known to those skilled in the art. It does not refer only to steam directly flowing over the adsorbent, but also is used to describe steam used for any heating that is required during adsorption processes. Indeed, many known adsorbents in degrade if exposed to steam. If an adsorbent degrades in the presence of steam, then it is said to be steam sensitive. On the other hand, if an adsorbent is steam insensitive then it is understood to be able to generally withstand direct steam without degradation of its adsorption characteristics. This is not to say that a steam insensitive adsorbent would never degrade in the presence of steam, but rather, would not degrade beyond that which would be expected by a steam sensitive adsorbent under a purge gas other than steam.

(6) Temperature Swing Adsorption Processes

(7) Swing adsorption processes can have an adsorption step in which a feed mixture (typically in the gas phase) is flowed over an adsorbent that can preferentially adsorb a more readily adsorbed component relative to a less readily adsorbed component. A component may be more readily adsorbed because of kinetic or equilibrium properties of the adsorbent. The adsorbent is typically contained in a contactor that is part of the swing adsorption unit. In some aspects, a plurality of contactors can be used as part of a swing adsorption system. This can allow adsorption and desorption to be performed as a continuous process, with one or more contactors being used for adsorption while one or more additional contactors are used for desorption. As contactors approach maximum loading during adsorption and/or approach complete desorption under the desorption conditions, the flows to the contactors can be switched between adsorption and desorption. It is noted that after the desorption step, the adsorbent may retain a substantial loading of the gas component. In various aspects, the loading of the adsorbent with the adsorbed gas component at the end of the desorption step can be at least about 0.1 mol/kg, or at least about 0.2 mol/kg, or at least about 0.5 mol/kg, or at least about 1.0 mol/kg, and/or about 3.0 mol/kg or less, or about 2.5 mol/kg or less, or about 2.0 mol/kg or less, or about 1.5 mol/kg or less. Additionally or alternately, the loading at the end of the desorption step can be characterized relative to the loading at the end of the prior adsorption step. The loading at the end of the desorption step can be at least about 1% of the loading at the end of the prior adsorption step, or at least about 10%, or at least about 20%, or at least about 30%, or at least about 50%, and/or about 70% or less, or about 60% or less, or about 50% or less, or about 40% or less, or about 30% or less, or about 20% or less, or about 10% or less.

(8) The method of adsorbent regeneration designates the type of swing adsorption process. Pressure swing adsorption (PSA) processes rely on the fact that gases under pressure tend to be adsorbed within the pore structure of the microporous adsorbent materials. The higher the pressure, the greater the amount of targeted gas component that will be adsorbed. When the pressure is reduced, the adsorbed targeted component is released, or desorbed. PSA processes can be used to separate gases of a gas mixture because different gases tend to fill the micropore or free volume of the adsorbent to different extents due to either the equilibrium or kinetic properties of the adsorbent. TSA processes also rely on the fact that gases under pressure tend to be adsorbed within the pore structure of the microporous adsorbent materials. When the temperature of the adsorbent is increased, the adsorbed gas is released, or desorbed. By cyclically swinging the temperature of adsorbent beds, TSA processes can be used to separate gases in a mixture when used with an adsorbent that is selective for one or more of the components in a gas mixture.

(9) Temperature swing adsorption (TSA) processes, can employ an adsorbent that is repeatedly cycled through at least two stepsan adsorption step and a thermally assisted regeneration step. Regeneration of the adsorbent can be achieved by heating the adsorbent to an effective temperature to desorb target components from the adsorbent. The adsorbent can then be cooled so that another adsorption step can be completed. Such cooling may be supplied by a cooling fluid either directly or indirectly. The temperature swing adsorption process can be conducted with rapid cycles, in which case they are referred to as rapid cycle temperature swing adsorption (RCTSA). A rapid cycle thermal swing adsorption process is defined as one in which the cycle time between successive adsorption steps is less than about 10 minutes, preferably less than about 2 minutes, for example less than about 1 minute. RC-TSA processes can be used to obtain very high product recoveries in the excess of 90 vol %, for example greater than 95 vol % or, in some cases, greater than 98 vol %. The term adsorption as used herein includes physisorption, chemisorption, and condensation onto a solid support, absorption into a solid supported liquid, chemisorption into a solid supported liquid, and combinations thereof.

(10) It is noted that a TSA cycle can also typically include a change in the temperature of the adsorbent from the temperature for the adsorption step to the temperature for the desorption step. The adsorption step can be defined based on the time when the gas flow is started for the input gas containing the component for adsorption and when the gas flow is stopped. The desorption step can be defined based on the time when gas being desorbed from the adsorbent is collected to the time collection is stopped. Any time in the cycle outside of those steps can be used for additional adjustment of the adsorbent temperature.

(11) A potential advantage of a TSA separation can be that the process can be performed at a convenient pressure, or with a small amount of variation around a convenient pressure. For example, a goal of a TSA separation can be to develop a substantially pure stream of a gas component that is adsorbed and then desorbed. In this type of aspect, a convenient pressure for the desorption step can be a temperature of about 1 bar (0.1 MPa) or less. Attempting to desorb a stream at greater than about 0.1 MPa can require substantial additional temperature increase for desorption. Additionally, ambient pressure can be a convenient pressure for the adsorption step as well, as many streams containing a gas component for adsorption can correspond to waste or flue gas streams that may be at low pressure. In some aspects, the pressure difference between the adsorption and desorption steps can be about 1 MPa or less, or about 0.2 MPa or less, or about 0.1 MPa or less, or about 0.05 MPa or less, or about 0.01 MPa or less.

(12) A variety of types of solid adsorbents are available for separation of components from a gas flow using temperature swing adsorption (TSA). During a conventional TSA process, at least one component in a gas flow can be preferentially adsorbed by the solid adsorbent, resulting in a stream with a reduced concentration of the adsorbed component. The adsorbed component can then be desorbed and/or displaced from the solid adsorbent, optionally to form a stream having an increased concentration of the adsorbed component.

(13) One of the ongoing challenges with swing adsorption processes is balancing between the desire to increase the working capacity of the adsorbent and the desire to reduce the cycle time. For an idealized process, the working capacity of an adsorbent can be increased by increasing the severity of the difference between the conditions during adsorption and desorption of a target component that is adsorbed out of a gas flow. This can correspond to increasing the difference in pressure between adsorption and desorption (typically for PSA), increasing the difference in temperature between adsorption and desorption (typically for TSA), or a combination thereof.

(14) In practical application, the amount of pressure and/or temperature difference between adsorption and desorption can be limited by a desire to improve total cycle time. Increasing the differential in pressure and/or temperature between adsorption and desorption can cause a corresponding increase in the time required for transitioning between the adsorption and desorption portions of a cycle. This can include one or both of the transition from adsorption to desorption or the transition from desorption to adsorption.

(15) A further complication in swing adsorption processes can be related to achieving full working capacity and/or achieving full restoration of the adsorbent monolith to a desired state prior to the next adsorption step. Equilibrium adsorption isotherms can describe the potential working capacity that may be achieved during a full swing adsorption cycle. However, achieving a desired desorption condition does not guarantee that equilibrium is reached at that condition. For example, in temperature swing adsorption, it can be desirable to reduce or minimize the desorption temperature so long as the temperature still achieves a desired amount of desorption. This can often correspond to a temperature of less than about 200 C. At such temperatures, desorption to equilibrium values may take a long time relative to a cycle time, as random fluctuations within the temperature ensemble state may be needed to achieve desorption of individual adsorbed compounds.

(16) The problem with incomplete desorption can be further exacerbated if other fluids are present in the desorption environment. For example, one potential option for increasing the rate of temperature change during a swing adsorption process could be to use a liquid phase fluid to provide better thermal contact and/or heat capacity. However, such a fluid can potentially become trapped in the porous structures found in many adsorbents. Simply increasing the temperature of the adsorbent monolith to the desorption temperature may be insufficient to dislodge such fluids that are within the pores of the adsorbent.

(17) In various aspects, the above difficulties with balancing the driving force for desorption with the desire for shorter cycle times can be reduced, mitigated, or minimized by not to operating the TSA process to the full capacity of the adsorbent bed. In other words, the TSA process can be used as a concentrator to form a CO.sub.2-rich stream to be further separated by a second stage adsorption process. This reduces the heat of adsorption in the TSA process and also decreases the steam usage required to regenerate the adsorbent.

(18) Displacement Adsorption/Desorption Processes

(19) Displacement Adsorption/Desorption (DD) processes employ gas-solids contactors in which the sorbent is alternately exposed to the feed gas and to steam wherein the gas and steam are essentially at the same temperature. In the steaming step the carbon dioxide adsorbed from the gas is released from the sorbent by a combination of concentration swing and desorptive displacement, thereby regenerating the sorbent for re-use. No external application or removal of heat is used, and the process operates at essentially constant pressure. The process is notably identifiable and distinguishable and beneficial as compared to pressure swing or partial pressure swing separation in that during the adsorption of CO.sub.2 the bed temperature decreases below the average bed temperature as determined over the entire cycle and during CO.sub.2 displacement/desorption the bed temperature increases above the average. The process is further distinguished and beneficial as compared to thermal swing separation in that no external heat is applied and the desorption gas, steam, is essentially isothermal with the feed gas. The gas-solids contactors may use moving solid sorbents, or solid sorbents contained in packed beds or in parallel-channel beds (monoliths). The packed bed or monoliths can be rotating or stationary. To permit continuous flow of inlet and outlet streams, multiple beds can be combined with appropriate valving to switch individual beds between adsorption and desorption. Such multiple bed arrangements can be operated to achieve counter-current staging. The water and energy from the regeneration steam can be recaptured after use and recycled back into the process.

(20) Some DD regeneration processes use contact with steam to remove the adsorbed gas from the sorbent. The regeneration mechanism can be by a combination of concentration swing and desorptive displacement of the adsorbed gas with steam. The disclosure can further relate to a method to recycle the steam and recover its energy through a multi-stage condenser/heat exchangers system. The advantage of this option is that it increases system efficiency.

(21) DD processes can be used for removal of CO.sub.2 from a combustion flue gas or natural gas stream or other streams. An advantage is that the adsorbent can be rapidly regenerated essentially isothermally with steam and discharge a moist CO.sub.2 stream wherein the CO.sub.2 concentration is higher than that in the original feed gas. Another advantage of the sorbent is that it can be used in an adiabatic reactor design. The sorbent adsorbs water during regeneration with steam and then desorbs water during CO.sub.2 adsorption so that the net reactions are exothermic during steaming and endothermic during adsorption. In this way the system does not require external thermal management on the adsorber and regenerator beds. This modest temperature swing is also important because it thermally assists both adsorption and desorption, again without the addition of external thermal management.

(22) High process efficiency can be important in order for CO.sub.2 capture to be economical. The regeneration system can be designed to recycle the steam and recover its energy.

(23) The process can be carried out in a cyclic adsorption/regeneration cycle and can include various intermediate purges and stream recycles. Such a process can be performed with co-directional flow of the feed gas and regeneration steam, but can be preferably performed with counter-current feed adsorption/steam regeneration steam flows.

(24) The process can include the steps of passing a gas stream comprising CO.sub.2 over a sorbent to adsorb the CO.sub.2 to the sorbent, and then recovering the CO.sub.2 by desorbing the CO.sub.2 from the sorbent. As noted above, and discussed in more detail below, the adsorption/desorption process can be based on concentration swing and desorptive displacement. Concentration swing adsorption (CSA) processes including the adsorption and desorption steps are governed by change in fugacity of the adsorbate, in this case, CO.sub.2, in the gas stream, in comparison to the adsorbent. The adsorbate, in this case CO.sub.2, is adsorbed when its fugacity is high in the gas stream and low in the adsorbent. Conversely, it is desorbed when its fugacity is reduced in the gas stream relative to the amount in the adsorbent. By way of example, an adsorbent having a high level of CO.sub.2 might still adsorb additional CO.sub.2 when the gas stream has a relatively higher fugacity of CO.sub.2 versus the adsorbent. And an adsorbent having a low level of CO.sub.2 can adsorb CO.sub.2 when the gas stream has a low fugacity of CO.sub.2 so long as the relative fugacity of CO.sub.2 in the sorbent is still lower than the CO.sub.2 in the gas stream. One of ordinary skill in the art would also recognize that relative fugacity does not imply relative concentration in the absolute value sense, i.e. does not mean that a 2% adsorbed CO.sub.2 content is necessarily larger than a 1% CO.sub.2 gas level, because the ability of the gas to retain CO.sub.2 versus the ability of adsorbent to adsorb additional CO.sub.2 will be governed by various equilibrium relationships.

(25) DD processes also include desorbing the CO.sub.2 from the sorbent. This step might also be referred to as a regeneration step because the sorbent is regenerated for the next passage of a CO.sub.2 gas stream across the sorbent. The desorption of CO.sub.2 from the sorbent comprises treating the sorbent with steam. This desorption step can be driven by a one or more forces. One desorption force is concentration swing, as with the adsorption step above. The partial pressure of CO.sub.2 in the incoming steam is nearly zero, and thus the adsorbed CO.sub.2 can shift to the steam phase. The second desorption force is desorption by displacement. The water molecules in the steam can adsorb onto the sorbent and displace the CO.sub.2 from the sorbent.

(26) As an optional step, the processes, methods and systems of the disclosure can also include one or more purging step, in which a non-adsorbent gas, i.e. not steam or a CO.sub.2 feed stream, can be passed across the sorbent. The gas can be any gas known to one or ordinary skill in the art, such as for example an inert gas or air. In an embodiment, the purge gas can be a nitrogen stream, an air stream, or a dry air stream. Alternatively the purge gas can be a CO.sub.2 feed gas or steam that is recycled into a process step. The purge step can be conducted at any time. For example, prior to the passing of the CO.sub.2 feed stream across the sorbent, a purge gas can be passed to remove residual and adsorbed water vapor. This purge gas can be run back into the regeneration side in order for the water vapor to be readsorbed onto the regeneration side. The purging step can also occur between the adsorption step or steps, and the desorption or regeneration step or steps. The purge gas can be non-reactive, but can still optionally remove adsorbed CO.sub.2 from a sorbent based on concentration swing. Thus, in an embodiment, the purging step can be conducted after adsorption steps, and can be conducted to remove residual gas prior to desorption, which can be optionally recycled into the process. Moreover, the purge step can also be optionally diverted into two streams: 1) an initial purge stream to remove the first gas, and 2) a separate purge stream that can contain the initial purified or desorbed CO.sub.2, which could be optionally captured as part of the final product stream. Furthermore, in an embodiment, a purging step can be conducted after the desorption or regeneration step(s) is complete, thereby optionally removing residual water and/or steam which can be recycled back into the process. Each purging step can thereby reduce an excess gas stream which can, for example lead to a more efficient process or produce a more CO.sub.2 enriched product stream because a final product stream is not diluted by a preceding gas source. By way of specific example, a purging step conducted after the initial adsorption can remove residual, dilute CO.sub.2 feed stream, leading to a more concentrated CO.sub.2 product stream. The resulting gas stream from the purging step can be recycled into the system, or split into a recycle and a product stream.

(27) Additionally, different separations processes are more effective at different concentrations of adsorbate in a feed. Specifically, TSA processes are generally more effective at lower adsorbate concentrations, while DD processes are generally more effective at higher adsorbate concentration. For example, in FIG. 3 shows graph of steam usage in moles as a function of CO.sub.2 concentration for a single stage displacement process. As shown, as CO.sub.2 loading increases, the amount of steam usage decreases. In other words, displacement processes have been shown to be more efficient when there is a higher concentration of CO.sub.2 in the incoming feed.

(28) Different processes likewise have disadvantages. In DD processes when CO.sub.2 concentration in the incoming feed is at lower levels, the amount of steam required to separate the CO.sub.2 to an acceptable level is cost prohibitive. Regarding TSA processes, adsorption is exothermic. In many TSA adsorbents, especially in certain metal organic frameworks (MOFs), the amount of heat generated when loading the adsorbent to capacity is unacceptable. McDonald et al. (519 NATURE 303, 307) explain, Because of the exothermic nature of all adsorption processes, the incorporation of labour and material intensive coolant pipes into an adsorbent bed (a component of the considerable infrastructure cost for carbon capture) is necessary to maintain isothermal adsorption conditions . . . . The physical size of adsorption units is dictated, to a great extent, by the need to provide sufficient contact area between the coolant and sorbent for effective heat removal.

(29) Examples of Adsorbent Structures

(30) In various aspects, an adsorbent structure can correspond to a contactor for use in a swing adsorption vessel. More generally, in this discussion an adsorbent structure can correspond to any type of structure, either rigid or non-rigid, that includes or incorporates an adsorbent suitable for adsorption of a gas component during a swing adsorption process. This can include conventional contactor adsorbent structures, such as parallel plate contactors, adsorbent monoliths, and other conventional structures. This can also include non-rigid structures, such as flexible, curtain-like, and/or fabric-like adsorbents that may be able to exhibit larger amplitude fluctuations in position in response to an induced vibration. Still other adsorbent structures can correspond to beds of adsorbent particles, either in a conventional adsorbent bed configuration or in a non-traditional configuration, such as use of bed of adsorbent particles under trickle flow conditions.

(31) A variety of contactors corresponding to adsorbent structures are known, such as the contactors (adsorbent structures) described in U.S. Patent Application Publication 2008/0282892, the entirety of which is incorporated herein by reference. For example, FIG. 1 hereof is a representation of a parallel channel contactor of the present disclosure in which the parallel channels are formed from laminated sheets containing adsorbent material. Laminates, laminates of sheets, or laminates of corrugated sheets can be used in pressure and/or temperature swing adsorption processes. Laminates of sheets are known in the art and are disclosed in U.S. patent applications US20060169142 A1 and U.S. Pat. No. 7,094,275 B2. When the adsorbent is coated onto a geometric structure or components of a geometric structure that are laminated together, the adsorbent can be applied using any suitable liquid phase coating techniques. Non-limiting examples of liquid phase coating techniques that can be used in the practice of the present disclosure include slurry coating, dip coating, slip coating, spin coating, hydrothermal film formation and hydrothermal growth. When the geometric structure is formed from a laminate, the laminate can be formed from any material to which the adsorbent of the present disclosure can be coated. The coating can be done before or after the material is laminated. In all these cases the adsorbent is coated onto a material that is used for the geometric shape of the contactor. Non-limiting examples of such materials include glass fibers, milled glass fiber, glass fiber cloth, fiber glass, fiber glass scrim, ceramic fibers, metallic woven wire mesh, expanded metal, embossed metal, surface-treated materials, including surface-treated metals, metal foil, metal mesh, carbon-fiber, cellulosic materials, polymeric materials, hollow fibers, metal foils, heat exchange surfaces, and combinations of these materials. Coated supports typically have two major opposing surfaces, and one or both of these surfaces can be coated with the adsorbent material. When the coated support is comprised of hollow fibers, the coating extends around the circumference of the fiber. Further support sheets may be individual, presized sheets, or they may be made of a continuous sheet of material. The thickness of the substrate, plus applied adsorbent or other materials (such as desiccant, catalyst, etc.), typically ranges from about 10 micrometers to about 2000 micrometers, more typically from about 150 micrometers to about 300 micrometers.

(32) In various aspects, the present disclosure eliminates many of the inefficiencies contained in the prior art as can be seen with reference to FIG. 1 and FIG. 2. As shown therein, a two stage adsorbent contactor is provided. Gaseous stream 101 enters the first stage adsorbent 102 as shown. Gaseous stream 101 can be, for example, a flue gas from a natural gas or coal-fired power plant. Such flue gasses generally contain between 3-7 mol. % CO.sub.2 (for natural gas plants) or between 10-20 mol. % CO.sub.2 (for coal-fired plants). Such streams are generally between 60 C. and 90 C. and are at low pressuresi.e. 2 bar or less. First stage adsorbent 102 is preferably a steam sensitive adsorbent. Within first stage adsorbent 102, there can be a plurality of cylindrical or substantially cylindrical rings 105. Said cylindrical or substantially cylindrical rings 105 contain gas permeable walls such that gaseous stream 101 is permitted to permeate different rings 105 within first stage adsorbent 102. The first stage adsorbent 102 can be comprised of a MOF. Additionally or alternatively, the first stage adsorbent 102 is disposed radially about a central axis; wherein the first stage adsorbent has an interior surface that is a distance x from the central axis and an exterior surface that is a distance y from the central axis, wherein y is greater than x, thereby forming a void space between the central axis and the interior surface of the first stage adsorbent.

(33) Also provided is second stage adsorbent 103. Second stage adsorbent 103 is preferably steam insensitive. Within second stage adsorbent 103, there can be a plurality of cylindrical or substantially cylindrical rings 106. Said cylindrical or substantially cylindrical rings 106 contain gas permeable walls such that a first CO.sub.2-rich stream is permitted to permeate different rings 106 within second stage adsorbent 103. The second stage adsorbent 103 can comprise a support and a metal compound selected from the group consisting of alkali or alkaline earth. Additionally or alternatively, second stage adsorbent 103 is disposed within the void space of the first stage adsorbent 102 when the first stage adsorbent 102 is disposed radially about a central axis; wherein the first stage adsorbent has an interior surface that is a distance x from the central axis and an exterior surface that is a distance y from the central axis, wherein y is greater than x, thereby forming a void space between the central axis and the interior surface of the first stage adsorbent 102.

(34) FIG. 2 illustrates an example process utilizing the apparatus described above is illustrated. Gaseous stream 201 enters first stage adsorbent 202. Gaseous stream 201 is subjected to a TSA process with first stage adsorbent 202 such that a first CO.sub.2-lean stream 208 is formed during the adsorption phase, which is comprised nearly entirely of nitrogen. CO.sub.2 is then desorbed from first stage adsorbent 202 using a hot purge gas thereby forming a first CO.sub.2-rich stream 207. In one aspect, the CO.sub.2 content of the gaseous stream 201 is between 3-20 mol. %. In another aspect, the CO.sub.2 content of the first CO.sub.2-rich stream 207 is about 20-35 mol. %. In another aspect, the TSA process comprises contacting the gaseous stream 201 with the first stage adsorbent 202 at a first temperature, said first temperature being less than an adsorption temperature of CO.sub.2 for the first stage adsorbent 202, heating the first stage adsorbent 202 with a hot purge gas, wherein the hot purge gas is at a second temperature, said second temperature being greater than a desorption temperature of CO.sub.2 for the first stage adsorbent 202. In another aspect of the TSA process the hot purge gas comprises N.sub.2, CO.sub.2, or flare gas, such as methane. In another aspect of the TSA process, the temperature differential between the first temperature and the second temperature is less than 90 C., less than 70 C., less than 50 C., less than 30 C., or less than 20 C. In another aspect, the first stage adsorbent 202 is heated by the hot purge gas by indirect heat exchange.

(35) In another aspect, the method comprises contacting the first CO.sub.2-rich stream 207 with a second stage adsorbent 203 such that CO.sub.2 is adsorbed in the second stage adsorbent 203 and a second CO.sub.2-lean 209 stream is formed. In another aspect, the method comprises desorbing CO.sub.2 from the second stage adsorbent thereby forming a second CO.sub.2-rich stream 210; wherein the second CO.sub.2-rich stream 210 has a higher CO.sub.2 concentration by mol. % than the first CO.sub.2-rich stream 207.

(36) As shown in FIG. 2, the contacting the first CO.sub.2-rich stream 207 and the desorbing CO.sub.2 from the second stage adsorbent 203 steps are performed using a displacement process, wherein the displacement process comprises, contacting the first CO.sub.2-rich stream 207 with the second stage adsorbent 203 such that CO.sub.2 is adsorbed into the second stage adsorbent 203; and contacting the second stage adsorbent 203 with steam such that CO.sub.2 is desorbed from the second stage adsorbent 203. In another aspect, CO.sub.2 is desorbed from the second stage adsorbent 203 via one or both of concentration swing and displacement desorption. In another aspect, the displacement process is conducted at an initial temperature; wherein the initial temperature does not vary more than 10 C. during the contacting the first CO.sub.2-rich stream with the second stage adsorbent 203 and the contacting the second stage adsorbent 203 with steam steps.

(37) In another aspect, the temperature swing process and displacement process described above are used as the first and second stage adsorption/desorption processes, respectively. In another aspect, the ratio of steam usage in moles to CO.sub.2 recovered in moles is less than 3. In another aspect, the heat of condensation from the CO.sub.2 that is desorbed from the second stage adsorbent is used to heat the gaseous stream.

(38) With reference to FIG. 1, it is to be understood that the flow path of the various feed and product streams disclosed herein, such as those depicted in as product streams 104, and the associated headers, valve manipulations, etc. would be readily recognizable to one of ordinary skill in the art. Accordingly, such mechanisms are not shown in the figures for simplicity.

Additional Embodiments

(39) Additionally or alternately, the present disclosure can include one or more of the following embodiments.

Embodiment 1

(40) An adsorbent contactor for separation of CO.sub.2 from a gaseous stream, comprising a first stage adsorbent, said first stage adsorbent being steam sensitive; and a second stage adsorbent, said second stage adsorbent being steam insensitive.

Embodiment 2

(41) The adsorbent contactor of embodiment 1, wherein the first stage adsorbent comprises a metal organic framework.

Embodiment 3

(42) The adsorbent contactor of embodiment 1 or 2, wherein the second stage adsorbent comprises a support and a metal compound selected from the group consisting of alkali or alkaline earth.

Embodiment 4

(43) The adsorbent contactor of any of the previous embodiments, wherein the first stage adsorbent is disposed radially about a central axis; wherein the first stage adsorbent has an interior surface that is a distance x from the central axis and an exterior surface that is a distance y from the central axis, wherein y is greater than x, thereby forming a void space between the central axis and the interior surface of the first stage adsorbent.

Embodiment 5

(44) The adsorbent contactor of embodiment 4, wherein the second stage adsorbent is disposed within the void space of the first stage adsorbent.

Embodiment 6

(45) The adsorbent contactor of any of the previous embodiments, wherein the first stage adsorbent and the second stage adsorbents comprise a plurality of cylindrical or substantially cylindrical adsorbent beds, wherein the walls of the plurality of cylindrical or substantially cylindrical adsorbent beds are gas permeable.

Embodiment 7

(46) The adsorbent contactor of any of the previous embodiments, wherein the first stage adsorbent comprises a metal organic framework and the second stage adsorbent comprises a support and a metal compound selected from the group consisting of alkali or alkaline earth.

Embodiment 8

(47) A method for separation of CO.sub.2 from a gaseous stream, comprising contacting the gaseous stream with a first stage steam sensitive adsorbent such that CO.sub.2 is adsorbed into the first stage adsorbent and a first CO.sub.2-lean stream is formed; desorbing CO.sub.2 from the first stage adsorbent thereby forming a first CO.sub.2-rich stream; contacting the first CO.sub.2-rich stream with a second stage steam insensitive adsorbent such that CO.sub.2 is adsorbed in the second stage adsorbent and a second CO.sub.2-lean stream is formed; and desorbing CO.sub.2 from the second stage adsorbent thereby forming a second CO.sub.2-rich stream; wherein the second CO.sub.2-rich stream has a higher CO.sub.2 concentration by mol. % than the first CO.sub.2-rich stream.

Embodiment 9

(48) The method of embodiment 8, wherein the first stage adsorbent consists of a metal organic framework.

Embodiment 10

(49) The method of embodiment 8 or 9, wherein the second stage adsorbent comprises a support and a metal compound selected from the group consisting of alkali or alkaline earth.

Embodiment 11

(50) The method of any of embodiments 8-10, wherein the contacting the gaseous stream and the desorbing CO.sub.2 from the first stage adsorbent steps are performed using a temperature swing process.

Embodiment 12

(51) The method of any of embodiments 8-11, wherein the contacting the first CO.sub.2-rich stream and the desorbing CO.sub.2 from the second stage adsorbent steps are performed using a displacement process.

Embodiment 13

(52) The method of any of embodiments 8-12, wherein the pressure of the gaseous stream is less than 2 bar.

Embodiment 14

(53) The method of any of embodiments 8-13, wherein the temperature of the gaseous stream is between about 60 C. and 90 C.

Embodiment 15

(54) The method of any of embodiments 8-14, wherein the temperature swing process comprises, contacting the gaseous stream with the first stage adsorbent at a first temperature, said first temperature being less than an adsorption temperature of CO.sub.2 for the first stage adsorbent, heating the first stage adsorbent with a hot purge gas, wherein the hot purge gas is at a second temperature, said second temperature being greater than a desorption temperature of CO.sub.2 for the first stage adsorbent.

Embodiment 16

(55) The method of embodiment 15, wherein the hot purge gas comprises N.sub.2.

Embodiment 17

(56) The method of embodiments 15 or 16, wherein the hot purge gas comprises N.sub.2 and CO.sub.2.

Embodiment 18

(57) The method of any of embodiments 15-17, wherein the hot purge gas comprises flare gas, such as methane.

Embodiment 19

(58) The method of any of embodiments 15-18, wherein the first stage adsorbent is heated by the hot purge gas by indirect heat exchange.

Embodiment 20

(59) The method of embodiment 15, wherein the temperature differential between the first temperature and the second temperature is less than 90 C.

Embodiment 21

(60) The method of embodiment 15, wherein the temperature differential between the first temperature and the second temperature is less than 70 C.

Embodiment 22

(61) The method of embodiment 15, wherein the temperature differential between the first temperature and the second temperature is less than 50 C.

Embodiment 23

(62) The method of embodiment 15, wherein the temperature differential between the first temperature and the second temperature is less than 30 C.

Embodiment 24

(63) The method of embodiment 12, wherein the displacement process comprises, contacting the first CO.sub.2-rich stream with the second stage adsorbent such that CO.sub.2 is adsorbed into the second stage adsorbent; and contacting the second stage adsorbent with steam such that CO.sub.2 is desorbed from the second stage adsorbent.

Embodiment 25

(64) The method of any of embodiments 12-24, wherein CO.sub.2 is desorbed from the second stage adsorbent via one or both of concentration swing and displacement desorption.

Embodiment 26

(65) The method of any of embodiments 12-24, wherein the displacement process is conducted at an initial temperature; wherein the initial temperature does not vary more than 10 C. during the contacting the first CO.sub.2-rich stream with the second stage adsorbent and the contacting the second stage adsorbent with steam steps.

Embodiment 27

(66) The method of embodiment 11, wherein the contacting the first CO.sub.2-rich stream and the desorbing CO.sub.2 from the second stage adsorbent steps are performed using a displacement process; wherein the displacement process comprises, contacting the first CO.sub.2-rich stream with the second stage adsorbent such that CO.sub.2 is adsorbed into the second stage adsorbent; contacting the second stage adsorbent with steam such that CO.sub.2 is desorbed from the second stage adsorbent.

Embodiment 28

(67) The method of any of embodiments 8-27, wherein the steam usage in moles to CO.sub.2 desorbed in moles ratios is less than 3.

Embodiment 29

(68) The method of any of embodiments 8-28, wherein the first the first stage adsorbent is disposed radially about a central axis; wherein the first stage adsorbent has an interior surface that is a distance x from the central axis and an exterior surface that is a distance y from the central axis, wherein y is greater than x, thereby forming a void space between the central axis and the interior surface of the first stage adsorbent.

Embodiment 30

(69) The method of any of embodiments 8-29, wherein the second stage adsorbent is disposed within the void space of the second stage adsorbent.

Embodiment 31

(70) The method of any of embodiments 8-30, wherein the heat of condensation from the CO.sub.2 that is desorbed from the second stage adsorbent is used to heat the gaseous stream.

Embodiment 32

(71) The method of any of embodiments 8-31, wherein the CO.sub.2 content in the gaseous stream is about 3-10 mol. %.

Embodiment 33

(72) The method of any of embodiments 8-32, wherein the CO.sub.2 content in the first CO.sub.2-rich stream is about 20-35 mol. %.

Embodiment 34

(73) A system for separation of CO.sub.2 from a gaseous stream, comprising; a first stage adsorbent, said first stage adsorbent being steam sensitive; wherein said first adsorbent is subject to a temperature swing process, said temperature swing process comprising, contacting the gaseous stream with the first stage adsorbent at a first temperature, said first temperature being less than an adsorption temperature of CO.sub.2 for the first stage adsorbent, heating the first stage adsorbent with a hot purge gas, wherein the hot purge gas is at a second temperature, said second temperature being greater than a desorption temperature of CO.sub.2 for the first stage adsorbent, thereby forming a first CO.sub.2-rich stream and a first CO.sub.2-lean stream; a second stage adsorbent, said second stage adsorbent being steam insensitive; wherein said second stage adsorbent is subject to a displacement process, said displacement process comprising, contacting the first CO.sub.2-rich stream with the second stage adsorbent such that CO.sub.2 is adsorbed into the second stage adsorbent; contacting the second stage adsorbent with steam such that CO.sub.2 is desorbed from the second stage adsorbent, thereby forming a second CO.sub.2-rich stream and a second CO.sub.2-lean stream; wherein the second CO.sub.2-rich stream has a higher CO.sub.2 concentration by mol. % than the first CO.sub.2-rich stream.

Embodiment 35

(74) The system of embodiment 34, wherein the first stage adsorbent is disposed radially about a central axis; wherein the first stage adsorbent has an interior surface that is a distance x from the central axis and an exterior surface that is a distance y from the central axis, wherein y is greater than x, thereby forming a void space between the central axis and the interior surface of the first stage adsorbent.

Embodiment 36

(75) The system of embodiment 34 and 35, wherein the second stage adsorbent is disposed within the void space of the first stage adsorbent.

Embodiment 37

(76) The system any of embodiments 34-36, wherein the first stage adsorbent and the second stage adsorbents comprise a plurality of cylindrical or substantially cylindrical adsorbent beds, wherein the walls of the plurality of cylindrical or substantially cylindrical adsorbent beds are gas permeable.

(77) Although the present disclosure has been described in terms of specific embodiments, it is not so limited. Suitable alterations/modifications for operation under specific conditions should be apparent to those skilled in the art. It is therefore intended that the following claims be interpreted as covering all such alterations/modifications as fall within the true spirit/scope of the disclosure.

(78) Examples of CO.sub.2 Concentration in First Stage Adsorben

(79) The following calculations are based on sophisticated modeling techniques, which mimic CO.sub.2 concentration that would occur during a first stage adsorption process of the present disclosure.

Example 1

(80) A high capacity MOF adsorbent was subjected to a thermal swing cycle which consisted of the consecutive steps of feeding a bed of said adsorbent with dimensions 1 sq. m cross-section and 2 m length, with 0.045 kg/s of flue gas containing 6% CO2 at 80 C. for 150 s, regenerating with countercurrent hot N.sub.2 at 120 deg C. for 180 s followed by cooling with countercurrent N.sub.2 at 80 deg C. for 60 s. The process is made continuous by using 3 beds that are run out of phase with each other, such that one bed is one feed while the other two beds are being either regenerated or cooled. Computer simulations of the cyclic process, using properties of the specified MOF adsorbent show that a combined product from both heating and cooling steps containing 22.7% CO.sub.2 is produced. Simultaneously a purified N.sub.2 product (or green flue gas) is produced containing 99.9% N.sub.2. The recovery of the CO.sub.2 is 98.3% from this first stage of the hybrid contactor.

(81) TABLE-US-00001 Feed Heat Cool N.sub.2 product CO.sub.2 product Moles 232.97 38.53 10.71 221.10 60.63 CO.sub.2 fraction 0.060 0.001 0.000 0.001 0.227 N.sub.2 fraction 0.940 0.999 1.000 0.999 0.773

Example 2

(82) A high capacity MOF adsorbent was subjected to a thermal swing cycle which consisted of the consecutive steps of feeding a bed of said adsorbent with dimensions 1 sq. m cross-section and 2 m length, with 0.04 kg/s of flue gas containing 6% CO.sub.2 at 70 deg C. for 180 s, regenerating with countercurrent hot N.sub.2 at 110 deg C. for 240 s followed by cooling with countercurrent N.sub.2 at 70 deg C. for 120 s. The process is made continuous by using 3 beds that are run out of phase with each other, such that one bed is one feed while the other two beds are being either regenerated or cooled. Computer simulations of the cyclic process, using properties of the specified MOF adsorbent show that a combined product from both heating and cooling steps containing 22.2% CO.sub.2 is produced. Simultaneously a purified N.sub.2 product (or green flue gas) is produced containing 99.9% N.sub.2. The recovery of the CO.sub.2 is 99.9% from this first stage of the hybrid contactor.

(83) TABLE-US-00002 Feed Heat Cool N.sub.2 product CO.sub.2 product Moles 248.51 34.25 21.42 236.22 67.68 CO.sub.2 fraction 0.060 0.001 0.000 0.0004 0.222 N.sub.2 fraction 0.940 0.999 1.000 0.999 0.778

Example 3

(84) A high capacity MOF adsorbent was subjected to a thermal swing cycle which consisted of the consecutive steps of feeding a bed of said adsorbent with dimensions 1 sq. m cross-section and 2 m length, with 0.045 kg/s of flue gas containing 6% CO.sub.2 at 80 deg C. for 150 s, regenerating with countercurrent hot N.sub.2 at 120 deg C. for 240 s followed by cooling with countercurrent N.sub.2 at 80 deg C. for 60 s. The process is made continuous by using 3 beds that are run out of phase with each other, such that one bed is one feed while the other two beds are being either regenerated or cooled. Computer simulations of the cyclic process, using properties of the specified MOF adsorbent show that a combined product from both heating and cooling steps containing 22.2% CO.sub.2 is produced. Simultaneously a purified N2 product (or green flue gas) is produced containing 99.8% N.sub.2. The recovery of the CO.sub.2 is 97.1% from this first stage of the hybrid contactor.

(85) TABLE-US-00003 Feed Heat Cool N.sub.2 product CO.sub.2 product Moles 232.97 38.53 10.70 220.97 61.23 CO.sub.2 fraction 0.060 0.001 0.001 0.0018 0.222 N.sub.2 fraction 0.940 0.999 0.999 0.998 0.778

Example 4

(86) A lower capacity MOF adsorbent was subjected to a thermal swing cycle which consisted of the consecutive steps of feeding a bed of said adsorbent with dimensions 1 sq. m cross-section and 3 m length, with 0.02 kg/s of flue gas containing 6% CO.sub.2 at 80 deg C. for 180 s, regenerating with concurrent hot CO.sub.2/N.sub.2 mixture at 100 deg C. for 90 s followed by concurrent hot CO.sub.2/N.sub.2 mixture at 130 deg C. for 90 s, subsequently conducting countercurrent pure N.sub.2 at 130 deg C. for 90 s, followed by cooling with countercurrent N.sub.2 for 90 s. The process is made continuous by using 3 beds that are run out of phase with each other, such that one bed is one feed while the other two beds are being either regenerated or cooled. Computer simulations of the cyclic process, using properties of the specified lower capacity MOF adsorbent (ref. 2) show that a combined product from all staged the three staged heating steps and the cooling step contains 33.4% CO.sub.2. Simultaneously a purified N.sub.2 product (or green flue gas) is produced containing 99.4% N.sub.2. The recovery of the CO.sub.2 is 86.5% from this first stage of the hybrid contactor after accounting for the amounts of 50% CO.sub.2/N.sub.2 streams used in the staged heating steps which are recycled into the process.

(87) TABLE-US-00004 N.sub.2 CO.sub.2 Feed Heat-1 Heat-2 Heat-3 Cool product product Moles 124.25 24.99 24.99 64.25 32.13 176.32 94.13 CO.sub.2 fraction 0.06 0.5 0.5 0.000 0.000 0.006 0.334 N.sub.2 fraction 0.94 0.5 0.5 1.000 1.000 0.994 0.666

Example 5

(88) A high capacity MOF adsorbent was subjected to a thermal swing cycle which consisted of the consecutive steps of feeding a bed of said adsorbent with dimensions 1 sq. m cross-section and 2.5 m length, with 0.03 kg/s of flue gas containing 14% CO.sub.2 at 100 deg C. for 60 s, regenerating with countercurrent hot N.sub.2 at 120 deg C. for 120 s followed by cooling with countercurrent N.sub.2 at 100 deg C. for 60 s. The process is made continuous by using 4 beds that are run out of phase with each other, such that one bed is one feed while the other two beds are being either regenerated or cooled. Computer simulations of the cyclic process, using properties of the specified MOF adsorbent show that a combined product from both heating and cooling steps containing 20.3% CO.sub.2 is produced. Simultaneously a purified N.sub.2 product (or green flue gas) is produced containing 99.93% N.sub.2. The recovery of the CO.sub.2 is 98.3% from this first stage of the hybrid contactor.

(89) TABLE-US-00005 Feed Heat Cool N.sub.2 product CO.sub.2 product Moles 59.50 25.69 10.70 54.70 40.34 CO.sub.2 fraction 0.140 0.001 0.001 0.0007 0.203 N.sub.2 fraction 0.860 0.999 0.999 0.9993 0.797