Search NASA⌕ Search

Engineering topics

Realff, Matthew

Publications and source records attributed to Realff, Matthew.

Demonstration of a Continuous Motion Direct Air Capture System

Global Thermostat (GT) has developed a process that addresses the primary technical challenges associated with direct air capture (DAC): the ability to process enormous volumetric flowrates of air and provide the energy for regeneration at acceptable cost. However, at current, there is opportunity for improvement in overall capture costs and especially in capital costs. While GT has advanced its base technology to TRL levels supporting commercial deployments, its research strategy includes alternative technology embodiments that enable substantial reductions in the cost per tonne of CO 2 removed. The objective of this project is to advance the most promising of these embodiments, where a DAC plant is operated in a continuous fashion rather than a discrete stepwise fashion (GT’s commercial scale technology approach). The Continuous Motion Direct Air Capture (cDAC) System’s advantages over the GT baseline stepwise DAC platform have been proposed primarily as a reduction in the complexity required for starting and stopping a movement system, relaxing requirements for other components designed for a rapid switching application, and a flattening of the sharp instantaneous fluid flowrates into steady-state mass & energy flows to enable smoother operation and easier heat integration. These advantages can lead to shorter cycle times, greater plant reliability, and lower capital expense. The primary objective of this project is the design, construction, commissioning, and operation of a field-test unit (FTU) at a scale in the range of ~200 tons CO 2 per year. Data generated from the operation campaign would then be used in a prescreening techno-economic analysis (TEA) and life cycle analysis (LCA), allowing this process to be compared to other carbon capture technologies.

42 ENGINEERING↗

“Hybridizing heat-integrated 3D printed modules with mass manufacturable, low pressure drop fiber sorbents” (Final Report)

The overall objective of this proposal was to research, develop, and evaluate a modular direct air capture (DAC) system that is simple and scalable. This system was based on the adsorption of CO 2 into commercial polyamines supported by porous fiber sorbents, which can be produced at kilometer per hour scales using our pre-pilot spinning line. We have housed these fiber materials in novel 3D printed modular housing systems that provide easy-to-manufacture and localized heat integration and flow control. This hybridization of fiber sorbent technology with modular housing provided several advantages that led to lower air pressure drops, higher sorbent productivity, as well as ease of manufacturing and assembly unrivaled by existing and emerging heat integrated contactor designs. The modular housing was fabricated with the following features, at a minimum: (i) a tapered air intake to reduce pressure drop related to entrance effects, (ii) a structured network of heat transfer channels to enable localized cooling and heating during adsorption and desorption, respectively, and (iii) low pressure drop supports for the fiber sorbents. This hybrid manufacturing approach provides a facile method for taking fiber sorbents from lab scale to pilot scale as it dramatically simplifies the fabrication of heat integrated contactor structures.

42 ENGINEERING↗

Design of Transition-Metal/Zeolite Catalysts for Direct Conversion of Coal-derived CO 2 to Aromatics

This project introduces a lab-scale, stand-alone process to produce aromatics from CO 2 . Besides reducing the amount of coal-derived CO 2 emission, this process can provide new approaches to produce valuable chemicals such as benzene, toluene, and xylene (BTX). These chemicals are the starting material in various industries such as pharmaceuticals, polymers, paints, and coatings. The focus of the project is on developing a suitable reaction configuration, feed composition, and catalyst combination that leads to high aromatics selectivity and CO 2 conversions. To achieve these objectives, computational catalysis will accompany hands-on experiments to provide insights to potential transition metals or alloys that may serve as optimal active sites for different steps of the reaction mechanism, such as reduction of CO 2 and dehydration (in the case of alcohol intermediates) and oligomerization (in the case of paraffins or olefins) of intermediate hydrocarbons.

20 FOSSIL-FUELED POWER PLANTS↗