(97g) CFD Modeling of High-Flux Plate-and-Frame Membrane Modules for Carbon Capture at Industrial and Power Generation Plants.

Industrial emissions of carbon dioxide (CO₂) constitute a significant portion of global emissions. To address the urgent need to reduce atmospheric CO₂ levels and achieve net-zero emissions by 2050, carbon capture technologies (CCT) have emerged as promising solutions. Among these, membrane processes have gained traction as energy-efficient methods for CO₂ capture over the past two decades.

This study investigates the application of CO₂-selective flat sheet membranes for capturing CO₂ emissions from point sources. Utilizing Computational Fluid Dynamics (CFD) models, we design high-flux plate-and-frame membrane modules to ensure uniform flow distribution among membrane elements, minimize dead-end zones, and alleviate concentration polarization issues commonly encountered in gas separation membranes. Our objective is to drive advancements in membrane technology by optimizing module designs based on specific membrane properties and operating conditions.

Our modeling approach encompasses Multiphysics processes, incorporating fluid flow and transport of concentrated species within the membrane module. Previously, we showed that our numerical results demonstrate excellent agreement between experimental findings and model predictions regarding CO₂ recovery, CO₂ mole fraction in the retentate and permeate streams, and stage-cut.

Recently, we successfully scaled up our design to a larger, stacked version featuring additional membranes and a greater surface area, capable of handling higher flow rates. While our earlier results were based on a single 24 cm² membrane operating at a maximum flow rate of 600 sccm, our current models accommodate up to 5 membranes for a total surface area of 120 cm² with flow rates reaching 3200 sccm. These results were validated for the new scaled up design with experimental data establishing further the reliability of our models.

Moreover, whereas previous work assumed the gas feed stream was comprised solely of CO₂ and N₂ for simplicity, our latest models, currently undergoing validation, incorporate CO₂, N₂, and O₂. These models can accommodate up to 10 membranes, totaling a surface area of 960 cm². The integration of computational fluid dynamics (CFD) with experimental data enhances our understanding of the process, facilitating the development of efficient CO₂ separation through membrane systems both from the view point of optimizing the module design and the overall process.