Technical Optimization of Pressure Drop in Solid Sorbent-Based Direct Air Capture with GKD Mesh Technology

In Solid Sorbent-based Direct Air Capture (DAC) systems, pressure drop is a significant factor that affects operational efficiency, energy consumption, and CO2 capture rates. The optimization of pressure drop is critical, as high resistance in the flow of air through the system directly translates to increased power requirements for compressors or fans. This issue becomes even more pronounced in continuous operation, where energy losses accumulate over time.

At GKD, we address these challenges by focusing on minimizing the interference resistance, which is the resistance created when the airflow transitions from open space through a packed bed of solid sorbents. This resistance occurs primarily due to the interaction between the mesh, which supports the solid sorbents, and the sorbent particles themselves. Our mesh technology is specifically designed to reduce these losses, enabling more efficient DAC processes.

Key technical considerations for reducing pressure drop in DAC systems:

Mesh-Sorbent Interface Optimization: In DAC systems utilizing solid sorbents, the sorbent materials—whether amine-functionalized materials or zeolites—interact directly with the mesh used for containment and support. Pressure drop is driven by the velocity and turbulence of the air as it passes through this sorbent bed. By optimizing the weave geometry and mesh opening size, GKD meshes provide smoother airflow transitions and less drag, leading to lower pressure losses across the system.

• Laminar Flow Improvement: Our approach emphasizes the design of mesh structures that promote laminar flow, reducing the development of turbulent regions. Turbulence is a major contributor to pressure drop in packed beds and mesh systems. By carefully choosing the pore size and weave pattern based on computational fluid dynamics (CFD) models, GKD can reduce the turbulence that occurs in the flow path, improving system efficiency.
• Minimizing Packed Bed Resistance: In many DAC systems, sorbents are packed densely to maximize surface area for CO2 adsorption. However, this dense packing increases resistance to airflow. Our mesh designs help maintain optimal spacing between sorbent particles, avoiding overpacking, which can create unnecessary pressure loss. This balance between particle packing and airflow resistance is critical to maintaining a low energy footprint in the DAC process.
• Material Selection for High Durability: Meshes used in DAC systems are subjected to high air velocities, moisture, temperature fluctuations, and potentially corrosive gases. GKD designs its meshes from materials that resist wear and corrosion, ensuring long-term performance without significant increases in pressure drop due to material degradation. Stainless steel and high-grade alloys are commonly used for their durability and low-friction surface properties.
• Thermal and Chemical Stability: Solid sorbent-based systems often operate at elevated temperatures, particularly during the regeneration phase of the sorbents (e.g., desorption of CO2). Our meshes are engineered to withstand these thermal cycles without losing structural integrity or adding to the pressure drop due to mesh deformation or clogging.
• Dynamic Pressure Drop Reduction: In real-world DAC applications, systems are subject to dynamic changes in air velocity and loading conditions. GKD’s mesh technology is designed to maintain a stable pressure drop across a wide range of operational conditions. This adaptability ensures consistent CO2 capture efficiency while reducing the energy burden on air moving equipment, such as blowers and fans.

By carefully engineering these aspects, GKD’s mesh technology contributes to a more efficient DAC process, where energy consumption is minimized without sacrificing the effectiveness of CO2 capture. The result is a significant improvement in the overall system efficiency, which is essential for the economic viability of large-scale DAC operations.

?For engineers and system designers in the DAC field, GKD’s tailored mesh solutions offer a proven method for managing pressure drop, improving operational stability, and enhancing CO2 capture performance. Collaboration with DAC manufacturers ensures that our mesh technology is integrated seamlessly into existing and future systems.