Effect of Operation Symmetry on Pressure Swing Adsorption Process

In a multi-bed pressure swing adsorption (PSA) process, cycle steps with gas flow transferring from one bed to another such as equalization, purge, etc. are generally practiced to enhance the product recovery. However, if the flows for the connected beds in these steps are not balanced, the PSA process may not operate in a symmetrical manner. In the modeling of the PSA process, most of the simulations consider only one bed and assume that the rest of the beds would behave in a same way. In order to assess the impact of bed symmetry on the PSA performance, a new PSA model capable of studying bed symmetry in a two-bed system is developed. Experimental results from this paper show that uneven equalization flow can result in a lower product purity and a peculiar purity curve at different equalization levels. This phenomenon can be successfully predicted by this model. Simulation results also show that in large-scale PSA units, asymmetrical operation can cause drastically different temperature profiles in different adsorbers and hence a much lower performance. This paper demonstrates the importance of maintaining operation symmetry in PSA processes.     

Parametric Study of a Pressure Swing Adsorption Process

The performance of a pressure swing adsorption (PSA) process for production of high purity hydrogen from a binary methane-hydrogen mixture is simulated using a detailed, adiabatic PSA model. An activated carbon is used for selective adsorption of methane over hydrogen. The effects of various independent process variables (feed gas pressure and composition, purge gas pressure and quantity, configuration of process steps) on the key dependent process variables (hydrogen recovery at high purity, hydrogen production capacity) are evaluated. It is demonstrated that many different combinations of PSA process steps, their operating conditions, and the feed gas conditions can be chosen to produce an identical product gas with different hydrogen recovery and productivity.     

Pressure Swing Adsorption Technologies for Carbon Dioxide Capture

The principles of pressure swing adsorption (PSA) for carbon dioxide capture are reviewed. Previous work on PSA, relevant modeling and experimental investigation for specifically carbon dioxide separation are also presented and significant findings highlighted. Simple rules for PSA process design based on analysis of the inherent properties of adsorbate-adsorbent systems encompassing equilibrium isotherm, adsorption kinetics, shape of breakthrough curves, screening and selection of adsorbent, bed porosity, adsorption time, purge to feed ratio, residence time, pressure equalization and rinse steps are provided to promote better understanding of the technology so that it gains wider acceptance in the future to address the global environmental concern, particularly in the removal of carbon dioxide as a greenhouse gas.     

Analysis of Equilibrium PSA Performance with an Analytical Solution

Five-step PSA cycles consisting of pressurization with product, adsorption, co-current depressurization, blowdown, and purge steps have been analyzed with equilibrium model assuming uncoupled linear isotherms and isothermal condition. Unlike the previous models, the proposed model is not restricted to the operating conditions that ensure a complete shock transition of concentration profile at the end of the high pressure adsorption step. The operating conditions could have two classifications: one is utilizing the column completely before blowdown, and the other is not. As the selectivity increases, it is more difficult to utilize the column completely before the blowdown step. There is an optimum co-current depressurization pressure which maximizes the recovery at the given extent of purge. The optimum co-current depressurization pressure decreases as the purge quantity decreases. On the less selective adsorbent, the recovery at the optimum co-current depressurization pressure increases with the decrease of purge quantity without much sacrifice of the throughput. But, on the highly selective adsorbent, there is an extent of purge and corresponding value of cocurrent depressurization pressure below which the recovery is not greatly improved while the throughput decreases rapidly, which limits the number of pressure equalization steps can be included.     

Heuristics for synthesis and design of pressure-swing adsorption processes

Simulation based synthesis and design of adsorptive enrichment of CO from tail gas having 51?% CO are presented. The adsorption breakthrough curve simulation using this feed gas composition, helped to provide a starting guess of the adsorption step duration in a pressure-swing adsorption cycle for meeting the purity and recovery targets. Use of smaller bed dimensions facilitated the simulation of many cycles. These simulations helped to decide the operating pressure range, operating temperature, constituent steps of the cycle, their sequence, direction of pressurization of the bed, number of beds in the cycle and the composition of the streams to be used for pressurization and/or rinse and/or purge steps. Only an optimally designed pressure-vacuum-swing adsorption cycle achieves the stiff separation targets of getting an extract having 80?% pure CO at 80?% recovery in a single-stage with an adsorbent that uses physical adsorption and offers CO/CH₄ sorption selectivity of just 2.44. Additional simulations are done wherein the bed sizes and velocities are increased to predict the performance of a large-scale unit. These require deciding only the durations of the steps that are finalized from the small-scale unit simulations. These durations were kept fixed and the bed dimensions were varied till the separation targets are obtained for the particular feed rate. The scale-up criteria was matching residence times in the bed. A strategy for treating a feed gas having only 30?% CO is also discussed and a novel concept of cascaded PSA is evaluated using simulations. Some heuristics are evolved from the studies.     

Hydrogen separation by multi-bed pressure swing adsorption of synthesis gas

The performance of multi-bed pressure swing adsorption (PSA) process for producing high purity hydrogen from synthesis gas was studied experimentally and theoretically using layered beds of activated carbon and zeolite 5A. Nonisothermal and nonadiabatic models, considering linear driving force model and Dual-site Langmuir adsorption isotherm model, were used. The effects of the following PSA variables on separation process were investigated: linear velocity of feed, adsorption time and purge gas quantity. As a result, we recovered a high purity H₂ product (99.999%) with a recovery of 66% from synthesis gas when the pressure was cycled between 1 and 8 atm at ambient temperature.     

Separation of a binary gas mixture by pressure swing adsorption: Comparison of different PSA cycles

Gas separation of a binary gas mixture by various pressure swing adsorption (PSA) cycles was studied by a numerical simulation in order to provide a guidance in selecting PSA cycles. PSA cycles considered in this study are 3, 4-step cycles for production of only one component and a cycle with pressure equalization for production of a light component. 4 and 5-step cycles for simultaneous production of both components of a binary gas mixture are also considered. Separation of a CH₄/CO₂ gas mixture with zeolite 5A was chosen as a case study. Performances of cycles were examined and compared in view of purity, recovery and productivity. Their relative advantages were discussed. Inclusion of a purging step to a 3-step cycle for production of only one component improves a cycle performance. Further performance improvement of a cycle for production of a light component can be achieved by employing pressure equalization. Sircar's 4-step cycle with a recycle of effluent shows the best performance in view of purity and recovery among cycles for simultaneous production of both components.Nomenclature B Langmuir adsorption constant, bar^–1 - C concentration of sorbate in gas phase, mol/m³ - D defined by Eq. (7) - n amount of sorbate in solid phase, mol/kg - n _s monolayer amount adsorbed, mol/kg - P pressure, bar - R gas constant, J/mol K - T temperature, K - t time, s - U effluent gas velocity, m/s - z height of one cell, m - bulk density of a bed, kg/m³ - bed void fraction - A CH₄ - B CO₂ - H high pressure feed step - P purge step - R heavy-component rinse step - i cell number (i=1 toN)     

Kinetic Separation of Oxygen and Argon Using Molecular Sieve Carbon

A pressure-swing adsorption (PSA) simulation study was performed for the separation of a mixture of 95% O₂ and 5% Ar using a molecular sieve carbon (MSC) as the adsorbent. Two PSA cycles have been outlined to maximize the recovery of either argon or oxygen as a high purity product. The effect of cycle parameters such as cocurrent depressurization pressure, purge/feed ratio, pressure ratio and adsorption pressure on the separation of O₂/Ar has been studied. It was found that it is feasible to obtain an argon product of purity in excess of 80% with reasonably high recovery using one of the cycles. The other cycle is capable of producing high purity oxygen (>99%) at high recovery (>50%) with reasonably high product throughputs. The PSA process can be conducted at room temperature and hence has an advantage over conventional processes like cryogenic distillation and cryogenic adsorption.     

Periodic State Heat Effects in Pressure Swing Adsorption-Solvent Vapor Recovery

Heat effects in the pressure swing adsorption (PSA)-n-butane vapor recovery process were investigated at the periodic state by computer simulation. The PSA process utilized a two-bed, four-step, vacuum swing cycle and BAX activated carbon as the adsorbent. The heat effects were manifested by varying the heat transfer coefficient (h) from isothermal to adiabatic, while simultaneously varying the adsorbed phase heat capacity (Cp_a) from zero to that of the saturated liquid. In terms of the bed capacity factor (BCF), isothermal operation always resulted in the best performance, whereas adiabatic operation was not the worst; independent of Cp_a, the worst performance occurred at an intermediate h. Cp_a also had a significant effect on the BCF, where a larger Cp_a (i.e., a larger heat sink) always decreased the BCF and thus improved the process performance. A factorial analysis showed that the effect of Cp_a on the BCF became even more pronounced as the cycle time increased. h and Cp_a had essentially no effect on the solvent vapor enrichment under the conditions investigated. Overall, this study demonstrated that the effects of h and Cp_a are uniquely coupled; thus knowing their magnitudes is paramount to obtaining accurate predictions from a PSA-solvent vapor recovery model.     

Sensitivity of PSA process performance to input variables

Mathematical models for pressure swing adsorption (PSA) processes essentially require the simultaneous solutions of mass, heat and momentum balance equations for each step of the process using appropriate boundary conditions for the steps. The key model input variables needed for estimating the separation performance of the process are the multicomponent adsorption equilibria, kinetics and heats of adsorption for the system of interest. A very detailed model of an adiabatic Skarstrom PSA cycle for production of high purity methane from a ethylene-methane bulk mixture is developed to study the sensitivity of the process performance to the input variables. The adsorption equilibria are described by the heterogeneous Toth model which accounts for variations of isosteric heats of adsorption of the components with adsorbate loading. A linear driving force model is used to describe the kinetics. The study shows that small errors in the heats of adsorption of the components can severely alter the overall performance of the process (methane recovery and productivity). The adsorptive mass transfer coefficients of the components also must be known fairly accurately in order to obtain precise separation performance.     

Fractional factorial design study of a pressure swing adsorption-solvent vapor recovery process

A two-level fractional factorial study was performed by computer simulation on the periodic state process performance of a pressure swing adsorption-solvent vapor recovery process (PSA-SVR). The goal was to investigate factor (parameter) interaction effects on the process performance, i.e., interaction effects that cannot be ascertained from the conventional “one-at-a-time” approach. Effects of seven factors, i.e., the purge to feed ratio, pressure level, pressure ratio, heat transfer coefficient, feed concentration, feed volumetric flow rate and bed length to diameter ratio, on the process performance were investigated. The results were judged in terms of the light product purity, heavy product enrichment (and relative enrichment) and recovery, and bed capacity factor. Only the purge to feed ratio, pressure ratio, and feed concentration had significant effects on the benzene vapor enrichment (and relative enrichment); and no two-factor and higher interactions were observed. The light product purity was affected by all seven factors; and the relative importance of the effect of each factor depended on the levels of the other factors, i.e., significant two-factor interaction effects existed. Two-factor interaction effects also existed on the benzene vapor recovery, although the effects of all seven factors and their interactions were relatively small. The bed capacity factor was affected mainly by the purge to feed ratio, the heat transfer coefficient and the feed concentration; two factor and higher order interaction effects were insignificant. Overall, this study demonstrated the utility of fractional factorial design for revealing factor interactions and their effects on the performance of a PSA-SVR process.     

Hydrogen PSA process product purity control method and controller

It is well known in the industry that a primary means for controlling the pressure swing adsorption (PSA) process product gas purity is the adjustment of PSA feed time or adsorption time. If the product impurity is too high, the feed time is shortened and if the impurity level is below the target the feed time is increased. Conventionally, the plant operator monitors the product purity and manually adjusts the feed time. Several control methodologies such as classical feedback and feedforward systems were suggested to automate this task with limited success. A novel control methodology based on the measurement of impurity fronts within the adsorber bed was developed by the Praxair Adsorption R&D team. The response of the concentration measurements inside the adsorber vessel to the process upsets and changes in feed time is more rapid than in the product stream. Consequently, closed loop control performance can be made much more effective and the operating impurity set points for product gas can be more aggressive resulting in longer PSA feed times, higher bed utilization and thus higher hydrogen recovery. The control methodology will be discussed in greater detail along with the advantages it has to offer such as improved process performance, disturbance rejection capability and improved process robustness. The control methodology will be illustrated using the hydrogen PSA process as an example.     

Graphical approach for complex PSA cycle scheduling

A simple graphical approach for complex pressure swing adsorption (PSA) cycle scheduling has been developed. This new methodology involves a priori specifying the cycle steps, their sequence, and the number of beds, and then following a systematic procedure that requires filling in a 2-D grid based on a few simple rules, some heuristics and some experience. The outcome or solution is a grid comprised of columns that represent the total cycle time, rows that represent the total number of beds, and cells that represent the duration of each cycle step, i.e., the complete cycle schedule. This new approach has been tested successfully against several cycle schedules taken from the literature, including a two-bed four-step Skarstrom cycle, a four-bed nine-step process with two equalization steps, a nine-bed eleven-step process with three pressure equalization steps, and a six-bed thirteen-step process with four pressure equalization steps and four idle steps. This approach also revealed the existence of numerous cycle schedules for each bed and cycle step combination examined. Although it cannot identify the total number of permutations or which one is better, it does provide a very straightforward way to determine some of the possible cycle schedules of virtually any PSA process that can be conceived.     

Pressure-Swing Adsorption Using Layered Adsorbent Beds with Different Adsorption Properties: I—Results of Process Simulation

A simulation study was conducted on layered-bed pressure-swing adsorption, PSA, processes with adsorbents that differ in their adsorption properties. As an example, an oxygen, O₂, vacuum-swing adsorption, VSA, process was analyzed to investigate relationships between process performance and adsorption properties of the adsorbents used. For two adsorbents with identical nitrogen-to-oxygen, N₂/O₂, selectivity but different N₂ and O₂ capacities, placing the high-capacity adsorbent at the product end and the low-capacity adsorbent at the feed end of the adsorption bed gives a better performance than the case of reversing layering of these adsorbents. However, for two adsorbents with different values of N₂/O₂ selectivity but identical N₂ capacity, changing the bed-layer configuration does not show a significant difference in O₂-VSA performance. The advantages of layering a high-capacity adsorbent on product end of the bed are demonstrated by an examination of the N₂-loading difference in a VSA cycle. The modeling study also reveals an effect of cycle features (e.g., equalization step) on the effectiveness of using layered-bed configurations in VSA/PSA processes. It suggests that layering appropriately two adsorbents with different adsorption properties could result in better VSA/PSA-process performance than using a single-layer bed with either of the two adsorbents.     

Novel simulated moving-bed adsorber for the fractionation of gas mixtures

The separation of propylene-propane mixture is an energy intensive operation commercially practiced using cryogenic distillation. The separation by pressure swing adsorption has been studied as an alternative. A fixed-bed pressure swing adsorption yields the heavy component as a pure product. The product recovery and the productivity are not high. In a moving-bed process, because of the counter-current solid-gas contact, the separation achieved is similar to that of the fractionation by distillation. Although the moving-bed operation offers the upper limit for the performance of a cyclic adsorptive process, due to mechanical complexities in the handling of solids the 'simulated' moving-bed is preferred. By moving the inlet and outlet ports of streams located along the length of the bed, a moving-bed process can be realized in a fixed bed. We describe here a 'moving-port' system which permits injection or withdrawal of the fluid along the axial direction in a fixed bed. A fixed bed embedded with the moving-port systems emulates a simulated moving-bed adsorber. The proposed adsorber can fractionate a binary gas mixture into two product streams with high purities. It is similar to the Sorbex process of UOP but does not have the eluent as an additional separating agent. A parametric study indicates that high purity products and a higher productivity by an order of magnitude can be achieved with simulated moving-beds compared to the fixed beds.     

Tuning of Pressure Swing Adsorption Systems Based on Differential Pressure Profile

A method for tuning a Pressure Swing Adsorption (PSA) system aimed to achieve symmetrical operating conditions based on pressure differential in the adsorption vessels is developed in this study. Simulation of an oxygen Pressure-Vacuum Swing Adsorption (PVSA) process indicates that the pressure drop inside the adsorption vessel is closely related to the nitrogen concentration and gas velocity. The technique is applied to the tuning of an oxygen PVSA process. Adsorbent vessels of the PSA system are monitored and tuned by making corrective adjustments in each of the steps in a PSA cycle in response to imbalances in the differential pressure profiles in each of the adsorbent vessels. The method developed in this study provides a faster, easier, and more effective way to bring a PSA plant to its symmetrical, optimal state than those based on other parameters such as concentration, temperature, and pressure profile. This paper is dedicated to the memory of Professor Wolfgang Schirmer.     

CO_2 residual concentration of potassium-promoted hydrotalcite for deep CO/CO_2 purification in H_2-rich gas

Elevated-temperature pressure swing adsorption is a promising technique for producing high purity hydrogen and controlling greenhouse gas emissions. Thermodynamic analysis indicated that the CO in H_2-rich gas could be controlled to trace levels of below 10 ppm by in situ reduction of the CO_2 concentration to less than 100 ppm via the aforementioned process. The CO_2 adsorption capacity of potassiumpromoted hydrotalcite at elevated temperatures under different adsorption(mole fraction, working pressure) and desorption(flow rate, desorption time, steam effects) conditions was systematically investigated using a fixed bed reactor. It was found that the CO_2 residual concentration before the breakthrough of CO_2 mainly depended on the total amount of purge gas and the CO_2 mole fraction in the inlet syngas.The residual CO_2 concentration and uptake achieved for the inlet gas comprising CO_2(9.7 mL/min) and He(277.6 mL/min) at a working pressure of 3 MPa after 1 h of Ar purging at 300 mL/min were 12.3 ppm and0.341 mmol/g, respectively. Steam purge could greatly improve the cyclic adsorption working capacity, but had no obvious benefit for the recovery of the residual CO_2 concentration compared to purging with an inert gas. The residual CO_2 concentration obtained with the adsorbent could be reduced to 3.2 ppm after 12 h of temperature swing at 450 °C. A new concept based on an adsorption/desorption process, comprising adsorption, steam rinse, depressurization, steam purge, pressurization, and high-temperature steam purge, was proposed for reducing the steam consumption during CO/CO_2 purification.     

Comparison of Finite Difference Techniques for Simulating Pressure Swing Adsorption

Three different finite-difference routines were compared for solving the nonlinear, coupled, partial differential and algebraic equations that describe pressure swing adsorption processes. A successive substitution method (SS), a block LU decomposition procedure (BLUD), and the method of lines approach with adaptive time stepping (DASSL) were used to simulate and compare the computation times required to reach the periodic state for two different PSA systems: PSA-air drying and PSA-solvent vapor recovery. For both systems, the results showed that DASSL was nearly twice as fast as BLUD, whereas SS was nearly an order of magnitude slower than BLUD. DASSL and BLUD were also very robust and accurate, as nearly identical bed profiles were obtained from both methods under both transient and periodic state conditions.     

Optimizing the separation of gaseous enantiomers by simulated moving bed and pressure swing adsorption

The resolution of racemic gas mixtures by simulated moving bed (SMB) and pressure swing adsorption (PSA) is investigated by dynamic simulation and optimization. Enantiomer separation of inhalation anesthetics is important because there is evidence that the purified enantiomers may have different pharmacological properties than the racemate. The model parameters reported in an experimental investigation performed elsewhere are used to study the feasibility of this separation using SMB and PSA configurations. Both processes were modeled in gPROMS^® as systems of differential algebraic equations. Operating conditions are optimized such that the feed throughput and product recovery for each process were maximized subject to equal constraints on the pressures and superficial gas velocities. SMB was found to be capable of resolving racemic feed mixtures with purity and recovery exceeding 99%. On the other hand, PSA was also able to provide a single purified enantiomer with low recovery of about 30% which may limit its application to enantiomer separation. Nevertheless, PSA consumes less desorbent, and achieves higher throughput at the sacrifice of lower recovery.     

Performance comparison of suspended bed and batch contactor chromatography

In some applications, the purification and recovery of biomolecules is performed via a cascade of batch adsorption and desorption stages using agitated contactors and related filtration devices. Suspended bed chromatography is a recent process-scale innovation that is applicable to these separations. This hybrid technique exploits the benefits of combining batch adsorption in an agitated contactor with elution in an enclosed column system. To some extent, the process is similar to batch contactor chromatography but can be fully contained and significantly quicker. The process has two steps; first the fluid containing the sample is mixed with the adsorbent in a stirred tank. Second, the slurry suspension is transferred directly into a specialized column, such as an IsoPak column. The media with the adsorbed product is formed as a packed bed, whilst the suspension liquid is passed out of the column. The product is then eluted from the packed bed utilizing standard column-chromatography techniques. The performance of the suspended bed and the agitated contactor operations are demonstrated both by full-scale experimental results and process simulations. The purification of ovalbumin from a hen-egg white feedstock by anion-exchange chromatography was used as a case study in order to prove the concept. With the availability of both pump-packed systems and shear-resistant media, suspended bed chromatography is a better alternative for a range of applications than the traditional batch separations using agitated contactors.