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.     

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.     

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.     

Design of a H2 PSA for cogeneration of ultrapure hydrogen and power at an advanced integrated gasification combined cycle with pre-combustion capture

A novel hydrogen pressure swing adsorption system has been studied that is applied to an advanced integrated gasification combined cycle plant for cogenerating power and ultrapure hydrogen (99.99+ mol%) with CO₂ capture. In designing the H₂ PSA, it is essential to increase the recovery of ultrapure hydrogen product to its maximum since the power consumption for compressing the H₂ PSA tail gas up to the gas turbine operating pressure should be minimised to save the total auxiliary power consumption of the advanced IGCC plant. In this study, it is sought to increase the H₂ recovery by increasing the complexity of the PSA step configuration that enables a PSA cycle to have a lower feed flow to one column for adsorption and more pressure equalisation steps. As a result the H₂ recovery reaches a maximum around 93 % with a Polybed H₂ PSA system having twelve columns and the step configuration contains simultaneous adsorption at three columns and four-stage pressure equalisation.     

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.     

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.     

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.     

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.     

Multicomponent gas separation by selective surface flow (SSF) and poly-trimethylsilylpropyne (PTMSP) membranes

A selective surface flow (SSF) membrane consisting of a thin layer of a nanoporous carbon was produced in a tubular form using a macroporous alumina support. The membrane was tested for hydrogen enrichment applications. Simulated waste gases from a petrochemical refinery and a hydrogen pressure swing adsorption unit were used as the feed gas to the membrane. Very high rejections of C₁C₃ hydrocarbons (saturated and unsaturated) and carbon dioxide over hydrogen were exhibited by the membrane at low feed gas pressures. The hydrogen enriched stream was produced at the feed gas pressure.The separation characteristics of a polymeric poly-trimethylsilylpropyne (PTMSP) membrane in a tubular form was also tested for the same applications using identical conditions of operation. This membrane also selectively rejected heavier components of the feed gas mixture over hydrogen and produced the hydrogen enriched stream at the feed gas pressure. The SSF membrane exhibited much higher hydrogen recovery and hydrocarbon rejections than the PTMSP membrane for these applications under identical conditions of operations using identical support materials.     

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.     

Backfill Cycle of a Layered Bed H2 PSA Process

The backfill cycle of two-bed PSA process using activated carbon beds, zeolite 5A beds, and layered beds was studied experimentally and theoretically to recover high purity H₂ from coke oven gas. In a layered bed PSA, a comparison was made between two PSA processes with/without a backfill step before the feed pressurization step. Since the backfill step made the adsorption bed rich in H₂ and this led to a rather steep concentration wave front at the feed pressurization step, incorporating a backfill step resulted in an increase in product purity with a decrease in recovery. Each step of the single-adsorbent and layered bed PSA processes with a backfill step was simulated with a dynamic model incorporating mass, energy, and momentum balances. The model agreed well with the experimental results in predicting the product H₂ purity and recovery, thus giving a basic understanding of the bed dynamics of a backfill cycle. While the concentration and temperature profiles of a layered bed in each step showed characteristic behavior of each adsorbent in each layer, the product purity of a layered bed was not between the limits of two single-adsorbent bed processes. The concentration profiles predicted by simulation showed that CO and N₂ played an important role in obtaining high H₂ purity.     

Capture of CO2 from flue gas streams with zeolite 13X by vacuum-pressure swing adsorption

Vacuum swing adsorption (VSA) capture of CO₂ from flue gas streams is a promising technology for greenhouse gas mitigation. In this study we use a detailed, validated numerical model of the CO2VSA process to study the effect of a range of operating and design parameters on the system performance. The adsorbent used is 13X and a feed stream of 12% CO₂ and dry air is used to mimic flue gas. Feed pressures of 1.2 bar are used to minimize flue gas compression. A 9-step cycle with two equalisations and a 12-step cycle including product purge were both used to understand the impact of several cycle changes on performance. The ultimate vacuum level used is one of the most important parameters in dictating CO₂ purity, recovery and power consumption. For vacuum levels of 4 kPa and lower, CO₂ purities of >90% are achievable with a recovery of greater than 70%. Both purity and recovery drop quickly as the vacuum level is raised to 10 kPa. Total power consumption decreases as the vacuum pressure is raised, as expected, but the recovery decreases even quicker leading to a net increase in the specific power. The specific power appears to minimize at a vacuum pressure of approximately 4 kPa for the operating conditions used in our study. In addition to the ultimate vacuum level, vacuum time and feed time are found to impact the results for differing reasons. Longer evacuation times (to the same pressure level) imply lower flow rates and less pressure drop providing improved performance. Longer feed times led to partial breakthrough of the CO₂ front and reduced recovery but improved purity. The starting pressure of evacuation (which is not necessarily equal to the feed pressure) was also found to be important since the gas phase was enriched in CO₂ prior to removal by vacuum leading to improved CO₂ purity. A 12-step cycle including product purge was able to produce high purity CO₂ (>95%) with minimal impact on recovery. Finally, it was found that for 13X, the optimal feed temperature was around 67°C to maximize system purity. This is a consequence of the temperature dependence of the working selectivity and working capacity of 13X. In summary, our numerical model indicates that there is considerable scope for improvement and use of the VSA process for CO₂ capture from flue gas streams.     

Heavy reflux PSA cycles for CO2 recovery from flue gas: Part I. Performance evaluation

This study evaluated nine stripping PSA cycle configurations, all with a heavy reflux (HR) step, some with a light reflux (LR) step, and some with a recovery (REC) or feed plus recycle (F+R) step, for concentrating CO₂ from stack and flue gas at high temperature (575 K) using a K-promoted HTlc. Under the process conditions studied, the addition of the LR step always resulted in a better process performance; and in all cases, the addition of a REC or F+R step surprisingly did not affect the process performance except at low feed throughputs, where either cycle step resulted in a similar diminished performance. The best cycle based on overall performance was a 5-bed 5-step stripping PSA cycle with LR and HR from countercurrent depressurization (CnD) (98.7% CO₂ purity, 98.7% CO₂ recovery and 5.8 L STP/hr/kg feed throughput). The next best cycle was a 5-bed 5-step stripping PSA cycle with LR and HR from LR purge (96.5% CO₂ purity, 71.1% CO₂ recovery and 57.6 L STP/hr/kg feed throughput). These improved performances were caused mainly by the use of a very small purge to feed ratio (γ=0.02) for the former cycle and a larger one (γ=0.50) for the latter cycle. The former cycle was good for producing CO₂ at high purities and recoveries but at lower feed throughputs, and the latter cycle was useful for obtaining CO₂ at high purities and feed throughputs but at lower recoveries. The best performance of a 4-bed 4-step stripping PSA cycle with HR from CnD was disappointing because of low CO₂ recoveries (99.2% CO₂ purity, 15.2% CO₂ recovery and 72.0 L STP/hr/kg feed throughput). This last result revealed that the recoveries of this cycle would always be much lower than the corresponding cycles with a LR step, no matter the process conditions, and that the LR step was very important to the performance of these HR cycles for this application and process conditions studied.     

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.     

Adsorption and diffusion of nitrogen, methane and carbon dioxide in aluminophosphate molecular sieve AlPO4-11

The knowledge about the adsorption and diffusion properties (specially about diffusion) of aluminophosphate molecular sieves is very scarce in the literature. These materials offer interesting properties as adsorbents as they have a polar framework and do not contain charge-balancing cations. In this work, the adsorption isotherms of nitrogen, methane and carbon dioxide over an AlPO₄-11 sample synthesized in our laboratories have been measured with a volumetric method at 25, 35, 50 and 65 °C over a pressure range up to 110 kPa. The adsorption capacities of each gas are determined by the strength of interaction with the pore surface (carbon dioxide > methane > nitrogen). The equilibrium selectivity to carbon dioxide is quite high with respect to other adsorbents without cations due to the polarity of the aluminophosphate framework. The adsorption Henry’s law constants and diffusion time constants of nitrogen, methane and carbon dioxide in the synthesized AlPO₄-11 material have been measured from pulse experiments. A pressure swing adsorption (PSA) process for recovering methane from a carbon dioxide/methane mixture (resembling biogas) has been designed using a dynamic model where the measured adsorption equilibrium and kinetic information has been incorporated. The simulation results show that the proposed process could be simpler than other PSA processes for biogas upgrading based on cation-containing molecular sieves such as 13X zeolite, as it can treat the biogas at atmospheric pressure, and it requires a lower pressure ratio, to produce high purity methane with high recovery.     

Performance of a Two-Bed Pressure Swing Adsorption Process with Incomplete Pressure Equalization

Incomplete pressure equalization (PE) is practiced in a commercial oxygen concentrator for medical use by adopting simultaneous PE and feed-pressurization for pressurizing an adsorption bed. In such a cycle configuration, extent of equalization during PE affects process performance. In order to assess the effect, performance of pressure swing adsorption (PSA) process with incomplete PE was determined by both simulations and experiments. In simulations, an equilibrium model was used with the assumptions of multicomponent Langmuir isotherms, isothermal operation, and no pressure drop through a bed. The required parameters for simulations were measured in separate experiments. PSA experiments were performed for a two-bed cycle with PE. Two kinds of pressurization, feed and product, were examined. Effects of purge amount and extent of equalization on process performance were assessed in view of productivity and light-component recovery. From the obtained results performance contours were constructed. 95 oxygen mole percent production from air with zeolite 13× was considered as a case study. In both pressurizations, an optimal specific purge and an extent of equalization for the productivity and recovery were observed, but with a different level of equalization. For a maximum productivity feed-pressurization favored incomplete PE, while a maximum recovery occurred at complete PE for both pressurizations. The simulations depicted well existence of optimum conditions, though they showed quantitative disagreement with experiments.     

Production of oxygen enriched air by rapid pressure swing adsorption

A novel rapid pressure swing adsorption (RPSA) process is described for production of 25–50% oxygen enriched air. The embodiment consists of one or more pairs of adsorbent layers contained in a single adsorption vessel. The layers undergo simultaneous pressurization-adsorption and simultaneous depressurization-purge steps. A total cycle time of 6–20 seconds is used. The process yields a very large specific oxygen production rate and a reasonable oxygen recovery for production of 20–50 mole% oxygen enriched gas.It is demonstrated by a simple mathematical model of isothermal single adsorbate pressure swing ad(de)sorption concept on a single adsorbent particle that the specific production rate of a PSA process cannot be indefinitely increased by reducing the cycle time of operation when adsorbate mass transfer resistances are finite.     

Capture of CO<Subscript>2</Subscript> from flue gas by vacuum pressure swing adsorption using activated carbon beads

Vacuum pressure swing adsorption (VPSA) for CO₂ capture has attracted much research effort with the development of the novel CO₂ adsorbent materials. In this work, a new adsorbent, that is, pitch-based activated carbon bead (AC bead), was used to capture CO₂ by VPSA process from flue gas. Adsorption equilibrium and kinetics data had been reported in a previous work. Fixed-bed breakthrough experiments were carried out in order to evaluate the effect of feed flowrate, composition as well as the operating pressure and temperature in the adsorption process. A four-step Skarstrom-type cycle, including co-current pressurization with feed stream, feed, counter-current blowdown, and counter-current purge with N₂ was employed for CO₂ capture to evaluate the performance of AC beads for CO₂ capture with the feed compositions from 15–50% CO₂ balanced with N₂. Various operating conditions such as total feed flowrate, feed composition, feed pressure, temperature and vacuum pressure were studied experimentally. The simulation of the VPSA unit taking into account mass balance, Ergun relation for pressure drop and energy balance was performed in the gPROMS using a bi-LDF approximation for mass transfer and Virial equation for equilibrium. The simulation and experimental results were in good agreement. Furthermore, two-stage VPSA process was adopted and high CO₂ purity and recovery were obtained for post-combustion CO₂ capture using AC beads.     

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.     

A non-linear equilibrium analysis of blowdown policy in pressure—swing—adsorption separation

Using the local non-linear equilibrium approach, we investigated pressure—swing—adsorption (PSA) cycles directed toward the removal of an adsorbable impurity present in large amounts in an inert substance. Three blowdown policies are compared (the blowdown is the part of the PSA cycle in which the pressure of a column is released by rejecting gas). In one such policy, the gas resulting from blowdown is rich in the impurity and is rejected as waste. In a second policy in contrast, the production is adjusted so that the blowdown gas is pure and is considered as a product or is reused to recompress or purge another column. The third policy is intermediate, in the sense that part of the blowdown gas is pure and recovered, and part is impure and rejected.The equilibrium approach presented neglects mass-transfer and dispersion effects, but accounts for non-linear equilibria and variations in gas velocity. It thus allows analytical or semi-analytical expressions to be obtained for quantities such as the inert recovery ratio, and hence an easy qualitative discussion of the effects of operating parameters on the recovery. It is shown that the intermediate policy (partial recovery of the blowdown gas) is optimal. The adsorption of methane and ethane on activated carbon from helium or hydrogen are presented as illustrations.