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.     

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.     

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.     

Arithmetic approach for complex PSA cycle scheduling

An algebraic model was derived for obtaining complex pressure swing adsorption (PSA) cycle schedules. This new approach involves a priori specifying the cycle steps, their sequence and any constraints, and then solving a set of analytical equations. The solution identifies all the cycle schedules for a given number of beds, the minimum number of beds required to operate the specified cycle step sequence, the minimum number and location of idle steps to ensure alignment of coupled cycle steps, and a simple screening technique to aid in identifying the best performing cycles that deserve further examination. The methodology was tested successfully against 10, 12 and 16 bed PSA systems in the literature that all utilized the same 13 step cycle sequence that has four pressure equalization steps. It completely resolved all the corresponding cycle schedules for these 13 step multi-bed PSA systems with ease, and showed that the number of cycle schedules was hundreds to thousands of times greater than the few ever reported in the literature for each one. Overall, this new methodology for complex PSA cycle scheduling can be applied to any number of cycle steps, any corresponding cycle step sequence, and any number of constraints, with the outcome being the complete set of cycle schedules for any number of beds greater than or equal to the minimum number it determines.     

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.     

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.     

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.     

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.     

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.     

Fixed-bed adsorption of carbon dioxide/methane mixtures on silicalite pellets

The adsorption of carbon dioxide and methane on silicalite pellets packed on a fixed bed has been studied. Equilibrium and kinetic measurements of the adsorption of carbon dioxide and methane have been performed, and a binary adsorption isotherm for carbon dioxide/methane mixtures has been obtained. A model based on the LDF approximation for the mass transfer has been used to describe the breakthrough curves obtained experimentally. A PSA cycle has been proposed for obtaining methane with purity higher than 98% from carbon dioxide/methane mixtures containing 38% and 50% methane, and its performance has been simulated using the proposed model. The simulation results show that silicalite can be a suitable adsorbent for employment in a PSA separation process for carbon dioxide removal from coalseam and landfill gases.     

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.     

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.     

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.     

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.     

Partial-discard strategy for obtaining high purity products using simulated moving bed chromatography

A new "partial-discard" operation strategy was developed to improve the performance, especially purity, achievable in simulated moving bed (SMB) chromatography. This strategy was applied to the four-zone SMB process with two columns per zone for binary separation within the linear range. The "partial-discard" strategy significantly enhanced the purity or enrichment when the discard time and discard length were controlled. In addition, the "partial-feed with partial-discard" strategy improved remarkably the extract and raffinate purities at an intermediate feed time compared with the "partial-feed" operation. Adjustments of the discard length and discard time played key roles in achieving the desired product purity in SMB chromatographic performance.     

Expanded Bed Adsorption Chromatography for Recovery of Phycocyanins from the Microalga Spirulina Platensis

We carried out the purification of C-phycocyanin and allophycocyanin from Spirulina platensis taking advantage of the adsorption properties of the expanded beds. Initially, phycobiliproteins were released from the microalga cells by osmotic shock. Next, phycocyanins were recovered by applying the centrifuged cell suspension directly to the anion exchanger Streamline-DEAE using expanded bed columns, equilibrated with 50 mM sodium phosphate buffer, pH 7.0. After adsorption, washing was carried out in the expanded-bed mode. Having removed unbound proteins and cellular debris, the bed was allowed to sediment and phycocyanins rich solution was eluted with a downward flow of 500 mM sodium phosphate buffer, pH 7.0. Finally, we utilized conventional gel filtration and ion exchange chromatography methods for separation and purification of C-phycocyanin and allophycocyanin. The purification steps were monitored using sodium dodecyl sulfate-polyacrylamide gel electrophoresis, and the purity of recovered phycocyanins was confirmed by absorption and emission spectroscopy. The main advantage of this new method is the high yield achieved in the steps of product extraction and adsorption by expanded bed adsorption, so reducing both processing times and costs.     

Partial port-closing strategy for obtaining high throughput or high purities in a four-zone simulated moving bed chromatography for binary separation

The “partial port-closing” operation strategy for a four-zone simulated moving bed (SMB) chromatographic process for binary separation was developed to improve the SMB performance. This strategy included the partial extract-closing (PEC) and the partial raffinate-closing (PRC) operations. In case of the PEC operation, the extract port is made to be closed during the first-half stage of a switching period. During the latter-half stage, the extract port is made to be open. In case of the PRC operation, the raffinate port is made to be open during the first-half stage of a switching period. During the latter-half stage, the raffinate port is made to be closed. If the operating conditions are chosen properly in each operation using a highly efficient optimization tool, the product stream can be collected during only the period that the product is almost separated from impurity. During the other period that the product is contaminated with impurity, the collection of the product stream can be stopped by closing the product port. The uncollected product stream is then allowed to keep migrating through the adjacent zone within the SMB process. Such a partial port-closing operation including PEC and PRC was found to surpass a conventional SMB operation remarkably in throughput and product purity.     

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.     

Bi-level optimizing control of a simulated moving bed process with nonlinear adsorption isotherms

A bi-level optimizing control scheme originally proposed for a simulated moving bed (SMB) with linear isotherms has been extended to an SMB with nonlinear isotherms. Cyclic steady state optimization is performed in the upper level to determine the optimum switching period and time-varying feed/desorbent flow rates, and repetitive model predictive control is run in the lower level for purity regulation, taking the decision variables from the upper level as feed-forward information. Experimental as well as numerical study for an SMB process separating a high-concentration mixture of aqueous L-ribose and L-arabinose solutions showed that the proposed scheme performs satisfactorily against various disturbances. In contrast, an alternative scheme based on an SMB model with linear isotherms showed a limitation in the control performance; this scheme was apt to fail in purity regulation.     

Process intensification in PSA processes for upgrading synthetic landfill and lean natural gases

Process intensification aims at reducing the size of equipment by orders of magnitude and is actively perused in separation processes. Its feasibility in Pressure Swing Adsorption (PSA) processes has been explored. A 4-bed PSA and a 3-bed PSA, which emulate the moving bed processes, and duplex PSA and a modified duplex PSA have been selected for the exploratory studies. Simulation studies on the separation of a mixture of CH₄–CO₂ over 5A zeolite were carried out to compare the performance of these processes. An index has been proposed to quantify the process intensification. The 3-bed PSA and the modified duplex PSA exhibited superior performance compared to the other two for a purity of 99.9 mol% of both the products. However, the performances of the processes other than duplex were comparable when purities were set at 95 mol%. In 3-bed PSA a modest process intensification of four times reduction in size and two times reduction in energy requirement appears to be feasible if benchmarked against the PSA based on the variant of the Skarstrom cycle.