Compressor integrated hybrid TSA / PSA dehydration of co2

Abstract

A method for regenerating an adsorption bed for dehydration of a process fluid by using at least a portion of the process fluid from a main process compressor includes directing a first portion from a first outlet of an adsorption bed system into a dehydrated process fluid inlet of the adsorption bed system for regenerating at least one adsorption bed in the adsorption bed system; directing a second portion into a higher pressure compression section of the main process compressor; and directing a hydrated process fluid from a second outlet into a lower pressure compressor section of the main process compressor.

Description

Docket No. 2025PF00105WOCOMPRESSOR INTEGRATED HYBRID TSA / PSA DEHYDRATION OF CO2CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US provisional application 63 / 759,608 filed on February 18, 2025.BACKGROUND

[0002] Aspects of the present invention generally relate to dehydration of CO2 in Carbon capture, utilization, and storage (CCUS) systems, and more specifically to compressor integrated hybrid systems for dehydrating CO2.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0003] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0004] FIG. 1 illustrates an aspect of the subject matter in accordance with one embodiment.

[0005] FIG. 2 illustrates an aspect of the subject matter in accordance with one embodiment.

[0006] FIG. 3 illustrates a method 300 for regenerating an adsorption bed for dehydration of a process fluid by using at least a portion of the process fluid from a main process compressor in accordance with one embodiment.DETAILED DESCRIPTION

[0007] In the following detailed description, various specific details are set forth in order to provide a thorough understanding of such embodiments. However, those skilled in the art will understand that disclosed embodiments may be practiced without these specific details that the aspects of the present invention are not limited to the disclosed embodiments, and that aspects of the present invention may be practiced in a variety of alternative embodiments. In other instances, methods, procedures, and components, which would be well-understood by one skilled in the art have not been described in detail to avoid unnecessary and burdensome explanation.Docket No. 2025PF00105WO

[0008] Furthermore, various operations may be described as multiple discrete steps performed in a manner that is helpful for understanding embodiments of the present invention. However, the order of description should not be construed as to imply that these operations need be performed in the order they are presented, nor that they are even order dependent, unless otherwise indicated. Moreover, repeated usage of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it may.

[0009] The invention advantageously enhances carbon dioxide (CO2) dehydration in carbon capture, utilization, and storage (CCUS) plants by integrating the regeneration of one or more adsorption beds with the main process CO2 compressor, rather than relying on a separate blower or compressor for regeneration. This integration leverages the main CO2 compressor to recycle regeneration gas, eliminating the need for stand-alone regeneration compressors or blowers, reducing enthalpy requirements, and lowering overall energy consumption, as the main compressor imparts energy to the regeneration stream. Significantly, the regeneration stream is recycled back into the compressor instead of being purged.

[0010] In one aspect, a Pressure Swing Adsorption (PSA) process is employed by depressurizing and purging the adsorbent bed, while in another aspect, a Temperature Swing Adsorption (TSA) process is applied by heating the bed to remove contaminants. During adsorption, CO2 flows through the adsorption beds to remove water. For regeneration, the beds are both depressurized (PSA effect) and heated (TSA effect), while the regeneration gas is recycled through the main CO2 compressor.

[0011] Importantly, the pressure reduction during PSA provides significant benefits: it lowers the partial pressure of water and other contaminants, accelerating desorption and improving regeneration efficiency. This pressure drop also reduces the thermal energy necessary during TSA, as contaminants are more easily removed at lower pressures, thereby optimizing heat input and minimizing energy demand. By combining pressure swing and temperature swing effects, improved bed utilization, and reduced operating costs, while maintaining high dehydration performance.

[0012] A further advantage is that the main CO2 compressor is typically designed to comply with major industry standards such as API 617 or equivalent codes, ensuring high reliability and availability. This eliminates the need for sparing blowers at a typical 2 x 100% configuration, which would otherwise be necessary to achieve similar reliability if separateDocket No. 2025PF00105WOregeneration compressors were used. Consequently, the design simplifies equipment redundancy, reduces capital expenditure, and improves operational robustness.

[0013] Aspects of the invention have several advantages:

[0014] Utilization of the main CO2 compressor for the recycling of regeneration gas, thereby eliminating standalone regeneration compressors by novelly integrating their function into the main CO2 compressor. Advantageously, integration of regeneration pressure drop management can be performed in the main compressor, providing bed life extension and improved energy efficiency, energy. Additionally, blowers would have a lower efficiency than the main CO2 compressor. Footprint of the system is also reduced allowing for a more compact design.

[0015] Reduction in necessary enthalpy of regen gas for bed regeneration. Highlight operational synergy between PSA and TSA cycles under compressor-driven energy recovery.

[0016] Simultaneously generating operational synergy between PSA and TSA cycles under compressor-driven energy recovery.

[0017] FIG. 1 shows a schematic of system 100 for regenerating an adsorption bed for dehydration of a process fluid by using at least a portion of the process fluid from a main process compressor, such as in a compressor-integrated hybrid TSA / PSA system 100.

[0018] In an embodiment, the system 100 includes an adsorption bed system 106 having a first outlet 146 for discharging a dehydrated process fluid 130, a second outlet 154 for discharging a hydrated process fluid 128, and a dehydrated process fluid inlet 148 for receiving a first portion 126 of the dehydrated process fluid 130. In an aspect, the system 100 includes a main process compressor 102 configured for receiving a second portion 152 of the dehydrated process fluid 130 in a higher pressure compression section 116 and receiving the hydrated process fluid 128 in a lower pressure compressor section 114. In another aspect, the system 100 includes a pressure reducing device 140 for reducing a downstream pressure of the first portion 126 of a dehydrated process fluid 130. In an embodiment depicted int FIG. 2 a pressure reducing device 202 for reducing a downstream pressure of the hydrated process fluid 128. In an aspect, the hydrated process fluid 128 has a higher water content than the dehydrated process fluid 130, and the higher pressure compression sections 116 has an operating pressure greater that an operating pressure of the lower compression lower pressure compressor section 114. Significantly, neither system 100 or 200 use of a separate device, such as a blower, for providing a dehydrating fluid separate from the main process compressor 102Docket No. 2025PF00105WO

[0019] In an embodiment, the process fluid comprises at least a portion of carbon dioxide, and the system 100 is a part of a CCUS plant. In an aspect, the system 100 comprises a controller 132 in communication with at least one flow rate sensor 142 and a surge controller 144 for dynamically adjusting an operating parameter of the system 100 based on an operating condition of the system 100. In embodiments, the operating parameter is at least one of pressure and temperature, and the operating condition is at least one of a carbon dioxide flow rate and a moisture content.

[0020] In block 302 of Fig. 3, a method 300 of regenerating an adsorption bed for dehydration of a process fluid, such as a process fluid comprising at least a portion of carbon dioxide by using at least a portion of the process fluid from a main process compressor includes directing a first portion 126 of a dehydrated process fluid 130 from a first outlet 146 of an absorption adsorption bed system 106 into a dehydrated process fluid inlet 148 of the absorption adsorption bed system 106 for regenerating at least one adsorption bed 150 in the adsorption bed system 106. In block 304, method 300 directs a second portion 152 of the dehydrated process fluid 130 into a higher pressure compression section 116 of the main process compressor. In block 306, method 300 directs a hydrated process fluid 128 from a second outlet 154 of the adsorption bed system 106 into a lower pressure lower pressure compressor section 114 of the main process compressor 102. In an aspect, the hydrated process fluid 128 has a higher water content than the dehydrated process fluid 130, and the higher pressure compression section 116 has an operating pressure greater that an operating pressure of the lower pressure compressor section 114. Significantly, the method 300 is performed without the use of a separate device, such as a blower, to provide a dehydrating fluid separate from that provided by the main process compressor 102. In an aspect, a mass flow of the first portion 126 of the dehydrated process fluid 130 is about 20% of a mass flow of the dehydrated process fluid 130. In embodiments, the method 300 further comprises reducing an output pressure of the adsorption bed system 106 to align with a desired input pressure of the lower pressure compressor section 114. In one aspect, the output pressure is reduced in the first portion 126 of a dehydrated process fluid 130. In another aspect, the output pressure is reduced in the hydrated process fluid 128. In other embodiments, the reduction of operating pressure comprises decreasing the enthalpy necessary for sufficient heating for the first portion 126 of a dehydrated process fluid 130 to accomplish a desired regeneration of an adsorption bed 150, wherein a regeneration of the adsorption bed system may be synchronized with a compressionDocket No. 2025PF00105WOcycle of the main process compressor 102. In yet another embodiment, the method 300 includes dynamically adjusting pressure and temperature parameters of the system 100 based on a carbon dioxide flow rate and / or a moisture content.

[0021] Although exemplary embodiments of the present disclosure have been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form. For example, the system may be implemented in various configurations depending on the specific requirements of the CCUS project, and may be adapted to different compressor architectures and adsorption bed designs. Heat exchangers for thermal management such as higher pressure section aftercooler 156, higher pressure section aftercooler 118 lower pressure section interchanger 108 and lower pressure section aftercooler 120, and high lower pressure section aftercooler 120 in addition to other valving and control systems for pressure and flow regulation, and separation vessels 104, 110 , and 204 and holding vessels 112 may be provided.LISTING OF DRAWING ELEMENTS100 system102 main process compressor104 separation vessel106 adsorption bed system108 lower pressure section interchanger110 separation vessel112 holding vessel114 lower pressure compressor section116 higher pressure compression section118 higher pressure section aftercoolerDocket No. 2025PF00105WOlower pressure section aftercooler inlet flowoutlet flowfirst portionhydrated process fluid dehydrated process fluid controllersensed inputscontrol outputshydrated stream inputpressure reducing deviceflow rate sensorsurge controllerfirst outletdehydrated process fluid inlet adsorption bedsecond portionsecond outlethigher pressure section aftercooler hydrated stream inputsystemDocket No. 2025PF00105WOpressure reducing device separation vessel methodblockblockblock

Claims

Docket No. 2025PF00105WOCLAIMSWhat is claimed is:

1. A method for regenerating an adsorption bed for dehydration of a process fluid by using at least a portion of the process fluid from a main process compressor, the method comprising:directing a first portion from a first outlet of an adsorption bed system into a dehydrated process fluid inlet of the adsorption bed system for regenerating at least one adsorption bed in the adsorption bed system,directing a second portion into a higher pressure compression section of the main process compressor, anddirecting a hydrated process fluid from a second outlet into a lower pressure compressor section of the main process compressor, wherein the hydrated process fluid has a higher water content than the first portion of the dehydrated process fluid, and wherein the higher pressure compression section has an operating pressure greater that an operating pressure of the lower pressure compressor section.

2. The method of claim 1, wherein the process fluid comprises at least a portion of carbon dioxide.

3. The method of claim 1, wherein the method is performed without the use of a separate device for providing a dehydrating fluid separate from the main process compressor.

4. The method of claim 3, wherein the separate device is a blower.

5. The method of claim 1, wherein a mass flow of the first portion of the dehydrated process fluid is about 20% of a mass flow of the dehydrated process fluid.

6. The method of claim 1, further comprising reducing a output pressure of the adsorption bed system to align with a desired input pressure of the lower pressure compressor section.

7. The method of claim 6, wherein the output pressure is reduced in the first portion.

8. The method of claim 6, wherein the output pressure is reduced in the hydrated process fluid.8Docket No. 2025PF00105WO9. The method of claim 6, wherein reducing the operating pressure comprises decreasing the enthalpy necessary for sufficient heating for the first portion to accomplish a desired regeneration of the adsorption bed.

10. The method of claim 1, wherein a regeneration of the adsorption bed system is synchronized with a compression cycle of the main process compressor.

11. The method of claim 1, further comprising dynamically adjusting pressure and temperature parameters of the main process compressor based on a carbon dioxide flow rate and / or a moisture content.

12. A system for regenerating an adsorption bed for dehydration of a process fluid by using at least a portion of the process fluid from a main process compressor, the system comprising:an adsorption bed system having a first outlet for discharging a dehydrated process fluid, a second outlet for discharging a hydrated process fluid, and a dehydrated process fluid inlet for receiving a first portion of the dehydrated process fluid;the main process compressor configured for receiving a second portion in a higher pressure compression section and receiving the hydrated process fluid in a lower pressure compressor section;and a pressure reducing device for reducing a downstream pressure of at least one of the first portion and the hydrated process fluid;wherein the hydrated process fluid has a higher water content than the dehydrated process fluid, and wherein the higher pressure compression section has an operating pressure greater that an operating pressure of the lower pressure compressor section.

13. The system of claim 12, wherein the process fluid comprises at least a portion of carbon dioxide.

14. The system of claim 12, wherein the system comprises a controller in communication with at least one sensor and one controller for dynamically adjusting an operating parameter of the system based on an operating condition of the system.

15. The system of claim 14, wherein the operating parameter is at least one of pressure and temperature.Docket No. 2025PF00105WO16. The system of claim 14, wherein the operating condition is at least one of a carbon dioxideflow rate and a moisture content.10

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