Adsorbent Regeneration Using Heated Feed Gas
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Solution Overview
Problem
Conventional methods for regenerating adsorbents used in industrial gas drying require external gases like nitrogen or air, leading to equipment complexity and inefficiencies, and leave residual impurities in the gas stream, while also being costly and inefficient in terms of energy usage.
Innovation Solution
A method utilizing the feed gas from a chemical reaction for regeneration, where the gas is heated and cooled using existing plant equipment, allowing for continuous adsorbent regeneration and drying by alternating beds between adsorption and regeneration modes, with water separation and heat exchange processes to manage moisture effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods use external gases (nitrogen or air) for adsorbent regeneration, then the adsorbent can be regenerated, but the equipment complexity increases and residual impurities remain in the gas stream
Solution Approach 1:
The feed gas serves multiple functions: it is the reactant for the chemical reaction, the drying medium for the product stream, and the regeneration gas for the adsorbent. This multi-functionality eliminates the need for separate external gas supplies and simplifies the overall system architecture while ensuring effective adsorbent regeneration.
Solution Approach 2:
The invention merges the reaction gas stream and regeneration gas stream into a single feed gas stream. The product stream from the chemical reaction, which would otherwise require separate drying and regeneration processes, is directly used to regenerate the adsorbent after water separation, combining multiple process functions into an integrated system.
2Reliability
If conventional methods use external gases for regeneration, then adsorbent can be restored, but operational costs increase due to additional equipment and energy consumption
Solution Approach 1:
The system uses its own product stream (after water separation) to regenerate the adsorbent, rather than requiring external gas supplies. The feed gas automatically serves as the regeneration medium, eliminating the need for separate heating systems, gas storage tanks, and control equipment, thereby reducing operational costs and energy consumption.
Solution Approach 2:
Instead of discarding the product stream after water separation, the invention recovers and reuses it as the regeneration gas for the adsorbent. This recovery approach eliminates waste and reduces the need for additional energy-intensive regeneration processes, lowering operational costs while maintaining effective adsorbent regeneration.
3Reliability
If external gases are used for regeneration, then adsorbent can be regenerated, but nitrogen or air residues contaminate the dried gas stream
Solution Approach 1:
The regeneration gas is the same feed gas that will eventually become the dried product stream. Since the adsorbent is regenerated with the same gas composition that passes through it for drying, there is no introduction of foreign substances like nitrogen or air, ensuring the dried gas stream remains free from contamination and maintains its required purity.
4Reliability
If conventional regeneration methods are used, then adsorbent can be restored, but additional equipment for heating and cooling is required
Solution Approach 1:
The feed gas heating system serves dual purposes: it heats the feed gas for the chemical reaction and simultaneously provides the thermal energy needed for adsorbent regeneration. The same heater that prepares the feed gas for reaction also heats the portion of gas used for regenerating the adsorbent, eliminating the need for separate heating equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces operational costs, eliminates the need for external regeneration gases, ensures continuous gas drying, and effectively removes moisture from product streams, enhancing the efficiency and simplicity of the gas drying process.
Implementation Method 1
removing remainder of the moist from the partially dried product stream by passing the stream through at least one bed of solid adsorbent and adsorbing the moist
Implementation Method 2
passing at least part of the gaseous feed stream having been dried in a water separation step and heated in the heater through the bed of loaded adsorbent and desorbing moist into the dried heated feed stream
Implementation Method 3
heating and cooled using existing plant equipment
Implementation Method 4
heated in the heater through the bed of loaded adsorbent
Data Source
Figure 1
AI summary
Method for removal of moist contained in a gaseous product stream (8) having been obtained by reaction of a gaseous feed stream (2) being heated in a process heater (4) prior to the reaction (6) comprising the steps of removing part of the moist by cooling the product stream below its dew point and separating water (14) from the cooled product stream to obtain a partially dried product stream (16); removing remainder of the moist from the partially dried product stream (16) by passing the stream through at least one bed of solid adsorbent (20a,20b) and adsorbing the moist and withdrawing a dried product stream (24) until the adsorbent is saturated with the moist; regenerating the saturated adsorbent (20a,20b) by passing at least part (26) of the gaseous feed stream having been heated in the process heater (4) through the bed of loaded adsorbent (20a,20b) and desorbing moist into the heated feed stream and passing the heated and moist laden feed stream (34) to the reaction (6); and cooling the regenerated adsorbent (20a,20b) by passing at least a part (36) of the feed stream prior to the heating of the stream through the regenerated adsorbent (20a,20b); passing the feed stream (28) being withdrawn from the adsorbent (20a,20b) through the heater (4) and subsequently to the reaction (6).