Self-Supported Adsorbent Sheets for PSA Pressure Drop Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current adsorbent materials used in pressure swing adsorption applications lack sufficient strength and durability, leading to physical degradation under pressure cycles, high pressure drop, and inefficient gas flow, which limits system efficiency and increases maintenance costs.
Innovation Solution
A self-supported adsorbent material comprising adsorbent particles and a polymer binder, arranged in a parallel passage contactor structure with overlapping layers and reinforcement fibers, which allows for high gas flow and mechanical stability, and is produced through a thermally induced phase separation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If granule-shaped adsorbent materials are used in pressure swing adsorption, then adsorption capacity is achieved, but mechanical strength and durability deteriorate due to physical degradation from pressure cycles
Solution Approach 1:
The invention uses composite materials by combining adsorbent particles with a polymer binder matrix. The binder holds the particles together to form mechanically strong monoliths that can withstand pressure swing cycles, while maintaining the adsorption capacity of the particles. This composite structure resolves the contradiction between durability and mechanical strength.
Solution Approach 2:
The invention employs porous monolith structures where adsorbent particles are embedded in a polymer binder matrix. The porous structure allows gas flow while the polymer matrix provides mechanical strength and durability. This approach maintains adsorption capacity while significantly improving mechanical strength and resistance to pressure cycle degradation.
2Productivity
If beds of granules are used, then adsorption function is provided, but pressure drop increases leading to reduced flow rate
Solution Approach 1:
The invention segments the adsorbent bed into multiple monoliths arranged in parallel, rather than using a single bed of granules. This segmentation creates multiple flow paths, reducing the pressure drop across each individual monolith and allowing higher overall gas flow rates while maintaining adsorption capacity.
Solution Approach 2:
The porous monolith structure provides controlled porosity that facilitates gas flow through the adsorbent material. The interconnected pores allow efficient mass transfer and reduce pressure drop compared to dense granule beds, thereby improving gas flow rate and productivity.
3Strength
If high binder content is used to improve strength, then mechanical strength increases, but adsorbent particle concentration decreases
Solution Approach 1:
The invention optimizes the binder content parameter to achieve the minimum necessary for mechanical strength while maximizing adsorbent particle concentration. By carefully controlling the binder concentration and using efficient binder distribution, the invention maintains adequate mechanical strength with minimal binder content, thereby maximizing the quantity of active adsorbent particles.
Solution Approach 2:
The composite material design uses a polymer binder as a matrix to hold adsorbent particles together. The binder content is optimized to provide just enough mechanical strength and structural integrity while minimizing the volume occupied by binder, thus maximizing the concentration of active adsorbent particles in the composite material.
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
The solution provides a mechanically stable adsorbent material that maintains performance over 200,000 to 1,000,000 cycles, reduces pressure drop, and enhances gas adsorption efficiency, allowing for longer cycle times and reduced maintenance costs.
Implementation Method 1
The adsorbent sheet is made by a thermally induced phase separation process
Implementation Method 2
Pressure swing adsorption applications
Data Source
Figure 1A~1B
Figure 1C~2B
Figure 3A~3B
AI summary
Provided herein are a parallel passage contractors, which may be useful in pressure swing adsorption (PSA), pressure and temperature swing adsorption (PTSA), or vacuum pressure swing adsorption (VPSA) systems, having one or more self-supported adsorbent sheets arranged in multiple, overlapping layers mechanically spaced to allow gas flow. Also provided are systems utilizing such parallel passage contactors and methods for preparing the contactors.