High-Pressure PSA Integration for Hydroprocessing Hydrogen Recovery
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Solution Overview
Problem
Current hydroprocessing units face inefficiencies in hydrogen recovery and utilization, leading to increased capital and operating expenses, particularly in complexes lacking integrated high-pressure pressure swing adsorption (PSA) units, which limits the overall economics and hydrogen balance.
Innovation Solution
Incorporating a PSA unit within the make-up gas compression system of hydroprocessing units at higher pressures (3447.4 kPa to 6894.8 kPa) and utilizing a chiller to reduce feed gas temperature, thereby enhancing hydrogen recovery and reducing equipment size and compression power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional stand-alone PSA unit is used at low pressure (300-400 psig), then the PSA unit can operate with standard equipment, but hydrogen recovery is limited to 85-90% and additional booster compressors are required
Solution Approach 1:
The patent applies parameter changes by operating the PSA unit at significantly higher pressure (500-1000 psig) compared to conventional low-pressure operation (300-400 psig). This pressure increase improves hydrogen recovery by 3-6 percentage points and eliminates the need for additional booster compressors, directly resolving the contradiction between ease of manufacture and hydrogen recovery loss
2Loss of substance
If a PSA unit is integrated into the make-up gas compression system at high pressure, then hydrogen recovery increases by 3-6 percentage points, but equipment complexity and initial investment increase
Solution Approach 1:
The patent merges the PSA unit with the existing make-up gas compression system, integrating hydrogen recovery functionality into the hydrocracker's compression infrastructure. This integration improves hydrogen recovery while minimizing additional equipment by utilizing the existing high-pressure environment and compression capabilities
Solution Approach 2:
The patent extracts the need for separate booster compressors by taking out the compression function and incorporating it directly into the PSA unit operation at high pressure. This eliminates redundant equipment while maintaining improved hydrogen recovery
3Device complexity
If PSA hydrogen product is produced at low pressure, then equipment requirements are simpler, but multiple stages of make-up gas compression are required to reach reaction system pressure
Solution Approach 1:
The patent changes the pressure parameter of the PSA operation from conventional low pressure to high pressure (500-1000 psig), matching the hydrocracker operating pressure range. This eliminates the need for multiple compression stages and reduces compression power consumption while maintaining simpler equipment requirements
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 increases hydrogen recovery by 3 to 6 percentage points, reduces equipment count, and decreases costs by allowing smaller PSA units and lower compressor power consumption, providing a synergistic benefit that conventional stand-alone PSA units cannot achieve.
Implementation Method 1
a pressure swing adsorption (PSA) unit to derive pure hydrogen (99.9 mol%) that is used as make-up gas to the hydrocracking unit
Implementation Method 2
the compressed gas stream is sent to a pressure swing adsorption unit containing a plurality of beds with at least 5 pressure equalization steps to produce a hydrogen stream
Implementation Method 3
utilizing a chiller to reduce feed gas temperature, thereby enhancing hydrogen recovery
Data Source
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AI summary
The invention provides a process for providing a hydrogen stream to a process utilizing hydrogen comprising obtaining a gas stream containing hydrogen and compressing the gas stream to a pressure of at least 600 psig, Then the compressed gas stream is sent to a pressure swing adsorption unit containing a plurality of beds with at least 5 pressure equalization steps to produce a hydrogen stream. The hydrogen stream can then be compressed and sent to a process utilizing hydrogen. The compressed gas stream may be chilled before entering the pressure swing adsorption unit.