Modular PSA Tower Pairs With Integrated Flow Blocks for Scalable Capacity
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Solution Overview
Problem
Existing PSA systems face challenges in modifying capacity and efficiency due to limitations in chamber size and external piping, making it difficult to increase or decrease system size and efficiency.
Innovation Solution
A modular pressure-swing adsorption (PSA) system with interchangeable tower pairs and control blocks, allowing for easy expansion or reduction in size and minimizing external gas volume by replacing external piping with integrated gas flow passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the chamber size is increased to increase system capacity, then the productivity is improved, but the device complexity and ease of manufacture deteriorate
Solution Approach 1:
The PSA system is divided into multiple identical modular units, each comprising a pair of chambers (towers). These modules can be independently manufactured and then assembled in series to achieve the desired system capacity. This segmentation allows flexible scaling without increasing the complexity of individual chamber design or manufacturing.
2Ease of operation
If external piping is used to direct gases between chambers, then the ease of operation is improved, but the loss of substance and loss of energy increase due to larger external gas volume
Solution Approach 1:
The gas flow control function is merged directly into the chamber structure through integrated manifolds. The manifolds are formed as integral parts of the chamber assembly, eliminating the need for separate external piping. This merging reduces the volume of gas held outside the chambers and simplifies the overall system while maintaining ease of operation through the manifold's inherent flow distribution capability.
3Productivity
If custom chamber sizes are used to optimize performance, then the productivity is improved, but the ease of manufacture deteriorates due to extrusion process limitations
Solution Approach 1:
A single standardized chamber design serves multiple functions: it can be used in various positions (first or second chamber), paired with different chamber counts, and configured for different gas separation applications. The universal modular design allows the same chamber component to be manufactured using standard extrusion processes while being adaptable to diverse performance requirements through system configuration rather than custom chamber design.
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
Enables flexible capacity adjustment and improved efficiency by allowing easy addition or removal of tower pairs and reducing external gas volume, enhancing operational efficiency.
Implementation Method 1
The adsorbent material can be a carbon molecular sieve (CMS), which has a distinctive pore structure such that it selectively adsorbs oxygen and other trace gases in the compressed air stream.
Implementation Method 2
When pressure in the chamber is reduced to ambient, the adsorbed gas component becomes dislodged from the material, and that component can also be withdrawn, either as another product gas or as waste. The process by which the gas component becomes dislodged from the material is known as regeneration.
Data Source
AI summary
A pressure-swing adsorption (PSA) system includes a plurality of substantially similar pairs of towers, each tower containing adsorbent material for separating a gas into components. Each tower has a top header and the bottom headers, the headers being connected to extensions which define conduit segments. When a new pair of towers is placed alongside an existing pair of towers, the conduit segments are aligned to define longer conduits spanning all of the pairs of towers. Thus, the longer conduits can be used to direct gas into towers from all of the pairs, and to withdraw product gas from towers in all of the pairs. The capacity of the PSA system can thus be easily expanded or reduced. Some or all of the piping used to direct gas to and from the towers is replaced by one or more control blocks, which define passages for gas flow.