Process including a cryogenic distillation of air and a pre purification step including a rapid cycle pressure swing adsorption process using adsorbent laminates comprising alumina and zeolite.
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Solution Overview
Problem
Current air pre-purification processes for cryogenic air separation struggle with efficient removal of water, carbon dioxide, nitrous oxide, and hydrocarbons, leading to operational issues, safety hazards, and energy waste due to incomplete regeneration of adsorbents and large equipment sizes.
Innovation Solution
The implementation of a rapid cycle pressure swing adsorption (RCPSA) process using composite adsorbent laminate sheets with a mixture of zeolite, alumina, and silica gel, which reduces switch loss, pressure drop, and cycle time while maintaining high impurity removal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional PSA processes are used with traditional adsorbent beds, then impurity removal is achieved, but equipment size is large and regeneration is incomplete
Solution Approach 1:
The patent employs thin film laminate adsorbent structures instead of traditional bulky adsorbent beds. The laminate configuration allows for compact design while maintaining effective adsorption capacity, directly reducing equipment volume while preserving impurity removal efficiency
Solution Approach 2:
The patent uses composite adsorbent laminates comprising multiple layers with different adsorption characteristics. This composite structure enables simultaneous removal of multiple impurities (water, CO2, N2O, hydrocarbons) in a single compact unit, improving reliability while minimizing equipment size
2Reliability
If conventional PSA processes are used, then impurity removal is achieved, but energy consumption is high due to incomplete regeneration
Solution Approach 1:
The patent implements rapid cycle pressure swing adsorption with optimized periodic cycling. The enhanced cycle frequency and duration distribution improve adsorbent regeneration completeness, reducing energy consumption while maintaining impurity removal efficiency
Solution Approach 2:
The patent modifies operational parameters including pressure swing magnitude, cycle time, and temperature conditions to optimize the adsorption-desorption cycles. These parameter changes enhance regeneration efficiency and reduce energy loss while preserving purification performance
3Productivity
If rapid cycle pressure swing adsorption is implemented, then productivity increases and cycle time decreases, but process complexity increases
Solution Approach 1:
The patent divides the air purification process into multiple parallel adsorption columns operating in sequence through rapid cycling. This segmentation allows continuous operation at high productivity while managing complexity through modular configuration and automated control
Solution Approach 2:
The patent introduces automated control systems and intermediary components to manage the rapid cycling process. These intermediaries coordinate the complex multi-column operation, simplifying process control while enabling high-speed cyclic operation for increased productivity
4Reliability
If traditional adsorbent beds are used, then impurity removal is achieved, but switch loss is high
Solution Approach 1:
The patent implements preliminary pressure equalization and flow conditioning steps before adsorbent bed switching. This preliminary action prepares the system for smooth transitions, minimizing turbulence and preventing premature breakthrough, thereby reducing switch loss while maintaining purification efficiency
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 achieves low CO2 breakthrough levels, increased productivity, and improved air purity with reduced equipment size and energy consumption, enhancing the safety and efficiency of air separation processes.
Implementation Method 1
a rapid cycle pressure swing adsorption (RCPSA) process using adsorbent laminates comprising alumina and zeolite
Implementation Method 2
The cryogenic separation of air requires a pre-purification step
Data Source
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AI summary
A rapid cycle pressure swing adsorption (RCPSA) air purification process, apparatus, and device for the removal of at least one of water, carbon dioxide, nitrous oxide, and one or more hydrocarbons from a feed air stream prior to cryogenic air separation.