PSA Unit Compressor Shutdown Management
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Solution Overview
Problem
PSA units face significant production losses and increased investment costs when one of the offgas compression means is shut down, as existing solutions either reduce feed and production gas flows by 50% or require costly compressor upgrades.
Innovation Solution
A method that adjusts operating parameters in PSA units to increase the pressure of the second gas stream, allowing for compression by a single compressor to maintain production rates above 75% of nominal levels with minimal additional investment, by modifying the pressure cycle and feed gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one compressor is shut down during temporary shutdown or maintenance, then the reliability of the compression system is improved, but the production capacity of the PSA unit deteriorates significantly
Solution Approach 1:
The invention applies dynamics by making the PSA unit adaptable to different operating conditions. The control system dynamically adjusts operating parameters (pressure cycle, feed gas flow rate, production gas flow rates) based on the number of available compressors, allowing the system to transition between nominal operation with two compressors and reduced operation with one compressor, thereby maintaining optimal productivity under varying reliability conditions
Solution Approach 2:
The invention changes operating parameters to maintain productivity during compressor shutdown. Specifically, the pressure of the second stream at the PSA outlet is increased to a fifth pressure P5 higher than P3, and other parameters such as feed gas flow rate and production gas flow rates are adjusted accordingly. This allows the single remaining compressor to handle the offgas flow while maintaining production capacity above 75% of nominal levels
2Productivity
If the feed gas flow and production gas flow are reduced by 50% during compressor shutdown, then the production loss is minimized, but the investment cost increases due to required system adjustments
Solution Approach 1:
The invention changes operating parameters to maintain productivity during compressor shutdown. Specifically, the pressure of the second stream at the PSA outlet is increased to a fifth pressure P5 higher than P3, and other parameters such as feed gas flow rate and production gas flow rates are adjusted accordingly. This allows the single remaining compressor to handle the offgas flow while maintaining production capacity above 75% of nominal levels
Solution Approach 2:
The invention applies dynamics by making the PSA unit adaptable to different operating conditions. The control system dynamically adjusts operating parameters (pressure cycle, feed gas flow rate, production gas flow rates) based on the number of available compressors, allowing the system to transition between nominal operation with two compressors and reduced operation with one compressor, thereby maintaining optimal productivity under varying reliability conditions
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 enables production rates close to nominal levels with reduced production losses and investment costs by optimizing the pressure cycle and feed gas flow, while maintaining high hydrogen purity and capacity.
Implementation Method 1
PSA units face significant production losses and increased investment costs when one of the offgas compression means is shut down
Implementation Method 2
a PSA unit with one or more adsorbers, operating in pressure cycles
Implementation Method 3
comprising the step of compressing the second stream in at least two compressors in parallel to a fourth pressure P4 higher than P3
Data Source
AI summary
In a PSA separation method with compression (C1, C2) of at least one offgas (3), in case of temporary shutdown of one of the compressors (C1, C2), the operating parameters of the PSA unit (S) are changed to increase the outlet pressure of the offgas (3), in order to maintain a production level above 50% with a single compressor (C1).