PSA Unit Feed Stream Merging for Hydrogen Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for hydrogen recovery in refineries and petrochemical operations using multiple PSA units face inefficiencies, including excess feed stream disposal, high operating costs, and adsorbent material damage due to operating at maximum capacity, which reduces hydrogen recovery and increases fuel gas consumption.
Innovation Solution
Combining a steam reformer hydrogen product stream with an offgas stream to create a single feed for a second PSA unit, reducing the load on the steam reformer and PSA units, and recycling tail gases to enrich the hydrocarbon content and heating value of the tail gas, thereby increasing hydrogen recovery and reducing fuel gas consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple PSA units are operated at maximum capacity to achieve maximum hydrogen recovery, then hydrogen recovery is improved, but adsorbent material is damaged due to impurity carryover between adsorbent layers
Solution Approach 1:
The patent combines multiple PSA units into a single PSA unit that processes a combined feed stream from steam reformer and refinery offgas. This consolidation allows the system to achieve maximum hydrogen recovery while operating at moderate capacity, preventing adsorbent damage from impurity carryover that occurs when multiple units operate at maximum capacity.
2Productivity
If multiple PSA units are operated at maximum capacity to achieve maximum hydrogen recovery, then hydrogen recovery is improved, but operating costs increase due to increased feed stream and fuel gas stream requirements
Solution Approach 1:
The patent combines multiple PSA units into a single PSA unit that processes a combined feed stream from steam reformer and refinery offgas. This consolidation reduces operating costs by eliminating redundant feed streams and fuel gas requirements while maintaining maximum hydrogen recovery through integrated processing.
3Reliability
If excess feed stream for PSA units is sent to flare or burned as fuel gas, then PSA unit capacity constraints are maintained, but hydrogen recovery is reduced and fuel gas consumption increases
Solution Approach 1:
The patent combines the steam reformer product stream with refinery offgas feed stream into a single combined feed stream for one PSA unit. This integration allows excess offgas that would otherwise be flared or burned to be effectively utilized as additional feed, increasing hydrogen recovery while maintaining PSA unit operational reliability through proper capacity management.
4Reliability
If excess feed stream for PSA units is sent to flare or burned as fuel gas, then PSA unit capacity constraints are maintained, but fuel gas consumption increases
Solution Approach 1:
The patent combines the steam reformer product stream with refinery offgas feed stream into a single combined feed stream for one PSA unit. This integration eliminates the need to flare or burn offgas as fuel by utilizing it as additional feed material, thereby reducing fuel gas consumption while maintaining PSA unit operational reliability.
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 enhances total hydrogen recovery, reduces the load on steam reformers and PSA units, decreases fuel gas consumption, and minimizes excess gases being flared or burned as fuel, while enriching the hydrocarbon content and heating value of the tail gas from the PSA unit.
Implementation Method 1
a single pressure swing adsorption (PSA) unit be utilized within a refinery or petrochemical operation to recover hydrogen from a flow stream
Implementation Method 2
The use of pressure swing adsorption (PSA) to separate gas mixtures is well known in the art
Implementation Method 3
combining a steam reformer hydrogen product stream with an offgas stream
Data Source
AI summary
A method of hydrogen recovery in refineries and petrochemical operations in which some or all of the feed streams for separate PSA units are combined and utilized as feed for a single PSA unit, and in which some or all of steam reformer product and refinery offgas streams being used as feed streams for separate PSA units are combined and utilized as feed for a single PSA unit. Total hydrogen recovery is increased by maximizing hydrogen recovery from refinery offgases. The load on the steam reformer is reduced by lowering the reformer feed stream. Refinery fuel gas consumption is reduced in the steam reformer furnace. The amount of a PSA feed stream being burned as fuel or sent to flare is reduced. The load on the PSA unit receiving feed from refinery offgases is reduced. The hydrocarbon content and heating value of the tail gas from the PSA unit fed by the steam reformer product stream is enriched.