Rapid cycle pressure swing adsorption process and adsorbent laminates for use therein
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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 allows for faster mass transfer, reduced pressure drop, and increased productivity, enabling the simultaneous removal of H2O, CO2, and N2O at very short cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pressure swing adsorption (PSA) processes are used for air pre-purification, then removal of H2O and CO2 is achieved, but the process requires long cycle times and large equipment sizes, reducing productivity
Solution Approach 1:
The adsorbent bed is segmented into multiple functional layers with distinct adsorbent materials (activated alumina for H2O, 13X zeolite for CO2, and CuX zeolite for N2O and hydrocarbons). Each layer targets specific impurities, enabling simultaneous removal of multiple contaminants in a single pass through the bed, thus reducing cycle time and increasing productivity
Solution Approach 2:
The invention uses composite adsorbent materials comprising different types of adsorbents (alumina, zeolites) with complementary adsorption characteristics. These composite materials provide enhanced mass transfer rates and broader impurity removal capability, allowing rapid cycle operation while maintaining effective purification
2Reliability
If adsorbent regeneration is performed frequently to maintain purification efficiency, then impurity removal is improved, but switch loss and energy consumption increase
Solution Approach 1:
The adsorbent bed is designed with multiple layers that progressively remove different impurities at different stages of the adsorption cycle. This preliminary action distribution allows for more efficient regeneration sequences, reducing the frequency and intensity of switch operations needed to maintain purification efficiency, thereby minimizing switch loss
Solution Approach 2:
The multi-layer adsorbent system enables self-regeneration capabilities where the structure and composition of the layers facilitate automatic restoration of adsorption capacity during pressure cycling, reducing the need for external intervention and minimizing energy-intensive switch operations
3Reliability
If larger adsorbent beds are used to remove all impurities including N2O and hydrocarbons, then purification completeness is improved, but equipment size and capital cost increase
Solution Approach 1:
The adsorbent bed is divided into multiple functional layers, each containing adsorbent materials specifically selected for removing particular impurities (activated alumina for H2O, 13X zeolite for CO2, CuX zeolite for N2O and hydrocarbons). This segmentation allows compact equipment design while achieving complete impurity removal through targeted adsorption in each layer
Solution Approach 2:
Different regions of the adsorbent bed are assigned different adsorbent materials with specific adsorption properties tailored to local impurity removal needs. This local quality optimization enables effective removal of all impurity types in a compact configuration, avoiding the need for oversized uniform beds
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 significantly reduces switch loss, increases air recovery, and achieves very low CO2 breakthrough levels, improving air purity and productivity while minimizing equipment size and energy consumption.
Implementation Method 1
pressure swing adsorption (RCPSA) air purification process and adsorbent laminate sheets for use in said process
Implementation Method 2
rapid cycle pressure swing adsorption (RCPSA) process
Implementation Method 3
composite adsorbent laminate sheets with a mixture of zeolite, alumina, and silica gel
Data Source
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.