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Nitrogen Generation by Pressure Swing Adsorption

Nitrogen Generation by Pressure Swing Adsorption

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Contents.

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Introduction

4

The process

PSA process cycle

Plant control and turn down

Start-up and shut-down

Turndown operation

Operation and maintenance

Safety aspects

Safety, health, environment and quality (SHEQ)

Building / shelter

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G- series nitrogen PSA

The advantages of Linde N 2 -PSA

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A- series nitrogen PSA

The N 2 -PSA layout

The scope of supply

Contact

Cover page: N 2 PSA Plant / El Chacay / Chile / Minera Los Pelambres

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Introduction.

The experience The use of the Pressure Swing Adsorption (PSA) process has seen tremendously growth during the last decades mainly due to its simplicity and low operating costs. Major applications have been the recovery of high purity hydrogen, methane and carbon dioxide as well as the generation of nitrogen and oxygen. In addition, it has gained significance for the bulk removal of carbon dioxide from direct reduction top-gases.

Linde as the world leader in adsorption technology has designed and supplied more than 500 PSA plants - including the world´s largest units and units with highest availability.

The Linde nitrogen PSA generators The Linde nitrogen PSA generators are designed for onstream applications, where there is need for clean, dry nitrogen of high purity for inerting, blanketing and purging.

Depending on client needs, the PSA plant can be designed for nitrogen product purity in the range of a few percent oxygen content or with oxygen content in the ppmv level.

The nitrogen product is normally delivered between 4 barg to 9 barg (60 psig to 130 psig). In case a higher product pressure is required a downstream nitrogen compressor will be applied.

The capacities of the Linde nitrogen PSA gen- erators range from small plants with product requirements of only several Nm³/h, up to large-scale plants with several thousand Nm³/h nitrogen product flows.

Linde N 2 -PSA systems are available in two plant series:

– The G-series, fully standardized with a range of 26 capacity types.

– The A-series, a tailored modular plant series that features highest capacities and purities. This series can be supplied to the needs of customer‘s specifications.

Linde´s PSA systems have proven to be success- ful in cases where performance, flexibility, availability and reliability are the determining factors. High quality and easy accessibility to all components minimize and facilitate main- tenance to the maximum extent.

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The process.

The separation of nitrogen and oxygen from air takes place in an adsorber vessel filled with carbon molecular sieve. This is based on the fact of faster kinetic diffu- sion of oxygen molecules into the pore struc- ture of the carbon molecular sieve than for nitrogen molecules.

Pressure time diagram for nitrogen PSA process

molecules. Pressure time diagram for nitrogen PSA process Carbon molecular sieve Adsorber A A: C B:

Carbon molecular sieve

Adsorber A A: C B: B D C: D: E: Pressure equalization Back purge step
Adsorber A
A:
C
B:
B
D
C:
D:
E:
Pressure equalization
Back purge step
Nitrogen production
Pressure equalization
Depressurization
A
E
Adsorber B
Time
Pressure

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to atmosphere PSA N 2 -buffer O 2 -analyzer AE Nitrogen Adsorber A Silencer Adsorber
to
atmosphere
PSA N 2 -buffer
O
2 -analyzer
AE
Nitrogen
Adsorber A
Silencer
Adsorber B
Compressed air
Air
compressor
Nitrogen
Air
Waste gas
Waste

PSA process cycle

Typical process flow diagram of a Linde nitrogen PSA plant

The PSA process cycle consists of two key mechanisms:

product flows from adsorber bed A into a nitro- gen product receiver prior to entering the pro-

tion and the oxygen enriched waste gas is vented to the atmosphere. Depressurisation

– Pressurisation/adsorption

duct piping. Simultaneously, adsorber bed B is

permits the release of oxygen, carbon dioxide,

– Depressurisation/desorption

depressurised to atmospheric pressure.

and water vapor previously adsorbed during

Compressed air alternately pressurises each

Upon completion of nitrogen production from adsorber bed A, an equalisation step occurs.

nitrogen production from adsorber bed A. At the same time, adsorber bed B is brought to opera-

of two identical adsorber beds. Beginning at

Adsorber bed B (atmospheric pressure) is pres-

ting pressure, and begins its nitrogen production

a

point in the cycle where one adsorber bed (A)

surised to an intermediate pressure as the gas

portion of the cycle.

is

being pressurised and the other adsorber bed

remaining in adsorber bed A (at operating pres-

(B) is undergoing depressurisation, the descrip- tion of the PSA process cycle is as follows:

sure) flows into adsorber bed B. During this step, air is not consumed nor is product gas generated.

Following nitrogen production, adsorber bed B undergoes equalisation and subsequent de-

As compressed air enters adsorber bed A, mois- ture, oxygen, and carbon dioxide are adsorbed. After operating pressure is reached, nitrogen

Therefore a nitrogen receiver is applied to allow for a constant flow, purity and pressure of the nitrogen product throughout the PSA cycle. Adsorber bed A then undergoes depressurisa-

pressurisation. The cycle continues at the point where adsorber bed A undergoes pressurisation and adsorber bed B is depressurised.

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Plant control and turn down The N 2 -PSA plant is controlled by a programm- able logic controller (PLC).

Its main control features include:

– Automatic operation of the entire N 2 -PSA plant

– Supervision of process parameters with safety shut down and alarm in case of abnormal plant operation

– Control of the process values on a display

– Sophisticated plant diagnostics

The (im)purity of the product is being checked continuously by an automatic online O 2 -analyzer.

Typical A-series nitrogen PSA

Start-up and shut-down The start-up of the plant is a simple push button operation. The product is being delivered within a short time from start-up.

At shut-down of the plant, a precisely defined programme cycle continues to run for a few minutes before complete shut-down is reached. The adsorbers are then in regenerated condi- tions and prepared for restart of operation. After restart product in accordance with specification can be produced within a few minutes.

Turndown operation The plant flowrate can be reduced by inserting an “idle” step in the cycle thus saving plant power.

This is performed automatically by the PLC. The PLC program adjusts process parameters accordingly.

saving plant power. This is performed automatically by the PLC. The PLC program adjusts process parameters

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Refinery Glass Metals Purging Preserving Treating Blanketing Petro- LINDE N 2 -PSA APPLICATIONS Oil &
Refinery
Glass
Metals
Purging
Preserving
Treating
Blanketing
Petro-
LINDE N 2 -PSA
APPLICATIONS
Oil & gas
chemical
Storing
Filling
Spinning
Inerting
Chemical
Food
Electronics

Operation and maintenance The LINDE N 2 -PSA plant is designed to run un- attended during normal operation. The plant requires a minimum of operating and mainte- nance attention. The N 2 -PSA will be designed and constructed to provide proper flexibility and easy accessibility for operation and maintenance of the machinery, valves and instrumentation.

Safety aspects The plant operates at moderate temperatures and pressures. All necessary safety devices to avoid increased pressures, excessive or insuf- ficient temperature or other failure functions are provided.

Application of PSA generated Nitrogen

Building/shelter Due to the severe ambient conditions and in or- der to protect the PSA unit from driving rain and direct sunlight, it is strongly recommended to install the PSA unit in a closed shelter, at least a roof covering the valve skid and the compressor shall be supplied.

Safety, health, environment and quality (SHEQ) Controls relating to safety, health, environment and quality are a pre-requisite for the Linde work processes.

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G-series nitrogen PSA.

The G-series comprises fully standardized nitrogen PSA generators with 26 plant sizes and hence providing optimal solution within its product range and purity.

Particular features of G-series nitrogen PSA

– Fully standardized

– Low investment

– Compact arrangement

– Existing standard documentation

– Short delivery, installation and commissioning time

The product ranges for the G-series plants are:

N 2 -product range

50 - 1,500 Nm³/h

Nitrogen (N 2 +Ar) purity

97 - 99.9 %

Oxygen impurity

3 - 0.1 %

Typical G-series nitrogen PSA plant for the generation of nitrogen, 310 Nm³/h, 0.5% O 2

Oxygen impurity 3 - 0.1 % Typical G-series nitrogen PSA plant for the generation of nitrogen,

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A-series nitrogen PSA plant designed according to individual project specification

A-series Nitrogen PSA

The A-series comprise fully tailored nitrogen PSA generators. With its A-series PSA plants Linde is able to follow individual customers project specifications, standards and require- ments. (e.g. for refineries etc.)

Particular features of A-series nitrogen PSA

– Tailor made according to individual project specifications and requirements

– High capacity and purity range

– Modular and prefabricated design

The product ranges for the A-series plants are:

N 2 -product capacity

50 - 5,000 Nm³/h

Nitrogen (N 2 +Ar) purity

97 - 99.9999 %

Oxygen impurity

3 % - 1 ppm

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The advantages of Linde N 2 -PSA The Linde PSA process for the generation of nitrogen provides remarkable advantages:

First quality

– Only components are used which have proven highest durability.

Low nitrogen product cost

– The Linde PSA system produces high purity nitrogen at lowest cost compared to convent- ional cryogenic units or liquids supplied from outside.

Typical G-series nitrogen PSA plant mounted in a container

Highest reliability

– The PSA system provides highest reliability. The control system allows for the production of nitrogen at the specified flow and purity within minutes of demand using simple push button.

Easy turn-down

– Excellent flexibility to match actual client needs are achieved with the PSA system as it provides a turn-down ratio between 0% and 100% at unchanged purity and at nearly proportional energy consumption.

Fully automatic operation

– The PLC based control system controls the purity and the flow by automatically adjusting the cycle time of the PSA system. A modbus port for the communication with a plantwide DCS and/or a communication board for the remote control by a modem can be supplied as an option.

Modular skid design

– The shop fabricated valve skid design reduces the on-site costs for erection and commissio- ning.

Easy maintenance

– Only routine maintenance is required. All components are easily accessible.

and commissio- ning. Easy maintenance – Only routine maintenance is required. All components are easily accessible.

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The N 2 -PSA layout All components on the skid – including nitrogen product analyzer and control system – are com- pletely piped and wired for quick assembly at the job site.

The Linde N 2 -PSA nitrogen generators can be designed for indoor or outdoor installation.

The scope of supply The scope of supply mainly comprises the following material and equipment:

– Air compressor, if required

– Adsorber vessels

– Specially selected adsorbent material

– PSA buffer drum

– Valve skid

– Control system

– Nitrogen product O 2 -analyzer

– Nitrogen product compressor, if required

Heavy industrial standard for LINDE nitrogen PSA plants

A-series nitrogen PSA plant with high pressure nitrogen storage

Heavy industrial standard for LINDE nitrogen PSA plants A-series nitrogen PSA plant with high pressure nitrogen

HA/N/1.1.e/09

Designing Processes - Constructing Plants.

Linde´s Engineering Division continuously develops extensive process engineering know-how in the planning, project management and construction of turnkey industrial plants.

The range of products comprises:

− Petrochemical plants

− LNG and natural gas processing plants

− Synthesis gas plants

− Hydrogen plants

− Gas processing plants

− Adsorption plants

− Air separation plants

− Cryogenic plants

− Biotechnological plants

− Furnaces for petrochemical plants and refineries

Linde and its subsidiaries manufacture:

− Packaged units, cold boxes

− Coil-wound heat exchangers

− Plate-fin heat exchangers

− Cryogenic standard tanks

− Air heated vaporizers

− Spiral-welded aluminium pipes

More than 3,800 plants worldwide document the leading position of the Engineering Division in international plant construction.

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