Pressure Swing Adsorption

By
Naresh Ganveer
AM Process (HGU/SRB)
Presentation Outline

 Basics of PSA Process

 PSA Process Steps
 Process Description
 PSA Control System
 Process Parameters
 Adsorbents
 Performance Measurement
 Troubleshooting
 Pressure Swing Adsorption
 Basic Principle
 Ability of adsorbents to adsorb more
impurities at high pressure than at low
pressure
 ‘Pressure Swing’ cycle Pressure vs time
profile in ONE
vessel

Feed Gas - Adsorption

Pressure

Tail Gas – Regeneration

Time
ADSORBTION SELECTIVITY
Components of a Polybed PSA System

 Vessels with
Adsorbent
 Piping and
Valve Skid
 Tail Gas
Drum
 Control
System
 Basic Flow Diagram
Hydrogen Product
H2 @ High Purity
High Pressure (~22.5 kg/cm2)

Feed Gas
H2 + Impurities
High Pressure

Tail Gas
Impurities (+H2)
Low Pressure
Typical 0.3 – 5.0 kg/cm2
 Material Balance (12-bed operation )
Feed Product Purge gas
Composition mol%
Hydrogen 71.50 > 99.95 20.85
CO 3.51 < 20 ppmv 9.74
CO2 22.00 61.10
Methane 2.68 balance 7.44
Water 0.31 0.87

Flow (Nm3/h) 168421 107781 60640

Pressure (kg/cm2(g)) 23.4 22.55 0.50
Temperature ( 0C) 40.00 45.00 30.00

H2 recovery = 89.0 %
 PSA Process - Five Steps

 Adsorption

 Co-current depressurisation

 Counter-current depressurisation

 Purge at low pressure

 Repressurisation
 PSA Process - Internal Steps

Provide Eq.
(Co-current) Final Rep.

Provide Purge
(Co-current)

Blowdown Receive Eq.

(Counter-current)

ADSORPTION DEPRESSURISE PURGE REPRESSURISE

Time One Cycle

 Definition of terms
 Cycle includes a complete adsorption and
regeneration sequence
 A cycle is divided in:
• 12 sub-cycles in 12 bed operation
• 10 sub-cycles in 10 bed operation
• 8 sub-cycles in 8 bed operation
 Time-wise a sub-cycle is defined as the period
between the start of adsorption of two
consecutive absorbers
Process Flow Diagram
 Process Description
 Adsorption
Product

A B C D E F G H I J K L

Feed gas
Total adsorption time = 90 sec
Pressure in the adsorber A = 23.4 kg
 Equalisation 1 (Providing)

A B C D E F G H I J K L

Time = 10 sec Pressure in the adsorber A = 18 kg

Repressurises adsorber E Pressure in the adsorber E = 18 kg
  Equalisation 2 (Providing)

A B C D E F G H I J K L

Time = 19 sec Pressure in the adsorber A = 12.8 kg

Repressurises adsorber F Pressure in the adsorber F = 11.4 kg
 Equalisation 3 (Providing)

A B C D E F G H I J K L

Time = 11 sec Pressure in the adsorber A = 8.3 kg

Repressurises adsorber G Pressure in the adsorber G = 6.9 kg
  Equalisation 4 (Providing)

A B C D E F G H I J K L

Time = 10 sec Pressure in the adsorber A = 4.8 kg

Repressurises adsorber H Pressure in the adsorber H = 3.0 kg
 Provide Purge

A B C D E F G H I J K L

Time = 20 sec To tail gas

drum
Pressure in the adsorber A = 2.5 kg
 Dump

A B C D E F G H I J K L

To tail gas
drum
Time = 34 sec
Pressure in the adsorber A = 0.5 kg
 Receive Purge

A B C D E F G H I J K L

To tail gas
drum

Time = 86 sec
 Equalisation 4 (Receiving)

A B C D E F G H I J K L

Time = 10 sec
Repressurised with gas from adsorber F
Pressure in the adsorber A = 3.0 kg
Pressure in the adsorber F = 4.8 kg
 Equalisation 3 (Receiving)

A B C D E F G H I J K L

Time = 11 sec
Repressurised with gas from adsorber G
Pressure in the adsorber A = 6.9 kg
Pressure in the adsorber G = 8.3 kg
 Equalisation 2 (Receiving)

A B C D E F G H I J K L

Time = 19 sec
Repressurised with gas from adsorber H
Pressure in the adsorber A = 11.4 kg
Pressure in the adsorber H = 12.8 kg
 Equalisation 1 (Receiving)

A B C D E F G H I J K L

Time = 10 sec
Repressurised with gas from adsorber I
Pressure in the adsorber A = 18 kg
Pressure in the adsorber I = 18 kg
  Final Repressurisation

A B C D E F G H I J K L

Feed gas
Time = 20 sec
Pressure in the adsorber A = 23.4 kg
 Switchover
 10-bed operation
 Expected H2 Recovery = 86.0 %
 Only 2 adsorber are in the adsorption step at the
same time.
 The receiving purge step lasts approx. 65 seconds
at 100% capacity
 At 100% capacity, sub-cycle time is 34 seconds
 8-bed operation
 Expected H2 Recovery = 80.5 %
 Only 2 adsorber are in the adsorption step at the
same time.
 Only 2 equalisations takes place.
 The receiving purge step lasts approx. 75 seconds
at 100% capacity
 At 100% capacity, sub-cycle time is 40 seconds
 PSA control system
 To reduce internal and external fluctuations, the
repressurisation, dump and provide purge steps are
varied with the running sub-cycle time and thus with
the unit’s capacity
 The parameters determining the calculation of these
durations as well as the parameters fixing the pressure
profiles during these steps are set by the UOP start-up
engineer.
 The corresponding loops can be only in CAS mode
control
 Repressurisation control
 Objective – To minimise product flow fluctuations
 Calculate the repressurisation time
 The starting set point is the pressure at the end of equalisation 1
 The set point is continuously calculated in function of the
running repressurisation time and directed to reach the
adsorption pressure at the end of repressurisation.
 The process variable is the pressure transmitter signal of the
adsorber
 The output signal of the repressurisation loop is sent to the
valve 18-XCV-6301x corresponding to the adsorber in
repressurisation
 Dump control
 Purpose – To minimise purge gas pressure variations into the
tail gas drum, in order to limit the purge gas flow variations
 Calculate the dump time
 The starting set point is the pressure at the end of provide purge
 The set point is then directed towards the tail gas drum pressure
corresponding to the pre-set pressure profile within a dump
time
 The process variable is the pressure transmitter signal of the
adsorber
 The output signal of the repressurisation loop is sent to the
valve 18-XCV-6304x corresponding to the adsorber in
repressurisation
 Provide purge control
 Purpose – To give the steady purge gas flow to the tail gas drum
The starting set point is the pressure at the end of equalisation 4
 The set point is then directed to the desired pressure following a
pre-set pressure profile within a time that is capacity
dependent
 The process variable is the pressure transmitter signal of the
adsorber
 The output signal of the repressurisation loop is sent to the
valve 18-XCV-6304x corresponding to the adsorber in
repressurisation
 Process Parameters

 Feed and offgas pressure

 Feed gas composition

 Process temperature
 Feed and offgas pressure
 The normal operating pressure of 23.4 kg/cm2(g) should
be maintained to achieve the product purity
 Optimum performance is obtained when the purge
gas pressure is at a min. (0.5 kg/cm2(g)).
 Operating at a higher purge gas pressure will result
in reduced capacity, reduced purity and recovery.
 Feed gas composition
 High molecular weight impurities or entrained liquids will
be strongly adsorbed by the adsorbent and may not desorbs
during regeneration step and thus reduce its capacity.

 Operation with high impurity concentration in feed can result in

low product quality.

 Feed gases containing less than 50% by volume H2 can not be

economically upgraded.
 Process temperature
 Operation at high temperature will reduce the capacity of
the adsorbents to adsorb impurities and can result in
impure product.
 Operation of PSA unit at maximum 50 oC is allowed.
 Performance Measurement

 Hydrogen Product Purity

 PSA Capacity

 PSA Hydrogen Recovery

 Product Purity and Capacity
 PSA adsorber bed has fixed capacity to remove impurities
 Adsorption time = f( bed size, feed flow)

KF  TSC (design )  F (design )

TSC 
1000  F (actual )

Where,
TSC = Sub-cycle time
KF = Capacity factor
F = Feed to unit
 It is always possible to operate PSA at short adsorption time
Product Hydrogen will always be on-spec, but
- H2 recovery will be low
- Tail gas flow will be rich in H2
 The adsorption time has to be set to maximise the hydrogen
recovery & still meeting the product specifications
 If product purity is not acceptable and adsorption time is at its
minimum, the only adjustment left is a reduction of the
feed rate to the PSA unit.
 PSA Hydrogen Recovery

Flow Based Method Composition Based Method

- Results are less accurate - Results are more accurate

H 2 
P  yP
H 2 
 y F  yW  y P
F  yF  y P  yW  y F
Where,
F = Feed flow
P = Product flow
W = Purge gas flow
y = mole % H2
 Troubleshooting
 Causes for bad PSA performance
Poor recovery or poor purity results from
1. Excessive impurities in the feed
2. End pressure of equalization not reached
3. Excessive purge gas pressure
4. Deactivated adsorbent
 Adsorbent Degradation
 PSA is operated at low product purity
 PSA is pressurized with low purity hydrogen from the
product side
 PSA adsorbent comes into contact with liquids
 Heavy hydrocarbons in the feed
 High feed gas temperature
 When adsorber is depressurized from the top
 Adsorbents
 Selected for their ability to remove specific feed
components based on their relative adsorption strength
and mass transfer characteristics
 Loaded in layers and the impurities removed as the gas
flows through the bed of adsorbent.
 In the bed heavy components are adsorbed at the
bottom and lighters at the top.
 By careful design and good control the adsorbent
lifetime exceeds 20 yrs.
 The adsorbents used in the bed from top towards bottom
are,

 H1 (Molecular Sieves)
 H16 (Molecular Sieves)
 H2-14 (Activated Carbon)
 H2-15 (Activated Carbon)
 H5 (Molecular Sieves)
 Adsorber vessel Design & Fabrication

 As a result of pressure differential cycles and exposure

of high purity hydrogen, the materials in the PSA
adsorber vessels are exposed to mechanical fatigue.
 Cracks are more likely initiate and grow at welds
 PSA adsorber vessels becomes inoperable due to the
development of through-thickness cracks
 In case of PSA adsorber vessels, a fatigue analysis is
mandatory.
 Fatigue Design
 Design is based on the ASME Pressure Vessel Code
Section VIII, Division 2
 Allowable stress amplitude is found from the curve
of stress amplitude plotted against number of cycles
for the particular material to be used.
 Nominal stresses are calculated from the formulas in
the code
 The peak stresses are obtained by multiplying
nominal stresses by a stress index
 Fabrication
Fabrication Specifications
 Materials: Fine grain, normalized, 100% ultrasonic
examination
 Welding: Full penetration welds, weld hardness
controlled, weld profile contoured, 100% postweld
heat treatment, peaking of shell seams controlled
 Nondestructive Examination (NDE): 100%
radiography, 100% magnetic particle examination,
extensive ultrasonic examination
 10 bed PSA
 Feed gas coming from a catalytic reforming unit, off
gas from a hydrocracker unit or mixture of both.

 For 10 bed, H2 recovery = 87.5 %

8 bed, H2 recovery = 86 %
6 bed, H2 recovery = 84.5 %
 HCU CRU Combined Product Purge gas
feed
Composition mol %
Hydrogen (H2) 85.65 94.03 90.94 > 99.9 55.85
Methane (CH4) 6.79 2.27 3.94 Balance 18.95
Ethane 1.77 2.20 2.04 10.03
Propane 2.04 1.21 1.52 7.46
i-Butane 1.56 0.14 0.66 3.26
n-Butane 0.80 0.12 0.37 1.81
Pentane 1.12 0.01 0.42 2.08
Hexanes+ 0.02 0.01 0.06
Water 0.27 25 ppmv 0.10 0.50
H2S 100 ppmw 37 ppmv 181 ppmv
Ammonia 5 ppmw 2 ppmv 9 ppmv
CO 47 ppmw 17 ppmw Balance 86 ppmv
CO+CO2 30 ppmw 2 ppmv Balance 8 ppmv
Chlorides 1 ppmw < 1 ppmw < 1 ppmv 2 ppmv

Flow (kg/h) 4718 4527 9245 3192 6053

 Q&A
Thank you….