Process intensification of the high-purity nitrogen production in twin-bed Pressure Swing Adsorption plants

Adsorption Equilibrium, Thermodynamic, and Kinetic Study of O2/N2/CO2 on Functionalized Granular Activated Carbon

A volumetric system was used to assess carbon-based adsorbents for evaluation of the gas separation, equilibrium, and kinetics of oxygen (O₂), nitrogen (N₂), and carbon dioxide (CO₂) adsorption on granular activated carbon (GAC) and functionalized GAC at 298, 308, and 318 K under pressures up to 10 bar. The effects of ZnCl₂, pH, arrangement of the pores, and heat-treatment temperature on the adsorptive capabilities of O₂, N₂, and CO₂ were evaluated. High-performance O₂ adsorption resulted with a fine sample (GAC-10-500) generated with a 0.1 wt % loading of ZnCl₂. The optimal sample structure and morphology were characterized by field-emission scanning electron microscopy, Fourier transform infrared spectroscopy, and powder X-ray diffraction. On the basis of the adsorption-desorption results, the fine GAC provides a surface area of 719 m²/g. Moreover, it possessed an average pore diameter of 1.69 nm and a micropore volume of 0.27 m³/g. At 298 K, the adsorption capacity of the GAC-10-500 adsorbent improved by 19.75% for O₂ but was not significantly increased for N₂ and CO₂. Isotherm and kinetic adsorption models were applied to select the model best matching the studied O₂, N₂, and CO₂ gas uptake on GAC-10-500 adsorbent. At 298 K and 10 bar, the sip isotherm model with the highest potential adsorption difference sequence and gas adsorption difference compared with pure GAC adsorbent as O₂ > N₂ > CO₂ follows well for GAC-10-500. Eventually, the optimal sample is more effective for O₂ adsorption than other gases.

Process intensification and digital twin – the potential for the energy transition in process industries

The work defines and discusses process intensification (PI) and digital twin (DT) as potential tools to accelerate the energy transition through their applications in the process industries. The PI technologies take advantage of innovative principles in equipment design and control to improve the physical process, while the DT offers the virtual model of the plant as an environment for production optimization. The effects of both tools on the energy transition are evaluated not only from the point of applications but also from the possibility of implementation and barriers in process industries. Although they are beneficial, the deployment of PI and DT requires not only infrastructure and capital investment but the knowledge and cooperation of different levels of plant personnel. Besides review of individual implementation, this work explores the concept of combining PI and DT which can make them the enabler of each other and bring a breakthrough in optimization of process design and control.

Dynamic simulation of high-purity twin-bed N2-PSA plants

At present, nitrogen production from air by pressure swing adsorption (PSA) is simulated almost exclusively at low product purity levels (< 99% N2). However, with increasing global demand for highly purified gases provided by energy-efficient separation processes the requirement for either extensive experimental research in the high-purity range or predictive computer simulations arises. This paper presents a mathematical model of a twin-bed PSA plant equipped with a carbon molecular sieve (Shirasagi MSC CT-350) for the generation of high-purity nitrogen (99.9–99.999% N2). The model is implemented in the process simulator Aspen Adsorption™. The influence of operating conditions as well as the cycle organisation on the process performance is validated, especially the influence of pressure, temperature, half-cycle time, purge flow rate, and cutting time. The precision of the performance prediction by numerical simulations is critically discussed. Based on the new insights efficiency improvement strategies with a focus on reduced energy consumption are introduced and discussed by means of radar charts.