A method and system for manufacturing and using a self-supporting structure in processing unit for adsorption or catalytic processes. The self-supporting structure has greater than 50% by weight of the active material in the self-supporting structure to provide an open-celled structure providing access to the active material. The self-supporting structures, which may be disposed in a processing unit, may be used in swing adsorption processes and other processes to enhance the recovery of hydrocarbons.

A process for separating carbon dioxide from a feed gas comprising carbon dioxide may comprise compressing the feed gas in a feed gas compressor to produce a compressed feed gas. The process may also comprise separating the compressed feed gas by an adsorption process comprising: using a plurality of adsorbent beds to produce a carbon dioxide-enriched product stream and a carbon dioxide-depleted stream, and a blowdown step. A blowdown gas may be removed from the adsorbent bed. The process may also comprise compressing the blowdown gas in the feed gas compressor and combining the blowdown gas with the compressed feed gas.

A multi-stage process to remove contaminant gases from raw methane streams is provided. The present technology is an innovative solution to recover and purify biogas by use of a process having at least two pressure swing adsorption stages. Taking advantage of the presence of carbon dioxide in the raw biogas streams, nitrogen and oxygen are bulky removed in the first stage, using selective adsorbents, and a nitrogen and oxygen-depleted intermediate stream is yielded to the second stage. The second stage employs an adsorbent or adsorbents to selectively remove carbon dioxide and trace amounts of remaining nitrogen and oxygen, thus producing a purer methane stream that meets pipeline and natural gas specifications.

The present invention relates to an intensified 5-bed and 6-bed PSA process cycles features, as well as fast rate adsorbents that enable the intensified PSA system to meet cost and performance target are identified. The proposed capital efficient H.sub.2PSA system offers opportunity to reduce PSA capital expenditure by ten percent (10%).

A system and method for sulfur recovery, including hydrogenating Claus tail gas, quenching the hydrogenated gas, adsorbing water and hydrogen sulfide from the quenched gas, and regenerating adsorbent with carbon dioxide and/or nitrogen and heating the adsorbent in a regeneration temperature ramp to desorb primarily hydrogen sulfide in a first part of the temperature ramp.

The present invention generally relates to a pressure swing adsorption process for separating an adsorbate impurity from a feed stream comprising product gas, said process comprising feeding the feed stream to an adsorbent bed at a pressure of from about 60 psig to 2000 psig, wherein said adsorbent bed comprises adsorbent having: An isosteric heat of adsorption of from about 5 kJ/mol to about 30 kJ/mol, as determined by the LRC method, for the adsorbate, and an equivalent 65 kJ/mol or less isosteric heat of adsorption for the product,
wherein the adsorbent has a rate of adsorption for the adsorbate impurity that is at least 10 times greater than the rate of adsorption for the product gas as determined by the TGA method and recovering said product gas with a reduced a level of said adsorbate impurity. The invention also related to an adsorbent useful in PSA separations, particularly separating N.sub.2 from methane, CO.sub.2 from methane O.sub.2 from N.sub.2 and the like.

Provided are apparatus and systems for performing a swing adsorption process. This swing adsorption process may involve performing a startup mode process prior to beginning a normal operation mode process to remove contaminants from a gaseous feed stream. The startup mode process may be utilized for swing adsorption processes, such as TSA and/or PSA, which are utilized to remove one or more contaminants from a gaseous feed stream.

The process of the present invention provides high recovery and low capital cost giving it an economic advantage over previously known purification processes. The present process has particular applicability to the purification of synthesis gases comprising at least hydrogen (H.sub.2), carbon monoxide (CO), methane (CH.sub.4), CO.sub.2, and H.sub.2O to obtain a gas stream including at least H.sub.2, CO, and CH.sub.4, that is substantially free of H.sub.2O and CO.sub.2. The process also has applicability to the purification of natural gases inclusive of at least CH.sub.4, N.sub.2, CO.sub.2, and H.sub.2O to produce a gas stream including at least CH.sub.4 and N.sub.2, but which is substantially free of H.sub.2O and CO.sub.2.

A process and apparatus for producing a hydrogen-enriched product and recovering CO.sub.2 from an effluent stream from a hydrogen production unit are described. The effluent from the hydrogen production unit, which comprises a mixture of gases comprising hydrogen, carbon dioxide, water, and at least one of methane, carbon monoxide, nitrogen, and argon, is sent to a PSA system that produces at least two product streams for separation. The PSA system that produces at least two product streams separates the gas mixture into a high-pressure hydrogen stream enriched in hydrogen, optionally a second gas stream containing the majority of the impurities, and a low-pressure tail gas stream enriched in CO.sub.2 and some impurities. The CO.sub.2-rich tail gas stream is compressed and sent to a CO.sub.2 recovery unit, where a CO.sub.2-enriched stream is recovered. The CO.sub.2-depleted overhead gas stream is recycled to the PSA system that produces at least two product streams.

Provided are apparatus and systems for performing a swing adsorption process. This swing adsorption process may involve performing dampening for fluctuations in the streams conducted away from the adsorbent bed unit. The process may be utilized for swing adsorption processes, such as rapid cycle TSA and/or rapid cycle PSA, which are utilized to remove one or more contaminants from a gaseous feed stream.