Intensified pressure swing adsorption system and process cycles

Abstract

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%).

Claims

1. A pressure swing adsorption process for producing a gas stream enriched with hydrogen from a feed gas stream utilizing a 5 or 6 adsorbent vessels pressure swing adsorption system, wherein said pressure swing adsorption (PSA) system carries out an efficient process cycle having two pressure equalization steps, no idle step, each pressure equalization and blowdown step being ≥25 seconds, wherein the critical provide purge step is positioned to allow the longest purge time, and the first dedicated provide purge gas is positioned to provide the last purge step for the receiving bed for a clean rinse.

2. The pressure swing adsorption process of claim 1, wherein each pressure equalization step time and blow down step time of the process cycle is equal or greater than 20% of the adsorption/feed step time.

3. The pressure swing adsorption process of claim 1, wherein total purge time is in a range of 20%-30% of the total cycle time for 5-bed PSA system, and in a range of 17%-30% of the total cycle time for 6-bed PSA system.

4. The pressure swing adsorption process of claim 1, wherein the process cycle has a feed flux >100 mol/m.sup.2/sec.

5. A pressure swing adsorption process for separating a pressurized supply feed gas containing one or more strongly adsorbable component from at least one less strongly adsorbable product gas component in a six bed adsorption system to produce a continuous stream of product gas enriched in the less strongly adsorbable component and a stream of offgas that is enriched in the strongly adsorbable components, in accordance with to the following cycle chart: TABLE-US-00013 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 B1 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg3b Pg1 E2′ E1′ PP1 PP2 PPG2 B2 E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg3b Pg1 E2′ PPG2 B3 Pg3b Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 PPG2 B4 Pg3a Pg4 Pg2 Pg3b Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD PPG2 B5 PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg3b Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG2 B6 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg1 Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 PPG2 where: A1 = First Adsorption Step A2 = Second Adsorption Step A3 = Third Adsorption Step E1 = First Equalization Down Step PPG1 = First Provide Purge Gas Step E2/PPG2 = Second Equalization Down/Second Provide Purge Gas Overlapping Step PPG3 = Third Provide Purge Gas Step PPG4 = Fourth Provide Purge Gas Step BD = Blowdown Step Pg3a = Third (a) Receive Purge Gas Step Pg4 = Fourth Receive Purge Gas Step Pg2 = Second Receive Purge Gas Step Pg3b = Third (b) Receive Purge Gas Step Pg1 = First Receive Purge Gas Step E2′ = Second Equalization Up Step E1′ = First Equalization Up Step PP1 = First Product Pressurization Step PP2 = Second Product Pressurization Step.

6. A pressure swing adsorption process for separating a pressurized supply feed gas containing one or more strongly adsorbable component from at least one less strongly adsorbable product gas component in a six bed adsorption system to produce a continuous stream of product gas enriched in the less strongly adsorbable component and a stream of offgas that is enriched in the strongly adsorbable components, in accordance with to the following cycle chart: TABLE-US-00014 1 2 3 4 5 6 7 8 9 10 11 12 B1 A1 A2 E1 E2/ PPG2 BD Pg2a Pg1 Pg2b E2′ E1′ PP PPG1 B2 E1′ PP A1 A2 E1 E2/ PPG2 BD Pg2a Pg1 Pg2b E2′ PPG1 B3 Pg2b 2 E1′ PP A1 A2 E1 E2/ PPG2 BD Pg2a Pg1 PPG1 B4 Pg2a Pg1 Pg2b E2′ E1′ PP A1 A2 E1 E2/ PPG2 BD PPG1 B5 PPG2 BD Pg2a Pg1 Pg2b 2 E1′ PP A1 A2 E1 E2/ PPG1 B6 E1 E2/ PPG2 BD Pg2a Pg1 Pg2b E2′ E1′ PP A1 A2 PPG1 where: A1 = First Adsorption Step A2 = Second Adsorption Step E1 = First Equalization Down Step E2/PPG1 = Second Equalization Down/First Provide Purge Gas Overlapping Step PPG2 = Second Provide Purge Gas Step BD = Blowdown Step Pg2a = Second (a) Receive Purge Gas Step Pg1 = First Receive Purge Gas Step Pg2b = Second (b) Receive Purge Gas Step E2′ = Second Equalization Up Step E1′ = First Equalization Up Step PP = Product Pressurization Step.

7. A pressure swing adsorption process for separating a pressurized supply feed gas containing one or more strongly adsorbable component from at least one less strongly adsorbable product gas component in a five bed adsorption system to produce a continuous stream of product gas enriched in the less strongly adsorbable component and a stream of offgas that is enriched in the strongly adsorbable components, in accordance with to the following cycle chart: TABLE-US-00015 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 B1 A1 A2 A3 E1 PPG1 E2/ PPG3 BD Pg2 Pg3 Pg1 E2′ E1′ PP1 PP2 PPG2 B2 E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 BD Pg2 Pg3 Pg1 E2′ PPG2 B3 Pg3 Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 BD Pg2 PPG2 B4 PPG3 BD Pg2 Pg3 Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG2 B5 E1 PPG1 E2/ PPG3 BD Pg2 Pg3 Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 PPG2 where: A1 = First Adsorption Step A2 = Second Adsorption Step A3 = Third Adsorption Step E1 = First Equalization Down Step PPG1 = First Provide Purge Gas Step E2/PPG2 = Second Equalization Down/Second Provide Purge Gas Overlapping Step PPG3 = Third Provide Purge Gas Step BD = Blowdown Step Pg2 = Second Receive Purge Gas Step Pg3 = Third Receive Purge Gas Step Pg1 = First Receive Purge Gas Step E2′ = Second Equalization Up Step E1′ = First Equalization Up Step PP1 = First Product Pressurization Step PP2 = Second Product Pressurization Step.

8. The pressure swing adsorption process of claim 1, wherein the feed gas stream contains one or more strongly adsorbed component selected from a group consisting of hydrocarbon CO.sub.2, CO, Ar, N.sub.2, and water vapor.

9. The pressure swing adsorption process of claim 1, wherein each adsorbent bed contains alumina, carbon, and zeolite material configured in layers.

10. The pressure swing adsorption process of claim 9, wherein carbon and zeolite each be layered by different particle sizes to achieve the desired mass transfer rate and pressure drop.

11. The pressure swing adsorption process of claim 9, wherein zeolite has particle sizes from 1.0 mm to 2.0 mm.

12. The pressure swing adsorption process of claim 9, wherein carbon has particle sizes from 1.5 mm to 3.5 mm.

13. The pressure swing adsorption process of claim 9, wherein zeolite mass transfer coefficient for CO is K.sub.CO≥10 sec.sup.−1.

14. The pressure swing adsorption process of claim 9, wherein zeolite mass transfer coefficient for CO is K.sub.CO≥20 sec.sup.−1.

15. The pressure swing adsorption process of claim 9, wherein activated carbon mass transfer coefficient for CO is K.sub.CO≥7 sec.sup.−1.

16. The pressure swing adsorption process of claim 9, wherein activated carbon mass transfer coefficient for CO is K.sub.CO≥14 sec.sup.−1.

17. The pressure swing adsorption process of claim 1, wherein each pressure equalization step time and blow down step time of the process cycle is in a range of about 20%-35% of the adsorption/feed step time.

18. The pressure swing adsorption process of claim 1, wherein the process cycle has a feed flux in a range of about 120-140 mol/m.sup.2/sec.

19. The pressure swing adsorption process of claim 9, wherein zeolite has particle sizes ranging from about 1.0-1.5 mm.

20. The pressure swing adsorption process of claim 9, wherein carbon has particle sizes ranging from about 1.8-3.0 mm.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The objects and advantages of the invention will be better understood from the following detailed description of the preferred embodiments thereof in connection with the accompanying figures wherein:

(2) FIG. 1 illustrates the results for 6-bed SMR H.sub.2PSA processes, with pilot validated performance for 6-1-3 (P/F=1) and 6-1-2 (P/F>1) cycles; and

(3) FIG. 2 depicts the results for 5-bed CO coldbox H.sub.2PSA processes, with pilot validated performance for 5-1-2 (P/F<1) and 5-1-2 (P/F=1) cycles.

DETAILED DESCRIPTION OF THE INVENTION

(4) The invention provides a pressure swing adsorption process for the separation of a pressurized feed gas supply containing one or more strongly adsorbable components and at least one less strongly adsorbable product gas in a multiple bed system. The feed gas is supplied to a feed end of an adsorbent bed containing solid adsorbent material(s), which preferentially adsorbs the more strongly adsorbable component(s) and withdrawing the least strongly adsorbable product component from an exit end of the adsorber bed, producing in cycle including steps in which the continuous feed gas sequentially co-currently flows through each of the adsorber beds to produce gas product using continuous feed gas, pressurization steps, pressure equalization steps, blowdown step(s), and purge step(s).

(5) The novel PSA cycles of the present invention will now be described with reference to various embodiments. In one embodiment of the invention, the novel PSA system employs an eighteen step, six adsorbent bed PSA cycle having two equalization steps, and one bed on feed (referred herein as “the 6-1-2 PSA cycle”). This 6-1-2 PSA cycle has one (1) less pressure equalization steps designed to achieve the better and or equivalent performance to the conventional 6-1-4 or 6-1-3 PSA cycles in which more pressure equalization steps are given. Thus, rather than utilizing an extra pressure equalization step, additional time is provided for pressure equalization, blowdown, and purge steps for improved operational reliability and process performance. Furthermore, each pressure equalization step reduced provides two extra steps for optimizing cycle steps arrangement. In general, it is preferred that all equalization down steps are completed before commencing provide purge gas steps to achieve better gas concentration fronts within the pressurized bed. Under certain conditions, as provided by the current invention, a provide purge gas step inserted in between two equalization down steps can be advantageous for eliminating the hold or idle step in the process, and for providing the cleanest purge gas as a final boost of purge for the receiving bed. This intercepting provide purge gas step is configured for a short duration and with small pressure change to maintain the desired pressure levels for the following equalization steps. On the other hand, a process becomes inefficient when a redundant or unproductive step is coupled with another critical step within the same time step, for examples, E2b is coupled to E4 (Table 3, 6-1-4 cycle), Hold is coupled to E3 (Table 4, 6-1-3 cycle). The present invention provides processes with coupled critical steps, and or decoupled redundant and critical steps, in order to satisfy minimum operational and reliability requirements, before stretching PSA performance by freely adjusting the critical provide purge step that has the potential of providing the longest purge time (for example in Table 1, PPG3 provides for Pg3a and Pg3b). Judicious step time allocation is necessary to optimize PSA working capacity, mitigate fluidization risk, and facilitate cycle time adjustment versus plant rate. Specifically, pressure equalization step ≥25 sec, blowdown step ≥25 sec, receive purge gas steps comprised of combination of critical and less critical steps with duplicate purge steps to maximize purge duration.

(6) With reference to Tables 1-2, the embodiment of a preferred cycle is that of the 6-1-2 PSA cycle with 18 steps, and a more preferred cycle of the 6-1-2 PSA cycle with 12 steps, shown in Table 2. The latter has been validated to produce equivalent process performance to that of 6-1-2 PSA cycle in Table 1.

(7) TABLE-US-00002 TABLE 1 6-1-2 cycle - Proposed Advanced cycle 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 B1 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg3b Pg1 E2′ E1′ PP1 PP2 PPG2 B2 E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg3b Pg1 E2′ PPG2 B3 Pg3b Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 PPG2 B4 Pg3a Pg4 Pg2 Pg3b Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 PPG4 BD PPG2 B5 PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg3b Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG2 B6 E1 PPG1 E2/ PPG3 PPG4 BD Pg3a Pg4 Pg2 Pg3b Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 PPG2 where: A1 = First Adsorption Step A2 = Second Adsorption Step A3 = Third Adsorption Step E1 = First Equalization Down Step PPG1 = First Provide Purge Gas Step E2/PPG2 = Second Equalization Down/Second Provide Purge Gas Overlapping Step PPG3 = Third Provide Purge Gas Step PPG4 = Fourth Provide Purge Gas Step BD = Blowdown Step Pg3a = Third (a) Receive Purge Gas Step Pg4 = Fourth Receive Purge Gas Step Pg2 = Second Receive Purge Gas Step Pg3b = Third (b) Receive Purge Gas Step Pg1 = First Receive Purge Gas Step E2′ = Second Equalization Up Step E1′ = First Equalization Up Step PP1 = First Product Pressurization Step PP2 = Second Product Pressurization Step

(8) TABLE-US-00003 TABLE 2 Simplified version of 6-1-2 cycle - Proposed Advanced Cycle 1 2 3 4 5 6 7 8 9 10 11 12 B1 A1 A2 E1 E2/ PPG2 BD Pg2a Pg1 Pg2b E2′ E1′ PP PPG1 B2 E1′ PP A1 A2 E1 E2/ PPG2 BD Pg2a Pg1 Pg2b E2′ PPG1 B3 Pg2b E2′ E1′ PP A1 A2 E1 E2/ PPG2 BD Pg2a Pg1 PPG1 B4 Pg2a Pg1 Pg2b E2′ E1′ PP A1 A2 E1 E2/ PPG2 BD PPG1 B5 PPG2 BD Pg2a Pg1 Pg2b E2′ E1′ PP A1 A2 E1 E2/ PPG1 B6 E1 E2/ PPG2 BD Pg2a Pg1 Pg2b E2′ E1′ PP A1 A2 PPG1 where: A1 = First Adsorption Step A2 = Second Adsorption Step E1 = First Equalization Down Step E2/PPG1 = Second Equalization Down/First Provide Purge Gas Overlapping Step PPG2 = Second Provide Purge Gas Step BD = Blowdown Step Pg2a = Second (a) Receive Purge Gas Step Pg1 = First Receive Purge Gas Step Pg2b = Second (b) Receive Purge Gas Step E2′ = Second Equalization Up Step E1′ = First Equalization Up Step PP = Product Pressurization Step

(9) TABLE-US-00004 TABLE 3 6-1-4 cycle (related art) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 B1 A1 A2 A3 E1 E2a E2b E3 PPG E4/ BD2 Pg E4′ E3′ E2a′ E2b′ E1′ PP1 PP2 BD1 B2 E1′ PP1 PP2 A1 A2 A3 E1 E2a E2b E3 PPG E4/ BD2 Pg E4' E3' E2a′ E2b′ BD1 B3 E3′ E2a′ E2b′ E1′ PP1 PP2 A1 A2 A3 E1 E2a E2b E3 PPG E4/ BD2 Pg E4′ BD1 B4 BD2 Pg E4′ E3′ E2a′ E2b′ E1′ PP1 PP2 A1 A2 A3 E1 E2a E2b E3 PPG E4/ BD1 B5 E3 PPG E4/ BD2 Pg E4′ E3′ E2a′ E2b′ E1′ PP1 PP2 A1 A2 A3 E1 E2a E2b BD1 B6 E1 E2a E2b E3 PPG E4/ BD2 Pg E4′ E3′ E2a′ E2b′ E1′ PP1 PP2 A1 A2 A3 BD1 where: A1 = First Adsorption Step A2 = Second Adsorption Step A3 = Third Adsorption Step E1 = First Equalization Down Step E2a = Second (a) Equalization Down Step E2b = Second (b) Equalization Down Step E3 = Third Equalization Down Step PPG = Provide Purge Gas Step E4/BD1 = Fourth Equalization Down/First Blowdown Overlapping Step BD2 = Second Blowdown Step Pg = Receive Purge Gas Step E4′ = Fourth Equalization Up Step E3′ = Third Equalization Up Step E2a′ = Second (a) Equalization Up Step E2b′ = Second (b) Equalization Up Step E1′ = First Equalization Up Step PP1 = First Product Pressurization Step PP2 = Second Product Pressurization Step

(10) TABLE-US-00005 TABLE 4 6 -1-3 zycle (modified related art) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 B1 A1 A2 A3 E1 Hold E2 PPG1 E3/ PPG3 BD Pg2 Pg3 Pg1 E3′ E2′ E1′ PP1 PP2 PPG2 B2 E1′ PP1 PP2 A1 A2 A3 E1 Hold E2 PPG1 E3/ PPG3 BD Pg2 Pg3 Pg1 E3′ E2′ PPG2 B3 Pg1 E3′ E2′ E1′ PP1 PP2 A1 A2 A3 E1 Hold E2 PPG1 E3/ PPG3 BD Pg2 Pg3 PPG2 B4 BD Pg2 Pg3 Pg1 E3′ E2′ E1′ PP1 PP2 A1 A2 A3 E1 Hold E2 PPG1 E3/ PPG3 PPG2 B5 PPG1 E3/ PPG3 BD Pg2 Pg3 Pg1 E3′ E2′ E1′ PP1 PP2 A1 A2 A3 E1 Hold E2 PPG2 B6 E1 Hold E2 PPG1 E3/ PPG3 BD Pg2 Pg3 Pg1 E3′ E2′ E1′ PP1 PP2 A1 A2 A3 PPG2 where: A1 = First Adsorption Step A2 = Second Adsorption Step A3 = Third Adsorption Step E1 = First Equalization Down Step Hold = Hold step E2 = Second Equalization Down Step PPG1 = First Provide Purge Gas Step E3/PPG2 = Third Equalization Down/Second Provide Purge Gas Overlapping Step PPG3 = Third Provide Purge Gas Step BD = Blowdown Step Pg2 = Second Receive Purge Gas Step Pg3 = Third Receive Purge Gas Step Pg1 = First Receive Purge Gas Step E3′ = Third Equalization Up Step E2′ = Second Equalization Up Step E1′ = First Equalization Up Step PP1 = First Product Pressurization Step PP2 = Second Product Pressurization Step

(11) The performance characteristic of these cycles compared to those of the related art 6-1-4 and 6-1-3 PSA cycles in Tables 3-4, respectively. Performance comparison for 6-1-4, 6-1-3 and 6-1-2 cycles illustrated using a steam methane reformer (SMR) feed are shown below, in Tables 5-6. Table 5 illustrates the difference in an example of 6-bed PSA cycle performance comparison for using 4 and 3 pressure equalization steps.

(12) TABLE-US-00006 TABLE 5 Example 1. 6-bed PSA cycles with 4 and 3 pressure equalization steps 74.6% H.sub.2, 16.5% CO.sub.2, 3.7% CO, SMR Feed Compositions 4.5% CH.sub.4, <1% N.sub.2, H.sub.2O 6-1-4 6-1-3 Process Cycle (related art) (modified related art) H.sub.2 Recovery (%) 86.5 88.8 BSF (ft.sup.3/MMscfd) 207 199 Feed Flux (mol/m.sup.2/sec) 130 130 Purge Time (sec) 43 106 Feed Time (sec) 77 106 Cycle Time (min) 7.7 10.6

(13) As shown in Example 1 (Table 5, above) the 6-1-4 PSA cycle with 4 equalization steps significantly underperforms in terms of hydrogen recovery as compared to the 6-1-3 PSA cycle. This is contrary to conventional pressure swing adsorption of more pressure equalization steps enhancing recovery. Further, as shown in Example 2 (Table 6, below) another simulation was conducted where for the SMR feed, a 6-1-3 PSA cycle was run and compared to a 6-1-2 PSA cycle where the number of equalizations has been stepped down from 3 to 2, and was run at higher feed flux and much lower Bed Size Factor (but equivalent for purposes of comparison). It will be understood by those skilled in the art that the term “Bed Size Factor” or “BSF” as utilized herein refers to the amount of adsorbent per MMSCFD H.sub.2 produced. This is generally understood to be a measure of the PSA size and indirect indication of the relative PSA cost. Thus, a smaller BSF number is preferred as it corresponds to the less amount of adsorbent needed to produce target amount of hydrogen product.

(14) TABLE-US-00007 TABLE 6 Example 2. 6-bed PSA cycles with 3 and 2 pressure equalization steps 74.6% H.sub.2, 16.5% CO.sub.2, 3.7% CO, SMR Feed Compositions 4.5% CH.sub.4, <1% N.sub.2, H.sub.2O 6-1-3 6-1-2 Process Cycle (modified related art) (invention) H.sub.2 Recovery (%) 85.8 85.5 BSF (ft.sup.3/MMscfd) 149 149 Feed Flux (mol/m.sup.2/sec) 140 140 Purge Time (sec) 55 115 Feed Time (sec) 55 70 Cycle Time (min) 5.5 7.0

(15) As can be seen from this Example 2, the hydrogen recovery is virtually same though with one less pressure equalization steps. The newly designed 6-1-2 PSA cycle has a purge time that is longer than the one for the 6-1-3 PSA cycle, and the purge time has a more significant impact than the number of pressure equalization steps when absorber bed size is reduced and adsorbents mass transfer rates are rather limited. For intensified PSA process with short cycle time of the present invention, reducing pressure equalization steps allow for more purge time, which is essential to achieve the desired recovery performance.

(16) An additional benefit of the present 6-1-2 PSA cycle in that the reduced pressure equalization steps is that it allows one to design longer equalization time which helps to mitigate fluidization risk during the pressure equalization steps. Fluidization risk increases as flow rates of the depressurizing gas are increased to complete the pressure equalization steps within shorter step times in an intensified PSA system. Reducing each pressure equalization step makes available two extra step times that can be used to address critical process needs such as relaxing equalization times to prevent gas flow velocity from exceeding the minimum fluidization velocity.

(17) During the operation of a plant employing a six bed PSA process cycle it may be desirable to operate the plant in the turndown mode for a limited period of time. In the case of a six bed/vessel PSA system, this mode enables the continuous production with only five vessels online while one of the beds or valves associated with a given bed failed and need to be serviced. On the other hand, a five bed PSA system may be adopted over six bed PSA system for lower production demand or for lower cost option. Whatever the circumstances may be (for turndown or normal operations) the plant from a capital efficiency point of view, smaller BSF, less number of vessels, valves and instrumentation are desirable, since all of them offers opportunity to reduce cost.

(18) The newly designed advanced 5-1-2 PSA cycle with 2 pressure equalization steps achieves better performance than 5-1-3 PSA cycle with 3 pressure equalization steps. Instead of extra pressure equalization step, additional time is allowed for pressure equalization, blow down, and purge steps for improved operational reliability and process performance. In addition, an intercepting provide purge gas step is introduced in between two equalization down steps to eliminate the redundant step and to provide the cleanest purge gas as a final boost of purge for the receiving bed. The cycle step is further configured to satisfy pressure equalization step ≥25 sec, blowdown step ≥25 sec, a freely adjustable provide purge step for stretching PSA performance and receive purge gas steps comprised of combination critical and less critical steps to maximize purge duration. PSA cycle charts are summarized in Tables 7 and 8.

(19) TABLE-US-00008 TABLE 7 5-1-2 cycle - Proposed Advanced Cycle 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 B1 A1 A2 A3 E1 PPG1 E2/ PPG3 BD Pg2 Pg3 Pg1 E2′ E1′ PP1 PP2 PPG2 B2 E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 BD Pg2 Pg3 Pg1 E2′ PPG2 B3 Pg3 Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG3 BD Pg2 PPG2 B4 PPG3 BD Pg2 Pg3 Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 E1 PPG1 E2/ PPG2 B5 E1 PPG1 E2/ PPG3 BD Pg2 Pg3 Pg1 E2′ E1′ PP1 PP2 A1 A2 A3 PPG2 where: A1 = First Adsorption Step A2 = Second Adsorption Step A3 = Third Adsorption Step E1 = First Equalization Down Step PPG1 = First Provide Purge Gas Step E2/PPG2 = Second Equalization Down/Second Provide Purge Gas Overlapping Step PPG3 = Third Provide Purge Gas Step BD = Blowdown Step Pg2 = Second Receive Purge Gas Step Pg3 = Third Receive Purge Gas Step Pg1 = First Receive Purge Gas Step E2′ = Second Equalization Up Step E1′ = First Equalization Up Step PP1 = First Product Pressurization Step PP2 = Second Product Pressurization Step

(20) TABLE-US-00009 TABLE 8 5-1-3 cycle (related art) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 B1 A1 A2 A3 E1a E1b E2 PPG E3/ BD2 PG E3′ E2′ E1a′ E1b′ PP BD1 B2 E1a′ E1b′ PP A1 A2 A3 E1a E1b E2 PPG E3/ BD2 PG E3′ E2′ BD1 B3 PG E3′ E2′ E1a′ E1b′ PP A1 A2 A3 E1a E1b E2 PPG E3/ BD2 BD1 B4 PPG E3/ BD2 PG E3' E2′ E1a′ E1b′ PP A1 A2 A3 E1a E1b E2 BD1 B5 E1a E1b E2 PPG E3/ BD2 PG E3′ E2′ E1a′ E1b′ PP A1 A2 A3 BD1 where: A1 = First Adsorption Step A2 = Second Adsorption Step A3 = Third Adsorption Step E1a = First (a) Equalization Down Step E1a = First (a) Equalization Down Step E2 = Second Equalization Down Step PPG = Provide Purge Gas Step E3/BD1 = Third Equalization Down/First Blowdown Overlapping Step BD2 = Second Blowdown Step PG = Receive Purge Gas Step E3′ = Third Equalization Up Step E2′ = Second Equalization Up Step E1a′ = First (a) Equalization Up Step E1b′ = First (b) Equalization Up Step PP1 = First Product Pressurization Step PP2 = Second Product Pressurization Step

(21) Performance comparison for 5-1-3 and 5-1-2 cycles are illustrated using carbon monoxide (CO) coldbox feed in Example 3 and results summarized in Table 9, below.

(22) TABLE-US-00010 TABLE 9 Example 3. 5-bed PSA cycles with 3 and 2 pressure equalization steps 87.1% H.sub.2, 12.6% CO, COCB Feed Compositions 0.06% CH.sub.4, <1% N.sub.2, Ar 5-1-3 5-1-3 5-1-2 Process Cycle (related art) (related art) (invention) H.sub.2 Recovery (%) 86.8 85.2 86.7 BSF (ft.sup.3/MMscfd) 190 142 140 Feed Flux (mol/m.sup.2/sec) 120 120 120 Purge Time (sec) 84 48 119 Feed Time (sec) 124 88 119 Cycle Time (min) 10.3 7.3 9.9

(23) As shown in this Example 3, when the feed composition is the same, the 5-1-2 PSA cycle of the present invention outperforms the 5-1-3 PSA cycle in recovery with smaller BSF. For similar recovery performance of the 5-1-2 cycle, a 5-1-3 cycle requires much larger BSF which acquires longer purge time and cycle time. Therefore, a five bed PSA system devising 5-1-3 cycle is very inefficient in both cost and performance. For intensified PSA design, purge time plays a more important role than pressure equalization steps for achieving target recovery and small BSF.

(24) Further process intensification to improve capital efficiency is demonstrated by devising process cycles of the present invention while utilizing faster rate adsorbents. Tables 10 and 11 show PSA performance impact from adsorbents with higher mass transfer coefficients.

(25) As illustrated in this Example 4 (Table 10, below) the 6-bed PSA having a 6-1-2 PSA cycle with SMR feed is provided. If the adsorbent rate from the baseline is doubled, 1% higher PSA recovery performance is achieved. Further increase adsorbent rate, recovery performance improves but at slower rate.

(26) Furthermore the 5-bed PSA having a 5-1-2 PSA cycle with CO coldbox feed is illustrated in Example 5 (Table 11, below). Fast rate adsorbent enhances PSA recovery performance. Compared to SMR feed 6-bed PSA, the amount of improvement is more incremental. These results are largely contributed by inferior 5-bed process cycle due to limited number of vessels for cycle steps configuration and optimization. In addition, higher CO concentration as limiting species in CO coldbox feed could potentially require even longer purge time to regenerate CO.

(27) TABLE-US-00011 TABLE 10 Example 4. Adsorbents MTC impact on 6-bed PSA performance 74.6% H.sub.2, 16.5% CO.sub.2, 3.7% CO, SMR Feed Compositions 4.5% CH.sub.4, <1% N.sub.2, H.sub.2O Process Cycle 6-1-2 (invention) Mass Transfer Coefficients (sec.sup.−1) 100% 200% 400% H.sub.2 Recovery (%) 85.5 86.5 87.0 BSF (ft.sup.3/MMscfd) 149 148 147 Feed Flux (mol/m.sup.2/sec) 140 140 140 Purge Time (sec) 115 123 126 Feed Time (sec) 70 74 76 Cycle Time (min) 7.0 7.4 7.6

(28) TABLE-US-00012 TABLE 11 Example 5. Adsorbents MTC impact on 5-bed PSA performance 87.1% H.sub.2, 12.6% CO, COCB Feed Compositions 0.06% CH.sub.4, <1% N.sub.2, Ar Process Cycle 5-1-2 (invention) Mass Transfer Coefficients (sec.sup.−1) 100% 200% 400% H.sub.2 Recovery (%) 86.7 87.3 87.7 BSF (ft.sup.3/MMscfd) 140 139 138 Feed Flux (mol/m.sup.2/sec) 120 120 120 Purge Time (sec) 119 123 126 Feed Time (sec) 119 123 126 Cycle Time (min) 9.9 10.3 10.5

(29) All process conditions and model results in Examples 1-5 for describing the impacts of process cycles and adsorbent rates on process performance are summarized and plotted in FIGS. 1-2. Recovery validation using pilot plant testing results are provided for 6-1-3, 6-1-2, and 5-1-2 cycles using conventional adsorbents (MTC x1). Pilot-model recovery gap is <1% for CO coldbox feed condition, and ˜1.5% for SMR feed condition. This is due to the discrepancy of intrabed thermal dynamics between pilot and model results is more prevalent for the SMR feed condition. Overpredicted temperature swing and heat effects have caused model to breakthrough earlier thus yielding to much lower H.sub.2 recovery compared to the pilot results. Nonetheless, this process model is able to predict the impact of process cycles and adsorbent rates on recovery performance, both in trend and in magnitude. From the overall results, it is demonstrated that 6-bed and 5-bed process cycles with less pressure equalization steps perform much better or equivalent at similar BSF numbers. For intensfied PSA designs with small BSF, less pressure equalization steps offer the benefits of longer purge time and cycle time to debottleneck PSA working capacity and mitigate fludization risk. Faster rate adsorbents can be used to further enhance recovery performance. The intensified 5-bed and 6-bed PSA systems can achieve up to thirty percent (30%) BSF reduction while meeting the H.sub.2 recovery performance.

(30) While the invention has been described in detail with reference to specific embodiment thereof, it will become apparent to one skilled in the art that various changes and modifications can be made, and equivalents employed, without departing from the scope of the appended claims.