Integrated pressure swing adsorption/membrane separation process

Claim 2

In a pressure swing adsorption process containing at least one adsorption bed in which at least one more readily adsorbable gas component is separated from at least one less readily adsorbable gas component and in which a purge effluent is obtained during the purging of said adsorption bed, and further in which a displacement gas is introduced into the absorption bed to displace the at least one less readily absorbable gas component contained within the bed, the improvement which comprises passing at least a portion of the purge effluent through a membrane separation unit to concentrate the at least one more readily adsorbable gas component to form a concentrated gas stream and using said concentrated gas stream as the displacement gas in said pressure swing adsorption process.

Claim 3

A gas separation method for removing at least one gas component from a feed gas mixture comprising: (a) passing the feed gas mixture to at least one adsorbent bed maintained at an adsorption pressure in which the at least one gas component is more adsorbable than less adsorbable gas components contained within the feed gas mixture, said bed having a feed end and a product end; (b) displacing the less adsorbable gas components contained within the bed with a displacement gas having a concentration of the more adsorbable at least one gas component which is higher than that of the feed gas mixture; (c) depressurizing the bed by at least countercurrent depressurization in which substantially the more adsorbable at least one gas component is released from the inlet end of the bed; (d) purging the bed with a purge gas to obtain a purge effluent from the feed end of the bed, said purge effluent including said more adsorbable at least one gas component and said less adsorbable gas components; (e) repressurizing the bed to the adsorption pressure; and (f) concentrating the more adsorbable at least one gas component in said purge effluent with a semi-permeable membrane to provide at least a portion of the said displacement gas.

Claim 4

A gas separation method for removing at least one gas component from a feed gas mixture comprising: (a) passing the feed gas mixture to at least one adsorbent bed maintained at an adsorption pressure in which the at least one gas component is more adsorbable than less adsorbable gas components contained within the feed gas mixture, said bed having a feed end and a product end; (b) displacing the less adsorbable gas components contained within the bed with a displacement gas having a concentration of the more adsorbable at least one gas component which is higher than that of the feed gas mixture; (c) depressurizing the bed by at least countercurrent depressurization in which substantially the more adsorbable at least one gas component is released from the inlet end of the bed; (d) purging the bed with a purge gas to obtain a purge effluent from the feed end of the bed, said purge effluent including said more adsorbable at least one gas component and said less adsorbable gas components; (e) repressurizing the bed to the adsorption pressure; and (f) concentrating the more adsorbable at least one gas component in said purge effluent with a semi-permeable membrane to provide at least a portion of the said displacement gas.

Claim 5

The method of claim 2 further including the step of cocurrently depressurizing the bed to allow the release of substantially the less adsorbable gas components from the product end of the bed either before, simultaneous with, or after the displacing step.

Claim 6

The method of claim 3, wherein the released less adsorbable gas components from the concurrent depressurization step is used at least in part of the repressurization of an adsorption bed.

Claim 7

The method of claim 2, wherein the depressurization of step (c) further comprises the simultaneous release of substantially the less adsorbable gas components from at least one other location of the bed.

Claim 8

The method of claim 5, wherein during the depressurization of step (c), substantially the less adsorbable gas components are released from the product end of the bed and substantially the more adsorbable at least one gas component is simultaneously released from the inlet end of the bed.

Claim 9

The method of claim 5, wherein the released less adsorbable gas components from the at least one other location is used for purging an adsorbent bed.

Claim 10

The method of claim 2, wherein said step of concentrating further comprises the step of compressing said purge effluent prior to being concentrated with the semi- permeable membrane.

Claim 11

The method of claim 8, wherein the purge effluent is compressed to adsorption pressure prior to being concentrated with the semi-permeable membrane.

Claim 12

The method of claim 9, wherein said step of concentrating further comprises the step of flowing the compressed effluent to the semi-permeable membrane which is selectively permeable to the less adsorbable gas components and recovering a non-permeate at adsorption pressure which is used as the said displacement gas and a permeate at a pressure less than adsorbtion pressure comprising substantially the less adsorbable gas components.

Claim 13

The method of claim 10, wherein the permeate is used for purging an adsorbent bed.

Claim 14

The method of claim 2, wherein the more adsorbable at least one gas component is a member selected from the group consisting of methane, carbon monoxide, oxygen and combinations thereof.

Claim 15

The method of claim 2, wherein the less adsorbable gas components are selected from the group consisting of hydrogen, nitrogen and combinations thereof.

Claim 16

The method of claim 2, wherein the membrane comprises a composite membrane having a porous support layer and a separation layer positioned on the support layer.

Claim 17

The method of claim 14, wherein the composite membrane is in hollow fiber form.

Claim 18

The method of claim 2, wherein the bed is repressurized to a pressure of from about 600 psig to about 1,000 psig.

Claim 19

A gas separation method for removing at least one gas component from a feed gas mixture comprising: (a) passing the feed gas mixture to at least one adsorbent bed maintained at an adsorption pressure in which the at least one gas component is more adsorbable than less adsorbable gas components contained within the feed gas mixture, said bed having a feed end and a product end; (b) cocurrently depressurizing the bed to allow the release of substantially the less adsorbable gas components from the product end of the bed; (c) displacing less absorbable gas components contained within the bed with a displacement gas having a concentration of the more adsorbable at least one gas component which is higher than that of the feed gas mixture; (d) depressurizing the bed by simultaneously allowing the release of substantially the more adsorbable at least one gas component from the inlet end of the bed and allowing the release of substantially the less adsorbable gas components from the product end of the bed; (e) purging the bed with a purgge gas to obtain a purge effluent from the feed end of the bed, said purge effluent including said more adsorbable at least one gas component and said less adsorbable gas components; (f) repressurizing the bed to the adsorption pressure; (g) compressing at least a portion of the purge effluent to adsorption pressure to form a compressed purge effluent; and (h) concentrating the more adsorbable at least one gas component in said compressed purge effluent with a semi-permeable membrane, wherein the membrane is selectively permeable to the less adsorbable gas components and recovering a non-permeate at adsorption pressure which is used as the said displacement gas and a permeate at a pressure lower than adsorption pressure comprising substantially the less adsorpable gas components.

Claim 20

A gas separation method for removing at least one gas component from a feed gas mixture comprising: (a) passing the feed gas mixture to at least one adsorbent bed maintained at an adsorption pressure in which the at least one gas component is more adsorbable than less adsorbable gas components contained within the feed gas mixture, said bed having a feed end and a product end; (b) cocurrently depressurizing the bed to allow the release of substantially the less adsorbable gas components from the product end of the bed; (c) displacing less absorbable gas components contained within the bed with a displacement gas having a concentration of the more adsorbable at least one gas component which is higher than that of the feed gas mixture; (d) depressurizing the bed by simultaneously allowing the release of substantially the more adsorbable at least one gas component from the inlet end of the bed and allowing the release of substantially the less adsorbable gas components from the product end of the bed; (e) purging the bed with a purgge gas to obtain a purge effluent from the feed end of the bed, said purge effluent including said more adsorbable at least one gas component and said less adsorbable gas components; (f) repressurizing the bed to the adsorption pressure; (g) compressing at least a portion of the purge effluent to adsorption pressure to form a compressed purge effluent; and (h) concentrating the more adsorbable at least one gas component in said compressed purge effluent with a semi-permeable membrane, wherein the membrane is selectively permeable to the less adsorbable gas components and recovering a non-permeate at adsorption pressure which is used as the said displacement gas and a permeate at a pressure lower than adsorption pressure comprising substantially the less adsorpable gas components.

Claim 21

A gas separation system for removing at least one gas component from a feed gas mixture comprising: (a) a selective adsorption unit having at least one adsorbent bed in which the at least one gas component is more adsorbable than less adsorbable gas components contained within the feed gas mixture, said adsorption unit having at least one feed inlet, a first outlet for a product comprising the less adsorbable gas components, a second outlet for purge effluent, a second inlet for introducing displacement gas, means for feeding the feed gas mixture to the at least one feed inlet and means for recovering the product gas from the first outlet; (b) a semi-permeable membrane separation unit comprising at least one semi-permeable membrane which is selectively permeable to the less adsorbable gas components having a gas inlet, a first outlet for permeated gas, and a second outlet for non-permeated gas; and (c) means for directing the purge effluent from the second outlet of the adsorption unit to the gas inlet of the membrane separation unit, and means for directing the non-permeated gas from the second outlet of the membrane separation unit to the second inlet of the adsorption unit for introducing the non-permeated gas to be used as a displacement gas in the adsorption unit.

Claim 22

A gas separation system for removing at least one gas component from a feed gas mixture comprising: (a) a selective adsorption unit having at least one adsorbent bed in which the at least one gas component is more adsorbable than less adsorbable gas components contained within the feed gas mixture, said adsorption unit having at least one feed inlet, a first outlet for a product comprising the less adsorbable gas components, a second outlet for purge effluent, a second inlet for introducing displacement gas, means for feeding the feed gas mixture to the at least one feed inlet and means for recovering the product gas from the first outlet; (b) a semi-permeable membrane separation unit comprising at least one semi-permeable membrane which is selectively permeable to the less adsorbable gas components having a gas inlet, a first outlet for permeated gas, and a second outlet for non-permeated gas; and (c) means for directing the purge effluent from the second outlet of the adsorption unit to the gas inlet of the membrane separation unit, and means for directing the non-permeated gas from the second outlet of the membrane separation unit to the second inlet of the adsorption unit for introducing the non-permeated gas to be used as a displacement gas in the adsorption unit.

Claim 23

The system of claim 18, wherein the means for directing the purge effluent includes a gas compressor, a conduit means from the adsorption unit to the gas compressor, and a conduit means from the gas compressor to the membrane separation unit.

Claim 24

The system of claim 18, wherein the membrane separation unit comprises semi-permeable membrane hollow fibers assembled within the separation unit.

Claim 25

The system of claim 20, wherein the gas inlet and the second outlet for non-permeated gas of the membrane separation unit are in fluid communication within said separation unit on the outside of said hollow fibers, and said first outlet for permeated gas being in fluid communication with the inside of said hollow fibers.

Claim 26

The system of claim 18, wherein the semi-permeable membrane is a composite membrane having a porous support layer and a separation layer positioned on the support layer.

Claim 27

The system of claim 18, which further includes means for directing the permeated gas from the first outlet of the membrane separation unit to the first outlet of the adsorption unit, for introducing the permeated gas as a purge gas in the adsorption unit.