PSA Exhaust CO₂ Recovery Device
The skid-mounted system can include feed gas pretreatment, separation vessels, vacuum machinery, automated cycle controls, and battery-limit interface points for downstream process integration, compression, or liquefaction.
Overview
The PSA Exhaust CO₂ Recovery Device is an engineered gas separation system designed to recover and upgrade carbon dioxide from Pressure Swing Adsorption (PSA) tail gas streams.
The skid-mounted system can include feed gas pretreatment, separation vessels, vacuum machinery, automated cycle controls, and battery-limit interface points for downstream process integration, compression, or liquefaction.
CO₂ Recovery Performance
|
Parameter |
Baseline PSA/VPSA Scope |
Optional Downstream Scope |
Engineering Notes |
|
Product CO₂ Capacity |
500–10,000 Nm³/h feed gas (1–20 t/h CO₂) |
Multi-skid modular expansion |
At 0°C, 101.325 kPa |
|
Product CO₂ Purity |
95.0–99.0 vol% (dry basis) |
Up to 99.9 vol% |
Subject to impurity limits |
|
CO₂ Recovery Rate |
80–90% |
90–95% with recycle |
Depends on feed conditions |
|
Outlet Pressure |
0.02–0.15 MPa(g) |
2.0–2.5 MPa(g) with booster |
Confirm downstream requirements |
|
Product Dew Point |
Moisture-saturated gas |
−40°C to −60°C with dryer |
Specify guaranteed value |
|
Specific Power Consumption |
0.12–0.25 kWh/Nm³ CO₂ |
Includes booster and dryer |
Excludes liquefaction |
Typical Upstream Feed Gas Sources
Hydrogen PSA Tail Gas (SMR / Reforming): CO₂ concentration: 45–70 vol%; balance components may include H₂, CH₄, CO, and H₂O.
Ammonia & Methanol Syngas Purge Gas: CO₂ concentration: 30–60 vol%; balance components may include N₂, H₂, CH₄, and CO.
Coal-to-Chemicals / Shift Gas Desorption Stream: CO₂ concentration: 50–85 vol%; other components may include CO, H₂, and trace amounts of H₂S and COS.
Feed Gas Operating Limits & Impurity Tolerances
Feed CO₂ Concentration: 30–70 vol% (typical operating range).
Inlet Feed Pressure: 0.01–0.5 MPa(g) (10–500 kPa(g)) at the skid battery limit.
Inlet Feed Temperature: 15–40°C. Temperatures above 45°C may require an upstream gas cooler, depending on the process design.
Hydrogen Sulfide (H₂S) & Total Sulfur: ≤ 10 ppmv. H₂S concentrations above 10 ppmv may require upstream desulfurization to protect the adsorbent, subject to the selected adsorbent's sulfur tolerance.
Moisture & Free Liquids: Free water droplets must be removed using an inlet knockout drum. The allowable moisture content of the gas after separation must be specified in the design basis.
Oil Aerosol Content: ≤ 0.01 mg/m³. Coalescing filtration may be required if the feed gas comes from lubricated blowers or compressors.
PSA Adsorption & Regeneration Process
Feed Pretreatment: Free liquids and particulates are intercepted to prevent contamination of active adsorbents and process control valves.
Selective Adsorption: Feed gas passes through active adsorption vessels where CO₂ is preferentially adsorbed by target-selected media.
Desorption & Regeneration: Adsorbed CO₂ is released through a controlled reduction in bed pressure. Depending on the selected cycle, regeneration may use pressure blowdown, vacuum-assisted desorption, or a combination of these steps.
Equalization & Switching: Multi-bed vessel sequencing with pressure equalization steps balances vessel pressures, conserves utility power, and maintains steady downstream gas flow.
Product Buffering: Regenerated CO₂ flows to a surge vessel to buffer cyclic switching variations before reaching the skid battery limit.
Quality Assurance
Welding Qualifications: Welding procedures and personnel are qualified to ASME Section IX or equivalent national standards.
Non-Destructive Testing: RT, UT, or PT inspections are performed according to design codes, pressure ratings, and contract requirements.
Pressure Testing: Pressure vessels undergo hydrostatic testing, while assembled piping headers receive pneumatic tightness testing.
Quality Documentation: The project quality dossier includes EN 10204 3.1 material certificates, NDT records, pressure-test reports, and factory inspection documents.
Compliance: Manufacturing follows an ISO 9001-certified quality system, with applicable pressure-vessel codes and regional standards supported when required.
Installation & Integration
Battery Limits: Flanged connections are provided for feed gas, CO₂ product, purge gas, and condensate drainage in accordance with applicable ASME, EN, or DIN standards.
Foundations: A level concrete pad must support the skid's static weight and the dynamic loads generated by vacuum equipment or compressors.
Installation Conditions: Systems are suitable for indoor or outdoor installation within the specified ambient range. Cold-weather insulation and heat tracing are available.
Scope of Supply: The supplier provides skid-mounted equipment, internal piping, and controls. The buyer provides civil works, external piping, main power cables, and utilities.
Engineering Documents: GA drawings, foundation load data, and interface schedules are supplied for review.
FAQ
Q: Should I choose PSA/VPSA or amine absorption?
A: PSA/VPSA is generally more economical for low-pressure feed gas containing more than 30% CO₂. Amine absorption is better suited to dilute streams below 20% CO₂, such as boiler flue gas.
Q: What purity can be expected from a 99% product?
A: Typical limits include H₂ below 0.1%, CH₄ below 0.5%, CO below 100 ppm, and N₂ below 0.5%. Final guarantees depend on the feed-gas composition.
Q: How much CO₂ can be recovered?
A: A 5,000 Nm³/h feed stream containing 55% CO₂ can produce approximately 4.9 t/h, or 117 t/day, at a 90% recovery rate.
Q: What is the total energy consumption?
A: The complete process typically consumes 0.30–0.52 kWh/Nm³ of CO₂, including VPSA separation, compression to 2.0 MPa, and liquefaction. This equals approximately 150–265 kWh per ton of liquid CO₂.
Q: Can sulfur-containing gas be treated?
A: Yes, but H₂S and COS must generally be reduced to below 10 ppmv upstream, using zinc oxide or activated carbon, to prevent permanent adsorbent damage.
Q: How long do the adsorbent and main components last?
A: CO₂-selective adsorbent typically lasts 5–8 years, switching valves 3–5 years, and vacuum pumps require overhaul every 16,000–24,000 operating hours.
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