Heavy reflux PSA cycles for CO₂ recovery from flue gas: Part I. Performance evaluation

Abstract

This study evaluated nine stripping PSA cycle configurations, all with a heavy reflux (HR) step, some with a light reflux (LR) step, and some with a recovery (REC) or feed plus recycle (F+R) step, for concentrating CO₂ from stack and flue gas at high temperature (575 K) using a K-promoted HTlc. Under the process conditions studied, the addition of the LR step always resulted in a better process performance; and in all cases, the addition of a REC or F+R step surprisingly did not affect the process performance except at low feed throughputs, where either cycle step resulted in a similar diminished performance. The best cycle based on overall performance was a 5-bed 5-step stripping PSA cycle with LR and HR from countercurrent depressurization (CnD) (98.7% CO₂ purity, 98.7% CO₂ recovery and 5.8 L STP/hr/kg feed throughput). The next best cycle was a 5-bed 5-step stripping PSA cycle with LR and HR from LR purge (96.5% CO₂ purity, 71.1% CO₂ recovery and 57.6 L STP/hr/kg feed throughput). These improved performances were caused mainly by the use of a very small purge to feed ratio (γ=0.02) for the former cycle and a larger one (γ=0.50) for the latter cycle. The former cycle was good for producing CO₂ at high purities and recoveries but at lower feed throughputs, and the latter cycle was useful for obtaining CO₂ at high purities and feed throughputs but at lower recoveries. The best performance of a 4-bed 4-step stripping PSA cycle with HR from CnD was disappointing because of low CO₂ recoveries (99.2% CO₂ purity, 15.2% CO₂ recovery and 72.0 L STP/hr/kg feed throughput). This last result revealed that the recoveries of this cycle would always be much lower than the corresponding cycles with a LR step, no matter the process conditions, and that the LR step was very important to the performance of these HR cycles for this application and process conditions studied.