Apparatus and system for testing swing adsorption processes

• US 10,328,382 B2
• Filed: 08/22/2017
• Issued: 06/25/2019
• Est. Priority Date: 09/29/2016
• Status: Active Grant

• Current Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Original Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Inventors: Barnes, William, Nagavarapu, Ananda K.
• Primary Examiner(s): Lawrence, Jr., Frank M
• Application Number:
  US15/683,101
• Publication Number:
  US 20180085705A1
• Time in Patent Office: 672 Days
• Field of Search: 95 96- 98, 95104, 95105, 95117, 95139, 96109, 96110
• CPC Class Codes: B01D 2256/24 Hydrocarbons
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/80 Water
• CPC Class Codes: B01D 2259/40054 treated before its reuse
• CPC Class Codes: B01D 53/0462 Temperature swing adsorption
• CPC Class Codes: B01D 53/0473 Rapid pressure swing adsorption
• CPC Class Codes: B01D 53/0476 Vacuum pressure swing adsorption
• CPC Class Codes: G01N 33/00 Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
• CPC Class Codes: Y02C 20/40 of CO2

Abstract

Provided are apparatus and systems for testing the performance a swing adsorption process. This test system is integrated with an operational system that processes a feed stream to form a product stream. The test system includes a test swing adsorption system configured to perform a swing adsorption process on the test feed stream that is based on two or more streams from different locations in the operational system. Then, passing the streams from different steps to different locations in the operational system to be recycled into the operational system.

Claims

1. A process for removing contaminants from a feed stream and testing one or more swing adsorption processes, the process comprising:

performing a process to remove one or more contaminants from a feed stream in an operational system to form a process product stream;

separating one or more streams in the process from the operational system to form a test feed stream;

passing the test feed stream to a test system;

performing one or more swing adsorption processes on the test feed stream in the test system to remove one or more test contaminants from the test feed stream to form a test product stream having less test contaminants than the test feed stream and a test purge product stream containing at least a portion of the one or more test contaminants;

mixing at least a portion of the test product stream with a first stream in the operational system prior to the forming the process product stream; and

mixing at least a portion of the test purge product stream with a second stream in the operational system prior to the forming the process product stream.

2. The process of claim 1, wherein the performing one or more swing adsorption processes comprise performing a first swing adsorption process that comprises:

a) performing one or more adsorption steps, wherein each of the adsorption steps comprises passing the test feed stream from the operational system through a test swing adsorption system in the test system to remove the one or more test contaminants from the test feed stream and to form the test product stream;

b) performing one or more purge steps, wherein each of the purge steps comprise passing a test purge stream through the test swing adsorption system to form the test purge product stream; and

c) repeating the steps a) to b) for at least one additional cycle.

3. The process of claim 2, wherein the test purge stream is provided in a counter flow direction relative to the flow of the test feed stream.

4. The process of claim 2, wherein the one or more test contaminants comprise water.

5. The process of claim 2, wherein the one or more test contaminants comprise carbon dioxide (CO₂).

6. The process of claim 2, wherein the performing the one or more swing adsorption processes comprises performing a second swing adsorption process that comprises:

i) performing one or more acid gas adsorption steps, wherein each of the acid gas adsorption steps comprises passing a portion of the test product stream from the test swing adsorption system through a second swing adsorption system to remove acid gas from the portion of the test product stream and form a second test product stream;

ii) performing one or more acid gas purge steps, wherein each of the acid gas purge steps comprises passing a portion of the test product stream through the second swing adsorption system to form a second test purge product stream; and

iii) repeating the steps i) to ii) for at least one additional cycle.

7. The process of claim 6, further comprising:

mixing at least a portion of the second test product stream the first stream or a third stream in the operational system prior to the forming the process product stream; and

mixing at least a portion of the second test purge product stream with the second stream or a fourth stream in the operational system prior to the forming the process product stream.

8. The process of claim 1, wherein the one or more swing adsorption processes are performed for a cycle duration greater than 1 second and less than 600 seconds.

9. The process of claim 1, wherein the one or more swing adsorption processes are performed for a cycle duration greater than 2 seconds and less than 300 seconds.

10. The process of claim 1, wherein the feed stream is a hydrocarbon containing stream having greater than one volume percent hydrocarbons based on the total volume of the feed stream.

11. The process of claim 1, wherein the feed pressure is in the range between 400 pounds per square inch absolute (psia) and 1,400 psia.

12. The process of claim 1, further comprising blending two or more streams from different locations in the process of the operational system to form the test feed stream, wherein each stream of the two or more streams have a different composition from the remaining streams in the two or more streams.

13. The process of claim 12, further comprising adjusting temperature of the test feed stream prior to performing the one or more swing adsorption processes on the test feed stream in the test system.

14. The process of claim 12, further comprising increasing pressure of the test feed stream prior to performing the one or more swing adsorption processes on the test feed stream in the test system.

15. The process of claim 1, wherein the operational system is configured to remove one or more contaminants to have the process product stream comply with a pipeline specification, while the test system is configured to remove one or more test contaminants to have the test product stream or the second test product stream comply with a cryogenic specification.

16. The process of claim 1, further comprising communicating with one or more sensors and/or one or more control valves to manage one of the flow rate, composition, temperature, pressure and any combination thereof within streams of the test system.

17. A system for testing one or more swing adsorption processes associated with an operational system, the system comprising:

an operational system configured to perform a process to remove one or more contaminants from a feed stream to form a process product stream;

a test system in fluid communication with the operational system and comprising;

one or more separation units in fluid communication with the operational system and configured to separate one or more streams from the operational system to form a test feed stream;

a swing adsorption system comprising one or more adsorbent bed units, wherein each of the one or more adsorbent bed units is configured to receive the test feed stream in an adsorption step and to separate test contaminants from the test feed stream and to output a test product stream having less test contaminants than the test feed stream;

a recycle unit in fluid communication with the swing adsorption system and configured to receive the test product stream and to pass at least a portion of the test product stream to one of the one or more adsorbent bed units in a purge step and form a test purge product stream; and

one or more conduits configured to pass the test product stream to the operational system and to pass the test purge product stream to the operational system.

18. The system of claim 17, further comprising a blending unit in fluid communication with the one or more separation units and configured to blend two or more streams from different locations in the operational system to form the test feed stream.

19. The system of claim 17, wherein the test system further comprises:

a second swing adsorption system comprising one or more second adsorbent bed units, wherein each of the one or more second adsorbent bed units is configured to separate second test contaminants from at least a portion of the test product stream in an adsorption step, wherein the second test contaminants is different from the test contaminants;

a recycle unit configured to receive the second test product stream and pass at least a portion of the second test product stream to one of the one or more second adsorbent bed units to perform a second purge step and form a second test purge product stream; and

one or more conduits configured to pass the second test product stream to the operational system and to pass the second test purge product stream to the operational system.

20. The system of claim 18, further comprising a control unit configured to:

obtain measured data from a plurality of locations in the operational system, wherein the measured data includes one or more of operation conditions, flow rates and any combination thereof;

calculate a flow rate for each of the plurality of locations in the operational system, wherein the flow rate for each of the plurality of locations is based on a predetermined test composition of the test feed stream; and

calculate an adjustment to an operation condition in the test feed stream, wherein the operation condition comprise one of pressure, temperature and any combination thereof.

21. The system of claim 20, further comprising one or more sensors configured to monitor each of the plurality of locations to obtain the measurement data and to communicate the measurement data to the control unit.

22. The system of claim 21, further comprising one or more flow control mechanisms configured to adjust the flow rate for the each of the plurality of locations and to communicate the flow rate for each of the plurality of locations to the control unit.

23. The system of claim 17, wherein the swing adsorption system is configured to operate on a cycle duration greater than 1 second and less than 600 seconds.

24. The system of claim 17, wherein the swing adsorption system is configured to operate on a cycle duration greater than 2 seconds and less than 300 seconds.