Swing adsorption processes using zeolite structures

• US 10,603,626 B2
• Filed: 08/04/2017
• Issued: 03/31/2020
• Est. Priority Date: 09/01/2016
• Status: Active Grant

• Current Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Original Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Inventors: Wang, Yu, Deckman, Harry W., Wittrig, Ashley M., Strohmaier, Karl G., Leta, Daniel P., Ravikovitch, Peter I.
• Primary Examiner(s): Nguyen, Tam M
• Application Number:
  US15/669,161
• Publication Number:
  US 20180056235A1
• Time in Patent Office: 970 Days
• Field of Search: None
• CPC Class Codes: B01D 2253/1085 characterized by a silicon-aluminium ratio
• CPC Class Codes: B01D 2253/1122 Metals
• CPC Class Codes: B01D 2253/308 Pore size
• CPC Class Codes: B01D 2253/3425 Honeycomb shape
• CPC Class Codes: B01D 2256/24 Hydrocarbons
• CPC Class Codes: B01D 2256/245 Methane
• CPC Class Codes: B01D 2257/80 Water
• CPC Class Codes: B01D 2259/40056 Gases other than recycled product or process gas
• CPC Class Codes: B01D 2259/4009 using hot gas
• CPC Class Codes: B01D 53/02 by adsorption, e.g. preparative gas chromatography solid sorbent compositions B01J20/00, preparation of inorganic compounds or elements C01
• CPC Class Codes: B01D 53/0423 Beds in columns
• CPC Class Codes: B01D 53/0462 Temperature swing adsorption
• CPC Class Codes: B01D 53/0473 Rapid pressure swing adsorption
• CPC Class Codes: B01D 53/261 by adsorption
• CPC Class Codes: B01J 20/18 Synthetic zeolitic molecular sieves
• CPC Class Codes: B01J 20/28042 Shaped bodies; Monolithic structures
• CPC Class Codes: B01J 20/2808 being less than 2 nm, i.e. micropores or nanopores
• CPC Class Codes: B01J 20/3408 of aluminosilicate molecular sieves
• CPC Class Codes: B01J 20/3458 in the gas phase
• CPC Class Codes: C10L 2290/542 Adsorption of impurities during preparation or upgrading of a fuel
• CPC Class Codes: C10L 3/106 : of water

Abstract

The present disclosure describes the use of a specific adsorbent material in a rapid cycle swing adsorption to perform dehydration of a gaseous feed stream. The adsorbent material includes a zeolite 3A that is utilized in the dehydration process to enhance recovery of hydrocarbons.

Claims

1. A process for removing water from a gaseous feed stream comprising water and hydrocarbons, the process comprising performing a rapid cycle swing adsorption process by:

a) performing an adsorption step, wherein the adsorption step comprises passing the gaseous feed stream through an adsorbent bed unit having a substantially parallel channel contactor to separate water from the gaseous feed stream to form a product stream, wherein the substantially parallel channel contactor comprises an adsorbent material being a zeolite 3A having (i) a K to Al atomic ratio is in a range between 0.3 and 1.0; and

(ii) a Si to Al atomic ratio is in a range between 1.0 and 1.2;

b) interrupting the flow of the gaseous feed stream;

c) performing a regeneration step, wherein the regeneration step comprises removing at least a portion of the water from the substantially parallel channel contactor; and

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

2. The process of claim 1, wherein the regeneration step further comprises performing a purge step, wherein the purge step comprises passing a purge stream into the adsorbent bed unit to remove the at least a portion of the water from the substantially parallel channel contactor to form a purge product stream.

3. The process of claim 2, wherein the purge step comprises heating the substantially parallel channel contactor to promote the removal of the at least a portion of the water from the substantially parallel channel contactor to form a purge product stream.

4. The process of claim 3, wherein the purge step comprises passing a heated purge stream through the substantially parallel channel contactor to promote the removal of the at least a portion of the water from the substantially parallel channel contactor to form a purge product stream.

5. The process of claim 2, wherein the purge stream is predominately methane.

6. The process of claim 1, wherein the rapid cycle swing adsorption process comprises a rapid cycle pressure swing adsorption process, a rapid cycle temperature swing adsorption process or any combination thereof.

7. The process of claim 1, wherein residence time for gas in the gaseous feed stream contacting the adsorbent material in the substantially parallel channel contactor during the adsorption step is less than 0.5 seconds.

8. The process of claim 1, wherein the concentration of water in the product stream is less than 1 parts per million on a mole basis.

9. The process of claim 1, wherein the adsorbent material has the K to Al atomic ratio is in a range between 0.4 and 0.8.

10. The process of claim 1, wherein the adsorbent material has greater than 80% of the non-potassium cations in the zeolite 3A being Na.

11. The process of claim 1, wherein the adsorbent material is fouling tolerant, wherein fouling tolerant is defined as the adsorbent material having a CO₂ capacity at 25°

C. and less than 3 minute equilibration times in isotherm measurement of less than 2 milli moles/gram at 760 torr.

12. The process of claim 1, wherein average size of zeolite aggregates in the zeolite 3A are less than 10 microns.