Separation Technology

Hydrogen separation employs pressure swing adsorption (PSA) technology with molecular sieve beds that preferentially adsorb CO₂, CO, CH₄, and other impurities while allowing hydrogen to pass through. The process cycles between adsorption at elevated pressure and regeneration at lower pressure, producing high-purity hydrogen typically 99.9-99.999%. ERGIL designs multi-bed systems enabling continuous hydrogen production while individual vessels regenerate.

Vessel Configuration

Vertical pressure vessels contain layered adsorbent beds optimized for the specific feed gas composition. Inlet distribution systems ensure uniform gas flow across the bed cross-section. Internal piping manages cycle valve sequencing for adsorption, depressurization, purge, and repressurization steps. Outlet collection systems deliver purified hydrogen at specification pressure. ERGIL engineers vessel sizing based on feed flow rate, hydrogen partial pressure, required purity, and recovery efficiency targets.

Process Integration

Complete PSA systems include multiple separation vessels, automatic cycle valves, buffer tanks, pressure regulation, and control systems. Feed gas conditioning may incorporate upstream filtration, temperature control, or compression to optimize separation performance. Tail gas from regeneration cycles can be routed to fuel systems or further processing. ERGIL provides full process design integrating hydrogen separation with existing plant operations.

Applications

Refinery hydrogen recovery from catalytic reformer off-gas, hydrocracker purge streams, and hydrotreater recycle loops. Petrochemical hydrogen purification from steam methane reformer syngas or ammonia plant purge gas. Industrial hydrogen recovery from metal treatment atmospheres or electronics manufacturing processes. Typical feed hydrogen concentrations range from 40-90% with recovery rates achieving 85-95%.

Design Standards

Pressure vessels designed and fabricated per ASME Section VIII Division 1 or EN 13445. Operating pressures from 150 to 600 psig depending on feed conditions. Carbon steel or stainless steel construction with internal coatings when required for corrosive components. Adsorbent materials selected for feed gas characteristics including sulfur tolerance for refinery applications. Full NDT inspection and hydrostatic testing.

Control Systems

Automated PLC control manages complex valve sequencing and cycle timing. Purity analyzers monitor hydrogen quality with feedback control maintaining specifications. Pressure and temperature monitoring throughout the cycle optimizes performance and protects equipment. Remote monitoring capabilities provide operational data and predictive maintenance alerts.

Performance Benefits

Hydrogen recovery reduces purchased hydrogen or natural gas feedstock requirements. Lower operating costs through improved hydrogen utilization efficiency. Reduced emissions by capturing hydrogen that would otherwise be flared or combusted. Modular designs allow capacity expansion as hydrogen demands increase. Proven technology with decades of industrial application.

ERGIL delivers engineered hydrogen separation systems from single vessels to complete PSA units, backed by process guarantees and comprehensive commissioning support.