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Abstract With expanding areas of applications, increasing needs for efficient cycles, and growing de- mands for efficient modeling, it has become essential to develop new systematic strategies for optimal design and operation of PSA systems. Although industrial usage of PSA is widespread, we observe a drought of any systematic methodology to design PSA cycles in PSA literature due to inherent complexity of cyclic PSA processes. We present a generic PSA superstruc- ture to synthesize optimal PSA configurations. The superstructure is rich enough to predict a number of different PSA operating steps, and their optimal sequence by solving an optimal control problem. Because of low operating costs and high performance, PSA is considered as a promising op- tion for both post-combustion and pre-combustion CO2 capture. Since commercial PSA cycles consider CO2 as a waste stream, cycle development specifically targeted towards high-purity CO2 separation is essential. We utilize superstructure approach for this purpose and succeed in synthesizing optimal cycles which can separate CO2 at a purity as high as 95%, or with a low power consumption of 465 kWh/tonne CO2 captured, for post-combustion capture. When applied for pre-combustion capture, superstructure approach yields cycles with an extremely low power number of 46.8 kWh/tonne CO2 captured. Large number of spatial nodes required to capture steep adsorption fronts lead to a large set of DAEs, and thus to a challenging PSA optimization problem. We generate reduced-order models (ROMs) which are not only orders of magnitude smaller, but also reasonably accurate. Consequently, replacing DAEs with these ROMs yields a cheap optimization problem. How- iiiPDF Image | Design and Operation of Pressure Swing Adsorption Processes
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