Introduction to Gas Adsorption;

Molecular Sieves
Introduction to Gas Adsorption
Objectives of this module:
At the end of this module you will:
• Understand what is Gas Adsorption, Gas Desorption and Gas Absorption
• Understand the differences between Gas Adsorption and Gas Absorption.
• Describe the equipment used in Gas Adsorption.
• Understand the Gas Adsorption process flow.
• Understand the purpose of after-filters.
• Understand the main operational problems you may encounter in a Gas Adsorption
system.
• Understand the consequences of liquid breakthrough in a Gas Adsorption system.
• Understand the importance of operating a Gas Adsorption unit in line with the
operating procedures.
• Understand the hazards of the Gas Adsorption process and the safety precautions to be
taken.
 What is Gas Adsorption?

• Adsorption is a process that uses special solids (called adsorbents) to physically

adsorb gaseous or liquid mixtures onto its surface.

• Typical solid materials used as the adsorbents can be Molecular Sieve, Alumina Gel
and Silica Gel.

• Some Gas Adsorbent material is shown below:

Molecular Sieve Alumina gel Silica gel

 Adsorbent Materials

Shown below are some more types of Gas Adsorbent material.

• As you can see there are many types available to capture unwanted gases from
product streams.
 Gas Adsorption and Gas Absorption mechanisms

What is the difference between 1)Gas Adsorption and 2) Gas Absorption?

1) Gas Adsorption is the process of trapping or binding of molecules to an

adsorbent surface such as molecular sieve.
A good example of the gas adsorption process is the use of a molecular sieve bed
for the removal of CO2 and H2O from a natural gas stream.
Dry Gas
(Product)
Drying Feed
Gas
Outlet

Regenerator
Gas
Inlet
Molecular
Sieve
(Adsorbent)
Feed
Gas Inlet

Wet Gas
Regenerator Regeneration
Gas Outlet
(Feedstream)

Gas Adsorber
 Gas Adsorption and Gas Absorption Mechanisms

2) Gas Absorption is normally a process where a gas diffuses into a liquid to form a
solution.
• A good example of this process is the use of TEG (Tri-ethylene GLYCOL) to absorb and
remove water from a natural gas stream.
 Gas Adsorption Equipment

Gas Adsorption Three Gas Adsorption

Gas Adsorption Drier Bed being loaded
Drier Bed internals Drier Beds in parallel
With adsorbent material
 Gas Adsorption - Typical Equipment
Feed gas
outlet

Inert Ceramic
Balls
Wire mesh

Adsorbent
material e.g.
Molecular
Sieve

Wire mesh Inert Ceramic

Balls

Feed gas Sample

inlet Point
Gas Adsorption- Typical equipment layout

Open Cycle Molecular Sieve Dehydration System.

 Gas Adsorption Mechanism
Molecular sieve (adsorbent) material
has a strong attraction to gas
molecules that come into contact with Dry Gas
it.
The sieve material traps the ‘unwanted’
(Product)
gas to its surface. This process of
trapping molecules is called Adsorption.

Desorption is the removal of these gas

molecules from the adsorbent. This
takes place once the sieve material is
saturated.

Wet Gas
Drier Vessel Molecular Sieve (Feedstream)
(Adsorbent)
 Gas Adsorption and Gas Desorption

Desorption and
Gas Adsorption
‘Regeneration’ of the drier bed.

Gas Drying
Feed
Gas
Outlet

Regenerator
Gas
Inlet

Feed
Gas Inlet

Regenerator Regeneration
Gas Outlet

Gas Adsorber
 Gas Adsorption Process description
Simplified drawing of
Product
Two Gas Adsorption Gas out
Drier Beds operating Product
Gas out
in parallel After filter

After filter
Regeneration
Gas in Gas
flow Key:
Valve open
Adsorber on Adsorber on
Drying Regeneration Valve closed
This adsorber bed is Cycle Cycle
online and capturing Regeneration
unwanted gases. Gas + unwanted This adsorber bed is
Gas offline and is saturated
flow Gases out
with unwanted gases.
These unwanted gases
are driven away using
clean regeneration gas.
Feed
Gas in
 Regeneration cycle

Product
Gas out
Product
Gas out
After filter

After filter
Regeneration
Gas in Gas Key:
flow Valve open

Valve closed
Adsorber on Adsorber on
Drying Regeneration
Cycle Cycle • The regeneration process is
Regeneration normally controlled
Gas + unwanted automatically by opening or
Gas closing valves on the
flow Gases out
Adsorber unit as it cycles
through from one drier bed to
the next.
• The operator is able to stop
Feed
the PLC program if any
Gas in
operational problems are
encountered.
 Regeneration cycle

Product
Gas out
Product
Gas out
After filter

After filter
Regeneration
Gas in Gas
flow Key:
Valve open
Adsorber on Adsorber on
Valve closed
Drying Regeneration
Cycle Cycle
• The drier bed can be
Regeneration
regenerated by passing a hot
Gas + unwanted
Gas gas (sometimes Nitrogen as it
flow Gases out
is inert) countercurrent to the
normal flow through the drier
bed.
• This heating period is
Feed followed by a cooling period
Gas in before the drier is able to be
brought back online.
 After-filters
Product
Gas out
Product
Gas out
After filter

After filter
Regeneration
Gas in

Adsorber on Adsorber on The purpose of the after-filter

Drying Regeneration is to capture any fine dusts e.g.
Cycle Cycle molecular sieve adsorbent
Regeneration that has slipped through the
Gas + unwanted Adsorber beds.
Gases out

Key:
Feed Valve open
Gas in
Valve closed
 Operating Issues

Liquid breakthrough
is a major problem to
be avoided at all times $$$$$$$

Some of the consequences

of liquid breakthrough are shown
Below:
• Damaged to Equipment
downstream .
• Product goes off specification
• The plant may shutdown.
• Potential financial penalties
from the customer due to
production loss.

All the above cost lost $$$!!!

Follow procedures. Keep
instruments maintained.
 Operating Issues

Liquid breakthrough How can it happen? Here are some

is a major problem to examples of how things can go wrong.
be avoided at all times $$$
• Operating Procedures not being followed
correctly!
• Adsorber bed not regenerated correctly
• Specification of feed gas changed
• Gas Analyser upstream and/or
downstream of adsorber bed not
working correctly!
• Adsorber bed activity reducing with age
• Incorrect timings for bed regeneration
process

Company $$$$$$$ = Your $$$$$$$

Operating Issues

Liquid breakthrough
is a major problem to
be avoided at all times!!

How can liquid breakthrough be

avoided?
• Operating Procedures to be
strictly followed
• Regular calibration of gas
analysers
• Regular plant checks on the
adsorber unit
• Strict operational monitoring of
the adsorber unit
Follow your procedures.$$$$
$
 Operating Issues

What are other operating

issues that you may
encounter in a Gas
Adsorption unit?
• Commissioning of the
gas adsorption unit
must be carried out as
per manufacturer
instructions. This is
extremely important to
avoid problems later
when the unit is
brought into line.
• $$$$$$$$$$$$$$$
Gas Adsorption
Drier Bed being loaded
With adsorbent material
Operating Issues

What are other operating issues

that you may encounter in a Gas
Adsorption unit?

• Incorrect filling of vessel with

adsorbent material can cause
problems when the unit is started up
e.g. gas channelling.

• Adsorbent dust can cause valve

operation problems.
Operating Issues

• Adsorbent material does not last

forever so will have to be replaced
as per the manufacturer’s
recommendation.
• Great care and attention is
required when emptying and re-
filling the drier vessels with
adsorbent material.
• Manual handling respiration issues
need to be carefully considered.
Operating Issues

WARNING!!!!!!!!!!!
• Absorbent material when exposed
to air can be extremely explosive,
especially when dry and dusty, the
material may also contain
hydrocarbons especially when
being removed for inspections etc.

FOLLOW
MANUFACTURERS
INSTRUCTIONS, AND
OPERATIONAL
PROCEDURES
 Gas Adsorption Hazards

What are the

hazards that you
may encounter
in a Gas
Adsorption unit?

• Molecular Sieve, Alumina and Silica gel

are active material so need careful
handling.
• Extreme care needs to be taken when
handling molecular sieve. Refer to the
Gas Adsorption relevant MSDS (Material Safety Data
Drier Bed being loaded
With adsorbent material
Sheet) for the adsorbent that is in use.
 Gas Adsorption Hazards

What are the

hazards that you
may encounter
in a Gas
Adsorption unit?

• Removing and replacing the adsorbent

can be hazardous and needs carefully
controlling.
• There is a potential manual handling
hazard as Adsorbent may have to be
Gas Adsorption removed from the vessel for inspection at
Drier Bed being loaded
With adsorbent material
maintenance turnarounds.
So beware
 So Beware
• Three contractor employees died at a natural gas processing
plant as a result of inhalation of H2S released during the
unloading of molecular sieves from a NGL drier.
• Two of the victims were trying to rescue the first worker.

• Identified main areas for remedial actions are:

• Lack of detailed knowledge of the properties of molecular sieves.

• Inadequate awareness of hazards and management of risks.
• Insufficient and inadequate controls (system of work)
• Ineffective emergency response.
 Gas Adsorption Hazards

! What are the hazards that you may

encounter in a Gas Adsorption unit? !
The simple message is that
Molecular Adsorbents need
to be treated with the
greatest respect!

Gas Adsorption
Drier Bed being loaded
With adsorbent material
 Good Luck

Thank you
Please work safely