Optimization of synthesis procedures for structured PSA adsorbents

Structured adsorbents in the form of supported thin zeolite films may represent a competitive alternative to traditional zeolite adsorbents in form of beads or pellets used in PSA processes, due to the reduction of mass- and heat-transfer limitations typical of packed beds. Thin NaX films were grown by hydrothermal treatment using a clear solution on cordierite monoliths. Films grown by a multiple synthesis procedure were dense and uniform with a very small amount of sediments adjacent to the film, which may be an advantage in PSA applications. The CO2 adsorption capacity and the pressure drop for the supported films were compared to those of a packed NaX bed. Although the adsorption capacity of the column filled with the structured adsorbents was 67 times lower than when the column was filled with zeolite beads, the pressure drop was 100 times lower for the structured adsorbent. The adsorption capacity can be increased by increasing the film thickness or the cell density of the monoliths without increasing the pressure drop significantly, indicating the potential advantage of structured adsorbents in PSA processes. Further investigations are needed in order to prove this hypothesis.