nanomaterials Article Application of Nanosize Zeolite Molecular Sieves for Medical Oxygen Concentration Mingfei Pan, Hecham M. Omar and Sohrab Rohani * Department of Chemical and Biochemical Engineering, Faculty of Engineering, University of Western Ontario, London, ON N6A 5B9, Canada; [email protected] (M.P.); [email protected] (H.M.O.) * Correspondence: [email protected]; Tel.: +1-519-661-4116 Received: 19 June 2017; Accepted: 21 July 2017; Published: 25 July 2017 Abstract: The development of a portable oxygen concentrator is of prime significance for patients with respiratory problems. This paper presents a portable concentrator prototype design using the pressure/vacuum swing adsorption (PVSA) cycle with a deep evacuation step (−0.82 barg) instead of desorption with purge flow to simplify the oxygen production process. The output of the oxygen concentrator is a ~90 vol % enriched oxygen stream in a continuous adsorption and desorption cycle (cycle time ~90 s). The size of the adsorption column is 3 cm in diameter and 20 cm in length. A Li+ exchanged 13X nanosize zeolite is used as the adsorbent to selectively adsorb nitrogen from air. A dynamic model of the pressure and vacuum swing adsorption units was developed to study the pressurization and depressurization process inside the microporous area of nanosized zeolites. The describing equations were solved using COMSOL Multiphysics Chemical Engineering module. The output flow rate and oxygen concentration results from the simulation model were compared with the experimental data. Velocity and concentration profiles were obtained to study the adsorption process and optimize the operational parameters. Keywords: nanosize zeolite; microporous adsorption; bidisperison dynamic model; portable oxygen concentrator; COMSOL Multiphysics 1. Background Air pollution is becoming a worldwide problem particularly in heavily populated cities like Beijing, Los Angeles, and Mexico City. Air pollution leads to acute and chronic respiratory problems that are becoming a growing concern from both global and individual levels. Wearing disposable face masks has become a popular method to get some protection from exposure to pollutants. However, for people with poor autonomous respiration ability, like chronic obstructive pulmonary disease (COPD) patients, it is hard to breathe through disposable face masks. As a result, there is a growing need to address the health and quality of life through a light-weight and portable oxygen concentrator with a medical grade oxygen supply (O2 concentration: ~88–92 vol %). Currently, oxygen concentration techniques are based on air separation processes such as cryogenic technique, membrane separation and pressure swing adsorption (PSA) that can effectively produce enriched oxygen using ambient air as the source. Although cryogenic distillation acts as the leading process for air separation in an industrial oxygen plant, the pressure swing adsorption (PSA) technique has the advantage of reducing energy consumption for small production scales. Compared to the membrane separation technique, which requires higher pressure and expensive selective permeable materials, pressure swing adsorption using nanosize zeolite adsorbents is a more feasible solution for portable oxygen concentrator development. Due to the large microporous surface area inside the zeolite adsorbents, the portable oxygen concentrator using the PSA technique can adsorb nitrogen from air and output an enriched oxygen stream under high-pressure conditions. The concentrator can be regenerated by Nanomaterials 2017, 7, 195; doi:10.3390/nano7080195 www.mdpi.com/journal/nanomaterials Nanomaterials 2017, 7, 195 2 of 19 decreasing the pressure to release the adsorbed nitrogen. In this way, a continuous oxygen stream supply can be generated to assist an individual and increase the fraction of inspired oxygen. The oxygen concentration system is usually coupled with a filtration system to remove PM 2.5 and improve the quality of product gas stream. The pressure swing adsorption process was patented by Finlayson and Sharp in 1932 (GB Patent 365092) describing an air separation process with pressurization adsorption and depressurization desorption steps [1]. In 1958, two different pressure swing adsorption units were patented: one using fractional product purge flow for desorption step (Skarstrom, 1958) and the other using pressure vacuum adsorption (PVSA) step (Montgareuil and Domine, 1958) [2,3]. The selectivity for zeolite adsorbents to adsorb nitrogen compared to oxygen is due to the interaction between electrostatic field of the cationic zeolite and the quadrupole moment of the nitrogen and oxygen. The quadrupole of nitrogen is three times higher than that of oxygen, which leads to a selective adsorption onto the zeolite surface [4]. The most common type of commercial zeolite for oxygen concentration process is zeolite 13X due to its outstanding nitrogen to oxygen adsorption selectivity. However, 13X zeolite modified with Li+ exchange method exhibits a higher nitrogen adsorption capacity at the active cation sites of the zeolite framework [5–7]. JLOX-101 LiX zeolite provided by LUOYANG JIANLONG Chemical is designed specifically for a PVSA process with high oxygen selectivity [8]. The PSA system was first installed in industrial plants as a replacement for cryogenic separation plants due to lower capital and operating costs. Portable pressure swing adsorption oxygen concentrators have been designed and developed in the past two decades due to the synthesis of more effective zeolites with higher gas adsorption capacity and selectivity. The PSA oxygen concentrator is able to provide a continuous oxygen flow using the ambient air as the gas source. Two-bed or multi-bed PSA systems are utilized alternating adsorption and desorption operations of the zeolite columns to achieve continuous oxygen separation. For on-site medical grade oxygen production, a cylinder gas source or several powerful air compressors are usually installed for the rapid pressure swing adsorption process to maintain the productivity of high purity oxygen stream [9–11]. Considering the mobility of small-scale concentrators, a variety of simplified designs would be added to the pressure swing adsorption process for system miniaturization. In this paper, we compare the performance of a portable miniature PVSA oxygen concentrator unit with two adsorption columns, an air compressor, four solenoid valves and a back-pressure regulator (total weight less than 2 kg) built in our laboratory with the simulation results under modified Montgareuil and Domine cycle using COMSOL Multiphysics Chemical Engineering module. Compared to the conventional PSA cycle using purge flow with intermediate evacuation pressure (−0.6 barg) to regenerate the adsorption column, the deep vacuum (−0.82 barg) desorption step of the PVSA cycle reduces the column and compressor size from the perspective of industrial prototype design. A dual-head air compressor is selected to generate pressure and vacuum condition simultaneously for the dual-column adsorption unit, which simplifies the gas source generation. The oxygen concentrator unit can provide a ~90 vol % enriched oxygen stream to meet the concentration requirement of medical-grade oxygen. 2. Materials and Methods Figure1 shows the schematic of the oxygen concentrator using a two-column PVSA cycle. The concentrator consists of two adsorption zeolite columns, a dual-head air compressor (Parker Hannifin Corp., TTC IIS Miniature Diaphragm Pump, Hollis, NH, USA), five three-way solenoid valves (Parker Hannifin Corp., X-Valve, Hollis, NH, USA), a back-pressure regulator, an oxygen sensor (Teledyne GB300 Oxygen analyzer, Thousand Oaks, CA, USA), a surge tank, a pressure sensor (Freescale Semiconductor, MPXV7002DPT1CTND, Austin, TX, USA) and a cooling fan (avoiding the temperature rise of the air compressor) [12–15]. The oxygen sensor is an electrochemical transducer named Micro-fuel Cell calibrated by the Faraday type calibration method based on the product gas Nanomaterials 2017, 7, 195 3 of 19 from electrolysis of water [16]. The valve sequence is shown in Table1. The concentrator operation consists of four different steps. In step 1, column 1 is pressurized by the compressor while column 2 is connected to ambient air to decrease the pressure. In step 2, the pressure inside column 1 reaches the working pressure (1.79 barg) with enriched oxygen flowing out through the backpressure regulator (set at 1.79 barg) to the surge tank. Meanwhile the pressure in column 2 decreases to vacuum (set Nanomaterials 2017, 7, 195 3 of 19 at −0.82 barg) via the air compressor to regenerate the zeolite. In steps 3 and 4, the adsorption and desorptionthe working positions pressure of (1.79 column barg) 1with and enriched 2 are reversed oxygen toflowing regenerate out through the saturated the backpressure column 1 and pressurizeregulator the regenerated (set at 1.79 barg) column to the 2. Bysurge switching tank. Meanwhile the valve the sequence pressure (stepin column 1 ! 42 !decreases1), a continuous to enrichedvacuum oxygen (set stream at −0.82 can barg) be obtainedvia the air fromcompressor the surge to regenerate tank. The the flow zeolite. directions In steps of 3 theand two4, the different adsorption and desorption positions of column 1 and 2 are reversed to regenerate the saturated types ofcolumn valves 1 (normallyand pressurize open the and regenerated distributor column three-way 2. By switching solenoid the valve valves) sequence are shown (step 1 in → Figure4