Helium recovery demonstration using the cascade dual reflux pressure swing adsorption process based on the cost-estimated field-testing facility.
The challenge
Helium is a scarce and expensive noble gas with unique applications in various fields. Australia has potential helium-rich gas fields, but only one helium production facility at the Darwin LNG plant. The untapped helium resources are an excellent opportunity for Australia’s export industry, and Australia should develop this strategic resource like the gas industry in North America.
Recently, UWA researchers patented a novel process, known as Cascade Dual Reflux Pressure Swing Adsorption (CDR PSA), for the low-cost, non-cryogenic recovery of helium from natural gas that is well-suited to smaller-scale gas reserves. A pilot-scale pressure swing adsorption (PSA) facility, has been constructed and is being prepared for operational testing.
In this project, the performance of the (Cascade) DR PSA technology is demonstrated, developing a cost estimation of a field-testing facility for the technology, and optimizing the operation parameters of the facility to establish the optimal operation envelope.
Helium concentrations in gas wells in Australia (and elsewhere) can vary by an order of magnitude from 0.03 mol% to 10 mol%. This wide range of helium percentages makes it challenging to design and operate a processing facility at its optimal capacity. Therefore, optimising the operation parameters for a given facility for different helium concentrations is necessary.
The solution and the outcome
This project will revolutionise helium recovery, addressing the critical need for a more efficient and economical solution. The main findings of this project include:
- The pilot-scale helium recovery and purification facility has proven to be effective and informative for the design of larger commercial-scale facilities. The pilot-scale operation has provided valuable insights into the facility’s instrumentation, control, and optimal operation.
- The skid-mounted CDR PSA facility for a helium field development with 1 mol% helium in the feed and a flow rate of 0.54 MMSCFD has been estimated to cost approximately 3.9 million US dollars. The skid design has several advantages, such as flexibility, sustainability, and adaptability for field production.
- The operation parameters for the CDR PSA facility have been optimised to achieve the highest possible helium purity and recovery for different feed gas compositions. The facility can upgrade 0.5 mol% or higher helium feed to more that 99 mol% helium products with a recovery of 95% or higher. For feed gas with 0.2 mol% or lower helium content, another processing stage is required upstream of the CDR PSA en enrich the helium to 0.5 – 1 mol%. A membrane process placed before the CDR PSA process will pre-enrich helium to a viable concentration while minimising the impact on natural gas transport to achieve the most cost-effective production of helium.
The impact for the future
This pilot-scale facility represents a major step up in the technology’s demonstrated readiness and begins true engineering development of the technology as an operational system. The next phase of developing helium production technology aims to contribute fresh engineering insights to the synergy of membrane and adsorption separation processes, enabling optimal system design and control. The successful development of this technology will facilitate a stable helium supply and enable significant advancements in industries that depend on helium, driving innovation and delivering benefits across sectors.
Project researchers
- Dr Gongkui Xiao
- Prof. Eric May
Project status
Complete
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