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The present invention relates to a six bed pressure swing adsorption (PSA) system utilizing new and advanced cycles to obtain enhanced hydrogen recovery from a hydrogen containing feed gas (i.e., synthesis gas). In one such cycle each of the six beds has four pressure equalization steps, and at leas

The present invention relates to a six bed pressure swing adsorption (PSA) system utilizing new and advanced cycles to obtain enhanced hydrogen recovery from a hydrogen containing feed gas (i.e., synthesis gas). In one such cycle each of the six beds has four pressure equalization steps, and at least one of the beds is receiving and processing said feed gas to obtain a hydrogen product gas (i.e., a 6-1-4 cycle).

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1. A pressure swing adsorption process for separating a pressurized supply feed gas containing one or more strongly adsorbable component from at least one less strongly adsorbable product gas component in a six bed adsorbent system to produce a continuous stream of product gas enriched in the less s

1. A pressure swing adsorption process for separating a pressurized supply feed gas containing one or more strongly adsorbable component from at least one less strongly adsorbable product gas component in a six bed adsorbent system to produce a continuous stream of product gas enriched in the less strongly adsorbable component and a continuous stream of offgas that is enriched in the strongly adsorbable components; wherein, the process cycle has eighteen steps including four bed-to-bed equalization steps, in accordance to following cycle chart: Step:Bed #1234567891011121314151617181A1A2/A3/E1E2E2E3PPGE4/BD2PGE4′E3′E2′E2′E1′PP1PP2PP1PP2BD12E1′PP1PP2A1A2/A3/E1E2E2E3PPGE4/BD1BD2PGE4′E3′E2′E2′PP1PP23E3′E2′E2′E1′PP1PP2A1A2/A3/E1E2E2E3PPGE4/BD2PGE4′PP1PP2BD14BD2PGE4′E3′E2′E2′E1′PP1PP2A1A2/PP1A3/PP2E1E2E2E3PPGE4/BD15E3PPGE4/BD2PGE4′E3′E2′E2′E1′PP1PP2A1A2/A3/E1E2E2BD1PP1PP26E1E2E2E3PPGE4/BD2PGE4′E3′E2′E2′E1′PP1PP2A1A2/A3/PP2BD1PP1wherein:A1 = First Adsorption StepA2/PP1 = Second Adsorption Step/First Product PressurizationA3/PP2 = Third Adsorption Step/Second Product PressurizationE1 = First Equalization DownE2 = Second Equalization DownE3 = Third Equalization DownPPG = Provide Purge GasE4/BD1 = Fourth Equalization Down/First BlowdownBD2 = Second BlowdownPG = PurgeE4′ = Equalization Up (using gas from E4 step)E3′ = Equalization Up (using gas from E3 step)E2′ = Equalization Up (using gas from E2 step)E1′ = Equalization Up (using gas from E1 step)PP1 = First Product PressurizationPP2 = Second Product Pressurization 2. The pressure swing adsorption process of claim 1, wherein the six bed system is in turndown mode with five beds online, where the process cycle has fifteen steps including three bed-to-bed equalizations steps, while one of the beds is in production. 3. The pressure swing adsorption process of claim 1, wherein said less strongly adsorbable product gas is hydrogen. 4. The pressure swing adsorption process of claim 1, wherein the supply feed gas contains one or more strongly adsorbable component selected from the group consisting of hydrocarbons, carbon dioxide, carbon monoxide, argon, nitrogen and water vapor. 5. The pressure swing adsorption process of claim 1, wherein each adsorbent bed contains alumina, carbon and zeolite material configured in layers in this particular order. 6. The pressure swing adsorption process of claim 5, where the carbon and zeolite layers are each subdivided into two layers with different particle size. 7. The pressure swing adsorption process of claim 6, where the first of the subdivided carbon layers encountered by the supply feed gas has a particle size of about 0.5 to 1.5 mm and an affinity for the carbon dioxide impurity. 8. The pressure swing adsorption process of claim 6, where the second of the subdivided carbon layers encountered by the supply feed gas has a particle size of about 2.0 to 3.0 mm and an affinity for the methane impurities. 9. The pressure swing adsorption process of claim 6, where the first of the subdivided zeolite layers encountered by the supply feed gas has a particle size of about 0.5 to 2.0 mm and an affinity for the carbon monoxide impurity. 10. The pressure swing adsorption process of claim 6, where the second of the subdivided zeolite layers encountered by the supply feed gas has a particle size of about 2.0 to 3.0 mm and an affinity for the nitrogen impurity. 11. A pressure swing adsorption process for separating a pressurized supply feed gas containing one or more strongly adsorbable component from at least one less strongly adsorbable product gas component in a five bed adsorbent system to produce a continuous stream of product gas enriched in the less strongly adsorbable component and a continuous stream of offgas that is enriched in the strongly adsorbable components; wherein, the process cycle has fifteen steps including three bed-to-bed equalization steps, in accordance with the following cycle chart: Step:Bed #1234567891011121314151A1A2A3/PPE1E1E2PPGE3/BD1BD2PGE3′E2′E1′E1′PP2E1′E1′PPA1A2A3/PP1E1E1E2PPGE3/BD1BD2PGE3′E2′3PGE3′E2′E1′E1′PP1A1A2A3/PPE1E1E2PPGE3/BD1BD24PPGE3/BD1BD2PGE3′E2′E1′E1′PPA1A2A3/PPE1E1E25E1E1E2PPGE3/BD1BD2PGE3′E2′E1′E1′PPA1A2A3/PPwhere:A1 = First Adsorption StepA2 = Second Adsorption StepA3/PP1 = Third Adsorption Step/First Product PressurizationE1 = First Equalization DownE2 = Second Equalization DownPPG = Provide Purge GasE3/BD1 = Third Equalization Down/First BlowdownBD2 = Second BlowdownPG = PurgeE3′ = Equalization Up (using gas from E3 step)E2′ = Equalization Up (using gas from E2 step)E1′ = Equalization Up (using gas from E1 step)PP1 = First Product Pressurization 12. A pressure swing adsorption process for separating a pressurized supply feed gas containing one or more strongly adsorbable component from at least one less strongly adsorbable product gas in a six bed adsorbent system where the process cycle has eighteen steps including three bed-to-bed equalizations steps, while two of the beds are in production, in accordance to following cycle chart: BedStep:#1234567891011121314151617181A1A2A3A4A5A6/E1E1E2PPGE3/BD2PGE3′E2′E1′E1′PPPPBD12E1′E1′PPA1A2A3A4A5A6/PPE1E1E2PPGE3/BD1BD2PGE3′E2′3PGE3′E2′E1′E1′PPA1A2A3A4A5A6/PPE1E1E2PPGE3/BD1BD24PPGE3/BD2PGE3′E2′E1′E1′PPA1A2A3A4A5A6/E1E1E2BD1PP5E1E1E2PPGE3/BD2PGE3′E2′E1E1′PPA1A2A3A4A5A6/BD1PP6A4A5A6/E1E1E2PPGE3/BD2PGE3′E2′E1′E1′PPA1A2A3PPBD1wherein:A1 = First Adsorption StepA2 = Second Adsorption StepA3 = Third Adsorption StepA4 = Fourth Adsorption StepA5 = Fifth Adsorption StepA6/PP = Sixth Adsorption Step/Product PressurizationE1 = First Equalization DownE2 = Second Equalization DownPPG = Provide Purge GasE3/BD1 = Third Equalization Down/First BlowdownBD2 = Second BlowdownPG = PurgeE3′ = Equalization Up (using gas from E3 step)E2′ = Equalization Up (using gas from E2 step)E1′ = Equalization Up (using gas from E1 step)PP = Product Pressurization