AbstractWith increasing nitrogen purity, PSA plants require an over-proportional air demand with the consequence that high-purity PSA systems engender a distinct interest in energy-saving measures. This paper presents process intensification strategies with the focus on a reduced energy consumption. Therefore, the influence of PSA configuration and cycle organisation on process performance was investigated. Results are presented at two product purity levels (10 ppm/1000 ppm O2) and two operating temperatures (25 °C/45 °C) in a lab-scale twin bed PSA (2 × 2 L). It is shown that dedicated strategies are available to intensify the PSA process; however, their effects are dependent on ambient conditions and product purity levels.