AU2016269434A1 - Process for obtaining a liquid oxygen-rich and a gaseous oxygen-rich air product in an air separation system, and an air separation system - Google Patents

Process for obtaining a liquid oxygen-rich and a gaseous oxygen-rich air product in an air separation system, and an air separation system Download PDF

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AU2016269434A1
AU2016269434A1 AU2016269434A AU2016269434A AU2016269434A1 AU 2016269434 A1 AU2016269434 A1 AU 2016269434A1 AU 2016269434 A AU2016269434 A AU 2016269434A AU 2016269434 A AU2016269434 A AU 2016269434A AU 2016269434 A1 AU2016269434 A1 AU 2016269434A1
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air
turbine
compressed
pressure
column
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AU2016269434B2 (en
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Tobias Lautenschlager
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Linde GmbH
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Linde GmbH
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04248Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion
    • F25J3/04284Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion using internal refrigeration by open-loop gas work expansion, e.g. of intermediate or oxygen enriched (waste-)streams
    • F25J3/0429Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion using internal refrigeration by open-loop gas work expansion, e.g. of intermediate or oxygen enriched (waste-)streams of feed air, e.g. used as waste or product air or expanded into an auxiliary column
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04406Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air using a dual pressure main column system
    • F25J3/04412Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air using a dual pressure main column system in a classical double column flowsheet, i.e. with thermal coupling by a main reboiler-condenser in the bottom of low pressure respectively top of high pressure column
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04151Purification and (pre-)cooling of the feed air; recuperative heat-exchange with product streams
    • F25J3/04163Hot end purification of the feed air
    • F25J3/04169Hot end purification of the feed air by adsorption of the impurities
    • F25J3/04175Hot end purification of the feed air by adsorption of the impurities at a pressure of substantially more than the highest pressure column
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04151Purification and (pre-)cooling of the feed air; recuperative heat-exchange with product streams
    • F25J3/04187Cooling of the purified feed air by recuperative heat-exchange; Heat-exchange with product streams
    • F25J3/04193Division of the main heat exchange line in consecutive sections having different functions
    • F25J3/042Division of the main heat exchange line in consecutive sections having different functions having an intermediate feed connection
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04248Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion
    • F25J3/04284Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion using internal refrigeration by open-loop gas work expansion, e.g. of intermediate or oxygen enriched (waste-)streams
    • F25J3/0429Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion using internal refrigeration by open-loop gas work expansion, e.g. of intermediate or oxygen enriched (waste-)streams of feed air, e.g. used as waste or product air or expanded into an auxiliary column
    • F25J3/04296Claude expansion, i.e. expanded into the main or high pressure column
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04248Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion
    • F25J3/04284Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion using internal refrigeration by open-loop gas work expansion, e.g. of intermediate or oxygen enriched (waste-)streams
    • F25J3/0429Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion using internal refrigeration by open-loop gas work expansion, e.g. of intermediate or oxygen enriched (waste-)streams of feed air, e.g. used as waste or product air or expanded into an auxiliary column
    • F25J3/04303Lachmann expansion, i.e. expanded into oxygen producing or low pressure column
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04248Generation of cold for compensating heat leaks or liquid production, e.g. by Joule-Thompson expansion
    • F25J3/04375Details relating to the work expansion, e.g. process parameter etc.
    • F25J3/04393Details relating to the work expansion, e.g. process parameter etc. using multiple or multistage gas work expansion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/0446Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air using the heat generated by mixing two different phases
    • F25J3/04466Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air using the heat generated by mixing two different phases for producing oxygen as a mixing column overhead gas by mixing gaseous air feed and liquid oxygen
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04763Start-up or control of the process; Details of the apparatus used
    • F25J3/04769Operation, control and regulation of the process; Instrumentation within the process
    • F25J3/04787Heat exchange, e.g. main heat exchange line; Subcooler, external reboiler-condenser
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04763Start-up or control of the process; Details of the apparatus used
    • F25J3/04769Operation, control and regulation of the process; Instrumentation within the process
    • F25J3/04793Rectification, e.g. columns; Reboiler-condenser
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04763Start-up or control of the process; Details of the apparatus used
    • F25J3/04769Operation, control and regulation of the process; Instrumentation within the process
    • F25J3/04812Different modes, i.e. "runs" of operation
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2200/00Processes or apparatus using separation by rectification
    • F25J2200/04Processes or apparatus using separation by rectification in a dual pressure main column system
    • F25J2200/06Processes or apparatus using separation by rectification in a dual pressure main column system in a classical double column flow-sheet, i.e. with thermal coupling by a main reboiler-condenser in the bottom of low pressure respectively top of high pressure column
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2200/00Processes or apparatus using separation by rectification
    • F25J2200/90Details relating to column internals, e.g. structured packing, gas or liquid distribution
    • F25J2200/94Details relating to the withdrawal point
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2210/00Processes characterised by the type or other details of the feed stream
    • F25J2210/40Air or oxygen enriched air, i.e. generally less than 30mol% of O2
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2215/00Processes characterised by the type or other details of the product stream
    • F25J2215/50Oxygen or special cases, e.g. isotope-mixtures or low purity O2
    • F25J2215/52Oxygen production with multiple purity O2
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2235/00Processes or apparatus involving steps for increasing the pressure or for conveying of liquid process streams
    • F25J2235/50Processes or apparatus involving steps for increasing the pressure or for conveying of liquid process streams the fluid being oxygen

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Separation By Low-Temperature Treatments (AREA)
  • Oxygen, Ozone, And Oxides In General (AREA)

Abstract

Abstract Process for obtaining a liquid oxygen-rich and a gaseous oxygen-rich air product in an air separation system, and an air separation system A process is proposed for the low-temperature separation of air, in which an air 5 separation system (100) having a main heat exchanger (3) and a distillation column system (6, 7) is used, which distillation column system comprises a high-pressure column (61) operated at a first pressure level, a low-pressure column (62) operated at a second, lower pressure level, and a mixing column (7). A first compressed-air stream (h) is fed in the gaseous state into the mixing column (7), in particular directly above 10 the sump, and, in the mixing column (7), is sent in counterflow to an oxygen-rich stream (n). The first compressed-air stream (h) is formed using air that is compressed to a starting pressure level above the first pressure level and thereafter is cooled to a first temperature level and is expanded in a first turbine (4). A second compressed-air stream (g) is fed into the high-pressure column (62), which second compressed air 15 stream is likewise formed using the air that is compressed to the starting pressure level and thereafter cooled to the first temperature level and expanded in the first turbine (4). In contrast, a third compressed-air stream (f) is fed into the low-pressure column (62), which third compressed-air stream is formed using air which, although it is likewise compressed to the starting pressure level, is thereafter cooled to a second temperature 20 level, expanded in a second turbine (4) and cooled further in the main heat exchanger (3) to a third temperature level. The air in the first turbine (4) is expanded to the first pressure level and the air in the second turbine (5) is expanded to the second pressure level. The air that is expanded in the first and second turbines (4, 5) is fed to the first turbine (4) at the first temperature level and to the second turbine (5) at the second 25 temperature level, wherein the first temperature level is at least 20 K below the second. The mixing column (7) is operated at the first pressure level or a third pressure level that differs from the first pressure level by at most I bar. A liquid oxygen-rich air product is passed in the liquid state out of the air separation system (100). A corresponding air separation system (100) is likewise subject matter of the present 30 invention. (Figure 1) TD C.0lM crn ix) CCu

Description

1
Process for obtaining a liquid oxygen-rich and a gaseous oxygen-rich air product in an air separation system, and an air separation system
The invention relates to a process for obtaining a liquid oxygen-rich and a gaseous oxygen-rich air product in an air separation system and to an air separation system equipped to carry out such a process.
Prior Art
Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.
The production of air products in liquid or gaseous state by low-temperature separation of air in air separation systems is known and described, for example, in H.-W. Haring (Editor), Industrial Gases Processing, Wiley-VCH, 2006, in particular section 2.2.5, "Cryogenic Rectification".
For a number of industrial applications, at least not exclusively pure oxygen is required. This opens up the possibility of optimizing air separation systems with respect to their construction and operating costs, in particular of their energy consumption. For details, reference may be made to specialist literature, e.g. F.G. Kerry, Industrial Gas Handbook: Gas Separation and Purification, CRC Press, 2006, chapter 3.8, "Development of Low Oxygen-Purity Processes".
To obtain gaseous pressurized oxygen of low purity, inter alia, air separation systems having what are termed mixing columns can be used, as have been known for a long period and are described in a number of documents, e.g. DE 2 204 376 A1 (equivalent to US 4 022 030 A), US 5 454 227 A, US 5 490 391 A, DE 198 03 437 A1, DE 199 51 521 A1, EP 1 139 046 B1 (US 2001/052244 A1), EP 1 284 404 A1 (US 6 662 595 B2), DE 102 09 421 A1, DE 102 17 093 A1, EP 1 376 037 B1 (US 6 776 004 B2), EP 1 387 136 A1 and EP 1 666 824 A1. An air separation system having a mixing column is also disclosed in FR 2 895 068 A1.
In a mixing column, close to the head, an oxygen-rich liquid is fed in, and close to the sump gaseous compressed air, termed mixing-column air, is fed in and they are sent in counterflow to one another. Owing to the intensive contact, a certain proportion of the 2016269434 06 Dec 2016 2 more volatile nitrogen transfers from the mixing-column air into the oxygen-rich liquid. The oxygen-rich liquid in this case is vaporized in the mixing column and can be taken off at the head of the mixing column as what is termed “impure’' oxygen. The impure oxygen can be withdrawn from the air separation system as gas product. The mixing-5 column air itself is liquefied during passage through the mixing column, to a certain degree enriched with oxygen, and can be taken off from the sump of the mixing column. This liquefied stream can then be fed into the distillation column system used at a point suitable from the point of view of energy and/or separation technique. Owing to the use of a mixing column, the energy required for the mass separation can be 10 considerably reduced at the cost of the purity of the gaseous oxygen product. A disadvantage of known air separation systems, including those which operate using mixing columns, is the limited flexibility in operation. The cold requirement is covered in such systems generally by expanding air in what is termed an injection turbine. Such 15 an injection turbine expands air from a pressure level of, for example, 5.0 to 6.0 bar to a pressure level of, for example, 1.2 to 1.6 bar (these are in each case absolute pressures; specific pressure levels used in the context of the present invention are stated hereinafter). In corresponding systems, a distillation column system having (at least) one high-pressure column and one low-pressure column are provided. The high-20 pressure column, in the example case explained, is operated at the stated pressure level of 5.0 to 6.0 bar, and the low-pressure column at the stated pressure level of 1.2 to 1.6 bar. The air expanded in the injection turbine is fed into the low-pressure column, The expansion is possible owing to the stated pressure difference between high-pressure column and low-pressure column. The air expanded in this manner into the 25 low-pressure column interferes with the rectification, however, for which reason the amount of air expandable in the injection turbine and therefore the refrigeration output of the system overall is strictly limited. Therefore, significant amounts of liquid products cannot be withdrawn from systems having such interconnections, 30 The maximum withdrawal amount of liquid nitrogen and liquid oxygen in conventional systems using mixing columns is therefore, as with other typical air separation systems for providing gaseous air products (termed gas systems), also limited to at most approximately 0.5% of the amount of air used. 3
Although a process as described in WO 2014/037091 A2 permits an increase in the liquid production, for reasons further explained hereinafter, it does not always offer sufficient flexibility in the case of fluctuating demand for liquid and gaseous oxygen-rich air products.
It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.
Preferred embodiments of the present invention may provide for improved possibilities for efficient and flexible generation of liquid and gaseous oxygen-rich air products in air separation systems having corresponding mixing columns.
Disclosure of the Invention
According to a first aspect, the present invention provides process for the low-temperature separation of air, in which an air separation system having a main heat exchanger and a distillation column system is used, which distillation column system comprises a high-pressure column operated at a first pressure level, a low-pressure column operated at a second, lower pressure level, and a mixing column, and in which an oxygen-rich stream having a first oxygen content is withdrawn in the liquid state from the low-pressure column and is fed in the liquid state with the first oxygen content into the mixing column, in addition, a first compressed-air stream is fed in the gaseous state into the mixing column and, in the mixing column, is sent in counterflow to the oxygen-rich stream having the first oxygen content, an oxygen-rich stream having a second oxygen content below the first oxygen content is withdrawn from the mixing column overhead and is passed out of the air separation system, the first compressed-air stream is formed using air that is compressed to a starting pressure level above the first pressure level and thereafter is cooled to a first temperature level, is fed at the first temperature level to a first turbine and is expanded in the first turbine, and a liquid oxygen-rich air product is passed in the liquid state out of the air separation system at least at times, 3a wherein - a second compressed-air stream is fed into the high-pressure column, which second compressed-air stream is likewise formed using the air that is compressed to the starting pressure level and thereafter cooled to the first temperature level and expanded in the first turbine, - a third compressed-air stream is fed into the low-pressure column, which third compressed-air stream is formed using air that is compressed to the starting pressure level and thereafter cooled to a second temperature level, fed at the second temperature level to a second turbine, expanded in the second turbine and cooled further in the main heat exchanger to a third temperature level, - the air is expanded in the first turbine to the first pressure level and in the second turbine to the second pressure level, and the mixing column is operated at the first pressure level or a third pressure level that differs from the first pressure level by at most 1 bar, and - in that the first temperature level is at least 20 K below the second temperature level.
According to a second aspect, the present invention provides air separation system having a main heat exchanger and a distillation column system that comprises a high-pressure column equipped for operation at a first pressure level, a low-pressure column equipped for operation at a second, lower pressure level, and a mixing column, and in which means are provided that are equipped to withdraw in the liquid state an oxygen-rich stream having a first oxygen content from the low-pressure column and to feed it in the liquid state with the first oxygen content into the mixing column, in addition, to feed a first compressed-air stream in the gaseous state into the mixing column and, in the mixing column, to send it in counterflow to the oxygen-rich stream having the first oxygen content, to withdraw from the mixing column overhead an oxygen-rich stream having a second oxygen content below the first oxygen content and to pass it out of the air separation system, 3b to form the first compressed-air stream using air that is compressed to a starting pressure level above the first pressure level and thereafter is cooled to a first temperature level, is fed at the first temperature level to a first turbine and is expanded in the first turbine, and to pass a liquid oxygen-rich air product in the liquid state out of the air separation system at least at times, wherein means that are equipped to feed a second compressed-air stream into the high-pressure column and to form this second compressed-air stream likewise using the air that is compressed to the starting pressure level and thereafter cooled to the first temperature level and expanded in the first turbine, - to feed a third compressed-air stream into the low-pressure column and form this third compressed-air stream using air that is compressed to the starting pressure level and thereafter cooled to a second temperature level, fed at the second temperature level to a second turbine, expanded in the second turbine and cooled further in the main heat exchanger to a third temperature level, - to expand the air in the first turbine to the first pressure level and in the second turbine to the second pressure level and to operate the mixing column at the first pressure level or a third pressure level that differs from the first pressure level by at most 1 bar, and in that the first temperature level is at least 20 K below the second temperature level.
Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising", and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.
Embodiments of the present invention propose a process for obtaining a liquid oxygen-rich and a gaseous oxygen-rich air product in an air separation system, and an air separation system equipped for carrying out such a process.
In air separation systems, turbocompressors are used to compress the air. This applies, for example, to the "main air compressor" which is distinguished in that it compresses all of the 2016269434 06 Dec 2016 3c amount of air fed into the distillation column system, that is to say all of the feed air. Correspondingly, a "post-compressor" can also be provided in which some of the amount of air compressed in the main air compressor is brought to a still higher pressure. This can also be constructed as a turbocompressor. To compress partial amounts of air, typically, 5 further turbocompressors are provided, which are also called boosters, which, however, in comparison to the main air compressor or the post-compressor, only perform a compression in a relatively small scope.
At a plurality of points in air separation systems, in addition, air can be expanded, for which purpose, inter alia, expansion machines in the form of turboexpanders can be used, here 10 also called for short "turbines". Turboexpanders can also be coupled to turbocompressors and drive them. If one or more turbocompresssors are driven without externally supplied energy, that is to say only via one or more turboexpanders, for such an arrangement the expression "turbine booster" can also be used. In a turbine booster, the turboexpander and the turbocompressor are mechanically coupled. 4 2016269434 06 Dec 2016
The present application, to characterize pressures and temperatures, uses the expressions "pressure level” and “temperature level", which is intended to signify that pressures and temperatures in a corresponding system need not be used in the form of exact pressure or temperature values, in order to realize the inventive concept. 5 However, such pressures and temperatures typically vary in certain ranges that are for example ± 1%, 5%, 10%, 20% or even 50% about a mean. Generally, values within a "level” are not more than 5% or 10% apart. Corresponding pressure levels and temperature levels can in this case be in disjoint ranges or in ranges that overlap one another. In particular, pressure levels, for example, include unavoidable pressure 10 drops, or expected pressure drops, for example owing to cooling effects or pipe losses. The same applies correspondingly to temperature levels. In the case of pressure levels stated here in bar, these are absolute pressures.
In the context of this application, obtaining air products, in particular oxygen-rich and 15 nitrogen-rich air products or oxygen products and nitrogen products is the subject concerned. A "product" leaves the system described and is stored, for example, in a tank, or consumed. Therefore, it no longer solely participates exclusively in the internal system circuits, but can be used appropriately before leaving the system, for example as a cold carrier in a heat exchanger. The expression “product” therefore does not 20 include such fractions or streams that remain in the system itself and are used exclusively there, for example as recycle, coolant or purge gas.
The expression "product" in addition Includes a quantitative statement. A “product” corresponds to at least 1%, in particular at least 2%, for example at least 5% or at least 25 10% of the amount of air used in a corresponding system. Relatively small amounts even of liquid fractions customarily arising in avowed gas systems and optionally withdrawable from such a system are therefore not "products" within the meaning of this application. For example, in known distillation column systems, small amounts of a liquid fraction deposited in the sump are continuously withdrawn from the low-pressure 30 column in order to avoid an enrichment of undesirable components such as methane,
In this case, however, these are not "products” within the meaning of this application, on account of the amount alone. Owing to the withdrawal of liquid products, a considerable amount of cold is "withdrawn" from an air separation system which otherwise could be recovered in part by vaporizing these liquid products, Such a 35 withdrawal, however, is only effective from a certain amount of withdrawal, that is to 2016269434 06 Dec 2016 5 say only from the point when a “product" within the meaning of the definition given above, is actually withdrawn. A liquid or gaseous “oxygen-rich air product", in the language of this application, is a 5 fluid in the appropriate state of matter that has an oxygen content of at least 75%, in particular at least 80%, on a molar, weight or volume basis. The “impure oxygen" which is withdrawn from the mixing column, is therefore also an oxygen-rich air product.
Advantages of the Invention 10
The present invention proposes a process for the low-temperature separation of air, in which an air separation system having a main heat exchanger and a distillation column system is used, which distillation column system comprises a high-pressure column operated at a first pressure level, a low-pressure column operated at a second 15 pressure level and a mixing column. The second pressure level is lower than the first.
As is already known, for example from WO 2014/037091 A2 mentioned at the outset, in such a process, an oxygen-rich stream having a first oxygen content can be withdrawn in the liquid state from the low-pressure column, which stream is not passed out 20 directly in the liquid state or vaporized from the air separation system, but, in particular after warming, is fed in the liquid state with the first oxygen content into the mixing column, in particular into the upper region, for example at the head. In addition, a first compressed-air stream is fed in the gaseous state into the mixing column and, in the mixing column, is sent in counterflow to the oxygen-rich stream having the first oxygen 25 content. The first compressed-air stream is fed into the mixing column preferably directly above the sump.
By such an operation of the mixing column, it is possible to withdraw overhead therefrom an oxygen-rich stream having a second oxygen content below the first 30 oxygen content and to pass it out of the air separation system as a gaseous oxygen-rich air product. The oxygen-rich stream having the second oxygen content is the "impure" oxygen mentioned, the (second) oxygen content of which, however, is sufficient for certain applications and permits the energetic optimization mentioned. 6 2016269434 06 Dec 2016
In a corresponding system, a pure oxygen stream can be withdrawn in the liquid state from the low-pressure column, in particular the sump thereof, and, with its oxygen content, be passed out as liquid oxygen-rich air product in the liquid state from the air separation system. The same is shown correspondingly in WO 2014/037091 A2. The 5 pure oxygen stream has an oxygen content above the first oxygen content. In this case, therefore, a further liquid oxygen-rich air product is provided that has a high oxygen content. The withdrawal proceeding thereby of two oxygen-rich streams from the low-pressure column (namely the oxygen-rich stream having the first oxygen content and, in addition, the pure oxygen stream) is a process option if, in addition to 10 the gaseous oxygen-rich air product, a liquid oxygen-rich air product in the form of pure liquid oxygen is required. If no such liquid oxygen-rich air product is required in the form of pure liquid oxygen, or if the required purity of a liquid oxygen-rich air product is about one to two percentage points above the desired purity of the gaseous oxygen-rich air product, then, only an oxygen-rich stream can also be withdrawn in the liquid 15 state from the low-pressure column. For example then, a part thereof, as explained previously, can be fed into the mixing column and a part can be passed out in liquid form from the air separation system, i.e. be used as liquid oxygen-rich air product.
In any case, in the present invention, a liquid oxygen-rich air product is also passed out 20 of the air separation system in the liquid state at least at times, for example a corresponding liquid oxygen-rich air product from the low-pressure column having the first oxygen content or corresponding pure oxygen. Other oxygen-rich air products can also be passed out of the air separation system in the liquid state. As product, the amount thereof comprises at least the values stated above with respect to "products". 25 The amounts in which a corresponding liquid oxygen-rich air product can be passed in the liquid state out of the air separation system is very flexible, owing to the measures proposed according to the invention. if, hereinbefore, oxygen-rich streams are mentioned, namely, in particular, the oxygen-30 rich stream having the first oxygen content and optionally the pure oxygen stream having the higher oxygen content and further oxygen-rich streams, which can be withdrawn in the liquid state from the low-pressure column, these are streams which are used for producing corresponding oxygen-rich air products. They are therefore, as mentioned above with regard to the expression “product”, passed out of the low-35 pressure column in an amount which differs markedly from streams that are not 7 2016269434 06 Dec 2016 provided as products, for example purge streams, which are only used for removing impurities, for example from a sump of the low-pressure column. The oxygen-rich stream having the first oxygen content and optionally the pure oxygen stream and other oxygen-rich streams are therefore withdrawn in each case from the low-pressure 5 column in an amount which is in the region mentioned above with respect to a “product".
In the context of the present invention, the first compressed-air stream that is fed into the mixing column is formed using air that is compressed to a starting pressure level 10 above the first pressure level and thereafter is cooled to a first temperature level, in particular in the main heat exchanger, and is expanded in a first turbine. As also explained hereinafter, the present invention is used, in particular, in what are termed high air pressure (HAP) processes, that is to say processes in which all of the amount of air that is fed to a distillation column system is compressed to a pressure which is 15 markedly above the highest operating pressure used in the distillation column system. “Markedly above" in the present case is taken to mean a pressure difference of at least 1.0 bar, in particular more. By using an appropriate first turbine, additional cold can be generated which compensates for cold losses, in particular due to the withdrawal of liquid oxygen-rich air products from the air separation system, in the context of the 20 present invention, therefore, some of the cold requirement is covered by expansion of the air used for providing the first compressed-air stream, which air is expanded in the first turbine.
The present invention additionally proposes that a second compressed-air stream is 25 fed into the high-pressure column, which second compressed-air stream is likewise formed using the air that is compressed to the starting pressure level and thereafter cooled to the first temperature level, in particular in the main heat exchanger, and expanded in the first turbine. Some of the air expanded in the first turbine is therefore, after its expansion in the first turbine, fed into the mixing column, and a further part into 30 the high-pressure column.
In addition, the present invention proposes that a third compressed-air stream is fed into the low-pressure column, which third compressed-air stream is formed using air that is compressed to the starting pressure level and, in particular in the main heat 35 exchanger, thereafter cooled to a second temperature level, expanded in a second 2016269434 06 Dec 2016 8 turbine, and thereafter cooled further in the main heat exchanger to a third temperature level.
The air, in the context of the present invention, is expanded in the first turbine to the 5 first pressure level, i,e. the pressure level of the high-pressure column, and in the second turbine to the second pressure level, i.e. the pressure level of the low-pressure column. The mixing column, in the context of the present invention, is operated at the first pressure level, i.e. the pressure level of the high-pressure column, or at a third pressure level that differs from the first pressure level by at most 1 bar. 10
The air that is expanded in the first turbine and the air that is expanded in the second turbine, in the context of the present invention, is fed to the first turbine at the first temperature level and to the second turbine at the second temperature level, wherein the first temperature level is at least 20 K, in particular at least 30 K, or at least 40 K, 15 below the second temperature level. In particular, the first temperature level can be 25 to 35 K or 28 to 32 K, more particularly approximately 30 K, below the second temperature level. Regarding the respective temperature levels, reference may also be made to the explanations hereinafter. The first turbine is in this case a “cold” turbine, and the second turbine is a "warm" turbine. 20 if, in conventional processes or systems in which an HAP process of the previously described type is realized, and a mixing column is used, it is wished to reduce the liquid production, i.e. the amount at which liquid air products are passed in the liquid state out of the air separation system, the pressure of the main air compressor would have to be 25 decreased for a constant amount of air flowing through the main air compressor. A correspondingly reduced pressure at a constant amount of air, however, increases the actual volume of compressed air. Therefore, in conventional systems, the apparatuses arranged in the warm part, in particular the air purification and precooling units, would have to be dimensioned so as to be markedly larger. This is not desirable for economic 30 reasons. In addition, a pressure decrease at a constant amount of air is typically not optimal with respect to the efficiency of the main air compressor used.
For a process in which the mixing column pressure which is guided by the required pressure of the gaseous oxygen product is markedly below or above the pressure of 9 2016269434 06 Dec 2016 the high-pressure column, a process is suggested as is described in the previously explained WO 2014/037091 A2. 5 if, in contrast, the required pressure of the compressed product is at or close to the pressure level of the high-pressure column of approximately 5 bar, i.e. at the first pressure level or at a third pressure level that differs by at most 1 bar from the first pressure level, as in the context of the present invention, then an HAP process using a medium-pressure turbine and also an injection turbine offers advantages with respect 10 to system flexibility for providing the liquid oxygen product and the operating costs, as has been acknowledged according to the invention.
The "medium-pressure turbine" is the first turbine mentioned, and the "injection turbine", in the context of the present application, is formed by the second turbine. 15 Because the process according to the invention is constructed as an HAP process, only one single main air compressor is required, which markedly reduces the capital costs. The intake pressures of both turbines are preferably at the same level, in particular that of the outlet pressure of the main air compressor. 20 If a comparatively large amount of the liquid oxygen product is to be provided ("higher liquid production"), in the context of the present invention the starting pressure level (that is to say the pressure level provided by the main air compressor), and simultaneously thereto the amount of the air fed into the low-pressure column in the form of the third compressed-air stream (that is to say the “injection air" that is 25 expanded in the second turbine, that is to say the “injection turbine"), can be elevated. The increased amount of the air expanded in the second turbine therefore increases what is termed the “air factor”, that is to say the total amount of air required for the rectification. 30 The simultaneous increase in pressure and amount mentioned conducts more exergy to the system, the main air compressor delivers more output and the liquid production can be elevated. At the same time, the actual volume of the air in the warm part remains approximately constant in the context of the present invention, since not only pressure but also amount are increased. In the characteristic diagram of the main air 35 compressor, in this manner, not only the amount but also the pressure of the 2016269434 06 Dec 2016 10 compressed air have been increased, which generally advantageously affects the efficiency of the main air compressor.
If, in contrast, a comparatively small amount of the liquid oxygen product is to be 5 provided ("lower liquid production1'), the starting pressure level and simultaneously thereto the amount of the air that is fed into the low-pressure column in the form of the third compressed-air stream, is in contrast reduced. The reduced amount of the air expanded in the second turbine reduces the air factor. 10 The simultaneous fall in pressure and amount therefore conducts less exergy to the system, the main air compressor delivers less output and the liquid production falls. At the same time, in turn, the actual volume of the air in the warm part remains approximately constant. In the characteristic diagram of the main air compressor, in this manner, not only the amount but also the pressure of the compressed air have 15 been reduced, which generally affects the efficiency of the main air compressor more advantageously than a pure fall in pressure.
In the context of the present invention, advantageously, a fourth compressed-air stream is used, which fourth compressed-air stream is fed into the high-pressure 20 column and formed using air which is compressed to the starting pressure level and thereafter is cooled to a third temperature level and is expanded by means of a throttle. A corresponding fourth compressed-air stream corresponds to a throttle stream of a conventional air separation process. 25 Advantageously, the process according to the invention comprises a first process mode and a second process mode, wherein in the first process mode, the liquid oxygen-rich air product is passed out of the air separation system in the liquid state in a larger amount than in the second process mode, and wherein in the first process mode, a larger amount of air is expanded in the second turbine than in the second process 30 mode and as a result, at the same time the third compressed-air stream in the first process mode comprises the same larger amount of air than in the second process mode. In other words, for withdrawal of a larger amount of a liquid oxygen-rich air product in the context of the present invention, the amount of injection air that is expanded by the second turbine and fed into the low-pressure column is increased. 11 2016269434 06 Dec 2016
This can cover an additional cold requirement which exists on account of the withdrawal of the liquid oxygen product.
The liquid oxygen-rich air product that in each case is passed out of the air separation 5 system is withdrawn from the low-pressure column. In this case, either the pure oxygen, as described above, or a liquid oxygen product with a lower oxygen content can be used. If such a liquid oxygen-rich air product is "passed out in the liquid state”, this means that no vaporization within the air separation system proceeds, if it is stated above that in the first process mode the liquid oxygen-rich air product is passed out of 10 the air separation system in the liquid state in a larger amount than in the second process mode, this can also comprise the fact that in the second process mode, no liquid oxygen-rich air product is passed out, The amount of the liquid oxygen-rich air product that is passed out of the air separation system in the liquid state in the first process mode can be, for example, 1.5 times, twice, 3 times, 4 times or 5 times the 15 corresponding rate in the second process mode,
The increase of the amount of air that is expanded in the second turbine and at the same time is comprised by the third compressed-air stream advantageously proceeds taking into account what is termed an injection equivalent. The injection equivalent 20 comprises firstly the amount of the amount of air expanded by the second turbine, which at the same time corresponds to the amount of air comprised by the third compressed-air stream, and additionally the amount of nitrogen-rich streams which are likewise withdrawn from the high-pressure column. These nitrogen-rich streams are liquid nitrogen and compressed nitrogen that are provided as nitrogen-rich air products 25 of a corresponding air separation system. These nitrogen-rich streams are not used as liquid recycle to the high-pressure column and the low-pressure column. Advantageously, the sum of the amount of air expanded in the second turbine and at the same time comprised by the third compressed-air stream and the amount of such nitrogen-rich streams comprises, in the first process mode, 12 to 18%, and in the 30 second process mode, 0 to 8%, of the total amount of air fed overall into the distillation column system. This total amount of air fed overall into the distillation column system also comprises the air expanded in the second turbine.
Such variability may be achieved, in particular, by the first turbine being constructed or 35 operated in a variable speed manner, in such a manner that a correspondingly differing 12 2016269434 06 Dec 2016 air throughput can be achieved in the differing operating modes. The expression "variable-speed1' turbine, in the context of this application, is only used as a delimitation from turbines, the speed of rotation of which is set, for example by means of correspondingly controlled brakes, to a fixed speed of rotation. The same also applies 5 correspondingly to the second turbine.
As mentioned above, the process according to the invention is advantageously used in combination with what are termed HAP processes, in which all of the air fed into the distillation column system is compressed, using a main air compressor, to a pressure 10 level that is above the pressure level of the high-pressure column. Therefore, advantageously all of the air fed into the distillation column system is brought to the starting pressure level using a main air compressor.
In the context of the present invention, as already described above in other words, in 15 the first process mode the air factor, that is to say the amount of air used to obtain a fixed amount of product, is markedly higher than in the second process mode, because the amount of air expanded in the second turbine at the same time comprised by the third compressed-air stream and fed into the low-pressure column is higher than in the second process mode. In the first process mode, as mentioned, a larger amount of 20 liquid product is withdrawn than in the second process mode. Therefore, a larger amount of air must also be conducted through the main air compressor than in the second process mode. Owing to the higher air factor, in this case, the final pressure of the main air compressor, that is to say the pressure level termed here “starting pressure level”, still remains lower, however, than in the case of a lower air factor. 25
In the second process mode, the air factor in contrast is markedly lower than in the first process mode because the amount of air expanded in the second turbine and at the same time comprised by the third compressed-air stream and fed into the low-pressure column is lower than in the first process mode. In the second process mode, as 30 mentioned, a smaller amount of liquid product is withdrawn than in the first process mode. This leads to a reduction of the amount of air conducted through the main air compressor with simultaneously lower final pressure (that is to say the pressure level termed here “starting pressure level”) compared with the first process mode. As mentioned, in contrast, in conventional processes the amount of air conducted through 35 the main air compressor must be maintained at a reduced pressure, which leads to an 2016269434 06 Dec 2016 13 increased actual volume of this amount of air. This is no longer the case in the context of the invention, and the load case in the second operating mode is therefore no longer dimensioning for the warm part of the air separation system. At the same time, the pressure difference with respect to the final pressure of the main air compressor (that is 5 to say the “starting pressure lever1) in the first and second process modes is less than would be the case in conventional processes, because, as mentioned, owing to the greater air factor, the final pressure of the main air compressor in the first process mode remains lower than in the case of a smaller air factor. Since not only the amount of air compressed in the main air compressor but also the pressure used there fall, this 10 load case is generally better situated in the characteristic diagram than in the case of a constant compressed amount of air and a more intensively lowered pressure.
Advantageously, the air expanded in the first turbine and the second turbine is fed to the first turbine and to the second turbine at the same pressure level, in particular the 15 starting pressure level, Advantageously, in the context of the present invention, in this case, the starting pressure level in the first process mode is 1 to 10 bar above the starting pressure level in the second process mode. Overall, in the context of the present application, the starting pressure level can be 6 to 15 bar, the first pressure level can be 4.3 to 6.9 bar, in particular approximately 5.4 bar, and the second 20 pressure level can be 1.3 to 1.7 bar, in particular approximately 1.4 bar. The third pressure level, if the mixing column is not operated at the first pressure level, differs, as mentioned, by at most 1 bar from the first. The first temperature level is preferably 110 to 140°C, the second temperature level 130 to 240°C, and the third temperature level 97 to 102°C. 25
The turbines used in the context of the present invention can be braked in different ways. In particular, a generator, a booster and/or an oil brake can be used.
The process according to the invention is suitable, in particular, for cases in which the 30 first oxygen content is less than 99 mol per cent, for example 98 to 99 mol per cent, and the second oxygen content is 80 to 98 mol per cent. The oxygen content of the pure oxygen stream, if formed, is advantageously 99 to 100 mol per cent. A process using a mixing column proves in these cases to be particularly energy-efficient. 2016269434 06 Dec 2016 14
The present invention further extends to an air separation system having a main heat exchanger and a distillation column system that comprises a high-pressure column equipped for operation at a first pressure level, a low-pressure column equipped for operation at a second, lower pressure level, and a mixing column. 5
In a corresponding system, means are provided that are equipped to withdraw in the liquid state an oxygen-rich stream having a first oxygen content from the low-pressure column and to feed it in the liquid state with the second oxygen content into the mixing column, in particular into the upper region, in addition, to feed a first compressed-air 10 stream in the gaseous state into the mixing column, in particular in the vicinity of the sump, and, in the mixing column, to send it in counterflow to the oxygen-rich stream having the first oxygen content, to withdraw from the mixing column overhead an oxygen-rich stream having a second oxygen content below the first oxygen content and to pass it out of the air separation system, and to form the first compressed-air stream 15 using air that is compressed to a starting pressure level above the first pressure level and thereafter is cooled to a first temperature level and is expanded in a first turbine.
As mentioned, a pure oxygen stream can also be withdrawn in the liquid state from the 20 low-pressure column and passed in the liquid state out of the air separation system. In such a case, means are present that are equipped for this purpose. In each case, means are provided that are equipped to pass a liquid oxygen-rich air product in the liquid state out of the air separation system at least at times. 25 According to the invention, means are provided that are equipped to feed a second compressed-air stream into the high-pressure column and to form this second compressed-air stream likewise using the air that is compressed to the starting pressure level and thereafter cooled to the first temperature level and expanded in the first turbine, to feed a third compressed-air stream into the low-pressure column and 30 form this third compressed-air stream using air that is compressed to the starting pressure level and thereafter cooled to a second temperature level, expanded in a second turbine and cooled further in the main heat exchanger to a third temperature level, and to expand the air in the first turbine to the first pressure level and in the second turbine to the second pressure level and to operate the mixing column at the 15 2016269434 06 Dec 2016 first pressure level or a third pressure level that differs from the first pressure level by at most 1 bar.
These means are, according to the invention, additionally equipped to feed the air that 5 is expanded in the first turbine and the air that is expanded in the second turbine to the first turbine at the first temperature level and to the second turbine at the second temperature level, wherein the first temperature level is at least 20 K below the second temperature level. 10 In particular, such an air separation system is equipped for operation in a first process mode and a second process mode, by means being provided that are equipped to pass in the liquid state, in the first process mode, the liquid oxygen-rich air product out of the air separation system in a larger amount than in the second process mode, and to expand, in the first process mode, a larger amount of air in the second turbine than in 15 the second process mode, so that as a result the third compressed-air stream in the first process mode comprises the same larger amount of air than in the second process mode.
The invention will be explained in more detail hereinafter with reference to the 20 accompanying drawings which illustrate preferred embodiments of the present invention.
Brief description of the drawings 25 Figure 1 shows an air separation system according to an embodiment of the invention in the form of a schematic system diagram.
Detailed description of the drawings 30 Figure 1 shows an air separation system according to a particularly preferred embodiment of the invention, which is designated overall as 100, A feed air stream a is drawn into the air separation system 100 by means of a main air compressor 2 via a filter 1 and, in the example shown, is compressed to a pressure 35 level of 6 to 15 bar (abs.). The compression can be followed by drying, cooling and 2016269434 06 Dec 2016 16 purification steps of known kind that, for the sake of clarity, are not illustrated in Figure 1. A correspondingly compressed and purified air stream b is divided into two substreams 5 c and d which are fed at the said pressure level to a main heat exchanger 3 on the warm side, cooled therein and withdrawn at different temperature levels.
From the substream c, two substreams e and f are formed by a withdrawal from the main heat exchanger 3 at different temperature levels. The substream e is expanded in 10 an expansion machine 4, and the substream f in an expansion machine 5. Since the substream e is cooled to a lower temperature than substream f, the expansion machine 4 is also designated as a “cold” expansion machine, and the expansion machine 5, in contrast, as a “warm” expansion machine. 15 The expansion of the two substreams e and f proceeds in each case starting from the mentioned pressure level of 5 to 15 bar (abs.). The substream e, in the example shown, is expanded to a pressure level of approximately 5.4 bar (abs.), and the substream f, in contrast, is expanded to a pressure level of approximately 1.4 bar (abs.). In each case generators 41 and 51 are coupled to the expansion machines 4 20 and 5, respectively.
The substream e, after expansion thereof in the expansion machine 4, is further divided into two substreams g and h. The substream g is fed close to the sump of a high-pressure column 61 which is constructed as part of a double column 6. The substream 25 h is expanded into a mixing column 7 close to the sump. The high-pressure column 61 is operated at the pressure level mentioned of approximately 5.4 bar (abs.), the mixing column 7 at a somewhat lower pressure level of approximately 5.0 bar (abs.).
The substream f, after expansion thereof in the expansion machine 5 to an 30 intermediate temperature level, is recirculated to the main heat exchanger 3, withdrawn therefrom on the cold side, and fed into a low-pressure column 62 which is likewise constructed as part of the double column 6. The low-pressure column 62 is operated at the mentioned pressure level of approximately 1.4 bar (abs.). 2016269434 06 Dec 2016 17
The substream d is withdrawn from the main heat exchanger 3 on the cold side and, starting from the mentioned pressure level of 6 to 15 bar (abs.), is expanded into the high-pressure column 61. 5 In the high-pressure column 61, a liquid, oxygen-enriched fraction is deposited at the sump side and taken off in the form of the stream i. The stream i is conducted through a counter-current subcooler 8 and then expanded into the low-pressure column 62. A nitrogen-rich overhead product from the head of the high-pressure column 61 is 10 taken off and in part conducted in the form of stream k through a main condenser 63 of the double column 6 and liquefied there at least in part. A part of the liquid nitrogen-rich overhead product of the high-pressure column 61 is (see link A) conducted in the form of stream I through the counter-current subcooler and delivered at the system limit as liquid nitrogen-rich air product. A further part of the liquefied nitrogen-rich overhead 15 product of the high-pressure column 61 is recirculated as return to the high-pressure column 61.
From an intermediate tray of the high-pressure column 61, a nitrogen-enriched stream m is taken off, iikewise conducted through the counter-current subcooler 8 and 20 expanded close to the head into the low-pressure column 62.
In the sump of the low-pressure column, a liquid oxygen-rich fraction is formed which (see link B) is taken off in the form of stream n, conducted in part through the counter-current subcooler 8 and delivered as liquid oxygen-rich air product at the system limit. 25
From an intermediate tray of the low-pressure column 62, an oxygen-enriched stream o is taken off, pressurized in the liquid state by means of a pump 9, conducted through the counter-current subcooler 8, warmed in the main heat exchanger 3 and fed into the mixing column 7 close to the head. The mixing column 7 is operated as explained 30 several times. From the head of the mixing column 7, a stream p which is depleted in oxygen in comparison with the stream o is taken off, warmed in the main heat exchanger 3 and delivered as gaseous oxygen product at the system limit. 2016269434 06 Dec 2016 18
From the head of the low-pressure column 62, an impure nitrogen stream q is taken off, conducted through the counter-current subcooler 8 and the main heat exchanger 3 and used, for example, in a purification appliance for stream a. 5 A nitrogen-rich stream r is formed from nitrogen-enriched overhead product of the low-pressure column 61 that is not conducted through the main condenser 63.
The air separation system 100 illustrated in Figure 1 is equipped for two process modes that have been explained above. In a first process mode, the amount of the 10 liquid air product passed in the liquid state out of the air separation system 100 here in the form of stream n is greater than in the second process mode. At the same time, in the first process mode, via the turbine 5, a larger amount of air is expanded than in the second process mode, in such a manner that the air factor increases. In the second process mode, owing to the decreased air factor, the pressure and the amount of the 15 stream b, that is to say the final pressure of the main air compressor 2 and the amount of the air conducted therethrough, fail.

Claims (15)

  1. Claims
    1. Process for the low-temperature separation of air, in which an air separation system having a main heat exchanger and a distillation column system is used, which distillation column system comprises a high-pressure column operated at a first pressure level, a low-pressure column operated at a second, lower pressure level, and a mixing column, and in which - an oxygen-rich stream having a first oxygen content is withdrawn in the liquid state from the low-pressure column and is fed in the liquid state with the first oxygen content into the mixing column, - in addition, a first compressed-air stream is fed in the gaseous state into the mixing column and, in the mixing column, is sent in counterflow to the oxygen-rich stream having the first oxygen content, - an oxygen-rich stream having a second oxygen content below the first oxygen content is withdrawn from the mixing column overhead and is passed out of the air separation system, - the first compressed-air stream is formed using air that is compressed to a starting pressure level above the first pressure level and thereafter is cooled to a first temperature level, is fed at the first temperature level to a first turbine and is expanded in the first turbine, and - a liquid oxygen-rich air product is passed in the liquid state out of the air separation system at least at times, wherein - a second compressed-air stream is fed into the high-pressure column, which second compressed-air stream is likewise formed using the air that is compressed to the starting pressure level and thereafter cooled to the first temperature level and expanded in the first turbine, - a third compressed-air stream is fed into the low-pressure column, which third compressed-air stream is formed using air that is compressed to the starting pressure level and thereafter cooled to a second temperature level, fed at the second temperature level to a second turbine, expanded in the second turbine and cooled further in the main heat exchanger to a third temperature level, - the air is expanded in the first turbine to the first pressure level and in the second turbine to the second pressure level, and the mixing column is operated at the first pressure level or a third pressure level that differs from the first pressure level by at most 1 bar, and - in that the first temperature level is at least 20 K below the second temperature level.
  2. 2. Process according to Claim 1, in which a fourth compressed-air stream is fed into the high-pressure column, which fourth compressed-air stream is formed using air which is compressed to the starting pressure level and thereafter is cooled to a third temperature level and is expanded by means of a throttle.
  3. 3. Process according to Claim 1 or 2 which comprises a first process mode and a second process mode, wherein - in the first process mode, the liquid oxygen-rich air product is passed out of the air separation system in a larger amount than in the second process mode, and - in the first process mode, a larger amount of air is expanded in the second turbine than in the second process mode and as a result, at the same time the third compressed-air stream in the first process mode comprises the same larger amount of air than in the second process mode.
  4. 4. Process according to Claim 3, in which one or more nitrogen-rich streams are withdrawn from the high-pressure column and are passed out of the air separation system, wherein the amount of air expanded in the second turbine and at the same time comprised by the third compressed-air stream is adjusted in such a manner that a sum of the amount of the amount of air expanded by the second turbine and at the same time comprised by the third compressed-air stream and the amount comprised by the nitrogen-rich stream or streams, in the first process mode, corresponds to 12 to 18 per cent of the total amount of air fed into the distillation column system and in the second process mode corresponds to 0 to 8 per cent of the total amount of air fed into the distillation column system.
  5. 5. Process according to Claim 3 or 4, in which all of the air fed into the distillation column system is brought to the starting pressure level using a main air compressor.
  6. 6. Process according to Claim 5, in which, in the first process mode, a larger amount of air is conducted through the main air compressor at a higher pressure than in the second process mode.
  7. 7. Process according to any one of the preceding claims, in which the air expanded in the first turbine and the second turbine is fed to the first turbine and to the second turbine at the same pressure level.
  8. 8. Process according to any one of Claims 3 to 7, in which the starting pressure in the first process mode is 1 to 10 bar above the starting pressure in the second process mode.
  9. 9. Process according to any one of the preceding claims, in which the starting pressure level is 6 to 15 bar (abs.), the first pressure level is 4.3 to 6.9 bar (abs.) and the second pressure level is 1.3 to 1.7 bar (abs.).
  10. 10. Process according to any one of the preceding claims, in which the first temperature level is 110 to 140°C, the second temperature level is 130 to 240°C, and the third temperature level is 97 to 102°C.
  11. 11. Process according to any one of the preceding claims, in which the first turbine and/or the second turbine is or are braked using a generator, a booster and/or an oil brake.
  12. 12. Process according to any one of the preceding claims, in which the first oxygen content is 99 to 100 mol per cent and the second oxygen content is 80 to 98 mol per cent.
  13. 13. Process according to any one of the preceding claims, in which the first turbine and the second turbine are variable-speed turbines.
  14. 14. Air separation system having a main heat exchanger and a distillation column system that comprises a high-pressure column equipped for operation at a first pressure level, a low-pressure column equipped for operation at a second, lower pressure level, and a mixing column, and in which means are provided that are equipped to - withdraw in the liquid state an oxygen-rich stream having a first oxygen content from the low-pressure column and to feed it in the liquid state with the first oxygen content into the mixing column, - in addition, to feed a first compressed-air stream in the gaseous state into the mixing column and, in the mixing column, to send it in counterflow to the oxygen-rich stream having the first oxygen content, - to withdraw from the mixing column overhead an oxygen-rich stream having a second oxygen content below the first oxygen content and to pass it out of the air separation system, - to form the first compressed-air stream using air that is compressed to a starting pressure level above the first pressure level and thereafter is cooled to a first temperature level, is fed at the first temperature level to a first turbine and is expanded in the first turbine, and - to pass a liquid oxygen-rich air product in the liquid state out of the air separation system at least at times, wherein means that are equipped to - feed a second compressed-air stream into the high-pressure column and to form this second compressed-air stream likewise using the air that is compressed to the starting pressure level and thereafter cooled to the first temperature level and expanded in the first turbine, - to feed a third compressed-air stream into the low-pressure column and form this third compressed-air stream using air that is compressed to the starting pressure level and thereafter cooled to a second temperature level, fed at the second temperature level to a second turbine, expanded in the second turbine and cooled further in the main heat exchanger to a third temperature level, - to expand the air in the first turbine to the first pressure level and in the second turbine to the second pressure level and to operate the mixing column at the first pressure level or a third pressure level that differs from the first pressure level by at most 1 bar, and - in that the first temperature level is at least 20 K below the second temperature level.
  15. 15. Air separation system according to Claim 14, which is equipped for operation in a first process mode and a second process mode, by means being provided that are equipped to - pass, in the first process mode, the liquid oxygen-rich air product out of the air separation system in a larger amount than in the second process mode, and - to expand, in the first process mode, a larger amount of air in the second turbine than in the second process mode, so that as a result the third compressed-air stream in the first process mode comprises the same larger amount of air than in the second process mode.
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