CN111316054A - Method for utilizing multi-stage compressor intercooler discharge as coolant for process air - Google Patents

Method for utilizing multi-stage compressor intercooler discharge as coolant for process air Download PDF

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Publication number
CN111316054A
CN111316054A CN201880059571.9A CN201880059571A CN111316054A CN 111316054 A CN111316054 A CN 111316054A CN 201880059571 A CN201880059571 A CN 201880059571A CN 111316054 A CN111316054 A CN 111316054A
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China
Prior art keywords
air
cooling
cooling medium
discharge water
temperature
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CN201880059571.9A
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Chinese (zh)
Inventor
哈马德·穆罕默德·穆迪
纳伊夫·纳扎勒·侯赛尼
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SABIC Global Technologies BV
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SABIC Global Technologies BV
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes 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
    • F25J3/04—Processes 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
    • F25J3/04006—Providing pressurised feed air or process streams within or from the air fractionation unit
    • F25J3/04012—Providing pressurised feed air or process streams within or from the air fractionation unit by compression of warm gaseous streams; details of intake or interstage cooling
    • F25J3/04018—Providing pressurised feed air or process streams within or from the air fractionation unit by compression of warm gaseous streams; details of intake or interstage cooling of main feed air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes 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
    • F25J3/04—Processes 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
    • F25J3/04406—Processes 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
    • F25J3/04412—Processes 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/58—Cooling; Heating; Diminishing heat transfer
    • F04D29/582—Cooling; Heating; Diminishing heat transfer specially adapted for elastic fluid pumps
    • F04D29/5826—Cooling at least part of the working fluid in a heat exchanger
    • F04D29/5833—Cooling at least part of the working fluid in a heat exchanger flow schemes and regulation thereto
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/58—Cooling; Heating; Diminishing heat transfer
    • F04D29/582—Cooling; Heating; Diminishing heat transfer specially adapted for elastic fluid pumps
    • F04D29/5846—Cooling; Heating; Diminishing heat transfer specially adapted for elastic fluid pumps cooling by injection
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/0002—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0012—Primary atmospheric gases, e.g. air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/06—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by partial condensation
    • F25J3/063—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by partial condensation characterised by the separated product stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2200/00—Processes or apparatus using separation by rectification
    • F25J2200/04—Processes or apparatus using separation by rectification in a dual pressure main column system
    • F25J2200/06—Processes 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2205/00—Processes or apparatus using other separation and/or other processing means
    • F25J2205/02—Processes or apparatus using other separation and/or other processing means using simple phase separation in a vessel or drum
    • F25J2205/04—Processes or apparatus using other separation and/or other processing means using simple phase separation in a vessel or drum in the feed line, i.e. upstream of the fractionation step
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2215/00—Processes characterised by the type or other details of the product stream
    • F25J2215/42—Nitrogen or special cases, e.g. multiple or low purity N2
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2215/00—Processes characterised by the type or other details of the product stream
    • F25J2215/50—Oxygen or special cases, e.g. isotope-mixtures or low purity O2
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2215/00—Processes characterised by the type or other details of the product stream
    • F25J2215/58—Argon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/02—Compressor intake arrangement, e.g. filtering or cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/04—Compressor cooling arrangement, e.g. inter- or after-stage cooling or condensate removal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2245/00—Processes or apparatus involving steps for recycling of process streams
    • F25J2245/02—Recycle of a stream in general, e.g. a by-pass stream

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Compressor (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Separation By Low-Temperature Treatments (AREA)

Abstract

A system and method for treating air prior to separation of air components is disclosed. The system includes an air cooler, one or more compression stages operating in series, and one or more intercoolers installed between two adjacent compression stages. The discharge tank is configured to collect discharge water from the one or more intercoolers and provide a cooling medium to the air cooler. Atmospheric air is first sprayed with the discharge water in the air cooler to form a cooling air stream. The cooling air stream is then compressed in one or more compression stages and cooled by an intercooler between two adjacent compression stages. The discharge water from one or more of the charge air coolers is collected and recycled as cooling medium to cool the atmospheric air before it enters the first compression stage.

Description

Method for utilizing multi-stage compressor intercooler discharge as coolant for process air
Cross Reference to Related Applications
This application claims priority from U.S. provisional patent application No. 62/559,166, filed 2017, 9, 15, the disclosure of which is incorporated herein by reference in its entirety.
Technical Field
The present invention generally relates to air compression processes. More particularly, the present invention relates to an air compression process that cools air fed to a multi-stage compressor using discharge water from an intercooler of the multi-stage compressor as a cooling medium.
Background
Atmospheric air is typically treated in an air separation plant to produce nitrogen, oxygen, argon, and other inert gases. These products separated from air find application in many industries including the chemical industry, medical industry and semiconductor industry.
Typically, the atmosphere is first cleaned by a filter to remove dust suspended in the air. The clean atmospheric air is then compressed by an air compressor unit. During compression, clean air is compressed and cooled by a series of air compressors and intercoolers. The moisture in the clean air is condensed in the intercooler and separated from the air. After further removal of trace amounts of water from the compressed air by molecular sieves, at least a portion of the compressed air is liquefied, typically using a heat exchanger, to form pure oxygen. The remaining gases are further distilled in the higher and lower pressure columns to produce purified nitrogen and purified argon.
However, conventional air separation processes are energy intensive. An energy consumption analysis of the overall cryogenic air separation process shows that, although the process involves multiple cooling steps and high and low pressure distillation processes, the most energy is consumed in the cryogenic air separation unit is the multi-stage air compressor. Accordingly, there is a need for improvements in this area.
Disclosure of Invention
A method of compressing air for an air separation unit has been discovered. This method provides a solution to the problems associated with air separation processes described above. This solution consists in a method for treating air before separating its components. Notably, by cooling the atmospheric air prior to its delivery to the multi-stage compressor, the atmospheric air delivered to the compressor becomes denser and the temperature of the atmospheric air can be reduced. This is beneficial for reducing the energy consumption of the multi-stage compressor, since the volume of the air is reduced when it is cooled, thereby reducing the power required to compress the air. Further, it is possible to perform a cooling process of the atmospheric air using the discharge water collected from the intercooler of the multi-stage compressor as a cooling medium, thereby avoiding additional costs for the cooling medium. For example, in such a method, the discharge water from each of the intercoolers of the multi-stage compressor can be collected in a storage tank and sprayed and mixed into the atmospheric air through a water sprayer and a water mist, thereby cooling the atmospheric air. As a result of the cooling, the method can reduce the energy required to compress the atmosphere compared to using existing methods.
Embodiments of the invention include methods of treating air prior to separating air components. The method includes cooling air with a cooling medium to produce cooled air. The method also includes compressing the cooling air in a compressor unit that includes one or more compressors and one or more intercoolers. Still further, the method includes collecting the discharge water from the one or more intercoolers, wherein the discharge water is used as a cooling medium.
Embodiments of the invention include methods of treating air prior to separating air components. The method includes cooling air with a cooling medium to produce cooled air. The method may further include compressing the cooling air in a multi-stage compressor unit. The multi-stage compressor unit comprises at least two compressors for two compression stages and at least one intercooler for cooling compressed air from the at least two compressors. The method also includes collecting discharge water from at least one intercooler of the multi-stage compressor unit. In this method, the discharge water is used as a cooling medium.
Embodiments of the invention include methods of treating air prior to separating air components. The method includes measuring the humidity and temperature of the air. The air is cooled by the cooling medium if the humidity of the air exceeds a predetermined humidity value and the temperature of the air exceeds a predetermined temperature value. The method also includes compressing the cooling air in a multi-stage compressor unit. The multi-stage compressor unit comprises at least three compressors for three compression stages and at least two charge air coolers. Still further, the method includes collecting the discharge water from at least one intercooler of the multi-stage compressor unit. The discharge water is used as a cooling medium.
The following includes definitions of various terms and phrases used throughout this specification.
The term "about" or "approximately" is defined as approximately as understood by one of ordinary skill in the art. In one non-limiting embodiment, the term is defined as within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.
The terms "wt.%", "vol.%, or" mol.% refer to weight percent, volume percent, or mole percent, respectively, of a component based on the total weight, volume, or total moles of the material comprising the component. In a non-limiting example, 10 moles of a constituent in 100 moles of a material is 10 mol.% of the constituent.
The term "substantially" and variations thereof are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.
The term "avoid …" or any variation of that term, when used in the claims and/or specification, includes any measurable decrease or complete inhibition to achieve a desired result.
The term "effective" when used in the specification and/or claims refers to being sufficient to achieve a desired, expected, or intended result.
The use of the words "a" or "an" when used in conjunction with the words "comprising," including, "or" having "in the claims or the specification may mean" one, "but it is also consistent with the meaning of" one or more, "" at least one, "and" one or more than one.
In the context of the present invention, at least nineteen embodiments are now described. Example 1 is a method of treating air prior to separating the air components. The method comprises the following steps: cooling the air with a cooling medium to produce cooled air; compressing the cooling air in a compressor unit comprising one or more compression stages and one or more charge air coolers to produce compressed process air; and collecting the discharge water from the one or more intercoolers, wherein the discharge water is used as the cooling medium. Embodiment 2 is the method of embodiment 1, wherein the compressor unit is a multi-stage compressor unit. Embodiment 3 is the method of embodiment 2, wherein the multi-stage compressor unit comprises at least two compression stages and at least one intercooler for cooling compressed air from the at least two compression stages. Embodiment 4 is the method of any of embodiments 2 and 3, wherein the multi-stage compressor unit includes at least three compression stages in series and at least two intercoolers for cooling compressed air from the at least three compression stages. Embodiment 5 is the method of any of embodiments 1-4, further comprising the step of measuring the humidity and temperature of the air prior to cooling the air, wherein the step of cooling the air with the cooling medium is performed in response to the air humidity being greater than a predetermined humidity value and the air temperature being greater than a predetermined temperature value. Embodiment 6 is the method of embodiment 5, wherein the predetermined humidity value comprises 8.42 × 10-3The humidity ratio of (c). Embodiment 7 is the method of any one of embodiments 5 and 6, wherein the predetermined temperature value is about 15 ℃. Embodiment 8 is the method of any of embodiments 1-7, wherein the discharge water is in a ratio of air to cooling medium of 37:1 to 1000:1Is used as the cooling medium. Embodiment 9 is the method of any one of embodiments 1 to 8, wherein the discharge water directly contacts the air in the cooling step. Embodiment 10 is the method of any one of embodiments 1 to 9, wherein cooling the air with the cooling medium is performed by spraying the air with the cooling medium and mixing the air with the cooling medium. Embodiment 11 is the method of any one of embodiments 1 to 10, wherein the discharge water is collected and stored in a storage tank. Embodiment 12 is the method of any one of embodiments 1-11, wherein the cooling air has a temperature of 15 ℃ to 30 ℃. Embodiment 13 is the method of any one of embodiments 1 to 12, wherein the cooling air has a density of 1.05 x 10-3g/cm3To 1.25X 10-3g/cm3. Embodiment 14 is the method of any of embodiments 1-13, wherein the intercooler includes a heat exchanger. Embodiment 15 is the method of any one of embodiments 1 to 14, wherein the temperature of the cooling medium is 10 ℃ to 35 ℃. Embodiment 16 is the method of any one of embodiments 1 to 15, wherein the compressed process air is at a pressure of 0.54MPa to 0.59 MPa. Embodiment 17 is the method of any one of embodiments 1 to 16, wherein the compressed process air is gaseous. Embodiment 18 is the method of any one of embodiments 1 to 17, wherein the compressed process air is sent to a cryogenic separation unit and separated into one or more of nitrogen, oxygen, and argon.
Example 19 is a method of treating air prior to separating air components. The method comprises the following steps: measuring air humidity and temperature; cooling the air with a cooling medium to produce cooled air if the humidity of the air exceeds a predetermined humidity value and the temperature of the air exceeds a predetermined temperature value; compressing the cooling air in a multi-stage compressor unit comprising at least three compression stages and at least two charge air coolers; and collecting discharge water from at least one of the intercoolers of the multi-stage compressor unit, wherein the discharge water is used as a cooling medium.
Other objects, features and advantages of the present invention will become apparent from the following drawings, detailed description and examples. It should be understood, however, that the drawings, detailed description, and examples, while indicating specific embodiments of the present invention, are given by way of illustration only and are not intended to be limiting. In addition, it is contemplated that variations and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In other embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with any of the features from the other embodiments. In other embodiments, additional features may be added to the specific embodiments described herein.
Drawings
For a more complete understanding, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows a schematic view of an air compression system according to an embodiment of the invention;
FIG. 2 shows a schematic flow diagram of a method of compressing air in accordance with an embodiment of the invention; and
fig. 3 shows the results of a sensitivity analysis based on simulations performed on a method of compressing air according to an embodiment of the invention.
Detailed Description
Currently available methods of compressing atmospheric air include directly compressing atmospheric (or clean atmospheric) air with a multi-stage compressor. This is very energy intensive, especially as the atmospheric air temperature rises and the atmospheric cooling volume expands. The present invention provides a solution to this problem. This solution is premised on a method of compressing atmospheric air that includes the step of cooling the atmospheric air fed to the multi-stage compressor prior to flowing the air into the multi-stage compressor. Thus, the volume of atmospheric air can be reduced, thereby reducing the power required to compress the air. The cooling medium used in the cooling step can be at least some of the discharge water collected from the intercooler of the multi-stage compressor, thereby recycling water in the atmospheric air and saving the cost of the cooling medium. The humidity level in the atmospheric air may be sufficient to provide all of the cooling medium required in the process of the present invention.
These and other non-limiting aspects of the invention are discussed in further detail in the sections that follow.
A. Air compression system
The air compression system may be part of a cryogenic air separation unit that provides compressed air for a subsequent cryogenic air separation process. For conventional air compression systems, atmospheric air or filtered atmospheric air is fed directly into the inlet of the multi-stage compressor. Since atmospheric air is typically obtained from the outdoor environment, the volume of the air expands as the outdoor temperature increases. For example, atmospheric air in summer can be highly expanded when the ambient temperature is greater than 35 ℃ or even greater than 40 ℃. This may increase the power load of existing air compressor systems, further increasing the operating cost of the overall air separation process. The present invention provides a system that is capable of cooling atmospheric air prior to its entry into a multi-stage air compressor, thereby reducing the power load on the air compressor. In addition, the present invention requires minimal capital expenditure and substantially no additional operating costs to facilitate cooling the atmosphere prior to multi-stage compression. More specifically, the air compression system of the present invention uses the discharge water collected from the intercooler of the multi-stage air compressor as a cooling medium for the atmospheric air, avoiding the need for any other coolant. The discharge water can be simply sprayed and mixed into the atmospheric air by a water sprayer or mister, thereby minimizing the cost of the equipment or apparatus.
Referring to FIG. 1, a schematic diagram illustrates an air compression system 100 for reducing the power load of a multi-stage air compressor, according to an embodiment of the present invention. As shown in fig. 1, the air compression system 100 may include an air cooler 101 adapted to receive and cool atmospheric air. In an embodiment of the present invention, the air cooler 101 may be a water spray cooler. In some aspects, the water spray cooler may comprise a water spray or mist suitable for mixing water with atmospheric air. The outlet of the air cooler 101 may be in fluid communication with the inlet of the multi-stage air compressor unit.
According to an embodiment of the invention, the multi-stage air compressor unit may comprise one or more compressors and one or more charge air coolers. In a more specific embodiment, the multi-stage air compressor unit can include at least two compressors (two compression stages) and at least one intercooler for cooling compressed air from the first stage compressor. In an embodiment of the invention, at least two compressors are mounted in series. An intercooler may be installed between two adjacent compressor stages. Non-limiting examples of the intercooler include a heat exchanger having various cooling media such as cooling water or other cooling media.
In an embodiment of the invention, as shown in fig. 1, the multi-stage air compressor unit may comprise three compressors (three compression stages) and two intercoolers in series, each of the intercoolers being mounted between two adjacent compressors (compression stages). In a more specific embodiment of the present invention, as shown in FIG. 1, a first stage compressor 102 (first compression stage) is in fluid communication with an air cooler 101. First stage compressor 102 (first compression stage) may be adapted to receive cooling air stream 11 from air cooler 101 and compress the cooling air to form first compressed air stream 12. The pressure of the first compressed air stream 12 may be from 0.22MPa to 0.27MPa and all values and ranges therebetween, including 0.23MPa, 0.24MPa, 0.25MPa, 0.26 MPa.
An outlet of the first stage compressor 102 may be in fluid communication with an inlet of a first stage intercooler 103 adapted to cool the first compressed air stream 12 to form a first cooled and compressed air stream 13 and a first discharge water stream 14. In certain aspects, the first stage intercooler 103 may be configured to reduce the temperature of the compressed air stream 12 by 75 ℃ to 80 ℃, including 76 ℃, 77 ℃, 78 ℃, and 79 ℃. A water outlet of the first stage intercooler 103 may be in fluid communication with an inlet of a discharge storage tank 104 configured to receive the first discharge water stream 14 from the first stage intercooler 103. According to an embodiment of the invention, the outlet of the emissions storage tank 104 may be in fluid communication with the air cooler 101. The emissions storage tank 104 may be configured to provide water as a cooling medium for cooling the atmospheric air. In more particular embodiments, the emissions storage tank may be adapted to provide water to the water spray and/or water mist of the air cooler 101 to mix the atmospheric air with the emission water. In some aspects, the emissions storage tank may further include an overflow valve adapted to drain overflow drain water when excess drain water collects in the emissions storage tank.
According to an embodiment of the invention, the cooling air outlet of the first stage intercooler may be in fluid communication with the second stage compressor 105 (second compression stage) to flow the first cooling and compressed air stream 13 from the first stage intercooler 103 to the second stage compressor 105. A second stage compressor 105 (second compression stage) may be provided to further compress the cooled and compressed air stream 13 to form a second compressed air stream 15. In certain aspects, the pressure of the second compressed air stream 15 can be from 0.39MPa to 0.45MPa and all values and ranges therebetween, including 0.40MPa, 0.41MPa, 0.42MPa, 0.43MPa, and 0.44 MPa.
An outlet of the second stage compressor 105 (second compression stage) may be in fluid communication with an inlet of a second stage intercooler 106. Second stage intercooler 106 may be adapted to cool second compressed air stream 15 to form a second cooled and compressed air stream 16 and a second discharge water stream 17. The second stage intercooler 106 may be configured to reduce the temperature of the second compressed air stream 15 by 60 ℃ to 65 ℃ and all values and ranges therebetween, including 61 ℃, 62 ℃, 63 ℃, and 64 ℃. A water outlet of the second stage intercooler 106 may be in fluid communication with the emissions storage tank 104 to flow the second stream of emissions water 17 into the emissions storage tank 104. The air outlet of second stage intercooler 106 may be in fluid communication with a third stage compressor 107 (third compression stage) configured to further compress second cooled and compressed air stream 16 to form compressed process air stream 18. In certain aspects, the pressure of the compressed process air stream 18 can be from 0.54MPa to 0.59MPa and all ranges and values therebetween, including 0.55MPa, 0.56MPa, 0.57MPa, and 0.58 MPa. The temperature of the compressed process air stream 18 can be from 80 ℃ to 90 ℃ and all ranges and values therebetween, including 81 ℃, 82 ℃, 83 ℃, 84 ℃, 85 ℃, 86 ℃, 87 ℃, 88 ℃ and 89 ℃. According to an embodiment of the invention, the third stage compressor 107 (third compression stage) may be in fluid communication with an air separation unit. Non-limiting examples of air separation units may include a cryogenic high pressure distillation column and a cryogenic low pressure distillation column. In an embodiment of the present invention, for an air compression system 100 including more than three air compressors (three compression stages) and more than two intercoolers, the discharge water from each intercooler may be collected in the discharge storage tank 104 as the cooling medium for the water cooler 101. The last air compressor (last compression stage) through which the air passes may be in fluid communication with the air separation unit.
In a more specific embodiment, the air compression system 100 may further include a control system adapted to control the flow rate of the discharge water used to cool the atmospheric air flowing into the air cooler 101. In certain aspects, the control system may include a temperature sensor configured to measure the temperature of the atmospheric air flowing into the air cooler 101. The control system may also include a humidity sensor arranged to measure the humidity and humidity level of the atmospheric air flowing into the air cooler 101. The control system may further comprise a flow controller arranged to adjust the flow rate of the discharge water in the air cooler 101 in response to measurements from the temperature sensor and/or the humidity sensor. In certain aspects, when the humidity measurement from the humidity sensor is not less than about 8.42 x 10-3And/or the temperature measurement from the temperature sensor is not less than about 15 deg.c, the discharge water can be used to spray atmospheric air flowing into the air cooler. When the humidity measurement from the humidity sensor is less than about 8.42 x 10-3At this time, the drain water cannot be collected in the drain tank 104, and therefore the flow rate of the drain water in the water cooler may be substantially zero. When the temperature measurement from the temperature sensor is below about 15 deg.c, or when the air humidity is saturated, the flow controller may set the flow rate of the discharged water to zero because spraying water on the atmospheric air may cause dew condensation rather than cooling the atmospheric air.
B. Method for treating air before separating air
In an embodiment of the invention, a method of treating air prior to separating air components is provided. Fig. 2 illustrates a method 200 of treating air prior to separating air components. The method 200 may be implemented by the air compression system 100 as shown in fig. 1. As shown in block 201, the method 200 may include measuring the humidity and/or temperature of the air. In an embodiment of the invention, the measurement at block 201 may be performed at the inlet of the water cooler 101.
According to an embodiment of the invention, as shown in block 202, the method 200 may include cooling air with a cooling medium to produce cooled air. In certain aspects, during cooling at block 202, the air may be cooled by the latent heat of the cooling medium, and the cooling medium may be evaporated. In a more specific embodiment, the cooling medium may include drain water collected from one or more of the first stage intercooler 103 and the second stage intercooler 106. At block 202, the cooling medium may be in direct contact with air. In certain aspects, in the cooling step of block 202, the discharge water can be sprayed and mixed into the air. In embodiments of the invention, the ratio of air to cooling medium in the step of cooling air may be 37:1 to 1000:1 and all ranges and values therebetween, including 37:1 to 50:1, 50:1 to 100:1, 100:1 to 150:1, 150:1 to 200:1, 200:1 to 250:1, 250:1 to 300:1, 300:1 to 350:1, 350:1 to 400:1, 400:1 to 450:1, 450:1 to 500:1, 500:1 to 550:1, 550:1 to 600:1, 600:1 to 650:1, 650:1 to 700:1, 700:1 to 750:1, 750:1 to 800:1, 800:1 to 850:1, 850:1 to 900:1, 900:1 to 950:1, and 950:1 to 1000: 1.
In certain aspects, the step of cooling the air with the discharge water at block 202 may be performed in response to the humidity of the air measured at block 201 being no less than a predetermined humidity value and the temperature of the air measured at block 201 being no less than a predetermined temperature value. The predetermined humidity value may comprise about 8.42 x 10-3The humidity ratio of (c). The predetermined temperature value may be about 15 deg.c. In an embodiment of the present invention, the step of cooling the air at block 202 may not use the discharge water from one or more intercoolers of the air compressor unit as a cooling medium when the air humidity measured at block 201 is less than a predetermined humidity value and/or the air temperature measured at block 201 is less than a predetermined temperature value. As described above, when the humidity ratio of the air is less than 8.42X 10-3When this is the case, no discharge water can be collected as the cooling medium. When the air temperature is lower than 15 c, or when the air humidity is saturated, the spray of the discharged water may cause dew condensation instead of cooling the air. In certain aspects, the air temperature prior to cooling at block 202 may be greater than 30 ℃, greater than 35 ℃, and greater than 40 ℃.
In certain aspects, the temperature of the cooling air can be 15 ℃ to 30 ℃ and all ranges and values therebetween, including 15 ℃ to 18 ℃, 18 ℃ to 21 ℃, 21 ℃ to 24 ℃, 24 ℃ to 27 ℃, and 27 ℃ to 30 ℃. The step of cooling the air at block 202 may reduce the air temperature by 10 ℃ to 16 ℃ and all ranges and values therebetween. The density of the cooling air may be 1.05 x 10-3g/cm3To 1.25X 10-3g/cm3And all ranges and values therebetween, including 1.05 x 10-3g/cm3To 1.07X 10-3g/cm3，1.07×10-3g/cm3To 1.09X 10-3g/cm3、1.09×10-3g/cm3To 1.11X 10-3g/cm3、1.11×10-3g/cm3To 1.13X 10-3g/cm3、1.13×10-3g/cm3To 1.15X 10-3g/cm3、1.15×10-3g/cm3To 1.17X 10-3g/cm3、1.17×10-3g/cm3To 1.19X 10-3g/cm3、1.19×10-3g/cm3To 1.21X 10-3g/cm3、1.21×10-3g/cm3To 1.23X 10-3g/cm3And 1.23X 10-3g/cm3To 1.25X 10-3g/cm3。
According to an embodiment of the invention, method 200 may further include compressing the cooling air in a compressor unit as shown in block 203. The compressor unit may be a multi-stage air compression unit of the air compressor system 100. More specifically, the compressing step at block 203 may include compressing the cooling air stream 11 in the first stage compressor 102 (first compression stage) to form a first compressed air stream 12. In certain aspects, the pressure of the first compressed air stream 12 may be from 0.22MPa to 0.27MPa and all ranges and values therebetween. The compressing step at block 203 may also include cooling first compressed air stream 12 in first stage intercooler 103 to form first cooled and compressed air stream 13 and first discharge water stream 14. In certain aspects, the cooling in the first stage intercooler 103 can reduce the temperature of the first compressed air stream 12 by 0.75 ℃ to 80 ℃ and all ranges and values therebetween, including 0.75 ℃ to 1 ℃,1 ℃ to 5 ℃, 5 ℃ to 10 ℃, 10 ℃ to 15 ℃, 15 ℃ to 20 ℃, 25 ℃ to 30 ℃, 30 ℃ to 35 ℃, 35 ℃ to 40 ℃, 40 ℃ to 45 ℃, 45 ℃ to 50 ℃, 50 ℃ to 55 ℃, 55 ℃ to 60 ℃, 60 ℃ to 65 ℃, 65 ℃ to 70 ℃, 70 ℃ to 75 ℃, and 75 ℃ to 80 ℃.
First cooled and compressed air stream 13 may be further compressed in second stage compressor 105 (second compression stage) to form second compressed air stream 15. In certain aspects, the pressure of the second compressed air stream 15 can be from 0.39MPa to 0.45MPa and all ranges and values therebetween, including 0.40MPa, 0.41MPa, 0.42MPa, 0.43MPa, and 0.44 MPa. Similarly, second compressed air stream 15 may be cooled by second stage intercooler 106 to form a second cooled and compressed air stream 16 and a second discharge water stream 17. In certain aspects, cooling in the second stage intercooler 106 may reduce the temperature of the second compressed air stream 15 by 60 ℃ to 65 ℃ and all ranges and values therebetween, including 61 ℃, 62 ℃, 63 ℃, and 64 ℃. Second cooled and compressed air stream 16 can be further compressed in third stage compressor 107 (third compression stage) to form compressed process air stream 18. In certain aspects, the pressure of the compressed process air stream 18 can be from 0.54MPa to 0.59MPa and all ranges and values therebetween, including 0.55MPa, 0.56MPa, 0.57MPa, and 0.58 MPa. The temperature of the compressed process air stream 18 can be from 80 to 90 ℃ and all ranges and values therebetween, including 81 ℃, 82 ℃, 83 ℃, 84 ℃, 85 ℃, 86 ℃, 87 ℃, 88 ℃ and 89 ℃.
In an embodiment of the present invention, the multi-stage compressor unit of air compressor system 100 may include n compressors (n compression stages) and n-1 intercoolers, where n represents the number of compression stages in a multi-stage compressor unit (n is a positive integer, and n ≧ 2). The compression at block 203 may include compressing the cooling air stream 11 with n compressors in series and cooling the compressed air with n-1 intercoolers, each of the n-1 intercoolers being mounted between two adjacent compression stages. The compressed process air from the nth compressor may have a pressure of from 0.54MPa to 0.8MPa and a temperature of from 75 ℃ to 90 ℃. In an embodiment of the invention, the compressed process air may be in gaseous form (for gaseous air only). The discharge water may be formed in and collected from at least one of the n-1 charge air coolers.
In an embodiment of the present invention, as shown in block 204, the method 200 may further include collecting the discharge water from one or more intercoolers. The collected drain water may be used as a cooling medium at block 202. In some more specific embodiments, the discharge water may be collected from the first stage intercooler 103 and/or the second stage intercooler 106 to the discharge storage tank 104. The discharge water from the discharge tank 104 may be sprayed and mixed into the air in the air cooler 101. In certain aspects, the temperature of the discharge water collected from the intercooler can be from 10 ℃ to 35 ℃, and all values and ranges therebetween, including 10 ℃ to 12 ℃, 12 ℃ to 14 ℃, 14 ℃ to 16 ℃,16 ℃ to 18 ℃, 18 ℃ to 20 ℃, 20 ℃ to 22 ℃, 22 ℃ to 24 ℃, 24 ℃ to 26 ℃, 26 ℃ to 28 ℃, 28 ℃ to 30 ℃, 30 ℃ to 32 ℃, and 32 ℃ to 35 ℃. In a more specific embodiment, the drain water collected from the intercooler is sufficient to cool the air in the air cooler 101 when the humidity ratio of the air is above 0.842%. Thus, the cooling at block 202 may be performed in a closed loop without adding supplemental water to the air cooler 101 and/or the emissions storage tank 104. In certain aspects, when the humidity ratio of the air is less than 2.70%, make-up water may be added to the air cooler 101 and/or the emissions storage tank 104. When the air humidity reaches saturation (maximum humidity), spraying water on the air may cause condensation.
Although embodiments of the present invention have been described with reference to the block diagram of fig. 2, it is to be understood that the operations of the present invention are not limited to the specific block diagram shown in fig. 2 and/or the specific order of the block diagrams. Thus, embodiments of the invention may use various block diagrams in a different order than fig. 2 to provide the functionality described herein.
Specific examples are included below as part of the present disclosure. This example is for illustrative purposes only and is not intended to limit the present invention. One of ordinary skill in the art will readily recognize that parameters can be changed or modified to produce substantially the same results.
Examples of the invention
(simulation of air compression Process)
A method of treating air prior to separation of air components according to an embodiment of the present invention was simulated on an ASPEN PLUS platform. The creation and validation of a model for the simulation run uses real process data from the air separation plant. The initial conditions for feeding air into the air compression system included a temperature of 17.4 ℃ and a pressure of 1.01 bar. The flow rate for feeding air into the air compression system was 403839 standard cubic meters per hour. The composition of air comprises 74.62 mol.% nitrogen, 22 mol.% oxygen, 0.89 mol.% argon, and 2.4 mol.% water. Simulation results show that the method of the present invention reduces the power consumption of the compressor in terms of megawatts compared to conventional methods that do not apply cooling at the inlet of the multi-stage compressor.
Sensitivity analysis was performed using the simulation results to optimize the fraction of the discharge water recycled as the cooling medium. According to the results shown in fig. 3, under the initial conditions described above, the optimum fraction of the discharge water recycled as cooling medium is about 80%, with the power consumption of the air compressor unit at its lowest point of about 31.2 megawatts and the temperature of the mixed air (i.e. the temperature of stream 11) being about 29 ℃.
Although the embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the embodiments as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure above, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims (19)

1. A method of treating air prior to separating air components, the method comprising:
cooling the air with a cooling medium to produce cooled air;
compressing the cooling air in a compressor unit comprising one or more compression stages and one or more charge air coolers to produce compressed process air; and
collecting discharge water from the one or more intercoolers, wherein the discharge water is used as the cooling medium.
2. The method of claim 1, wherein the compressor unit is a multi-stage compressor unit.
3. The method of claim 2, wherein the multi-stage compressor unit comprises at least two compression stages and at least one intercooler for cooling compressed air from the at least two compression stages.
4. A method according to any one of claims 2 and 3, wherein the multi-stage compressor unit comprises at least three compression stages in series and at least two charge air coolers for cooling compressed air from the at least three compression stages.
5. The method according to any one of claims 1 to 2, further comprising measuring the humidity and temperature of the air prior to cooling the air, wherein the step of cooling the air with the cooling medium is performed in response to the air humidity being greater than a predetermined humidity value and the air temperature being greater than a predetermined temperature value.
6. The method of claim 5, wherein the predetermined humidity value comprises 8.42 x 10-3The humidity ratio of (c).
7. The method of claim 5, wherein the predetermined temperature value is about 15 ℃.
8. The method according to any one of claims 1 to 2, wherein the discharge water is used as the cooling medium at a ratio of air to cooling medium of 37:1 to 1000: 1.
9. The method of any one of claims 1 to 2, wherein the discharge water directly contacts air in the cooling step.
10. The method according to any one of claims 1 to 2, wherein cooling the air with the cooling medium is performed by spraying the air with the cooling medium and mixing the air with the cooling medium.
11. The method of any one of claims 1 to 2, wherein the discharge water is collected and stored in a storage tank.
12. The method according to any one of claims 1 to 2, wherein the temperature of the cooling air is 15 ℃ to 30 ℃.
13. The method of any of claims 1-2, wherein the cooling air has a density of 1.05 x 10- 3g/cm3To 1.25X 10-3g/cm3。
14. The method according to any of claims 1-2, wherein the charge air cooler comprises a heat exchanger.
15. The method according to any one of claims 1 to 2, wherein the temperature of the cooling medium is 10 ℃ to 35 ℃.
16. The method of any of claims 1-2, wherein the compressed process air is at a pressure of 0.54MPa to 0.59 MPa.
17. The method of any of claims 1-2, wherein the compressed process air is gaseous.
18. The method of any one of claims 1 to 2, wherein the compressed process air is sent to a cryogenic separation unit and separated into one or more of nitrogen, oxygen, and argon.
19. A method of treating air prior to separating air components, the method comprising:
measuring the humidity and temperature of the air;
cooling the air with a cooling medium to produce cooled air if the humidity of the air exceeds a predetermined humidity value and the temperature of the air exceeds a predetermined temperature value;
compressing the cooling air in a multi-stage compressor unit comprising at least three compression stages and at least two charge air coolers; and
collecting discharge water from at least one of charge air coolers of the multistage compressor unit, wherein the discharge water is used as the cooling medium.
CN201880059571.9A 2017-09-15 2018-07-25 Method for utilizing multi-stage compressor intercooler discharge as coolant for process air Pending CN111316054A (en)

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