ES2767727T3 - Method for controlling an adsorption phase of a gas generator and a gas generator applying such a method. - Google Patents

Abstract

1. A gas generator comprises: - at least one container, comprising: an inlet and an outlet to allow a gas flow through them and an adsorbent material capable of selectively adsorbing a first gaseous component of a mixture gaseous and allowing an outlet gas stream comprising primarily a second gaseous component to flow through the outlet; - means for providing an inlet gas flow at the container inlet; characterized in that the device further comprises: - a flow meter placed at the outlet of the container to measure the outgoing gas flow; - means for determining the concentration of the second gaseous component, placed at the outlet of the container; - a controller unit connected to the flow meter and to the means for determining the concentration of the second gaseous component, the controller is configured to receive measured values of the outlet gas flow and of the measured concentration; - the controller unit further comprises a processing unit that is provided with an algorithm configured to: - calculate the capacity of the container, whereby the capacity is the maximum volume of the second gaseous component per unit of time that can be supplied in a condition of current operation and at a set value of concentration. - comparing the measured outflow gas flow with the calculated capacity, - comparing the determined concentration of the second gaseous component with a set value, and: A. the controller unit is further provided with means to maintain the inlet gas flow during a predetermined time interval, Δs, when the measured concentration is equal to or greater than a set value, and when the measured output gas flow is less than the calculated capacity and means to subject the container to a regeneration cycle after the interval of predetermined time, Δs. 2. The gas generator according to claim 1, characterized in that the controller unit is further programmed to maintain the inlet gas flow at the container inlet for a predetermined nominal cycle time interval, Δs0, and to stop the inlet gas flow after the predetermined nominal cycle time interval, Δs0, when the measured concentration is less than the set value. 3. The gas generator according to claim 2, characterized in that the controller unit is further programmed to apply a regeneration cycle to the container. The gas generator according to claim 1, further characterized in that it comprises at least two containers, each of the containers comprises an inlet and an outlet to allow a gas flow through them, and an adsorbent material capable of selectively adsorbing a first gaseous component of a gaseous mixture and allowing an outlet gas stream comprising primarily a second gaseous component to flow through the outlet. The gas generator according to claim 4, further characterized in that it is programmed to selectively provide the inlet gas flow through the inlet of any one of at least two containers. 6. The gas generator according to claim 1, further characterized in that it comprises a bypass connection to allow each of at least two containers to be vented to the outside environment. 7. The gas generator according to claim 4, characterized in that the controller unit further comprises means for initiating a regeneration cycle for one of at least two adsorption containers and for selectively directing the inlet gas flow through from each other from at least two regeneration containers. 8. The gas generator according to claim 1, characterized in that the controller unit further comprises means for measuring a time interval, {del} t1, in which one of at least two containers is in the adsorption phase and stops compare the measured time interval with a minimum set time interval, Δt2, and: - if Δt1> Δt2 and if the measured concentration is equal to or greater than a set value, and when the measured outflow is less than the calculated capacity , then the controller unit further comprises means for maintaining the inflow gas flow during the predetermined time interval, Δs; or - if Δt1 <= Δt2 and if the measured concentration is equal to or greater than a set value, and when the measured outflow is less than the calculated capacity, then the controller unit further comprises means to maintain the inlet gas flow during the predetermined nominal cycle time interval, Δs0. 9. The gas generator according to claim 4, characterized in that each of at least two containers comprises an adsorbent medium comprising carbon molecular sieves. 10. A gas generator according to claim 1, characterized in that the first gaseous component is oxygen and the second gaseous component is nitrogen. 11. A gas generator according to claim 1, characterized in that the controller unit further comprises means for comparing the outflow with the calculated capacity and for maintaining the inlet gas flow for a predetermined time interval when the flow of output is greater than a first threshold value that is calculated as a percentage of the calculated capacity. 12. A controller unit characterized in that it comprises: means for measuring the flow of exhaust gas at the outlet of a regeneration container, means for determining the concentration of a second gaseous component at the outlet of the regeneration container, a processing unit for comparing the measured data with the set values and to control the time interval in which the gas flow is guided through the inlet of the container, the controller is configured to be provided in a gas generator according to any of the claims 1 to 9.

Description

DESCRIPTION

Method for controlling an adsorption phase of a gas generator and a gas generator applying such method

This invention relates to a method for controlling an adsorption phase of a gas generator, said generator comprising an adsorbent medium capable of selectively adsorbing a first gaseous component of an inlet gas flow comprising a gaseous mixture and allowing a flow of Exit gas mainly comprising a second gaseous component, said method comprising the steps of: directing the inlet gas flow through an inlet of said gas generator; measure the outlet gas flow; determining the concentration of said second gaseous component at the outlet of said container.

Methods for maintaining a relatively constant concentration of a gaseous component generated from fractionation of a gaseous mixture are known in the art.

An example can be found in US 4,323,370 filed in the name of LINDE AKTIENGESELLSCHAFT, where a cyclic adsorption process for fractionation of a gas mixture is described. The process maintains the level of the residual concentration of the adsorbed component substantially constant by controlling the volume of the product gas stream withdrawn during the adsorption phase of an adsorbent.

Another example can be found in EP 0129304 A2, which shows a molecular sieve type gas separation system. The system maintains the concentration of a constituent gas in the gaseous product supplied by the system within predetermined limits, responding to the relevant concentration of the constituent gas in the gaseous product. A similar system is disclosed in EP0250235.

One of the drawbacks of such a process is the amount of energy used for adsorption. Since, when the adsorption phase is increased, the productivity of a system that implements said process decreases. This happens because a larger volume of gas will have to be processed and while one of the gaseous components is used after the adsorption process has taken place, the other gaseous component is trapped inside the adsorber, filling a larger volume of the container and eventually saturating the adsorbent bed. This will cause the device to consume more energy and eventually provide a gaseous component with a lower concentration than necessary.

Another drawback is the low efficiency of the adsorption process because the duration of the adsorption cycle is not correlated with the concentration requirements for the gaseous component.

An identified risk is the possibility of facing a concentration of the gaseous component lower than that required, and the aforementioned document does not offer an immediate solution, which could jeopardize the process or the user's network.

Taking into account the aforementioned drawbacks and risks, an objective of the present invention is to provide a method for controlling an adsorption phase of a gas generator, during which the concentration of a gaseous component is maintained at the desired level, while At the same time, the energy consumption of the adsorption process decreases.

Another objective of the present invention is to maintain the increase in energy efficiency during a varied demand for said gaseous component.

Another object of the present invention is to provide a method that helps maintain a high level of energy efficiency during subsequent adsorption cycles.

Yet another object of the present invention is to provide a method that ultimately reduces the maintenance costs of the overall system.

The present invention solves at least one of the above problems and / or other problems by providing a method according to claim 1. More particularly, the invention provides a method for controlling an adsorption phase of a gas generator, said comprising gas generator at least one container comprising an inlet and an outlet to allow a flow of gas therethrough and an adsorbent medium capable of selectively adsorbing a first gaseous component of a gaseous mixture and allowing an outflow of gas comprising mainly a second gaseous component, said method comprising the steps of:

- directing an inlet gas flow through the inlet of said container;

- measuring the outgoing gas flow at the outlet of said container;

- determining a concentration of said second gaseous component at the outlet of said container,

where the method also includes the steps of:

A1) calculate a capacity of the container, where the capacity is the maximum volume of the second gaseous component per unit time that can be supplied in a current operating condition and an established value of the concentration;

A2) compare the measured outflow gas flow with the calculated capacity;

A3) keep the container in the adsorption phase for a predetermined time interval, As, if the measured outflow gas flow is less than the calculated capacity and if the determined concentration of the second gaseous component at the outlet of the container is greater than or equal to than the set value, and subjecting the container to a regeneration cycle after said predetermined time interval, As.

In fact, by comparing the calculated capacity of the generator with the measured output flux and also comparing the determined concentration with a set value, the method according to the present invention provides an accurate view regarding the state of the container at a given time and maintains the desired concentration level for the second gaseous component at the generator outlet.

Also, since the method takes into account the measured value of the output flow and the capacity of the generator, saturation of the adsorbent medium is avoided, allowing the generator to work with great efficiency and maintain the required concentration of the second gaseous component throughout the adsorption process.

Tests have shown that the efficiency of the adsorption process decreases if the time interval for the adsorption cycle is prolonged. As such, when the adsorption cycle is maintained for a relatively long period of time, a larger volume of gas will enter the generator and the adsorbent will have to absorb an increasing number of oxygen molecules.

As a consequence, the oxygen front created in the adsorbent bed will move towards the outlet of the gas generator. Due to this, the concentration level of the second gaseous component can be affected at the outlet. In such a case, the productivity of the gas generator falls and the reliability of the adsorption process decreases.

Because the method of the present invention not only compares the concentration of the second gaseous component at the outlet of the gas generator with a set value, but also compares the calculated capacity of the generator with the outlet flow before modifying the interval of During which time the generator is maintained in the adsorption phase, the desired concentration for the second gaseous component is ensured and optimum energy consumption is also achieved throughout the operation of the gas generator.

Another known fact is that gas generators are designed to operate in the most severe and difficult operating conditions when talking about parameters like temperature and pressure. And, when these parameters fluctuate due, for example, to the change of seasons or the use of the generator in another geographical area, the generator is oversized. Known generators could not solve such a problem, but the method according to the present invention allows efficient use of generator power regardless of these fluctuations.

In fact, tests have shown that, by implementing the method according to the present invention, the generator consumes up to 40% less energy.

Another known fact is that, within a typical production line, the desired concentration and volume of the second gaseous component normally fluctuate and the method according to the present invention keeps the generator in the adsorption phase for a predetermined time interval that it is determined based on the desired concentration and volume. Therefore, an adjustment is made to the operating capacities of the gas generator, to achieve lower energy consumption through efficient logic.

Preferably, after said predetermined time interval, the generator is subjected to a regeneration cycle, during which the molecules of the first gaseous component are removed from the generator and the adsorbent bed is brought to an initial stage, with nominal adsorbent characteristics.

In a preferred embodiment according to the present invention, the method further comprises the step of comparing the determined concentration with a set value and if said concentration is below the set value, stopping the inlet gas flow and subjecting the generator to a regeneration cycle. Because of this, the required concentration of the second gaseous component is maintained at the desired level.

Interruption of the inlet gas flow can be performed immediately after the comparison between the determined concentration and the established value reveals a negative result or the method according to the present The invention can interrupt the inlet gas after a predetermined nominal cycle time, Aso, calculated from the start of the adsorption cycle.

The present invention is further directed to a gas generator according to claim 16. More particularly, the invention is directed to a gas generator comprising:

- at least one container, comprising: an inlet and an outlet to allow a flow of gas through it and an adsorbent material capable of selectively adsorbing a first gaseous component of a gaseous mixture and allowing an outflow of gas to flow. it mainly comprises a second gaseous component flowing through said outlet;

- means for providing an inlet gas flow at the inlet of said container;

where the device also includes:

- a flow meter placed at the outlet of the container to measure an outlet gas flow;

- means for determining a concentration of said second gaseous component, placed at the outlet of the container;

- a controller unit connected to the flow meter and to the means for determining the concentration of said second gaseous component, said controller unit being configured to receive measured values of the outlet gas flow and of the determined concentration;

- said controller unit further comprises a processing unit that is provided with an algorithm configured to:

- calculate the capacity of the container, where the capacity is the maximum volume of the second gaseous component per unit of time that can be supplied in a current operating condition and an established value of the concentration,

- compare the measured output gas flow with the calculated capacity,

- comparing the determined concentration of said second gaseous component with the established value, and:

A. said controller unit also being programmed to maintain the inlet gas flow for a predetermined time interval, As, when said determined concentration is equal to or greater than a set value and when said measured outlet gas flow is less than calculated capacity, and subjecting the container to a regeneration cycle after said predetermined time interval, As.

Due to the capabilities of the controller unit, the user of such a device will obtain the best result with less energy consumption and will benefit from an easy-to-use user interface.

Also, since the device is controlled by said controller unit and since the logic specified above is applied, maintenance costs are reduced, since the parts that make up the device are protected from operation in limit conditions that could cause premature wear . The controller unit helps to apply all changes at the best time calculated according to the design of the device, so as to extend the life of the device.

With the intention of better showing the characteristics of the invention, some preferred configurations according to the present invention are described, by way of example and without limitation, with reference to the attached drawings, where:

Figure 1 schematically represents a gas generator according to an embodiment of the present invention; Figures 2 and 3 schematically represent a gas generator according to other embodiments of the present invention;

Figures 4 schematically represent the energy consumption as a function of the output flow.

Figure 1 shows a gas generator 1 comprising an inlet 2 and an outlet 3, to allow a gas flow through it. Said gas generator further comprises an adsorbent means (not shown) capable of selectively adsorbing a first gaseous component of an inlet gas stream comprising a gaseous mixture, and allowing an outlet gas stream comprising primarily a second gaseous component.

In the context of the present invention, it should be understood that adsorption also includes absorption. The present invention is directed to a method for controlling an adsorption phase of a gas generator, wherein an inlet gas flow is directed through said inlet 2 of the gas generator 1 and the outlet gas flow is measured at the outlet 3 of the gas generator 1 to determine the concentration of said second gaseous component at the outlet of a container 4.

Furthermore, the method comprises a step in which the generator capacity is calculated and the calculated value is compared with the measured output flow. If, after said comparison, the measured outflow is less than the calculated capacity and if the determined concentration is greater than or equal to a set value, the gas generator 1 remains in the adsorption phase for a predetermined time interval , As.

In the context of the present invention, the capacity of the generator must be understood as the maximum volume of the second gaseous component per unit of time that can be supplied by the gas generator 1 under the current operating conditions and at the established concentration value.

Preferably, said predetermined time interval, As is calculated in such a way that the gas generator 1 can maintain said established value of the concentration and, therefore, so that the adsorbent medium is not completely saturated. Due to this, the gas generator 1 is kept in the adsorption phase as long as possible, without jeopardizing the concentration level of the resulting second gas component and without allowing said gas generator 1 to consume more energy than necessary to an optimal result.

After said predetermined time interval, As, the gas generator undergoes a regeneration cycle. During said regeneration cycle, the adsorbent medium is allowed to remove gas molecules from the first gaseous component, bringing said adsorbent to optimal adsorption capacities and preparing gas generator 1 for another adsorption cycle.

In the context of the present invention, an adsorption cycle is to be understood as a time interval in which the adsorbent medium comprised within the gas generator 1 is used to fractionate the gaseous mixture of the inlet gas flowing through the inlet 2 and consequently adsorbs the first gaseous component and allows a gas mainly comprising a second gaseous component to flow through outlet 3.

Preferably, said predetermined time interval As has as its starting point the moment in which the gas generator 1 started the adsorption cycle and as the end point when said gas generator 1 ended the adsorption cycle.

In another embodiment, according to the present invention, said predetermined time interval As has the starting point at the present time and an end point in the future and is determined based on the calculated capacity of the measured outflow and the set value of concentration of said second gaseous component. Based on the typical behavior of the adsorbent medium, said final time can be approximated.

In another embodiment, according to the present invention, the method further comprises the step of comparing the determined concentration with a set value and if said concentration is below the set value, interrupting the inlet gas flow and subjecting the generator to a regeneration cycle.

The inlet gas flow can be interrupted immediately when said comparison reveals that the established value for the concentration is not met, or the method can contemplate a tolerance of, for example, approximately 5 seconds or more before stopping the inlet gas flow .

Preferably, the method comprises the step of stopping the inlet gas flow after a predetermined nominal cycle time, Aso. Said predetermined nominal cycle time, Aso is a calculated minimum time interval in which, under commonly known operating conditions, the gas generator 1 can generate the second gaseous component with a relatively high concentration.

Said predetermined nominal cycle time, Aso has a starting point at the time when the gas generator 1 started the adsorption cycle and the end point at the time when the gas generator 1 ended the adsorption cycle.

Preferably, the capacity of the generator is determined based on the following formula:

Qcap = Specific capacity x Generator volume x Kpc x Ktc

so Kpc is the pressure correction factor for a capacity and Ktc is the temperature correction factor for a capacity.

In the context of the present invention, said specific capacity is to be understood as the capacity of the gas generator 1 per cubic meter of adsorbent medium and under nominal conditions of pressure and temperature, such as, for example, and not limited to: a pressure of approximately 7 bar and a temperature of approximately 20 ° C.

Kpc and Ktc are two correction factors that depend on the set value of the second gas component and on the current temperature or pressure, respectively, measured at the generator level.

Said temperature is preferably measured with the help of a temperature sensor T and the pressure is measured with the help of a pressure sensor P.

Preferably, the method according to the present invention further comprises the step of comparing the amount of time that the generator is in the adsorption phase, Atl, with an established minimum time interval, At2.

Where Atl is a counter that preferably starts when the gas generator 1 starts an adsorption cycle and is defined by Atl = tc - ti, where tc is the current time and ti is the initial time.

Preferably, the method comprises the step of resetting the counter when the gas generator 1 initiates an adsorption cycle. More specifically, preferably, the method comprises the step of resetting both tc and ti values when the gas generator 1 initiates an adsorption cycle.

At2 is a counter that preferably starts when the gas generator 1 starts an adsorption cycle and is defined by At2 = td - ti, where td is the minimum amount of time that the gas generator stays in the cycle of adsorption regardless of the values of the other parameters and ti is the initial time when gas generator 1 starts an adsorption cycle.

Preferably, the method comprises the step of resetting the counter when the gas generator 1 initiates an adsorption cycle. More specifically, preferably, the method comprises the step of resetting the value of ti when the gas generator 1 initiates an adsorption cycle and preferably maintains the value of td constant.

After comparing Atl with At2, the method comprises the step of keeping the gas generator 1 in the adsorption phase during said predetermined time interval, As if Atl> At2 and if the determined concentration is greater than or equal to said established value and if the measured outflow is less than the calculated capacity; or keep the gas generator 1 in the adsorption phase for the predetermined nominal cycle time, Aso, and then subject it to a regeneration cycle if Atl <= At2 or if the determined concentration is less than said set value and if the flow of measured output is less than calculated capacity.

Preferably, but not limited to, the first gaseous component is oxygen and the second gaseous component is nitrogen.

The method according to the present invention further comprises the step of directing the inlet gas flow through inlet 5 of at least one container 4, part of generator 1.

Preferably, the method further comprises alternatively directing the inlet gas flow through inlet 5 of at least two vessels 4 (Figure 2) or through at least four vessels 4 (Figure 3) or more.

Because the method comprises the step of alternately directing the inlet gas flow through inlet 5 of two vessels 4 or four vessels 4 or more, the efficiency of the adsorption process increases because, as soon as one vessel is subjected 4 to a regeneration cycle, another container 4 can be used, without interrupting the generation of the second gaseous component at outlet 3 of gas generator 1.

In another embodiment, when a container 4 is subjected to a regeneration cycle, the outgoing gas flow from a container 4 is directed to the inlet 5 of at least one other container 4. Due to this, the container 4 which is in phase The regeneration plant will receive a gaseous mixture at its outlet 6, which will comprise a relatively high concentration of the second gaseous component, said gaseous mixture will push the gaseous content of the container that is regenerating towards the inlet and further towards the external environment through a valve 11 a tap or the like placed at the inlet 5 of the container 4. This allows said container 4 to regenerate in a shorter period of time and better prepares it for the next adsorption cycle.

Another possible step performed by the method according to the present invention is to compare the outflow with the calculated capacity and to maintain the inlet flow for a predetermined time interval if the outflow is greater than a first threshold compared to the calculated capacity. Due to this, optimal operation of the gas generator 1 is applied, further reducing energy consumption.

Preferably, but not limited to, the method uses at least one threshold and further comprises at least one of the following steps:

- maintaining the inflow gas flow for a predetermined nominal time interval, Aso, if the measured outflow is greater than a first threshold when compared to the calculated capacity; or

- maintaining the inlet gas flow for a first predetermined time interval, thus, if the measured outflow is less than said first threshold when compared to the calculated capacity.

Preferably, but not limited to, the method uses one or more set thresholds and further comprises at least one of the following steps:

- maintaining the inflow gas flow for a predetermined nominal time interval, Aso, if the measured outflow is greater than a first threshold when compared to the calculated capacity; or

- maintaining the inflow gas flow for a first predetermined time interval, Aso, if the measured outflow is less than said first threshold when compared to the calculated capacity; or

- maintaining the inflow gas flow for a second predetermined time interval, As2, if the measured outflow is less than a second threshold when compared to the calculated capacity; or

- maintaining the inlet gas flow for a third predetermined time interval, As3, if the measured outflow is less than a third threshold when compared to the calculated capacity.

By applying logic as described above, the efficiency of the system is further increased.

Preferably two or more of the time intervals described above have a different duration when compared to each other.

Preferably, but not limited to, said nominal time interval, Aso, may be a value selected within the range: from 15 to 65 seconds or from 20 to 65 seconds or from 20 to 45 seconds.

Preferably, but not limited to, said first predetermined time interval, Thus, may be a value selected within the range: from 45 to 85 seconds or from 45 to 60 seconds.

Preferably, but not limited to, said second predetermined time interval, As2, may be a value selected within the range: from 60 to 120 seconds or from 60 to 80 seconds.

Preferably, but not limited to, said third predetermined time interval, As3, may be a value selected within the range: from 80 to 300 seconds or from 80 to 180 seconds. In the context of the present invention, it should be understood that the time intervals defined above are merely examples and that other values may also be used.

Preferably, but not limited to, said first threshold may be selected at approximately 80%, said second threshold may be selected at approximately 60%, and said third threshold may be selected at approximately 40%.

In the context of the present invention, it should be understood that the thresholds defined above are merely examples and that other values may also be used.

In another embodiment according to the present invention, the method further comprises at least one of the following steps:

- maintain the inlet gas flow for a predetermined nominal time interval, Ap0, if the measured outflow is greater than or equal to a first threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a first predetermined time interval, Api, if the measured outflow is less than said first threshold when compared to the calculated capacity; or

- maintaining the inflow gas flow for a second predetermined time interval, Ap2, if the measured outflow is less than a second threshold when compared to the calculated capacity; or

- maintaining the inflow gas flow for a third predetermined time interval, Ap3, if the measured outflow is less than a third threshold when compared to the calculated capacity; or

- maintaining the inlet gas flow for a fourth predetermined time interval, Ap4 interval, if the measured outflow is less than a fourth threshold compared to the calculated capacity; or

- maintaining the inlet gas flow for a fifth predetermined time interval, Ap5, if the measured outflow is less than a fifth threshold when compared to the calculated capacity; or

- maintaining the inflow gas flow for a sixth predetermined time interval, Ap6, if the measured outflow is less than a sixth threshold when compared to the calculated capacity; or

- maintaining the inflow gas flow for a seventh predetermined time interval, Ap7, if the measured outflow is less than a seventh threshold when compared to the calculated capacity; or

- maintain the inlet gas flow for an eighth predetermined time interval, Ap8, if the measured outflow is less than an eighth threshold when compared to the calculated capacity; or

- maintain the inlet gas flow for a ninth predetermined time interval, Apg, if the measured outflow is less than a ninth threshold when compared to the calculated capacity.

Preferably two or more of the time intervals described above have a different duration when compared to each other.

Preferably two or more of the time intervals: Aso, Asi, As2, As3 and Api, Ap2, Ap3, Ap4, Aps, Ap Ap9, Celery have a different duration when compared to each other, so that, depending on the flow output and calculated capacity, the adsorbing medium will allow the generator to work under optimal conditions for a different period of time, depending on the threshold reached or not reached.

Preferably, but not limited to, said predetermined nominal time interval, Apo, may be a value selected within the range: between 15 and 50 seconds; said first predetermined time interval, Api, can be a value selected within the interval: between 30 and 60 seconds; the second predetermined time interval, Ap2, can be a value selected within the interval: between 40 and 70 seconds; said third predetermined time interval, Ap3, can be a value selected within the interval: between 50 and 80; said fourth predetermined time interval, Ap4, can be a value selected within the interval: between 60 and 90 seconds; said fifth predetermined time interval, Ap5, can be a selected value within the interval:

between 70 and 100 seconds; said sixth predetermined time interval, Ap6, can be a value selected within the interval: between 80 and 130 seconds; said seventh predetermined time interval, Ap7, can be a value selected within the interval: between 90 and 150 seconds; said eighth predetermined time interval, Ap8, can be a value selected within the interval: between 100 and 200 seconds; and said ninth predetermined time interval, Ap9, can be a value selected within the interval: between 110 and

300 seconds.

In the context of the present invention, it should be understood that the time intervals defined above are merely examples and that other values may also be used.

Preferably, said thresholds and time intervals are calculated based on the type and size of generator 1 and the type and volume of the adsorbent medium.

Preferably, but not limited to, said first threshold may be selected at approximately 90%, said second threshold may be selected at approximately 80%, said third threshold may be selected at approximately 70%, said fourth threshold may be selected at approximately 60%. %, said fifth threshold can be selected at approximately 50%, said sixth threshold can be selected at approximately 40%, said seventh threshold can be selected at approximately 30%, said eighth threshold can be selected at approximately 20% and said ninth threshold is you can select about 10%.

In the context of the present invention, it should be understood that the thresholds defined above are merely examples and that other values may also be used.

Because the method applies such steps, a rapid and precise adaptation of the generation of said second gaseous component is carried out, depending on the demand at output 3 and the risk that the gas generator 1 is oversized or undersized is eliminated for demand. Consequently, the gas generator will operate with optimal parameters over the entire operating range. Another benefit found is the reduced volume of the inlet gas flow.

In the context of the present invention, it should be understood that the number of intervals may vary, for example, from two to twenty or even more, depending on the capabilities of the gas generator and the desired results.

In another embodiment, according to the present invention, the method can be applied continuously, where the cycle times are continuously interpolated between defined set points. Due to this, even higher energy consumption can be measured (Figure 4).

In yet another embodiment, according to the present invention, the method may further comprise the step of maintaining a container 4 in a regeneration cycle for a time interval that depends on the length of the time interval in which said container was kept in an adsorption cycle and / or of the established concentration value for the second gaseous component.

By way of example, but not limited to, when the time interval in which a container 4 is maintained in an adsorption cycle is prolonged, preferably the time interval in which said container 4 is maintained in the cycle of regeneration is also prolonged.

Typically, but not limited to, the nominal time interval in which a container 4 is maintained in a regeneration cycle may be approximately 30 seconds, and such time interval may be prolonged to approximately 60 seconds or more.

Preferably, said regeneration cycle can be carried out through a fixed flow valve or a fixed restrictor such as a nozzle or orifice, or an open / close valve, or said regeneration cycle can be carried out with the help of a capable flow controller. to regulate the volume of gas removed through it.

Since, during the regeneration cycle, both the first gaseous component and the second gaseous component are evacuated from container 4, by prolonging the time interval in which the regeneration cycle is maintained, a greater gas volume comprising a high concentration of the second gaseous component. However, if a flow controller or an open / close valve is used to regulate the time and therefore the total volume of regeneration gas is used, this volume is minimized and the container 4 is prepared to the next adsorption cycle efficiently.

The present invention is further directed to a gas generator 1 comprising at least one container 4 (Figure 1), said container 4 having an inlet 5 and an outlet 6. The gas generator allows a gas mixture to flow through said inlet 5 and by using an adsorbent material (not shown), a first gaseous component is trapped therein and allows a gas flow comprising primarily a second gaseous component to flow through said outlet 6.

The gas generator 1 further comprises a flow meter 7 placed at the outlet 6 of the container.

The gas generator 1 further comprises a module 8 for determining the concentration of said second gaseous component, said module also being placed in the outlet 6 of the container 4.

Preferably, but not limited to, said module 8 measures the concentration of the first gaseous component from the outgoing gas flow and determines the concentration of the second gaseous component by deducting the measured value from 100.

In a preferred embodiment according to the present invention, said first gaseous component is oxygen and said second gaseous component is nitrogen.

Preferably, but not limited to, said module 8 is an oxygen level transmitter, which detects the amount of oxygen in the gas flowing to outlet 6 of a container 4. Said oxygen level transmitter can measure the concentration of oxygen from the exhaust gas stream continuously or with a certain sampling rate.

Said module 8 preferably forms part of the gas generator 1.

The gas generator 1 further comprises a controller unit 9 connected through a wired or wireless connection to the flow meter 7 and to the module 8 to determine the concentration of said second gaseous component, said controller being configured to receive measured values of the flow of exhaust gas and the measured concentration.

The controller unit 9 may further comprise a storage unit for storing said received measured values or may send said values through a wired or wireless connection to an external electronic module.

This wireless connection can be made through a radio signal or a Wi-Fi signal. Preferably, the gas generator 1 comprises a wireless receiver (not shown) to allow a communication.

For the sake of clarity, wired connections have not been included in the drawings.

Furthermore, said controller can receive said measurements immediately as they are made or within a certain time interval. You can also receive all measurement values, or you can receive only one measurement taken after a certain time interval.

Furthermore, these measurements can be carried out continuously or with a determined sampling frequency.

Preferably, said controller unit 9 further comprises a processing unit which is provided with an algorithm configured to: calculate the capacity of the container 4, compare the measured outflow gas flow with the calculated capacity, and compare the determined concentration of said second component gaseous with a set value.

Said capacity of the container 4 should be understood as the maximum volume of the second gaseous component per unit time that can be supplied at outlet 6, under current operating conditions and with the concentration value established for the second gaseous component.

In another preferred embodiment, the time intervals and thresholds previously defined herein are stored within the storage unit. Preferably, such time intervals and thresholds are defined before said gas generator 1 comes into operation.

Preferably, said controller unit 9 is further programmed to maintain the inlet gas flow for a predetermined time interval, As, when said measured concentration is equal to or greater than a set value, and when said measured outlet gas flow is less than the calculated capacity.

In another preferred embodiment according to the present invention, the controller unit 9 is further programmed to maintain the inlet gas flow 5 at the inlet of the container 4 for a predetermined nominal cycle time interval, Aso, and to stop the flow inlet gas after said predetermined nominal cycle time interval, Aso, when said measured concentration is less than the set value.

To prepare vessel 4 for another adsorption cycle, controller unit 9 is further programmed to apply a regeneration cycle to said vessel 4 after said predetermined time interval, As, or after said nominal cycle time interval, Aso , respectively.

For greater efficiency of the adsorption process, the gas generator 1, according to the present invention, preferably comprises at least two containers 4, each of said containers comprising an inlet 5 and an outlet 6 to allow a flow of gas to through them and an adsorbent material (not shown), capable of selectively adsorbing a first gaseous component to form a gaseous mixture and allowing an exhaust gas flow comprising mainly a second gaseous component to flow through said outlet 6.

In a preferred embodiment according to the present invention, each one of said containers 4 comprises a flow meter 7 and a module 8 for determining the concentration of the second gaseous component, placed at outlet 6 of each container.

In another embodiment, according to the present invention, the outlets 6 of all the containers are connected to form a common outlet, and said common outlet further comprises a flow meter 7 and a module 8 for determining the concentration of the second gaseous component.

Preferably, said controller unit 9 is further programmed to selectively provide said inlet gas flow through inlet 5 of any one of at least two vessels 4.

In another preferred embodiment, the container 4 further comprises a valve 10 at the inlet 5 to allow said inlet gas flow to reach the adsorbent medium of said container 4.

Preferably, each of said containers 4 comprises a valve 10 to allow the inlet gas flow to reach the adsorbent medium.

Preferably, said controller unit 9 is programmed to open and close each of said valves 10 whenever the inlet gas flow needs to reach the adsorbent medium of one of said containers 4.

Preferably, but not limited to, the controller unit 9 is programmed to open said valves 10 so that only one container 4 is in the adsorption phase at a time.

Preferably, the controller unit 9 opens the outlet valve 12 simultaneously with the valve 10 of each respective container.

The controller unit 9 preferably recalculates the specific capacity of the generator 1 based on the temperature and pressure measurements made with the temperature sensor T and the pressure sensor P.

The gas generator 1, according to the present invention, may further comprise a bypass connection 11 to allow each of the at least two containers 4 to be vented to the outside environment.

Preferably, said bypass connection 11 can be in the form of a valve or a tap or the like.

Preferably, the controller unit 9 is further programmed to initiate a regeneration cycle for one of the at least two adsorption vessels 4 and to selectively direct the inlet gas flow through one of the at least two other regeneration vessels 4 (Figure 3). This is preferably done with the help of valve 10, placed at the inlet of container 4.

In another embodiment according to the present invention, the controller unit 9 is further programmed to measure a time interval, Atl, in which one of the at least two containers 4 is in the adsorption phase and to compare the measured time interval with an established minimum time interval, At2, and:

- if Atl> At2 and if the measured concentration is equal to or greater than a set value, and when said measured outflow is less than the calculated capacity, then the controller unit 9 maintains the inlet gas flow during said interval of predetermined time, As; or

- if Atl <= At2 and if the measured concentration is equal to or greater than a set value, and when said measured output flow is less than the calculated capacity, then the controller unit 9 maintains the inlet gas during said time interval of predetermined nominal cycle, Aso.

Preferably, but not limited to, each of the at least two vessels 4 comprises an adsorbent medium comprising carbon molecular sieves.

In another preferred embodiment, said inlet gas flow can be provided from an outlet of a compressor unit 12 'and the outlet gas flow can be directed to a user's network 13.

Preferably, but not limited to, said outlet gas flow reaches a nitrogen receptor (not shown) before heading to said user's network 13.

In another embodiment, according to the present invention, the concentration of said second gaseous component is determined after said nitrogen receptor and before the user network 13.

If the determined concentration is less than the set value, the nitrogen receptor is preferably subjected to a wash cycle. During such a wash cycle, the gaseous mixture present within the nitrogen receptor is allowed to reach the outside environment. Preferably, said washing cycle is carried out by opening a valve placed at the outlet of the nitrogen receiver.

In another preferred embodiment according to the present invention, the gas generator 1 further comprises a user interface (not shown) preferably connected to the controller unit 9.

By using said user interface, a user of a gas generator 1 according to the present invention can select different parameters so that the output gas flow corresponds to the requirements of his network, such as a selected parameter of a group comprising: said established value of concentration of the second gaseous component, the energy consumption of the gas generator, the use of a compressor unit or another inlet gas flow generator, the type of adsorption medium used, the number of containers to be used or any combination thereof.

Said user interface may be in the form of a touch screen comprising different options, or in the form of potentiometers that allow the user to select different options, or in the form of manually operated connections, such as valves or levers, that allow the user to configure the gas generator 1 according to of your needs.

Said user interface may form an integral part of the gas generator 1 or it may form part of an external electronic module, communicating with said gas generator 1 through a wired or wireless connection.

Example 1 for the capacity correction pressure factor, Kpc, preferably interpolated according to, but not limited to, the following table:

So, said first established value of concentration refers to said established value of concentration for the second gaseous component, which can be a value selected preferably between 95 and 99.5%.

Said second established value of concentration refers to said established value of concentration for the second gaseous component, which can be a value preferably selected between 99.5 and 99.999%.

Example 2 for the capacity temperature correction factor, Ktc, preferably interpolated according to, but not limited to, the following table:

So, said first established value of concentration refers to said established value of concentration for the second gaseous component, which can be a value selected preferably between 95 and 99.5%.

Said second established value of concentration refers to said established value of concentration for the second gaseous component, which can be a value preferably selected between 99.5 and 99.999%.

The present invention is in no way limited to the embodiments described by way of example and shown in the drawings, but said gas generator can be made with all kinds of variants, without deviating from the scope of the invention.

Claims (24)

1. A method for controlling an adsorption phase of a gas generator (1), said gas generator (1) comprising at least one container (4) comprising an inlet (5) and an outlet (6) to allow a gas flow therethrough and an adsorbent medium capable of selectively adsorbing a first gaseous component of a gaseous mixture and allowing an outgoing gas flow primarily comprising a second gaseous component, said method comprising the steps of: - directing an inlet gas flow through the inlet (5) of said container (4); - measuring the outgoing gas flow at the outlet (6) of said container (4) with a flow meter (7) placed at the outlet (6) of said container (4); - determining a concentration of said second gaseous component at the outlet (6) of said container (4), where the method also includes the steps of: A1) calculating a capacity of the container (4), where the capacity is the maximum volume of the second gaseous component per unit time that can be supplied in a current operating condition and an established value of the concentration of the second gaseous component at the outlet; A2) compare the measured outflow gas flow with the calculated capacity; A3) keep the container (4) in the adsorption phase for a predetermined time interval, As, if the measured outflow gas flow is less than the calculated capacity and if the determined concentration of the second gaseous component in the outlet (6) of the container (4) is greater than or equal to the set value, and subjecting the container (4) to a regeneration cycle after said predetermined time interval, As. 2. The method according to claim 1, further comprising the step of comparing the determined concentration with the established value and if said concentration is below the established value, interrupt the inlet gas flow and subject the container to a cycle of regeneration. The method according to claim 2, further comprising the step of stopping the inlet gas flow after a predetermined nominal cycle time, Aso. 4. The method according to claim 1, wherein the generator capacity is determined based on the following formula: Qcap = Specific capacity x Generator volume x Kpc x Ktc so Kpc is the pressure correction factor for a capacity and Ktc is the temperature correction factor for a capacity. 5. The method according to any of the preceding claims, wherein said method further comprises the step of comparing the amount of time that the container is in the adsorption phase, At1, with an established minimum time interval, At2. 6. The method according to claims 3 and 5, wherein said method comprises one of the following steps: - if Atl> At2 and if the measured outflow is less than the calculated capacity and if the determined concentration is greater than or equal to said set value, then the vessel remains in the adsorption phase during said predetermined time interval, As ; or - if Atl <= At2 or if the determined concentration is less than said set value and if the measured outflow is less than the calculated capacity, then the vessel remains in the adsorption phase for the predetermined nominal cycle time, Aso , and then undergoes a regeneration cycle. 7. The method according to claim 1, wherein the first gaseous component is oxygen and the second gaseous component is nitrogen. The method according to claim 1, further comprising directing the inlet gas flow through the inlet of at least one container, part of the generator. 9. The method according to claim 8, further comprising alternately directing the inlet gas flow through the inlet of at least two vessels. The method according to claim 9, further comprising directing the outgoing gas flow from one container to the inlet of at least one other container during the regeneration cycle. 11. The method according to claim 1, comparing the outflow with the calculated capacity and maintaining the inlet flow for a predetermined time interval if the outflow is greater than a first threshold compared to the calculated capacity. 12. The method according to claim 11, wherein the method further comprises at least one of the following steps: - maintaining the inflow gas flow for a predetermined nominal time interval, Aso, if the measured outflow is greater than a first threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a first predetermined time interval, As1, if the measured outflow is less than said first threshold when compared to the calculated capacity. 13. The method according to claim 11 or 12, wherein the method further comprises at least one of the following steps: - maintaining the inflow gas flow for a predetermined nominal time interval, Aso, if the measured outflow is greater than a first threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a first predetermined time interval, As1, if the measured outflow is less than said first threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a second predetermined time interval, As2, if the measured outflow is less than a second threshold when compared to the calculated capacity; or - maintaining the inlet gas flow for a third predetermined time interval, As3, if the measured outflow is less than a third threshold when compared to the calculated capacity. 14. The method according to claim 11 or 12, wherein the method further comprises at least one of the following steps: - maintaining the inflow gas flow for a predetermined nominal time interval, Apo, if the measured outflow is greater than or equal to a first threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a first predetermined time interval, Ap1, if the measured outflow is less than said first threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a second predetermined time interval, Ap2, if the measured outflow is less than a second threshold when compared to the calculated capacity; or - maintaining the inlet gas flow for a third predetermined time interval, Ap3, if the measured outflow is less than a third threshold when compared to the calculated capacity; or - maintain inlet gas flow for a fourth predetermined time interval, Ap4, interval if the measured outflow is less than a fourth threshold when compared to the calculated capacity; or - maintaining the inlet gas flow for a fifth predetermined time interval, Ap5, if the measured outflow is less than a fifth threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a sixth predetermined time interval, Ap6, if the measured outflow is less than a sixth threshold when compared to the calculated capacity; or - maintaining the inflow gas flow for a seventh predetermined time interval, Ap7, if the measured outflow is less than a seventh threshold when compared to the calculated capacity; or - maintain the inlet gas flow for an eighth predetermined time interval, Ap8, if the measured outflow is less than an eighth threshold when compared to the calculated capacity; or - maintain inlet gas flow for a ninth predetermined time interval, Ap9, if the measured outflow is less than a ninth threshold when compared to the calculated capacity. 15. The method according to claim 12 to 14, wherein two or more of the time intervals have a different duration when compared to each other. 16. A gas generator (1) comprising: - at least one container (4), comprising: an inlet (5) and an outlet (6) to allow a gas flow through it and an adsorbent material capable of selectively adsorbing a first gaseous component of a gaseous mixture and allowing an outlet gas flow mainly comprising a second gaseous component to flow through said outlet (6); - means for providing an inlet gas flow at the inlet of said container; where the device also includes: - a flow meter (7) placed at the outlet (6) of the container (4) to measure an outlet gas flow; - means for determining a concentration (8) of said second gaseous component, placed in the outlet (6) of the container (4); - a controller unit (9) connected to the flow meter (7) and to the means for determining the concentration (8) of said second gaseous component, said controller unit (9) being configured to receive measured values of the outgoing gas flow and of the determined concentration; - said controller unit (9) further comprises a processing unit that is provided with an algorithm configured to: - calculating the capacity of the container (4), where the capacity is the maximum volume of the second gaseous component per unit of time that can be supplied in a current operating condition and an established value of the concentration, - compare the measured output gas flow with the calculated capacity, - comparing the determined concentration of said second gaseous component with the established value, and: said controller unit (9) also being programmed to maintain the inflow gas flow for a predetermined time interval, As, when said determined concentration is equal to or greater than the established value and said measured flue gas flow is less than the calculated capacity, and subjecting container (4) to a regeneration cycle after said predetermined time interval, As. 17. The gas generator according to claim 16, wherein the controller unit is further programmed to maintain the inlet gas flow at the inlet of the container for a predetermined nominal cycle time interval, Aso, and to stop the inlet gas flow after said predetermined nominal cycle time interval, Aso, when said measured concentration is less than the set value. 18. The gas generator according to claim 17, wherein the controller unit is further programmed to apply a regeneration cycle to said container. 19. The gas generator according to claim 16, further comprising at least two containers, each of said containers comprising an inlet and an outlet to allow a flow of gas through them, and an adsorbent material capable of selectively adsorbing a first gaseous component from a gaseous mixture and allowing an outlet gas stream comprising primarily a second gaseous component to flow through said outlet. 20. The gas generator according to claim 19, which is further programmed to selectively provide said inlet gas flow through the inlet of any one of the at least two vessels. 21. The gas generator according to claim 16, further comprising a bypass connection to allow each of the at least two containers to be vented to the outside environment. 22. The gas generator according to claim 19, wherein the controller unit is further programmed to initiate a regeneration cycle for one of the at least two adsorption vessels and to selectively direct the inlet gas flow through one of the at least two other regeneration vessels. 23. The gas generator according to claim 16, wherein the controller unit is further programmed to measure a time interval, At1, wherein one of the at least two vessels is in the adsorption phase and to compare the interval of time measured with a set minimum time interval, At2, and: - if Atl> At2 and if the measured concentration is equal to or greater than a set value and when said measured outflow is less than the calculated capacity, then the controller unit maintains the inlet gas flow during said predetermined time interval , As; or - if Atl <= At2 and if the measured concentration is equal to or greater than a set value and when said measured output flow is less than the calculated capacity, then the controller unit maintains the inlet gas during said cycle time interval default nominal, Aso. 24. The gas generator according to claim 19, wherein each of the at least two containers comprises an adsorbent medium comprising carbon molecular sieves.