A moderate pressure air separation unit and air separation cycle is disclosed that provides for up to about 96% recovery of argon and an overall nitrogen recovery of 98% or greater. The air separation is configured to produce a high purity oxygen enriched stream which is used as the refrigerant to condense the argon in the argon condenser, with the resulting vaporized oxygen stream used to regenerate the temperature swing adsorption prepurifier unit. Argon recovery is facilitated with the use of an argon superstaged column.

The distillation column system has a high-pressure column, a low-pressure column, a main condenser and a low-pressure-column top condenser. Feed air is cooled in a main heat exchanger and introduced into the high-pressure column. An oxygen-enriched liquid stream is withdrawn from the high-pressure column and introduced into the low-pressure column. A gaseous nitrogen stream is withdrawn from the high-pressure column, warmed in the main heat exchanger and withdrawn as gaseous pressurized nitrogen product. The high-pressure column has a barrier-plate section arranged immediately above the point at which the feed air is introduced. The oxygen-enriched liquid stream is withdrawn from the high-pressure column above the barrier-plate section. A purge stream is withdrawn below the barrier-plate section. The gaseous nitrogen stream, before being warmed in the main heat exchanger, is warmed in a counter-current subcooler in indirect heat exchange with the oxygen-enriched liquid stream from the high-pressure column.

The distillation column system has a high-pressure column, a low-pressure column, a main condenser and a low-pressure-column top condenser. Feed air is cooled in a main heat exchanger and introduced into the high-pressure column. An oxygen-enriched liquid stream is withdrawn from the high-pressure column and introduced into the low-pressure column. A gaseous nitrogen stream is withdrawn from the high-pressure column, warmed in the main heat exchanger and withdrawn as gaseous pressurized nitrogen product. The high-pressure column has a barrier-plate section arranged immediately above the point at which the feed air is introduced. The oxygen-enriched liquid stream is withdrawn from the high-pressure column above the barrier-plate section. A purge stream is withdrawn below the barrier-plate section. The gaseous nitrogen stream, before being warmed in the main heat exchanger, is warmed in a counter-current subcooler in indirect heat exchange with the oxygen-enriched liquid stream from the high-pressure column.

A nitrogen generating method for producing product nitrogen using a nitrogen generating device comprising a main heat exchanger for cooling feed air, a nitrogen rectification column into which the feed air cooled in the main heat exchanger is introduced, and a nitrogen condenser which condenses a vapour stream fed from the nitrogen rectification column and circulates the same to the nitrogen rectification column, the method including a control step for discharging liquid nitrogen condensed by the nitrogen condenser and stored in a liquid nitrogen buffer, which is provided in an upper gas phase portion of the nitrogen rectification column or separately from the nitrogen rectification column, to a rectification portion of the nitrogen rectification column in response to an increase in an amount of product nitrogen or an increase in a flow rate of the feed air.

A nitrogen liquefier configured to be integrated with an argon and nitrogen producing cryogenic air separation unit and method of nitrogen liquefaction are provided. The integrated nitrogen liquefier and associated methods may be operated in at least three distinct modes including: (i) a nil liquid nitrogen mode; (ii) a low liquid nitrogen mode; and (iii) a high liquid nitrogen mode. The present systems and methods are further characterized in an oxygen enriched stream from the lower pressure column of the air separation unit is an oxygen enriched condensing medium used in the argon condenser.

The invention relates to a method for cooling, purifying and separating a gaseous mixture containing at least one impurity, in which the gaseous mixture is cooled to a temperature no higher than the temperature at which the at least one impurity solidifies in a heat exchanger having cooling passages, the cooling passages being at least partially covered with a coating and/or physically treated and/or chemically treated, the coating and/or the treatment serving to limit or even prevent the solidified impurity from forming and/or adhering to a surface of the passages; at least one portion of the solidified impurity exiting the cooling passages of the heat exchanger is collected; and the gaseous mixture is withdrawn from the heat exchanger.