A method for starting up an air separation plant having a higher-pressure column, a lower-pressure column, and a falling film vaporizer disposed within a lower section of the lower-pressure column is provided. The method can include the steps of: introducing a cooled and compressed air stream into the higher pressure column; withdrawing an oxygen-enriched liquid stream from a bottom section of the higher-pressure column and introducing said oxygen-enriched liquid stream to an upper section of the lower-pressure column; and exchanging heat between nitrogen gas coming from a top section of the higher-pressure column and liquid oxygen from the lower-pressure column within the falling film vaporizer. During a start-up period, flow of liquid oxygen is at least reduced to the closed core. This reduces the available heat exchange area during start up, which increases ΔT and ΔP in the condenser/reboiler.

A liquefier device which may be a retrofit to an air separation plant or utilized as part of a new design. The flow needed for the liquefier comes from an air separation plant running in a maxim oxygen state, in a stable mode. The three gas flows are low pressure oxygen, low pressure nitrogen, and higher pressure nitrogen. All of the flows are found on the side of the main heat exchanger with a temperature of about 37 degrees Fahrenheit. All of the gasses put into the liquefier come out as a subcooled liquid, for storage or return to the air separation plant. This new liquefier does not include a front end electrical compressor, and will take a self produced liquid nitrogen, pump it up to a runnable 420 psig pressure, and with the use of turbines, condensers, flash pots, and multi pass heat exchangers. The liquefier will make liquid from a planned amount of any pure gas oxygen or nitrogen an air separation plant can produce.

A method for obtaining one or more air products by means of an air separation unit comprising a first booster, a second booster, a first decompression machine, and a rectification column system which has a high-pressure column operated at a first pressure level and a low-pressure column operated at a second pressure level below the first pressure level. All of the air supplied to the rectification column system is first compressed to a third pressure level, which lies at least 3 bar above the first pressure level, as a feed air quantity. A first fraction of the feed air quantity is supplied to a first booster at the third pressure level and at a temperature level of −140 to −70 ° C. and is compressed to a fourth pressure level using the first booster.

Enhancements to a dual column, nitrogen producing cryogenic air separation unit are provided. Such enhancements include an improved air separation cycle that uses multiple condenser-reboilers and recycles a portion of the vapor from one or more of the condenser-reboilers to the incoming feed stream and or the compressed purified air streams to yield improvements in such dual column, nitrogen producing cryogenic air separation units. The multiple condenser-reboilers preferably include an integrated condenser-reboiler arrangement comprising a heat exchanger having a set of nitrogen condensing passages, a first set and second set of boiling passages, and a phase separator.

A method and the apparatus for the cryogenic separation of air in an air separation plant which has a main air compressor, a main heat exchanger and a distillation column system with a high-pressure column and a low-pressure column. All of the feed air is compressed in the main air compressor to a first air pressure which is at least 3 bar higher than the operating pressure of the high-pressure column. A first part of the compressed total air flow, as first air flow at the first air pressure, is cooled and liquefied or pseudo-liquefied in the main heat exchanger, then expanded and introduced into the distillation column system. A second part of the compressed total air flow, as second air flow, is post-compressed in an air post-compressor to a second air pressure and at least part is further compressed in a first turbine-driven post-compressor to a third air pressure.

Enhancements to a dual column, nitrogen producing cryogenic air separation unit with waste expansion are provided. Such enhancements include an improved air separation unit arrangement that uses: (i) three condenser-reboilers; (ii) a reverse reflux stream from the condenser-reboiler associated with the lower pressure column to the higher pressure column; (iii) a waste expansion cycle, and (iv) a recycle stream of a portion of the boil off vapor from one or more of the condenser-reboilers. The improved air separation cycle minimizes the backpressure of the lower pressure column and yields improvements in the nitrogen recovery as well as reductions in unit power consumption compared to conventional dual column, nitrogen producing cryogenic air separation units employing waste expansion.

Enhancements to a dual column, nitrogen producing cryogenic air separation unit are provided. Such enhancements include an improved air separation cycle that uses three condenser-reboilers and recycles a portion of the vapor from one or more of the condenser-reboilers to the incoming feed stream and or the compressed purified air streams to yield improvements in the performance of such dual column, nitrogen producing cryogenic air separation units in terms of overall nitrogen recovery as well as power consumption.

Enhancements to a dual column, nitrogen producing cryogenic air separation unit with waste expansion are provided. Such enhancements include an improved air separation cycle that uses: (i) three condenser-reboilers; (ii) a reverse reflux stream from the condenser-reboiler associated with the lower pressure column to the higher pressure column; and (iii) a recycle stream of a portion of the vapor from one or more of the condenser-reboilers that is recycled back to the incoming feed stream and or the compressed purified air streams to yield improvements in the performance of such dual column, nitrogen producing cryogenic air separation units in terms of overall nitrogen recovery as well as power consumption compared to conventional dual column, nitrogen producing cryogenic air separation units employing waste expansion.

A method and apparatus for transferring a first liquid removed from an outlet of a first distillation column to an inlet of a second distillation column is provided. The second distillation column operates at a higher pressure than the first distillation column, and the inlet of the second distillation column is at higher elevation as compared to the outlet of the first distillation column. The method advantageously transfers the first liquid from the outlet to the inlet by mixing with a sufficient amount of a lower density second liquid that results in a mixed liquid having a reduced density as compared to the first liquid.

A method of efficient cold recovery from a liquid hydrogen stream includes warming a cold liquid hydrogen stream by indirect heat exchange with a cold feed air stream in an ASU sub-cooler, thereby producing a warmed liquid hydrogen stream. Wherein at least a portion of the cool inlet air stream is introduced into a cold booster, thereby producing the compressed cool feed air stream. Wherein at least a first portion of the further cooled feed air stream is introduced into an expander, thereby producing an expanded feed air stream. Wherein a second portion of the further cooled feed air stream is further cooled, thereby producing the cold feed air stream. And, wherein the liquid oxygen stream has a first molar mass flow rate, and the cold liquid hydrogen stream has a second molar flow rate that is between 1.5 and 2.5 times the first molar mass flow rate.