Method and apparatus for the cryogenic separation of air

Abstract

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.

Claims

1. A method for 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, said method comprising: compressing feed air in the main air compressor to a first air pressure which is at least 3 bar higher than an operating pressure of the high-pressure column, in order to form a compressed feed air flow, splitting the compressed feed air flow into at least a first air flow and a second air flow, cooling and liquefying or pseudo-liquifying the first air flow at said first air pressure in the main heat exchanger, then expanding said first air flow and introducing said first air flow into the distillation column system, compressing the second air flow in an air post-compressor to a second air pressure which is higher than the first air pressure, to form a compressed second air flow, splitting the compressed second air flow into at least a third air flow and a fourth air flow, further compressing the compressed second air flow, before the compressed second air flow is split, or further compressing the third air flow or the fourth air flow in a post-compression system to a third air pressure which is higher than the second air pressure, wherein the post-compression system has at least one first turbine-driven post-compressor, introducing the third air flow at a first turbine inlet pressure into a first turbine, where the third air flow is expanded, performing work, and then introducing the third air flow into the distillation column system, wherein the first turbine drives the first turbine-driven post-compressor, cooling and liquefying or pseudo-liquifying the fourth air flow, in the main heat exchanger, then expanding said fourth air flow and introducing said fourth air flow into the distillation column system, withdrawing a first product stream from the distillation column system in liquid form, pressurizing the first product stream, in liquid form, to a first elevated product pressure, evaporating or pseudo-evaporating and further heating the first product stream at the first elevated product pressure in the main heat exchanger to form a first compressed gas product and withdrawing the first compressed gas product from the air separation plant, cooling a sixth air flow in the main heat exchanger to a first intermediate temperature, and compressing the sixth air flow in a cold compressor to a fourth air pressure which is higher than the third air pressure, and cooling and liquefying or pseudo-liquifying the sixth air flow at the fourth air pressure in the main heat exchanger, then expanding the sixth air flow and introducing the sixth air flow into the distillation column system, wherein said method has at least a first mode of operation and a second mode of operation, and in both said first mode of operation and said second mode of operation at least one liquid product is produced in the distillation column system and withdrawn in liquid form from the air separation plant, in the first mode of operation the at least one liquid product is withdrawn from the air separation plant in a first amount, in the second mode of operation the at least one liquid product is withdrawn in a second amount, wherein the second amount of the at least one liquid product is 15 to 50% of the first amount of the at least one liquid product, and in the first mode of operation a first amount of the sixth air flow flows through the cold compressor, in the second mode of operation a second amount of the sixth air flow flows through the cold compressor, and the first amount of the sixth air flow is less than the second amount of the sixth air flow.

2. The method according to claim 1, wherein a fifth air flow at the first air pressure is introduced into a second turbine where the fifth air flow is expanded, performing work, wherein the second turbine drives the cold compressor, and the fifth air flow is then introduced into the distillation column system, and wherein in the first mode of operation a first amount of the fifth air flow flows through the second turbine, in the second mode of operation a second amount of the fifth air flow flows through the second turbine, and the first amount of the fifth air flow is less than in the second amount of the fifth air flow.

3. The method according to claim 1, wherein the third air flow is introduced into the first turbine at the third air pressure.

4. The method according to claim 1, wherein the third air flow is expanded in the first turbine to an outlet pressure which is equal to the operating pressure of the high-pressure column.

5. The method according to claim 2, wherein the fifth air flow is expanded in the second turbine to an outlet pressure which is equal to the operating pressure of the high-pressure column.

6. The method according to claim 2, wherein, in the second mode of operation, the fifth air flow is expanded in the second turbine to an outlet pressure which is equal to an operating pressure of the low-pressure column.

7. The method according to claim 1, wherein in both the first and second modes of operation, after expansion, at least one part of at least one of the following air flows is introduced into the high-pressure column: the first air flow, the third air flow, and/or the fourth air flow.

8. The method according to claim 2, wherein, after expansion, at least one part of the fifth air flow is introduced into the high-pressure column.

9. The method according to claim 1, wherein the main air compressor and the air post-compressor are formed by a combined machine with common drive wherein the main compressor is a first set of stages of the combined machine and the air post-compressor is a second set of stages of the combined machine.

10. The method according to claim 1, wherein in the first mode of operation the fourth air flow is introduced into the distillation column system in a first amount and in the second mode of operation the fourth air flow is introduced into the distillation column system in a second amount, and wherein the second amount of the fourth air flow is less than the first amount.

11. The method according to claim 1, wherein, the second mode of operation, the compressed second air flow is split into the third air flow, the fourth air flow, and a seventh air flow, and wherein the seventh air flow is expanded, performing work, in a third turbine and is then introduced into the distillation column system.

12. The method according to claim 11, wherein, in the first mode of operation, the third turbine drives a third turbine-driven post-compressor which is part of the post-compression system.

13. The method according to claim 1, further comprising withdrawing a second product stream flow in liquid form from the distillation column system, pressurizing the second product stream in liquid form to a second elevated product pressure, evaporating or pseudo-evaporating and further heating the second product stream in the main heat exchanger, and then withdrawing the second product stream from the air separation plant, wherein first product stream is withdrawn from a lower region of the low-pressure column, and/or wherein the second product stream is withdrawn from an upper region of the high-pressure column or from a top condenser of the high-pressure column.

14. An air separation plant for cryogenic separation of air comprising: a main heat exchanger, a distillation column system having a high-pressure column and a low-pressure column, a main air compressor for compressing a feed air to form compressed feed air at a first air pressure which is at least 3 bar higher than an operating pressure of the high-pressure column, at least one first passage within said main heat exchanger for cooling a first part of the compressed feed air at the first air pressure in the main heat exchanger, an expansion device for expanding the first part of the compressed feed air, after passage through the main heat exchanger, and a first line for removing the first part of the compressed feed air from the expansion device and introducing the first part of the compressed feed air into the distillation column system, an air post-compressor for post-compressing a second part of the compressed feed air to a second air pressure, a post-compression system for further compressing at least a first part of the second part of the compressed feed air to a third air pressure which is higher than the second air pressure, wherein the post-compression system has at least one first turbine-driven post-compressor, a first turbine for work-performing expansion of a third air flow from a first turbine inlet pressure, wherein the first turbine is coupled to the first turbine-driven post-compressor, at least one second passage within said main heat exchanger for cooling a fourth air flow in the main heat exchanger, an expansion device for expanding cooled fourth air flow and a second line for introducing expanded fourth air flow into the distillation column system, first pipeline means for withdrawing at least one liquid product from the distillation column system, means for pressurizing at least one liquid product in liquid form to a first elevated product pressure, at least one third passage within said main heat exchanger for heating the at least one liquid product at the first elevated pressure in the main heat exchanger, and second pipeline means for withdrawing heated first product flow from the air separation plant to form a first compressed gas product, at least one fourth passage within said main heat exchanger for cooling a sixth air flow in the main heat exchanger to a first intermediate temperature, a cold compressor for further compressing the sixth air flow to a fourth air pressure which is higher than the third air pressure, at least one fifth passage within said main heat exchanger for cooling compressed sixth air flow at the fourth air pressure in the main heat exchanger, an expansion device for expanding the sixth air flow and a third line for introducing the cooled sixth air flow into the distillation column system, and at least one liquid product pipeline for withdrawing the at least one liquid product from the air separation plant, wherein in a first mode of operation a first amount of the at least one liquid product is withdrawn via said at least one liquid product pipeline and in a second mode of operation a second amount of the at least one liquid product is withdrawn via said at least one liquid product pipeline, and wherein the second amount of at least one liquid product is 15 to 50% of the first amount of at least one liquid product, and in the first mode of operation a first amount of the sixth air flow flows through the cold compressor and in the second mode of operation a second amount of the sixth air flow flows through the cold compressor, wherein the first amount of the sixth flow is less than the second amount of the sixth flow.

15. A method for 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, said method comprising: compressing feed air in the main air compressor to a first air pressure which is at least 3 bar higher than an operating pressure of the high-pressure column, in order to form a compressed feed air flow, splitting the compressed feed air flow into at least a first air flow and a second air flow, cooling and liquefying or pseudo-liquifying the first air flow at said first air pressure in the main heat exchanger, then expanding said first air flow and introducing said first air flow into the distillation column system, compressing the second air flow in an air post-compressor to a second air pressure, which is higher than the first air pressure, to form a compressed second air flow, splitting the compressed second air flow into at least a third air flow and a fourth air flow, further compressing the compressed second air flow, before the compressed second air flow is split, or further compressing the third air flow or the fourth air flow in a post-compression system to a third air pressure which is higher than the second air pressure, wherein the post-compression system has at least one first turbine-driven post-compressor, introducing the third air flow at a first turbine inlet pressure into a first turbine, where the third air flow is expanded, performing work, and then introducing the third air flow into the distillation column system, wherein the first turbine drives the first turbine-driven post-compressor, cooling and liquefying or pseudo-liquifying the fourth air flow, in the main heat exchanger, then expanding said fourth air flow and introducing said fourth air flow into the distillation column system, withdrawing a first product stream from the distillation column system in liquid form, pressurizing the first product stream, in liquid form, to a first elevated product pressure, evaporating or pseudo-evaporating and further heating the first product stream at the first elevated product pressure in the main heat exchanger to form a first compressed gas product and withdrawing the first compressed gas product from the air separation plant, cooling a sixth air flow in the main heat exchanger to a first intermediate temperature, and compressing the sixth air flow in a cold compressor to a fourth air pressure which is higher than the third air pressure, and cooling and liquefying or pseudo-liquifying the sixth air flow at the fourth air pressure in the main heat exchanger, then expanding the sixth air flow and introducing the sixth air flow into the distillation column system, wherein said method has at least a first mode of operation and a second mode of operation, and in both said first mode of operation and said second mode of operation at least one liquid product is produced in the distillation column system and withdrawn in liquid form from the air separation plant, in the first mode of operation the at least one liquid product is withdrawn from the air separation plant in a first amount, in the second mode of operation the at least one liquid product is not withdrawn or is withdrawn in a second amount, wherein the second amount of the at least one liquid product is less than the first amount of the at least one liquid product, and in the first mode of operation a first amount of the sixth air flow flows through the cold compressor, in the second mode of operation a second amount of the sixth air flow flows through the cold compressor, and the first amount of the sixth air flow is less than the second amount of the sixth air flow.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention, and further details of the invention, are explained in more detail below with reference to exemplary embodiments represented schematically in the drawings, in which:

(2) FIG. 1 shows a first exemplary embodiment of a system according to the invention with two turbines;

(3) FIGS. 1A and 1B show two variants of FIG. 1;

(4) FIG. 2 shows a second exemplary embodiment with three turbines,

(5) FIGS. 2A and 2B show two variants of FIG. 2;

(6) FIG. 3 shows a third exemplary embodiment in which the turbine-cold compressor combination is also flowed through in the first mode of operation; and

(7) FIGS. 3A and 3B show two variants of FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

(8) The first exemplary embodiment of the invention is first explained below with reference to the first mode of operation, which in this case is configured for maximum liquid production. In this context, air flows only through the lines represented in bold in FIG. 1; in the first mode of operation, the remaining air lines are not flowed through. Atmospheric air 1 (AIR) is drawn in, via a filter 2, by a first set 3a of a main air compressor 3a and is compressed to a first air pressure of preferably 10 bar to 14 bar, for example 11.7 bar. In the concrete example, the main air compressor has four compressor stages. Downstream of the main air compressor 3a, the compressed total air 4 at the first air pressure is treated in a pre-cooling device 5 and then in a purification device 6. The purified total air 7 is split into a first air flow 100 and a second air flow 200.

(9) The first air flow 100 is cooled in a main heat exchanger 8, from the hot to the cold end, and in that context is (pseudo-)liquefied and then expanded in a throttle valve 101 to approximately the operating pressure of the high-pressure column explained below, which is preferably 5 bar to 7 bar, for example 6 bar. The expanded first air flow 102 is fed, via the line 9, to the distillation column system which has a high-pressure column 10, a main condenser 11, which is designed as a condenser-evaporator, and a low-pressure column 12.

(10) The second air flow 200 is post-compressed in an air post-compressor 3b, which in this case is formed by the end stage 3b of a combined machine 3a/3b, and in a first turbine-driven post-compressor 202c to a second air pressure of preferably 20 bar to 25 bar, for example 21.8 bar. The post-compressed second air flow 204 is split into a first and a second part, a third air flow 210 and a fourth air flow 220.

(11) The third air flow 210 is fed to the hot end of the main heat exchanger 8 and is removed again at a first intermediate temperature. The third air flow is fed, at this intermediate temperature and the second air pressure, to a first turbine 202t where it is expanded, performing work, to the operating pressure of the high-pressure column 10, which is 5 bar to 7 bar, for example 6 bar. The first turbine 202t is mechanically coupled to the first post-compressor 202c. The third air flow 211 which has been expanded so as to perform work is introduced into a separator (phase separator) 212 where a small liquid fraction is removed therefrom. It then flows, in purely gaseous form, via the lines 213 and 13 to the sump of the high-pressure column 10. The turbine inlet pressure is in this case equal to the second air pressure.

(12) The fourth air flow 220 is also guided to the hot end of the main heat exchanger 8, but flows through the latter to the cold end and is thereby cooled and (pseudo-)liquefied. It is then expanded in a throttle valve and arrives, via the lines 222 and 9, in the high-pressure column 10.

(13) The air separation plant represented in FIG. 1 also has a second turbine 14t which is coupled to a cold compressor 14c; in the exemplary embodiment, this machine is non-operational in the first mode of operation.

(14) In the distillation column system, the sump liquid 15 of the high-pressure column is cooled in a countercurrent subcooler 16 and is fed via line 17 to an argon part 500 which will be explained later. Thence, it flows in part in liquid form (line 18) and in part in gaseous form (line 19) at the low-pressure column pressure back out and is introduced at a suitable point into the low-pressure column 12. (If no argon part is present, the subcooled sump liquid is immediately expanded to low-pressure column pressure and introduced into the low-pressure column.)

(15) At least part of the liquid air guided via line 9 into the high-pressure column 10 is removed again via line 18, also cooled in the countercurrent subcooler 16 and is fed to the low-pressure column 12 via valve 21 and line 22.

(16) A first part 24 of the gaseous overhead nitrogen 23 of the high-pressure column 10 is introduced into the liquefaction space of the main condenser 11 where it is essentially entirely liquefied. A first part 26 of the liquid nitrogen 25 so obtained is given up to the high-pressure column 10 as recirculation. A second part 27 is cooled in the countercurrent subcooler 16 and is fed via valve 28 and line 29 to the top of the low-pressure column 12. In the first mode of operation, part of this is removed again via line 30 and is obtained as liquid nitrogen product (LIN) and is drawn off from the air separation plant.

(17) From the top of the low-pressure column, in which there prevails a pressure of 1.2 bar to 1.6 bar, for example 1.3 bar, gaseous low-pressure nitrogen 31 is removed, is heated in the countercurrent subcooler 16 and in the main heat exchanger 8 and is drawn off via line 32 as gaseous low-pressure product (GAN). Gaseous impure nitrogen 33 from the low-pressure column is also heated in the countercurrent subcooler 16 and the main heat exchanger 8. The hot impure nitrogen 34 can either be vented into the atmosphere (ATM) via line 35 or can be used, via line 36, as regeneration gas in the purification device 6.

(18) Liquid oxygen is drawn off, via line 37, from the sump of the low-pressure column 12 (specifically from the evaporation space of the main condenser 11). As the case may be, a first part 38 is subcooled in the countercurrent subcooler 16 and is obtained via line 39 as liquid oxygen product (LOX) and is drawn off from the air separation plant. A second part 40 forms the “first product flow”, is raised in a pump 41 to a first product pressure of for example 31 bar is evaporated or pseudo-evaporated at this high pressure in the main heat exchanger 16 and is heated to near ambient temperature. The hot high-pressure oxygen 42 is given off as oxygen-rich first compressed gas product (GOX IC).

(19) A further internal compression product can be obtained from a third part 43 of the liquid nitrogen 25 from the main condenser 11. This is raised as “second product flow” in a pump 44 in liquid form to a second product pressure of for example 12 bar. At this second product pressure, it is evaporated in the main heat exchanger 8 and heated to near ambient temperature. The hot high-pressure nitrogen 45 is then given off at the second product pressure as nitrogen-rich compressed gas product (GAN IC).

(20) If an argon product is required, the air separation plant also has an argon part 500 which functions as described in EP 2447563 A1 and produces a further liquid product in the form of pure liquid argon (LAR) which is drawn off via line 501.

(21) The “first total quantity of liquid products”, which is drawn off from the air separation plant in the first mode of operation, consists in this exemplary embodiment of the flows 30 (LIN), 39 (LOX) and 501 (LAR).

(22) In a second mode of operation, the plant is operated with a reduced “second total quantity of liquid products”. In general, the flow quantity is reduced in at least one of the lines 30 and 39, preferably in both. The operation of the argon part is preferably kept constant, such that the LAR quantity also remains equal. The quantities and pressures of the internal compression products 42, 45 also remain constant.

(23) The total quantity of air is reduced, such that already the first stages 3a of the main air compressor 3a/3b use less energy. In addition, the quantity and pressure of the second partial flow 204 are greatly reduced, such that the end stage 3b of the main air compressor 3a/3b is also under less load. The quantity of air in line 220 which is thus lacking for the internal compression is compensated for by the fact that a third part 230 of the second air flow 204 is raised in the cold compressor 14c to a third, even higher pressure of for example 45 bar and flows through the main heat exchanger as far as the cold end at this very high pressure. The cold pseudo-liquefied third part 232 is expanded in a throttle valve 233 to the high-pressure column pressure and is fed via the lines 234 and 9 to the high-pressure column 10.

(24) The cold compressor 14c is driven by the second expansion turbine 14t, in which a third partial flow 301 of the compressed total air flow 7, as “fifth air flow”, is expanded so as to perform work from the first air pressure to the operating pressure of the high-pressure column 10.

(25) The table below shows, in a concrete numerical example, a comparison between the first and second modes of operation, wherein in this case the second mode of operation is configured as pure gas operation (excluding argon).

(26) TABLE-US-00001 Constant product First mode of Second mode of Product parameters operation operation GOX IC 31 bar and 99.8 mol-% 18000 Nm3/h  18000 Nm3/h  LOX 99.8 mol-% 2000 Nm3/h 0 GAN IC 1 ppm O2 7000 Nm3/h 7000 Nm3/h LIN 1 ppm O2 2000 Nm3/h 0 LAR 1 ppm O2 maximum maximum N2 1 ppm O2 maximum maximum

(27) FIG. 1A differs from FIG. 1 in that the fifth air flow 301 to the second turbine 14t is not at the first air pressure but at the second air pressure downstream of the air post-compressor 3b. The additional power 400 feeds it from the outlet of the air post-compressor 3b to the hot end of the main heat exchanger and further via line 301 to the turbine inlet.

(28) In FIG. 1B, a still higher inlet pressure prevails at the turbine 14t, in that the fifth air flow 401/301 is at the third air pressure downstream of the hot post-compressor 202.

(29) FIG. 2 differs from FIG. 1 by a further turbine-compressor combination 50t/50c which is flowed through only in the first mode of operation. A third turbine 50t then drives a third turbine-driven post-compressor 50c. In the third turbine, a seventh air flow 401, which is formed by a fourth part 401 of the second air flow 204, is expanded so as to perform work. The third turbine 50t is operated with the same inlet and outlet pressures as the first turbine 202t. The expanded seventh air flow 402 is introduced into the separator 212. In the first mode of operation, the post-compressor 50c runs and generates the “third air pressure” in line 204. The two post-compressors 202c and 50c form, in the exemplary embodiment, the “post-compression system”.

(30) In the second mode of operation, the seventh air flow is reduced to zero, and the second air flow flows via a bypass line 51 past the second post-compressor 50c. In this mode of operation, the post-compressor 202c generates the “third air pressure” in lines 51 and 204. The third air pressure is lower in the second mode of operation than in the first mode of operation.

(31) In all exemplary embodiments, an aftercooler is located downstream of each compressor stage for removing the compression heat.

(32) A further difference with respect to FIG. 1 consists, in the embodiment of FIG. 2, in that the turbine inlet pressure at the first turbine 202t (as also at the third 50t) is lower than the second air pressure, because the turbine air (the third and also the seventh air flow) is branched off (line 210x) upstream of the first turbine-driven post-compressor 202c. Such a reduced turbine inlet pressure (which permits a raised level of the second air pressure) can also be used in analogous fashion in FIG. 1.

(33) Of course, in FIGS. 1 and 2, intermediate forms between the first mode of operation and pure gas operation, in which LOX and/or LIN are produced in reduced quantity greater than zero, are also possible; these are then also considered “second mode of operation” within the meaning of the claims. However, in these exemplary embodiments the turbine-cold compressor combination is switched off in the first mode of operation. It is brought into operation only in the second mode of operation.

(34) FIG. 2A differs from FIG. 2 in that the fifth air flow 301 to the second turbine 14t is not at the first air pressure, rather at the second air pressure downstream of the air post-compressor 3b. The additional power 400 feeds it from the outlet of the air post-compressor 3b to the hot end of the main heat exchanger and further via line 301 to the turbine inlet.

(35) In FIG. 2B, the second turbine 14t is omitted. The cold compressor 14c is driven by an electric motor.

(36) In the exemplary embodiment of FIG. 3, the turbine-cold compressor combination is also not switched off in the maximum liquid operation, that is to say in the first mode of operation. FIG. 3 also differs from FIG. 1 by the following method features:

(37) The fourth air flow 210a/220 is already branched off upstream of the first post-compressor 202c and is used as a relatively low-pressure throttle flow.

(38) Equally, the air 230a/230 for the second turbine 14t (the third part of the second air flow) is already branched off upstream of the first post-compressor 202c.

(39) Here, the pressure increase produced by the two turbine-driven post-compressors 202c and 14c is therefore used principally for increasing the pressure in the sixth air flow, which is used as a particularly high-pressure throttle flow. The first turbine 202t is operated at a higher inlet pressure than the second turbine 14t.

(40) With the reduction in liquid production when transitioning from the first to the second operation case, the load on the second turbine 14t is increased and the load on the first turbine 202 is reduced.

(41) Notwithstanding the representation in FIG. 3, the throttle flow 210a and the turbine flow 230a can also be branched off only after the turbine-driven hot post-compressor 202, as is represented in FIG. 1.

(42) In all variants of the invention, the second turbine 14t can also be formed such that it injects not into the high-pressure column 10 but into the low-pressure column 12; by virtue of the correspondingly raised pressure ratio, more energy can be made available for the cold compressor.

(43) FIG. 3A differs from FIG. 3 in that the fifth air flow 301 to the second turbine 14t is not at the first air pressure but at the third air pressure downstream of the hot post-compressor 202c. It is fed via the additional line 301a to the hot end of the main heat exchanger and further via line 301 to the turbine inlet.

(44) In FIG. 3B, the second turbine 14t is omitted. The cold compressor 14c is driven by an electric motor.

(45) The effect of the invention can be further increased by connecting, downstream of the cold compressor 14c, a second cold compressor which can be switched off. This modification can be used in all exemplary embodiments, for example in those of FIGS. 3 and 3B. In the second mode of operation, the flow from the first cold compressor 14c is fed through a second cold compressor before it is fed back into the main heat exchanger. The second cold compressor is driven with an electric motor. In the first mode of operation, the second cold compressor is switched off and the flow from the first cold compressor 14c flows via a bypass line past the second cold compressor.