PROCESS FOR SEPARATION OF GASES WITH REDUCED MAINTENANCE COSTS

Abstract

The invention relates to a specific process and apparatus for separation of gas mixtures with reduced maintenance costs.

Claims

1-15. (canceled)

16. A method for separating gases from a crude gas stream comprising at least two components, wherein in an apparatus comprising a feed stream separation stage, a retentate separation stage and a permeate separation stage, each stage being a membrane separation stage with gas separation membranes, a) a feed stream is separated in the feed stream separation stage into a first permeate stream and a first retentate stream, b) the first retentate stream is separated in the retentate separation stage a second permeate stream and a second retentate stream, c) the first permeate stream is separated in the permeate separation stage into a third retentate stream and a third permeate stream, d) the second retentate stream is removed as a first product, e) the third permeate stream is removed as a second product, and f) the second permeate stream and the third retentate stream are combined with the crude gas stream to give the feed stream, and wherein i) the combined gas volume of the second permeate stream and the third retentate stream is from 60 to 200% of the volume of the crude gas stream, ii) the total capacity of the gas separation membranes in the retentate separation stage is higher than the total capacity of the gas separation membranes in the feed stream separation stage, the total capacity being measured for nitrogen Grade 4.8 under standard conditions as defined in the description, and iii) the quotient of the pressure ratio over the permeate separation stage to the pressure ratio over the feed stream separation stage is in a range of from 0.5 to 8.

17. The method of claim 16, wherein the apparatus comprises a compressor arranged up-stream of the feed stream separation stage.

18. The method of claim 16, wherein the apparatus comprises at least one vacuum device arranged in at least one permeate stream of the feed stream separation stage, the retentate separation stage and/or the permeate separation stage.

19. The method of claim 16, wherein the first permeate stream is not subjected to a recompression.

20. The method of claim 16, wherein the ratio of the total capacity of the gas separation membranes in the retentate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 1.05 to 10.

21. The method of claim 20, wherein the ratio of the total capacity of the gas separation membranes in the retentate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 1.5 to 6.

22. The method of claim 16, wherein the ratio of the total capacity of the gas separation membranes in the permeate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 0.5 to 3.

23. The method of claim 22, wherein the ratio of the total capacity of the gas separation membranes in the permeate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 0.8 to 1.

24. The method of claim 16, wherein the combined gas volume recycled with the second permeate stream and the third retentate stream is from 65 to 85% of the volume of the crude gas stream.

25. The method of claim 16, wherein the quotient of the pressure ratio over the permeate separation stage to the pressure ratio over the feed stream separation stage is in a range of from 1 to 3.

26. The method of claim 16, wherein the gas separation membranes in the feed stream separation stage have a pure gas selectivity for CO.sub.2/CH.sub.4 of at least 10.

27. The method of claim 26, wherein the gas separation membranes in the feed stream separation stage have a pure gas selectivity for CO.sub.2/CH.sub.4 of from 20 to 100.

28. The method of claim 16, wherein the gas separation membranes comprise a separation-active layer of a material selected from the group consisting of polyamides, polyetherimides, polyaramides, polybenzoxazoles, polybenzothiazoles, polybenzimidazoles, polysulfones, cellulose acetate, cellulose acetate derivatives, polyphenylene oxides, polysiloxanes, polymers with intrinsic microporosity, mixed matrix membranes, facilitated transport membranes, polyethylene oxides, polypropylene oxides and polyimides.

29. The method of claim 28, wherein the gas separation membranes comprise a separation-active layer of a polyimide consisting of monomer units A and B ##STR00004## with 0≦x≦0.5 and 1≧y≧0.5, wherein each R is an identical or different radical selected from the group consisting of radicals L1, L2, L3 and L4 ##STR00005##

30. The method of claim 28, wherein the gas separation membranes comprise a separation-active layer of a polyimide selected from the group of polyimides with CAS number 9046-51-9 and polyimides with CAS number 134119-41-8.

31. The method of claim 17, wherein the second permeate stream and the third retentate stream are combined with the crude gas stream on the suction side of the compressor.

32. The method of claim 17, wherein the compressor is a multistage compressor and the second permeate stream, the third retentate stream, or both are introduced into the compressor between two compression stages.

33. The method of claim 16, wherein the gas separation membranes are hollow fiber membranes.

34. The method of claim 16, wherein the retentate pressure of the feed stream separation stage and of the retentate separation stage are adjusted with a pressure reducing valve in the second retentate stream to a value of from 1 to 100 bar.

35. The method of claim 34, wherein the retentate pressure of the feed stream separation stage and of the retentate separation stage are adjusted to a value of from 10 to 70 bar.

36. The method of claim 16, wherein the pressure on the permeate side of the feed stream separation stage is adjusted with a pressure reducing valve on the retentate side of the permeate separation stage to a value of from 1 to 30 bar.

37. The method of claim 34, wherein the pressure on the permeate side of the feed stream separation stage is adjusted to a value of from 2 to 10 bar.

38. The method of claim 16, wherein the crude gas stream is selected from the group consisting of biogas, natural gas, air, a gas mixture comprising carbon dioxide and methane, a gas mixture comprising hydrogen and methane, a gas mixture comprising carbon monoxide and methane, a gas mixture comprising helium and methan, a gas mixture comprising helium and nitrogen, a gas mixture comprising hydrogen and carbon monoxide, a gas mixture comprising a permanent gas having a boiling point of less than 110 Kelvin at 1 atm and a non permanent gas having a boiling point above or equal to 110 Kelvin at 1 atm, a gas mixture comprising carbon dioxide and a hydrocarbon, and a gas mixture comprising nitrogen and a hydrocarbon.

39. An apparatus for separating gases from a crude gas stream comprising at least two components, said apparatus comprising a feed stream separation stage, a retentate separation stage and a permeate separation stage, each stage being a membrane separation stage with gas separation membranes, g) the feed stream separation stage separating a feed stream into a first permeate stream and a first retentate stream, h) the retentate separation stage separating the first retentate stream into a second permeate stream and a second retentate stream, i) the permeate separation stage separating the first permeate stream into a third retentate stream and a third permeate stream, j) the second permeate stream and the third retentate stream being combined with the crude gas stream to give the feed stream, and wherein i) the apparatus is configured to adjust the combined gas volume of the second permeate stream and the third retentate stream to from 60 to 200 % of the volume of the crude gas stream, ii) the total capacity of the gas separation membranes in the retentate separation stage is higher than the total capacity of the gas separation membranes in the feed stream separation stage, the total capacity being measured for nitrogen Grade 4.8 under standard conditions as defined in the description, and iii) the apparatus is configured to adjust the quotient of the pressure ratio over the permeate separation stage to the pressure ratio over the feed stream separation stage is in a range of from 0.5 to 8.

40. The apparatus of claim 39, further comprising a compressor arranged up-stream of the feed stream separation stage.

41. The apparatus of claim 39, further comprising at least one vacuum device arranged in at least one permeate stream of the feed stream separation stage, the retentate separation stage and/or the permeate separation stage.

42. The apparatus of claim 39, wherein the ratio of the total capacity of the gas separation membranes in the retentate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 1.05 to 10.

43. The apparatus of claim 42, wherein the ratio of the total capacity of the gas separation membranes in the retentate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 1.5 to 6.

44. The apparatus of claim 39, wherein the ratio of the total capacity of the gas separation membranes in the permeate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 0.5 to 3.

45. The apparatus of claim 44, wherein the ratio of the total capacity of the gas separation membranes in the permeate separation stage to the total capacity of the gas separation membranes in the feed stream separation stage is in a range of from 0.8 to 1.

46. The apparatus of claim 39, configured to adjust the combined gas volume of the second permeate stream and the third retentate stream to from 65 to 85% of the volume of the crude gas stream.

47. The apparatus of claim 39, configured to adjust the quotient of the pressure ratio over the permeate separation stage to the pressure ratio over the feed stream separation stage is in a range of from 1 to 3.

48. The apparatus of claim 39, wherein the gas separation membranes in the feed stream separation stage have a pure gas selectivity for CO.sub.2/CH.sub.4 of at least 10.

49. The apparatus of claim 48, wherein the gas separation membranes in the feed stream separation stage have a pure gas selectivity for CO.sub.2/CH.sub.4 of from 20 to 100.

50. The apparatus of claim 39, wherein the gas separation membranes comprise a separation-active layer of a material selected from the group consisting of polyamides, polyetherimides, polyaramides, polybenzoxazoles, polybenzothiazoles, polybenzimidazoles, polysulfones, cellulose acetate, cellulose acetate derivatives, polyphenylene oxides, polysiloxanes, polymers with intrinsic microporosity, mixed matrix membranes, facilitated transport membranes, polyethylene oxides, polypropylene oxides and polyimides

51. The apparatus of claim 50, wherein the gas separation membranes comprise a separation-active layer of a polyimide consisting of monomer units A and B ##STR00006## with 0≦x<0.5 and 1≧y≧0.5, wherein each R is an identical or different radical selected from the group consisting of radicals L1, L2, L3 and L4 ##STR00007##

52. The apparatus of claim 50, wherein the gas separation membranes comprise a separation-active layer of a polyimide selected from the group of polyimides with CAS number 9046-51-9 and polyimides with CAS number 134119-41-8.

53. The apparatus of claim 39, wherein the second permeate stream and the third retentate stream are combined with the crude gas stream on the suction side of the compressor.

54. The apparatus of claim 39, wherein the compressor is a multistage compressor and the second permeate stream, the third retentate stream, or both are introduced into the compressor between two compression stages.

55. The apparatus of claim 39, wherein the gas separation membranes are hollow fiber membranes.

56. The apparatus of claim 39, further comprising a pressure reducing valve in the second retentate stream configured to adjust the retentate pressure of the feed stream separation stage and of the retentate separation stage to a value of from 1 to 100 bar.

57. The apparatus of claim 56, configured to adjust the retentate pressure of the feed stream separation stage and of the retentate separation stage to a value of from 10 to 70 bar.

58. The apparatus of claim 39, further comprising a pressure reducing valve on the retentate side of the permeate separation stage configured to adjust the pressure on the permeate side of the feed stream separation stage to a value of from 1 to 30 bar.

59. The apparatus of claim 58, configured to adjust the pressure on the permeate side of the feed stream separation stage to a value of from 2 to 10 bar.

Description

List of figures:

[0206] FIG. 1: Illustrative connection arrangement of several membrane modules according to invention

LIST OF REFERENCE NUMERALS

[0207] 1: Feed stream separation stage

[0208] 2: Retentate separation stage

[0209] 3: Permeate separation stage 3

[0210] 4: One-stage or multistage compressor

[0211] 5: Feed stream

[0212] 6: First permeate stream

[0213] 7: First retentate stream

[0214] 8: Second retentate stream

[0215] 9: Second permeate stream

[0216] 10: Third retentate stream

[0217] 11: Third permeate stream

[0218] 12: Optional pressure-reducing valve in the first retentate stream 7

[0219] 13: Optional pressure-reducing valve in the second retentate stream 8

[0220] 14: Optional pressure-reducing valve in the third retentate stream 10

[0221] 15: Vacuum device (not reproduced in the FIGS.

[0222] 16: Mixing chamber (not reproduced in the FIGS.

[0223] 17: Crude gas stream