EP2600089B1 - Method of operation of a cryogenic air separation unit - Google Patents

Method of operation of a cryogenic air separation unit Download PDF

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Publication number
EP2600089B1
EP2600089B1 EP20110306601 EP11306601A EP2600089B1 EP 2600089 B1 EP2600089 B1 EP 2600089B1 EP 20110306601 EP20110306601 EP 20110306601 EP 11306601 A EP11306601 A EP 11306601A EP 2600089 B1 EP2600089 B1 EP 2600089B1
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EP
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Prior art keywords
air
threshold
period
compressed
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP20110306601
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German (de)
French (fr)
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EP2600089A1 (en
Inventor
Jérôme Beauvisage
Shingo Hamashima
Hirofumi Indo
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LAir Liquide SA pour lEtude et lExploitation des Procedes Georges Claude
Original Assignee
LAir Liquide SA pour lEtude et lExploitation des Procedes Georges Claude
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Priority to EP20110306601 priority Critical patent/EP2600089B1/en
Priority to JP2012262485A priority patent/JP2013117371A/en
Publication of EP2600089A1 publication Critical patent/EP2600089A1/en
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Publication of EP2600089B1 publication Critical patent/EP2600089B1/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04763—Start-up or control of the process; Details of the apparatus used
    • F25J3/04866—Construction and layout of air fractionation equipments, e.g. valves, machines
    • F25J3/04951—Arrangements of multiple air fractionation units or multiple equipments fulfilling the same process step, e.g. multiple trains in a network
    • F25J3/04957—Arrangements of multiple air fractionation units or multiple equipments fulfilling the same process step, e.g. multiple trains in a network and inter-connecting equipments upstream of the fractionation unit (s), i.e. at the "front-end"
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04006—Providing pressurised feed air or process streams within or from the air fractionation unit
    • F25J3/04012—Providing pressurised feed air or process streams within or from the air fractionation unit by compression of warm gaseous streams; details of intake or interstage cooling
    • F25J3/04018—Providing pressurised feed air or process streams within or from the air fractionation unit by compression of warm gaseous streams; details of intake or interstage cooling of main feed air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04763—Start-up or control of the process; Details of the apparatus used
    • F25J3/04769—Operation, control and regulation of the process; Instrumentation within the process
    • F25J3/04781—Pressure changing devices, e.g. for compression, expansion, liquid pumping
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04763—Start-up or control of the process; Details of the apparatus used
    • F25J3/04769—Operation, control and regulation of the process; Instrumentation within the process
    • F25J3/04812—Different modes, i.e. "runs" of operation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2205/00—Processes or apparatus using other separation and/or other processing means
    • F25J2205/84—Processes or apparatus using other separation and/or other processing means using filter
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/02—Compressor intake arrangement, e.g. filtering or cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/24—Multiple compressors or compressor stages in parallel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/40—Processes or apparatus involving steps for increasing the pressure of gaseous process streams the fluid being air

Definitions

  • the present invention relates to a method of operation of a cryogenic air separation unit.
  • all the air to be separated by distillation is compressed in a compressor, for example a centrifugal compressor.
  • the compressor is typically designed in order to produce the maximum performance (pressure, flow rate) whatever the climatic conditions are.
  • a compressor will be designed for summer operating conditions (warm air temperature, high relative humidity and high cooling water temperature).
  • the production of gas or liquid from the air separation unit is not required to vary with the climatic conditions.
  • the machine is designed for an extreme environment which is applicable only a few days per year. For the rest of the year, the machine is over performing, and has to be used in reduced mode, therefore far from its optimum operating point.
  • This method uses a main air compressor configuration for reducing the Total Cost of Ownership (TCO) of the air separation unit, for example a single column nitrogen generator.
  • TCO Total Cost of Ownership
  • a process for operating an air separation unit wherein air to be separated in a cryogenic air separation unit is compressed in one of at least two compressors, purified, cooled and separated in the air separation unit to produce a fluid product, each compressor comprising at least two stages and cooling being provided between the stages using at least one stream of cooling water wherein:
  • the air separation unit comprises two main air compressors MAC1, MAC2, a filtration unit 1, a purification unit 15 for removing carbon dioxide and humidity from the air and a cold temperature unit operating at cryogenic temperature and containing a column system.
  • the column system may be a single column nitrogen generator, a double column producing oxygen and/or nitrogen or a triple column.
  • the first main air compressor MAC1 is composed of three stages in series A1, B1, C1. Between each pair of stages, there is a cooler R1, R1' which is cooled using a stream of cooling water W1, W1' There is also a final cooler after stage C1 which is not shown.
  • the second main air compressor MAC2 is composed of three stages in series A2, B2, C2. Between each pair of stages, there is a cooler R2, R2' which is cooled using a stream of cooling water W2, W2'. There is also a final cooler after stage C1 which is not shown.
  • the compressors may contain more or less than three stages.
  • stream 3 is compressed in first main air compressor MAC1 to form first compressed air stream 11.
  • the first compressed air stream 11 is purified in a purification unit 15 and sent as stream 17 to the cold temperature unit 19 to be separated.
  • a product stream of a given quantity is formed.
  • the product stream 21 may be gaseous oxygen or nitrogen or liquid oxygen or nitrogen. Other products may of course be produced.
  • the second main air compressor MAC2 is not used, though it may be capable of being used, for example in the case of breakdown and/or maintenance of the first main air compressor MAC 1.
  • first compressed air stream 7 is purified in the purification unit 15 and sent as stream 17 to the cold temperature unit 19 to be separated. A product stream of a given quantity is formed.
  • the first main air compressor MAC1 is not used, though it may be capable of being used for example in the case of breakdown and/or maintenance of the second main air compressor MAC2.
  • the atmospheric temperature is determined by measuring the temperature of stream 3 and/or stream 5 using element TIC or by measuring the air temperature at some other position (eg in the open air).
  • first or second main air compressor it is also possible to decide whether to use the first or second main air compressor as a function of the degree of humidity.
  • the degree of humidity of the feed air is below a second threshold, only the first main air compressor is used and when the degree of humidity is above that threshold, only the second air main air compressor is used.
  • the degree of humidity may be measured by measuring the humidity of stream 3 and/or stream 5 using element HIC or by measuring the humidity at some other point.
  • a typical value for the humidity threshold might be chosen within the range of 60 to 85%.
  • first or second main air compressor it is also possible to decide whether to use the first or second main air compressor as a function of the cooling water temperature.
  • a third threshold when the temperature of the cooling water is below a third threshold, only the first main air compressor is used and when the water temperature is above that threshold, only the second air main air compressor is used.
  • a typical value for the cooling water temperature threshold might be 20°C.
  • both the air temperature and the water temperature be above certain threshold or that both the water temperature and humidity be above given thresholds, or that all three criteria be above given thresholds, in order to start using the second main air compressor and stop using the first main air compressor.
  • the cooling water temperature may be determined by measuring the temperature of at least one of streams W1, W1', W2, W2' either upstream or downstream of the cooler R1, R1', R2, R2' using element TIC. The cooling water temperature could also be measured in a storage tank for the water.
  • a more sophisticated technique to switch between the compressors could involve calculating a theoretical compressed air flow V for stream 3 or 5, based on the feed air temperature and/or feed air humidity and/or the temperature of the cooling water. This would then be compared with a required air stream R needed to produce a required product stream 21, for example nitrogen. When the deviation between V and R exceeds a given value, the process switches from using first compressor MAC1 to second compressor MAC2.
  • the switch from one compressor to another can of course be done manually.
  • the first air compressor is dimensioned to operate for the maximum volumetric flow possible for temperatures below the first threshold or degrees of humidity below the second threshold or cooling water temperature below the third threshold.
  • the second air compressor is dimensioned for a maximum flow higher than the maximum flow of the first air compressor.
  • the maximum flow for the second air compressor may be at least 10% higher than for the first main air compressor.
  • the second air compressor only operates when the atmospheric temperature is above 35°C, or above 40°C. This may mean that the second air compressor only operates for a few days in the year and the first air compressor operates for all the rest of the year.
  • the first main air compressor may supply all the feed air during the night and the second main air compressor may supply all the feed air during the day.
  • the average daytime temperature is above 35°C whereas at night the temperature can fall to 0°C.
  • the cooling water temperature will also probably vary to a large extent. It will be necessary to determine the optimum cut-off temperature when the first main air compressor stops operating and the second main air compressor comes into operation. In these cases, the degree of humidity may or may not also be taken into account.
  • first main air compressor which operates only for the coldest days in the winter, supplying all the feed air to an air separation unit and a second main air compressor which operates the rest of the time supplying all the feed air instead of the first main air compressor.
  • the process according to the invention allows an overall energy reduction of about 8 ⁇ 10% (depending on the machine size and operating point of use), and a reduction of up to 10 ⁇ 14% of yearly operation cost, including savings in liquid nitrogen, for a plant producing nitrogen, because of reduced plant unavailability. This liquid nitrogen would otherwise have needed to be vaporized to provide the maximum amount of product required. Even though the invention requires extra investment, the estimated reduction of TCO is in the range of 2 ⁇ 5%.
  • the power consumption of the two main air compressors can be optimized, since their aerodynamic performance is designed for different conditions to avoid long term operation at off design point as far as possible.
  • the first main air compressor is designed for normal climatic conditions and the second main air compressor is designed for extreme climatic conditions
  • compressors of the same frame size for the first and second compressor.
  • One of the compressors can then be adapted by altering the aerodynamic design condition and thus a competitive plant power consumption can be proposed.
  • the compressor can be adapted by changing pinion rotors, diffusers and inlet covers only, and the other components and equipment such as scroll, bull gear, gearbox, bearing, seal, gas coolers, main motor, oil system, etc. can remain the same for both the first and second main air compressors.
  • spare parts designed for the extreme climatic condition ofthe second main air compressor may be shared with the first main air compressor.
  • MAC 1 & MAC 2 In addition to MAC 1 & MAC 2, another aerodynamic design components, which designed for different condition aiming at average climatic condition or lower flow rate/wider turn down operation may be available as capital spares to optimize plant operation and power consumption much more based on what is required. Those capital spares can be installed, either on MAC1 or MAC2 which is in stand-by, to be ready for operation without disturbing plant continuous operation.
  • the use of a common filter 1 is not essential.
  • the means for measuring flow and/or humidity and/or temperature may be placed on a common conduit feeding both first and second compresssors MAC1, MAC2.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Separation By Low-Temperature Treatments (AREA)

Description

  • The present invention relates to a method of operation of a cryogenic air separation unit. In such methods, all the air to be separated by distillation is compressed in a compressor, for example a centrifugal compressor. The compressor is typically designed in order to produce the maximum performance (pressure, flow rate) whatever the climatic conditions are. Typically, a compressor will be designed for summer operating conditions (warm air temperature, high relative humidity and high cooling water temperature). Generally, the production of gas or liquid from the air separation unit is not required to vary with the climatic conditions. For geographies where the climatic conditions can vary throughout the year, the machine is designed for an extreme environment which is applicable only a few days per year. For the rest of the year, the machine is over performing, and has to be used in reduced mode, therefore far from its optimum operating point.
  • Accordingly, it is an object of this invention to provide an improved method of operating an air separation unit. This method uses a main air compressor configuration for reducing the Total Cost of Ownership (TCO) of the air separation unit, for example a single column nitrogen generator.
  • According to the present invention, there is provided a process for operating an air separation unit wherein air to be separated in a cryogenic air separation unit is compressed in one of at least two compressors, purified, cooled and separated in the air separation unit to produce a fluid product, each compressor comprising at least two stages and cooling being provided between the stages using at least one stream of cooling water wherein:
    1. i) during a first period, in which the temperature of the air to be compressed is below a first threshold and/or the degree of humidity of the air to be compressed is below a second threshold and/or the temperature of the stream of cooling water is below a third threshold, the air to be separated in the air separation unit is compressed only in a first of the at least two compressors and
    2. ii) during a second period, in which the temperature of the air to be compressed is above the first threshold and/or the degree of humidity of the air to be compressed is above the second threshold and/or the temperature of the stream of cooling water is above a third threshold, the air to be separated in the air separation unit is compressed only in a second of the at least two compressors.
  • According to optional features ofthe invention:
    • during the first period the temperature of the air to be compressed is below the first threshold and during the second period the temperature of the air to be compressed is above the first threshold.
    • during the first period the degree of humidity ofthe air to be compressed is below the second threshold and during the second period the degree of humidity of the air to be compressed is above the second threshold.
    • during the first period, the temperature of the cooling water stream is below the third threshold and during the second period, the temperature of the cooling water stream is above the third threshold.
    • the second compressor is designed to compress a maximum flow of air higher than the maximum flow which the first compressor is designed to compress.
    • the first period designates a number of days in the year and the second period the rest ofthe year.
    • at least part ofthe first period_falls during the night
    • at least part of the second period falls during the day.
    • most or all ofthe first period_falls during the night
    • most of the second period falls during the day
    • during the first period, the second compressor is capable of operating and during the second period, the first compressor is capable of operating.
    • a theoretical value V for the feed air stream is calculated, a value R for the required air stream to produce a required product stream is calculated and when the deviation between R and V exceeds a threshold, the feed air is sent to the second compressor only.
  • The invention will be described in detail with reference to the enclosed figure, showing a method of operating an air separation unit operating according to the invention.
  • The air separation unit comprises two main air compressors MAC1, MAC2, a filtration unit 1, a purification unit 15 for removing carbon dioxide and humidity from the air and a cold temperature unit operating at cryogenic temperature and containing a column system. The column system may be a single column nitrogen generator, a double column producing oxygen and/or nitrogen or a triple column. The first main air compressor MAC1 is composed of three stages in series A1, B1, C1. Between each pair of stages, there is a cooler R1, R1' which is cooled using a stream of cooling water W1, W1' There is also a final cooler after stage C1 which is not shown. The second main air compressor MAC2 is composed of three stages in series A2, B2, C2. Between each pair of stages, there is a cooler R2, R2' which is cooled using a stream of cooling water W2, W2'. There is also a final cooler after stage C1 which is not shown. The compressors may contain more or less than three stages.
  • According to the process, during a first period when the atmospheric temperature is below a first threshold, all the air to be distilled is filtered in filter 1 to form stream 3, stream 3 is compressed in first main air compressor MAC1 to form first compressed air stream 11. The first compressed air stream 11 is purified in a purification unit 15 and sent as stream 17 to the cold temperature unit 19 to be separated. A product stream of a given quantity is formed. The product stream 21 may be gaseous oxygen or nitrogen or liquid oxygen or nitrogen. Other products may of course be produced. When the atmospheric temperature is below the first threshold, the second main air compressor MAC2 is not used, though it may be capable of being used, for example in the case of breakdown and/or maintenance of the first main air compressor MAC 1.
  • During a second period, when the atmospheric temperature is above the first threshold, all the air to be distilled is filtered in filter 1 forming stream 5, stream 5 is compressed in second main air compressor MAC2 to form first compressed air stream 7. The first compressed air stream 7 is purified in the purification unit 15 and sent as stream 17 to the cold temperature unit 19 to be separated. A product stream of a given quantity is formed. When the atmospheric temperature is above the first threshold, the first main air compressor MAC1 is not used, though it may be capable of being used for example in the case of breakdown and/or maintenance of the second main air compressor MAC2. The atmospheric temperature is determined by measuring the temperature of stream 3 and/or stream 5 using element TIC or by measuring the air temperature at some other position (eg in the open air).
  • It is also possible to decide whether to use the first or second main air compressor as a function of the degree of humidity. Thus when the degree of humidity of the feed air is below a second threshold, only the first main air compressor is used and when the degree of humidity is above that threshold, only the second air main air compressor is used. Alternatively, it may be required that both the temperature and the degree of humidity be above certain threshold, in order to start using the second main air compressor and stop using the first main air compressor. The degree of humidity may be measured by measuring the humidity of stream 3 and/or stream 5 using element HIC or by measuring the humidity at some other point. A typical value for the humidity threshold might be chosen within the range of 60 to 85%.
  • It is also possible to decide whether to use the first or second main air compressor as a function of the cooling water temperature. Thus when the temperature of the cooling water is below a third threshold, only the first main air compressor is used and when the water temperature is above that threshold, only the second air main air compressor is used. A typical value for the cooling water temperature threshold might be 20°C.
  • Alternatively, it may be required that both the air temperature and the water temperature be above certain threshold or that both the water temperature and humidity be above given thresholds, or that all three criteria be above given thresholds, in order to start using the second main air compressor and stop using the first main air compressor. The cooling water temperature may be determined by measuring the temperature of at least one of streams W1, W1', W2, W2' either upstream or downstream of the cooler R1, R1', R2, R2' using element TIC. The cooling water temperature could also be measured in a storage tank for the water.
  • A more sophisticated technique to switch between the compressors could involve calculating a theoretical compressed air flow V for stream 3 or 5, based on the feed air temperature and/or feed air humidity and/or the temperature of the cooling water. This would then be compared with a required air stream R needed to produce a required product stream 21, for example nitrogen. When the deviation between V and R exceeds a given value, the process switches from using first compressor MAC1 to second compressor MAC2.
  • The switch from one compressor to another can of course be done manually.
  • The first air compressor is dimensioned to operate for the maximum volumetric flow possible for temperatures below the first threshold or degrees of humidity below the second threshold or cooling water temperature below the third threshold.
  • The second air compressor is dimensioned for a maximum flow higher than the maximum flow of the first air compressor. For example, the maximum flow for the second air compressor may be at least 10% higher than for the first main air compressor.
  • In certain cases, the second air compressor only operates when the atmospheric temperature is above 35°C, or above 40°C. This may mean that the second air compressor only operates for a few days in the year and the first air compressor operates for all the rest of the year.
  • Alternatively, where there is a considerable difference between night temperatures and day temperatures, the first main air compressor may supply all the feed air during the night and the second main air compressor may supply all the feed air during the day. For example, in some countries, the average daytime temperature is above 35°C whereas at night the temperature can fall to 0°C. The cooling water temperature will also probably vary to a large extent. It will be necessary to determine the optimum cut-off temperature when the first main air compressor stops operating and the second main air compressor comes into operation. In these cases, the degree of humidity may or may not also be taken into account.
  • It is of course possible to have a first main air compressor which operates only for the coldest days in the winter, supplying all the feed air to an air separation unit and a second main air compressor which operates the rest of the time supplying all the feed air instead of the first main air compressor.
  • Since both main air compressors operate at their optimal conditions, the process according to the invention allows an overall energy reduction of about 8∼10% (depending on the machine size and operating point of use), and a reduction of up to 10∼14% of yearly operation cost, including savings in liquid nitrogen, for a plant producing nitrogen, because of reduced plant unavailability. This liquid nitrogen would otherwise have needed to be vaporized to provide the maximum amount of product required. Even though the invention requires extra investment, the estimated reduction of TCO is in the range of 2∼5%.
  • According to the invention, the power consumption of the two main air compressors can be optimized, since their aerodynamic performance is designed for different conditions to avoid long term operation at off design point as far as possible.
  • The first main air compressor is designed for normal climatic conditions and the second main air compressor is designed for extreme climatic conditions
  • It is possible to use compressors of the same frame size for the first and second compressor. One of the compressors can then be adapted by altering the aerodynamic design condition and thus a competitive plant power consumption can be proposed.
  • The compressor can be adapted by changing pinion rotors, diffusers and inlet covers only, and the other components and equipment such as scroll, bull gear, gearbox, bearing, seal, gas coolers, main motor, oil system, etc. can remain the same for both the first and second main air compressors.
  • In this case, spare parts designed for the extreme climatic condition ofthe second main air compressor may be shared with the first main air compressor.
  • In addition to MAC 1 & MAC 2, another aerodynamic design components, which designed for different condition aiming at average climatic condition or lower flow rate/wider turn down operation may be available as capital spares to optimize plant operation and power consumption much more based on what is required. Those capital spares can be installed, either on MAC1 or MAC2 which is in stand-by, to be ready for operation without disturbing plant continuous operation.
  • The use of a common filter 1 is not essential. The means for measuring flow and/or humidity and/or temperature may be placed on a common conduit feeding both first and second compresssors MAC1, MAC2.

Claims (9)

  1. Process for operating an air separation unit wherein air to be separated in a cryogenic air separation unit is compressed in one of at least two compressors, purified, cooled and separated in the air separation unit to produce a fluid product, each compressor comprising at least two stages and cooling being provided between the stages using at least one stream of cooling water wherein:
    i) during a first period, in which the temperature of the air to be compressed is below a first threshold and/or the degree of humidity of the air to be compressed is below a second threshold and/or the temperature of the stream of cooling water is below a third threshold, the air to be separated in the air separation unit is compressed only in a first of the at least two compressors (MAC1), and
    ii) during a second period, in which the temperature of the air to be compressed is above the first threshold and/or the degree of humidity of the air to be compressed is above the second threshold and/or the temperature of the stream of cooling water is above a third threshold, the air to be separated in the air separation unit is compressed only in a second (MAC2) of the at least two compressors.
  2. Process according to Claim 1 wherein during the first period the temperature of the air to be compressed is below the first threshold and during the second period the temperature of the air to be compressed is above the first threshold.
  3. Process according to Claim 1 or 2 wherein during the first period the degree of humidity of the air to be compressed is below the second threshold and during the second period the degree of humidity of the air to be compressed is above the second threshold.
  4. Process according to any preceding claim wherein during the first period, the temperature of the cooling water stream is below the third threshold and during the second period, the temperature of the cooling water stream is above the third threshold.
  5. Process according to any preceding claim wherein the second compressor (MAC2) is designed to compress a maximum flow of air higher than the maximum flow which the first compressor (MAC1) is designed to compress.
  6. Process according to any preceding claim wherein the first period designates a number of days in the year and the second period the rest of the year.
  7. Process according to any preceding claim wherein at least part of the first period falls during the night and at least part of the second period falls during the day.
  8. Process according to any preceding claim wherein during the first period, the second compressor (MAC2) is capable of operating and during the second period, the first compressor (MAC1) is capable of operating.
  9. Process according to any preceding claim wherein a theoretical value V for the feed air stream is calculated, a value R for the required air stream to produce a required product stream is calculated and when the deviation between R and V exceeds a threshold, the feed air is sent to the second compressor (MAC2) only.
EP20110306601 2011-12-01 2011-12-01 Method of operation of a cryogenic air separation unit Not-in-force EP2600089B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP20110306601 EP2600089B1 (en) 2011-12-01 2011-12-01 Method of operation of a cryogenic air separation unit
JP2012262485A JP2013117371A (en) 2011-12-01 2012-11-30 Method of operation of cryogenic air separation unit

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP20110306601 EP2600089B1 (en) 2011-12-01 2011-12-01 Method of operation of a cryogenic air separation unit

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EP2600089A1 EP2600089A1 (en) 2013-06-05
EP2600089B1 true EP2600089B1 (en) 2014-09-03

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Publication number Priority date Publication date Assignee Title
MY186128A (en) 2015-06-17 2021-06-24 Nuovo Pignone Tecnologie Srl Method for handling the shutdown of a turbomachine string in a liquefaction plant of a gaseous product
JP7460973B2 (en) 2020-03-05 2024-04-03 日本エア・リキード合同会社 air separation equipment

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH02293575A (en) * 1989-05-08 1990-12-04 Kobe Steel Ltd Air separation device
JP2873473B2 (en) * 1989-11-07 1999-03-24 株式会社大分サンソセンター Air liquefaction separation method
US6116027A (en) * 1998-09-29 2000-09-12 Air Products And Chemicals, Inc. Supplemental air supply for an air separation system
FR2784308B1 (en) * 1998-10-09 2001-11-09 Air Liquide GAS SEPARATION PROCESS AND PLANT WITH PRODUCTION OF A VARIABLE GAS FLOW
JP3492955B2 (en) * 1999-10-12 2004-02-03 株式会社神戸製鋼所 Air separation device and operating method thereof
FR2929385A1 (en) * 2008-03-28 2009-10-02 Air Liquide Air separation apparatus for use with distillation column, has unit sending processed air flows coming from exchangers to average or low pressure column without mixing air flows in downstream of exchangers and in upstream of double column
FR2949846B1 (en) * 2009-09-10 2012-02-10 Air Liquide PROCESS AND PLANT FOR PRODUCING OXYGEN BY AIR DISTILLATION

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EP2600089A1 (en) 2013-06-05

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