Air separation equipment

Abstract

This invention provides a distributor module for process technology equipment, particularly for air separation equipment, which can be connected via fluid lines to a main air compressor assembly, at least two adsorbers (each of which can operate in an adsorption phase and a regeneration phase), and a main heat exchanger assembly. The module includes a compressor port, a port pair for each adsorber to be connected, comprising a first adsorber port and a second adsorber port, a first heat exchanger port, a second heat exchanger port, and a residual gas port or residual gas outlet; and valve and baffle assemblies adapted to selectively connect each port pair: in a first state, fluidly connecting the compressor port to the first adsorber port of the port pair and fluidly connecting the second adsorber port of the port pair to the first heat exchanger port; or in a second state, fluidly connecting the second heat exchanger port to the second adsorber port of the port pair and fluidly connecting the first adsorber port of the port pair to the residual gas port or residual gas outlet; wherein the distributor module has a bottom surface, and the height of the distributor module measured perpendicular to the bottom surface is greater than the two lateral dimensions measured parallel to the bottom surface of the distributor module.

Description

Technical Field

[0001] This invention relates to a distributor module for process technology equipment, particularly for air separation equipment, and an air separation device. Prior Technology

[0002] The production of liquid or gaseous air products by separating air at low temperatures in air separation equipment is a known art and is described, for example, in H.-W. Häring (Hrsg.), Industrial Gases Processing, Wiley-VCH, 2006, particularly in section 2.2.5, "Cryogenic Rectification".

[0003] Air separation equipment includes distillation column systems, which are traditionally configured as, for example, two-column systems, particularly the classic Linde two-column system, but can also be configured as three-column or multi-column systems. In addition to distillation columns for obtaining liquid and / or gaseous nitrogen and / or oxygen gases (i.e., nitrogen-oxygen separation distillation columns), distillation columns for obtaining other air components (especially rare gases such as krypton, xenon, and / or argon) can also be installed. The terms "distillation" and "refining," as well as "column" and "column," and the compound terms formed therefrom, are often used synonymously.

[0004] As is known to us, prior art also used the so-called SPECTRA method to perform cryogenic separation of air to provide pressurized nitrogen as the main product, as described in EP 2 789 958 A1 and further patent documents cited in that case. The simplest design is a single-tower method.

[0005] Air separation involves several basic steps, including compression, precooling, purification, cooling, and distillation. For example, compression occurs in a multi-stage turbo compressor with intercooling and recooling capabilities, achieving a pressure of approximately 5 bar or higher. Before compression, dust particles can be removed in a so-called high-pressure filter. Subsequent precooling can be achieved using a water-operated direct-contact cooler, where partial dissolution of water-soluble impurities also occurs. The water used can be further cooled, for example, in a trickle-flow evaporative cooler (Rieselverdunstungskühler) with residual nitrogen from distillation (also known as "cooling nitrogen").

[0006] Pre-cooled air is typically purified or cleaned in an adsorber or molecular sieve adsorber. Moisture, carbon dioxide, and hydrocarbons are removed in these adsorbers. Two (or more) adsorbers are usually provided, operating alternately in the adsorption and regeneration phases to ensure continuous operation of the air separation equipment.

[0007] To facilitate liquefaction, the purified air is cooled to approximately -175°C in one or more main heat exchangers. Cooling is achieved through internal heat exchange with the cold gas stream generated by the equipment in a counter-current flow. At this point, at least residual nitrogen from distillation is typically used; alternatively, a gas with a significantly higher oxygen content than air, up to pure oxygen, may be used. During the subsequent expansion, the air is further cooled and liquefied due to the Joule-Thomson effect. The actual separation (distillation) of the air takes place in the separation columns (distillation towers) of the column system, initially producing an oxygen-rich bottom fraction and a nitrogen-rich top fraction.

[0008] Air separation equipment is typically assembled from prefabricated components. However, this is often problematic because sufficiently qualified assemblers are either unavailable or prohibitively expensive. This is particularly true regarding the connection of the adsorber to the compressor and cooling stages. Therefore, improvements are necessary to make the construction of air separation equipment more reliable and simpler. Summary of the Invention

[0009] According to the present invention, this objective is achieved by a dispenser module having the features of an independent claim and an air separation device; the appendix relates to a preferred embodiment.

[0010] Before describing the features and advantages of the present invention, some basic principles of the present invention will be explained in detail and the terms used below will be defined.

[0011] The apparatus used in the air separation equipment is described in the cited technical literature, for example in section 2.2.5.6 "Apparatus" of the Häring case (see above). In consideration of the conventions of language used within the framework of this application, reference is explicitly made to the cited technical literature where the following definitions are not different.

[0012] In the usage of this case, liquids and gases may be abundant or scarce in one or more components, where "abundant" can mean at least 75%, 90%, 95%, 99%, 99.5%, 99.9%, or 99.99%, and "scarce" can mean a maximum of 25%, 10%, 5%, 1%, 0.1%, or 0.01% molar content, weight content, or volume content. The term "major" is equivalent to the definition of "abundant." Furthermore, liquids and gases may be enriched or depleted of one or more components, where these terms refer to the content in the initial liquid or initial gas used to obtain the liquid or gas.

[0013] Using the initial liquid or gas as a reference, if the liquid or gas contains at least 1.1 times, 1.5 times, 2 times, 5 times, 10 times, 100 times, or 1000 times the content of the corresponding component, it is called "enrichment"; if the liquid or gas contains at most 0.9 times, 0.5 times, 0.1 times, 0.01 times, or 0.001 times the content of the corresponding component, it is called "depletion". For example, when "oxygen", "nitrogen", or "argon" is mentioned, it also refers to a liquid or gas that is rich in oxygen or nitrogen, but is not necessarily composed only of oxygen, nitrogen, or argon.

[0014] This application uses the terms "pressure level" and "temperature level" to characterize pressure and temperature. This is to indicate that, in order to realize the concept of the invention, it is not necessary to use precise pressure and temperature values ​​to describe the corresponding pressure and temperature in the corresponding equipment. However, such pressure and temperature typically fluctuate within a specific range of average values ​​(e.g., 1%, 5%, 10%, or 20%). The corresponding pressure and temperature levels may be in non-overlapping or overlapping ranges. For example, pressure levels specifically include unavoidable or foreseeable pressure losses. The same applies to temperature levels. The pressure levels given herein in bar are absolute pressures.

[0015] When referring to an "expander," it generally refers to a conventional turboexpander. This expander can also be coupled to a compressor, which can be a turbo compressor. The combination of a turboexpander and a turbo compressor is typically called a "turbocharger." In a turbocharger, the turboexpander and turbo compressor are mechanically coupled, which can be achieved at the same speed (e.g., via a common shaft) or at different speeds (e.g., via a separate drive). The term "compressor" is commonly used here. A "cooled compressor" here refers to a compressor that delivers fluids at temperatures well below 0°C, particularly below -50°C, -75°C, or -100°C, and up to -150°C or -200°C. The corresponding fluid flow is cooled to the corresponding temperature level, particularly through a main heat exchanger (see below).

[0016] The "main air compressor" is characterized by compressing all air fed into and separated by the air separator. In contrast, one or more other compressors, such as booster compressors, may be configured as appropriate, but only a portion (or multiples of this portion if the air is recycled) of the air already compressed in the main air compressor is further compressed. Correspondingly, the "main heat exchanger" of the air separator is characterized by cooling most of the air fed into and separated by the air separator. This is carried out wholly or at least partially in the countercurrent flow of the material stream exiting the air separator. In the terminology of this application, the material stream or "product" "extracted" from the air separator in this manner no longer participates in the internal circulation of the equipment, but is instead a fluid continuously extracted from it.

[0017] The "heat exchanger" used within the framework of this invention can employ a conventional design. The heat exchanger is used for indirect heat transfer between at least two fluids, for example, those flowing counter-currently, such as between a hot, pressurized air flow and one or more cold fluids, or between a cryogenic liquid air product and one or more hot or relatively hot, and in some cases still cryogenic, fluids. The heat exchanger can consist of a single heat exchanger section or several parallel and / or series heat exchanger blocks (e.g., one or more plate heat exchanger blocks). For example, there are plate heat exchangers. Such heat exchangers have "channels" consisting of mutually separated fluid channels containing heat exchange surfaces, connected separately and in parallel with other channels to form "channel groups." The characteristic of the heat exchanger is that heat exchange occurs within the heat exchanger between two flow media (i.e., at least one fluid flow to be cooled and at least one fluid flow to be heated) at a given point in time.

[0018] A "condenser-evaporator" refers to a heat exchanger that allows indirect heat exchange between a condensing fluid flow and an evaporating fluid flow. Every condenser-evaporator has a liquefaction chamber and an evaporation chamber. The liquefaction chamber and evaporation chamber have either a liquefaction channel or an evaporation channel. The condensing fluid flow condenses (liquefies) in the liquefaction chamber, and the evaporating fluid flow evaporates in the evaporation chamber. The evaporation chamber and liquefaction chamber are composed of a group of channels that allow for heat exchange between them.

[0019] "Adsorbent" or "molecular sieve adsorbent" specifically refers to a device used to separate gas mixtures. These devices utilize the physical effect of adsorption, where substances or molecules from a gas or liquid aggregate on a solid surface. The adsorbed substances / molecules can then be removed from the solid surface again using purified gas that has passed through the adsorber. In air separation equipment, impurities, particularly H₂O, CO₂, and acetylene, are removed from air compressed by the main air compressor using an adsorber, which is then cooled to a low temperature. Zeolite adsorbers are preferred; these are adsorbers containing zeolite crystals on which the substances to be adsorbed aggregate, with adsorption occurring in pores approximately 1 nm in diameter on the zeolite crystal surface. The zeolite crystals are bound by a ceramic material, forming spherical or rod-shaped elements in the millimeter range.

[0020] Air separation equipment typically includes multiple adsorbers, often two, which operate alternately in adsorption and regeneration phases. In the adsorption phase, air from the main air compressor passes through the adsorber, typically at a pressure level of 5 to 40 bar. The pressure is then reduced to ambient pressure. In the regeneration phase, purified gas (usually dried residual nitrogen drawn from a distillation column and passed through the main heat exchanger) flows counter-currently through the adsorber, including a preheating phase using warm purified gas and a cooling phase using cold purified gas. The pressure level in the adsorber is then raised again to the pressure level of the air from the main air compressor. Adsorption typically occurs at the final pressure of the main air compressor. Regeneration is performed at the lowest possible pressure using dried gas drawn after the adsorber. The use of multiple adsorbers allows for uninterrupted air purification.

[0021] The term "module" should be understood as an assembly formed by interconnected elements fixed within the module. These elements are interconnected through a supporting structure such as a support frame, support shell, or similar structure. That is, a module is a structural unit in which several elements are arranged in a fixed manner. In particular, a module or its elements can be moved as a whole, for example, from the manufacturing site to the construction site.

[0022] The term "fluid connection" refers to a connection made via fluid lines. Fluid can be exchanged between components in a fluid connection.

[0023] The relative spatial terms "above," "below," "above," "below," "above," "below," "beside," "side by side," "vertical," and "horizontal" here refer to the spatial orientation of the distillation columns of an air separation device during normal operation. The arrangement of two distillation columns or other components "stacked" here means that the upper end of the lower component and the lower end of the upper component are at the same or lower ground level, and the projections of the two components in the horizontal plane overlap each other. Specifically, two components can be precisely stacked, meaning that the axes of the two columns extend along the same vertical straight line.

[0024] The distributor module for process equipment according to the invention is connected via fluid lines to a main air compressor assembly, at least two adsorbers (each of which can operate in both adsorption and regeneration phases), and a main heat exchanger assembly, and includes a compressor port, a port pair comprising a first adsorber port and a second adsorber port for each adsorber to be connected, a first heat exchanger port and a second heat exchanger port, and a residual gas port or residual gas outlet; and a valve and baffle assembly. The valve and baffle assembly is adapted (i.e., particularly controllable) to selectively: in a first state of the port pair, fluidly connect the compressor port to the first adsorber port of the port pair and fluidly connect the second adsorber port of the port pair to the first heat exchanger port; or in a second state of the port pair, fluidly connect the second heat exchanger port to the second adsorber port of the port pair and fluidly connect the first adsorber port of the port pair to the residual gas port or residual gas outlet. The distributor module has a bottom surface, and the height of the distributor module measured perpendicular to the bottom surface is greater than the two lateral dimensions of the distributor module measured parallel to the bottom surface. This condition can be stated as follows: the side surface of the smallest possible imaginary cube surrounding the dispenser module is larger than the side / edge of the cube's surface in contact with the floor surface (bottom surface).

[0025] The preferred equipment for this process is an air separation device.

[0026] Valve and baffle assemblies typically include multiple valves and baffles to alternately guide fluid flows (air flow, regeneration gas flow) to the adsorber. Integrating the valve and baffle assembly into a single module facilitates quick and easy assembly. After erecting the distributor module on the base, it is essentially only necessary to connect the ports to other components (main air compressor assembly, adsorber, main heat exchanger assembly) via fluid lines. Due to its relatively large height compared to its lateral dimensions, it occupies a small area within the overall footprint of the process equipment or air separation unit.

[0027] "Bottom surface" refers to the side of the distributor module that contacts the floor surface when the distributor module is installed on the floor surface of a process equipment (especially an air separation unit) for operation; that is, the bottom surface is accordingly set or designed. In other words, after installation, the bottom surface is located at the bottom. The bottom surface is usually not formed by closed sidewalls or similar structures. Instead, it typically has frame elements that can be directly or indirectly anchored to the floor. Lateral dimensions can be, for example, the maximum or average dimension or extension of the distributor module measured parallel to the bottom surface.

[0028] The height is preferably at least 1.5 times larger than the lateral dimension, more preferably at least 2 times larger, even more preferably at least 3 times larger, and most preferably more than 5 times larger. The lateral dimension is preferably one of the following: the maximum dimension of the distributor module parallel to the bottom surface, the average dimension of the distributor module parallel to the bottom surface, or the root of the bottom surface area. Preferably, the height should be at most 5 times the lateral dimension. These relative dimensions or characteristics, taking into account the typical dimensional requirements for valves / baffles and fluid lines, allow the distributor module to have a smaller bottom surface area, thereby indirectly allowing the air separation equipment to have a smaller overall area. At the same time, it facilitates the transport of the distributor module.

[0029] The "height" of the distributor module refers to the vertical dimension measured when the distributor module is in its upright position (during normal operation), corresponding to the "transport length" during horizontal transport. The height direction corresponds to the vertical direction. Similarly, the "lateral dimension" refers to the horizontal dimension measured when the distributor module is in its upright position (i.e., orthogonal to the vertical direction). "Up" and "down," and further, "above" and "below," are defined starting from the bottom surface, meaning the bottom surface is the lower side of the distributor module. That is, the bottom surface extends accordingly in the horizontal direction. As mentioned earlier, a "stacked" arrangement of components means that the upper end of the lower component of two components is located below the lower end of the upper component of two components (at the same or lower ground height in the upright position), and the projections of the two components in the horizontal plane overlap each other. In particular, the two components can be precisely stacked. These components can be device parts of the distributor module, especially device parts of valve and baffle assemblies (such as valves and / or baffles).

[0030] The distributor module preferably includes a regenerated gas heater that is fluidly connected to a second heat exchanger port. The distributor module also preferably includes fluid lines and / or fluid ports for connecting a booster compressor, which is thus fluidly connected to a first heat exchanger port. The regenerated gas heater is specifically designed to heat and is adapted to heat the regenerated gas. Corresponding power supply lines can also be included in the distributor module. These embodiments facilitate further integration, thereby further simplifying assembly. As an alternative or supplement to the regenerated gas heater included in the distributor module, fluid lines and / or fluid ports that can be used to establish fluid connections with external regenerated gas heaters not integrated into the distributor module can also be provided in the distributor module.

[0031] The distributor module preferably includes a control unit suitable for controlling the valve and baffle assembly, wherein a port pair operates according to a first state to operate the adsorber connected to the port pair in the adsorption phase, and according to a second state to operate the adsorber connected to the port pair in the regeneration phase; further preferably, the control unit is configured to control the valve and baffle assembly to alternately operate at least one port pair according to the first state. The control unit is advantageously housed in a housing or container having a passage (in the form of a door). All instruments that transmit signals electrically can be connected to the I / O cards of the process control system, in this case, such I / O cards are also located on the distributor module, thereby improving prefabrication.

[0032] The distributor module preferably includes an instrument air distribution device with instrument air ducts fluidly connected to control ports of valves and / or baffles included in valve and baffle assemblies; more preferably, the distributor module is provided with an I / O card connected to control elements of the instrument air distribution device for data exchange, the control elements being used to operate the instrument air, wherein the I / O card can be connected to data lines, particularly busbars; wherein the control unit is connected to the I / O card via data lines (for data exchange), as appropriate. Valves / baffles included in the distributor module can be pneumatically controlled or moved by the so-called instrument air. The instrument air is directed from the instrument air ducts to the control ports of the valves / baffles. The instrument air distribution device particularly includes operating elements (connected to the instrument air ducts) by which the pressurization of each instrument air duct can be controlled. The operating elements (e.g., valves) can be controlled by electrical operating signals transmitted from the control unit via data lines. Specifically, busbars or field busbars can be used for this purpose. Control systems, including control units or components potentially located on the distributor module, typically have the following structure: a process control system (i.e., control software running on a computer) is connected to an I / O card (input / output card) via a busbar or similar cable. This I / O card, for example, controls operating elements via 4-20 mA signals, which in turn open or close control / instrument air for valves. Conversely, signals and measurements from the operating elements (instruments) are transmitted to the process control system via the I / O card and busbar. The I / O card is preferably located on the distributor module. Preferably, the device for generating instrument air can also be located or installed in the distributor module.

[0033] The distributor module preferably includes one or more measuring devices, particularly temperature measuring devices and / or pressure measuring devices and / or flow measuring devices; wherein, if necessary, the one or more measuring devices (particularly via I / O cards) are connected to the control unit via data lines to transmit the measured values ​​to the control unit. In this way, all the data required for control can be collected and used by the control unit. This further enhances the level of pre-configuration.

[0034] The distributor module preferably includes an exhaust silencer located at the residual gas port or residual gas outlet. The term "residual gas outlet" refers to a component used to discharge residual gas into the environment or atmosphere. If there is excess residual gas that is not needed for adsorber regeneration, this residual gas can also be introduced into an evaporative cooler that uses latent heat of vaporization to cool water. This cooled water can be used to cool the process air before it enters the adsorber during the adsorption stage.

[0035] The distributor module preferably includes a support frame, particularly a steel support frame, on which valve and baffle assemblies, an optional regenerated gas heater, an optional control unit or components thereof, an optional booster compressor, and an optional exhaust muffler are mounted; wherein fluid lines for connecting these components, as well as for connecting the compressor ports, the first and second heat exchanger ports, and the first and second adsorber ports, are also mounted on the support frame. The support frame provides the distributor module with high stability. Advantageously, access passages, such as steps, platforms, and doors, to components of the distributor module can be mounted or installed on the support frame (on the fixing elements provided for this purpose).

[0036] Further preferably, the support frame is substantially cubic (i.e., has a cubic outer contour or a cubic outline) and has a length, width, and depth; wherein the height is equal to the length, and the lateral dimension is equal to the width, depth, or their average; wherein preferably, the width and depth are independently within the range of 3.5 m to 7 m, and preferably, the length is preferably within the range of 10 m to 30 m, further preferably within the range of 15 m to 25 m, and even more preferably within the range of 15 m to 20 m.

[0037] The distributor module is preferably designed such that, when connected to the main air compressor assembly, at least two adsorbers, and the main heat exchanger assembly, it independently directs airflow to each adsorber during its adsorption phase and then directs the airflow from the adsorber to the main heat exchanger assembly after passing through the adsorber; and during the regeneration phase of the adsorber, it directs the regeneration gas flow from the main heat exchanger assembly to the adsorber and then directs the regeneration gas flow to the residual gas outlet after passing through the adsorber. Corresponding control of the valve and baffle assemblies can be achieved by a control device, which may in particular be included in the distributor module.

[0038] Preferably, in the distributor module or valve and baffle assembly, the regulating fittings (i.e., the first valve and / or baffle) that prevent / allow fluid flow from the compressor port to the adsorber or port pair are arranged horizontally or nearly horizontally. The baffles are preferably arranged in a horizontal plane; more preferably, particularly when the baffles are three-bar baffles, these baffles are arranged horizontally or nearly horizontally. The baffles that switch the air path or regeneration gas to the adsorber are preferably designed as horizontally mounted three-bar baffles. The baffles can be arranged in an open state, i.e., the pipeline branches in front of the baffle and has a regeneration gas supply line, or the regeneration gas line branches and only one air line leads to that regeneration gas line, which is distributed only in the tee between the baffles.

[0039] Preferably, in the distributor module or valve and baffle assembly, the second valve and / or baffle that prevents / allows fluid flow between the port pair and the heat exchanger port is arranged in a vertical or near-vertical plane; wherein the second valve and / or baffle is preferably spatially arranged above the first valve and / or baffle. That is, in the distributor module or valve and baffle assembly, the regulating fittings (i.e., valves and / or baffles) that prevent / allow fluid flow to the main heat exchanger assembly and / or the heat exchanger port are preferably arranged in a vertical plane. Here, particularly when the (second) baffle is a three-bar baffle, such baffles may also be arranged horizontally or near-horizontally.

[0040] More preferably, in the distributor module or valve and baffle assembly, the regulating fittings (i.e., valves and / or baffles) that prevent / allow fluid flow to the adsorber or port pair are spatially arranged above or below the regulating fittings (i.e., valves and / or baffles) that prevent / allow fluid flow to the main heat exchanger assembly or heat exchanger port.

[0041] Preferably, the regulating fittings (i.e., valves and / or baffles assigned to both the port pair and the heat exchanger port) are arranged as close as possible to the port pair in the distributor module or valve and baffle assembly.

[0042] Preferably, all adjustment fittings or baffles designed as three-bar baffles are installed in horizontally extending pipelines.

[0043] The distributor module preferably includes or is equipped with a device for reducing the pressure of gaseous oxygen (GOX). Related fire-resistant devices can also be installed on the distributor module.

[0044] The distributor module preferably has a branch that is fluidly connected to the second heat exchanger port. Through this branch, the residual gas line branches off from the main heat exchanger assembly for regenerating the adsorber (i.e., leading to the relevant second adsorber port, and subsequently to the silencer) or for precooling the evaporative cooler.

[0045] The air separation device according to the invention includes a distributor module according to the invention, and further includes a main air compressor assembly connected to the distributor module via fluid lines, at least two adsorbers (each of which can operate in both an adsorption phase and a regeneration phase), and a main heat exchanger assembly. The distributor module preferably also includes one or more process lines from and leading to the main heat exchanger.

[0046] The air separation device preferably further includes a separation column assembly, wherein the main heat exchanger assembly is arranged between the distributor module and the separation column assembly; preferably, the main heat exchanger assembly is installed in the main heat exchanger module, and / or, the separation column assembly is installed in the separation column module. By arranging or placing the main heat exchanger assembly between the distributor module and the separation column assembly, particularly low space requirements can be achieved.

[0047] In air separation equipment, the height of the distributor module is between the heat exchanger height minus 5 m and the heat exchanger height plus 5 m, relative to the heat exchanger height of the main heat exchanger assembly or the main heat exchanger module; wherein the height of the distributor module is preferably greater than the heat exchanger height (i.e., the height of its upper edge in the main heat exchanger module after the heat exchanger is installed).

[0048] During the adsorption phase, the adsorber preferably has a bottom-up flow path, while during the regeneration phase, it preferably has a top-down flow path. That is, the ports of the adsorber are connected to the corresponding ports of the distributor module.

[0049] In air separation equipment, the distributor module is preferably arranged directly adjacent to the main heat exchanger assembly or the main heat exchanger module, with a distance of less than 4 m, more preferably less than 2 m, and most preferably less than 1 m. Larger connecting pipelines (LPGAN, residual gas, etc.) can be laid close to the main heat exchanger module in a plane parallel to the main heat exchanger module.

[0050] In air separation equipment, the adsorber and the distributor module are preferably arranged at the smallest possible distance (measured by the distance from the side wall of the adsorber, such as the container wall, to the distributor module), preferably less than 2 m, and more preferably less than 1 m.

[0051] The air separation equipment preferably includes devices for reducing the pressure of gaseous oxygen (GOX) and / or fire-prevention devices. More preferably, such devices are included in or installed in the distributor module as appropriate.

[0052] The invention will now be explained in more detail with reference to the accompanying drawings, in which preferred designs of the invention are illustrated. Simple Explanation of the Diagram

[0053] [Figure 1] A simplified schematic diagram illustrating an air separation device according to the prior art. [Figure 2A] and [Figure 2B] illustrate a top view and a side view of an air separation device, which includes a distributor module according to an embodiment of the present invention. [Figure 3A] and [Figure 3B] schematically illustrate exemplary layouts of valves and baffles in valve and baffle assemblies. Implementation

[0054] Figure 1 is a simplified schematic diagram illustrating an air separation device according to prior art. The device is generally labeled 100.

[0055] The heat exchanger block 1 may include one or more heat exchangers located in a corresponding refrigeration or cold box (i.e., an insulation wall surrounding the area to be insulated). This heat exchanger block is provided with an airflow (shown in dashed lines) that has previously been compressed in compressor 2 and purified in adsorber unit 3. Additional devices such as filters and precooling units are not shown. Generally, the compressed airflow can be divided into multiple fractions, which are then recompressed to different pressure levels and pass separately through the heat exchanger block (not shown). Adsorber unit 3 typically includes multiple adsors that can operate alternately and be regenerated accordingly.

[0056] In heat exchanger 1, the supplied, compressed, and purified air is cooled in countercurrent flow by cold gaseous enriched nitrogen UN 2 and pure GAN (and possibly other process streams reaching ambient temperature, i.e., enriched UN 2, GAN, GOX IC, GAN IC, etc.) from the top of separation column 5 as described below. At least a portion of the gaseous enriched nitrogen UN 2, after passing through heat exchanger 1 used to cool the purified air, is directed to adsorber unit 3 and used as regeneration gas, which passes through the adsorber during the regeneration phase. Other portions of the cold gaseous nitrogen, not shown here, are available as a product after flowing through the heat exchanger.

[0057] The cooled airflow enters the exemplary intermediate region of the separator column 5 in gaseous or partially liquid form (e.g., through the expansion valve 4), and it is also conceivable that it will enter other regions of the separator column, particularly the lower region. The corresponding equipment may also include recompression of the (fractionated) airflow and cooling in a high-pressure heat exchanger. For clarity, these are also not illustrated. In the case of multiple air fractions, these air fractions may (after expansion by a turbine, as appropriate) at least partially enter different regions of the separator column. As mentioned earlier, as an alternative to the single separator column 5 shown in Figure 1, multiple separator columns in series, twin towers, and similar columns may also be used.

[0058] When separating liquefied air, the different boiling points of its components are utilized. For this purpose, liquid air drips down through a number of simplified sieves in separation column 5, forming a countercurrent with the rising unliquefied air. Liquid accumulates on the sieves and is passed through by rising vapor bubbles. Primarily, the higher-boiling-point oxygen liquefies from the gas stream, while the lower-boiling-point nitrogen evaporates from the droplets. For this reason, gaseous nitrogen (GAN) accumulates at the cooler top of separation column 5, while liquid oxygen (LOX) accumulates at the warmer bottom.

[0059] To further purify the fraction, liquid oxygen (LOX) from the bottom of separation column 5 is evaporated in evaporator 6, and gaseous nitrogen is liquefied in the so-called top condenser 7. The evaporated gaseous oxygen (LOX) and liquefied nitrogen (LIN) are then fed back to separation column 5, where repeated distillation is performed until the desired purity is achieved.

[0060] Fluid of appropriate purity can be extracted from the bottom or top of separation column 5 and stored in liquid tanks 8 and 9 for further use.

[0061] Further extraction, such as an oxygen / argon mixture (O / Ar), can be performed from separation column 5. High-purity argon can then be obtained from this mixture in a separate process conducted in another column. Separate columns are also required to obtain inert gases such as xenon, krypton, helium, and / or neon.

[0062] To cool the newly drawn-in air (see above), a portion of the acquired nitrogen (GAN) is extracted and fed back to heat exchanger 1 in the manner described above, at least a portion of which can be used as regeneration gas after flowing through the heat exchanger.

[0063] Figures 2A and 2B show a top view (Figure 2A) and a side view (Figure 2B) of an air separation device 200, in which a distributor module 20 according to an embodiment of the present invention is provided.

[0064] The illustrated air separation unit 200 comprises multiple modules, which facilitates a high degree of prefabrication. In addition to the distributor module 20, it includes a main compressor module 22, a main heat exchanger module 24, and a separation column module 26. Furthermore, the air separation unit includes two adsors 28 and 29. The components of the air separation unit 200 are arranged on a floor surface 30, such as a concrete slab. For clarity, support frames or pillar structures that may be required for the adsors and main heat exchanger modules, such as those shown in Figure 2B, are not illustrated, but are certainly available. In addition to the distributor module 20, as an alternative to the main compressor module, main heat exchanger module, and separation column module, a non-modular structure consisting of individual components that are not connected as modules and are at least partially independent of each other can be provided. Accordingly, as alternatives to the main compressor module, main heat exchanger module, and separator module, the main compressor assembly, main heat exchanger assembly, and separator assembly can be arranged more generally and independently, each including the same functional elements as the corresponding modules, wherein these functional elements are simply not connected into a module. The following embodiments are also applicable to the corresponding assemblies rather than modules.

[0065] The support frame, which may be needed to mount or secure the dispenser module, is not shown in the figure.

[0066] The main compressor module 22 draws in air 32 from the environment or atmosphere and compresses it (e.g., to a pressure in the range of 4-30 bar). In addition to the main compressor, which is symbolically illustrated, the main compressor module 22 typically includes a filter for filtering the intake air before compression and a cooling device for recooling the compressed air (e.g., cooling to approximately 20°C, not shown). Water can be used for this purpose, where cooling is achieved through contact cooling and / or evaporative cooling. One or more main compressor modules or main compressor assemblies may be provided. The air is typically cooled after the last compressor stage and before entering the distributor module, for example, in a recooler, using refrigeration equipment or a direct contact cooler.

[0067] Compressed air is directed to distributor module 20 via a fluid line called compressor line 34. The distributor module then directs the air into a fluid line called first adsorber lines 46 and 47, which leads to the adsorber in the adsorption stage. After passing through the adsorber, the purified air returns to distributor module 20 via another fluid line called second adsorber lines 48 and 49, and is then directed into a fluid line called first heat exchanger line 36, which connects to main heat exchanger module 24. In principle, if the air has already been divided into multiple fractions in the distributor module, multiple first heat exchanger lines and corresponding ports can be provided in the distributor module.

[0068] The main heat exchanger module 24 includes, for example, a main heat exchanger arranged in a refrigeration box or cold box, in which compressed, purified air is cooled in countercurrent flow by one or more cold fluid flows from the separation column module 26. Possible cold fluid flows are gaseous nitrogen (e.g., UN 2 and / or GAN) and gaseous oxygen (GOX). One of these cold fluid flows, preferably gaseous nitrogen-enriched UN 2, is directed from the main heat exchanger module 24 as a regeneration gas to the distributor module 20 via a fluid line referred to as the second heat exchanger line 38.

[0069] Even without detailed illustrations, multiple fluid lines are typically provided for this purpose (i.e., for various cold fluid flows) from the main heat exchanger module to the distributor module. Examples include a second heat exchanger line 38 for gaseous enrichment of nitrogen UN 2 and another fluid line (not shown) for gaseous pure nitrogen GAN. In this case, in addition to the second heat exchanger port 68 (see below), other ports can be provided in the distributor module to establish fluid connections with these fluid lines from the main heat exchanger module. Fluid lines connected to these ports can be provided in the distributor module to further deliver various fluid flows from the main heat exchanger module. In particular, fluid lines and devices (valves, ports) connected to these ports can be provided to enable the discharge of one or more fluid flows (e.g., as product flows), for example, to discharge gaseous pure nitrogen GAN as a product.

[0070] Compressed, purified, and cooled air is directed from the main heat exchanger module 24 to the separation column module 26 via at least one fluid line 40. Air separation occurs in the separation column module, where the air is separated into various air components (as described above with reference to Figure 1). For this purpose, the separation column module 26 includes one or more separation columns, for example, arranged in a refrigeration chamber or cold box. If multiple air fractions are cooled by the main heat exchanger module, multiple fluid lines can be correspondingly provided between the main heat exchanger module and the separation column module.

[0071] One or more cold fluid flows from the separation column module 26 are directed to the main heat exchanger module 24 by at least one fluid line 42. The fluid lines and / or containers that may be for liquid products and / or gaseous products (i.e., the separated air components) are not shown in Figures 2A and 2B.

[0072] The regenerated gas supplied by the main heat exchanger module 24 through the fluid line (second heat exchanger line) 38 is introduced by the distributor module into the fluid line (second adsorber line) leading to the adsorber in the regeneration stage. The regenerated gas returning from the adsorber to the distributor module 20 through another fluid line (first fluid line) is discharged into the environment as residual gas through the residual gas outlet 44.

[0073] The distributor module 20 has a bottom surface 21 and is vertically arranged on the floor surface 30 with this bottom surface. The vertical dimension or height H of the distributor module (i.e., the dimension of the distributor module 20 perpendicular to the bottom surface 21) is greater than the horizontal dimension of the distributor module (i.e., the dimension of the distributor module 20 parallel to the bottom surface 21). For example, the largest dimension parallel to the bottom surface can be used as the horizontal dimension. The average dimension parallel to the bottom surface can also be used as the horizontal dimension. The root of the bottom surface area can also be used as the horizontal dimension. When the distributor module (as shown) is basically cubic, that is, the bottom surface forms a rectangle with a depth T and a width B, for example, the larger of the width B and the depth T, or the average of the width B and the depth T, can be used as the horizontal dimension.

[0074] The height H of the distributor module is preferably at least 1.5 times, more preferably at least 2 times, and even more preferably at least 3 times, the lateral dimension of the distributor module. The advantages of a distributor module with this feature are twofold: firstly, the components of the distributor module can be arranged vertically within the module, resulting in a smaller footprint compared to a horizontal arrangement, thus keeping the overall area of ​​the air separation equipment relatively small. Secondly, it is possible to transport the distributor module horizontally from the manufacturing equipment to the air separation equipment (more precisely, to the construction site of the air separation equipment) via road. Furthermore, the piping and ports used to connect the heat exchanger module and the vertical distributor module are much shorter and integrated into the distributor module, eliminating the need for on-site installation.

[0075] For example, the lateral dimension can be in the range of 3 m to 7 m, preferably in the range of 3.5 m to 6 m, and the height H can be greater than 10 m, preferably in the range of 10 m to 30 m, further preferably in the range of 15 m to 25 m, and even more preferably in the range of 15 m to 20 m. When the distributor module is cubic, the depth T and width B can each be independently within the above-mentioned ranges regarding the lateral dimension (i.e., in the range of 3 m to 7 m, preferably in the range of 3.5 m to 6 m). For example, the height H of the distributor module (corresponding to the transport length in horizontal transport) can be approximately 23 m, the depth T (corresponding to the transport width) can be approximately 5.2 m, and the width B (corresponding to the transport height) can be approximately 4.8 m.

[0076] The distributor module 20 includes fluid ports for connecting to the fluid lines mentioned above. Specifically, it provides the following fluid ports: a compressor port 60 for connecting to compressor line 34; first adsorber ports 62 and 63 for connecting to first adsorber lines 46 and 47 for each adsorber; second adsorber ports 64 and 65 for connecting to second adsorber lines 48 and 49 for each adsorber; a first heat exchanger port 66 for connecting to first heat exchanger line 36; a second heat exchanger port 68 for connecting to second heat exchanger line 38; and a residual gas port 70 for connecting to residual gas outlet 44. There may also be other ports for connecting to evaporative coolers and / or for connecting or discharging products such as GAN, PGAN, GAN IC, GOXIC, and GOX. First adsorber ports and second adsorber ports assigned to the same adsorber form a port pair (46, 48 and 47, 49). If the residual gas outlet is preferably integrated into the distributor module, the residual gas port can be omitted. If two or more (main) heat exchangers are included in a main heat exchanger module (refrigeration box or cold box), the process lines may lead separately to the distributor module and be merged or converged there, or they may have already converged in a separate module arranged on or integrated into the main heat exchanger module.

[0077] The distributor module 20 includes a valve and baffle assembly 50, wherein the aforementioned ports are independently included in or connected to the valve and baffle assembly 50 via fluid lines. The valve and baffle assembly 50 includes valves and / or baffles that can be controlled to selectively operate each connected adsorber or port pair connected to the adsorber (port pairs assigned to the adsorber) in a first state and a second state. In the first state, the compressor port is fluidly connected to the first adsorber port, and the second adsorber port is fluidly connected to the first heat exchanger port; that is, airflow from the main compressor module is first introduced into the adsorber (in the adsorption stage) and then directed to the main heat exchanger module. In the second state, the second heat exchanger port is fluidly connected to the second adsorber port, and the first adsorber port is connected to the residual gas port or residual gas outlet; that is, regeneration gas flow from the main heat exchanger module is first introduced into the adsorber (in the regeneration stage) and then discharged into the environment. In this way, the adsorber can operate alternately in the adsorption and regeneration stages without interrupting the operation of the air separation equipment.

[0078] This arrangement of valves and baffles is known to those skilled in the art (see, for example, H.-W. Häring (ed.), Industrial Gases Processing, Wiley-VCH, 2006, particularly Figure 2.3A). However, according to the present invention, the valves and baffles are arranged in the distributor module. For completeness, Figures 3A and 3B show the corresponding valve and baffle assemblies, with each relevant port marked with a symbol. Figure 3A shows the arrangement of valve 90 and baffle 92 (which may be referred to as the first valve and / or baffle) connecting the first adsorber ports 62, 63 to the compressor port 60 and the residual gas port 70 (only a portion of which is marked with symbols), and Figure 3B shows the arrangement of valve / baffle (which may be referred to as the second valve and / or baffle) connecting the second adsorber ports 64, 65 to the first heat exchanger port 66 and the second heat exchanger port 68. It should be noted that the port positions shown in the figures are only illustrative and may not necessarily correspond to actual locations. Therefore, the different positions shown in Figures 3A and 3B compared to Figures 2A and 2B are merely for illustrative purposes. The valve / baffle in Figure 3A is preferably positioned on a horizontal plane; the valve / baffle in Figure 3B is preferably positioned on a vertical plane. The valve / baffle in Figure 3B is preferably positioned above the valve / baffle in Figure 3B.

[0079] The distributor module 20 preferably includes a regeneration gas heater 52 to heat the regeneration gas during the preheating stage of the adsorber regeneration phase. The regeneration gas heater is connected to the second heat exchanger port 68, positioned between the second heat exchanger port and the valve and baffle assembly 50, and connected to the latter via a fluid line. Alternatively, the regeneration gas heater can be placed adjacent to the distributor module. However, integration into the distributor module 20 is advantageous because it further enhances prefabrication.

[0080] Preferably, the residual gas outlet 44 can also be integrated into the distributor module. In particular, an exhaust muffler (not shown in the figure) can be installed on the residual gas outlet and the distributor module.

[0081] If the intention is to split the compressed, purified airflow from one of the adsorbers into multiple air fractions, and / or to recompress the airflow or air fractions, the corresponding fluid lines and valves, and / or possibly a compressor, can be installed in the distributor module. This also applies to all fluid lines from the heat exchanger that deliver the product (N₂, argon, O₂) via fluid lines and devices (valves, ports) integrated into the distributor module. Preferably, shut-off valves, flow and temperature measuring devices, and ports for further connection to the end user (via connecting bridges, etc.) are also located on the distributor module.

[0082] 1: Heat exchanger block 2: Compressor 3: Adsorber device 4: Expansion valve 5: Separation column 6: Evaporator 7: Top condenser 8,9: Liquid tanks 20: Distributor Module 21: Bottom 22: Main compressor module 24: Main heat exchanger module 26: Separation column module 28, 29: Adsorber 30: Floor surface 32: Air 34: Compressor Piping 36: First heat exchanger pipeline 38: Second heat exchanger pipeline; fluid pipeline 40, 42: Fluid pipelines 44: Residual Gas Outlet 46, 47: First Adsorber Piping 48, 49: Second Adsorber Piping 50: Valve and baffle assembly 52: Regenerated Gas Heater 60: Compressor port 62, 63: First Adsorber Port 64, 65: Second Adsorber Port 66: First heat exchanger port 68: Second heat exchanger port 70: Residual Gas Port 90: Valves 92: Baffle 200: Air separation equipment B: Width H: Height T: Depth

Claims

1. An air separation device (200), comprising: - Distributor module (20); - Main air compressor assembly (22); at least two adsorbers (28, 29), each of which can operate in both adsorption and regeneration phases; and - main heat exchanger assembly (24), - wherein the distributor module (20) is connected to the main air compressor assembly (22) via a fluid line, which is connected to the at least two adsorbers (28, 29) and the main heat exchanger assembly (24), and - having a compressor port (60), a port pair including a first adsorber port (62, 63) and a second adsorber port (64, 65) for each adsorber to be connected, and a first heat exchanger end The port (66) and the second heat exchanger port (68) and the residual gas port (70) or residual gas outlet (44); and a valve and baffle assembly (50) adapted to selectively: - in a first state of the port pair, fluidly connect the compressor port (60) to the first adsorber port (62, 63) of the port pair and fluidly connect the second adsorber port (64, 65) of the port pair to the first heat exchanger port (66), and - in a second state of the port pair, fluidly connect the second heat exchanger port (68) to the second adsorber port (64, 65) of the port pair. The first adsorber port (62, 63) of the port pair is fluidly connected to the residual gas port (70) or residual gas outlet (44); - wherein the distributor module has a bottom surface (21), and the height (H) of the distributor module measured perpendicular to the bottom surface is greater than the two lateral dimensions (T, B) of the distributor module measured parallel to the bottom surface, and - wherein in the distributor module or the valve and baffle assembly, the first valve and / or baffle that prevents / allows fluid flow to the adsorbers or the port pair is arranged horizontally or nearly horizontally, that is, the port lines to which the corresponding valves are connected are arranged horizontally or near horizontally. The arrangement is nearly horizontal; - wherein in the distributor module or the valve and baffle assembly, the second valve and / or baffle that prevents / allows fluid to flow between the port pair and the heat exchanger ports is arranged in a vertical or nearly vertical plane, i.e., the port line to which the corresponding valve is connected is arranged in a vertical or nearly vertical plane; - wherein the second valve and / or baffle is preferably spatially arranged above the first valve and / or baffle; and wherein - the height (H) of the distributor module (20) is between the heat exchanger height minus 5 m and the heat exchanger height plus 5 m relative to the heat exchanger height of the main heat exchanger assembly (24) or the main heat exchanger module.

2. The air separation device of claim 1, wherein the height (H) is at least 1.5 times larger than the lateral dimensions (T, B), preferably at least 2 times larger.

3. The air separation device as claimed in claim 1 or 2, wherein the lateral dimensions (T, B) of the distributor module are one of the following dimensions: - the maximum dimension of the distributor module parallel to the bottom surface (21), - the average dimension of the distributor module parallel to the bottom surface, - the root of the area of ​​the bottom surface.

4. The air separation device as claimed in claim 1 or 2, wherein the distributor module has ports (66, 68) that can be connected to the hot end of the main heat exchanger assembly (24) via fluid lines (36, 38), wherein the ports (66, 68) are arranged in the upper third of the height of the distributor module.

5. The air separation device as claimed in claim 1 or 2, wherein the distributor module has a port (60) that can be connected to the main air compressor assembly via a fluid line (34), wherein the port is arranged in the upper third of the height of the distributor module.

6. The air separation device as requested in item 1 or 2, wherein the first baffle and / or the second baffle, especially when designed as a three-bar baffle, are arranged horizontally or nearly horizontally, i.e., the port lines to which the corresponding valves are connected are arranged horizontally or nearly horizontally.

7. The air separation device as claimed in claim 1 or 2, including a regenerated gas heater (52) in fluid connection with the second heat exchanger port (68).

8. The air separation device as claimed in item 1 or 2, including an exhaust silencer disposed at the residual gas port (70) or the residual gas outlet (44).

9. The air separation device as claimed in claim 1 or 2, including a support frame, particularly a steel support frame, on which the valve and baffle assembly and / or the regenerated gas heater as claimed in claim 7 and / or the optional control unit and / or the exhaust muffler as claimed in claim 8 are mounted; wherein fluid lines for connecting these components and for connecting the compressor port, the first and second heat exchanger ports and the first and second adsorber ports are also mounted on the support frame.

10. The air separation device of claim 9, wherein the support frame is substantially cubic and has a length, a width and a depth; wherein the height is equal to the length, and the lateral dimension is equal to the width, the depth or an average thereof; wherein preferably, the width and the depth are independently within the range of 3.5 m to 7 m, and preferably, the length is preferably within the range of 10 m to 30 m.

11. The air separation device of claim 1 or 2 is designed such that, when the distributor module is connected to the main air compressor assembly, the at least two adsorbers and the main heat exchanger assembly, for each adsorber, an airflow is independently directed to the adsorber during the adsorption phase of the relevant adsorber, and the airflow is directed from the adsorber to the main heat exchanger assembly after passing through the adsorber; and a regeneration gas flow is directed from the main heat exchanger assembly to the adsorber during the regeneration phase of the relevant adsorber, and the regeneration gas flow is directed to the residual gas outlet after passing through the adsorber.

12. The air separation device as claimed in claim 1 or 2, including a control unit suitable for controlling the valve and baffle assembly, wherein, A port pair operates according to the first state to cause the adsorber connected to the port pair to operate in the adsorption phase, and according to the second state to cause the adsorber connected to the port pair to operate in the regeneration phase; wherein the control unit is preferably configured to control the valve and baffle assembly to alternately cause at least one port pair to operate according to the first state.

13. The air separation device of claim 1 or 2, comprising a separation column assembly (26), wherein the main heat exchanger assembly (24) is arranged between the distributor module (20) and the separation column assembly (26); wherein preferably, the main heat exchanger assembly is installed in the main heat exchanger module, and / or, the separation column assembly is installed in the separation column module.

14. The air separation device as requested in item 1 or 2, wherein the height (H) of the distributor module is greater than the height of the heat exchanger.

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