Apparatus and process for providing production gas output from an air separation system

Abstract

An apparatus and process for drying a product gas for supplying the gas to a downstream user such that the product gas may be dried to remove water from the gas that may be absorbed or adsorbed during an initial start-up phase of production and / or delivery of the product gas (e.g., from a conduit that may have been exposed to water during installation). Therefore, the product gas can be delivered downstream to the user instead of being exhausted. Some embodiments may be configured to utilize a removable, mobile water redistribution device that may be completed during an initial start-up phase of product gas delivery and that provides a pipeline layout of product gas is transported to a new location after the product gas has been dried via an operation for an initial start-up period.

Description

Technical Field

[0001] The present innovation relates to processes and apparatus for transporting product gases produced via air separation of a feed (e.g., a nitrogen product stream, an oxygen product stream, or an argon product stream, etc., output from an air separation unit processing air or an industrial gas stream). Background Art

[0002] Air separation processes have been used to separate air into different component streams of fluids (e.g., nitrogen, oxygen, etc.). Examples of systems developed in conjunction with air separation processes include U.S. Patent Nos. 4,022,030 and 4,822,395, International Patent Publication Nos. WO2020 / 169257, WO2020 / 244801, and WO2021 / 078405, and U.S. Patent Application Publication Nos. 2019 / 0331417, 2019 / 0331418, and 2019 / 0331419. Summary of the Invention

[0003] We have determined that air separation processing can result in a delay in the supply of nitrogen, oxygen, argon, or other air separation product gases to one or more downstream customers during the startup phase of the process. The startup phase of the process can occur after installation, after maintenance work is performed, or after a turnaround event occurs. For example, the equipment used to transport the produced product gas (e.g., nitrogen, oxygen, or argon) output from the air separation system to downstream users (e.g., customers who can utilize the nitrogen output from the air separation process, customers who can utilize the oxygen output from the air separation process, etc.) can have moisture absorbed by the product gas transported through the piping equipment. The absorption of water by the product gas after the product gas is output from the air separation unit may result in the product gas not being of a purity that meets the concentration requirements of the end user for use of the product gas, necessitating that the initially formed product gas be vented until the downstream piping used to transport the gas from the air separation unit to the customer's facility is sufficiently dry to avoid such impurity absorption issues. We have determined that this may occur even if the product gas output from the air separation unit meets the purity requirements for that gas due to water from newly installed piping equipment (e.g., piping, etc.) having been exposed to moisture (e.g., from rain, dew, frost, etc.) during installation, and this moisture being adsorbed by the product gas as the gas is transported from the air separation unit through this piping equipment to the customer facility.

[0004] We have determined that this type of impurity absorption problem could delay the provision of product gas to the end user for weeks - particularly where the piping equipment may have been exposed to rainwater during installation and the end user has higher product gas purity requirements (e.g., greater than 99.99 volume percent (vol%) nitrogen, between 99.9 vol% nitrogen and 100 vol% nitrogen, nitrogen purity with no more than 10 parts per billion (ppb) of water in the provided nitrogen, nitrogen purity between 5 ppb and 2 ppb of water, nitrogen purity between 3 ppb and 2 ppb of impurities, nitrogen purity between 100 ppb and 2 ppb of water, etc.).

[0005] We have determined that a product gas water redistributor can be included in the output piping path for supplying product gas to downstream end users, so that the product gas can be dried to remove water adsorbed from newly installed piping surfaces or recently exposed piping surfaces (e.g., as may occur due to maintenance work, etc.) when the gas is delivered to the customer site. The use of a water redistributor can facilitate drying of the product gas, thereby avoiding or minimizing the need to vent product gas produced by the air separation process during the initial startup phase of the air separation process. In some embodiments, the water redistributor can also facilitate subsequent humidification of the dry gas supplied to the water redistributor, thereby slightly humidifying the gas while maintaining it within customer purity specifications and allowing for regeneration of the device's adsorbent material.

[0006] For example, some embodiments of the water redistribution apparatus can be configured to function as a water adsorber apparatus or a water adsorber and desorber apparatus that can be configured to redistribute water absorption within the initially produced product gas so that when the product gas has absorbed excess water during transmission to a customer site, water that may be adsorbed by the product gas that is transferred through the transport pipeline layout during the supply of the product gas to the end user can be captured. This type of feature can allow the product gas to be delivered within customer purity requirements when the product gas would otherwise exceed customer purity requirements. Embodiments can be configured to redistribute how water is included in the product gas delivered to the end user during the startup phase of gas production or delivery of gas to a customer site so that the product gas delivered to the customer site is pure enough to meet the end user's product gas concentration requirements or purity specifications. This can help avoid or minimize the need to vent product gas produced during the initial startup of an air separation process.

[0007] We have determined that other embodiments may be configured for use in conjunction with drying a nitrogen, oxygen, or argon product stream that may be output from an air separation process for supply to a downstream end user during a startup phase of operation or a startup phase of product gas delivery, which may occur after the piping layout for providing product gas to the downstream user has been installed. Embodiments may be configured such that a water redistribution device may be utilized in conjunction with other types of air separation product stream piping layouts for redistribution of water adsorption that may occur from piping and other equipment installed for delivering the product gas stream to the end user to minimize or avoid discharge of the product stream initially formed during the startup phase of the air separation process and / or the startup phase of supplying the product gas stream to the downstream user.

[0008] Some embodiments of the water redistribution device can be configured as modular and removable. For example, the water redistribution device can be configured and arranged for installation on a slide, trailer or other type of mobile base for connection to a nitrogen output pipeline, an oxygen output pipeline or an argon output pipeline during the startup phase of an air separation process. After the output pipeline layout of the installation has been fully dried by passing the product gas through the output pipeline and the water redistribution device, the water redistribution device can be removed from the output pipeline layout and transported to a new device (installation) for use during the startup phase of the new device. Such modular and mobile processes can allow the capital cost associated with the water redistribution device to be recovered in multiple uses of multiple different devices. This type of process can also avoid having to use the water redistribution device only for the startup phase and then leaving the water redistribution device at the site without using it, so that the cost of manufacturing and using the water redistribution device that is not incorporated can be recovered more effectively. This type of process can also provide greater operational flexibility for air separation processing units and startup designs.

[0009] Other embodiments may be configured such that a utilized water redistribution device may be deactivated but remain at the site (e.g., a valve may be adjusted to adjust the flow of product gas so that the flow of product gas no longer passes through the water redistribution device, while the device remains connected to the piping layout). For example, such a process may be utilized in embodiments where it is desirable to maintain water redistribution functionality available for other uses at the site. Such a process may provide greater flexibility in addressing situations where an air separation process may experience product purity issues during operation, which may occur after the initial startup phase, such that the water redistribution device may be employed via valve adjustment so that the water redistribution device can be used again to dry the product gas stream to mitigate such issues that may arise during air separation operations.

[0010] In some embodiments, the water redistribution device may include a container having a bed of adsorbent material. The device may also include a heater that can be activated to heat the container and the bed of adsorbent material therein to promote regeneration of the adsorbent material. For example, during an initial phase, the product gas may be passed through the adsorbent material in the container to adsorb water in the product gas to maintain the purity of the product gas for provision to the customer. After a period of time (e.g., weeks, months, etc.) of drying the piping arrangement from the product gas passed through the piping arrangement, the product gas supplied to the device may be sufficiently dried and may be able to desorb water from the adsorbent material and still be within the customer's purity specifications. In response to detecting such a situation, the heater device may be activated to heat the container of the device so that the product gas passed through the adsorbent material serves as regeneration gas and some water is desorbed from the adsorbent material and enters the product gas while still keeping the product gas within the customer's product specifications. This regeneration phase of providing product gas may occur until the adsorbent material of the device is fully regenerated or sufficiently regenerated. After regeneration of the adsorbent material has occurred, delivery of the product gas to the customer location can be adjusted so that the product gas bypasses the water redistribution device to avoid the pressure drop associated with passing the gas through the water redistribution device because the piping layout through which the product gas is passed can be sufficiently dry from previous use.

[0011] In yet other embodiments, a heater may not be utilized to promote regeneration of the adsorbent material. In some alternative embodiments, a drier product gas may be passed through a water redistribution device to desorb water from the adsorbent material bed at an acceptable level within the desorption period, for regenerating the adsorbent material bed in a manner that promotes redistribution of adsorbed water from various piping elements, such that the product gas delivered to the customer site can still meet customer purity specifications. In some such embodiments, after the adsorbent bed has been sufficiently regenerated, the water redistribution device may then be bypassed, allowing the water redistribution device to be used for another purpose at a later point in time.

[0012] In some embodiments, the water redistribution device can be decoupled from the piping layout after it is bypassed by product gas for use at another location. In other embodiments, the water redistribution device can remain in place for subsequent use in the event of a production problem, shutdown, maintenance, or other problem that may arise during operation.

[0013] In a first aspect, an apparatus for producing and / or delivering product gas from an air separation unit (ASU) may include a water redistribution device (WRD) configured to receive product gas output from the ASU and remove water from the product gas to adjust the purity of the product gas so that the product gas has a purity within a preselected purification content specification. The WRD may be positionable between the ASU and a customer system to receive the product gas from the ASU and output the product gas having a purity within the preselected purification content specification to supply the product gas to the customer system.

[0014] Embodiments of the facility may include only a WRD, or may include a WRD and other components. For example, some embodiments of the facility may include an ASU and / or a customer system. Piping for transferring product gas from the ASU to the WRD and from the WRD to the customer system may also be included. Other components (e.g., valves, bypass piping, etc.) may also be provided.

[0015] For example, in the second aspect, the apparatus may include a piping arrangement having a WRD supply piping through which product gas may be passed to be supplied to the WRD, and a WRD bypass piping through which product gas may be passed to bypass the WRD and avoid passing through the WRD when supplying the product gas to a customer system via the piping arrangement.

[0016] In some embodiments, the piping layout may include separate locations upstream of the WRD and the WRD bypass line. The piping layout may also include a WRD supply valve for the WRD supply line, the WRD supply valve being adjustable between an open position for delivering the product gas to the WRD and a closed position for delivering the product gas to the WRD bypass line.

[0017] In other embodiments, the piping layout may include separate locations upstream of the WRD and WRD bypass piping, and a WRD bypass valve of the WRD bypass piping may be adjustable between a closed position for passing product gas to the WRD and an open position for passing product gas through the WRD bypass piping.

[0018] In yet other embodiments, the piping layout may include a WRD supply valve for the WRD supply conduit, the WRD supply valve being adjustable between an open position for delivering product gas to the WRD and a closed position for delivering product gas to a WRD bypass conduit. The WRD supply valve may be downstream of a separate location that is also upstream of the WRD and the WRD bypass conduit. In such embodiments, the WRD bypass conduit may also include a WRD bypass valve that is adjustable between a closed position for delivering product gas to the WRD and an open position for delivering product gas through the WRD bypass conduit.

[0019] In a third aspect, the WRD can include a vessel that holds a bed of adsorbent material. The adsorbent material can include a molecular sieve adsorbent material or other suitable adsorbent material. In some embodiments, for example, the WRD can include at least one adsorber having a bed of adsorbent material within the vessel of the WRD.

[0020] In a fourth aspect, a WRD can include a vessel that holds a bed of adsorbent material, and the WRD can be further configured to receive product gas through the WRD after the piping layout has been dried, such that water adsorbed by the bed of adsorbent material is desorbed into the product gas during a desorption phase of operation of the WRD, such that the desorbed water within the product gas still results in a product gas output from the WRD having a purity within a preselected purification content specification. For example, the WRD can be operated in a first adsorption phase, in which water within the piping through which product gas output from the ASU can pass is adsorbed or absorbed by the product gas and can be removed from the product gas via adsorption within the WRD. Subsequently, in a second desorption phase, which can occur after the adsorption phase, the WRD can desorb water previously adsorbed by the drier product gas that has passed through the dried piping layout to help regenerate the adsorbent material of the WRD.

[0021] In some embodiments, the apparatus may further include a regeneration heater coupled to the vessel for heating the vessel to regenerate the adsorbent material as the product gas passes through the WRD during the desorption phase of operation. In other embodiments, a regeneration heater may not be used or required to help promote the desorption of water from the adsorbent material and into the drier product gas passing through the WRD during the desorption phase of operation.

[0022] In a fifth aspect, the WRD can be supported by a mobile base. The mobile base can be connectable to a vehicle for transporting the WRD. For example, the mobile base can be positioned on or integrated into a trailer, truck, flatbed, mobile skid, or railcar. In some embodiments, for example, the mobile base can be a skid or mobile bed that can be towed or otherwise transported via a truck, barge, train, or other vehicle.

[0023] In a sixth aspect, a WRD may have an inlet connected to a container and an outlet connected to the container. The inlet may be removably connected to a piping arrangement, and the outlet may be removably connected to the piping arrangement. The inlet and outlet may be coupled to the piping arrangement to facilitate use of the WRD. The inlet and outlet may be decoupled from the piping arrangement to facilitate moving the WRD to a new location for use there.

[0024] In a seventh aspect, the product gas can be or include nitrogen, and the preselected purification content specification can be that the product gas has a water content of no more than 100 parts per billion (ppb) water and / or a nitrogen content of at least 99.9 volume percent nitrogen. For example, the preselected purification content specification can be that the product gas has a nitrogen content of between 100 ppb water and 2 ppb water, between 10 ppb water and 2 ppb water, or between 5 ppb water and 2 ppb water.

[0025] In the eighth aspect, the device of the first aspect may include one or more features of the second, third, fourth, fifth, sixth and / or seventh aspects. It should be understood that embodiments of the device may also include other features or other elements.

[0026] In a ninth aspect, a process for producing and / or delivering product gas from an air separation unit (ASU) is provided. Some embodiments of the process may include transferring product gas output from the ASU to a water redistribution device (WRD) to adjust the purity of the product gas so that the product gas has a purity within a preselected purification content specification. The WRD may be connectable to a piping layout positioned between the ASU and a client system to receive product gas from the ASU and output product gas having a purity within a preselected purification content specification for supplying the product gas to the client system. After water has been sufficiently removed from the piping layout via transferring the product gas to the WRD, the transfer of the product gas may be adjusted so that the product gas bypasses the WRD when transferring the product gas from the ASU to the client system.

[0027] It should be understood that embodiments of the apparatus may be configured to implement embodiments of the process. The process may also include other steps or other features.

[0028] For example, in the tenth aspect, the process can include, after performing the step of adjusting the delivery of the product gas so that the product gas bypasses the WRD, decoupling the WRD from the piping layout and moving the WRD to another location to connect with the piping layout at that location.

[0029] As another example, a process may include activating a regeneration heater coupled to a vessel of the WRD for heating the vessel to regenerate adsorbent material of the WRD after determining that water has been sufficiently removed from the piping layout via passing the product gas to the WRD and that desorption of water into the product gas passing through the WRD will result in the product gas output from the WRD having a purity within a preselected purification content specification.

[0030] As another example, the process may include starting up the ASU to produce product gas for supply to a customer system. For example, the start-up of the ASU may occur after repair work has been performed on the piping layout or after the piping layout has been installed and may have been exposed to ambient moisture (e.g., humidity and / or rain).

[0031] In the eleventh aspect, the WRD can have a preselected design and structure.For example, the WRD can include a vessel having a bed of adsorbent material therein.

[0032] In the twelfth aspect, passing the product gas output from the ASU to the WRD to adjust the purity of the product gas so that the product gas has a purity within a preselected purification content specification can also be performed, including passing the product gas through the WRD after the product gas has been passed through the piping arrangement so that the adsorbent material bed adsorbs water from the product gas during a first adsorption operating stage of the WRD, and passing the product gas through the WRD after the piping arrangement has been dried so that the water adsorbed by the adsorbent material bed is desorbed into the product gas during a second desorption operating stage of the WRD, so that the desorbed water in the product gas still causes the product gas output from the WRD to have a purity within the preselected purification content specification.

[0033] In the thirteenth aspect, the product gas can include nitrogen, and the preselected purification content specifications used in the process can be or include a water content of no more than 100 ppb water and / or a nitrogen content of at least 99.9 volume percent nitrogen.

[0034] In the fourteenth aspect, the product gas is nitrogen, oxygen, or argon. In yet other embodiments, it is contemplated that the product gas may be another type of gas.

[0035] In a fifteenth aspect, the process can include determining, based on sensor data from sensors of the piping arrangement, the surface area of the piping arrangement, and / or the period of time during which the product gas has been passed through the WRD, that water has been sufficiently removed from the piping arrangement by passing the product gas to the WRD so that the product gas can be passed to a client system without processing via the WRD. In some embodiments, adjusting the piping arrangement so that the WRD is bypassed and / or adjusting the WRD operation so that it can function during the desorption phase can be triggered as a result of such a determination.

[0036] In the sixteenth aspect, the process of the ninth aspect may include one or more features of the tenth aspect, the eleventh aspect, the twelfth aspect, the thirteenth aspect, the fourteenth aspect, and / or the fifteenth aspect. It should be understood that other embodiments of the process may include other features, process steps, or combinations of different features and process steps.

[0037] It should be understood that embodiments of the process and apparatus may utilize a variety of piping layouts and process control elements. Embodiments may utilize sensors (e.g., pressure sensors, temperature sensors, flow rate sensors, concentration sensors, etc.), controllers, valves, piping systems, and other process control elements. For example, some embodiments may utilize automated process control systems and / or distributed control systems (DCS). A variety of different piping layouts and process control systems may be utilized to meet a specific set of design criteria.

[0038] Further details, objects and advantages of our apparatus for product gas production and / or delivery, process for product gas production and / or delivery, process for product gas production and / or delivery for an air separation unit (ASU), apparatus for product gas production and / or delivery for an ASU, water redistribution device, and methods of making and using the same will become apparent as the following description of certain exemplary embodiments thereof proceeds. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Illustrative embodiments of our apparatus for product gas production and / or delivery, process for air separation product gas production and / or delivery, process for product gas production and / or delivery of an ASU, apparatus for product gas production and / or delivery of an ASU, water redistribution device, and methods of making and using the same are shown in the drawings included herein. It should be understood that like reference numerals used in the drawings may identify like components.

[0040] Figure 1 is a block diagram of a first exemplary embodiment of an apparatus for product gas production and / or delivery. Figure 1 For illustrative embodiments of processes for air separation product gas production and / or delivery, see .

[0041] Figure 2 is a block diagram of a first exemplary embodiment of a first exemplary water redistribution apparatus that may be utilized in a first exemplary embodiment of an apparatus for product gas production.

[0042] Figure 3 is a flow chart illustrating an exemplary embodiment of a process for air separation product gas production and / or delivery.A first exemplary embodiment of an apparatus for product gas production and / or delivery can implement this first exemplary embodiment of a process. DETAILED DESCRIPTION

[0043] See also Figures 1 to 3A product gas production and / or delivery apparatus 1 can be configured to utilize a water redistribution device to facilitate the supply of product gas to a downstream user, such that product gas formed during the initial startup of a production process and / or delivery process can be provided to the downstream user without venting or minimizing the venting of the initially provided product gas. For example, the product gas that can be transported via at least one output pipe for supplying the product gas to a downstream end user can be a high-purity nitrogen product, a high-purity oxygen product, or a high-purity argon product. Such a high-purity product gas can be, for example, between 99% and 100% oxygen by volume, between 99% and 100% nitrogen by volume, or between 99% and 100% argon by volume. In some embodiments, the product gas provided to the downstream user during the initial startup phase can have less than or equal to 100 parts per billion (ppb) water in the product gas, or the product gas provided to the downstream user during the initial startup phase can have between 5 ppb water and 2 ppb water, between 10 ppb water and 2 ppb water, between 20 ppb water and 2 ppb water, between 100 ppb water and 2 ppb water, or other preselected water concentration specifications.

[0044] Apparatus 1 may be configured as an apparatus for producing and / or delivering product gas. The product gas may be output from an air separation unit (ASU). Apparatus 1 may include a water redistribution device (WRD). In some embodiments, the WRD may be configured as an adsorber device that can adsorb moisture (e.g., water) from a gas passed through at least one adsorbent material bed (Bed) within a container of the WRD. The adsorbent material bed may be sized and configured to adsorb water from the gas for redistribution of the water within the gas passed through the WRD so that the product gas output from the WRD can be provided to a downstream end user within a preselected purification range (e.g., 99 vol% to 100 vol% pure nitrogen, 99 vol% to 100 vol% pure oxygen, 99 vol% to 100 vol% argon, a product gas having no more than 5 ppb water, a product gas having no more than 100 ppb water, etc.). For example, the bed of adsorbent material may include a 13X adsorbent material, a molecular sieve adsorbent material, or other suitable adsorbent material for adsorbing water from the product gas passing through the bed to dry the product gas and remove water from the product gas so that the product gas output from the WRD meets a preselected product gas purity content threshold (e.g., having between 5 ppb and 2 ppb water and between 99.9 vol% and 100 vol% nitrogen, having between 100 ppb and 2 ppb water and between 99.9 vol% and 100 vol% nitrogen, being at least 99.9 vol% oxygen and between 10 ppb and 2 ppb water, etc.).

[0045] The adsorbent material within the bed of the WRD vessel (BED) can be selected to help define the overall size of the WRD. In some embodiments, the adsorbent material can be selected to provide a WRD with a sufficiently small design size to facilitate economical manufacture and installation and / or use of the WRD, while also using a sufficient amount and type of adsorbent material suitable for adsorbing water that is expected to be present when the product gas is transported through newly installed piping elements that have been exposed to moisture. In some embodiments, the Henry's adsorption constant or Henry's adsorption isotherm of the adsorbent material of the bed can be selected to help minimize the size of the WRD vessel and adsorbent material bed, while providing sufficient water adsorption capacity for the expected water adsorption or water redistribution function provided for transporting the product gas through newly installed piping elements that may have been exposed to external conditions or moisture (e.g., rain, dew, frost, humid conditions, etc.).

[0046] The water adsorption capacity of the adsorbent material utilized in the bed (BED) of the WRD can be within a desired range to provide a desired water adsorption capacity. For example, in some embodiments, when operated at 30° C. in conjunction with a gas stream having a water partial pressure of 0.0000005 psi and 0.000015 psi (which is between 0.0344 Pa and 0.1 Pa), the adsorbent material utilized in the bed (BED) of the WRD can have a water adsorption capacity within a range of greater than 0.10 kg of water per 100 kg of adsorbent material and 0.40 kg of water per 100 kg of adsorbent material. For example, the adsorbent material can be selected to provide an adsorption capacity of at least 0.10 kg of water per 100 kg of adsorbent material when exposed to the product gas at 30° C. with a water partial pressure of 0.0344 Pa, and can provide an adsorption capacity of 0.40 kg of water per 100 kg of adsorbent material when exposed to the product gas at 30° C. with a water partial pressure of 0.1 Pa. As another example, when operated at 30°C in combination with a gas stream having a partial pressure of water between 0.0000005 psi and 0.000015 psi (which is between 0.0344 Pa and 0.1 Pa), the adsorbent material utilized in the bed of the WRD (BED) can have a range between adsorbing greater than or equal to 0.10 kg of water per 100 kg of adsorbent material and adsorbing 0.80 kg of water per 100 kg of adsorbent material.

[0047] Other embodiments may utilize other adsorbent materials with other types of adsorption profiles. There may be a trade-off between high adsorption capacity and the cost of the adsorbent material, as well as a trade-off between sizing the vessel for the WRD and the cost of manufacturing, shipping, installation, and / or use, due to the sizing of the vessel for the WRD that may be considered when providing the WRD for a particular embodiment to meet a particular set of design goals. In many cases, it is believed that an adsorbent material having a bed with a water adsorption capacity between 0.10 (kg water adsorbed per 100 kg adsorbent material) and 0.40 (kg water adsorbed per 100 kg adsorbent material) can provide sufficient water adsorption capacity for a particular operating environment while also allowing the WRD to be sized in an economical manner, which can allow for economical manufacturing, shipping, installation, and / or use.

[0048] The apparatus 1 can be configured to implement a process for producing and / or delivering a product gas for an ASU. As mentioned herein, the product gas can be, for example, nitrogen, argon, or oxygen. It is also contemplated that the product gas can be another product gas (e.g., xenon, neon, krypton, etc.).

[0049] For example, an ASU 3 may be provided that is configured to receive at least one feed gas (e.g., air, an industrial gas including flue gas, etc.) and perform separation of the feed gas to form at least one product stream. For example, air separation may utilize cooling and distilling the feed gas using one or more distillation columns. The product stream may include a product gas. For example, the product stream may be a product gas comprising nitrogen, oxygen, or argon. The purity of the resulting product gas may meet a preselected purity specification. For example, the preselected purity specification may be at least 99 vol% nitrogen or a nitrogen content between 99.9 vol% nitrogen and 99.999999 vol% nitrogen. As another example, the preselected purity specification may be at least 99 vol% oxygen or an oxygen content between 99.9 vol% oxygen and 99.999999 vol%. As yet another example, the preselected purity specification may be at least 99 vol% argon or an argon content between 99.9 vol% argon and 99.999999 vol%. The preselected purity content of the product gas may also be defined in other ways or include other requirements. For example, the preselected purity content of the product gas may include a requirement that the product gas may have less than or equal to 5 parts per billion (ppb) water to 2 ppb water within the product gas. As another example, the preselected purity content of the product gas may include a requirement that the product gas may have between 20 ppb and 2 ppb water (e.g., less than or equal to 20 ppb water) or between 10 ppb and 2 ppb water within the product gas.

[0050] A product stream may be output from the ASU 3 for supply to the customer system 20 via a product stream output piping arrangement 11 positioned between the ASU 3 and the customer system 20. The customer system 20 may include industrial equipment configured to utilize the product gas output from the ASU 3 for at least one customer-specific purpose via customer equipment at a customer site having the customer system 20.

[0051] The piping arrangement 11 may include piping systems, valves V, and other equipment for transporting the product gas output from the ASU 3 to the customer system 20. For example, the piping arrangement 11 may include an ASU product gas output piping 11a connected between an output compressor 5 (Comp.) and the ASU 3. The output compressor 5 may be used to increase the pressure of the product gas for delivery to the customer system 20. In some embodiments, it is contemplated that the output compressor 5 may not be required (e.g., because the ASU 3 outputs the product gas at a sufficiently high pressure that the compressor 5 is not required).

[0052] The piping arrangement may also include a compressor output piping 11b connected between the compressor 5 and the piping separation location 7. The piping separation location 7 (SL) may include a separator piping section sized and configured to allow the product gas passing through the piping arrangement 11 to be supplied to a WRD for processing therein or to bypass the WRD so that the product gas is not passed through the WRD, depending on the positions of various valves V of the piping arrangement 11. The piping separation location (SL) may be positioned between the ASU 3 and the customer system 20 to allow the WRD to be bypassed or not, depending on the water concentration and / or purity of the product gas detected as being feedable to the customer system 20.

[0053] Product gas purity detection can be provided via at least one sensor S connected to the piping arrangement 11 for detecting the purity of the product gas. In some embodiments, one or more sensors S can be configured as a water content detection sensor, a water content analyzer, or other types of sensor devices configured to provide data that can be used to detect the water concentration in the product gas. For example, there can be a first sensor S1 positioned upstream of the piping separation location 7 and a second sensor S2 positioned downstream of the WRD and downstream of the separation location 7 for detecting the water content in the product gas and / or the purity level of the product gas to determine whether the WRD can be bypassed. In other configurations or embodiments, the sensor can be another type of product gas composition detection mechanism or a product gas content analyzer.

[0054] In some embodiments, each of the sensor S and the valve V can be communicatively connected to a controller (CTRL) having a processor (CPU) connected to a non-transitory memory (MEM) and at least one transceiver (TCV). The controller (CTRL) can have a communication connection CC with the valve V, the sensor S, and the controller (CTRL), so that the controller can determine whether the purity content of the product gas to be delivered to the customer system 20 meets one or more predefined purity content thresholds based on data received from the first sensor S1 and the second sensor S2. The controller (CTRL) can communicate with the valve V to adjust the product gas flow for (1) supplying the product gas to the WRD for processing therein or (2) bypassing the WRD.

[0055] One or more of these sensors S can also be used to determine whether a valve should be adjusted to vent the product gas rather than delivering the gas to the customer system 20. For example, the controller (CTRL) can also be configured to utilize data from the second sensor S2 to determine whether venting the product gas is necessary based on the detected purity concentration of the product gas downstream of the WRD and the isolation location 7 that can be provided via the second sensor S2. If venting is necessary, the controller (CTRL) can communicate with the valves V so that one or more vent valves V can be adjusted to their open positions while the other valves V in the piping arrangement 11 are moved to their closed positions to provide such venting. For example, if it is detected that the product gas does not meet a preselected end-customer purity requirement (e.g., a water content less than or equal to 10 ppb and greater than or equal to 2 ppb), the controller (CTRL) can communicate with the valves V to vent the product gas until it is detected that the purity of the product gas meets or is within a preselected customer purity threshold. While such venting can be provided as a safety precaution, embodiments of the apparatus 1 can be configured to help minimize such venting or avoid the need for such venting.

[0056] The piping arrangement 11 may include a WRD supply conduit 11c positioned between the separation location 7 and the WRD so that product gas can be passed from the separation location 7 to the WRD to undergo processing therein (e.g., passed through at least one bed of adsorbent material of the WRD). The WRD supply conduit 11c may include a WRD supply valve V1 that is adjustable between an open position and a closed position to facilitate bypassing the WRD when the valve is in its closed position and supplying product gas to the WRD to undergo processing therein when the valve is in its open position. The WRD supply valve V1 may be communicatively connectable to a controller (CTRL) such that the controller can actuate adjustment of this valve from its open position to its closed position, and vice versa. As mentioned above, such adjustment may occur based on the controller's evaluation of sensor data received from the first and / or second sensors S1, S2.

[0057] The WRD can output the processed product gas via a WRD output conduit 11d of a piping arrangement 11 connected between the WRD and a customer system 20. In some configurations, the piping arrangement 11 can include a filter 9 downstream of the WRD and between the WRD and the customer system 20. The filter 9 can be configured to help facilitate filtering of the product gas to help remove impurities (e.g., particulate material, etc.) from the product gas output by the WRD. The piping arrangement can include a filter output conduit 11e connected between the filter 9 and the customer system 20 when the filter 9 is utilized. In such embodiments, the filter output conduit 11e can also be positioned between the customer system 20 and the WRD output conduit 11d.

[0058] The piping layout may also include a WRD exhaust line 11f, which may be connected to the filter output line 11e (when used) or the WRD output line 11d. The WRD exhaust line 11f may include a WRD exhaust valve V2. The WRD exhaust valve may be adjustable between an open position and a closed position to facilitate exhaust of product gas output from the WRD and / or filter 9 when the valve is in its open position, and to supply the product gas output from the WRD and / or filter to the client system 20 when the WRD exhaust valve V2 is in its closed position.

[0059] In some embodiments, the WRD discharge valve V2 can be communicatively connected to a controller (CTRL) so that the controller can actuate the opening or closing of the valve. As mentioned above, such adjustments can occur based on the controller's evaluation of sensor data received from the first and / or second sensors S1, S2.

[0060] A WRD output valve V3 may be included in the piping arrangement 11. Such a valve may be downstream of the WRD discharge valve V2 and may be connected to the filter output piping 11e (when used) and / or the WRD output piping 11d. The WRD output valve V3 may be adjustable between an open position and a closed position and communicatively connected to a controller (CTRL) for actuating adjustment of the position of the valve between its open and closed positions.

[0061] For example, if discharge is desired via an open WRD discharge valve, the WRD output valve V3 can be moved to a closed position. Furthermore, if the WRD is to be bypassed, this valve can be moved to its closed position. In the event that product gas is to be processed via the WRD, the WRD output valve V3 can be moved to its open position, allowing the processed gas output from the WRD to be delivered to the client system 20 through the piping arrangement 11. As mentioned above, adjustment of the position of the WRD output valve V3 can occur based on the controller's evaluation of sensor data received from the first and / or second sensors S1, S2, and communication with the WRD output valve V3 via the communication connection CC between the controller and the valve.

[0062] The WRD output conduit 11d and / or the filter output conduit 11e (when used) can be connected to the customer delivery output conduit 11o at the treated product gas supply location 13, so that when the WRD output valve V3 is in its open position, the treated product gas output from the WRD can be passed through the customer delivery conduit 11o so that the treated product gas can be passed to the customer inlet conduit 20a of the customer system 20. The customer system 20 can receive the product gas via the customer inlet conduit 20a for use at the customer system 20.

[0063] The piping arrangement 11 may also include a WRD bypass piping 11 g positioned downstream of and connected to the separation location 7 such that the product gas passed through the WRD bypass piping 11 g is not passed through the WRD. The WRD bypass piping 11 g may include several valves between the separation location 7 and the treated product gas supply location 13 of the customer delivery piping 11 o such that the product gas passed through the WRD bypass piping 11 g can be received by a customer inlet piping 20 a of a customer system 20 to receive the product gas for use at the customer system 20 without the product gas being processed by the WRD (e.g., by completely bypassing the WRD).

[0064] For example, WRD bypass conduit 11g can include a bypass conduit valve V4 and a first discharge conduit section 11h having a first discharge valve V5. WRD bypass conduit 11g can also be connected to a customer delivery output conduit 11o, which is positioned between WRD bypass conduit 11g and WRD output conduit 11d (and filter output conduit 11e when a filter is used). Product gas passing through WRD bypass conduit 11g can be passed through customer delivery output conduit 11o to be supplied to customer inlet conduit 20a for supply to customer system 20. When supplying product gas to customer system 20, such product gas may never pass through the WRD (and filter 9, when used).

[0065] A bypass line valve V4 can be positioned downstream of the separation location 7 and adjustable between an open position and a closed position. When the product gas is being delivered to the WRD for processing therein, the bypass line valve V4 can be in the closed position. When it is desired to bypass the WRD, the bypass line valve V4 can be moved to its open position. For example, a controller (CTRL) can be communicatively connected to the bypass line valve V4 to actuate the adjustment of this valve between its open and closed positions based on sensor data as mentioned above.

[0066] The first bleed valve V5 can also be adjusted between its open position and its closed position based on whether bleed is determined to be necessary. For example, when the product gas is determined to have a sufficient purity level to meet a preselected purity threshold, the first bleed valve V5 can be in the closed position. When bleed is determined to be necessary (e.g., due to a determination that the purity of the product gas is insufficient), the controller (CTRL) can communicate with the first bleed valve to move it to its open position. When the first bleed valve V5 is in its open position, the product gas passing through the bypass conduit 11g can be bleed rather than being delivered to the customer system 20.

[0067] The customer delivery output conduit 11o may include a second discharge conduit section 11i having a second discharge valve V6. The second discharge conduit section 11i and the second discharge valve V6 may be positioned upstream of the customer inlet conduit 20a and upstream of the outlet of the customer delivery output conduit 11o, which may be connected to the customer delivery valve V7 of the customer delivery conduit 20a.

[0068] A customer delivery valve V7 of the customer delivery conduit 11o can be positioned between the customer system 20 and the customer delivery output conduit 11o to control whether product gas can be supplied to the customer system 20 (e.g., when the customer delivery valve V7 is in its open position) or prevented from being supplied to the customer system 20 (e.g., when the customer delivery valve V7 is in its closed position). The customer delivery valve V7 can be downstream of the bypass conduit valve V4 and can also be downstream of the treated product gas supply location 13.

[0069] In the event that the data provided by the second sensor S2 indicates that the product gas fails to meet a preselected purity threshold, the second discharge valve V6 can be adjusted to its open position and the customer delivery valve V7 can be moved to its closed position so that such gas is discharged rather than provided to the customer system. In the event that the product gas is detected to be of sufficient purity (e.g., at least meeting the preselected purity threshold via detection provided by the second sensor S2 positioned upstream of the customer delivery valve V7), the second discharge valve V6 can be in its closed position and the customer delivery valve V7 can be in its open position so that the product gas can be delivered from the customer delivery pipeline 11o of the pipeline layout 11 to the customer system 20 via the customer inlet pipeline 20a. A controller (CTRL) can be communicatively connected to these valves V for actuating adjustments to their positions based on data provided by the second sensor S2 and / or the first sensor S1.

[0070] First sensor S1 can be used to determine whether product gas output from the ASU may need to be passed through the WRD for processing therein. For example, if data from first sensor S1 indicates that the product gas may not have a sufficient purity level, valve V can be adjusted between a closed position and an open position, allowing the product gas to pass through WRD supply conduit 11c for supply to the WRD. However, if data provided by first sensor S1 indicates that the product gas has a sufficient purity level, controller CTRL can use this data to determine that the WRD can be bypassed. This determination can also be based on the purity content data from second sensor S2 and the period of time that the gas has been passed through the WRD to absorb any water from sections of the piping layout that may have been exposed to moisture during the piping layout's installation phase.

[0071] In the event that the controller (CTRL) determines that the WRD can be bypassed, the WRD supply valve V1 and the WRD output valve V3 may be closed and the bypass valve V4 may be opened so that product gas passes through the bypass conduit 11g instead of the WRD supply conduit 11c.

[0072] In some embodiments, a controller (CTRL) may be provided such that the controller determination is automated. In other embodiments, the controller determination may be made as a result of receiving input from a user or operator who may provide manual or semi-automatic oversight or control. In some embodiments, the operator may utilize a computer device such as the controller (CTRL) or a computer device communicatively coupled to the controller (CTRL) to receive sensor data, evaluate the sensor data, and provide input to the controller and / or valve for adjusting various valve positions.

[0073] We have determined that utilizing the WRD and the bypass feature provided by the bypass conduit 11g can allow the initial startup of the ASU 3 and / or the initial supply of product gas via the newly installed piping arrangement 11 for delivery of the product gas to the customer system 20 to occur more quickly and avoid the venting of product gas that may be generated during the initial startup phase or initial delivery phase. For example, newly installed piping of the piping arrangement is often exposed to water during the installation process (e.g., the piping system or other piping elements may be external and installed underground or above ground and, during the construction phase, may be exposed to rainwater or other water sources from the weather or the external environment). Traditionally, it may be necessary to pass the product gas through such piping elements for several weeks to remove the water from the piping elements so that the product gas delivered through the piping arrangement does not absorb water and thereby reduce its purity content to an undesirable level that may exceed a preselected content specification. This is particularly true in high-purity situations (e.g., where the product gas has an extremely high purity exceeding 99.99 vol% of the product composition, such as nitrogen, oxygen, or argon). By utilizing a WRD, the product gas can be further dried by passing it through the adsorbent material of the WRD bed so that water from piping elements that may have been adsorbed by the product gas during the initial stages of transport or production is removed, and the purity of the product gas can thereby meet the customer's pre-selected purity specifications for use at the customer system 20. This can allow for the avoidance of venting (and loss of product) and an accelerated delivery timeframe of up to several weeks.

[0074] Additionally, the use of bypass piping 11g can avoid the pressure drop associated with the use of a WRD once piping arrangement 11g has been sufficiently dried by the product gas passing through the various piping systems and adsorbed water has been removed by the WRD. Once such conditions are determined to have been met, bypass piping 11g can be used to deliver the product gas to the customer system 20, and the WRD can be bypassed so that it is no longer utilized. This bypass can reduce compressor operation or eliminate the need for a compressor to continue providing product gas to the customer system 20.

[0075] Furthermore, we have determined that providing a bypass piping 11g arrangement can allow for providing a single WRD for removable coupling to the piping arrangement 11. Such a feature can allow a single WRD to be used at multiple different locations at different times to accommodate the start-up of product gas supply from the ASU to the customer system 20, allowing such supply to occur more quickly at the different locations while also allowing the capital costs associated with the WRD to be more efficiently distributed over multiple uses at the different locations.

[0076] For example, as in Figure 2As best seen in FIG, some embodiments of a WRD can be configured such that the WRD is a container having a bed of adsorbent material therein, the bed of adsorbent material being supported on a mobile base (MB). For example, the mobile base (MB) can be a truck trailer or skid. A vehicle (TRK) such as a truck or other type of vehicle can be connected to the mobile base (MB) to tow or otherwise transport the mobile base (MB) with the container of the WRD thereon to different locations, as indicated by the dashed arrows.

[0077] The WRD can be decoupled by decoupling the inlet (IT) and outlet (OT) of the WRD from the piping layout 11 and subsequently transporting the WRD to the new location via movement of the mobile base (MB). The WRD can be coupled to a new piping layout at a new location by coupling the inlet of the WRD to the WRD supply pipe 11c and coupling the outlet of the WRD to the WRD outlet pipe 11d of the piping layout 11 provided at the new location.

[0078] This type of coupling, use, decoupling, and movement of the WRD to a new location can be repeated several times to support new startups of product gas delivery and / or initial startups of ASU operations for different ASU sites at various geographically remote locations. The repeated availability of the WRD can allow a single WRD to support several different installations so that startup operations for providing product gas can occur more quickly while also maintaining the low capital costs associated with such improved delivery times. This type of operational functionality and mobility of the WRD can provide enhanced operational flexibility for ASU installations and ASU operations.

[0079] In some embodiments, the WRD can be configured as an adsorber. For example, the WRD can be configured as a vertical adsorber, a horizontal adsorber, or a radial adsorber having a bed of adsorbent material within a container of the adsorber. In some embodiments, the bed of adsorbent material (BED) can be a bed of molecular sieve adsorbent material (e.g., 13X adsorbent material, etc.). The bed of adsorbent material can be held within a cavity of a container (VL) of the WRD.

[0080] The WRD can be configured to help redistribute how water in the installed piping layout 11 is removed from the piping elements and incorporated into the product gas to better meet customer purity specifications. In some embodiments, the WRD can be operated so that the beds of adsorbent material are sized to provide drying of the product gas. After the product gas is sufficiently dried, the adsorbent material can retain the adsorbed moisture. Over time, as the piping elements dry out due to the passage of the product gas through those elements and the subsequent adsorption of water by the adsorbent material beds of the WRD, the product gas no longer adsorbs moisture from the piping elements. Conditions in the WRD vessel can change so that the adsorbent material no longer serves to adsorb water, but instead releases water to the drier product gas passing through the WRD, thereby regenerating the adsorbent material of the WRD's beds. Adsorption and subsequent desorption of water into the product gas passing through the WRD can be provided to accommodate customer purity specifications so that the product gas meets a preselected purity threshold, while also allowing the adsorbent material of the beds of the WRD to be regenerated for reuse (e.g., for subsequent bypass, decoupling from the piping layout, and movement to a new location as mentioned above after the adsorbent material has been regenerated, or for availability for new use on-site in response to new purity detection issues that may arise due to maintenance work, shutdowns, or other conditions, etc.).

[0081] The WRD may also include a regeneration heater (HTR) attached to the vessel (VL) to provide heating to the vessel (e.g., via at least one electrical heating element of the regeneration heater) to help heat the bed of adsorbent material during the regeneration phase of WRD processing of the product gas. The regeneration heater (HTR) may be activated to help promote desorption of water from the adsorbent material after determining that the piping elements of the piping arrangement have been dried and removed from the product gas provided by the operation of the WRD. This type of determination may be made based on the duration of operation of the WRD, an estimated amount of moisture that may need to be removed from the installed piping elements of the piping arrangement 11, and / or sensor data from the first sensor S1 and / or the second sensor S2.

[0082] In some embodiments, the ability of a WRD to instantaneously remove water from piping elements of a piping layout for subsequent redistribution via desorption can be enhanced by using a regeneration heater (HTR). For example, activation of this heater (HTR) can facilitate desorption of water from a bed of adsorbent material (BED) into a dry product gas in a manner that still allows the product gas to meet a preselected purity threshold for the customer system 20. This functionality can allow the pipeline drying process provided by the WRD to be an instantaneous process, as the adsorbent material of the WRD can be regenerated by desorbing water into the product gas after the piping elements have been dried via previous use of the WRD.

[0083] In some cases, it may not be necessary to use a heater (HTR) to promote regeneration of the adsorbent material. For example, if the WRD inlet conditions change over time, the moisture level in the gas supplied to the WRD will change over time and become lower and lower. Once the moisture level in the product gas at the WRD inlet reaches a certain dryness level, the water in the adsorbent material can be desorbed (e.g., transferred from the adsorbent material to the dry product gas). The bed size and size capacity of the WRD can be selected so that this type of water desorption can occur while still allowing the product gas output from the WRD to meet a preselected purity specification for the product gas. Whether to activate the heater to promote such regeneration can be based on the equilibrium conditions associated with the WRD processing of the product gas.

[0084] For example, the expected operating moisture profiles for the adsorbent material beds of the WRD as the processing time for treating the product gas increases, which we determined while evaluating embodiments of our apparatus and process, surprisingly show that the water content within the product gas can start at a high concentration during the initial processing of the gas product, and as the piping elements of the piping layout dry out due to operation and the transfer of the product gas through the piping elements and the WRD over the course of several days of operation, this water content will subsequently equilibrate to a low level equivalent to the equilibrium water pressure with water from the upstream gaseous product.

[0085] At some point during WRD treatment, the water concentration in the product gas passing from the WRD may exceed the water concentration in the inlet product gas fed to the WRD. This property is unique to sorbent-based processes with decaying inlet water concentrations, which may occur when piping elements of piping arrangement 11 dry out during operation (e.g., water from those elements is adsorbed by the adsorbent material of the WRD's beds).

[0086] Due to the time-dependent nature of water inlet, the adsorbent material in the bed of a WRD can have two distinct cycles in operational operation: a water adsorption cycle and a water desorption cycle, wherein the retained water will reach a maximum near the transition between the water adsorption cycle and the subsequent water desorption cycle. For example, over time, as the piping elements dry during the first water adsorption cycle of use of the WRD, the inlet gas gradually becomes drier, and when this maximum level of water saturation within the bed of adsorbent material is reached, the product gas passing through the WRD can begin to serve as a regeneration gas, rather than a gas that has undergone drying via water adsorption (e.g., passing the product gas through the WRD can transition from removing water from the product gas to desorbing water from the adsorbent material for adsorption into the product gas). At this second point in the operating curve of the WRD's use, the inlet product gas can begin to remove water from the adsorbent material, and the water previously captured by the WRD via adsorption will be released and enter the now drier product gas fed to the WRD.

[0087] As mentioned above, a heater (HTR) can optionally be provided such that when conditions are reached where increasing the temperature of the adsorbent material can help promote a desired rate of water desorption to regenerate the adsorbent material, the heater (HTR) can optionally be activated to help promote improved water desorption. This regeneration of the adsorbent material does not require the removal from the apparatus of water removed from piping elements and product gas via previous operation of the WRD (e.g., does not require venting), as the drier product gas can receive sufficiently low levels of water from the adsorbent material to still meet customer purity specifications while also promoting regeneration of the adsorbent material within the WRD bed.

[0088] After water is removed from the adsorbent material via this water desorption cycle of the product gas passing through the WRD, the adsorbent material can be ready to handle another significant transient water spike, whether from a process upset, maintenance following a shutdown, or removing the WRD from the first location to move it to a new location for use at the new location.

[0089] While full regeneration of the adsorbent material of the WRD can be provided, it is not necessary to remove the adsorbent material or the WRD after full regeneration. Instead, embodiments can be utilized in which the WRD and the adsorbent material of the WRD can be decoupled and removed (or simply bypassed) at any time after the piping elements have been sufficiently dried and the product gas passing through the piping elements can meet purity specifications without undergoing processing in the WRD. Furthermore, the WRD does not have to remain in operation until the adsorbent material itself reaches equilibrium with the product gas. Furthermore, for embodiments in which the WRD may not be mobile, the WRD can also remain on site indefinitely (e.g., the piping layout is positioned to bypass the product gas of the WRD).

[0090] As discussed above, a WRD can be sized so that the adsorbent material bed of the WRD has the capacity to adsorb the amount of water expected to be adsorbed or absorbed by new equipment that has been exposed to ambient humidity (e.g., external conditions, rain, dew, frost, etc.) during installation or maintenance work. In some embodiments, WRD sizing can be a function of the surface area of the piping elements through which the product gas will be transported and how much water is expected to be added to the product gas transported through the piping elements by that surface area. The type and amount of adsorbent material utilized in the WRD can be determined based on a combination of the amount of water that exceeds the equilibrium amount at the product gas purity specification and the operating pressure (water partial pressure), such that the amount of adsorbent material within the WRD bed is sufficient to adsorb and retain this water while maintaining equilibrium with the product gas at the expected water partial pressure.

[0091] The adsorption and subsequent desorption of water that can be provided by the WRD can allow water degassing of installed piping elements to occur in a manner that can avoid significant delays in the transport of product gas through the installed piping layout. Additionally, as mentioned above, it can help facilitate the reuse of the WRD at different locations without the need to physically replace the WRD's adsorbent material due to the regeneration of the material that can be provided. This type of functionality can avoid waste (e.g., product gas lost due to venting) and energy losses (e.g., energy losses associated with the production of the vented product gas) by limiting or avoiding the venting of product gas formed by the operation of the ASU 3.

[0092] Embodiments of the apparatus 1 may be configured to implement embodiments of our processes for air separation product gas production and / or delivery. Exemplary embodiments of such processes are for example Figure 3 For example, in a first step S1, an air separation process may be started up to produce and / or deliver product gas. This start-up may be the start-up of a new ASU facility or the installation of a piping arrangement 11 for delivering product gas to a customer system 20 for a pre-existing ASU facility.

[0093] In a second step S2, product gas can be supplied through the installed piping arrangement 11 for supplying the product gas to a downstream customer (e.g., a downstream customer system 20 via customer inlet piping 20a as discussed above). Providing the product gas in the second step S2 can occur during an initial or startup phase of production of the product gas and / or delivery of the product gas to the customer.

[0094] In a third step S3, the product gas can be passed through the WRD for processing in the WRD during an initial or startup phase of production and / or delivery of the product gas. The product gas can be passed through the WRD so that the product gas output from the WRD is supplied to a downstream customer (e.g., customer system 20) and meets preselected product gas purity specifications (e.g., customer product gas purity specifications).

[0095] As discussed above, the third step S3 of the process may also optionally include passing the product gas through the WRD to regenerate the adsorbent material of the WRD. This adsorbent material regeneration may occur in conjunction with the activation of a heater device (e.g., a heater (HTR)). For example, regeneration of the adsorbent material may occur after the product gas has sufficiently dried the piping elements of the piping arrangement.

[0096] In a fourth step S4, after sufficient water has been removed from the piping elements of piping arrangement 11 during the startup or initial phase of production and / or delivery of product gas, piping arrangement 11 can be adjusted so that the product gas is no longer passed through the WRD. For example, as discussed above, bypass piping 11g can be utilized so that the product gas bypasses the WRD when being supplied to the customer system 20 and is no longer passed to the WRD.

[0097] In the fifth step S5 ( Figure 3 In the embodiment shown as an optional step in dashed lines in FIG, the WRD can be decoupled from the piping layout 11 and subsequently moved to a new location to be connected to a new piping layout at the new location. As discussed above, this type of removability and mobility of the WRD can allow the WRD to be used at different remote locations at different times.

[0098] As discussed above, other embodiments may be utilized in which the WRD is left in its original location. The WRD may then be bypassed via bypass conduit 11g while still being available to process product gas at other times where it may be needed (e.g., process upset, maintenance after shutdown, etc.).

[0099] Embodiments of the process can provide the advantages and benefits discussed above.For example, embodiments of the process can allow for faster delivery of product gas to customer locations, help avoid or minimize venting of product gas, and provide improved operational flexibility.

[0100] It should be understood that other modifications can also be made to meet a set of specific criteria for different embodiments of the device 1 or process. For example, the layout of valves, piping systems and other piping elements (e.g., pipe connection mechanisms, pipes, seals, valves, etc.) used to interconnect different units of the device for fluid communication of fluid flows between different elements (e.g., pumps, compressors, fans, valves, pipes, etc.) can be arranged to meet a specific plant layout design that takes into account the available area of the device, the sizing equipment of the device and other design considerations. For example, the size of the container of the WRD, the type of WRD configuration (e.g., vertical adsorber, horizontal adsorber, radial adsorber, etc.), the size and configuration of valves, pipes and / or other elements can be modified to meet a set of specific design criteria. As another example, the flow rate, pressure and temperature of the fluid transmitted through one or more elements of the device 1 can be varied to take into account different plant design configurations and other design criteria. As another example, the processing unit and its layout can be adjusted to meet a set of specific design criteria. As another example, the material composition of the different structural components of the unit of the device can be any type of suitable material that may be needed to meet a set of specific design criteria.

[0101] As yet another example, embodiments of the apparatus 1 and process can each be configured to include other process control elements positioned and configured to monitor and control operations (e.g., temperature and pressure sensors, flow sensors, an automated process control system having at least one workstation including a processor, non-transitory memory, and at least one transceiver for communicating with the sensor elements, valves, and controllers to provide a user interface for the automated process control system that can be run at the workstation and / or another computer device in the factory, etc.). It should be understood that embodiments can also utilize a distributed control system (DCS) to implement one or more processes and / or control the operation of the apparatus or process.

[0102] As another example, it is contemplated that certain features described, alone or as part of an embodiment, may be combined with other individually described features or parts of other embodiments. Thus, elements and acts of the various embodiments described herein may be combined to provide further embodiments. Thus, while certain illustrative embodiments of processes, apparatus, systems, and methods of making and using the same have been shown and described above, it will be clearly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims.

Claims

1. An apparatus for producing and / or delivering a product gas from an air separation unit (ASU), the apparatus comprising: a water redistribution device (WRD) configured to receive product gas output from the ASU and remove water from the product gas to adjust the purity of the product gas so that the product gas has a purity within a preselected purification content specification, the WRD being positionable between the ASU and a customer system to receive the product gas from the ASU and output the product gas at the purity within the preselected purification content specification to supply the product gas to the customer system.

2. The apparatus according to claim 1, comprising the ASU and / or the client system.

3. The apparatus according to claim 1, comprising: A piping arrangement having a WRD supply piping through which the product gas can be passed to be supplied to the WRD, and a WRD bypass piping through which the product gas can be passed to bypass the WRD and avoid passing through the WRD when the product gas is supplied to the customer system via the piping arrangement.

4. The apparatus of claim 3 , wherein the piping layout includes a WRD supply valve of the WRD supply conduit adjustable between an open position for delivering the product gas to the WRD and a closed position for delivering the product gas to the WRD bypass conduit at separate locations upstream of the WRD and the WRD bypass conduit.

5. The apparatus of claim 3 , wherein the piping layout includes a separate location upstream of the WRD and the WRD bypass conduit, a WRD bypass valve of the WRD bypass conduit being adjustable between a closed position for passing the product gas to the WRD and an open position for passing the product gas through the WRD bypass conduit.

6. The apparatus of claim 5, comprising a WRD supply valve of the WRD supply conduit, the WRD supply valve being adjustable between an open position for delivering the product gas to the WRD and a closed position for delivering the product gas to the WRD bypass conduit.

7. The apparatus of claim 1, wherein the WRD comprises a vessel holding a bed of adsorbent material, the adsorbent material comprising a molecular sieve adsorbent material.

8. The apparatus of claim 3 , wherein the WRD includes a vessel holding a bed of adsorbent material, and the WRD is further configured to receive the product gas through the WRD after the piping arrangement has been dried, such that water adsorbed by the bed of adsorbent material is desorbed into the product gas during a desorption phase of operation of the WRD, such that the desorbed water within the product gas still causes the product gas output from the WRD to have the purity within the preselected purification content specification.

9. The apparatus according to claim 7, comprising: A regeneration heater is connected to the vessel for heating the vessel to regenerate the adsorbent material as the product gas passes through the WRD.

10. The apparatus of claim 7, wherein the WRD is supported by a mobile base connectable to a vehicle for transporting the WRD.

11. The apparatus of claim 7, wherein the WRD has an inlet connected to the container and an outlet connected to the container, the inlet being removably connected to the piping arrangement, and the outlet being removably connected to the piping arrangement.

12. The apparatus of claim 1 , wherein the product gas is nitrogen and the preselected purity content specification is a water content of no more than 100 parts per billion (ppb) water and / or a nitrogen content of at least 99.9 volume percent nitrogen.

13. A process for producing and / or delivering product gas from an air separation unit (ASU), the process comprising: passing the product gas output from the ASU to a water redistribution device (WRD) to adjust the purity of the product gas so that the product gas has a purity within a preselected purification content specification, the WRD being connectable to a piping arrangement positioned between the ASU and a customer system to receive the product gas from the ASU and output the product gas at the purity within the preselected purification content specification for supplying the product gas to the customer system; After water has been sufficiently removed from the piping layout via delivery of the product gas to the WRD, the delivery of the product gas is adjusted so that the product gas bypasses the WRD when it is delivered from the ASU to the customer system.

14. The process according to claim 13, comprising: After adjusting the delivery of the product gas so that the product gas bypasses the WRD, the WRD is decoupled from the piping layout and moved to another location to connect with the piping layout at the location.

15. The process of claim 13, comprising: After determining that water has been sufficiently removed from the piping layout via passing the product gas to the WRD and that desorption of the water into the product gas passing through the WRD will result in the product gas output from the WRD having the purity within the preselected purification content specification, a regeneration heater coupled to a vessel of the WRD is activated for heating the vessel to regenerate the adsorbent material of the WRD.

16. The process of claim 13, wherein the WRD comprises a vessel having a bed of adsorbent material therein; and wherein passing the product gas output from the ASU to the WRD to adjust the purity of the product gas so that the product gas has the purity within the preselected purification content specification comprises: passing the product gas through the WRD after the product gas has been passed through the piping arrangement such that the bed of adsorbent material adsorbs water from the product gas during a first adsorption stage of operation of the WRD; and Passing the product gas through the WRD after the piping arrangement has been dried causes water adsorbed by the bed of adsorbent material to desorb into the product gas during a second desorption operation stage of the WRD, such that the water desorbed within the product gas still causes the product gas output from the WRD to have the purity within the preselected purification content specification.

17. The process of claim 13, wherein the product gas is nitrogen and the preselected purification content specification is a water content of no more than 100 parts per billion (ppb) water and / or a nitrogen content of at least 99.9 volume percent nitrogen.

18. The process of claim 13, wherein the product gas is nitrogen, oxygen, or argon.

19. The process of claim 13, comprising: The ASU is started up to produce the product gas for supply to the customer system.

20. The process of claim 13, comprising: Determining based on sensor data from sensors of the piping layout, the surface area of the piping layout, and / or the time period over which the product gas has been passed through the WRD that the water has been sufficiently removed from the piping layout via passing the product gas to the WRD such that the product gas may be passed to the customer system without processing via the WRD.

Images