Apparatus and process for cryogenic regeneration of adsorbent material

Abstract

An apparatus and process that may be used for cryogenic regeneration of an adsorption system may include feeding a cryogenic regeneration gas to at least one offline adsorber for regenerating adsorbent material within a vessel of the offline adsorber. The regeneration time period may be set to promote regeneration of the adsorbent material without the need for high temperature regeneration to occur. Some embodiments may be configured such that post-cooling operation when the regeneration gas is fed to the adsorber may be avoided to allow embodiments to more efficiently utilize heating time.

Description

Technical Field

[0001] This invention relates to adsorbers, adsorption systems, processes for operating adsorption systems, and processes for regenerating adsorption materials. Background Technology

[0002] Purification units typically utilize adsorbers, which are generally available in four different common configurations: vertical, vertical cross-flow, horizontal, and radial. Purification units can be configured for temperature-switched adsorption (TSA). TSA systems can be designed to remove components with high freezing points, such as ambient moisture (e.g., water vapor) and carbon dioxide (CO2), which would otherwise freeze in downstream processing, causing operability problems such as clogging. Nitrous oxide (N2O), hydrocarbons, and other impurities can also be removed via front-end purification to prevent their accumulation in downstream processes.

[0003] The purification unit can alternatively be configured for pressure swing adsorption (PSA). Such systems utilize pressure cycling between low and high pressures to facilitate the removal of impurities from the fluid, and subsequently regenerate the adsorbent material by releasing the adsorbed impurities from the adsorbent material.

[0004] Examples of adsorbers, adsorption systems, TSA systems, and PSA systems can be found in U.S. patents 3,531,916, 4,472,178, 4,541,851, 4,784,672, 5,137,548, 5,232,474, 5,425,240, 5,614,000, 5,759,242, 5,846,295, 5,855,650, 5,914,455, 5,917,136, 6,086,659, 6,106,593, 6,152,991, 6,471,749, 6,506,236, 6,599,347, 6,866,075, 6,984,258, 7,022,159, and 7, As understood in U.S. Patent Application Publications 225,637, 7,264,651, 7,285,154, 7,413,595, 8,206,669, 8,262,783, 8,268,044, 8,404,024, 8,518,356, 8,734,571, 8,814,985, 9,108,145, 9,199,190, 9,463,434, 9,631,864, 9,731,241 and 11,137,205, U.S. Patent Application Publications 2011 / 0206581, 2011 / 0219950, 2019 / 0291078 and 2022 / 0001328 and Canadian Patent Publication 2,357,276A. Summary of the Invention

[0005] Conventional PSA systems typically require large amounts of adsorbent material and / or short run times because the adsorbent material may not be adequately regenerated using the cyclic pressure swing available in such systems. In contrast, TSA systems can generally help minimize the required size of the adsorber or adsorbent bed and can also provide longer run times. However, TSA systems also typically have a significantly increased cost in terms of the energy required to heat the adsorbent material for regeneration. Conventionally, offline adsorbent material is adequately heated at relatively high temperatures for regeneration in a TSA system. This heat is typically only available for the early stages of the regeneration process. This initial heating is followed by a cooling step, in which the initially supplied heat is pushed through the adsorbent bed to desorb impurities from the bed, thereby regenerating the material. In conventional TSA systems, the offline adsorbent bed typically undergoes cooling to restore the bed to or near its operating feed temperature before the adsorber is brought back online for purification to adsorb impurities, minimizing the chance that heat from the regeneration process might be transferred downstream of the adsorber when it is brought back online. It is generally desirable to avoid the transfer of such heat applied during the regeneration cycle downstream to other processing equipment (e.g., heat exchangers, towers, etc.), as this heat can cause instability in downstream processing, potentially leading to reduced yields or distillation performance in some applications (e.g., pre-purification for air separation systems). It is also generally desirable to avoid the transfer of such heat downstream during the regeneration cycle, as this heat can cause downstream equipment temperatures to exceed the equipment's maximum design temperature.

[0006] We have also found that cycling heat from a cooler online temperature state to a higher regeneration temperature state suitable for regeneration in a TSA system generates significant thermal stress on the adsorbent material and the adsorber container. This can be a particular concern for radial adsorbers, as the thermal expansion of their internal components (e.g., internal screens for retaining the adsorbent material) can be more difficult to manage (e.g., they may be more difficult to access and replace due to the internal configuration of such adsorbers). Thermal cycling of the adsorbent material and container can lead to a shortened lifespan due to the thermal stress experienced by the thermal expansion and contraction that occurs when the temperature changes significantly from a cooler online temperature to a significantly warmer regeneration temperature.

[0007] Implementation schemes of equipment and processes can be provided to facilitate the use of low-temperature regeneration schemes, rather than high-temperature regeneration schemes for the adsorbent material. Implementation schemes can be configured such that the adsorber undergoing regeneration does not need to be cooled to its operating temperature before being brought back online for purification processing. Furthermore, implementation schemes can be configured such that the heating load is low enough that supplemental heating devices are not required to provide regeneration and / or that smaller heating devices can be used for heating (e.g., smaller electric heaters, smaller heat exchangers, etc.). In some implementations, this type of method can allow regeneration by utilizing heat from one or more waste streams or via a feed aftercooler that can be positioned between the adsorption system and a compression system, which can compress the fluid feed for feeding into the adsorption system for purification.

[0008] The implementation scheme can be adjusted to utilize a lower temperature scheme for regeneration, allowing the adsorbent material to undergo regeneration for a longer period than usual. This longer regeneration period, which can be used in conjunction with lower temperature regeneration cycles, can offer surprising benefits. For example, we found that utilizing a longer regeneration period at a lower temperature prevents some adsorbent material near the inner wall of the container from being insufficiently heated for regeneration (e.g., this prevents adequate regeneration of material at the periphery of the adsorbent bed, as the inner wall acts as a radiator). This can help improve the efficiency of the regeneration process and can help prevent premature penetration of impurities, which can occur in conventional systems due to incomplete regeneration of the peripheral portion of the material bed near the walls of the adsorber container via the regeneration process.

[0009] We have found that utilizing low-temperature regeneration schemes can avoid the risk of adsorbent damage due to high-temperature exposure and / or significant thermal stress caused by periodic temperature fluctuations that may occur between offline and online states (e.g., regeneration and adsorption operation states). For example, avoiding high temperatures used for regeneration can prevent the formation of high-temperature steam during the regeneration process, in which water may be desorbed into the heated regeneration process gas, thus preventing damage to the adsorbent material during the regeneration phase of operation.

[0010] The implementation scheme can also allow for reduced capital and operating costs. For example, in implementations that may utilize electric heater-type devices or regeneration gas heater-type devices that utilize steam as the heating medium, such devices can be smaller and utilize less power due to the lower temperatures available during the regeneration phase. In implementations that may utilize heat exchangers, which utilize warm waste streams (e.g., low-calorific-weight waste streams) or feeds that can undergo cooling before being fed into the adsorption system, the heat exchangers can be smaller in size and may have minimal (if any) additional power required for such processing.

[0011] Furthermore, since lower heating temperatures can be used to heat the cryogenic regenerated gas, the design and flexibility of the equipment can be improved, as lower-grade waste heat streams can be used as heating media to provide heating for the regenerated gas. Examples of lower-grade waste heat streams can be fluid streams with temperatures of 50°C to 140°C, 60°C to 120°C, 60°C to 110°C, 50°C to 100°C, or 50°C to 90°C.

[0012] Implementation schemes utilizing cryogenic regeneration processes can also avoid the need for cooling steps in the regeneration process. For example, there may be no requirement to cool the adsorber, which has undergone regeneration, back to its operating temperature before it is brought online for purification processing. This simplifies the operation and avoids the use of different types of equipment (e.g., valves, more complex conduit arrangements, etc.). This operational simplification also improves reliability and allows for more efficient and flexible control systems, as control criteria associated with cooling steps in the regeneration process can be avoided, as can processing issues related to detecting the appropriate temperature for completing the regeneration phase.

[0013] In some embodiments, an aftercooler or postcooler unit may be positioned downstream of the adsorption system for operations where the initial operation of an adsorber that has undergone regeneration via cryogenic regeneration and has entered its online state without any cooling to its operating temperature may pose a risk to downstream processing. Such an aftercooler unit can prevent any type of heat pulse from being transferred to downstream equipment and can be selectively utilized as needed while the adsorption system is in use. Such an aftercooler unit may utilize ambient air coolers, cooling water heat exchangers, or other relatively low-cost cooling devices that can utilize readily available cooling media downstream of the adsorption system and upstream of the main heat exchanger or other downstream equipment (e.g., air separation distillation columns, etc.) that can be utilized in downstream processing. In some embodiments, the aftercooler unit can be used for continuous operation. In other embodiments, it is anticipated that the aftercooler unit can be operated continuously for at least an initial period of time after the adsorber has returned from its offline state to online status.

[0014] Utilizing an aftercooler device can help avoid any residual heat from the regeneration process, as well as heat harmfully transferred downstream of the adsorption system by the adiabatic compression of the gas in the adsorber container, which enters its online state by experiencing pressure increases for the purification process. For example, such heat may cause the mechanical design temperature of some downstream equipment to exceed the initial phase of adsorption after the adsorber container returns to online status for purification. This type of thermal disturbance can also destabilize distillation processes that may occur downstream of the adsorption system, leading to losses of argon recovery in some types of downstream air separation systems and / or an overall reduction in the operating efficiency that may be provided for downstream processing equipment.

[0015] Our process, system, and equipment implementations can be used in adsorption systems configured to utilize TSA processing. Some implementations of these types of adsorption systems can be pre-purification units (PPUs), for example, used to purify the feed of compressed air for air separation processing. We have surprisingly found that utilizing a lower-temperature regeneration cycle can provide unexpected benefits in terms of increased operational flexibility, improved operational reliability, and improved operational efficiency. This lower-temperature regeneration cycle has a longer regeneration period and does not cool the adsorption bed or the adsorber undergoing regeneration before bringing it back online. The implementations also offer lower capital costs associated with the installation and manufacture of such systems.

[0016] We believe that the implementation scheme can provide these types of benefits because we have surprisingly found that the temperature front can move across the adsorbent bed faster than the mass transfer front. This allows for cryogenic regeneration processing to avoid problems that are conventionally considered problematic, and also helps to avoid any need to cool the regenerated adsorbent before bringing the adsorber back online. This type of cryogenic regeneration is expected to be used for any combination of gas and adsorbent, where the temperature front will move faster than the solute front or contamination front during the regeneration of the adsorbent.

[0017] In a first aspect, a process for operating an adsorption device is provided. An embodiment of the process may include feeding compressed gas into at least one first adsorber of the adsorption device in an online state to remove one or more impurities from the compressed gas via the adsorbent material of the at least one first adsorber, for a pre-selected purification period; and feeding regeneration gas into at least one second adsorber of the adsorption device in an offline state at a pre-selected regeneration temperature within a pre-selected regeneration low temperature range, for a pre-selected regeneration period, to heat the adsorbent material of the at least one second adsorber to a pre-selected regeneration temperature to regenerate the adsorbent material of the at least one second adsorber.

[0018] In some embodiments, the pre-selected regeneration time period may be shorter than the pre-selected purification time period. Furthermore, in some embodiments, the pre-selected regeneration low temperature range may be between 50°C and 120°C. In some embodiments, the pre-selected regeneration temperature may be less than or equal to 120°C, less than or equal to 100°C, or less than or equal to 90°C, and the pre-selected regeneration temperature may also be greater than or equal to 50°C, greater than or equal to 60°C, or greater than or equal to 70°C.

[0019] In some embodiments, this process can be combined with a temperature-switching adsorption (TSA) process. In some embodiments, for example, the TSA process can be used in conjunction with a pre-purification unit of an air separation process. Other embodiments can utilize other types of adsorption processing for other types of industrial processes that can utilize adsorption systems.

[0020] In a second aspect, the process may further include switching at least one first adsorber from an online state to an offline state, and switching at least one second adsorber from an offline state to an online state, such that the regeneration of the adsorbent material of at least one second adsorber does not undergo cooling before the at least one second adsorber is adjusted to the online state. For example, when the second adsorber is in an offline state, the switching can be performed without passing ambient temperature gas or a colder gas colder than a pre-selected regeneration temperature through the adsorbent material of the second adsorber before the second adsorber is switched to the online state.

[0021] In a third aspect, the process may further include feeding compressed gas into at least one second adsorber in an online state and feeding regeneration gas into at least one first adsorber in an offline state at a pre-selected regeneration temperature within a pre-selected regeneration low temperature range, for a pre-selected regeneration time period, to heat the adsorbent material of at least one first adsorber to a pre-selected regeneration temperature, so as to regenerate the adsorbent material of at least one first adsorber.

[0022] The implementation may further include switching at least one second adsorber from an online state to an offline state, and switching at least one first adsorber from an offline state to an online state, such that the regeneration of the adsorbent material of at least one first adsorber does not undergo cooling before the first adsorber is adjusted to the online state. For example, when the first adsorber is in an offline state, the switching can be performed without passing ambient temperature gas or a colder gas colder than a pre-selected regeneration temperature through the adsorbent material of the first adsorber before the second adsorber is switched to the online state.

[0023] In the fourth aspect, the flow rate of the regeneration gas and the pre-selected regeneration time period can be selected such that the difference between the temperature of the regeneration gas output from the adsorbent material of at least one second adsorber in an offline state and the temperature of the regeneration gas fed into the adsorbent material of at least one second adsorber in an offline state does not exceed 30°C. For example, the flow rate of the regeneration gas and the pre-selected regeneration time period can be selected such that the difference between the temperature of the regeneration gas when it is fed into the adsorbent material bed of at least one second adsorber and the temperature of the regeneration gas when it is output from the adsorbent material bed of at least one second adsorber does not exceed 30°C.

[0024] Furthermore, the flow rate of the regeneration gas and the pre-selected regeneration time period can be chosen such that the difference between the temperature of the regeneration gas output from the adsorbent material of at least one first adsorber in an offline state and the temperature of the regeneration gas fed into the adsorbent material of at least one first adsorber in an offline state does not exceed 30°C. For example, the flow rate of the regeneration gas and the pre-selected regeneration time period can be chosen such that the difference between the temperature of the regeneration gas when it is fed into the adsorbent material bed of at least one first adsorber and the temperature of the regeneration gas when it is output from the adsorbent material bed of at least one first adsorber does not exceed 30°C.

[0025] In the fifth aspect, the pre-selected regeneration low temperature range can be between 50°C and 120°C, and the pre-selected regeneration time period can be between 1 hour and 8 hours, and can also be less than or equal to the pre-selected purification time period.

[0026] In a sixth aspect, it is possible to feed compressed gas into at least one first adsorber and regenerated gas into at least one second adsorber, such that the ratio of the molar flow rate of the regenerated gas fed into the at least one second adsorber to the molar flow rate of the compressed gas fed into the at least one first adsorber is within a pre-selected ratio range. For example, it is possible to feed compressed gas into at least one first adsorber and regenerated gas into at least one second adsorber, such that the ratio of the molar flow rate of the regenerated gas fed into the at least one second adsorber to the molar flow rate of the compressed gas fed into the at least one first adsorber can be between 0.1 and 0.4, or between 0.15 and 0.3.

[0027] In a seventh aspect, the process may further include passing the regenerated gas feed through at least one regenerated gas heating device to heat the regenerated gas to a pre-selected regeneration temperature. The at least one regenerated gas heating device may be an electric heater or a heat exchanger, which may utilize a low-grade heat source as the heating medium (e.g., steam, compressed feed from a compressor, etc.).

[0028] For example, in some embodiments, at least one regenerated gas heating device may be a heat exchanger that uses a low-grade hot waste stream as a heating medium to heat the regenerated gas. The low-grade hot waste stream may have a temperature in the range of 50°C to 140°C.

[0029] In an eighth aspect, the process may include feeding compressed gas as a heating medium into a primary regenerated gas heating device to heat the regenerated gas to a pre-selected regeneration temperature. The regenerated gas may also pass through the primary regenerated gas heating device for heating therein.

[0030] In other embodiments, the process may include feeding regenerated gas through a primary regenerated gas heating device to heat the regenerated gas via a heating medium fed into the primary regenerated gas heating device; and feeding the heated regenerated gas output from the primary regenerated gas through a secondary regenerated gas heating device to heat the regenerated gas to a pre-selected regeneration temperature. In some embodiments, compressed gas may be fed as a heating medium into the primary regenerated gas heating device to facilitate heating the regenerated gas to the pre-selected regeneration temperature. In some embodiments, the secondary regenerated gas heating device may be an electric heater or a heat exchanger that can use steam as a heating medium.

[0031] In a ninth aspect, the process may include cooling the compressed gas to a pre-selected heat exchanger feed temperature via an aftercooler device located between the heat exchanger and the first adsorber after removing one or more impurities from the compressed gas.

[0032] In the tenth aspect, the process of the first aspect may include one or more features of the second, third, fourth, fifth, sixth, seventh, eighth, and / or ninth aspects. Embodiments of the process may also include other features or elements. For example, examples of such other features or elements can be found in exemplary embodiments of the process discussed herein.

[0033] Eleventhly, an adsorption device is provided. An embodiment of the adsorption device can be configured to implement a process for operating the adsorption device.

[0034] An embodiment of the adsorption device may include a first adsorber, adjustable between an online state and an offline state. In the online state, compressed gas is fed into the container of the first adsorber to contact the adsorbent bed and remove one or more impurities from the compressed gas. In the offline state, regeneration gas is fed into the container of the first adsorber to contact the adsorbent bed and desorb one or more impurities from the adsorbent bed, thereby regenerating the adsorbent bed of the first adsorber. The adsorption device may also include a second adsorber, adjustable between an online state and an offline state. In the online state, compressed gas is fed into the container of the second adsorber to contact the adsorbent bed and remove one or more impurities from the compressed gas. In the offline state, regeneration gas is fed into the container of the second adsorber to contact the adsorbent bed and desorb one or more impurities from the adsorbent bed, thereby regenerating the adsorbent bed of the second adsorber.

[0035] The device may further include at least one regeneration gas heating device positioned upstream of the first and second adsorbers to heat the regeneration gas to a pre-selected regeneration temperature within a pre-selected regeneration low-temperature range for a pre-selected regeneration time period. In some embodiments, the pre-selected regeneration low-temperature range may be a temperature between 50°C and 120°C. For example, in some embodiments, the pre-selected regeneration temperature may be less than or equal to 120°C, less than or equal to 100°C, or less than or equal to 90°C, and the pre-selected regeneration temperature may also be greater than or equal to 50°C, greater than or equal to 60°C, or greater than or equal to 70°C.

[0036] In some implementations, the device can be configured to perform temperature-switching adsorption (TSA) processes.

[0037] In some implementations, the device can be configured as a pre-purification unit for an air separation process. Other implementations can be configured for other types of industrial processes that can utilize the adsorption system.

[0038] In a twelfth aspect, at least one regenerated gas heating device may include a first regenerated gas heating device. For example, at least one regenerated gas heating device may include a first regenerated gas heating device positioned to receive compressed gas from a compression system as a heating medium to heat the regenerated gas and cool the compressed gas. The compression system may be located upstream of the first adsorber and may also be located upstream of the second adsorber.

[0039] As another example, at least one regenerated gas heating device may include a first regenerated gas heating device positioned to receive a heating medium to heat the regenerated gas and to cool the heating medium. The heating medium may be a gas output from a heat exchanger or compressor located downstream of a first adsorber and also downstream of a second adsorber.

[0040] In the thirteenth aspect, at least one first adsorber and at least one second adsorber can be configured such that the ratio of the molar flow rate of the regenerated gas to the molar flow rate of the compressed gas is between 0.1 and 0.4 or between 0.15 and 0.3.

[0041] In a fourteenth aspect, the adsorption apparatus may further include an aftercooler device configured to cool compressed gas having had one or more impurities removed by at least one first adsorber when at least one first adsorber is online, to provide a heat exchanger feed at a preselected heat exchanger feed temperature, and the aftercooler device may also be configured to cool compressed gas having had one or more impurities removed by at least one second adsorber when at least one second adsorber is online, to provide a heat exchanger feed at a preselected heat exchanger feed temperature. In some embodiments, the aftercooler device may be a heat exchanger configured to use ambient air or water as a refrigerant.

[0042] In aspect fifteen, the device of aspect eleven may include one or more features of aspects twelfth, thirteenth, and / or fourteenth. Embodiments of the device may also include other features or elements. For example, examples of such other features or elements can be found in exemplary embodiments of the device discussed herein.

[0043] It should be understood that implementations of this process and equipment can utilize a variety of conduit devices and process control elements. Implementations can utilize sensors (e.g., pressure sensors, temperature sensors, flow rate sensors, concentration sensors, etc.), controllers, valves, piping, and other process control elements. For example, some implementations can utilize automated process control systems and / or distributed control systems (DCS). A wide variety of conduit devices and process control systems can be used to meet a specific set of design criteria.

[0044] Further details, objectives, and advantages of our adsorption apparatus, adsorption system, plant, process for low-temperature regeneration of adsorbent materials, process for operating the adsorption system, and methods of manufacture and use will become apparent from the following description of some exemplary embodiments thereof. Attached Figure Description

[0045] Exemplary embodiments of our adsorption equipment, processes for operating the adsorption system, processes for low-temperature regeneration of adsorbent materials, and methods of manufacturing and using the adsorption system are shown in the accompanying drawings. It should be understood that the same reference numerals used in the drawings may identify the same parts.

[0046] Figure 1 (Figure 1) (It can also be called) Figure 1 (FIG. 1) is a block diagram of an exemplary embodiment of device 1 that can utilize the adsorption device 5. Figures 2-3 The first and second exemplary embodiments of the adsorption device 5 shown can be used in this exemplary embodiment of the device 1.

[0047] Figure 2 (Figure 2) (It can also be called) Figure 2 FIG. 2 is a schematic diagram illustrating a first exemplary embodiment of the adsorption device 5. Figure 2 The process of operating the adsorption device 5 can also be understood in a first exemplary embodiment of the process, which can utilize an exemplary embodiment of the process for low-temperature regeneration of the adsorption material.

[0048] Figure 3 (Figure 3) (It can also be called) Figure 3 FIG. 3 is a schematic diagram illustrating a second exemplary embodiment of the adsorption device 5. Figure 3 The process of operating the adsorption device 5 can also be understood in a second exemplary embodiment of the process, which can utilize an exemplary embodiment of the process for low-temperature regeneration of the adsorption material.

[0049] Figure 4 (Figure 4) (It can also be called) Figure 4 FIG. 4 is a flowchart illustrating an exemplary embodiment of a process for operating an adsorption device. Embodiments of device 1 and adsorption device 5 can be configured to implement this exemplary embodiment of the process.

[0050] The reference numerals used in the accompanying drawings include the following: 1 Equipment 3. Compression System (COMP.SYS) 5. Adsorption equipment 7. Heat Exchanger (HX) 9. Air Separation Unit (ASU) 10 valves 110 Fluid Feed 120 Compressed feed stream 130°C cooled, compressed feed stream 140 Compressed fluid feed 150 Purified fluid feed 160 Cooled heat exchanger feed 210 Regenerated Gas 220 Warm regeneration gas stream 230 Regenerated Gas Offline Adsorber Feed 240 Waste Stream 310 Heating medium 320 Cooled heating medium A compressor Argon gas B Pre-purification cooler C. First Adsorber Container D. Second Adsorber Container E Aftercooler unit F Primary regeneration gas heating device G Secondary regeneration gas heating device GN Gaseous Nitrogen GO (Gaseous Oxygen) LN liquid nitrogen LO Liquid Oxygen PPU pre-purification unit RGI feeds the regeneration gas into the offline adsorber of adsorption unit 5. The regeneration gas output from adsorption unit 5 by RGO S1 First Step S2 Second Step S3 Third Step S4 Fourth Step S5 Fifth Step S6 Sixth Step Valve 10 is adjustable between an open position and a closed position. Figure 2 and Figure 3 In the diagram, when valve 10 is displayed as white filled with a black line, valve 10 is indicated to be in the open position. When in the closed position, valve 10 is displayed as solid black. Detailed Implementation

[0051] refer to Figures 1-4 Industrial equipment 1 can be configured to receive one or more feed fluid streams, or utilize one or more feed fluids and process the feed fluids to form one or more product fluids. The product fluids can be used for storage and / or transportation. Alternatively, the product fluids can be used in another downstream device or device process (e.g., to form an oxidant stream to feed into a combustion device for fuel combustion, etc.).

[0052] In some embodiments, device 1 may include a compression system 3 (COMP. SYS.) that receives a gas feed and compresses it to a pre-selected feed pressure for downstream feeding into the compression system 3 for downstream processing in device 1. In some embodiments, the feed may include or may be air. For example, in embodiments that may utilize an air separation unit (ASU), the feed may be or may include air.

[0053] The compression system 3 can output a pressurized feed to the adsorption device 5. In some embodiments, the adsorption device 5 can be configured as a pre-purification unit (PPU). For example, the PPU may include a temperature-switching adsorption (TSA) system or an adsorption system utilizing TSA. The adsorption device 5 can be configured to remove one or more impurities from the pressurized feed fluid output from the compression system 3, for feeding the purified feed to the main heat exchanger 7. For example, the adsorption device 5 can utilize one or more adsorbers having adsorbent material therein to remove water, carbon dioxide, and / or other components from the feed to purify the fluid feed, so that the purified feed can be fed to the main heat exchanger 7.

[0054] The heat exchanger (HX) may include at least one heat exchanger positioned to cool the pressurized and purified feed output from the adsorption unit 5 via heat exchange with one or more refrigerant process fluid flows fed into the heat exchanger 7. The one or more refrigerant process fluid flows may be warmed by absorbing heat from the purified feed fed into the heat exchanger 7 for use as a warm refrigerant process fluid flow for discharge, as regeneration gas for the adsorption unit 5, as a gaseous product transported via pipeline, or for other uses as a warm fluid output from the heat exchanger 7.

[0055] In some embodiments, one or more booster compressors may be present, located downstream of the compression system 3 and / or adsorption unit 5 and upstream of the heat exchanger 7 or a downstream processing unit (e.g., ASU 9) located downstream of the heat exchanger 7. The one or more booster compressors may be positioned to increase the pressure of one or more portions of the feed fluid output from the compression system 3 for feeding into the tower of the adsorption unit 5, the main heat exchanger 7 and / or ASU 9, or for other downstream processing applications.

[0056] The cooled, purified fluid feed from heat exchanger 7 can be fed to a downstream processing unit of the equipment (e.g., ASU 9). In some embodiments, the downstream processing unit may be, for example, ASU 9. In such embodiments, the purified feed may be purified air, and the feed may be air. ASU 9 may include multiple towers, including a low-pressure tower and a high-pressure tower, for receiving the purified air feed cooled by heat exchanger 7 for separating the air to form one or more product fluids. One or more product fluids may include, for example, gaseous nitrogen (GN), liquid nitrogen (LN), gaseous oxygen (GO), and / or liquid oxygen (LO). In some embodiments, ASU 9 may include a medium-pressure tower positioned and configured to receive fluid from the low-pressure tower and / or the high-pressure tower to also simultaneously form an argon (Ar) product stream. The argon product stream that can be formed may be liquid argon or gaseous argon for feeding to a storage tank or downstream processes that can utilize the argon fluid.

[0057] In some implementations, the gaseous products (e.g., gaseous nitrogen (GN) and / or gaseous oxygen (GO)) output from the tower assembly of ASU 9 can pass through the main heat exchanger 7 as a refrigerant to undergo warming therein. The warmed gaseous nitrogen (GN) and / or gaseous oxygen (GO) output from the main heat exchanger 7 can be fed as product gases into a pipeline or storage, or it can be fed into another equipment unit for another equipment process.

[0058] Other embodiments of apparatus 1 may utilize a different type of downstream processing instead of ASU 9. In yet another embodiment, apparatus 1 may also include other downstream processing units that may be positioned to receive one or more streams output from ASU 9 for use with fluids output from ASU 9 (e.g., a liquefier positioned to liquefy product streams output from the tower of ASU 9, a combustion device that may utilize oxygen output from ASU as an oxidant for fuel combustion, an ammonia manufacturing apparatus that may utilize nitrogen from ASU 9 to form ammonia, etc.).

[0059] ASU 9 or other downstream processing units can also output at least one waste stream as a refrigerant stream, which can be fed into heat exchanger 7 and also used to cool the purified fluid feed output from adsorption unit 5. The warm waste stream can be output from the heat exchanger for discharge, or it can be fed into adsorption unit 5 as a regeneration gas for the regeneration of the adsorbent material in the offline adsorber of adsorption unit 5.

[0060] In some implementations, the compression system 3 and other components of device 1 can be operated using renewable energy sources (e.g., electricity powered by solar panels, wind turbines, and / or other types of renewable energy). Other implementations may rely on conventional power generation systems (e.g., natural gas or coal-fired power generation systems).

[0061] An embodiment of the adsorption device 5, which can be used in the embodiment of device 1, can utilize multiple adsorbers. Each adsorber may include a container in which an adsorbent bed is retained. The adsorbers may be configured as vertical adsorbers, horizontal adsorbers, radial adsorbers, and / or other suitable types of adsorbers. The adsorbent material may include silica, alumina, activated carbon, molecular sieves, or other suitable types of adsorbent materials.

[0062] The adsorber may include at least one first adsorber C and at least one second adsorber D. The adsorber may be connected to a conduit assembly that allows the adsorber to be adjusted between online and offline states. The conduit assembly may include a plurality of valves 10 and conduit segments, such that the conduit assembly may be configured and controlled such that (i) when the first adsorber C is online, the second adsorber D may be offline, and (ii) when the second adsorber D is online, the first adsorber C may be offline. Valve 10 may be adjusted between an open position and a closed position, such that the first adsorber C and the second adsorber D may switch between online and offline states, such that the first adsorber C receives compressed feed when it is online and the second adsorber is offline, and the second adsorber D receives compressed feed when it is online and the first adsorber C is offline.

[0063] For example, when online, each adsorber can receive compressed fluid feed 140 from compression system 3 to purify the compressed feed. The received compressed fluid feed 140 can pass through the container of the online adsorber and be output as purified fluid feed 150. The purified fluid feed 150 output from the online adsorber of adsorber device 5 can optionally undergo post-cooling via at least one aftercooler device E located between the adsorber and the main heat exchanger 7. The purified feed can be fed as heat exchanger feed 160, which has undergone cooling in heat exchanger 7, to the heat exchanger 7 downstream of adsorber device 5. The aftercooler device E can be configured and positioned such that the heat exchanger is at a pre-selected heat exchanger feed temperature to help maintain downstream processing stability and also allow for more efficient utilization of the heat exchange provided by the heat exchanger 7 downstream of the aftercooler device E.

[0064] When each adsorber is offline, it can receive a regeneration gas feed that promotes the regeneration of the adsorbent bed within the adsorber container. This allows impurities adsorbed by the adsorbent during the online feed to be desorbed and discharged from the adsorber as waste stream 240. As described above, for example, the regeneration gas fed to the offline adsorber can be a warm waste stream output from ASU 9 or other downstream processing units.

[0065] The regeneration process for an offline adsorber can return the adsorbent material to a regenerated state, whereby the material can be used for further purification processing. The waste stream 240 that can be discharged from the adsorber may include impurities removed from the feed when the adsorber is online and may be discharged. In some embodiments, the waste stream 240 containing impurities discharged from the adsorber may be discharged when the adsorber is offline. In some embodiments, the waste stream 240 may be used for one or more other processes (e.g., carbon capture processes, heat exchanger processes, etc.) before discharge.

[0066] The first adsorber C and the second adsorber D can be positioned and configured to perform purification for a pre-selected time period, including adsorbent material. The adsorption device 5 can be configured such that the first adsorber C can remain online for the pre-selected purification time period, and after this time period, be switched to an offline state. The second adsorber D can be configured and positioned such that the second adsorber is offline while the first adsorber C is online. When the first adsorber C is switched offline, the second adsorber can be switched online via the adjustment of valve 10. Then, the second adsorber D can remain online for the pre-selected purification time period. When the first adsorber C is offline, it can receive regeneration gas at a pre-selected regeneration temperature for regeneration for a pre-selected regeneration time period. After the second adsorber is switched online, and after the pre-selected purification time period, the second adsorber D can be switched back to an offline state, and the first adsorber C can be switched back to an online state via the adjustment of valve 10. When online, the first adsorber C can be fed with compressed feed fluid 140 to purify the feed with regenerated adsorbent material for a pre-selected purification period. Then, when offline, the second adsorber D can receive regeneration gas at a pre-selected regeneration temperature to undergo regeneration for a pre-selected regeneration period while offline.

[0067] When the adsorber switches between its online and offline states, an offline adsorber can undergo repressurization to the operating pressure range. Additionally, an offline adsorber can be depressurized to the regeneration pressure range to facilitate regeneration.

[0068] After the pre-selected purification period, the first adsorber C can be switched back to offline mode, and the second adsorber D can be switched back to online mode via the adjustment of valve 10. Then, the second adsorber D can remain online for the pre-selected purification period, and the first adsorber C can undergo regeneration again for the pre-selected regeneration period. After the pre-selected purification period for the second adsorber, the second adsorber C can be switched back to offline mode, and the first adsorber D can be switched back to offline mode via the adjustment of valve 10. Then, the first adsorber C can remain online for the pre-selected purification period, and the second adsorber D can undergo regeneration again for the pre-selected regeneration period.

[0069] The cycle between online and offline states can occur many different times. The purification period (which may also be referred to as "runtime" or "adsorption time") can be between 2 hours and 8 hours (e.g., at least two hours and no more than eight hours, 2 hours–5 hours, 2.5 hours–6.5 hours, etc.). The pre-selected regeneration period can be between 1 hour and 8 hours. In some embodiments, the pre-selected regeneration period can be the same as the pre-selected purification period. In other embodiments, the pre-selected regeneration period can be shorter than the pre-selected purification period.

[0070] For example, in some embodiments, the pre-selected regeneration time period can be 1.5-3.5 hours, 2-3 hours, 2-3.5 hours, 2-4 hours, or 2-5 hours, and the pre-selected purification time period can be between 3 hours and 8 hours. In such embodiments, the pre-selected regeneration time period is no longer than the pre-selected purification time period, and preferably, the pre-selected regeneration time period is a shorter time period than the pre-selected purification time period.

[0071] The adsorption device 5 may include other components, such as one or more regeneration gas heating devices (e.g., at least one primary regeneration gas heating device F and optionally at least one secondary regeneration gas heating device G), for heating the regeneration gas stream to a pre-selected regeneration temperature within a low-temperature regeneration gas temperature range. Such temperature ranges may be, for example, 50°C to 120°C, 60°C to 100°C, or 60°C to 90°C.

[0072] In some embodiments, the flow rate and regeneration time period can be selected such that the regeneration gas to be fed into one or more offline adsorbers of the adsorption device 5 can be pre-selected such that the temperature difference between the regeneration gas output RGO from the adsorbent bed of the offline adsorber and the temperature of the regeneration gas feed RGI fed into one or more offline adsorbers for the regeneration of the adsorbent material in the container of the offline adsorber is not more than 30°C (e.g., the temperature difference between the regeneration gas temperature when it is fed into the adsorbent bed and the temperature when it is output from the adsorbent bed is not more than 30°C).

[0073] Some embodiments may also utilize at least one aftercooler device E, which may be positioned downstream of the adsorbers of the adsorption device 5, to cool the purified fluid output from one or more in-line adsorbers of the adsorption device 5. In some configurations, a primary regeneration gas heating device F may be configured to heat the regeneration gas and also contribute to cooling the compressed feed output from the compression system 3. In such embodiments, the compressed feed may be further cooled via a pre-purification cooler B positioned between the primary regeneration gas heating device F and one or more in-line adsorbers of the adsorption device 5, such that the compressed feed fed into the adsorber is within a pre-selected temperature range (e.g., 0°C-40°C or 0°C-30°C, etc.).

[0074] For example, in Figure 2 In an embodiment of the adsorption device 5 shown, the compression system 3 can provide a compressed fluid feed 140 at a preselected feed pressure within a preselected feed pressure range for feeding into one or more adsorbers in an online state. The compressed feed can pass through the material adsorption bed in the online adsorber for removing one or more impurities, such that a purified fluid feed 150 can be output from the online adsorber. In some embodiments, the purified fluid feed 150 can be cooled via an aftercooler device E (shown in dashed lines) to cool the purified fluid feed 150 to a preselected heat exchanger feed temperature for feeding into heat exchanger 7 as heat exchanger feed 160 at the preselected heat exchanger feed temperature, for cooling in heat exchanger 7. The preselected heat exchanger feed temperature can be within a preselected heat exchanger feed temperature range (e.g., 0°C-40°C, 0°C-30°C, 0°C-20°C, etc.).

[0075] In some embodiments, the aftercooler device E may be an ambient air heat exchanger, a heat exchanger using cooling water as the cooling medium, or other suitable type of heat exchanger for cooling the purified fluid feed 150. In other embodiments, the aftercooler device E may not be used at all.

[0076] While the online adsorber receives a compressed fluid feed from a compression system for purification, the offline adsorber may receive regeneration gas 210, which may be the regeneration gas RGI to be fed into the offline adsorber of adsorption unit 5. Regeneration gas 210 may be a warm waste fluid output from one or more towers of ASU 9, for example, after the waste fluid has been warmed by its use as a refrigerant for cooling heat exchanger feed 160 via heat exchanger 7. For example, in some embodiments where the downstream processing unit is ASU 9, such a waste stream that can be used as regeneration gas may consist primarily of nitrogen, a mixture of nitrogen and oxygen, or may be primarily oxygen, and may contain little or no impurities to be desorbed from the adsorbent material of the offline adsorber.

[0077] The feed gas 210 to the offline adsorber can be heated via a primary regeneration gas heating device F. The primary regeneration gas heating device F can be an electric heater, or it can be configured to use a waste stream of suitable hot fluid as the heating medium 310, which is fed into the primary regeneration gas heating device for heat exchange with the regeneration gas to warm the regeneration gas to a pre-selected regeneration gas feed temperature within a pre-selected low-temperature regeneration range. In some embodiments, this pre-selected low-temperature regeneration range can be 50°C-120°C, 60°C-100°C, or 60°C-90°C. In some embodiments, the regeneration gas flow rate and the pre-selected regeneration time period can be selected such that the temperature of the regeneration gas output from the offline adsorber is no more than 30°C lower than the temperature of the regeneration gas fed into the offline adsorber for the regeneration of the adsorbent material (e.g., lower than the temperature of the regeneration gas fed into the offline adsorber at the pre-selected regeneration gas feed temperature by more than 0°C and 30°C, lower than the temperature of the regeneration gas fed into the offline adsorber at the pre-selected regeneration gas feed temperature by more than 0°C and 20°C, etc.).

[0078] In some embodiments, the heating medium 310 fed into the primary regenerated gas heating device F may be output as a cooled heating medium 320, and there may not be enough heat to adequately heat the regenerated gas to the desired pre-selected regenerated gas feed temperature. In such cases or embodiments, at least one secondary regenerated gas heating device G (shown in dashed lines) may be provided to further heat the regenerated gas to the desired pre-selected regenerated gas feed temperature. As mentioned above, for some embodiments, this temperature may be within a pre-selected low-temperature regeneration range, which may be 50°C–120°C. In some embodiments, the primary regenerated gas heating device F may utilize the heat of a fluid waste stream, and the secondary regenerated gas heating device G may be an electric heater. In other embodiments, the primary and secondary heating devices may be different types of heat exchangers utilizing different heating medium streams. In some implementations, a primary gas heating device F and a secondary gas heating device G are used. The heating medium for heating the regeneration gas used in these devices can be a low-grade hot waste stream, which can have a low-grade heating temperature of 50°C to 140°C, 60°C to 120°C, 60°C to 110°C, or other types of low-grade heating temperature ranges.

[0079] For example, the feed of regenerated gas 210 can be fed into a primary regenerated gas heating unit F to be output as a warm regenerated gas stream 220. This warm regenerated gas stream can be further heated to a pre-selected regenerated gas feed temperature via a secondary regenerated gas heating unit G to be fed into the offline adsorber at the pre-selected regenerated gas feed temperature 230. In other embodiments, the primary regenerated gas heating unit F may have sufficient heating medium 310 fed therein to output the offline adsorber feed 230 at the pre-selected regenerated gas feed temperature.

[0080] For example, as from Figure 3 It can be understood that the heating medium 310 fed into the primary regenerated gas heating device F can be a low-grade heated fluid flow (e.g., a fluid flow that may not be particularly hot, but may be hotter than ambient conditions, or a fluid flow that may only be 30°C-80°C hotter than the regenerated gas flow to be heated, etc.). In some embodiments, the low-grade heated fluid flow that can be used as the heating medium 310 can be, for example, a low-grade heating temperature of 50°C to 140°C, or 60°C to 120°C, or 60°C to 110°C.

[0081] For example, a compressed feed stream 120 output from compressor A of compression system 3, compressor A can compress fluid feed 110. In embodiments where the downstream processing unit includes ASU 9, fluid feed 110 can be air; in some embodiments, compressed feed stream 120 can be compressed gas. Compressed feed stream 120 can be heating medium 310, which is fed to primary regeneration gas heating device F for heating regeneration gas 210.

[0082] The cooled heating medium 320 can be a cooled, compressed feed stream 130 output from the primary regeneration gas heating unit F. In this configuration, the primary regeneration gas heating unit F can function as both a regeneration gas heating unit and an aftercooler for the compression system. If the cooled compressed feed stream 130 is insufficiently cooled for feeding into the online adsorber of the adsorption unit 5, a pre-purification cooler B can be positioned between the adsorber of the adsorption unit 5 and the primary regeneration gas heating unit F to further cool the feed, allowing the compressed fluid feed 140 to be fed into the online adsorber at a suitable temperature within a pre-selected adsorber feed temperature range (e.g., 0°C–40°C). In some embodiments, the pre-purification cooler B can be an ambient air heat exchanger, a heat exchanger utilizing cooling water as a refrigerant, or other suitable cooling devices to cool the compressed feed to a suitable temperature within the pre-selected adsorber feed temperature range.

[0083] The compressed feed conduit can be positioned between the compressor A of the compression system 3 and the adsorption device 5 to feed the compressed feed to the primary regeneration gas heating device F for use as the heating medium 310 therein, and to output the cooled heating medium 320 and feed it to the online adsorber (via the pre-purification cooler B in some embodiments as described above).

[0084] In other embodiments, the pre-purification cooler B may not be necessary. Instead, the primary regeneration gas heating device F can adequately cool the compressed feed output from the compression system 3, such that the cooled heating medium 320, which is the cooled compressed feed 130 output from the primary regeneration gas heating device F, can be fed into the online adsorber as a compressed fluid feed 140 at a suitable temperature within a pre-selected adsorber feed temperature range (e.g., 0°C-40°C, etc.) without undergoing further cooling.

[0085] Heating medium 310 and any secondary regeneration gas heating device G can be used to select the regeneration gas flow rate and a pre-selected regeneration time period, such that the temperature difference between the regeneration gas output from the adsorbent bed of the offline adsorber and the temperature of the regeneration gas feed into one or more offline adsorbers for the regeneration of the adsorbent material in the container of the offline adsorber is not more than 30°C (e.g., the temperature difference between the regeneration gas temperature when it is fed into the adsorbent bed and the temperature when it is output from the adsorbent bed is not more than 30°C or not more than 20°C, etc.).

[0086] A regenerated gas feed duct assembly can be positioned between the heat exchanger 7 and the regenerated gas feed duct, allowing the regenerated gas to be fed to the offline adsorber after passing through the primary regenerated gas heater F and any optional secondary regenerated gas heater G that may be available. The regenerated gas feed duct may include a valve 10 adjustable between an open and closed position for selectively feeding the regenerated gas to the offline adsorber, while the other adsorbers remain online to receive the feed for outputting purified feed.

[0087] In other embodiments, the primary regeneration gas heating device F may utilize another fluid source as the heating medium 310. For example, compressed gas from a booster compressor and / or compressed gas from a gaseous nitrogen compressor may be used as the heating medium 310 to cool the compressed gas, instead of using the compressed feed output from compressor A of compression system 3. Other embodiments may utilize a warm or heated stream from another process element as the heating medium 310, such that the primary regeneration gas heating device F can utilize a heating medium 310 that can promote heat recovery to avoid waste heat loss (e.g., due to exhaust, etc.) and improve the efficiency of device 1 or its downstream processing unit, which may be downstream of heat exchanger 7 and / or adsorption device 5.

[0088] An embodiment of the adsorption device 5 can be configured such that the adsorber is configured to readily receive regeneration gas and compressed feed fluid for operation within a preselected ratio of molar flow rates of regeneration gas to feed gas, said preselected ratio being within a preselected purge / air ratio or "P / A" ratio. In some embodiments, the P / A ratio can be greater than 0.1 and less than 0.4. For example, in some embodiments, the P / A ratio can be greater than or equal to 0.1 and less than or equal to 0.3. For example, the adsorber can be sized and configured such that the molar flow rate of the regeneration gas passing through the offline adsorber can be between 10% and 40% or between 10% and 30% of the molar flow rate of the compressed fluid feed 140 passing through the online adsorber. As yet another example, the P / A ratio can be 0.15-0.3 (e.g., the adsorber can be sized and configured such that the molar flow rate of the regeneration gas passing through the offline adsorber can be between 15% and 30% of the molar flow rate of the compressed fluid feed 140 passing through the online adsorber).

[0089] An embodiment of the adsorption device 5 can be provided such that the temperature difference between the online adsorber performing purification and the offline adsorber undergoing regeneration has a pre-selected temperature difference. This pre-selected temperature difference can be chosen to promote low-temperature regeneration while also helping to minimize thermal stress, which may be generated by the different temperatures utilized in the online and offline states. In some embodiments, the temperature difference between the online adsorber performing purification and the offline adsorber undergoing regeneration may not exceed 100°C, not exceed 70°C, or be between 15°C and 30°C.

[0090] The adsorption unit 5 can be configured such that switching between online and offline states of the adsorber can occur during regeneration without any cooling. For example, an embodiment of the adsorption unit 5 can be configured such that the offline adsorber undergoes regeneration via a cryogenic regeneration gas and subsequently switches to the online state without feeding any colder regeneration gas into the offline adsorber. This allows for longer regeneration periods to facilitate the use of lower-temperature regeneration gases for improved operating efficiency and also allows for faster switching between online and offline states for improved operational flexibility. Furthermore, eliminating such a cooling step in the regeneration process allows for a simpler configuration utilizing fewer conduits and valves, and also involves a simpler control scheme for more efficient and flexible operation. Simplifying the regeneration process by eliminating the cooling step also improves reliability by avoiding process checks to verify cooling completion and by having fewer valves and other adjustable process conduit elements that may fail during use due to wear.

[0091] Furthermore, using a lower regeneration gas temperature range and a relatively long regeneration time can promote improved regeneration performance by allowing the adsorbent material to regenerate more fully. This is especially true for adsorbent material near the container sidewalls, where the sidewalls can act as heat sinks, which can prevent the adsorbent material from being regenerated more fully, potentially leading to the penetration of unwanted impurities from the feed through that area of ​​the adsorbent material bed.

[0092] The use of longer regeneration periods in conjunction with lower regeneration temperatures can also reduce the thermal stress generated by temperature cycling between the adsorber's operating temperature and its online and offline states. This reduction in temperature differences between these states helps to decrease the thermal stress that may result from cycling between hotter and colder temperatures, thus extending the lifespan of the adsorber container and the adsorbent material. Furthermore, utilizing lower regeneration temperatures helps to avoid the generation of hot vapors that could potentially cause permanent degradation of the adsorbent material. Therefore, this implementation scheme can provide further improved operational efficiency by increasing the lifespan of the adsorbent material and the adsorber, and reducing the risk of problems that may arise during operation, such as downtime for maintenance and / or adsorbent material replacement.

[0093] An implementation that utilizes the aftercooler device E can provide additional benefits. For example, using the aftercooler device E can prevent any residual heat from the regeneration process that may be present after the adsorber is switched to its online state from being transferred downstream to the heat exchanger 7, which could cause the mechanical design temperature of the downstream equipment to be exceeded, potentially leading to thermal stress or strain problems. Furthermore, it helps ensure that the required heat exchanger feed temperature is maintained to help control the temperature profile in downstream processes (e.g., ASU 9), where increased heat could cause interference with separation processes, potentially destabilizing the distillation processes occurring downstream of the adsorber unit 5 and the heat exchanger 7.

[0094] Utilizing lower regeneration temperatures also allows for the use of smaller regeneration gas heating devices, which reduces the investment costs associated with such devices and also lowers their operating costs. Therefore, it should be understood that different implementations can provide a variety of enhancements or benefits, leading to improved operational flexibility, improved operational efficiency, and other advantages.

[0095] The embodiments of apparatus 1 and adsorption apparatus 5 can be configured to implement a process for utilizing low-temperature regeneration gas. Such a process can be used in the process for operating adsorption apparatus 5. (Reference) Figure 4In the first step S1, compressed gas can be fed into the first adsorber C of the online adsorption device. As the compressed gas passes through the first adsorber C, one or more impurities can be removed from the compressed gas via the adsorbent material bed in the first adsorber. In some embodiments, an aftercooler device E can be used to cool the purified compressed gas output from the first adsorber C.

[0096] In the second step S2, the regeneration gas can be fed into the offline second adsorber D at a pre-selected regeneration gas temperature within a pre-selected low-temperature regeneration range. The regeneration gas can continue through the second adsorber for a pre-selected regeneration period. As discussed above, the regeneration gas can be a waste stream from ASU 9 or other equipment process units, which can be heated to a pre-selected regeneration temperature via a primary regeneration gas heating device F, which can utilize a relatively low-temperature heating medium 310. The heating medium can be, for example, compressed gas output from the compression system 3, or other suitable relatively low-heat waste streams or other types of low-heat process streams. In some embodiments, a secondary regeneration gas heating device G can also be used to heat the regeneration gas to its pre-selected regeneration gas temperature, such that the regeneration gas fed into the offline adsorber is at the desired temperature.

[0097] In the third step S3, the second adsorber D can be switched to an online state, and the first adsorber C can be switched to an offline state. Regeneration of the adsorbent material in the second adsorber D, which can occur via the feed regeneration gas, can take place, allowing the adsorbent material to be regenerated and the second adsorber D to be switched to an online state without any cooling of the adsorbent material in the second adsorber D. In the third step S3, the first adsorber C can also be switched to an offline state.

[0098] In the fourth step S4, compressed gas can be fed into the online second adsorber. The compressed gas can be purified by passing through the regenerated adsorbent material within the second adsorber D. In some embodiments, an aftercooler device E can be used to cool the purified compressed gas exiting from the second adsorber D.

[0099] In step S5, the regenerated gas can be fed into the offline first adsorber C at a pre-selected regenerated gas temperature within a pre-selected low-temperature regeneration range. The regenerated gas can pass through the first adsorber for a pre-selected regeneration period. As discussed above, the regenerated gas can be a waste stream from ASU 9 or other equipment process units, which can be heated to a pre-selected regeneration temperature via a primary regenerated gas heating device F, which can utilize a relatively low-temperature heating medium 310. The heating medium can be, for example, compressed gas output from the compression system 3, or other suitable relatively low-heat waste streams or other types of low-heat process streams. As can be understood from the above, in some embodiments, a secondary regenerated gas heating device G can also be used to heat the regenerated gas to its pre-selected regenerated gas temperature.

[0100] In step S6, the first adsorber C can be switched to an online state, and the second adsorber D can be switched to an offline state. Regeneration of the adsorbent material in the first adsorber D, which can occur via the feed regeneration gas, can take place, allowing the adsorbent material to be regenerated and the first adsorber C to be switched to an online state without any cooling of the adsorbent material in the second adsorber. In step S6, the second adsorber D can also be switched to an offline state.

[0101] like Figure 4 As shown, the operation cycle of purification and regeneration of the adsorber in adsorption device 5, as well as the switching between online and offline states, can be repeated. Embodiments of this process may also include other steps or features. For example, the regeneration gas flow rate and a pre-selected regeneration time period can be selected such that the temperature difference between the regeneration gas output RGO from the adsorbent bed of the offline adsorber and the temperature of the regeneration gas feed RGI fed into one or more offline adsorbers for regeneration of the adsorbent material within the container of the offline adsorber is no more than 30°C (e.g., the temperature difference between the regeneration gas temperature when it is fed into the adsorbent bed and the temperature when it is output from the adsorbent bed does not exceed 30°C).

[0102] The process can be implemented such that the molar flow rates of the regenerated gas and the feed gas are within a pre-selected purge / air ratio or "P / A" ratio. In some embodiments, the P / A ratio can be greater than 0.1 and less than 0.4. For example, in some embodiments, the P / A ratio can be greater than or equal to 0.1 and less than or equal to 0.3. (For example, the molar flow rate of the regenerated gas through the offline adsorber can be between 10% and 40% or between 10% and 30% of the molar flow rate of the compressed fluid feed 140 through the online adsorber, and the molar flow rate of the regenerated gas through the offline adsorber can be between 15% and 30% of the molar flow rate of the compressed fluid feed 140 through the online adsorber, etc.)

[0103] As described above, the purification period for the online adsorber to receive compressed fluid feed 140 can be between 2 hours and 8 hours or other suitable time periods. The pre-selected regeneration period can be between 1 hour and 8 hours, or other suitable time periods as described above (e.g., 2 hours-3 hours, 2 hours-4 hours, etc.).

[0104] This process can be implemented such that the temperature difference between the online adsorber performing purification and the offline adsorber undergoing regeneration has a pre-selected temperature difference. This pre-selected temperature difference can be chosen to promote low-temperature regeneration while also helping to minimize thermal stress, which may be generated by the different temperatures utilized in the online and offline states. In some embodiments, the temperature difference between the online adsorber performing purification and the offline adsorber undergoing regeneration may not exceed 100°C, not exceed 70°C, or be between 15°C and 30°C.

[0105] The implementation of this process can be configured such that the offline adsorber can undergo regeneration via a cryogenic regeneration gas and subsequently switch to an online state without feeding any colder regeneration gas to the offline adsorber for any cooling before switching it back online. This allows for longer regeneration periods to facilitate the use of lower-temperature regeneration gas for improved operating efficiency and also allows for faster switching between online and offline states for improved operational flexibility. Furthermore, eliminating such a cooling step in the regeneration process allows for a simpler configuration utilizing fewer conduits and valves, and also involves a simplified control scheme for more efficient and flexible operation. Simplifying the regeneration process by eliminating the cooling step also improves reliability by avoiding process checks to verify cooling completion and by having fewer valves and other adjustable process conduit elements that may fail during use due to wear.

[0106] Furthermore, using a lower regeneration gas temperature range and a relatively long regeneration time can promote improved regeneration performance by allowing the adsorbent material to regenerate more fully. This is especially true for adsorbent material near the container sidewalls of the adsorber, where the sidewalls can act as heat sinks, which can prevent the adsorbent material from being regenerated more fully, potentially leading to the penetration of unwanted impurities from the feed through this area of ​​the adsorbent bed.

[0107] The use of longer regeneration periods in conjunction with lower regeneration temperatures can also reduce the thermal stress generated by temperature cycling between the adsorber's operating temperature and its online and offline states. This reduction in temperature differences between these states helps to decrease the thermal stress that may result from cycling between hotter and colder temperatures, thus extending the lifespan of the adsorber container and the adsorbent material. Furthermore, utilizing lower regeneration temperatures helps to avoid the generation of hot vapors that could potentially cause permanent degradation of the adsorbent material. Therefore, this implementation scheme can provide further improved operational efficiency by increasing the lifespan of the adsorbent material and the adsorber, and reducing the risk of problems that may arise during operation, such as downtime for maintenance and / or adsorbent material replacement.

[0108] An implementation that utilizes the aftercooler device E to cool the purified compressed gas to a pre-selected temperature (e.g., a pre-selected heat exchanger feed temperature) can also help provide the additional benefits described above. For example, using the aftercooler device E can prevent any residual heat from the regeneration process that may be present after the adsorber is switched to its online state from being transferred downstream to the heat exchanger 7, which could cause the mechanical design temperature of the downstream equipment to be exceeded, potentially causing thermal stress or strain problems. Furthermore, it helps ensure that the required heat exchanger feed temperature is maintained to help control the temperature profile in downstream processes (e.g., ASU 9), where increased heat can cause interference with separation processes, potentially destabilizing the distillation processes occurring downstream of the adsorber unit 5 and heat exchanger 7.

[0109] Implementations of this process may also include other steps or features. For example, an implementation may include feeding at least one waste stream from ASU 9 into a heat exchanger for use as a refrigerant, and subsequently feeding the warm waste stream output from heat exchanger 7 as a regeneration gas into an offline adsorber for heating to a pre-selected regeneration gas temperature for feeding into the offline adsorber. Such waste streams may be waste streams with high nitrogen, high oxygen, or high argon content, or waste streams containing significant amounts of nitrogen and oxygen, or nitrogen or oxygen. In other implementations, other suitable types of streams may be used as regeneration gases.

[0110] It should also be understood that other modifications can be made to meet a specific set of criteria for different implementations of equipment 1, adsorption equipment 5 (e.g., PPU), or the process. For example, devices for interconnecting different units of the equipment to enable fluid communication between different components (e.g., pumps, compressors, fans, valves, conduits, etc.), including valves, pipes, and other conduit components (e.g., conduit connection mechanisms, tubing, seals, valves, etc.), can be arranged to meet a specific equipment layout design that takes into account the available area of ​​the equipment, the sized fittings of the equipment, and other design considerations. As another example, the flow rate, pressure, and temperature of the fluid passing through at least one adsorber of adsorption equipment 5 and through other equipment components can vary considering different equipment design configurations and other design criteria. As yet another example, the number of equipment units and their arrangement can be adjusted to meet a specific set of design criteria. As yet another example, the material composition of the units of equipment 1 and the different structural components of equipment 1 can be any type of suitable material, as needed to meet a specific set of design criteria.

[0111] As yet another example, embodiments of device 1, the adsorption equipment, the adsorption system, and the process can each be configured to include or utilize process control elements positioned and configured to monitor and control operations (e.g., temperature and pressure sensors, flow sensors, automated process control systems with at least one workstation including a processor, non-transient memory, and at least one transceiver for communicating with sensor elements, valves, and controllers to provide a user interface for the automated process control system that can run on the device's workstation and / or another computer device, etc.). It should be understood that embodiments can also utilize distributed control systems (DCS) to implement one or more processes and / or control the operation of the equipment or process.

[0112] As another example, specific features described individually or as part of an embodiment are intended to be combined with other individually described features or as part of other embodiments. Therefore, elements and actions of the various embodiments described herein can be combined to provide additional embodiments. Thus, while certain exemplary embodiments of processes, apparatus, systems, and methods of manufacture and use thereof have been shown and described above, it should be clearly understood that the invention is not limited thereto, but may be embodied and practiced differently in other ways within the scope of the appended claims.

Claims

1. A process for operating an adsorption device, comprising: Compressed gas is fed into at least one first adsorber of an online adsorption device to remove one or more impurities from the compressed gas via the adsorption material of the at least one first adsorber during a pre-selected purification period. as well as During a pre-selected regeneration period, at a pre-selected regeneration temperature within a pre-selected regeneration low temperature range, regeneration gas is fed into at least one second adsorber of the offline adsorption device to heat the adsorbent material of the at least one second adsorber to a pre-selected regeneration temperature, thereby regenerating the adsorbent material of the at least one second adsorber.

2. The process according to claim 1, comprising: The at least one first adsorber is switched from the online state to the offline state, and the at least one second adsorber is switched from the offline state to the online state, such that the regeneration of the adsorbent material of the at least one second adsorber does not undergo cooling before the at least one second adsorber is adjusted to the online state.

3. The process according to claim 2, comprising: During the preselected regeneration time period, at a preselected regeneration temperature within the preselected regeneration low temperature range, the compressed gas is fed into the at least one second adsorber in the online state and the regeneration gas is fed into the at least one first adsorber in the offline state, so as to heat the adsorbent material of the at least one first adsorber to the preselected regeneration temperature, thereby regenerating the adsorbent material of the at least one first adsorber.

4. The process according to claim 3, comprising: The at least one second adsorber is switched from the online state to the offline state, and the at least one first adsorber is switched from the offline state to the online state, such that the regeneration of the adsorbent material of the at least one first adsorber does not undergo cooling before the at least one first adsorber is adjusted to the online state.

5. The process according to claim 3, wherein the flow rate of the regeneration gas and the pre-selected regeneration time period are selected such that the temperature of the regeneration gas output from the adsorbent material of the at least one second adsorber in the offline state and the temperature of the regeneration gas fed into the adsorbent material of the at least one second adsorber in the offline state do not exceed 30°C.

6. The process according to claim 5, wherein the flow rate of the regeneration gas and the pre-selected regeneration time period are selected such that the temperature of the regeneration gas output from the adsorbent material of the at least one first adsorber in the offline state and the temperature of the regeneration gas fed into the adsorbent material of the at least one first adsorber in the offline state do not exceed 30°C.

7. The process according to claim 1, wherein the pre-selected regeneration low temperature range is in the range of 50°C to 120°C, and the pre-selected regeneration time period is between 1 hour and 8 hours, and is less than or equal to the pre-selected purification time period.

8. The process according to claim 1, wherein the flow rate of the regenerated gas and the pre-selected regeneration time period are selected such that the temperature of the regenerated gas when it is fed into the adsorbent bed of the at least one second adsorber is no more than 30°C different from the temperature of the regenerated gas when it is discharged from the adsorbent bed.

9. The process of claim 1, wherein feeding the compressed gas into the at least one first adsorber and feeding the regenerated gas into the at least one second adsorber are performed such that the ratio of the molar flow rate of the regenerated gas fed into the at least one second adsorber to the molar flow rate of the compressed gas fed into the at least one first adsorber is between 0.1 and 0.

4.

10. The process of claim 1, wherein feeding the compressed gas into the at least one first adsorber and feeding the regenerated gas into the at least one second adsorber are performed such that the ratio of the molar flow rate of the regenerated gas fed into the at least one second adsorber to the molar flow rate of the compressed gas fed into the at least one first adsorber is between 0.15 and 0.

3.

11. The process according to claim 1, comprising: The regenerated gas is fed through at least one regenerated gas heating device to heat the regenerated gas to a pre-selected regeneration temperature.

12. The process according to claim 11, wherein the at least one regenerated gas heating device uses a low-grade hot waste stream as a heating medium to heat the regenerated gas, the low-grade hot waste stream having a temperature in the range of 50°C to 140°C.

13. The process according to claim 1, comprising: The compressed gas is fed into the primary regeneration gas heating device as a heating medium to heat the regeneration gas to a pre-selected regeneration temperature.

14. The process according to claim 1, comprising: The regenerated gas is fed through a primary regenerated gas heating device to heat the regenerated gas via a heating medium fed into the primary regenerated gas heating device; as well as The heated regenerated gas output from the primary regenerated gas is fed through a secondary regenerated gas heating device to heat the regenerated gas to a pre-selected regeneration temperature.

15. The process according to claim 1, comprising: After removing the one or more impurities from the compressed gas, the compressed gas is cooled to a pre-selected heat exchanger feed temperature via an aftercooler device located between the heat exchanger and the first adsorber.

16. The process according to claim 1, wherein the pre-selected regeneration low temperature range is in the range of 50°C to 120°C.

17. An adsorption device, comprising: A first adsorber is adjustable between an online state and an offline state. In the online state, compressed gas is fed into the container of the first adsorber to contact the adsorbent material bed to remove one or more impurities from the compressed gas. In the offline state, regeneration gas is fed into the container of the first adsorber to contact the adsorbent material bed of the first adsorber to desorb the one or more impurities from the adsorbent material bed of the first adsorber, thereby regenerating the adsorbent material bed of the first adsorber. and A second adsorber is adjustable between an online state and an offline state. In the online state, compressed gas is fed into the container of the second adsorber to contact the adsorbent bed of the second adsorber to remove one or more impurities from the compressed gas. In the offline state, regeneration gas is fed into the container of the second adsorber to contact the adsorbent bed of the second adsorber to desorb the one or more impurities from the adsorbent bed of the second adsorber, thereby regenerating the adsorbent bed of the second adsorber. At least one regenerated gas heating device is positioned upstream of the first and second adsorbers to heat the regenerated gas to a preselected regeneration temperature within a preselected regeneration low temperature range during a preselected regeneration time period.

18. The adsorption apparatus of claim 17, wherein the at least one regeneration gas heating device comprises a first regeneration gas heating device, the first regeneration gas heating device being positioned to receive the compressed gas from a compression system as a heating medium to heat the regeneration gas and cool the compressed gas, the compression system being positioned upstream of the first adsorber and also upstream of the second adsorber.

19. The adsorption apparatus of claim 17, wherein the at least one regeneration gas heating device comprises a first regeneration gas heating device, the first regeneration gas heating device being configured to receive a heating medium to heat the regeneration gas and cool the heating medium, the heating medium being a gas output from a heat exchanger or compressor located downstream of the first adsorber and also downstream of the second adsorber.

20. The adsorption device according to claim 17, comprising: An aftercooler device is configured to cool the compressed gas through which the one or more impurities are removed by the at least one first adsorber when the at least one first adsorber is in the online state, to provide a heat exchanger feed at a preselected heat exchanger feed temperature, and the aftercooler device is further configured to cool the compressed gas through which the one or more impurities are removed by the at least one second adsorber when the at least one second adsorber is in the online state, to provide a heat exchanger feed at the preselected heat exchanger feed temperature.

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