Cold Box Module Segmentation for Large Air Separation Column Transport
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Solution Overview
Problem
Large air separation plants face challenges in transportation and installation due to the size of distillation columns, which limits prefabrication and increases on-site construction requirements, especially for larger plants where columns are partly packed.
Innovation Solution
The method involves prefabricating the distillation column into transportable modules, including a skirt system for stability during transport and a jacking system for vertical assembly, allowing for separate transportation and rapid on-site assembly of the cold box modules with minimal equipment and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large distillation columns are constructed in fabrication shops and transported to installation sites, then prefabrication is achieved and on-site construction is minimized, but transportation constraints prevent this approach for larger plants with bigger columns
Solution Approach 1:
The distillation column is divided into multiple sections that can be separately fabricated and transported. Each section is constructed as an independent module with its own cold box enclosure, allowing transportation within size constraints while maintaining the capability for prefabrication. The sections are then assembled on-site to form the complete large-scale column.
Solution Approach 2:
The column sections are transported in a horizontal orientation rather than vertical, changing the dimension of transportation from height to length. This allows large-diameter columns to be transported on standard roadways and waterways by lying them on their sides, effectively bypassing transportation size limitations.
2Length of moving object
If a lower degree of prefabrication is used for larger columns due to transportation constraints, then transportation becomes feasible, but on-site construction time and complexity increase
Solution Approach 1:
Extensive preliminary work is performed at the fabrication shop including constructing the cold box enclosures, installing insulation, placing column sections, and pre-assembling major components. This preliminary action maximizes prefabrication within transportation constraints, significantly reducing the scope of work required on-site and minimizing installation time.
Solution Approach 2:
Multiple functions are combined into single transportable modules: the column structure, cold box enclosure, insulation system, and supporting equipment are integrated into unified sections. This merging reduces the number of separate assembly operations needed on-site, thereby reducing installation time and complexity.
3Length of moving object
If the cold box is erected and installed at the installation site for larger plants, then transportation constraints are avoided, but construction requirements and equipment needs increase
Solution Approach 1:
The cold box is segmented into multiple transportable sections that are fabricated separately and assembled on-site. Each section is a complete, self-contained module with its own structural framework and insulation, reducing on-site construction requirements compared to erecting a single large cold box while maintaining transportation feasibility.
Solution Approach 2:
The cold box sections are designed with removable walls and adjustable configurations that allow them to be transported in a compact state and then expanded or reconfigured on-site. This parameter change enables the same structure to meet both transportation constraints and final installation requirements with minimal on-site construction.
Data Source
Figure 1A~1D
Figure 2A~2B
Figure 3
AI summary
A method for constructing a cold box module and resulting apparatus is provided. The method can include providing a cold box module having framing and an upper and lower module sections, introducing an upper column section (3) longitudinally into the upper module section while the upper module section is substantially horizontal; introducing a lower column section (1) longitudinally into the lower module section while the lower module section is substantially horizontal; releasably attaching the lower column section to the lower module section using shipping saddle spacers (91) and support saddles (9); and attaching a skirt attachment (81) to the lower column section and the lower module section, wherein the skirt attachment is configured to limit longitudinal movement of the lower column section when the lower module section is in a horizontal position during transport. After erecting the cold box module at the installation site, the shipping saddle spacers can be removed and the upper column section is lowered using a jacking system (90) located on the roof of the cold box module.