Modular Cold Box Assembly for Rapid Cryogenic Column Installation
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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, leading to longer installation times and higher costs.
Innovation Solution
A method and device for designing a cold box module that can be shipped in one or two pieces, with support saddles and a jacking system to facilitate horizontal transportation and vertical assembly, allowing for pre-installed platforms, lighting, and utility lines to minimize site work and reduce installation 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 limit the size of columns that can be shipped
Solution Approach 1:
The distillation column is divided into multiple sections (upper module section and lower module section) that can be fabricated separately, transported independently within size constraints, and assembled on-site. This segmentation allows larger overall column sizes to be achieved while complying with transportation limitations.
Solution Approach 2:
The column sections are nested within cold box modules during fabrication and transportation, with the column fitting inside the insulated enclosure. This nested configuration optimizes space utilization during transit and allows the column to be erected in its final vertical orientation after delivery.
2Loss of time
If more prefabrication is used to reduce on-site construction, then installation time is reduced, but transportation constraints prevent shipping of complete large-scale packages
Solution Approach 1:
The complete air separation plant package is segmented into modular units (cold box modules with integrated column sections) that can be shipped within transportation size limits. Each module is pre-fabricated with support saddles and associated equipment, enabling rapid on-site assembly while minimizing installation time.
Solution Approach 2:
Support saddles are pre-installed on the column sections during fabrication, and modules are pre-assembled with lighting, platforms, and utility lines before shipment. This preliminary action reduces the complexity and time required for on-site installation, as these components are already in position when the modules arrive at the installation site.
3Length of moving object
If columns are erected and installed on-site after transportation, then transportation constraints are satisfied, but installation time and costs increase
Solution Approach 1:
The column sections are merged with their respective cold box modules in a pre-assembled configuration before shipment. The support saddles are integrated onto the columns during fabrication, creating unified modules that require minimal additional work on-site. This merging reduces installation time while satisfying transportation size constraints.
Solution Approach 2:
The support saddles act as intermediaries that facilitate the connection between column sections and the cold box structure. Pre-installed on the columns, these saddles enable rapid assembly and alignment during on-site erection, reducing the time and complexity of installation while allowing the modules to be transported in a compact horizontal configuration.
4Ease of manufacture
If complete prefabricated packages are shipped, then on-site construction is minimized, but the size of air separation plants is limited by transportation capabilities
Solution Approach 1:
Large air separation plants are segmented into multiple cold box modules, each containing a column section with pre-installed support saddles. This segmentation allows the overall plant scale to exceed transportation limits while maintaining a high degree of prefabrication, as each module can be shipped independently and assembled on-site to create the complete large-scale plant.
Solution Approach 2:
The support saddles are designed as universal components that can be pre-installed on various column sections and integrated with different cold box module configurations. This multi-functionality allows the same pre-fabricated saddle design to be used across different plant scales and configurations, enabling scalable plant construction while maintaining standardized prefabrication processes.
Data Source
AI summary
A method for installation of a cryogenic distillation apparatus is provided. The method can include the steps of: providing an upper module section having an upper column section disposed within and secured to the upper module section, wherein the upper module comprises a roof; providing a lower module section having a lower column section disposed within and secured to the lower module section; erecting the lower module section from a horizontal position to a vertical position at an installation site; lifting the upper module section from a horizontal position and attaching the upper module section, while in a vertical position, to a top portion of the lower module section; lowering the upper column section, independent of the upper module section, toward the lower column section; and welding the upper column section and the lower column section together.