Apparatus and process for liquefying gases
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Solution Overview
Problem
Current air separation plants for liquefying gases like nitrogen and oxygen require large amounts of electrical power due to the need for numerous compressors and expanders, leading to high operational costs and inefficiencies.
Innovation Solution
An open loop refrigeration system that reduces electrical power consumption by utilizing the properties of non-compressible liquid nitrogen to achieve high pressures with less force, eliminating the need for electrical compressors and incorporating a liquefier device that can be retrofitted into existing air separation plants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional compressors and expanders are used to liquefy gases, then the liquefaction process can be achieved, but the electrical power consumption increases significantly
Solution Approach 1:
The invention extracts and eliminates the electrical compressor from the liquefaction system. Instead of using mechanical compression to achieve high pressure, the system uses a direct drive turbine that converts thermal energy directly into mechanical work, thereby removing the need for separate compression equipment and reducing electrical power consumption.
Solution Approach 2:
The invention replaces the conventional mechanical compression system with a direct drive turbine system. The turbine directly couples the heat engine to the compressor, eliminating the need for electrical motors and mechanical transmissions. This substitution of mechanical systems reduces electrical power consumption while maintaining liquefaction productivity.
2Stress or pressure
If multiple compressors and expanders are used to achieve high pressure, then the required pressure can be obtained, but the device complexity increases
Solution Approach 1:
The invention merges the compressor and turbine into a single integrated direct drive unit. The turbine and compressor share a common shaft and housing, allowing them to operate as one synchronized system. This merging reduces the number of separate components while maintaining the required pressure levels through coordinated operation.
Solution Approach 2:
The direct drive turbine-compressor unit serves multiple functions simultaneously: it compresses the gas to high pressure, recovers energy from the expansion process, and provides refrigeration. This multi-functional design reduces the overall number of components needed in the system while achieving the required pressure levels.
3Quantity of substance
If conventional liquefaction systems are used, then liquid gas can be produced, but the operational costs increase due to high power consumption
Solution Approach 1:
The invention implements a self-service system where the turbine-compressor unit generates its own driving power from the thermal energy of the process itself. The heat engine uses the temperature difference within the system to drive the turbine, which in turn drives the compressor. This self-powered operation eliminates the need for external electrical power, reducing operational costs while maintaining liquid gas production.
Solution Approach 2:
The invention utilizes phase transitions of the working fluid to generate mechanical work. The heat engine exploits the phase change between liquid and vapor to drive the turbine, converting thermal energy directly into mechanical energy. This phase transition-based energy conversion reduces reliance on external electrical power sources, thereby lowering operational costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly decreases power requirements, enabling the production of saleable liquid gases at a lower cost and increasing efficiency by leveraging the properties of liquid nitrogen to achieve high pressures with less energy input.
Implementation Method 1
The third step is to reduce the flow in pressure through a needle valve causing a Joule Thompson effect. The exit of the needle valve provides a two-phase liquid.
Implementation Method 2
The fourth step is to cool the liquid and gas down to all liquid, which is done in the flash pot. That is all the refrigeration needed.
Data Source
AI summary
A liquefier device which may be a retrofit to an air separation plant or utilized as part of a new design. The flow needed for the liquefier comes from an air separation plant running in a maxim oxygen state, in a stable mode. The three gas flows are low pressure oxygen, low pressure nitrogen, and higher pressure nitrogen. All of the flows are found on the side of the main heat exchanger with a temperature of about 37 degrees Fahrenheit. All of the gasses put into the liquefier come out as a subcooled liquid, for storage or return to the air separation plant. This new liquefier does not include a front end electrical compressor, and will take a self produced liquid nitrogen, pump it up to a runnable 420 psig pressure, and with the use of turbines, condensers, flash pots, and multi pass heat exchangers. The liquefier will make liquid from a planned amount of any pure gas oxygen or nitrogen an air separation plant can produce.