Air separation plant

Air separation plants produce about 99% of the gas, while electrolysis plants produce about 1%. 

Chemical Conversion. In both on-site and merchant air separation plants, special provisions must be made to remove certain impurities. The main impurity of this type is carbon monoxide, CO, which is difficult to separate from nitrogen using distiHation alone. The most common approach for CO removal is chemical conversion to CO2 using an oxidation catalyst in the feed air to the air separation unit. The additional CO2 which results, along with the CO2 from the atmosphere, is then removed by a prepuritication unit in the air separation unit. 

A, 5A, and 13X zeoHtes are the predorninant adsorbents for CO2 removal by temperature-swing processes. The air fed to an air separation plant must be H2O- and C02-ftee to prevent fouling of heat exchangers at cryogenic temperatures 13X is typically used here. Another appHcation for 4A-type zeoHte is for CO2 removal from baseload and peak-shaving natural gas Hquefaction faciHties. 

The Eastman Chemicals from Coal faciUty is a series of nine complex interrelated plants. These plants include air separation, slurry preparation, gasification, acid gas removal, sulfur recovery, CO /H2 separation, methanol, methyl acetate, and acetic anhydride. A block flow diagram of the process is shown in Eigure 3. The faciUty covers an area of 2.2 x 10 (55 acres) at Eastman s main plant site in Kingsport, Teimessee. The air separation plant is... 

The latest of three ethylene recovery plants was started in 1991. Sasol sold almost 300,000 t of ethylene in 1992. Sasol also produces polypropylene at Secunda from propylene produced at Sasol Two. In 1992 Sasol started constmction of a linear alpha olefin plant at Secunda to be completed in 1994 (40). Initial production is expected to be 100,000 t/yr pentene and hexene. Sasol also has a project under constmction to extract and purify krypton and xenon from the air separation plants at Sasol Two. Other potential new products under consideration at Sasol are acrylonitrile, acetic acid, acetates, and alkylamines. 

Medium Heat- Value Gas. Medium heat-value (medium Btu) gas (6,7) has a heating value between 9 and 26 MJ/m (250 and 700 Btu/fT). At the lower end of this range, the gas is produced like low heat-value gas, with the notable exception that an air separation plant is added and relatively pure oxygen (qv) is used instead of air to partially oxidize the coal. This eliminates the potential for nitrogen in the product and increases the heating value of the product to 10.6 MJ /m (285 Btu/fT). Medium heat-value gas consists of a mixture of methane, carbon monoxide, hydrogen, and various other gases and is suitable as a fuel for industrial consumers. 

Fig. 5. Production of helium-group gases in a classical air-separation plant.

Commercially pure (< 99.997%) helium is shipped directiy from helium-purification plants located near the natural-gas supply to bulk users and secondary distribution points throughout the world. Commercially pure argon is produced at many large air-separation plants and is transported to bulk users up to several hundred kilometers away by tmck, by railcar, and occasionally by dedicated gas pipeline (see Pipelines). Normally, only cmde grades of neon, krypton, and xenon are produced at air-separation plants. These are shipped to a central purification faciUty from which the pure materials, as well as smaller quantities and special grades of helium and argon, are then distributed. Radon is not distributed commercially. 

Russia, nitrogen (qv) from the adjacent air-separation plant, and reformed gas with the purified fuel gas stream from the plant. 

Both air and oxygen processes can be designed to be comparable in the following areas product quaUty, process flexibiUty for operation at reduced rates, and on-stream rehabiUty (97,182). For both processes, an on-stream value of 8000 h/yr is typical (196). The rehabiUty of the oxygen-based system is closely linked to the rehabiUty of the air-separation plant, and in the air process, operation of the multistage air compressor and power recovery from the vent gas is cmcial (97). 

For the same production capacity, the oxygen-based process requires fewer reactors, all of which operate in parallel and are exposed to reaction gas of the same composition. However, the use of purge reactors in series for an air-based process in conjunction with the associated energy recovery system increases the overall complexity of the unit. Given the same degree of automation, the operation of an oxygen-based unit is simpler and easier if the air-separation plant is outside the battery limits of the ethylene oxide process (97). 

Even the best modern low-temperature air separation plant has an efficiency only a small fraction of the theoretical optimum, that is, about 15 to 20 percent. The principal sources of inefficiency are threefold (1) the nonideality of the refrigerating process, (2) the imperfection of the heat exchangers, and (3) losses of refrigeration through heat leak. 

Experience in air separation plant operations and other ciyogenic processing plants has shown that local freeze-out of impurities such as carbon dioxide can occur at concentrations well below the solubihty limit. For this reason, the carbon dioxide content of the feed gas sub-jec t to the minimum operating temperature is usually kept below 50 ppm. The amine process and the molecular sieve adsorption process are the most widely used methods for carbon dioxide removal. The amine process involves adsorption of the impurity by a lean aqueous organic amine solution. With sufficient amine recirculation rate, the carbon dioxide in the treated gas can be reduced to less than 25 ppm. Oxygen is removed by a catalytic reaction with hydrogen to form water. 

While comparison of the absolute capital costs and costs of electricity among different power systems is difficult and uncertain, the structure of these costs is rather typical, and the costs of component units are usually within known ranges. For an oxygen-blown IGCC power system, the breakdown of the capital cost for the four component units is air separation plant (11 to 17 percent), fuel gas plant (33 to 42 percent), combined-cycle unit (32 to 39 percent), and balance of plant (2 to 21 percent). The breakdown of the cost of elec tricity is capital charge (52 to 56 percent), operating and maintenance (14 to 17 percent), and fuel (28 to 32 percent). 

The main market for turboexpanders has been in low-pressure air separation plants, expanding down from 5 bar, and in hydrocarbon processing plants, expanding natural gas from as high as 200 bar. The air separation expanders are roughly divided into two types. The first type ranges from a few horsepower up to 100 hp. Here, the expander power is too small to be economically recovered and is, therefore. 

The largest numher of turhoexpanders are applied in low-pressure air separation plants, expanding from 75 or 150 psi (517 or 1,034 kN/ m ) However, the greatest part of the total applied horsepower goes into hydroearhon proeesses. 

In natural gas applieations, ehanges in normal design eonditions are eommon over time, but even relatively stable applieations sueh as air separation are not totally immune from ehange. However, sinee die frequeney of ehanges in normal design eonditions for air separation plants is mueh less dian for namral gas proeessing plants, die following addresses turboexpanders in natural gas plant applieations. 

We next consider a number of plants in which the combustion process is modified by changing the oxidation of the fuel. Table 8. ID and Figs. 8.18-8.20. The first group (Dl, D2 and D3) are plants with PO—insufficient air is supplied to the PO reactor, less than that required to produee stoichiometric combustion. The second group (D4, D5 and D6) are plants where air is replaced as the oxidant by pure oxygen whieh is assumed to be available from an air separation plant. 

In cycle D4 [15, since the fuel is burnt with pure oxygen, the exhaust gases contain CO2 and H2O almost exclusively (Fig. 8.21). Cooling the exhaust below the dew point enables the water to condense and the resulting CO2 stream is obtained without the need for chemical absorption. The exjjensive auxiliary plant involved in direct removal of the CO2 is not needed, but of course there is now the additional expense of an air separation plant to provide the pure oxygen for combustion. 

Expansion turbines are related in many design features to the centrifugal compressor. The key exception being that the turbine receives a high pressure gas for expansion and power recovery to a lower pressure and is usually accompanied by the recovery of the energy from the expansion. For example, applications can be (1) air separation plants (2) natural gas expansion and liquefaction (for gas let-down in pipeline transmission to replace throttle valves where no... 

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