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AIR
AIR COMPOSITION
Dry Air is relatively uniform in composition, with primary constituents as shown below.
Ambient Air, may have up to about 5% (by volume) Water content and may contain a number of
other gases (usually in trace amounts) that are removed at one or more points in the Air
separation and product purification system.
Primary components of Dry Air
An air separation plant separates atmospheric air into its primary components, typically
nitrogen and oxygen, and sometimes also argon and other rare inert gases.
The most common method for air separation is cryogenic distillation. Cryogenic air separation
units (ASUs) are built to provide nitrogen or oxygen and often co-produce argon. Other methods
such as Membrane, pressure swing adsorption (PSA) and Vacuum Pressure Swing Adsorption
(VPSA), are commercially used to separate a single component from ordinary air. High purity
oxygen, nitrogen, and argon used for Semiconductor device fabrication requires cryogenic
distillation.
13. REFERENCES
3.^ Latimer, Chemical Engineering Progress (1967) Vol. 63 (2) pp. 35-59
6.^ W.F. Castle, "Air Separation and liquefaction: recent developments and prospects for
the beginning of the new millennium", International Journal of Refrigeration (2002) Vol.
25, pp. 158-172 [3]
7.^ Particulate matter from forest fires caused an explosion in the ASU of a Gas to Liquid
plant, see [4]
9.^ Higman, Christopher; van der Burgt, Maarten (ed) Gasification (2nd Edition)
Elsevier 2008 ISBN 978-0-7506-8528-3 p. 324
10. Wikipedia.
3. The process air is generally passed through a molecular sieve bed, which removes any
remaining water vapour, as well as carbon dioxide, which would freeze and plug the
cryogenic equipment. Molecular sieves are often designed to remove any gaseous
hydrocarbons from the air, since these can be a problem in the subsequent air distillation
that could lead to explosions.[6] The molecular sieves bed must be regenerated. This is
done by installing multiple units operating in alternating mode and using the dry coproduced waste gas to desorb the water.
4. Process air is passed through an integrated heat exchanger (usually a plate fin heat
exchanger) and cooled against product (and waste) cryogenic streams. Part of the air
liquefies to form a liquid that is enriched in oxygen. The remaining gas is richer in
nitrogen and is distilled to almost pure nitrogen (typically < 1ppm) in a high pressure
(HP) distillation column. The condenser of this column requires refrigeration which is
obtained from expanding the more oxygen rich stream further across a valve or through
an Expander, (a reverse compressor).
5. Alternatively the condenser may be cooled by interchanging heat with a reboiler in a low
pressure (LP) distillation column (operating at 1.2-1.3 bar abs.) when the ASU is
producing pure oxygen. To minimize the compression cost the combined
condenser/reboiler of the HP/LP columns must operate with a temperature difference of
only 1-2 kelvin, requiring plate fin brazed aluminium heat exchangers. Typical oxygen
purities range in from 97.5% to 99.5% and influences the maximum recovery of oxygen.
The refrigeration required for producing liquid products is obtained using the JT effect in
an expander which feeds compressed air directly to the low pressure column. Hence, a
certain part of the air is not to be separated and must leave the low pressure column as a
waste stream from its upper section.
6. Because the boiling point of argon (87.3 K at standard conditions) lies between that of
oxygen (90.2 K) and nitrogen (77.4 K), argon builds up in the lower section of the low
pressure column. When argon is produced, a vapor side draw is taken from the low
pressure column where the argon concentration is highest. It is sent to another column
rectifying the argon to the desired purity from which liquid is returned to the same
location in the LP column. Use of modern structured packings which have very low
pressure drops enable argon purities of less than 1 ppm. Though argon is present in less to
1% of the incoming, the air argon column requires a significant amount of energy due to
the high reflux ratio required (about 30) in the argon column. Cooling of the argon
column can be supplied from cold expanded rich liquid or by liquid nitrogen.
7. Finally the products produced in gas form are warmed against the incoming air to
ambient temperatures. This requires a carefully crafted heat integration that must allow
for robustness against disturbances (due to switch over of the molecular sieve beds[7]). It
may also require additional external refrigeration during start-up.
The separated products are sometimes supplied by pipeline to large industrial users near the
production plant. Long distance transportation of products is by shipping liquid product for large
quantities or as dewar flasks or gas cylinders for small quantities.
Polymeric membranes
Membrane processes using polymeric materials are based on the difference in rates of
diffusion of oxygen and nitrogen through a membrane which separates high-pressure
and low-pressure process streams. Flux and selectivity are the two properties that
determine the economics of membrane systems, and both are functions of the specific
membrane material. Flux determines the membrane surface area, and is a function of the
pressure difference divided by the membrane thickness. A constant of proportionality
that varies with the type of membrane is called the permeability. Selectivity is the ratio
of the permeabilities of the gases to be separated. Due to the smaller size of the oxygen
molecule, most membrane materials are more permeable to oxygen than to nitrogen.
Membrane systems are usually limited to the production of oxygen enriched air
2550% oxygen.. Active or facilitated transport membranes, which incorporate an
oxygen-complexing agent to increase oxygen selectivity, are a potential means to
increase the oxygen purity from membrane systems, assuming oxygen compatible
membrane materials are also available.
A typical membrane system is shown in Fig. 3. A major benefit of membrane
separation is the simple, continuous nature of the process and operation at near ambient
conditions. An air blower supplies enough head pressure to overcome pressure drop
through the filters, membrane tubes and piping. Membrane materials are usually
assembled into cylindrical modules that are manifolded together to provide the required
A.R. Smith, J. KlosekrFuel Processing Technology 70 (2001) 115134 119
Fig. 3. Polymeric membrane air separation process.
production capacity. Oxygen permeates through a fiber hollow fiber type. or through
sheets spiral wound type. and is withdrawn as product. A vacuum pump typically
maintains the pressure difference across the membrane and delivers oxygen at the
required pressure. Carbon dioxide and water usually appear in the oxygen enriched air
product, since they are more permeable than oxygen for most membrane materials.
As with adsorption systems, capital is essentially a linear function of production rate
and product backup is typically not available without a separate liquid oxygen storage
tank and delivery support system. Membrane systems readily fit applications up to 20
tonsrday, where air enrichment purities with water and carbon dioxide contaminants can
be tolerated. This technology is newer than adsorption or cryogenics and improvements
in materials could make membranes attractive for somewhat larger oxygen requirements.
The fast start-up time, due to the near ambient operation, is especially attractive for
oxygen-use systems than exhibit discontinuous usage patterns. The passive nature of the
process is also appealing.