PROCESS FOR SEPARATING A MIXED GAS INTO OXYGEN AND NITROGEN UNDER LOW TEMPERATURE AND LOW PRESSURE CONDITIONS

Abstract: A process for separating a mixing gas into oxygen and nitrogen under low temperature and low pressure conditions which comprises introducing a mixed gas comprising chiefly oxygen and nitrogen into at least two adsorption towers, each packed with sodium faujasite typical of which is Na-X, at a temperature not higher than room temperature under condi­ tions of an atmospheric pressure to 3 ata thereby causing the nitrogen in the mixed gas to be selectively adsorbed, collect­ ing highly pure oxygen or an oxygen-enriched gas from the outlet of the adsorption towers, and reducing the pressure of the at least two adsorption towers, in which the nitrogen gas been adsorbed, to a level of from 0.08 to 0.5 ata, to cause the nitrogen gas to be desorbed and the sodiumfaujasite to be regenerated.

Description: This invention relates to a process for separating a mixed gas mainly composed of O2 and N2, e.g. air, into O2 and N2 by making use of an adsorbent capable of selectively adsorbing N2 thereon. Separation of air into #2 and N2 by adsorption of N2 with adsorbents has several advantages that the apparatus is small in size and simple and is operated under little or no control of man with little need of maintenance, So, moderate- and small-size apparatus having the ability to produce O2 in an amount of from 10 to 3,000 Nm3-92/hr are recently used more and more. Thus, there is the tendency that the apparatus gradually expel use of liquid oxygen which is made by the low temperature gas separator and transported for application. One typical apparatus is briefly described below. The apparatus includes an air compressor, two or more adsorption towers for N2, and optionally, a vacuum pump. In the apparatus, when compressed air is fed into one tower, N2 in the air is adsorbed on the N2 absorbent filled therein and removed. The remaining high pressure #2 is passed downstream of the adsorption tower and collected. In the other tower, the adsorbed N2 is released under reduced pressure (in some cases, N2 may be removed by countercurrently passing part of the O2 product or by means of a potential vacuum pump) and then collected. The above procedures are alternately repeated to continuously separate #2 and N2 from each other. Typical N2 adsorbents which are used for packing in the adsorption towers are Na-A zeolite 60 to 708 of which is exchanged with Ca and which has been put into practice by Union Carbide Co., ttd. This exchanger serves to selectively adsorb N2 from a two-component mixed gas of O2 and N2 When using air, co-adsorption of O2 is assumed to be below 108 of the adsorption of N. This type of #2 and N2 separator has been described above as being advantagenous when designed in small or moderate size. For the production of 1 Nm in of 02r however, it requires a power consumption of 0.75 to 1 KWh, which is larger than a power consumption of 0.45 KWh required for the production of O2 by the large capacity low temperature gas separation process. Moreover, even if the apparatus is increased in capacity, only a reduced scale merit is expected. It is generally accepted that the adsorption technique is not competitive with the low temperature gas separation process in the capacity range not smaller than 3,000 Nm3-O2/hr. Various improved methods of overcoming the above disadvantages may be considered but such methods would usually involve the following problems when described in association with the present invention. With regard to the reduction of the power consumption, it may be possible to carry out the adsorption operation under low pressure while reducing the air pressure. However, the amount of adsorbed N2 lowers almost in proportion to the pressure, with the capacity of the apparatus increasing extremely. Next, in order to increase an amount of adsorption, it is considered to effect the adsorption operation under low temperature conditions. In this case, the amount of adsorbed N2 increases but adsorption and desorption speeds decrease considerably. This leads to a lower concentration of the #2 product than in the case using room temperature when compared at the same tower length. The decrease of temperature results in an increase of the co-adsorption of #2 at the time when N2 is adsorbed, with the power per unit production of oxygen increasing gradually. It is accordingly an object of the invention to provide a process for separating a mixed gas mainly composed of O2 and N2 into 2 and N which overcomes the disadvantages of the prior art processes. It is another object of the invention to provide the process of the above-mentioned type which makes use of sodium faujasite by which an increase amount of adsorption of N2 under low temperature and low pressure conditions is ensured while making. it possible to keep an adsorption speed within a practical range. It is a further object of the invention to provide the process whereby the adsorption selectivity to N2 is not so reduced even under low temperature an low pressure conditions. The above objects can be achieved, according to the invention, by a process for separating a mixing gas into oxygen and nitrogen under low temperature and low pressure conditions which comprises successively introducing a mixed gas comprising chiefly oxygen and nitrogen into at least two adsorption towers, each packed with a sodium faujasite typical of which is Na-X, at a temperature not higher than room temperature under conditions of an atmospheric pressure to 3 ata thereby causing the nitrogen in the mixed gas to be selectively adsorbed, collecting highly pure oxygen or an oxygen-enriched gas from the outlet of the respective absorption towers, and reducing the pressure of each adsorption tower in which the nitrogen has been adsorbed, to a level of from 0.08 to 0.5 ata thereby causing the adsorbed nitrogen gas to be desorbed and the adsorbent in the adsorption tower to be regenerated. FIG. 1 is a flow chart of an air separator illustrating an embodiment of the present invention, FIG. 2 is a graph showing the relation between power per unit amount of produced oxygen and absorption pressure FIG. 3 is a graph showing the relation between power per unit amount of produced oxygen and desorption pressure; FIG. 4 is a graph showing the relation between power per unit amount of produced oxygen and temperature; FIG. 5 is a graph showing the relation between concentration of #2 at the outlet of an adsorption tower; and FIG. 6 is a graph showing the relation between amount of an adsorbent required for production of 1 Nm -O2/hr and temperature. Referring now to the accompanying drawings and particularly to FIG. 1 showing Åa flow chart of an air separator embodying the invention. The air separator is used to separate air into #2 and N2 with use of an N2 adsorbent of a sodium faujasite such as Na-X. In the figure, air is passed through a line 1 to a compressor 2 in which it is compressed to a level of 1.05 to 3 ata (atm-absolute). The compressed air is fed from a line 3 into a dehumidifying and decarbonating unit 4 by which very clean, compressed air is obtained. A valve 5 located downstream of a line 3' is kept open and the clean compressed air is passed through a line 6 and an opened valve 7 into an adosrption tower 8. In the adsorption tower 8, N2 in the compressed air is removed by adsorption with an N2 adsorbent 9, so that a concentration of 2 increases as the air moves upwards. Subsequently, the compressed air is further passed through opened valves 10, 11, and 12 and a tank 13 for oxygen product placed intermediate between the valve 11 and a valve 12 and collected as oxygen product. On the other hand, part of the O2 product is fed toward a line 14 and its pressure is reduced by means of a reducing valve 15, followed by feeding through an opened valve 10' into an adsorption tower 8'. The tower 8' is connected through an opened valve 16 and a line 17 to a vacuum pump 18 by which its pressure is reduced. By this, the part of the O2 product is passed in the state of negative pressure countercurrently with the passage of air in the adsorption tower 8'. As a result, the N2 adsorbed on an adsorbent 9' in the absorption tower 8' is readily released and the adsorbent 9' is regenerated within a short time. When the adsorbent 9 for N2 in the tower 8 is saturated and the adsorbent 9' in the adsorption tower 8' from which N2 has been released is regenerated, the line 6 for the air passage is changed over to a line 6'. The above procedure is subsequently repeated, so that O2 product can be continuously collected. It will be noted that a zone extending from the line 3' for the clean compressed air through the line 17 for the gas mainly composed of the released N2 is heat-exchangeable by means of a heat exchanger 19. Likewise, a zone established between the line 21 for the O2 product and the line 3' is heat-exchangeable by means of a heat exchanger 22. In the line 3, is provided a compression refrigerator 20, so that the adsorption towers 8 and 8' are very efficiently cooled and desired low temperature conditions are readily attained. Upon changing-over of the adsorption towers, not only the line 6 is changed over to 6' (or vice versa), the valves 10, 15, 10' are first fully opened so that #2 remaining immediately after discharge from the adsorption tower 8 is partially transferred to the adsorption tower 8' which has been just regenerated. By this, blow-by of the inlet air accompanied by an increase of the pressure occurring immediately after the changing-over is prevented and the #2 remaining downstream of the adsorption tower and the compressed air present upstream of the tower are suppressed, in a minimum, from discharge to outside. Assuming that the pressure of the adsorption tower 8 is taken as P0 (ata) and the pressure of the adsorption tower 8' is as P1 (ata) the pressure after equalization is approximately (P0 + P1)/2 (ata). After the pressure of the adsorption tower 8' has reached about (Po + Pal)/2, the valves 10', 11' are opened so that the tank 13 for the O2 product and the adsorption tower are equalized, after which the adsorption tower 8' is filled with #2 of high pressure. Assuming that a dead capacity of the adsorption towers 8, 8' (i.e. capacity of the space not occupied by the adsorbent in the towers) is taken as V1 (liters), a capacity of the O2 product tank is as (V2 (liters), and the pressure of the tank 13 prior to equalization is substantially equal to P0 (ata), the equalized pressure, P2 (ata), is approximately as follows: EMI8.1 As compared with a sharp increase of pressure from P (ata) to Po (ata) at the time when the towers are merely changed over, the pressure in the above procedure is gently changed step by step, i.e. P1 (ata) + (Po + P1)/2#P2 (ata) Po (ata). Consequently, while the air is prevented from blow-by at the time of the pressure increase, it becomes possible to minimize discharge of the remaining O2 and compressed air in the desorption Step to outside. According to the procedure using the air separator described with reference to FIG. 1, air separation was effected. Operating factors and conditions of the apparatus are indicated in Table 1 below. Table 1 Operating Factors and Conditions of Adsorption System Adsorption Tower diameter: 60 cm, length: 850 mm Charge of adsorbent 1.5 kg/tower Number of towers 2 Tower-changing-over time 1.5 minutes Flow rate of product at 2 Nl/minute outlet Adsorption tower pressure 1 - 5 ata Pressure of regeneration 0.1 - 1 ata tower Temperature of adsorption 20 - -100 C tower Kind of adsorbent Na X, Ca Na1/3-A A Air was separated into #2 and N2 under operating conditions indicated in Table 1. The results are summarized in FIGS. 2 through 6. In these figures, there are illustrated improvements of the O2 and N2 adsorption and separation technique of the pressure swing type using sodium faujasite adsorbent (hereinafter referred to as Na-X) according to the invention over known air separation techniques using 60 - 708 Ca exchanger of known Na-A zeolite (hereinafter referred to as Ca2/3-Nal/3-A)* FIG. 2 shows the relation between adsorption pressure and power consumption per unit amount of product. In the figure, the abscissa indicates adsorption pressure, P0 ata, and the ordinate indicates a power consumption (KW) required for production of 1 Nm3/hr of 02+ 2Na-X and Ca 2/3 -Na1/3-A were used as the adsorbent and operating conditions were set such that the temperature was 20 C, the desorption pressure, P1, was 0.2 ata, and the superficial velocity in the tower, U, was 0.8 cm/second (at the outlet). Under these conditions, a power consumption was determined while changing the pressure of the adsorption tower in the range of from 1.5 to 4.5 ata In the figure, indicated by nowt is a curve for Na-X and by "o# is a curve for Ca2/3-Nal/3-A¯ As will be seen from FIG. 2, although it has been believed that Na-X is inferior to Ca2/3-N1/3-A in all the range of pressure, Na-X serves to separate oxygen from air in a smaller power consumption than C2/3-Na1/3-A provided that the adsorption pressure is below 3 ata. We believe that the above fact was first found by us because no Na-X was utilized in any conventionally proposed air separation techniques making use of N2 adsorbents or such utilization was never seen any literature. Next, operating conditions were set such that adsorption pressure, P0, = 1.5 ata, superficial velocity, U, = 0.8 cm/second, and temperature = 20 C. The power consumption was measured using Ca -Na2/3-A and Na-X as the adsorbent under a varying desorption pressure, P1, of from 0.1 to 0.5 ata. The results are shown in FIG. 3 in which the relation between desorption pressure and power consumption is shown. In the figure, the abscissa indicates the desorption pressure, P1 (ata), and the ordinate indicates the power consumption required for production of 1 Nm3/hr of O2 Indicated by "o" is a curve for Na-X and by "-" is a curve for Ca2/3-Nal/3-Ae No specific phenomena were found with respect to the desorption pressure. It should be noted that while the power consumption according to the known low temperature air separation process is in the range of 0.45 to 0.60 RWh/Nrn3 - 2 and the power consumption required for the existing separation process using N2 adsorbents has a lower limit in the vicinity of 0.7 KWh/Nm3-O2, the power consumption can be reduced remarkably in the practice of the invention. In other words, the practical desorption pressure is in the range of from 0.08 to 0.5 ata, preferably 0.1 to 0.3 ata according to the invention. Subsequently, the separation by adsorption was carried out under low temperature conditions. This is because an amount of adsorption of N2 usually increases with a decrease of temperature, so that the break through point is reduced with an expectation of compactness of the separator and improvement of separation efficiency. Operating conditions other than the temperature were set such that the adsorption pressure was 1.5 ata, the regeneration pressure was 0.2 ata and the superficial velocity, U, was 0.8 cm/second. The temperature was gradually decreased from room to lower temperatures to determine a power consumption required for production of 1 Nm Xhr of oxygen at the respective temperatures. FIG. 4 shows the relation between operating temperature and power consumption in which the abscissa indicates the temperature and the ordinate indicates the power consumption. Indicated by "o't is a curve for Na-X and by n-n us a curve for Ca2/3-Nal/3-A As will be seen from FIG. 4, with Ca2#3 -Na1/3-A, the power consumption rather increases with a decrease of the temperature. In contrast, with Na-X, the power consumption is kept decreased with a decrease of the temperature. The power consumption with respect to Na-X was checked in a range of temperature down to -60 0C, revealing that no problem was involved in separation of air by adsorption. According to the isobaric data of Na-X with regard to one component system, the utility of Na-X was not lost even to a temperature as low as -100 C. In this connection, lower temperatures are not favorable because coadsorption of #2 at the time of adsorption of N2 is not negligible. In the temperature range mentioned above, any cooling means as used in conventional low temperature air separators may also be used. The improved performance of Na-X in the low temperature range and the inadaptability of Ca2/3-Nal/3-A are also proved by checking the concentration of O2 at the outlet of the adsorption tower. FIG. 5 shows a graph showing the relation between temperature and concentration of O2 at the outlet of an adsorption tower. In the figure, the abscissa indicates the temperature and the ordinate indicates the concentration of O2 at the tower outlet. The mark "o" indicates a curve for Na-X and the mark "-" indicates a curve for Ca2/3-Nal/3-A. Operating conditions were set such that adsorption pressure, P0 = 1.5 ata, desorption pressure, P1 = 0.2 ata and superficial velocity, U = 0.4 - 0.8 cm/second. While the temperature was lowered, the separation by adsorption was carried out. The curve of FIG. 5 is for the case where U X 0.8 cm/second. As will be seen from FIG. 5 r with Ca2/3-Na -A, the concentration of 2 at the outlet of the adsorption tower does not substantially increase even in the low temperature range. On the other hand, with Na-X, the concentration of O2 sharply increases with a decrease of the temperature. In case where the superficial velocity was 0.4 cm/second and the temperature was -30 C, the concentration of O2 reached 96% (with the balance of argon) which exceeds an O2 concentration of 94.58 which is the upper limit of the theoretical for the air separation using N2 adsorbents. This leads to a novel process of producing highly pure O2 from which argon is partially eliminated by the use of Na-X in such a temperature range as described above. The improvement of the N2 adsorptivity at low temperatures will substantially mitigate the burden on the problem involved by the lowering of tower temperatures. The power cost and the purity of O2 have been chiefly described above. The cost associated with initial installation will be then described. The amount of an adsorbent which is required to produce 1 of of 2 per hour under operating conditions used in FIG. 5, i.e. adsorption pressure, P0 = 1.5 ata, desorption pressure, P1 = 0.2 ata and superficial velocity, U = 0.8 cm/second is shown in FIG. 6. FIG. 6 is a graph showing the relation between temperature and amount of adsorbent, in which the abscissa indicates the temperature and the ordinate indicates the weight of an adsorbent (kg) necessary for producing 1 Nm3 of O2/hr. Indicated by #o" is a curve for Na-X and by"-" is a curve for Ca -Na -A As will be seen from FIG. 6, the Ca2/3-Nal/3-A adsorbent is saved at low temperatures only by about 10% of the adsorbent required at room temperature. In contrast, with Na-X, about 458 of the adsorbent can be saved at -30 C. Thus, the use of Na-X gives a large effect in reducing a substantial amount of the adsorbent which occupies a substantial proportion of the installation cost. As described in detail hereinabove, according to the invention, a mixed gas, e.g. air, is subjected to the pressure swing-type separation into different types of gases by adsorption by the use of a sodium faujasite such as Na-X under conditions of an adsorption pressure not lower than 3 ata, a desorption pressure ranging from 0.08 to 0.5 ata and a temperature not higher than room temperature. By this, the power consumption required for producing 1 Nm of O2 per hour is from 0.45 to 0.6 KW for the low temperature air separation process and over 0.7 KW for existing adsorption and separation processes. This power consumption may be reduced to about 0.25 KW in the practice of the invention with an amount of an adsorbent being reduced to as low as 558 based on the case of the existing process. The power consumption and the amount of adsorbent required in the process of the invention are much smaller than those required in conventional adsorption processes. Thus, the process of the invention is very useful in separating a mixed gas mainly composed of nitrogen and oxygen into nitrogen and oxygen.

Claims: WHAT IS CLAIMED IS: 1. A process for separating a mixing gas into oxygen and nitrogen under low temperature and low pressure conditions which comprises introducing a mixed gas comprising chiefly oxygen and nitrogen into at least two adsorption towers, each packed with a sodium faujasite, at a temperature not higher than room temperature under conditions of an atmospheric pressure to 3 ata thereby causing the nitrogen in the mixed gas to be selectively adsorbed, collecting highly pure oxygen or an oxygen-enriched gas from the outlet of the adsorption towers, and reducing the pressure of the at least two adsorption towers, in which the nitrogen has been adsorbed, to a level of from 0.08 to 0.5 ata, to cause the nitrogen gas to be desorbed and the sodium faujasite adsorbent to be regenerated. 2. A process for separating a mixing gas into oxygen and nitrogen under low temperature and low pressure conditions which comprises the steps of: (a) introducing a mixed gas comprising chiefly oxygen and nitrogen into one of at least two adsorption towers, each packed with a sodium faujasite, at a temperature not higher than room temperature under conditions of an atmospheric pressure to 3 ata thereby causing the nitrogen in the mixed gas to be selectively adsorbed on the sodium faujasite in the one adsorption tower until the sodium faujasite is saturated with nitrogen while collecting highly pure oxygen or an oxygen-enriched gas from the outlet of the one adsorption tower; ; (b) changing over the introduction of the mixed gas from the one adsorption tower to the other adsorption tower so that nitrogen in the mixed gas is adsorbed in the other adsorption tower while collecting highly pure oxygen or an oxygen-enriched gas from the outlet of the other adsorption tower; (c) reducing the pressure of the one adsorption tower, in which the nitrogen has been adsorbed, to a level of from 0.08 to 0.5 ata, to cause the nitrogen gas to be desorbed and the sodium faujasite adsorbent to be regenerated, and ( ) repeating the above Procedure on the respective adsorption towers whereby highly pure oxygen or an oxygenenriched gas is continuously produced while regenerating the adsorbent. 3. A process according to Claim 1 or 2, wherein said mixed gas is air. 4. A process according to Claim 1 or 2, wherein said sodium faujaite is Na-X. 5. A process according to Claim 2, wherein part of the oxygen or oxygen-enriched gas collected in step (b) is partly fed to the step (c) countercurrently with the mixed gas whereby the nitrogen adsorbed on the sodium faujasite in the one adsorption tower is readily desorbed. 6. A process according to Claim 2, wherein the changingover of from the one adsorption tower to the other adsorption tower is carried out so that the pressure within the other adsorption tower is increased stepwise. 7. A process according to Claim 2, wherein the pressure in step (c) is from 0.1 to 0.3 ata.

Inventors: FUJIOKA, YUICHI NAGASAKI TECHNICAL INSTITUTE, FUKUDA, SHOZO C/O NAGASAKI TECHNICAL INSTITUTE, IZUMI, JUN C/O NAGASAKI TECHNICAL INSTITUTE, MAEHARA, KENICHI NAGASAKI SHIPYARD & ENGINE WORKS, SHIRAKAWA, SEIICHI NAGASAKI TECHNICAL INSTITUTE, TSUTAYA, HIROYUKI NAGASAKI TECHNICAL INSTITUTE, Maehara, Kenichi Nagasaki Shipyard &amp; Engine Works
Applicants: MITSUBISHI JUKOGYO KABUSHIKI KAISHA
Application year: 1984
Main classification: B01D53
IPC codes: B01D53, C01B13, C01B21