Hybrid air and nitrogen recycle liquefier

Abstract: Liquid nitrogen requirements of a process for the cryogenic distillation of air in which at least a portion of the refrigeration needs is provided by expansion of the feed air are met by elevating the discharge pressure of a nitrogen recycle compressor (135), cooling (540,541,542) the elevated pressure nitrogen recycle stream against process vapor streams and directly thereafter expanding (252) the cooled nitrogen recycle stream.

Description: The present invention is directed to a process producing large quantities of liquid product via the cryogenic distillation of air. Liquefied atmospheric gases, including nitrogen, oxygen and argon, are finding increasing uses in industry. Such liquefied atmospheric gases provide cryogenic capabilities for various industrial processes, are more economical to transport in merchant supply and provide ready and economical sources of gaseous product from liquid storage facilities. For instance, liquid nitrogen is increasingly used to freeze food products, to cryogenically embrittle used materials for cleaning or recycle, and as a supply of gaseous nitrogen inerting medium for various industrial processes. The conventional process for making large quantities of liquid nitrogen and/or liquid oxygen from an air feed is to include an expander scheme with the conventional multiple column distillation system. The expander scheme provides at least a portion of the large amount of refrigeration that is required to remove a large percentage of the air feed as liquid product vis-a-vis a small percentage of the air feed or no percentage of the air feed as liquid product. (As used herein, a "large percentage" of the air feed is defined as at least 15% of the air feed). This inclusion of an expander scheme with the conventional multiple column distillation system is generally referred to in the industry as a liquefier and that is how the term liquefier is used herein. The most common liquefier probably falls into the category of nitrogen recycle liquefiers. In a nitrogen recycle liquefier, the expander scheme is integrated with the recycling of low pressure column nitrogen overhead such as taught in US-A-3,605,422 and US-A-4,894,076. The nitrogen recycle liquefiers, no matter how many expanders there are, do not try to use the feed air for generating refrigeration before it is fed into the distillation column systems. US-A-3,605,422 discloses a process for obtaining liquid nitrogen and liquid oxygen products by the cryogenic distillation of a compressed air feed in which a portion of said feed is liquified by heat exchange against product streams and additional refrigeration is provided by recycling a gaseous stream from the distillation system. In the recycle system, a gaseous component withdrawn from the distillation system is in turn warmed, compressed, cooled, and expanded to cause partial liquification and the resultant liquified portion is returned to the distillation system. At least a part of the non-liquified portion is used to cool the compressed air feed and then recycled to the withdrawn gaseous component prior to compression thereof. In the exemplified process of US-A-3,605,422, the gaseous component is a portion of the overhead from the high pressure column of a dual column distillation column system. This portion is warmed in two stages by heat exchange against compressed recycle overhead and then compressed. Part of the compressed portion provides said compressed recycle overhead for said heat exchange and the remainder is cooled by heat exchange against an auxiliary refrigerant and subsequent expansion and then divided into two substreams. One substream is used to cool the compressed air feed and the other substream is added to the partially warmed overhead portion between said heat exchange stages. Similarly, part of said compressed recycle overhead is removed between said two heat exchange stages, cooled by expansion and divided into two substreams. One of these substreams is added to the overhead portion prior to warming and the other substream is used to cool the compressed air feed. The compressed recycle stream cooled by said two stage heat exchange is partially liquified by expansion. Part of the liquified portion is returned to the high pressure column as reflux and the remainder is reduced in pressure and used to scrub low pressure column overhead before feeding to the low pressure column as reflux. The substreams used to cool the compressed air feed are added to the warmed overhead portion prior to compression. US-A-4,152,130 introduced the concept of air recycling. In the air recycle liquefiers, a major fraction of the air streams entering cold box are compressed to pressures higher than that needed for the distillation system. At least a portion of the high pressure air is isentropically expanded to provide the refrigeration needed for liquefaction while another portion is cooled to a temperature below its critical temperature, so that liquid air can be obtained upon expansion of this cold air stream. This cooled and expanded liquid containing air is then fed into the distillation system for separation. A portion of the isentropically expanded, mainly vapor bearing air can also be fed into the distillation system to supplement the vapor feed necessary for the distillation system. Since all the air, including that fed to the distillation system, enters the cold box at pressures significantly higher than that required by the distillation system, the feed air is used for refrigeration generation or condensation before it enters the distillation system. As compared to the nitrogen recycle liquefiers, this reduces the recirculation flow needed for generating the desired refrigeration which translates into (1) less power loss due to pressure drop, (2) less energy degradation due to heat transfer of the recycle streams and (3) less heat exchanger area. A problem with the air recycle liquefier however, is that as the liquid demand (as a percentage of feed air) increases, the fraction of liquid air in the total feed air increases. This will have an adverse effect on the distillation operation since a large fraction of liquid air in the feed air means a reduced vapor flow to the distillation system, so that not enough vapor is rising in the higher pressure column to generate the boilup for the lower pressure column and to generate the liquid nitrogen which is demanded as reflux and as product. This problem can be overcome by vaporizing a portion or all of the liquid air (or some other liquid process stream) via heat exchange against a condensing stream of high pressure nitrogen as taught in US-A-4,705,548. This, however, introduces an extra step, namely condensation of nitrogen and vaporization of the liquid air. Since pressure drops as well as energy degradation are involved in this condensation/vaporization step, it means extra power consumption as well as an extra heat exchanger for the condensation/vaporization. It is an object of the present invention to improve the energy efficiency of the conventional air recycle liquefier by overcoming the above described problem. The present invention is an improvement to a process producing large quantities of liquid product via the cryogenic distillation of air. In the process to which the improvement pertains, an air feed is compressed, at least a portion thereof expanded to generate refrigeration to cool another portion of the compressed air feed to below its critical temperature and subsequently fed to a distillation column system. The present invention is an improved method to meet the nitrogen reflux and/or liquid nitrogen product requirements of the process and comprises: (a) compressing at least a portion of the nitrogen overhead from the distillation column system to a pressure greater than 200 psia (1.4 Mpa), and more preferably to a pressure greater than nitrogen's critical pressure of 492.9 psia (3,398.5 Kpa); (b) cooling the nitrogen from step (a) by heat exchange against process vapor streams; and (c) expanding the nitrogen from step (b) without any condensation against a vaporizing process stream wherein said expansion is performed directly after step (b). Thus, according to the present invention, there is provided a process for the cryogenic distillation of an air feed generating an amount of refrigeration sufficient to remove at least 15% of the air feed as a liquid nitrogen product stream and/or a liquid oxygen product stream, wherein the air feed is initially compressed; at least a portion of the compressed air feed is expanded to provide refrigeration to cool another portion of the compressed air feed to below its critical temperature; at least a portion of the air feed is fed to a distillation column system having a liquid nitrogen reflux requirement in which the air feed is rectified into a gaseous nitrogen overhead; and at least a portion of said nitrogen overhead is compressed and cooled against a process stream, characterized in that: (a) said nitrogen overhead portion is compressed to a pressure greater than 1.4 Mpa (200 psia); (b) the process stream is one or more process vapor streams; and (c) said cooled nitrogen overhead portion is expanded directly after cooling without any condensation against a vaporizing process stream, whereby at least a portion of the liquid nitrogen reflux requirement and/or of the liquid nitrogen product stream is provided. As mentioned above, it is preferred that the nitrogen overhead is compressed to a pressure greater than nitrogen's critical pressure. The expansion of cooled nitrogen overhead can be performed across a valve or in a dense fluid expander. The expanded nitrogen overhead portion can contain a vapor component in addition to containing said portion of the liquid nitrogen reflux requirement and/or of the liquid nitrogen product stream so that further refrigeration can be provided by warming said vapor component by heat exchange against one or more process streams. Further refrigeration also can be provided by compressing a second portion of said gaseous nitrogen overhead; cooling said compressed second nitrogen overhead portion by heat exchange against one or more process streams; expanding said cooled second nitrogen overhead portion in an expander to obtain a gaseous expander effluent; and warming said gaseous expander effluent by heat exchange against one or more process streams. At least a portion of the compression in the process can be provided by shaft work generated from expansion of the compressed feed air and/or from expansion of the gaseous nitrogen overhead portion(s). Preferably, the distillation column system comprises a high pressure column and a low pressure column. The air feed to the distillation column system is fed to the high pressure column for rectification into a high pressure nitrogen overhead and a high pressure crude liquid oxygen bottoms At least a portion of the high pressure crude liquid oxygen bottoms is fed to the low pressure column for distillation into the gaseous nitrogen overhead and a low pressure liquid oxygen bottoms. The high pressure column and the low pressure column are thermally linked such that at least a portion of the high pressure nitrogen overhead is condensed in a reboiler/condenser against a vaporizing low pressure column oxygen-rich liquid. At least a portion of the condensed high pressure nitrogen overhead is used as a portion of the liquid nitrogen reflux requirement and/or of the liquid nitrogen product stream. Advantageously, the low pressure column is operated at a pressure between 170 and 350 kPa (25 and 50 psia). In one preferred embodiment, the compressed air feed is cooled by heat exchange against one or more process streams and then split into a first split feed stream and a second split feed stream. The first split feed stream is expanded through an expander and recycled to the air feed while providing refrigeration to the air feed by heat exchange. The second split feed stream is further cooled by heat exchange against one or more process streams and then split into a third split feed stream and a fourth split feed stream. This third split feed stream is expanded through an expander and a portion thereof recycled to the air feed while providing refrigeration to the air feed by heat exchange. The fourth split feed stream is further cooled by heat exchange against one or more process streams and a portion thereof introduced into the low pressure column for rectification. The remaining portion of the fourth split feed stream and the remaining portion of the expanded third split feed stream are introduced into the high pressure column for rectification. A portion of the low pressure liquid oxygen bottoms can be removed as the liquid oxygen product stream and/or a portion of the low pressure liquid oxygen bottoms can be warmed by heat exchange against one or more process streams and subsequently removed as a gaseous oxygen product. A nitrogen enriched gaseous stream can be withdrawn from an upper location of the low pressure column, warmed by heat exchange against one or more process streams and subsequently removed as a nitrogen enriched gaseous stream. When the low pressure column is operated at 170 to 350 kPa (25 to 50 psia), additional refrigeration can generated by expanding said nitrogen enriched gaseous stream prior to said warming thereof and/or by expanding said gaseous oxygen product prior to said warming thereof. The distillation column system may further comprises an argon column in which an argon containing gaseous side stream removed from a lower intermediate location of the low pressure column is rectified into an argon-rich vapor overhead and an argon-lean bottoms liquid. The argon-lean bottoms liquid is returned to the low pressure column and at least a portion of the argon-rich vapor overhead is condensed in a reboiler/condenser against vaporizing high pressure crude liquid oxygen bottoms. A portion of the condensed argon-rich vapor overhead is removed as a liquid argon product and the remaining portion of thereof is used to provide reflux for the argon column. In the drawings:- Figure 1 is a schematic diagram of a conventional process producing large quantities of liquid product via the cryogenic distillation of air and Figure 2 is a schematic diagram of the embodiment of the process of the present invention. The skilled practitioner will appreciate that the temperature to which the nitrogen must be cooled in step (b) (hereinafter the "cooling temperature") is a function of (1) the pressure to which the nitrogen is compressed in step (a), (2) whether the expansion in step (c) is performed across a valve or in an expander (ie the isentropic efficiency of the expansion), (3) the pressure to which the nitrogen is expanded in step (c) and (4) the desired fraction of the nitrogen which is to be liquid at the end of step (c). These functionalities are provided on any standard Mollier chart for nitrogen. The key to the present invention is that the elevated pressure in step (a) makes it possible to remove significantly more enthalpy from the nitrogen stream at the cooling temperatures which can be obtained for the nitrogen stream in the front end/main heat exchanger ... so much more enthalpy that the enthalpy removing condensation step against a vaporizing process liquid stream is no longer required. In effect, the refrigeration that was formerly indirectly provided to the nitrogen in the conventional air recycle liquefier (ie by using the refrigeration to first liquefy a portion of the feed air and then using this portion of the feed air to liquefy the nitrogen) is now directly provided to the nitrogen in the main heat exchanger without an intervening liquid vaporization step. The increased nitrogen compression requirement which makes this possible is more than offset by a reduced air recycle flow through the air compressors since either less or no air is now required to be liquefied. The present invention essentially provides the advantages of both the air recycle liquefier (with respect to reducing the recirculation flow) and the nitrogen recycle liquefier (with respect to producing some liquid nitrogen directly). Regarding the situation where the expansion of the nitrogen in step (c) of the present invention is performed in a nitrogen expander as opposed to being performed across a valve, the skilled practitioner will appreciate that a dense fluid expander is appropriate in this situation since the feed to the expander is a dense fluid and/or the expander effluent will have a liquid component. In this situation, the vapor component of the dense fluid expander effluent can be warmed by heat exchange against process streams in order to provide additional refrigeration to the process. The present invention is best illustrated by applying it to a conventional air recycle liquefier. Figure 1 is representative of a conventional liquefier to which the present invention pertains. Figure 1 is based on the teachings of US-A-4,705,548. Referring now to Figure 1, an ambient air feed in stream 100 is compressed in compressor 110 and cleaned of impurities which will freeze out at cryogenic temperatures in cleaning bed 310. The resultant stream 201 is combined with an air recycle stream 234 to form stream 103 which is further compressed in compressors 140 and 150 prior to being cooled by heat exchange against warming process streams in heat exchanger 540. A portion of stream 103 is removed as stream 506 and expanded in expander 152. The remaining portion of stream 103 is further cooled by heat exchange against warming process streams in heat exchanger 541 after which a second portion of stream 103 is removed as stream 508 and expanded in expander 153. A portion of expander 153's discharge is removed as stream 124 and warmed by heat exchange against cooling process streams in heat exchanger 542 after which stream 124 is combined with expander 152's discharge and further warmed by heat exchange against cooling process streams in heat exchangers 541 and 540 to form the air recycle stream 234. The remaining portion of expander 153's discharge is fed to the bottom of high pressure column 711 as stream 510. The portion of stream 103 remaining after stream 508 is removed is further cooled by heat exchange against warming process streams in heat exchanger 542 to form stream 105. A portion of stream 105 is fed to an intermediate location of high pressure column 711 as stream 106 while the remaining portion is further cooled by heat exchange against warming process streams in heat exchangers 552 and 551 before being fed to an intermediate location of low pressure column 721 as stream 84. The high pressure column feed streams 106 and 510 are rectified into a high pressure nitrogen overhead in stream 10 and a high pressure crude liquid oxygen bottoms in stream 5. Stream 5 is subcooled by heat exchange against warming process streams in heat exchanger 552, reduced in pressure and subsequently warmed by heat exchange against a liquid oxygen product in heat exchanger 550. A portion of stream 5 is then fed to an intermediate location of low pressure column 721 as stream 910 while the remaining portion is fed to reboiler/condenser 732 at the top of crude argon column 731 as stream 52. An argon containing gaseous side stream 89 is removed from a lower intermediate location of the low pressure column and also fed to crude argon column 731 in which stream 89 is rectified into an argon-rich vapor overhead and an argon-lean bottoms liquid in stream 90 which is returned to the low pressure column. The argon-rich vapor overhead is condensed in reboiler/condenser 732 against the high pressure crude liquid oxygen bottoms in stream 52. A portion of the condensed argon-rich vapor overhead is removed as a liquid argon product in stream 160 while the remaining portion of the condensed argon-rich vapor overhead is used to provide reflux for the crude argon column. The portion of the high pressure crude liquid oxygen bottoms in stream 52 that is vaporized against the argon-rich vapor overhead is fed to the low pressure column in stream 15 while the portion which is not vaporized is fed to the low pressure column in stream 16. The low pressure column feed streams 910, 84, 15 and 16 are distilled into a low pressure nitrogen overhead in stream 130 and a low pressure liquid oxygen bottoms. The high pressure column and the low pressure column are thermally linked such that at least a portion of the high pressure nitrogen overhead in stream 10 is condensed in reboiler/condenser 722 against vaporizing low pressure liquid oxygen bottoms. The condensed high pressure nitrogen overhead is used to provide reflux for the high pressure column. The low pressure nitrogen overhead in stream 130 is combined with a vapor flash stream 85 from flash drum 782 to form stream 131. -Stream 131 is warmed by heat exchange against process streams in heat exchangers 551, 552, 542, 541 and 540 to form stream 491. A portion of Stream 491 is removed as a gaseous nitrogen product in stream 488 while the remaining portion is compressed in compressor 135 to approximately 120 psia (825 kPa) to form stream 482. Stream 482 is cooled to near its dew point by heat exchange against warming process streams in heat exchangers 540, 541 and 542. The resultant stream 163 is subsequently condensed in reboiler/condenser 723 against vaporizing high pressure crude liquid oxygen bottoms. The resultant stream 7 is expanded across valve 252 and subsequently fed as reflux to the high pressure column. A portion of the low pressure column reflux is removed from the high pressure column in stream 6. Stream 6 is subcooled by heat exchange against warming process streams in heat exchanger 551 and flashed in flash drum 782. A portion of the saturated liquid resulting from this flash is removed as a liquid nitrogen product in stream 250 while the remaining portion is used as reflux for the low pressure column in stream 80. The saturated vapor resulting from this flash in stream.85 is combined with the low pressure nitrogen overhead in stream 130 to form stream 131. A nitrogen enriched waste stream 440 is withdrawn from a upper intermediate location of the low pressure column, warmed by heat exchange against process streams in heat exchangers 551, 552, 542, 541 and 540 and subsequently removed as a gaseous waste product in stream 479. A portion of the low pressure liquid oxygen bottoms is removed in stream 117 and subcooled in heat exchanger 550 before being removed as a liquid oxygen product in stream 70. A portion of the vaporizing low pressure liquid oxygen bottoms is removed in stream 195 and warmed by heat exchange against cooling process streams in heat exchangers 542, 541 and 540 before being removed as a gaseous oxygen product in stream 198. Figure 2 is an embodiment of the present invention as applied to the flowsheet depicted in Figure 1. Figure 2 is identical to Figure 1 (similar features of Figure 2 utilize common numbering with Figure 1) except that reboiler/ condenser 723 has been eliminated. By elevating the discharge pressure of compressor 135, it is possible to remove significantly more enthalpy from stream 482 in the main heat exchanger (540-542) ... so much more that the enthalpy removing condensation step in reboiler/condenser 723 is no longer required. In effect, the refrigeration that was formerly indirectly provided to the nitrogen in reboiler/condenser 723 is now directly provided to the nitrogen in the main heat exchanger. Since less air is now required to be liquefied, the flow of air in stream 105 is decreased. Furthermore, due to increased liquefaction efficiency, the air compressor recycle flow in stream 124 can be reduced. Both of these factors more than offset the increased nitrogen compression requirement in compressor 135. Although not shown in Figure 2, the shaft work produced from the air expanders 152, 153 can be used to drive one or more of the compressors 110, 135, 140, 150 in the process. Similarly, where the expansion of the nitrogen in step (c) of the present invention is performed in a dense fluid expander as opposed to being performed across valve 252, the shaft work from this dense fluid expander can be used to drive one or more compressors in the process. Figure 2 produces almost all of the refrigeration for the process from expansion of the feed air. It should be pointed out that a recycle nitrogen stream could be used with at least one additional nitrogen expander (ie in addition to the dense fluid expander contemplated in step (c) of the present invention) to supplement the refrigeration. In such a case, the shaft work produced from this refrigeration providing nitrogen expander could also be used to drive one or more compressors in the process. To further improve the energy efficiency of the process as depicted in Figure 2, one may increase the operating pressure of the low pressure column from the conventional range of 17-24 psia (115-165 kPa) to an elevated range between 25 and 50 psia (170-350 kPa). This elevated pressure range increases the energy efficiency of the process by reducing the irreversibility of the conventional liquefier. Irreversibility is commonly called lost work or lost exergy. In the distillation system, exergy loss can be reduced by reducing the driving force for mass transfer. On an x-y equilibrium diagram, the driving force for mass transfer is shown by the distance between the equilibrium curve and the operating lines. At the same liquid to vapor flow ratios in the distillation column, the driving force can be reduced by elevating the column operating pressure to move the equilibrium curve closer to the operating lines. This effect is more noticeable in the low pressure column. Exergy loss can be further reduced in the conventional liquefier by reducing the driving force for heat transfer in the front end heat exchanger(s). On a plot of temperature versus enthalpy change, the driving force for heat transfer is shown by the distance between the line for the cooling stream and the line for the warming stream. Elevating the pressure of the low pressure column in turn allows elevation of the expander scheme discharge pressure. For a typical inlet pressure of 600 psia (4.1 MPa), elevating the expander scheme discharge pressure can adjust the shape of the cooling curves to allow a smaller average heat transfer driving force with the same size heat exchanger. An elevated pressure in the low pressure column also increases the density of the process gas streams, particularly the low pressure streams. Equipment sizes can be reduced for capital savings due to the lower volumetric gas flows. The upper limit of 50 psia (350 kPa) accounts for the fact that, as the pressure is continually elevated, the benefits of reduced irreversibility are eventually offset by the prohibitive number of additional trays that are required in the distillation system. In effect, the elevated pressure range represents an optimum trade off between reducing the irreversibility of the process at the expense of increasing the capital requirements of the process. It should be noted that where the above described elevated pressure range is utilized and where a large fraction of the product streams are not liquefied and are demanded at significantly lower pressure than that of the low pressure column or vented to the atmosphere, these product streams can be expanded to provide refrigeration. In particular, the nitrogen enriched gaseous stream 440 and/or the gaseous oxygen product stream 195 can be expanded prior to the warming thereof. Such an expansion exploits the fact that such product stream will also be at an elevated pressure. Although preferentially they should be isentropically expanded in an expander, if needed for economical reasons, they could be isenthalpically expanded across a valve. In summary, the present invention is an effective method for increasing the energy efficiency of a conventional air recycle liquefier.

Claims: A process for the cryogenic distillation of an air feed generating an amount of refrigeration sufficient to remove at least 15% of the air feed as a liquid nitrogen product stream and/or a liquid oxygen product stream, wherein the air feed is initially compressed; at least a portion of the compressed air feed is expanded to provide refrigeration to cool another portion of the compressed air feed to below its critical temperature; at least a portion of the air feed is fed to a distillation column system having a liquid nitrogen reflux requirement in which the air feed is rectified into a gaseous nitrogen overhead; and at least a portion of said nitrogen overhead is compressed and cooled against a process stream, characterized in that: (a) said nitrogen overhead portion is compressed to a pressure greater than 1.4 MPa (200 psia); (b) the process stream is one or more process vapor streams; and (c) said cooled nitrogen overhead portion is expanded directly after cooling without any condensation against a vaporizing process stream, whereby at least a portion of the liquid nitrogen reflux requirement and/or of the liquid nitrogen product stream is provided. A process as claimed in Claim 1, wherein said nitrogen overhead is compressed to a pressure greater than nitrogen's critical pressure. A process as claimed in Claim 1 or Claim 2, wherein said expansion of cooled nitrogen overhead is performed across a valve. A process as claimed in Claim 1 or Claim 2, wherein said expansion of cooled nitrogen overhead is performed in a dense fluid expander. A process as claimed in any one of the preceding claims, wherein said expanded nitrogen overhead portion contains a vapor component in addition to containing said portion of the liquid nitrogen reflux requirement and/or of the liquid nitrogen product stream and wherein further refrigeration is provided by warming said vapor component by heat exchange against one or more process streams. A process as claimed in any one of the preceding claims, wherein further refrigeration is provided by: (i) compressing a second portion of said gaseous nitrogen overhead; (ii) cooling said compressed second nitrogen overhead portion by heat exchange against one or more process streams; (iii) expanding said cooled second nitrogen overhead portion in an expander to obtain a gaseous expander effluent; and (iv) warming said gaseous expander effluent by heat exchange against one or more process streams. A process as claimed in any one of the preceding claims, wherein shaft work is generated from said expansion of the compressed feed air and/or from said expansion of the gaseous nitrogen overhead portion(s) and the shaft work is used to provide at least a portion of the compression in the process. A process as claimed in any one of the preceding claims, wherein the distillation column system comprises a high pressure column and a low pressure column; said air feed to the distillation column system is fed to the high pressure column in which the air feed is rectified into a high pressure nitrogen overhead and a high pressure crude liquid oxygen bottoms; at least a portion of the high pressure crude liquid oxygen bottoms is fed to the low pressure column in which the liquid oxygen bottoms is distilled into the gaseous nitrogen overhead and a low pressure liquid oxygen bottoms; the high pressure column and the low pressure column are thermally linked such that at least a portion of the high pressure nitrogen overhead is condensed in a reboiler/condenser against a vaporizing low pressure column oxygen-rich liquid; and at least a portion of the condensed high pressure nitrogen overhead is used as a portion of the liquid nitrogen reflux requirement and/or of the liquid nitrogen product stream. A process as claimed in Claim 8, wherein the low pressure column is operated at a pressure between 170 and 350 kPa (25 and 50 psia). A process as claimed in Claim 8 or Claim 9, wherein the expansion of at least a portion of the compressed air feed comprises: (a) cooling the compressed air feed by heat exchange against one or more process streams; (b) splitting the cooled compressed air feed into a first split feed stream and a second split feed stream; (c) expanding the first split feed stream through an expander and recycling the expanded first split feed stream to the air feed while providing refrigeration to the air feed by heat exchange; (d) further cooling the second split feed stream by heat exchange against one or more process streams; (e) further splitting the second split feed stream into a third split feed stream and a fourth split feed stream; (f) expanding the third split feed stream through an expander and recycling a portion of the expanded third split feed stream to the air feed while providing refrigeration to the air feed by heat exchange; (g) further cooling the fourth split feed stream by heat exchange against one or more process streams; (h) introducing a portion of the fourth split feed stream into the low pressure column for rectification; and (i) introducing the remaining portion of the fourth split feed stream and the remaining portion of the expanded third split feed stream into the high pressure column for rectification. A process as claimed in any one of Claims 8 to 10, wherein a portion of the low pressure liquid oxygen bottoms is removed as the liquid oxygen product stream. A process as claimed in any one of Claims 8 to 11, wherein a nitrogen enriched gaseous stream is withdrawn from an upper location of the low pressure column, warmed by heat exchange against one or more process streams and subsequently removed as a nitrogen enriched gaseous stream. A process as claimed in any one of Claims 8 to 12, wherein a portion of the low pressure liquid oxygen bottoms is warmed by heat exchange against one or more process streams and subsequently removed as a gaseous oxygen product. A process as claimed in Claim 12 or Claim 13, wherein the low pressure column is operated at 170 to 350 kPa (25 to 50 psia) and additional refrigeration is generated by expanding said nitrogen enriched gaseous stream prior to said warming thereof and/or by expanding said gaseous oxygen product prior to said warming thereof. A process as claimed in any one of Claims 8 to 14, wherein: (a) the distillation column system further comprises an argon column; (b) an argon containing gaseous side stream is removed from a lower intermediate location of the low pressure column and fed to the argon column in which the argon containing gaseous side stream is rectified into an argon-rich vapor overhead and an argon-lean bottoms liquid; (c) the argon-lean bottoms liquid is returned to the low pressure column; (d) at least a portion of the argon-rich vapor overhead is condensed in a reboiler/condenser against vaporizing high pressure crude liquid oxygen bottoms; (e) a portion of the condensed argon-rich vapor overhead is removed as a liquid argon product; and (f) the remaining portion of the condensed argon-rich vapor overhead is used to provide reflux for the argon column.

Inventors: AGRAWAL RAKESH, WOODWARD DONALD WINSTON, XU JIANGUO, AGRAWAL, RAKESH, WOODWARD, DONALD WINSTON, XU, JIANGUO
Applicants: AIR PROD & CHEM, AIR PRODUCTS AND CHEMICALS, INC.
Application year: 1993
Main classification: F25J3
IPC codes: F25J3