Patent Document

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     This invention was made with Government support under DOE Cooperative Agreement No. DE-FC26-97FT96052 between Air Products and Chemicals, Inc., and the United States Department of Energy. The Government has certain rights to this invention. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to module isolation devices for isolating the flow of gas from one module into one or more other modules that are joined together through one or more common headers. More specifically, this invention relates to isolation devices for Ion Transport Membrane (ITM) modules particularly designed for producing purified oxygen from an oxygen-containing gas (e.g., air) or for producing synthesis gas (often referred to herein as “syngas”). 
     The use of (ITM) modules for separating oxygen from an oxygen-containing gas, or for producing syngas is well known in the art. A representative patent disclosing ITM oxygen modules is Taylor et al. U.S. Pat. No. 5,681,373, assigned to the assignee of the present application. The Taylor et al. &#39;373 patent is hereby fully incorporated herein by reference. 
     A representative patent application disclosing ITM syngas modules is Carolan et al. publication number US 20040186018, assigned to the assignee of the present application. The Carolan et al. &#39;018 application is hereby fully incorporated herein by reference. 
     ITM oxygen and syngas modules typically are ceramic membranes that operate at high temperatures. These membranes operate with the process gas on one side of the membrane at a higher pressure than the process gas on the opposed side of the membrane. In common constructions a plurality of membrane modules are manifold together, both in series and in parallel, on a common header on the low-pressure gas side of the modules. 
     In an ITM oxygen module for separating oxygen from an oxygen-containing gas, the oxygen-containing gas is directed, under pressure, through passageways of the module to contact dense mixed conducting oxide layers of the multiple membranes making up the module. The driving force for separating the oxygen from the oxygen-containing gas is provided by creating a difference in oxygen partial pressure on opposite sides of the dense mixed conducting oxide layer of the various membranes, and the oxygen removed from the gas is then directed out of a product header, which generally is in communication with multiple ITM modules. 
     When the ITM modules are used for the production of synthesis gas the modules are generally heated to a temperature in the range of from 700 to 900° C., and the process temperature of the air inside the pipes that communicate with the ITM syngas modules are generally at the same operating temperature. In the production of synthesis gas a feed stock, which generally comprises a light hydrocarbon such as methane, natural gas, ethane, or other available light hydrocarbon mixtures known in the art, is introduced into passageways between the membranes of the ITM module. An oxygen-containing gas is introduced into the interior support layers of the various membranes of the module, wherein oxygen is permeated through the dense, mixed, outer conducting oxide layer of each of the membranes into engagement with the light hydrocarbon to form the synthesis gas. 
     If an individual membrane module fails, the high-pressure process gas will flow into the low-pressure process gas through the breach, or failure. In the case of an ITM oxygen module such failure results in a loss of purity of the permeate oxygen. In the case of an ITM syngas module, such failure results in syngas directly mixing with the source of air, which is a possible safety hazard. In addition, the failure may result in back pressuring the air feed to the other modules, may interfere with air flow or distribution and also may result in loss of the produced syngas. 
     From the above explanation it should be apparent that a need exists for a device or system that is capable of isolating an individual, failed module from the rest of the modules that are interconnected with the failed module by one or more common headers. Such an isolation device or system must be able to operate inside the process vessel, which is at an elevated temperature, and also must be reliable, and most preferably inexpensive in design. Shut off or isolation valves for use in conjunction with ITM modules are known in the art. These valves require an actuator to close them, and typically the actuators are pneumatic or electric solenoids triggered by an overpressure signal. These actuators are not designed for high temperature service in the inside of an ITM reactor vessel. In addition, lower cost devices would be beneficial. In this regard, a purely mechanical actuator is believed to have advantages over the use of pneumatic or electric solenoids from both a cost and reliability standpoint. 
     Use of a module isolation device or system will preserve product purity and also allows an ITM oxygen or syngas reactor to continue operating when individual modules fail, without compromising product purity, safety, or operability. 
     The problem addressed by the instant invention relates to the stopping of the flow of a gas resulting from a failed ITM module when the pressure of the gas exceeds a predetermined value. The device, including any actuator for it, must be able to operate at elevated temperatures, and must reliability permit the gas to flow through the device with an acceptable amount of restriction during normal operation. 
     Conventional technology using actuated valves responding to an overpressure signal from pressure transducers could accomplish the same function as the present invention, but with equipment of greatly increased complexity. Each module would require a separate pressure transducer to detect the presence of an increased pressure. Moreover, each module also would require an actuated valve. This may include the routing of pneumatic lines to each pneumatic actuator or electrical power to each electrical actuator. Hardware to perform the logic control of each actuator would also be required. For an ITM reactor, such as those employed in the preferred embodiments of this invention, the number and complexity of lines and equipment is significant. 
     U.S. Pat. No. 6,131,599 discloses a mechanically actuated pressure relief valve assembly controlled by a rupture disk. In the embodiment illustrated in FIG. 5 of the &#39;599 patent, an excess pressure drop across the pressure responsive piston 212 pushes the actuating rod 216 through the rupture disk 204, thereby shutting off flow between the inlet 188 and the outlet 190. It should be noted that the rupture disk in the FIG. 5 embodiment of the &#39;599 patent is not in flow communication with the process fluid. Stating this another way, the process fluid flows from the inlet to the outlet without in any way imposing the gas flow or pressure directly onto a surface of the rupture disk. In view of the fact that the device in the &#39;599 patent works by a pressure difference across the piston, it is only sensitive to excessive flow through the device. In other words, it does not detect elevated pressure in the device unless that pressure is accompanied by an increased flow of gas. The pressure difference across the device is a function of the operating conditions of the device, such as the working fluid composition, the velocity of the fluid, the viscosity of the fluid and the density of the fluid. Thus, changing the operating conditions of the device changes the pressure difference across the device and hence changes the flow rate at which the rupture disk ruptures to shut off the gas flow. This is a limitation that should be avoided, and is not present in the devices of the present invention. As will be pointed out hereinafter, the isolation devices of the present invention actually shut off the flow gas at a given overpressure across the rupture disk, even in the absence of significant flow, such as when the inlet and outlet of the device are isolated. 
     A further deficiency in the device disclosed in FIG. 5 of the &#39;599 patent is that it only is designed to operate with the valve seat and the actuator mechanism positioned on the outlet side of the housing. Such a device could not work on the air inlet of an ITM Syngas module. When an ITM Syngas module fails, the flow on the outlet leg will increase but the flow on the inlet leg will either stop or reverse due to the higher pressure in the module relative to the pressure of the feed air. A reversal of flow in the device disclosed in FIG. 5 of the &#39;599 patent would force the valve 212 to stay open and would not apply any force to the rupture disk. The present invention can be employed with the valve seat located on either the inlet or outlet side of the normal flow direction, thereby making the design of the present invention more versatile. 
     Taylor U.S. Pat. No. 5,067,511 discloses a high-pressure fluid emergency shut-off valve. FIG. 3 of the &#39;511 patent discloses a cross section of a typical valve in accordance with the teachings of that patent. Specifically, pressure at inlet 18 is transmitted through valve shaft 44 to an axial buckling pin 14. If the pressure is high enough, the pin 14 buckles to thereby allow the valve piston 47 to seat in valve seat 38, stopping fluid flow between inlet port 18 and outlet port 24. For pressure to be transmitted along valve shaft 44, sliding seals 48 are provided to maintain a pressure difference between the two ends of the shaft. The use of a buckling pin, as disclosed in the &#39;511 patent, is materially different from the use of rupture disks in the devices of the present invention. Moreover, the required use of sliding seals 48 in the construction disclosed in the &#39;511 patent makes such an arrangement unsuitable for use in high temperature applications, which are the preferred applications for the devices of the present invention. 
     Huff U.S. Pat. No. 4,240,458 discloses an excess pressure shut-off valve. FIGS. 2 and 3 of the &#39;458 patent show a cross section of a typical valve in accordance with the teachings of that patent. Excess pressure in space 20 causes diaphragm 24, which is a bi-stable snap-acting disk, to snap into the other stable position. This moves valve shaft 64 upward in the figure to move O-ring 76 into sealing engagement with sealing surface 18, thereby shutting off flow between inlet 14 and outlet 16 of the device. A principal drawback of the design disclosed in the &#39;458 patent is that the range of motion of the bi-stable snap-acting disk is small, being limited by the two stable positions of the disk. This results in a limited range of motion of the valve and hence only a limited opening of the valve into its fully opened position. In addition, any wear of the O-ring cannot be compensated for by additional axial movement of the valve shaft 64. The isolation valves employed in the module isolation devices of the present invention do not have these undesired, range-of-movement limitations. 
     Westman U.S. Pat. No. 5,810,057, assigned to the same assignee as the instant application, discloses a pressure vessel fill protective device consisting of a sliding piston 28, as shown in FIG. 1 of the patent. Port 58 is in flow communication with the head space of a vessel and also with a rupture disk 90. Port 56 is in flow communication with the head space of a vessel. In the event the head space of a vessel becomes over pressurized, the rupture disk 90 fails, depressurizing the space above the piston and thereby causing a force to be exerted on pin 40 to thereby cause that pin to fail. This results in the piston sliding upward to close off flow communication between ports 22 and 24. The system disclosed in the &#39;057 patent requires the use of a piston-type valve, which requires sliding seals that may not be amenable to use at elevated temperature conditions. As pointed out earlier, the most desired uses of the module isolation devices of this invention are in connection with ITM modules that operate at elevated temperature conditions. 
     Brazier et al. U.S. Pat. No. 6,484,742 discloses a pressure-activated shut-off valve, as illustrated in FIG. 11. Excessively high pressure will be transmitted through the shaft 308, causing pin 216 to buckle. As pin 216 buckles, the valve plug 314 seats against the valve seat 316 to stop fluid flow. To generate a pressure difference sufficient to move the valve shaft 308, a good pressure seal is required around that shaft as it passes through valve body 302. It is highly desirable to design a system which does not require the use of any seals around the valve shaft, particularly for systems intended for use in high temperature applications. For operation at high elevated temperature, the valve and shaft disclosed in the &#39;742 patent would need to be carefully constructed to prevent them from binding to each other. Alternatively, the seal area would have to be carefully insulated from any hot process fluid to prevent that area from becoming too hot. Also, unlike the present invention (as will become apparent from the discussion which follows) the pin that is required to buckle is not directly in the flow path through the cartridge assembly. 
     BRIEF SUMMARY OF THE INVENTION 
     Gas flow isolation devices or systems in accordance with this invention isolate the flow of gas from one module into one or more other modules that are joined to the one module through one or more common headers. These gas flow isolation devices or systems include an inlet passage and an outlet passage, with the inlet passage being adapted to communicate with an outlet from one of the modules to receive a flow of gas therefrom. The outlet passage communicates with the inlet passage for receiving the flow of gas from the module and directing the gas out of the isolation device, preferably into an outlet header adapted to communicate with isolation devices for other modules. Optionally, a flow restricting orifice can be provided through which the gas is required to pass as it enters the outlet header to reduce the pressure of the gas in that header. A valve system is movable from an opened condition to a closed condition to prevent the flow of gas from the inlet passage to the outlet passage when the pressure of gas in the isolation device exceeds a predetermined level. 
     The valve system in accordance with certain embodiments of this invention employs a rupture disk, a valve seat and a valve stem. The rupture disk has a first face and a second face, and the first face is in flow communication with the outlet from the module when the outlet is placed in flow communication with the inlet passage of the housing and the valve system is in an opened condition to permit the flow of gas form the inlet passage to the outlet passage of the isolation device. In this opened condition of the valve system the flow of gas also impinges upon the first face of the rupture disk to impose a pressure thereon. The second face of the rupture disk is in flow communication with a chamber maintained at a desired low pressure, and the rupture disk is designed to rupture when a predetermined pressure differential is established across the rupture disk. The valve seat is positioned between the inlet passage of the housing and the outlet passage and is located upstream of the rupture disk, that is, upstream of the direction of gas flow that acts upon the rupture disk. The valve stem of the value system has opposed first and second ends, with the first end being mechanically linked with the first face of the rupture disk and the second end being coupled to a valve member. The valve member is spaced from the valve seat when the first end of the valve stem is mechanically linked with the rupture disk to permit the flow of gas from the inlet passage to the outlet passage of the housing, and also into engagement with the first face of the rupture disk. The rupture disk ruptures upon a predetermined pressure differential across it being exceeded, thereby causing the valve member to seat against the valve seat and terminate the flow of gas from the inlet passage to the outlet passage and also through the rupture disk. 
     In accordance with certain embodiments of the invention the valve stem is vertically oriented and the first end of the valve stem is mechanically linked with the first face of the rupture disk by engaging that face. Thus, rupturing of the disk causes the valve stem, including its associated valve member, to move into engagement with the valve seat by the force of gravity. In addition, the flow of gas responsible for rupturing the disk creates a pressure drop across the valve member and this pressure drop assists in seating the valve member against the valve seat. 
     In certain embodiments of the invention the chamber that is maintained at a desired low pressure and that is in communication with the second face of the rupture disk is maintained in flow communication with low-pressure product gas flowing in the outlet header. 
     In certain embodiments of the invention the chamber that is maintained at a desired low pressure and that is in communication with the second face of the rupture disk is maintained at that pressure by employing a separate low-pressure gas therein. In this latter embodiment it is desirable to include a check valve that closes upon rupturing of the rupture disk, to thereby prevent the low-pressure gas in this latter chamber from entering into and contaminating the product gas in the outlet header. 
     In certain preferred embodiments of this invention the module is an Ion Transport Membrane module for separating oxygen from an oxygen-containing gas (e.g., air) and directing the purified oxygen into the inlet passage of the isolation device and then through the outlet passage into the outlet header for subsequent collection and use. 
     In other preferred embodiments of this invention the module is an Ion Transport Membrane module for producing syngas and the inlet passage of the module isolation device is in communication with spent, oxygen-containing gas exiting the module. 
     In accordance with embodiments of this invention wherein the module is an Ion Transport Membrane module for producing syngas, a second isolation device is provided for directing an oxygen-containing gas (i.e., a fresh gas (e.g., air) feed) to the module. The oxygen that permeates through the dense layer of the membranes of the module is contacted by a suitable feed stock, e.g., methane or other low hydrocarbon gas, to form, or produce, syngas. The outlet from the ITM syngas module transmits spent gas (i.e., the gas remaining after giving up oxygen to the feed stock) to the inlet of the first isolation device (i.e., a spent gas isolation device) and it is this spent gas that is directed from the inlet passage of the first spent gas isolation device to the outlet passage of that device when the valve system therein is in an opened condition. The second or fresh gas isolation device employs a valve system very similar to that employed in the spent gas isolation device, and is designed to close in the event of a module failure to prevent the back flow of syngas into the fresh gas supply. In a like manner, the valve system in the spent gas isolation device is designed to close in the event of a failure of the ITM module to thereby prevent syngas from intermixing with the spent gas and being directed out of the outlet passage of the spent gas isolation device. 
     In certain embodiments of the invention, the valve in the fresh gas isolation device includes a rupture disk having a first face that is in flow communication with the oxygen-containing gas inlet of the ITM module and the fresh gas outlet passage of the fresh gas isolation device when the valve system in that isolation device is in an opened condition. In this latter condition, back-pressure resulting from any backflow of syngas from the Ion Transport Membrane module is directly imposed on the first face of the rupture disk in the fresh gas isolation device. The second face of the rupture disk of the fresh gas isolation device is in flow communication with a chamber maintained at a desired low pressure, and the rupture disk is designed to rupture when the back-pressure exceeds a predetermined pressure level, i.e., when the pressure drop across the rupture disk exceeds a predetermined level. 
     In certain embodiments of the invention the valve assembly in the fresh gas isolation device includes a valve seat and a valve stem similar to that employed in the first or spent gas isolation device. That is, the valve stem has opposed first and second ends; the first end being mechanically linked with the first face of the rupture disk, preferably by engaging said first face, and the second end being coupled to a valve member. When the pressure differential across the rupture disk exceeds a predetermined value, caused by the back-flow of syngas from a failed module, the rupture disk fails, thereby causing the valve member to seat against the valve seat by both the force of gravity and the force imposed on the valve member by the pressure drop across the valve member created by the flow of syngas from the module. 
     In accordance with certain embodiments of this invention, a flow restrictor (e.g., a flow-restricting orifice) can be provided in the fresh gas inlet passage into the fresh gas isolation device and in the spent gas outlet passage of the spent gas isolation device. When such flow restrictors are employed, either a fresh gas header communicating with the fresh gas inlet passage or the spent gas header communicating with the spent gas outlet passage of the spent gas isolation device can be employed as the low pressure chamber or header communicating with the second face of the rupture disk in the respective fresh gas and spent gas isolation devices. 
     If desired, the low-pressure chamber in communication with the second side of the rupture disk in both the fresh gas isolation device and the spent gas isolation device can be in communication with a low-pressure gas that is completely isolated from the fresh gas flowing into the fresh gas isolation device and the spent gas exiting the spent gas isolation device, respectively. If the fresh gas feed header does not constitute the low-pressure header communicating with the second face of the rupture disk in the fresh gas isolation device, a check valve would be needed to prevent the fresh gas feed to a malfunctioning ITM module from passing into the low pressure header through the ruptured disk. In a like manner, if the spent gas header does not constitute the low-pressure header, a check valve would be needed in the spent gas isolation device to prevent spent gas from the spent gas header passing through the ruptured disk into the low pressure header. 
     Although embodiments of this invention wherein the valve stem is mechanically linked to the ruptured disk may function well for certain applications, there is a drawback to such a construction. In particular, as gas flow moves from the inlet passage to the outlet passage of the isolation device that flow can act upon the valve to cause the valve to flutter thereby causing the end of the valve stem engaging the rupture disk to vibrate against the disk. This can result in a premature rupturing of the rupture disk, when, in fact, the ITM module is still functioning in a normal manner. 
     In order to overcome the flutter problem associated with the above-described embodiments of the invention, alternative, and more preferred embodiments of this invention do not include the rupture disk as part of the valve system. Rather, the valve stem is maintained out of engagement with the rupture disk when the valve is in a normally opened condition. Specifically, the valve system includes a crushable member that normally biases the valve system into an open condition. This crushable member is independent of the rupture disk. When the crushable member is crushed, the valve system moves into a closed condition. In these alternative, preferred embodiments, the valve stem is out of force-transmitting engagement with the rupture disk when the valve stem is in an opened condition, and, in a preferred construction, does not engage the rupture disk at any time. The crushable member is designed to crush after the pressure differential across the rupture disk causes the rupture disk to fail. Specifically, after the rupture disk fails (i.e., by rupturing) the flow of gas through the rupture disk, from the high-pressure side to the low-pressure side thereafter, creates a pressure difference across the valve member, which forces the valve member downwardly to engage against its corresponding valve seat. In the most preferred embodiment, even in the closed condition of the valve system the valve stem does not break the plane occupied by the rupture disk, prior to rupturing. 
     In the most preferred embodiments of this invention, the crushable member is a compressible spring, which is capable of also expanding after being compressed to move the valve assembly into a normally opened position after the flow of gas from the module into the isolation devices(s) is discontinued. 
     In certain constructions of this invention the crushable member is supported against axial movement on a porous or perforated support surface that is connected against movement in the isolation device and that includes a passage in axial alignment with the valve stem. An actuating member is connected to the valve stem and is movable axially with the valve stem for engaging and crushing the crushable member after the rupture disk has been ruptured. 
     The embodiments of this invention employing crushable members to normally maintain the valve assembly in an opened condition can be employed in both a single module isolation device that commonly is employed in connection with an ITM oxygen module, and/or in one or both of the fresh gas and/or spent gas module isolation devices generally employed in connection with an ITM syngas module. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be described by way of example with reference to the accompanying drawings, in which: 
         FIG. 1  is a schematic view of one embodiment of a module isolation device in accordance with this invention; 
         FIG. 2  is a schematic view of an alternative embodiment of a module isolation device in accordance with this invention; 
         FIG. 3  is a schematic view of another embodiment of a module isolation device in accordance with this invention; 
         FIG. 4  is a schematic view of a module isolation device similar to that illustrated in  FIG. 1 , but employing a more preferred valve system; 
         FIG. 5  is a schematic view of a module isolation device similar to  FIG. 2 , but employing the more preferred valve system illustrated in  FIG. 4 ; 
         FIG. 6  is a schematic view of a module isolation device similar to  FIG. 3 , but employing the more preferred valve system illustrated in  FIG. 4 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , a module isolation device in accordance with one embodiment of this invention is illustrated at  10 . The module isolation device is employed to receive oxygen permeate from an Ion Transmission Membrane (ITM) oxygen module  12 . Exemplary ITM oxygen modules are disclosed in U.S. Pat. No. 5,681,373, the subject matter of which is hereby fully incorporated by reference. Also, as discussed earlier, ITM oxygen modules are described in Taylor et al. U.S. Pat. No. 5,681,373. This latter patent previously has been incorporated by reference herein. 
     The oxygen permeate from the ITM oxygen module  12  is the purified oxygen removed from an oxygen-containing gas (e.g., air) that initially is directed into passageways  14  provided between the membrane units  16  of the module. The membrane units  16  include a dense, mixed conducting oxide layer through which oxygen permeates. The oxygen permeate, i.e., the purified oxygen, is directed out of the module  12  through ceramic stack manifold  18  and a ceramic to metal seal  20  into inlet  22  of the module isolation device  10 . 
     Still referring to  FIG. 1 , the module isolation device  10  includes an outlet passage  26  downstream of the inlet passage  22  for receiving the flow of permeate oxygen. Optionally, the outlet passage  26  can include a flow restricting orifice  28  through which the oxygen passes prior to entering an oxygen collecting header or plenum  30 . The flow restricting orifice  28 , if needed, is designed to provide sufficient back pressure in the event of increased flow from the module  12 , such as from a leak, to increase the pressure acting on a rupture disk (described in detail hereinafter) to a value higher than the pressure encountered during normal operation of the module  12 . The higher pressure resulting from a malfunction of the ITM oxygen module  12  will rupture the rupture disk to isolate the module, as will be discussed in detail later in this application. It should be understood that the oxygen collecting plenum  30  generally is associated with one or more additional ITM oxygen modules that are arranged in series or parallel, such that the oxygen permeate from all of the modules flow into and through the common oxygen collecting plenum  30 . 
     A unique feature of this invention resides in the construction and operation of a module isolation valve  40  forming part of the module isolation device  10 . The valve  40  is designed to permit the flow of oxygen permeate from the inlet passage  22  through the outlet passage  26  when in an opened condition and to prevent the flow of the oxygen permeate to the outlet passage when in a closed condition. 
     The module isolation valve  40  includes a valve seat  42 , a valve stem  44  including a valve member  46  at one end thereof, and a rupture disk  48  having a first face  50  engaging an opposed end  52  of the valve stem  44 . The rupture disk  48  includes a second face  54  in flow communication with a low-pressure header  56  through a conduit  58 . If desired, heat insulation material  60  optionally can be provided around the valve stem  44  adjacent the rupture disk  48 . 
     It should be noted that when insulation material  60  is employed it is a porous material, e.g. alumina fiber, to permit flow communication of the oxygen permeate flowing into the module isolation device  10  through the inlet  22  with the first face  50  of the rupture disk  48  when the module isolation valve  40  is in an opened condition. The flow of oxygen permeate is schematically indicated by the arrows depicted in  FIG. 1 . 
     It should be noted that the specific construction of the ceramic to metal seal  20  does not constitute a limitation on the broadest aspects of this invention. Exemplary ceramic to metal seals usable in this invention are described in U.S. Pat. No. 6,302,402, the subject matter of which is hereby incorporated by reference. 
     In the illustrated embodiment, the valve member  46  is in the form of a globe valve, however, other types of linear-action valves, e.g., gate valves, angled valves, etc., would work equally well in the invention. Exemplary types of valves usable in this invention are disclosed in standard references, such as Perry&#39;s Handbook of Chemical Engineering, Chapter 10. It should be understood that the materials employed to construct the module isolation valve  40  need to be chosen to be compatible for service in the hot oxygen product stream. An exemplary material is a nickel superalloy, such as Haynes 214 or Haynes 230, sold by Haynes International of Kokomo, Ind. Alternatively, parts of the valve could be constructed of structural ceramics such as alumina, silicon carbide or silicon nitride. 
     The rupture disk  48  needs to be designed for proper operation at the temperature of use in the system. This disk  48  either can be exposed to the operating temperature of the oxygen process stream, or it can be insulated from the process stream, such as by employing insulation material  60 , and thereby operate at a lower temperature. 
     Having described the structural arrangement of elements in the module isolation device  10 , the manner in which the device functions to isolate the module  12  from other modules joined to the module isolation device  10  through one or more common headers (e.g., oxygen collecting plenum  30 ) will now be described. 
     During an upset condition, such as when a large leak develops in the ITM module  12 , the flow exiting the module into the inlet passage  22  of the module isolation device  10  will increase. Due to the flow resistance of the module isolation device  10  and the oxygen collecting plenum or manifold  30 , the pressure inside the module  12  also will increase. If a flow restrictor is employed between the module  12  and the oxygen collecting plenum or header  30 , (e.g., flow restricting orifice  28 ) the pressure inside the module  12  will increase even further. This increase in pressure is transmitted through the isolation device  10  against the first face  50  of the rupture disk  48 . This pressure increase resulting in an overpressure condition for the rupture disk  48  will cause the disk to rupture, or burst. When the rupture disk ruptures it no longer supports the lower end  52  of valve stem  44 , and the stem will drop under the force of gravity, the pressure drop across the valve member, and the viscous drag of the gas around the valve member  46  in the case of certain types of valves, such as globe valves. In this latter position the valve member  46  seats against valve seat  42  to close valve  40  and stop the flow of gas exiting from the ITM oxygen module  12  to the oxygen collecting plenum  30 . This causes the pressure on the upstream side of the valve member  46  to further increase to the pressure of the high-pressure gas, which further assists in maintaining a good seal between the valve member  46  and the valve seat  42 . 
     Once the valve member  46  seats against the valve seat  42 , the oxygen collecting plenum or header  30  is isolated from the leak, thereby preventing contamination of the purified oxygen from the failed module  12 . 
     In the illustrated embodiment, wherein the low pressure header  56  is a separate header from the oxygen collecting plenum or header  30 , a check valve in the conduit  58 , schematically indicated at  62 , is desired to prevent a backflow of gas from the low pressure header  56  into the permeate oxygen plenum  30  after the rupture disk  48  fails. That is, the check valve  62  precludes low pressure gas from the header  56  from passing through the opening in the ruptured disk  48  and into the oxygen collecting plenum  30  through outlet passage  26  of the isolation device  10 . 
     Referring to  FIG. 2 , a module isolation device  100  is depicted, which includes a number of elements that are the same as the elements employed in the module isolation device  10 . The elements in the module isolation device  100  that are the same as elements in the module isolation device  10  are identified by the same numerals, but with a suffix “A.” Suffice it to state that the module isolation device  100  disclosed is  FIG. 2  functions to receive permeate oxygen from ion transport membrane module  12 A in the same manner as described above in connection with the module isolation device  10  disclosed in  FIG. 1 . 
     The only difference between the module isolation device  100  and the module isolation device  10  is in the manner in which the low pressure header  56 A of the module isolation device  100  is provided to communicate with the second face  54 A of the rupture disk  48 A. Specifically, in the module isolation device  100  the oxygen collecting plenum or header  30 A is placed in direct communication with the second face  54 A of the ruptured disk  48 A through a conduit  102  of any desired configuration, whereby the low pressure flow of oxygen into the plenum  30 A through flow restricting orifice  28 A also constitutes the low pressure gas communicating with the second face  54 A of the ruptured disk  48 A. Thus, the oxygen collecting plenum  30 A actually functions as the low pressure header in the module isolation device  100 . By employing this latter arrangement the purity of the oxygen in the oxygen collecting plenum  30 A is ensured, and there is no need to provide a check valve, similar to the check valve  62  employed in the module isolation device  10 , in order to prevent the backflow of low pressure gas through the ruptured disk  48 A into the oxygen collecting plenum  30 A. Such a check valve is not required because the gas that is capable of flowing through the ruptured disk  48 A in a reverse direction actually is the same purified oxygen that is collected in the oxygen collecting plenum  30 A. 
     Referring now to  FIG. 3 , a pair of module isolation devices  200  and  300  are connected with an ITM syngas module  12 B on the airfeed line into the module and the spent air effluent from the module, respectively. Components of module isolation devices  200 ,  300  that operate in the same manner as components in the module isolation device  10  will be referred to by the same numerals, but with the suffixes “B” and “C,” respectively. The operation of ITM syngas modules are well known in the art and the specific construction thereof does not constitute a limitation on the broadest aspects of this invention. During operation of an ITM syngas module  12 B a high-pressure synthetic gas, e.g., methane or other light hydrocarbon gas, is directed through passageways  14 B of the module  12  and into engagement with permeate oxygen extracted from air fed into the module to thereby form the syngas. 
     In the discussion that follows the module isolation device  200  will sometimes be referred to as the “fresh gas isolation device,” “fresh air isolation device” or by words of similar import, and the module isolation device  300  will sometimes be referred to as the “spent gas isolation device,” “spent air isolation device,” “effluent isolation device” or by words of similar import. Although the description that follows describes a preferred embodiment in which the fresh oxygen-containing gas is air, in accordance with the broadest aspects of this invention other oxygen-containing gases can be employed. 
     In the illustrated embodiment, a fresh air feed header  202  receives fresh air to be directed into the ITM syngas module  12 B. This fresh air feed is directed into the fresh air isolation device  200  through an optional flow-restricting orifice  204 , and then through outlet conduit  206  of the device. The outlet conduit  206  communicates with air feed inlet  208  of the module  12 B. The air feed inlet  208  is provided by a ceramic conduit or tube that is concentric with an outer ceramic conduit or tube  210  that is connected to a ceramic to metal seal  212 . It is through this outer conduit  210  that the spent gas (e.g., the gas from which oxygen ions have been removed in the ITM syngas module  12 B) is directed into the spent air isolation device  300 . 
     It should be understood that the construction and operation of the spent air module isolation device  300  is identical to the construction and operation of the oxygen permeate isolation device  10  illustrated in  FIG. 1 , with the exception that the gas being isolated by the isolation device  300  is the spent air that gave up its oxygen to the synthetic gas, as opposed to pure oxygen removed from the air by the ITM oxygen module  12 . However, the structural features and operation of the module isolation device  300  is otherwise identical to that described above in connection with the module isolation device  10 . 
     As noted above, the air feed into module  12 B and the spent air effluent from that module are connected to the module through the concentric ceramic tubes  208 ,  210 , respectively. Each of these tubes is connected to metal piping through a ceramic to metal seal  212 . 
     Still referring to  FIG. 3 , the module isolation device  200  employs a module isolation valve  40 B upstream of the ceramic to metal seal  212  for the air feed leg. The module isolation device  300  employs a module isolation valve  40 C for the spent air effluent from the module  12 B, downstream of the ceramic to metal seal  212  for the spent air effluent leg. The flow of the fresh airfeed into the inner concentric tube  208  of the module  12 B is illustrated by arrows  214 , and the flow of spent effluent from the module  12 B is illustrated by arrows  216 . 
     During normal operation, both of the module isolation valves  40 B,  40 C are opened. Air feed passes from the airfeed header  202  through optional flow restricting orifice  204 , through the airfeed module isolation valve  40 B and through outlet conduit  206  communicating with the air feed inlet  208  into the ITM syngas module  12 B. 
     Spent air exiting the module  12 B (as depicted by arrows  216 ) passes through the spent air module isolation valve  40 C of the spent air isolation device  300 , through an optional flow-restricting orifice  28 C and into spent air header or plenum  30 C. The flow-restricting orifices  28 C,  204 , if needed, are designed to provide sufficient back pressure in the respective isolation devices  300 ,  200  in the event of an increased flow from the module  12 B, such as from a leak, to thereby increase the pressure acting on the rupture disks  48  B,  48 C in both module isolation devices  200 ,  300  to values sufficiently above the pressures normally encountered under steady state operating conditions. 
     As in the embodiments illustrated in  FIGS. 1 and 2 , the valve stems  44 B,  44 C of the module isolation valves  40 B,  40 C in the module isolation devices  200 ,  300  are mechanically linked to the first face  50 B,  50 C of the rupture disks  48 B, and  48 C, respectively. In the illustrated embodiment, the mechanical linkage is created by the first face  50 B,  50 C of the rupture disks  48 B,  48 C actually supporting ends  52 B,  52 C of the valve stems  44 B, and  44 C, respectively. 
     In the event of a malfunction of the module  12 B, resulting in the backflow of syngas through both the inner and outer concentric tubes  208 ,  210 , respectively, the high pressure backflow causes the rupture disks  48 B,  48 C to rupture, resulting in a closure of the respective module isolation valves  40 B,  40 C in the module isolation devices  200 ,  300 . This will prevent contamination of the spent air effluent and the fresh air infeed by the syngas. 
     As in the earlier described embodiments, the second face  54 B,  54 C of the rupture disks  48 B,  48 C in the fresh air isolation device  200  and in the spent air isolation device  300 , respectively, are in full communication with respective low pressure headers  56 B,  56 C. In the embodiment illustrated in  FIG. 3 , the low pressure headers  56 B,  56 C are separate from the fresh air feed header  202  into the module isolation device  200  and the spent air or effluent collection plenum  30 C of the module isolation device  300 . In this arrangement, it is desirable to employ check valves  62 B,  62 C in conduits  58 B,  58 C that communicate the low pressure headers  56 B,  56 C with the second faces  54 B,  54 C of the rupture disks  48 B,  48 C, in the same manner as described above in connection with the module isolation device  10  illustrated in  FIG. 1 . Specifically, these check valves  62 B,  62 C will prevent the flow of gas from the low pressure headers  56 B,  56 C into the airfeed header  202  of the fresh air isolation device  200  and into the spent air header  30 C of the spent air isolation device  300 , respectively. 
     Still referring to  FIG. 3 , in an alternative, and more preferred arrangement, the air feed header  202  is employed as the low pressure header in communication with the second face  54 B of the rupture disk  48 B in the fresh air module isolation device  200 , and the effluent plenum or header  30 C is employed as the low pressure header in communication with the second face  54 C of the rupture disk  48 C in the spent air isolation device  300 . This is achieved by providing conduits communicating the respective airfeed header  202  and the effluent air header  30 C with the region underlying the second faces  54 B,  54 C of the respective ruptured disks  48 B,  48 C, in the same manner that conduit  102  is employed in the module isolation device  100  illustrated in  FIG. 2 . In this latter arrangement there is no need for any check valves to prevent the flow of gas from the low pressure region underlying the rupture disks  48 B,  48 C into the air feed header  202  and spent air header  30 C of the module isolation devices  200  and  300 , respectively, since the low pressure region  56 B in the module isolation device  200  would contain the same air supply as in the air feed header  202 , and the low pressure region  56 C in the module isolation device  300  would contain the same effluent as in the spent air header  30 C of that module isolation device. 
     By way of brief description, and still referring to  FIG. 3 , the backflow of syngas resulting from a malfunction of the module  12 B will cause a significant pressure increase in the module isolation devices  200  and  300 , to thereby cause the rupture disks  48 B,  48 C therein to rupture and the corresponding module isolation valves  40 B,  40 C to close, in a manner similar to that described in connection with the module isolation device  10  depicted in  FIG. 1  and the module isolation device  100  depicted in  FIG. 2 . The closing of valves  40 B,  40 C isolates the undesirable backflow of syngas from a damaged module  12 B into either the fresh air feed into isolation device  200  or the effluent out of the isolation device  300 . 
     Referring to  FIGS. 4-6 , module isolation devices similar to module isolation devices  10 ,  100 ,  200  and  300 , respectively, are depicted. The embodiments depicted in  FIGS. 4-6  represent the most preferred embodiments and overcome a problem that potentially exists with the embodiments illustrated in  FIGS. 1-3 . 
     Specifically, in the embodiments depicted in  FIGS. 1-3 , the ruptured disks constitute part of the described module isolation valves  40 ,  40 A,  40 B and  40 C, and in the disclosed embodiments, actually engage the lower ends of their respective valve stems  44 ,  44 A,  44 B and  44 C to normally bias the isolation valves into their opened condition. 
     It was determined that during operation of the module isolation devices  10 ,  100  and  300 , the flow of gas against the valve members; particularly valve members  46 ,  46 A and  46 C, during normal operation of the modules  12 ,  12 A or  12 C caused the valve stems  44 ,  44 A and  44 C to vibrate against the rupture disks  48 ,  48 A,  48 C thereby creating the possibility of premature failure of those rupture disks. In other words, the vibration of the valve stems  44 ,  44 A and  44 C against the rupture disks  48 ,  48 A and  46 C, respectively, can cause those rupture disks to fail, and thereby cause the valve members  46 ,  46 A and  46 C to seat against their respective valve seats  42 ,  42 A and  42 C, even if no malfunction of the module  12 ,  12 A or  12 C occurs. This clearly is undesirable. 
       FIGS. 4-6  disclose module isolation devices that are identical to the module isolation devices  10 ,  100 ,  200  and  300 , respectively, except for the construction of the module isolation valves. Specifically, wherein the module isolation valves  40 ,  40 A,  40 B and  40 C employed in the embodiments illustrated in  FIGS. 1-3  include respective ruptured disks  48 ,  48 A,  48 B and  48 C as a component thereof, the module isolation valves employed in the embodiments illustrated in  FIGS. 4-6  do not include the rupture disk as a component thereof. In fact, as will be explained hereinafter, the valve stem of the valve assemblies illustrated in the embodiments of  FIGS. 4-6  do not engage the respective rupture disks at all, and actually are spaced from the rupture disks during movement between opened and closed conditions of the valves. 
     Referring specifically to  FIG. 4 , a module isolation device  400  is depicted for use in connection with an Ion Transport Membrane oxygen module  12 D, in the same manner as the module isolation device  10 . Components of the embodiment illustrated in  FIG. 4  that are identical to components of the embodiment illustrated in  FIG. 1  are identified by the same numerals, but with the suffix “D” and in many cases will not be discussed in detail herein, for purposes of brevity. 
     The sole difference between the module isolation device  10  illustrated in  FIG. 1  and the module isolation device  400  illustrated in  FIG. 4  is that the preferred embodiment of the module isolation device  400  includes three additional elements; namely, a stationary, perforated plate  402  connected to the module isolation device for supporting a crushable member  404  thereon, the crushable member  404 , preferably being a spring supported on the perforated plate  402 , and a stopper, or actuating member  406  affixed to the valve stem  44 D and movable with said valve stem. Optionally a porous insulation member  60 D can be provided to insulate a downstream region of the isolation device  400 , if desired. 
     As noted above, most preferably the crushable member  404  is a spring, which will not need to be replaced when the module isolation device  400  is repaired with a new rupture disk  48 D, after a rupture disk has ruptured because of a malfunction of module  12 D. Specifically, when the module isolation device  400  is shut down for repair, the compressed spring  404  will return to its normal, uncompressed state, and therefore does not need to be replaced. A preferred type of spring is a wave spring. 
     It should be noted that in this embodiment the lower surface  52 D of the valve stem  44 D is maintained out of engagement with the upper face  50 D of the rupture disk  48 D while the crushable member  404  acts against the actuating member  406  that is attached to the valve stem to normally maintain module isolation valve  40 D in an opened condition. 
     In the embodiment of the invention illustrated in  FIG. 4 , the module isolation valve  40 D includes valve seat  42 D, valve stem  44 D including a valve member  46 D at one thereof, and a crushable member  404 , e.g., a spring, retained on the stationary, perforate plate  402  and being compressible by an actuating member  406  attached to the valve stem. 
     Still referring to  FIG. 4 , in the event of a malfunction of the module  12 D the pressure within the isolation device  400  will increase to an undesirable level, and the rupture disk  48 D is engineered to rupture at that level. Subsequent to the rupturing of the disk  48 D the increased flow acting upon the valve member  46 D produces a pressure differential that forces the actuating member  406  against the spring  404  (or other crushable member), to thereby cause the valve member  46 D to seat against the valve seat  42 D while compressing the spring or other crushable member. 
     In the preferred embodiment, the lower end  52 D of the valve stem  44 D is maintained in a position where it does not move through the plane occupied by the rupture disk  48 D. 
     As should be apparent, in the module isolation device  400  illustrated in  FIG. 4  any vibration imposed upon the valve member  46 D by the flow of oxygen during normal operation of the ITM oxygen module  12 D will not cause the valve stem  44 D to vibrate against the rupture disk  48 D to thereby possibly cause a premature failure, or rupture, of that disk. 
     Turning to  FIG. 5 , a module isolation device  500  substantially similar to the module isolation device  100  depicted in  FIG. 2  is shown. Components of the module isolation device  500  depicted in  FIG. 5  that are identical to components of the module isolation device depicted in  FIG. 2  are identified by the same numerals, but with the suffix “E.” These latter components will not be described in detail herein, for purposes of brevity. 
     In fact, it should be apparent that the difference between the module isolation device  500  shown in  FIG. 5  and the module isolation device  100  shown in  FIG. 2  is that the module isolation valve assembly  40 E in the  FIG. 5  embodiment is modified to the preferred form  40 D employed in the module isolation device  400  shown in  FIG. 4 . Accordingly, components of the module isolation valve  40 E in the module isolation device  500  depicted in  FIG. 5  that are identical to components of the module isolation valve,  40 D in the module isolation device  400  depicted in  FIG. 4  are identified by the same numerals, but with the suffix “E.” 
     By way of brief explanation, in the event of a malfunction of the Ion Transport Membrane oxygen module  12 E, resulting in an increased pressure within the module isolation device  500 , the increased pressure acts directly on the first face  50 E of the rupture disk  48 E to cause the rupture disk to rupture. Thereafter, the increased flow of gas will act upon the valve member  46 E to move said valve member in a downward direction to seat the valve member against valve seat  42 E while compressing wave spring  404 E. As is described in connection with the module isolation device  400  disclosed in  FIG. 4 , in accordance with the broadest aspect of this embodiment of the invention the wave spring  404 E can be replaced with other types of crushable members, but most preferably the crushable member is in the form of a spring so that it will not need to be replaced when a module is repaired with a new rupture disk, after the original rupture disk fails due to a malfunction of the Ion Transport Membrane module  12 E. 
     Turning to  FIG. 6 , module isolation devices  600  and  700  are depicted, which are similar to the module isolation devices  200  and  300  illustrated in  FIG. 3 , and provide exactly the same functions as these latter module isolation devices. Moreover, the only difference between the module isolation devices depicted in  FIGS. 3 and 6  is in connection with the construction of the module isolation valves employed in the isolation devices. Components of module isolation devices  600  and  700  that are identical to components of module isolation devices  200  and  300  are designated by the same numerals, with the suffixes “F” and “G” respectively. Components of the module isolation valves in the module isolation devices  600  and  700  that are identical to the components of the module isolation valve in the module isolation device  400  illustrated in  FIG. 4  are designated by the same numerals, also with the suffixes “F” and “G” respectively. 
     Suffice it to state, that the module isolation devices  600 ,  700  employed in connection with an ITM syngas module, as shown in  FIG. 6 , functions in the same manner as the module isolation devices  200  and  300  employed in the  FIG. 3  embodiment, with the exception of the structure and operation of the isolation valves. In particular, in the module isolation devices  600  and  700  the module isolation valves  40 F and  40 G are each constructed in the same manner as the module isolation valve  40 D employed in the module isolation device  400 , and move between opened and closed positions in the same manner as in the module isolation device  400 . 
     Thus, the module isolation valves  40 F and  40 G actually prevent their respective valve stems  44 F,  44 G from engaging the rupture disks  48 F,  48 G in the respective module isolation devices  600  and  700 , to thereby prevent premature failure of those rupture disks resulting from vibration of the valve stems against the respective rupture disks caused by the normal flow of gas in the respective module isolation devices  600  and  700 . 
     The potential problem of premature rupturing of rupture disks, which is solved by the structure of the module isolation valves  40 F,  40 G in the module isolation devices  600 ,  700 , respectively, is prevalent in a module isolation device intended to function in the manner of module isolation device  700 , wherein the flow of gas during normal operation of the ITM module is in a direction against the rupture disk  48 G, which also is the direction tending to force or vibrate the valve stem against the rupture disk. 
     It should be understood that the flow of fresh air and spent air through module isolation devices  600  and  700  is the same as the flow of fresh air and spent air through the module isolation devices  300  and  400  in the  FIG. 3  embodiment, with the module isolation valves  40 G and  40 H moving to a closed position after rupturing of rupture disks  48 F and  48 G, by the same mechanism that module isolation valve  40 D is moved into a closed position in the module isolation device  400  disclosed in  FIG. 4 . Moreover, the low pressure headers  56 F and  56 G can be of the same construction and employed in the same manner as low pressure headers  56 C and  56 D in the module isolation devices  300  and  400 , respectively. 
     Alternatively, the low pressure region communicating with the lower faces  54 F,  54 G of rupture disk  48 F and  48 G can be provided by communicating the fresh air feed plenum  202 F with the lower surface of rupture disk  48 F through a connecting conduit, and by communicating the spent air plenum  30 G with the lower surface of rupture disk  48 G through a connecting conduit, essentially in the same manner as described in connection with the module isolation device  100  illustrated in  FIG. 2  and the modulation device  500  depicted in  FIG. 5 . 
     When the fresh air feed is employed to provide the low pressure area behind rupture disk  48 F, and the spent air is employed to provide the low pressure area behind rupture disk  48 G, there is no need to provide check valves in the low pressure sections to prevent contamination of the fresh air feed in the air feed header  202  or contamination of the spent gas in the spent gas collecting plenum  30 G when rupture disks  48 F and  48 G, respectively, are ruptured. The reason why such check valves are not be required was explained earlier in connection with the isolation devices  200 ,  300 ; modified to provide air feed plenum  202  as the low pressure area behind rupture disk  48 B and spent gas plenum  30 C as the low pressure area behind rupture disk  48 C. That explanation will not be repeated herein for purposes of brevity. 
     Although illustrated and described herein with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalence of the claims and without departing from the spirit of the invention.

Technology Category: 2