New Positioner
Figure 1. Replacing original positioner with digital device has allowed tighter flow-rate control.
The plant, which handles 4.2 million std ft3 of air per hour, first purifies and dries the air to remove contaminants, such as moisture, carbon dioxide and residual hydrocarbons, that would become solids at cryogenic temperatures. A compressor takes the air to about 75 psi. Most of the air then goes to the distillation process. A small side stream, about 0.5 million std ft3/hr, is compressed to 110 psi; its subsequent expansion to 7 psi provides cryogenic refrigeration for the distillation columns.
COMMON CONFIGURATION
The plant uses a distillation arrangement that's relatively standard throughout the air separation industry. It consists of three columns -- low pressure, high pressure and crude argon (Figure 2). The low-pressure column sits above the high-pressure column, with a condenser/reboiler between the two.
A compressor discharges air directly into the high-pressure column. As the incoming air works its way up the column, it loses additional heat. The oxygen continues to liquefy, forming an ultra-cold oxygen-rich liquid (containing about 40% oxygen, with the balance being nitrogen) at the bottom of the high-pressure column.
Nitrogen and argon flow upwards through the low-pressure column. Oxygen is drawn off the bottom and nitrogen comes off the top of that column. A middle side stream runs to the bottom of the crude argon column. This side stream is a saturated gas consisting of about 90% oxygen and 10% argon.
Meanwhile, the rich liquid goes to the top of the crude argon column, where it serves to condense argon reflux. This vaporizes the rich liquid, which returns as a vapor to the low-pressure column. The amount of rich liquid vaporized corresponds one-to-one with the amount of argon condensed.