AIR SEPARATION METHOD AND APPARATUS

Abstract

A method and apparatus for separating air in which an oxygen-rich liquid stream is pumped and then heated within a heat exchanger to produce an oxygen product through indirect heat exchange with first and second boosted pressure air streams. The first boosted pressure air stream is cold compressed at an intermediate temperature of the heat exchanger, reintroduced into the heat exchanger at a warmer temperature and then fully cooled and liquefied. The second boosted pressure air stream, after having been partially cooled, is expanded to produce an exhaust stream that is in turn introduced into a lower pressure column producing the oxygen-rich liquid. The second boosted pressure air stream is partially cooled to a temperature no greater than the intermediate temperature at which the cold compression occurs so that both the first and second boosted pressure air streams are able to take part in the heating of the oxygen-rich stream.

Description

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for separating air in which an oxygen-rich liquid stream produced by a distillation column arrangement is pressurized by pumping and then vaporized to produce an oxygen product as a vapor. More particularly, the present invention relates to such a method and apparatus in which the oxygen-rich liquid stream is heated through indirect heat exchange with an air stream that is subjected to cold compression at an intermediate temperature and another air stream that is partially cooled and expanded in a turboexpander that exhausts into the lower pressure column of the distillation column arrangement in order to impart refrigeration.

BACKGROUND OF THE INVENTION

Air is separated to produce oxygen, nitrogen and argon-rich products through the cryogenic rectification of the air. Such cryogenic rectification is conducted by compressing the air, purifying the air of higher boiling contaminants such as water vapor and carbon dioxide and then cooling the air to a temperature suitable to distill the air into its component parts.

Such distillation can be conducted in a higher pressure column thermally linked to a lower pressure column by a condenser reboiler. In such a distillation column system, a crude liquid oxygen column bottoms produced in the higher pressure column, also known as kettle liquid, is further refined in the lower pressure column to produce an oxygen-rich liquid column bottoms. The column bottoms of the lower pressure column is partially vaporized in the lower pressure column against the condensation of nitrogen-rich vapor produced in the higher pressure column by the condenser reboiler. The condensation of the nitrogen-rich vapor will typically produce liquid nitrogen reflux for both the high and the lower pressure columns. Oxygen-rich liquid and vapor products, removed from the lower pressure column, can be heated through indirect heat exchange with incoming compressed and purified air to produce an oxygen product.

Where oxygen is desired as a high pressure product, the oxygen-rich liquid can be pumped and then vaporized within a main heat exchange system used in cooling the incoming air. Pumping can also be used to pressurize liquid nitrogen streams where nitrogen is desired as a high pressure product. Part of the compressed and purified air can be compressed in a booster compressor and introduced into the main heat exchanger to engage in indirect heat exchange with the pumped liquid oxygen and potentially, the pumped liquid nitrogen liquid. The degree to which the air is compressed is dependent upon the pressure required for the high pressure product. Typically, the air is compressed to a supercritical pressure and then after having been cooled through the indirect heat exchange, liquefied, let down in pressure and introduced into the distillation column system.

It is also known to further compress the air, after having been compressed by the booster compressor, in a cold compressor that is connected to the heat exchanger used in the indirect heat exchange between the air and the pressurized streams. The cold compressor is connected to the heat exchanger so as to receive the compressed air at an intermediate temperature between the warm and cold ends of the heat exchanger or in other words, after the air has been partially cooled. The cold compressed air stream resulting from compression in the cold compressor is reintroduced back into the heat exchanger and then further cooled through indirect heat exchange with the pressurized stream or streams. Since the greatest heat exchange duty arises at a point in the heat exchanger where pressurized oxygen either vaporizes or pseudo vaporizes, it is particularly advantageous to remove the partially cooled compressed air from the heat exchanger where such vaporization or pseudo-vaporization occurs and then to add the cold compressed stream at a warmer location of the heat exchanger. The effect of this is to bring composite heating and cooling curves within the heat exchanger closer together with less of a temperature difference between the two curves. This minimization of temperature difference more is particularly advantageous because less electrical power will be consumed in compressing the air.

In any air separation plant there will be heat leakage into a cold box that is used in housing distillation columns and other equipment that operates at cryogenic temperature. In addition, there are also losses at the warm end of the heat exchanger used in cooling the air. Such losses are compensated through the generation and introduction of refrigeration into the air separation plant. Refrigeration is generated by expanding air or other process fluid, introducing the resulting cold exhaust into the distillation column system and removing the work of expansion from the plant by such means as warm compression or electrical power generation. It is known to expand the air from an operational pressure of the higher pressure column to that of the lower pressure column and then introduce the resulting exhaust into the lower pressure column. This typically will result in a reduction of oxygen recovery that would otherwise be obtained had the exhaust been introduced into the higher pressure column. However, in order to expand air into the higher pressure column, the air would have to be compressed to a higher pressure by a booster compressor that would consume energy. Hence, the advantage of generating refrigeration through expanding the air in a turboexpander to a pressure of the lower pressure column and then introducing the resulting exhaust into the lower pressure column is that a further savings is realized in ongoing electrical power costs.

An example of a process and air separation plant using cold compression is shown in U.S. Pat. No. 5,475,980. In this plant, part of the compressed air that is used to vaporize a pumped oxygen stream is withdrawn from the main heat exchanger, compressed in a cold compressor and then further cooled in the heat exchanger to produce a liquid that is introduced into the higher pressure column. During part of the cooling, a cold compressed stream is also expanded into a two phase flow to generate additional liquid and a vapor. The expander is coupled to and drives the cold compressor. The resulting liquid is introduced into the higher pressure column and the vapor is warmed in the heat exchanger and then subsequently expanded in a turboexpander to generate an exhaust stream that is introduced into the lower pressure column to impart refrigeration into the plant. As can be appreciated, the incoming air must be sufficiently compressed to not only heat the pumped oxygen stream, but also, to power the cold compressor through expansion of the air. The incoming compressed air must also be sufficiently compressed to heat the vapor that is to be warmed in the heat exchanger and subsequently expanded. The compression requirements involved in both the cold compression and heating the vapor stream represent ongoing power costs that are expended in the cycles shown in this patent. While, overall, the ongoing power costs expended in such a plant are in all likelihood less than would otherwise be expended without the cold compression, there exists an increase in plant equipment costs involved in complex piping, heat exchanger layouts and the addition of an expander to drive the cold compressor. A plant of similar complexity is shown in US Patent Appln. Ser. No. 2009/0064714. In this patent application, the cold compressor is driven by an expander that is used in generating part of the exhaust stream that is introduced into the lower pressure column. It is to be noted that such expansion will not impart any refrigeration into the air separation plant in that the work of expansion is expended in compressing the air and added back to the plant rather than being removed from the plant to generate the refrigeration. Consequently, an additional compressor and expander arrangement are required to generate refrigeration for the plant and therefore, another air stream is compressed, partially cooled to a temperature higher than the temperature at which the stream to cold compressed is withdrawn from the main heat exchanger, and then expanded in a turboexpander coupled to the compressor. The exhaust is then combined with the exhaust from the turboexpander used in driving the cold compressor.

U.S. Pat. No. 5,901,576 discloses a simpler arrangement than the patents discussed above. In this patent, an air separation plant is shown where cold compression is employed in conjunction with expansion of part of the air to the lower pressure column in connection with the generation of refrigeration. The air to be expanded is first compressed in a booster compressor that is driven by the turboexpander. The air is then partially cooled in the main heat exchanger and then expanded in the turboexpander. The resulting exhaust stream is introduced into the lower pressure column. The cold compressed stream is withdrawn from the main heat exchanger below the point that the partially cooled air stream is introduced into the turboexpander. After the cold compression, the cold compressed stream is introduced into a section of the main heat exchanger that operates at a yet lower temperature. As can be appreciated, since the cold compressed stream is being cooled toward the cold end of the heat exchanger, such stream is in effect warming the heat exchanger at such point. This warming results in an expenditure of energy and increased ongoing operational costs in the consumption of electrical power.

Although the use of a turboexpander coupled with cold compression is an attractive configuration to be incorporated into a plant that is designed to produce a high pressure oxygen product, since part of the air is being expanded into the lower pressure column, rather than all of the air being introduced into the higher pressure column, oxygen recovery will suffer. The cold compressor exacerbates the problem because it adds a heat of compression into a cold section of the plant that must be compensated for by an increased refrigeration requirement and therefore, an increased flow to the turboexpander and lower pressure column. The prior art discussed above does not fully address this problem in a simple manner.

As will be discussed, among other advantages, the present invention provides a method and apparatus for separating air and producing an oxygen product at pressure with the use of cold compression and an expander generating the refrigeration and exhausting into the lower pressure column that is carried out in a manner in which a better balance is obtained between energy consumption and oxygen recovery.

SUMMARY OF THE INVENTION

The present invention provides a method of separating air in which compressed and purified air is separated in a cryogenic rectification process such that an oxygen-rich liquid column bottoms is produced in a lower pressure column linked in a heat transfer relationship to a higher pressure column by a condenser reboiler. An oxygen-rich liquid stream is pumped to produce a pumped oxygen stream and at least part of the pumped oxygen stream is heated in a main heat exchange system to produce an oxygen product stream. At least part of the pumped oxygen stream is heated within the main heat exchange system by further compressing part of the compressed and purified air stream to produce a first boosted pressure air stream and a second boosted pressure air stream. The first boosted pressure air stream and the second boosted pressure air stream are partially cooled within the main heat exchange system. The first boosted pressure air stream, after having been partially cooled, is cold compressed at an intermediate temperature to produce a cold compressed air stream that is introduced into the main heat exchange system at a warmer temperature than the intermediate temperature and thereafter, is fully cooled to produce a liquid air stream. The second boosted pressure air stream is expanded in a turboexpander, after having been partially cooled, to produce an exhaust stream that is introduced into the lower pressure column to impart refrigeration into the cryogenic rectification process. The liquid air stream is expanded and introduced at least into one of the lower pressure column or higher pressure column.

The intermediate temperature, at which the first boosted pressure air stream is cold compressed is, about equal to a vaporization or pseudo-vaporization temperature of the oxygen-rich liquid stream. The second boosted pressure air stream is partially cooled to a temperature no greater than the intermediate temperature such that both the first and the second boosted pressure air stream assist in heating the oxygen-rich liquid stream at temperatures within the heat exchange system above the intermediate temperature. It is to be noted that the term “pseudo-vaporization temperature” as used herein and in the claims means the temperature at which a liquid pressurized to a supercritical pressure becomes a supercritical fluid.

The present invention inherently allows lower power consumption and higher oxygen recoveries than in the prior art by utilizing the second boosted pressure air stream to assist in heating the pumped liquid oxygen stream. As indicated above, the use of cold compression and an expander exhausting into the lower pressure column is inherently efficient from the standpoint of the electrical power and running costs consumed in compressing the air. The drawback in cold compression is that energy is added to the plant by the cold compressor that must be compensated for by an increased refrigeration demand. However, such an increased refrigeration demand requires additional air being sent to the turboxpander exhausting into the lower pressure column. This results in less air being introduced into the higher pressure column and a decrease in the oxygen recovery. The utilization of the second boosted pressure air stream to help in heating the air will result in less of a demand for heating to be supplied by the first boosted pressure air stream at warmer temperatures. This in turn will result in lower flow rates and lower pressures for the first boosted pressure air stream than would otherwise be required. The pressure elevation of the second boosted air stream reduces the flow rate of the second boosted air stream to provide the necessary refrigeration for the plant and compensate for cold compression. As such, the electrical power that would otherwise be consumed in compressing the first boosted pressure air stream is reduced, the air flow to the turboexpander is also reduced and the oxygen recovery is therefore, increased to obtain a better balance between energy consumption and oxygen recovery. Moreover, as will be discussed, this is accomplished without the use of redundant compressor and expander arrangements.

It is to be noted, that as used herein and in the claims, the term, “partially cooled” means cooled to a temperature between the warm and cold end temperatures of the main heat exchanger. The term “fully cooled” means cooled to a cold end temperature of the main heat exchanger. The term, “intermediate temperature” means, in general, a temperature between warm and cold end temperatures of the main heat exchanger. Preferably, the intermediate temperature is in a range of between 3.0 K below and 10.0 K above the vaporization or pseudo-vaporization temperature of the oxygen-rich stream.

A method in accordance with the present invention can be further optimized from an energy consumption standpoint by expanding the liquid air stream within a liquid expander prior to introduction of the liquid air stream into at least one of the lower pressure column or higher pressure column to impart additional refrigeration to the cryogenic rectification process. Further, a first compressed air stream composed of a portion of the air to be rectified can be cooled in the main heat exchange system and introduced into the higher pressure column. The first boosted pressure air stream can be formed by compressing a second compressed air stream, composed of a further portion of the compressed and purified air, in a first booster compressor. The second boosted pressure air stream can be formed by compressing a third compressed air stream, composed of a yet further portion of the compressed and purified air, in a second booster compressor and the second booster compressor is coupled to and driven by the turboexpander.

Oxygen recovery can be increased by removing an argon and oxygen containing stream from the lower pressure column and introducing such stream into an argon column to separate the argon and the oxygen and thereby to produce an oxygen containing liquid as a column bottoms and an argon-rich vapor column overhead. An oxygen containing stream composed of the oxygen containing liquid can be introduced into the lower pressure column to increase the oxygen recovery.

The cold compressor can be independently driven by a motor. This will also reduce energy consumption because the air when cold will be denser than warmer air and therefore, require less energy to compress the air than would otherwise be required at a warmer temperature. This reduction in electrical power requirement comes at the cost of providing a separate motor. However, this cost will be less than the cost of providing a separate turbine to run the cold compressor. Furthermore, the advantage of coupling the second booster compressor to the turbine is lost if the turbine is instead coupled to the cold compressor. In this regard, the term “independently driven” as used herein and in the claim means driven by a means other than with expansion work directly generated by the expansion of a process stream within the plant. Thus, the cold compressor drive could be by an electric motor or a steam turbine or other external means. In any embodiment, the motor can be a variable speed motor controlled by a variable speed drive. This allows the speed of the motor and therefore, the cold compressor to be reduced during a turndown operation of the cryogenic rectification process when production of the oxygen product stream is also reduced. The term “turndown operation” as used herein and in the claims means any operation of an air separation plant in which the air flow rate of the compressed and purified air entering the plant is reduced to in turn reduce production of the products produced by the plant, for instance, oxygen.

A nitrogen-rich vapor stream composed of a column overhead produced in the higher pressure column is condensed within the condenser reboiler to produce a liquid nitrogen reflux stream and at least part of the liquid nitrogen reflux stream is introduced into the higher pressure column as reflux. A nitrogen-rich liquid stream having a nitrogen concentration less than that of nitrogen-rich vapor can be withdrawn from the higher pressure column, subcooled, valve expanded and then introduced into the lower pressure column as reflux. The use of such a nitrogen-rich liquid stream to supply reflux to the lower pressure column has been found to also increase oxygen recovery.

The main heat exchange system can comprise a higher pressure heat exchanger of a banked heat exchanger arrangement also having a lower pressure heat exchanger. The first compressed air stream is fully cooled in the lower pressure heat exchanger and introduced into the higher pressure column and the first boosted pressure air stream is partially cooled in the higher pressure heat exchanger and discharged at the intermediate temperature. The cold compressor, after having compressed the first boosted pressure air stream at the intermediate temperature, can return the cold compressed air stream to the higher pressure heat exchanger at the warmer temperature. The second boosted pressure air stream after having been partially cooled within the higher pressure heat exchanger, can be introduced to the turboexpander connected to the higher pressure heat exchanger to form the exhaust stream that is introduced into the lower pressure column. The at least part of the pumped liquid oxygen stream is warmed in the higher pressure heat exchanger. First and second nitrogen-rich vapor streams, made up, at least in part, of lower-pressure nitrogen-rich vapor produced in the lower pressure column, are introduced into the lower pressure and higher pressure heat exchangers, respectively, and with flow rates selected to fully cool the first compressed air stream and to balance cold end temperatures of the lower and higher pressure heat exchangers.

A crude liquid oxygen stream composed of a crude liquid oxygen column bottoms of the higher pressure column is withdrawn from the higher pressure column, subcooled, valve expanded, partially vaporized in an argon condenser of the argon column to produce liquid and vapor phase streams. The liquid and vapor phase streams are introduced into the lower pressure column for further refinement of the crude liquid oxygen column bottoms and a waste nitrogen stream composed, at least in part, of the nitrogen rich vapor is divided into the first and second nitrogen-rich vapor streams. The first of the nitrogen-rich vapor streams is partially warmed in at least one subcooling heat exchanger used in the subcooling of the crude liquid oxygen stream and the nitrogen-rich liquid stream. A compressed, main feed air stream, composed of the compressed and purified air, can be divided into the first compressed air stream, the second compressed air stream and the third compressed air stream.

The present invention also provides an apparatus for separating air. In such apparatus, a lower pressure column is thermally linked to a higher pressure column by a condenser reboiler and is configured to produce an oxygen-rich liquid as an oxygen-rich liquid column bottoms of the lower pressure column through cryogenic rectification of compressed and purified air. A pump is connected to the lower pressure column to pump an oxygen-rich liquid stream composed of the oxygen-rich liquid column bottoms and thereby produce a pumped liquid oxygen stream. A means is provided for forming a first boosted pressure air stream and a second boosted pressure air stream from part of the compressed and purified air. A main heat exchange system is connected to the pump and configured to heat at least part of the pumped liquid oxygen stream and thereby form an oxygen-rich product through indirect heat exchange with the first boosted pressure air stream, the second boosted pressure air stream and a cold compressed stream.

The main heat exchange system in flow communication with the distillation column system so that the liquid air stream is introduced into at least one of the lower pressure column or higher pressure column. The main heat exchange system has a first intermediate outlet positioned to discharge the first boosted pressure air stream at an intermediate temperature about equal to a vaporization or pseudo-vaporization temperature of the oxygen-rich liquid stream, an inlet to introduce the cold compressed air stream into the main heat exchange system at a warmer temperature than the intermediate temperature and a second intermediate outlet positioned to discharge the second boosted pressure air stream at a temperature no greater than the intermediate temperature so that both the first and second boosted pressure air stream thereby assist in heating the oxygen-rich liquid stream at temperatures within the heat exchange system above the intermediate temperature. A cold compressor is connected between the first intermediate outlet and the inlet to compress the first boosted pressure air stream and thereby to form the cold compressed stream. A turboexpander is connected between the second intermediate outlet and the lower pressure column to expand the second boosted pressure air stream and thereby to form an exhaust stream that is introduced into the lower pressure column to impart refrigeration into the apparatus and a means is provided for expanding the liquid air stream.

The first intermediate outlet is preferably positioned so that the intermediate temperature is in a range of between 3.0 K below and 10.0 K above the vaporization or pseudo-vaporization temperature. Also, the liquid air expansion means can comprise a liquid expander positioned between the main heat exchange system of the distillation column system to expand the liquid air stream prior to introduction of the liquid air stream into the distillation column system and thereby to generate additional refrigeration.

The main heat exchange system can also be configured to fully cool a first compressed air stream composed of a portion of the air to be rectified and is connected to the higher pressure column so that the first compressed air stream is introduced into the higher pressure column. The means for forming the first boosted pressure air stream and the second boosted pressure air stream can comprise a first booster compressor and a second booster compressor. The first booster compressor is connected to the main heat exchange means to compress a second compressed air stream, composed of a further portion of the air to be rectified and thereby to form the first boosted pressure air stream. The second booster compressor is connected to the main heat exchange means to compress a third compressed air stream, composed of a yet further portion of the air to be rectified and thereby to form the second boosted pressure air stream. The second booster compressor is coupled to and driven by the turboexpander.

An argon column can be connected to the lower pressure column to receive an argon and oxygen containing stream from the lower pressure column and thereby separate the argon and the oxygen and produce an oxygen containing liquid as a column bottoms and an argon-rich vapor column overhead. The argon column is connected to the lower pressure column so that an oxygen containing stream composed of the oxygen containing liquid is introduced into the lower pressure column to increase the oxygen recovery.

Preferably, the cold compressor can be connected to a motor to independently drive the cold compressor. Further, the motor can be a variable speed motor. In such case, a variable speed drive is connected to the motor to control speed of the motor and therefore, the cold compressor to enable the speed of the cold compressor to be reduced during a turndown operation of the apparatus when production of the oxygen product stream is reduced.

The condenser reboiler can be connected to the higher pressure column so that a nitrogen-rich vapor stream composed of a column overhead produced in the higher pressure column is condensed within the condenser reboiler to produce a liquid nitrogen reflux stream and at least part of the liquid nitrogen reflux stream is introduced into the higher pressure column as reflux. The higher pressure column can also be connected to the lower pressure column so that a nitrogen-rich liquid stream having a nitrogen concentration less than that of nitrogen-rich vapor is withdrawn from the higher pressure column and then introduced into the lower pressure column as reflux. A subcooling heat exchanger is positioned between the higher pressure column and the lower pressure column and is configured so that the nitrogen-rich liquid stream is subcooled prior to introduction into the lower pressure column and an expansion valve is positioned between the subcooling heat exchanger and the lower pressure column so that the nitrogen-rich liquid stream is reduced in pressure to that of the lower pressure column prior to the introduction of the nitrogen-rich liquid stream into the lower pressure column.

The heat exchange system can be a banked heat exchanger arrangement having a higher pressure heat exchanger and a lower pressure heat exchanger. In such case, the lower pressure heat exchanger is connected to the higher pressure column to fully cool the first compressed air stream and to introduce the first compressed air stream, after having been fully cooled, into the higher pressure column. The higher pressure heat exchanger is connected to the first booster compressor and the second booster compressor and the pump and has the first intermediate outlet, the second intermediate outlet and the intermediate inlet. The higher and lower pressure heat exchanger are in flow communication with the lower pressure column to receive first and second nitrogen-rich vapor streams, made up, at least in part, of lower pressure nitrogen-rich vapor produced in the lower pressure column and to fully warm the first and second nitrogen-rich vapor streams. A means is provided for controlling flow rates of the first and second nitrogen-rich vapor streams such that cold end temperatures of the lower and higher pressure heat exchangers are balanced.

An argon condenser can be connected to the argon column to condense argon reflux for the argon column. The argon condenser is connected to the higher pressure column and also configured so that a crude liquid oxygen stream composed of a crude liquid oxygen column bottoms of the higher pressure column is partially vaporized in the argon condenser against condensing argon reflux to the argon column. The subcooling heat exchanger is also connected to the argon condenser and is also configured such that the crude liquid oxygen stream is subcooled prior to being partially vaporized in the argon reflux condenser. An additional expansion valve is positioned between the subcooling heat exchanger and the argon reflux condenser to expand the crude liquid oxygen stream. The subcooling heat exchanger is in turn connected to the lower pressure column so that a waste nitrogen stream composed, at least in part, of the lower pressure nitrogen rich vapor produced as column overhead of the lower pressure column is divided into the first and second nitrogen-rich vapor streams and the first of the nitrogen-rich vapor streams is partially warmed in the subcooling heat exchanger. The argon condenser is also connected to the lower pressure column so that liquid and vapor phase streams, composed of liquid and vapor phases produced through the partial vaporization of the crude liquid oxygen stream, are introduced into the lower pressure column for further refinement of the crude liquid oxygen column bottoms. The lower pressure heat exchanger, the first booster compressor and the second booster compressor are connected so that a compressed main feed air stream composed of the compressed and purified air is divided into the first compressed air stream, the second compressed air stream and the third compressed air stream.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims distinctly pointing out the subject matter that the Applicant regards as his invention, it is believed that the present invention will be better understood when taken in connection with the accompanying drawings in which:

FIG. 1 is a schematic diagram of an air separation plant designed to carry out a method in accordance with the present invention;

FIG. 2 is a schematic diagram of an alternative embodiment of an air separation plant designed to carry out a method in accordance with the present invention; and

FIG. 3 is a schematic, fragmentary diagram of a modification that can be incorporated into embodiment of the air separation plant illustrated in FIG. 2.

DETAILED DESCRIPTION

With reference to the FIG. 1, an air separation plant 1 is illustrated that is designed to produce an oxygen product stream 98 at pressure. In air separation plant 1, a compressed and purified air stream 10 is divided into a first compressed stream 12, a second compressed stream 14 and a third compressed stream 16. Although not illustrated, compressed and purified air stream 10 can originate from a main air compressor that compresses the air to a pressure of between 4.5 and 7.0 bar(a) and then purified of higher boiling contaminants by means of an adsorption bed system having known adsorbent beds operating in an out-of-phase cycle, typically, a temperature swing cycle. Such higher boiling contaminants are those that would solidify or concentrate at cryogenic temperatures; for instance, carbon dioxide, water vapor and hydrocarbons. The air separation plant 1 could be part of an enclave of such plants or similar plants; and therefore, the compressed and purified air stream 10 could be centrally generated. Alternatively, the air separation plant could be a single plant connected to an adsorption bed system fed by the main air compressor.

The compressed air is cooled in a main heat exchange system that in the illustrated embodiment is a banked arrangement having a higher pressure heat exchanger 18 and a lower pressure heat exchanger 20. These heat exchangers are so designated in that higher pressure heat exchanger 18 is designed to engage in indirect heat exchange with the use of higher pressure streams than those utilized in the indirect heat exchange conducted in the lower pressure heat exchanger 20. However, the present invention is not limited to such a banked arrangement in that it is also applicable to a series of heat exchangers operating in parallel in which all of the streams to be heated and cooled pass in indirect heat exchange. As would be well known in the art, any such heat exchange system, either a banked or unbanked arrangement, could use heat exchangers of brazed aluminum plate-fin construction. Higher pressure heat exchangers could be spirally wound type heat exchangers.

After having been cooled, the compressed air is rectified in a distillation column system having higher and low pressure distillation columns 22 and 24 that are thermally linked by a condenser reboiler 78. For illustration purposes only, the higher pressure heat exchanger can be designed to operate at a pressure that typically would be between 38.0 and 120.0 bar(a). The lower pressure heat exchanger 24 can be designed to operate at a pressure of between 4.5 and 7.0 bar(a). The distillation column system is designed to produce an oxygen-rich liquid stream 90 that after having been pumped in a pump 92 to produce a pumped liquid oxygen stream 96 is vaporized in the higher pressure heat exchanger 18. As would occur to those skilled in the art, part of the pumped liquid oxygen stream 96 could be sent to storage at pressure.

First compressed stream 12 is cooled to a temperature suitable for its rectification within the lower pressure heat exchanger 20 and is introduced into the bottom of the higher pressure column 22. First compressed stream 12 preferably constitutes 50 to 65 percent of the compressed and purified air stream 10 and second compressed stream 14 preferably constitutes 27.0 to 35.0 percent of the compressed and purified air stream 10.

Second compressed stream 14 is compressed in a first booster compressor 26 to produce a first boosted pressure air stream 28. It is understood that first booster compressor 26 is a multistage unit having intercoolers to remove the heat of compression between each stage of compression. Preferably, after removal of the heat of compression from the final stage within an after cooler 30, the first boosted pressure air stream 28 is partially cooled in the higher pressure heat exchanger 18 through indirect heat exchange with the pumped oxygen stream 96. The first boosted pressure air stream 28, at such point, is discharged from the higher pressure heat exchanger 18 from a first intermediate outlet 32 situated at an intermediate location of the higher pressure heat exchanger 18 and yet further compressed in a cold compressor 34 to produce a cold compressed air stream 36. The cold compressor 34 is independently driven by an electric motor 35. The cold compressed air stream 36 is reintroduced back into the higher pressure heat exchanger 18 through in inlet 37 and at a warmer temperature thereof than the temperature of the first boosted pressure air stream 28 upon discharge through first intermediate outlet 32 due to the heat of compression. The cold compressed air stream 36 is then further cooled within the higher pressure heat exchanger through indirect heat exchange with the pumped oxygen stream 96 to produce a liquid air stream 38. The resulting liquid air stream 38 is then expanded in an expansion valve 50 and introduced into the higher pressure column 22 as a subsidiary stream 52 and the lower pressure column as a subsidiary stream 54 that is first expanded to the lower column pressure of the lower pressure column 24 by an expansion valve 56. It is understood that depending upon the desired product slate; the liquid air could be introduced solely into the lower pressure column 24 or the higher pressure column 22.

It is to be noted that the liquid air stream 38 is usually distributed, as illustrated, so that a portion passes to the lower pressure column 24 and the other portion passes to the higher pressure column 22. Such distribution is determined by optimization so that power consumption is minimized. The flow passing to the lower pressure column 24 provides an advantage in that it relieves a compositional pinch that may otherwise occur due to the additional reflux it provides. However, had this flow instead have been passed to the higher pressure column 22, additional nitrogen reflux would have been generated from the higher pressure column, albeit at a lower rate. Hence, an optimal distribution of the liquid air stream 38 between the lower pressure column 24 and the higher pressure column 22 gives the best balance of additional direct liquid air reflux to the lower pressure column 24 and additional nitrogen reflux from the higher pressure column 22. The optimal balance of liquid air can shift to the point where all the liquid air is passed directly to the lower pressure column 24, although this is unusual. This may occur when the product demand is such that there is less nitrogen reflux available to the lower pressure column, or expander flow to the lower pressure column is high. The other extreme, where the entire liquid air stream is passed to the higher pressure column 22 most often will occur when, instead of passing liquid air directly to the lower pressure column 24, a synthetic liquid air stream is withdrawn from the higher pressure column 22 and then passed to the lower pressure column 24. This alternative configuration, known in the art, may be preferred when the liquid air stream otherwise isn't satisfactorily subcooled for direct passage into the lower pressure column 24. In this case, withdrawal of a synthetic liquid air stream of approximately air composition from the higher pressure column 22 reduces the flashoff upon feed to the lower pressure column 24.

Third compressed stream 16 is used in imparting refrigeration to the air separation plant 1. As known in the art, the addition of refrigeration is necessary to maintain the plant in thermal balance as a result of such factors as heat leakage into the plant through the cold box housing the plant, warm end losses in the heat exchange system and the removal of liquid products. Additionally, refrigeration must also be introduced to compensate for the cold compression of cold compressor 34. For such purposes, the second compressed stream is further compressed in a second booster compressor 40 to produce a second boosted pressure air stream 42. After cooling in an optional after cooler 43, the second boosted pressure air stream 42 is partially cooled in the higher pressure heat exchanger 18, removed from a second outlet 44 thereof, and then introduced into a turboexpander 45. Turboexpander 45 is coupled to the booster compressor 40 by means of a common shaft 46. The advantage of this is that the second compressed air stream 14 is created without the further expenditure of energy. The work of expansion is captured by shaft 46 to drive booster compressor 40. As a result, an exhaust stream 48 is discharged from turboexpander 45 and without further electrical power input into the air separation plant 1. The refrigeration is imparted by introducing the exhaust stream 48 into the lower pressure column 24.

The use of such a turbine loaded booster arrangement, as described directly above, is advantageous in that is produces a high expansion ratio across the turboexpander 45 without the input of additional electric power. However, there are other possibilities. In this regard, as another means used in forming the first boosted pressure air stream 28 and the second boosted pressure air stream 42, part of the air compressed by the first booster compressor 26 could be taken at an intermediate pressure and then, after aftercooling, could be introduced into the higher pressure heat exchanger 18 for partial cooling. It is also to be noted that the use of electric motor 35 to power cold compressor 34 is preferred in that the compression of the cold dense gas can be accomplished with a very low expenditure of overall energy. While, as in the prior art an expander could be used to power the cold compressor 34, this would not be preferred due to the cost of the additional expander and the more favorable use of the work of expansion to boost the inlet pressure of the expander.

Within the higher pressure column 22, an ascending vapor phase becomes ever richer in the more volatile components of the air, mainly nitrogen and a descending liquid phase becomes ever richer in the less volatile components of the air, mainly, oxygen. The ascending and descending vapor and liquid phases are brought into intimate contact with one another through mass transfer contacting elements 58 and 60 that can be structured packing, trays or random packing. This results in a crude liquid oxygen column bottoms, also known as kettle liquid, being created in the bottom of the higher pressure column 22 and a nitrogen-rich vapor column overhead being created in the top of the higher pressure column 22. A crude liquid oxygen stream 62 is then further refined in the lower pressure column by preferably first being subcooled in a subcooling heat exchanger 64 and then expanded to lower pressure column pressure of the lower pressure column 24 by means of an expansion valve 66. Contact between ascending vapor and descending liquid phases is accomplished within the lower pressure column 24 by means of mass transfer contacting elements 68, 70, 72 and 74 to produce an oxygen-rich liquid 76 in the bottom of the lower pressure column 24 and a nitrogen-rich vapor in the top of such column.

The higher and lower pressure columns 22 and 24 are thermally linked by means of a condenser reboiler 78. A stream 80 of the nitrogen-rich vapor produced in the higher pressure column 22 is condensed in the condenser reboiler 78 to produce a nitrogen-rich liquid stream 82 which is in turn introduced into the higher pressure column 22 as reflux, thereby to initiate formation of the descending liquid phase. A nitrogen reflux stream 84 can be formed from part of the nitrogen-rich liquid stream 82 and introduced into the lower pressure column 24 as reflux thereby to initiate formation of the descending liquid phase within such column. The remaining part of the nitrogen-rich liquid stream 82 is in turn introduced into the higher pressure column 22 as reflux, thereby to initiate formation of the descending liquid phase within such column. Preferably, the nitrogen reflux stream 84 is subcooled in a subcooling heat exchanger 86 and the valve expanded in an expansion valve 88 to a pressure compatible with its introduction in to the lower pressure column 24. The oxygen-rich liquid stream 90 is composed of the oxygen-rich liquid 76 produced in the lower pressure column 24. Such liquid stream is then pumped by pump 92 to produce a pumped liquid oxygen stream 96 which is vaporized in the higher pressure heat exchanger 18 through indirect heat exchange with the first boosted pressure air stream 28 and the cold compressed stream 36 to produce the pressurized oxygen product stream 98 (“GOX”). Part of the oxygen-rich liquid 76 could be taken as a liquid oxygen product stream 100 to a limited extent; and such stream would be valve expanded in a valve 102 prior to storage.

A nitrogen stream 104 is removed from the top of the lower pressure column and divided into subsidiary nitrogen containing streams 106 and 108. Subsidiary nitrogen containing stream 106 is warmed within the higher pressure heat exchanger 18 to produce a first nitrogen stream 110 (“WN₂”). Subsidiary nitrogen containing stream 108 is successively warmed in subcooling heat exchangers 86 and 84 and then fully warmed within the lower pressure heat exchanger 20 to produce a second waste nitrogen stream 112 (“WN₂”). These waste nitrogen streams serve to balance the cold end temperatures of the higher and lower pressure heat exchangers 18 and 20 so that the effective cooling of the feed streams and warming of the return streams is maximized given the available area of heat exchangers 18 and 20. This is conventional and the control of such balancing takes place by controlling the flow rate of the subsidiary nitrogen containing streams 106 and 108 by such means as appropriate selection of piping and valves.

As mentioned above, the pumped liquid oxygen stream 96 is heated through indirect heat exchange with both the first boosted pressure air stream 28 and the second boosted pressure air stream 42. In this regard, the first outlet 32 from which the first boosted pressure air stream 28 is removed from the higher pressure heat exchanger 18 is situated at an intermediate temperature that will be about equal to the temperature at which the pumped liquid oxygen stream 96 either vaporizes or pseudo-vaporizes in cases where the pumped liquid oxygen stream 96 has been pressurized to a supercritical pressure. In this context, the term “about” means between 5.0_K below to about 15.0_K above and preferably, in a range of between 3.0 K below and 10.0 K above the vaporization or pseudo-vaporization temperature. The resulting cold compressed stream 36 is introduced into an inlet 37 that is situated at a temperature that is consistent with the increase in temperature due to the heat of compression which would be warmer than the intermediate temperature of first outlet 32. The second outlet 44 from which the second boosted pressure air stream 42 is removed from the higher pressure heat exchanger 18 is situated so that the second boosted pressure air stream 42 has been cooled to a temperature no greater than the intermediate temperature achieved at the first outlet 32. Preferably the temperature at the second outlet 44 is at or no greater than 30.0 K below the intermediate temperature at first outlet 32. What this allows is for both first and second boosted pressure air streams 28 and 42 to both heat the pumped liquid oxygen stream 98. When this is coupled with the cold compression, the pressure and flow of the first booster compressor 26 will be able to be decreased to in turn decrease the overall power consumed by the air separation plant. As can be appreciated, the greatest benefit of the present invention over the prior art will be obtained where the oxygen product is a vapor rather than a supercritical fluid. In such case, over certain pressure ranges of the oxygen, it is possible to compress the air in the first booster compressor 26 to a subcritical pressure and the cold compressor 35 to a supercritical pressure. Even where the first booster compressor 26 is required to compress the air to a supercritical pressure, such pressure will be less than that otherwise required had the present invention not have been practiced.

With reference to FIG. 2, an air separation plant 2 is illustrated having many of the same components as the air separation plant 1 shown in FIG. 1. In order to avoid needless repetition, components of air separation plant 2 having the same description as those in FIG. 1 will have the same reference numbers and will not be further described below.

In FIG. 2, additional refrigeration can be imparted with the use of a liquid expander 120 that is connected to an electrical generator or oil-brake system, generally shown by reference number 122 to dissipate the work of expansion. This added refrigeration will compensate for the work of compression added by the cold compressor 34 and thereby allow even less air flow to the turboexpander 45 and therefore the low pressure column 24. As a result, oxygen recovery will increase. It will usually be most efficient to reduce the pressure of stream 28 without changing the pressure of stream 36 so cold compressor 34 is generating a higher pressure ratio. Such an increase in efficiency will be at the acquisition cost of the liquid expander 120. A yet further increase in oxygen production can be obtained by an argon rejection column 124. An argon and oxygen containing stream 126 is withdrawn from the low pressure column and introduced into the argon rejection column 124 for rectification. The rectification produces an oxygen containing column bottoms that is returned as an oxygen containing stream 128, lean in argon, to the low pressure column 24 to increase oxygen recovery. It is understood, therefore, that argon rejection column 124 is simply designed to separate the argon from the oxygen and not to produce an argon product. However, if an argon product were desired, either liquid or vapor, an appropriately staged argon column could be used for such purpose. Unlike air separation plant 1, the crude liquid oxygen stream, after having been subcooled in subcooling heat exchanger 64 and valve expanded in valve 66, is partially vaporized in argon condenser 130 to generate reflux for the argon rejecting column 124. The partial vaporization produces vapor and liquid phases of the crude liquid oxygen that are introduced into the lower pressure column 24 by way of vapor and liquid phase streams 132 and 134, respectively. Preferably, an argon-rich vapor stream 136, composed of the argon-rich vapor column overhead produced in the argon column 124, is condensed in the argon condenser 130 to produce a liquid argon stream 138 that is passed into a separation vessel 140 to produce an argon reflux stream 142 and a vapor stream 144, rich in argon, that is introduced into the waste nitrogen stream to produce a waste nitrogen stream 104′ that has a slightly lower nitrogen purity than nitrogen stream 104 shown in FIG. 1. Waste nitrogen stream 104′ is similar divided into subsidiary waste nitrogen containing streams 106′ and 108′ for balancing cold end temperatures of the higher and lower pressure heat exchangers 20 and 18. The subsidiary waste nitrogen containing streams 106′ and 108′ are withdrawn from the high and low pressure heat exchangers 18 and 20 as waste nitrogen streams 110′ and 112′ (“WN₂”).

As illustrated, a liquid nitrogen stream 148 can be removed from the liquid nitrogen produced by condenser reboiler 78 and divided into first and second subsidiary liquid nitrogen stream 150 and 152. First subsidiary liquid nitrogen stream 150 can be pressurized by a pump 154 to produce a pumped liquid nitrogen stream 156. Pumped liquid nitrogen stream 156 can in turn be subdivided into a first part 158 and a second part 158. The first part 158 can be fully warmed in the higher pressure heat exchanger 18 to produce a high pressure gaseous nitrogen product 162 (“HPGN₂”). Second part 160 can be expanded in a valve 164 and then fully warmed in the higher pressure heat exchanger 18 to produce a low pressure gaseous nitrogen product stream 166 (“LPGN₂”). The second subsidiary liquid nitrogen stream 152 can be subcooled in subcooling heat exchanger 86′ that differs from subcooling heat exchanger 86 by provision of heat exchange passages for such purpose. The resulting subcooled stream can be expanded in an expansion valve 168 and then taken as a liquid nitrogen product 170 (“LN₂”).

It is appropriate to point out here that an impure nitrogen reflux stream 84′ is withdrawn from the higher pressure column 22, subcooled in subcooling heat exchanger 86′ and then introduced as reflux into the lower pressure column 24. The use of the impure nitrogen reflux stream 84′ is particularly preferred because it also increases recovery of oxygen production. The flow rate of the impure nitrogen reflux stream 84′ from the higher pressure column 22 is greater than the flow rate would be had that stream been formed from part of the nitrogen-rich liquid stream 82. The lower draw point of stream 84 enables a greater withdrawal rate from the higher pressure column 22 without compromising the nitrogen purity attained in the liquid nitrogen product 170. The larger flow rate of the reflux stream improves the separation from low pressure column 24 and hence, the oxygen recovery. The draw point of impure nitrogen reflux stream 84′ is selected such that its composition does not appreciably degrade the composition of waste nitrogen vapor stream 104′ that is withdrawn from low pressure column 24, yet its flow is maximized within that limitation. As can be appreciated, impure nitrogen reflux stream 84′ could be used in connection with the air separation plant 1 shown in FIG. 1 with the taking of a liquid nitrogen product in a similar manner as has been described with respect to air separation plant 2.

It is understood, that both air separation plant 1 and air separation plant 2 are designed to principally supply gas. Therefore, the amount of liquid that could be removed from such a plant would be limited. For instance, the rates at which such liquid products would be removed would be about five percent of the removal of the gaseous oxygen product stream 98. It also is to be noted, that the pumping of the nitrogen product has been found to be usually less efficient than withdrawing nitrogen as a vapor and compressing it after warming in the main heat exchange system or in case of the illustrated embodiments, high pressure heat exchanger 18. However, it may be desirable to eliminate a nitrogen compressor by pumping the nitrogen to its required delivery pressure. In such case the high pressure air provides energy for heating both the oxygen and the nitrogen. The benefit of application of the present invention to a system that uses liquid pumping of nitrogen in addition to oxygen is relatively unaffected. This benefit occurs primarily due to the improved temperature profile in the heat exchange system used in heating the nitrogen at temperatures at and above where the oxygen is boiling or pseudo-boiling. Nitrogen, when it is pumped, is usually no more in flow than fifty percent of that of the oxygen. When the pumped nitrogen is of relatively low pressure, the flat temperature profile where it boils usually produces a pinch point near the cold end of the heat exchanger used for such boiling. However, since this occurs at a temperature below where oxygen boils, its effect on the efficiency of the air separation unit is similar for both the present invention and a prior art design. When the pumped nitrogen pressure is high, its effect on the composite cooling curve of the present invention as compared to a prior art is also very small. That is because nitrogen becomes supercritical at about 490 psia (34 bara) and 126 K. Above this it no longer produces a flat section in the temperature profile and its existence becomes virtually indiscernible in the heat exchanger temperature profile. Consequently, the pumping of nitrogen will have virtually no effect on the present invention and the present invention as set forth in the pending claims is not meant to exclude such an option.

With reference to FIG. 3, a modification of the air separation plant 2 is shown in which the cold compressor 34 is operated at variable speed to enhance the ability of the air separation plant 2 to be turned down. As will become apparent, the same modification could be incorporated into air separation plant 1. Turndown of an air separation plant is desirable during times in which electrical power is at a peak demand and is therefore, the most expensive. During a turndown operation of an air separation plant, less product will be produced and lower electrical power consumption in the compression of air will be realized. However, turndown of centrifugal compressors in general is very ineffective, below about 75% capacity, where the compressor power consumption is practically fixed. This 75% level corresponds to the point where the surge control line is reached and the compressor must then operate in recirculation to avoid surge. In such a mode of operation, part of air after having been compressed is recirculated back to the inlet of the compressor. For a cold compressor, the extra energy in such an operation is rejected in the main heat exchanger, as opposed to cooling water for a warm compressor. Therefore, more turbine refrigeration is required to balance it. This means that, in addition to the cold compressor recirculation flow, the turbine flow must be maintained at the same level when the plant is below 75% capacity. In reality, recirculation is not practical for a cold compressor and operation will be maintained at 75% capacity even though it is not necessary. The power penalty incurred in the operation of the main air compressors and possibly booster compressors, depending on plant design, can make such a turndown operation with cold compression not very attractive, if not impractical. It is to be mentioned that the turbine will usually have a greater flow range and ability to operate in a turndown mode than the cold compressor. However, the full range of operation cannot be utilized due to limitations on compressor turndown capability.

As illustrated, two feed air streams 180 and 182 are compressed by two main air compressors 184 and 186, respectively. Each of the main air compressors 184 and 186 can be multistage installations with interstage cooling between stages that feed a common after cooler 188 to remove the heat of compression. The resulting compressed air is feed to a prepurification unit 188 (“PPU”) that incorporates beds of adsorbent to remove higher boiling contaminants such as carbon dioxide and water vapor. The beds of adsorbent are operated in an out of phase cycle, commonly a temperature swing adsorption cycle or a pressure swing adsorption cycle or a combination of the two cycles. The result is compressed and purified air stream 10. The compressors 184 and 186 are preferably provided with inlet guide vanes 192 and 194 to allow the flow to be independently reduced to each of the compressors. Additionally, the booster air compressor 26 can also be provided with guide vanes 196. The use of two compressors 184 and 186 allow for a turndown operation of less than 50 percent. If less of a turndown operation is required one of such compressors could be used and in any case, turndown could be accomplished by the use of inlet guide vanes 192, 194 and 196 alone. A variable speed motor 35′ is used to drive the cold compressor 34 and the speed of the variable speed direct drive motor 35′ is controlled by a variable frequency drive 198 (“VFD”). Motor 35′ can be a permanent magnet motor or a high speed induction motor. The variable speed drive 198 allows the speed of the motor 35′ to be controlled and therefore, the speed of the compressor 34. The enablement of a wide speed range for the cold compressor 34 will in turn allow for a wide turndown range.

When the air separation plant 2, incorporating the features illustrated in FIG. 3, is to be turned down, the guide vanes 192, 194 and 196 of the main air compressors 184 and 186 and the booster air compressor 26 are gradually closed. This reduces the flow from the air compressors. Although not illustrated, cold compressor 34 could similarly incorporate such guide vanes. However, in the illustrated embodiment the speed of the electric motor 35′ is solely adjusted to decrease the speed of cold compressor 34. At the same time, the gaseous oxygen product flows of oxygen-enriched liquid streams 90 and 100 shown in FIG. 2 are decreased by means of, for example control valves not illustrated. Eventually, as the compressors 184, 186 and 26 are turned down, they will reach the low end of their flow capabilities. This is set by the surge limit. Below this level, surging operation will occur. To avoid this, booster air compressor 26 will have a recirculation line 200 and a control valve 202 that can be opened to return the cooled discharge flow to the feed end of the booster air compressor 26. This prevents surging operation so that the machine is not damaged, but operation at this capacity and lower will no longer reduce power. For main air compressors 184 and 186, vents 204 and 206 to atmosphere are used by opening control valves 208 and 210 to protect the compressors from surging operation, again without reducing power as the capacity. As indicated above, where turndown is to be effectuated below 75% of capacity or possibly, at or below 50% of capacity, one of the two compressors 184 and 186 can be shut down. Since, however, cold compressor 34 is turned down by means of a speed reduction, there is no extra energy that must be rejected in the main heat exchanger 18 and therefore, a resulting refrigeration requirement that must be met for the turndown of cold compressor 34. As such, the reduction of flow of the compressed and purified air stream 10 will reduce the flow and the refrigeration imparted by the turboexpander 45 in line with the reduction of refrigeration requirements due to the turndown operation of air separation plant 2.

Although the present invention has been described with reference to preferred embodiments, as will occur to those skilled in the art, numerous changes, additions and omission can be made without departing from the spirit and scope of the present invention as set forth in the appended claims.

Claims

1. A method of separating air comprising:

separating compressed and purified air in a cryogenic rectification process such that an oxygen-rich liquid column bottoms is produced in a lower pressure column linked in a heat transfer relationship to a higher pressure column by a condenser reboiler, an oxygen-rich liquid stream is pumped to produce a pumped oxygen stream and at least part of the pumped oxygen stream is heated in a main heat exchange system to produce an oxygen product stream;

heating the at least part of the pumped oxygen stream within the main heat exchange system by further compressing part of the compressed and purified air stream to produce a first boosted pressure air stream and a second boosted pressure air stream, respectively, partially cooling the first boosted pressure air stream and the second boosted pressure air stream within the main heat exchange system, cold compressing the first boosted pressure air stream, after having been partially cooled, at an intermediate temperature to produce a cold compressed air stream, introducing the cold compressed air stream into the main heat exchange system at a warmer temperature than the intermediate temperature and fully cooling the cold compressed air stream to produce a liquid air stream;

expanding the second boosted pressure air stream in a turboexpander, after having been partially cooled, to produce an exhaust stream and introducing the exhaust stream into the lower pressure column to impart refrigeration into the cryogenic rectification process; and

expanding the liquid air stream and introducing the liquid air stream into at least one of the lower pressure column or higher pressure column;

the intermediate temperature being about equal to a vaporization or pseudo-vaporization temperature of the oxygen-rich liquid stream and the second boosted pressure air stream partially cooled to a temperature no greater than the intermediate temperature such that both the first and the second boosted pressure air stream assist in heating the oxygen-rich liquid stream at temperatures within the heat exchange system above the intermediate temperature.

2. The method of claim 1, wherein the intermediate temperature is in a range of between 3.0 K below and 10.0 K above the vaporization or pseudo-vaporization temperature.

3. The method of claim 1, wherein the liquid air stream is expanded within a liquid expander prior to introduction of the liquid air stream into at least one of the lower pressure column or the higher pressure column to impart additional refrigeration to the cryogenic rectification process.

4. The method of claim 1, wherein:

a first compressed air stream composed of a portion of the compressed and purified air is cooled in the main heat exchange system and introduced into the higher pressure column;

the first boosted pressure air stream is formed by compressing a second compressed air stream, composed of a further portion of the compressed and purified air, in a first booster compressor;

the second boosted pressure air stream is formed by compressing a third compressed air stream, composed of a yet further portion of the compressed and purified air, in a second booster compressor; and

the second booster compressor is coupled to and driven by the turboexpander.

5. The method of claim 1, wherein:

an argon and oxygen containing stream is removed from the lower pressure column and introduced into an argon column to separate the argon and the oxygen and thereby to produce an oxygen containing liquid as a column bottoms and an argon-rich vapor column overhead; and

an oxygen containing stream composed of the oxygen containing liquid is introduced into the lower pressure column to increase the oxygen recovery.

6. The method of claim 1, wherein the cold compressor is externally driven by a motor.

7. The method of claim 6, wherein the motor is a variable speed motor controlled by a variable speed drive and speed of the motor and therefore, the cold compressor is reduced during a turndown operation of the cryogenic rectification process when production of the oxygen product stream is reduced.

8. The method of claim 1 or claim 2, wherein:

a first compressed air stream composed of a portion of the compressed and purified air is cooled in the main heat exchange system and introduced into the higher pressure column;

the first boosted pressure air stream is formed by compressing a second compressed air stream, composed of a further portion of the compressed and purified air, in a first booster compressor;

the second boosted pressure air stream is formed by compressing a third compressed air stream, composed of a yet further portion of the compressed and purified air, in a second booster compressor;

the second booster compressor is coupled to and driven by the turboexpander;

refrigeration is also imparted by expanding the liquid air stream within a liquid expander prior to introduction of the liquid air stream into the distillation column; and

the cold compressor is externally driven by a motor.

9. The method of claim 8, wherein:

an argon and oxygen containing stream is removed from the lower pressure column and introduced into an argon column to separate the argon and the oxygen and thereby to produce an oxygen containing liquid as a column bottoms and an argon-rich vapor column overhead; and

an oxygen containing stream composed of the oxygen containing liquid is introduced into the lower pressure column to increase the oxygen recovery.

10. The method of claim 8, wherein the motor is a variable speed motor controlled by a variable speed drive and speed of the motor and therefore, the cold compressor is reduced during a turndown operation of the cryogenic rectification process when production of the oxygen product stream is reduced.

11. The method of claim 9, wherein:

a nitrogen-rich vapor stream composed of a column overhead produced in the higher pressure column is condensed within the condenser reboiler to produce a liquid nitrogen reflux stream;

at least part of the liquid nitrogen reflux stream is introduced into the higher pressure column as reflux; and

a nitrogen-rich liquid stream having a nitrogen concentration less than that of nitrogen-rich vapor is withdrawn from the higher pressure column, subcooled, valve expanded and then introduced into the lower pressure column as reflux;

12. The method of claim 11, wherein:

the main heat exchange system comprises a higher pressure heat exchanger of a banked heat exchanger arrangement also having a lower pressure heat exchanger;

the first compressed air stream is fully cooled in the lower pressure heat exchanger and introduced into the higher pressure column;

the first boosted pressure air stream is partially cooled in the higher pressure heat exchanger and discharged at the intermediate temperature;

the cold compressor, after having compressed the first boosted pressure air stream at the intermediate temperature, returns the cold compressed air stream to the higher pressure heat exchanger at the warmer temperature;

the second boosted pressure air stream is partially cooled within the higher pressure heat exchanger, introduced to the turboexpander connected to the higher pressure heat exchanger to form the exhaust stream and the exhaust stream is introduced into the lower pressure column;

the at least part of the pumped liquid oxygen stream is warmed in the higher pressure heat exchanger; and

first and second nitrogen-rich vapor streams, made up, at least in part, of lower-pressure nitrogen-rich vapor produced in the lower pressure column, are introduced into the lower pressure and higher pressure heat exchangers, respectively, and with flow rates selected to fully cool the first compressed air stream and to balance cold end temperatures of the lower and higher pressure heat exchangers.

13. The method of claim 12, wherein:

a crude liquid oxygen stream composed of a crude liquid oxygen column bottoms of the higher pressure column is withdrawn from the higher pressure column, subcooled, valve expanded, partially vaporized in an argon condenser of the argon column to produce liquid and vapor phase streams;

the liquid and vapor phase streams are introduced into the lower pressure column for further refinement of the crude liquid oxygen column bottoms; and

a waste nitrogen stream composed, at least in part, of the nitrogen rich vapor is divided into the first and second nitrogen-rich vapor stream and the first of the nitrogen-rich vapor streams is partially warmed in at least one subcooling heat exchanger used in the subcooling of the crude liquid oxygen stream and the nitrogen-rich liquid stream.

14. The method of claim 13, wherein a compressed, main feed air stream, composed of the compressed and purified air, is divided into the first compressed air stream, the second compressed air stream and the third compressed air stream.

15. An apparatus for separating air comprising:

a lower pressure column thermally linked to a higher pressure column by a condenser reboiler and configured to produce an oxygen-rich liquid as an oxygen-rich liquid column bottoms of the lower pressure column through cryogenic rectification of compressed and purified air;

a pump connected to the lower pressure column to pump an oxygen-rich liquid stream composed of the oxygen-rich liquid column bottoms to produce a pumped liquid oxygen stream;

means for forming a first boosted pressure air stream and a second boosted pressure air stream from part of the compressed and purified air;

a main heat exchange system connected to the pump and configured to heat at least part of the pumped liquid oxygen stream and thereby form an oxygen-rich product through indirect heat exchange with the first boosted pressure air stream, the second boosted pressure air stream and a cold compressed stream;

the main heat exchange system in flow communication with the distillation column system so that the liquid air stream is introduced into at least one of the lower pressure column or higher pressure column and having a first intermediate outlet positioned to discharge the first boosted pressure air stream at an intermediate temperature about equal to a vaporization or pseudo-vaporization temperature of the oxygen-rich liquid stream, an inlet to introduce the cold compressed air stream into the main heat exchange system at a warmer temperature than the intermediate temperature and a second intermediate outlet positioned to discharge the second boosted pressure air stream at a temperature no greater than the intermediate temperature so that both the first and second boosted pressure air stream thereby assist in heating the oxygen-rich liquid stream at temperatures within the heat exchange system above the intermediate temperature;

a cold compressor connected between the first intermediate outlet and the inlet to compress the first boosted pressure air stream and thereby to form the cold compressed stream;

a turboexpander connected between the second intermediate outlet and the lower pressure column to expand the second boosted pressure air stream and thereby to form an exhaust stream that is introduced into the lower pressure column to impart refrigeration into the apparatus; and

means for expanding the liquid air stream.

16. The apparatus of claim 15, wherein the first intermediate outlet is positioned so that the intermediate temperature is in a range of between 3.0 K below and 10.0 K above the vaporization or pseudo-vaporization temperature.

17. The apparatus of claim 15, wherein the liquid air expansion means comprises a liquid expander is positioned between the main heat exchange system of the distillation column system to expand the liquid air stream prior to introduction of the liquid air stream into the distillation column system and thereby to generate additional refrigeration.

18. The apparatus of claim 15, wherein:

the main heat exchange system is also configured to fully cool a first compressed air stream composed of a portion of the air to be rectified;

the main heat exchange system is connected to the higher pressure column so that the first compressed air stream is introduced into the higher pressure column;

the means for forming the first boosted pressure air stream and the second boosted pressure air stream is a first booster compressor and a second booster compressor;

the first booster compressor is connected to the main heat exchange means to compress a second compressed air stream, composed of a further portion of the air to be rectified and thereby to form the first boosted pressure air stream;

the second booster compressor is connected to the main heat exchange means to compress a third compressed air stream, composed of a yet further portion of the air to be rectified and thereby to form the second boosted pressure air stream; and

the second booster compressor is coupled to and driven by the turboexpander.

19. The apparatus of claim 15 wherein:

an argon column is connected to the lower pressure column to receive an argon and oxygen containing stream from the lower pressure column and thereby separate the argon and the oxygen and produce an oxygen containing liquid as a column bottoms and an argon-rich vapor column overhead; and

the argon column connected to the lower pressure column so that an oxygen containing stream composed of the oxygen containing liquid is introduced into the lower pressure column to increase the oxygen recovery.

20. The apparatus of claim 15 wherein the cold compressor is connected to a motor to independently drive the cold compressor.

21. The method of claim 20, wherein:

the motor is a variable speed motor;

a variable speed drive is connected to the motor to control speed of the motor and therefore, the cold compressor to enable the speed of the cold compressor to be reduced during a turndown operation of the apparatus when production of the oxygen product stream is reduced.

22. The apparatus of claim 15 or claim 16, wherein:

the main heat exchange system is also configured to fully cool a first compressed air stream composed of a portion of the air to be rectified; the main heat exchange system is connected to the higher pressure column so that the first compressed air stream is introduced into the higher pressure column; the means for forming the first boosted pressure air stream and the second boosted pressure air stream is a first booster compressor and a second booster compressor; the first booster compressor is connected to the main heat exchange means to compress a second compressed air stream, composed of a further portion of the air to be rectified and thereby to form the first boosted pressure air stream; the second booster compressor is connected to the main heat exchange means to compress a third compressed air stream, composed of a yet further portion of the air to be rectified and thereby to form the second boosted pressure air stream; and the second booster compressor is coupled to and driven by the turboexpander; the cold compressor is connected to a motor to independently drive the cold compressor; and the liquid air expansion means comprises a liquid expander is positioned between the main heat exchange system of the distillation column system to expand the liquid air stream prior to introduction of the liquid air stream into at least one of the lower pressure column or higher pressure column and thereby generate additional refrigeration.

23. The apparatus of claim 22, wherein:

an argon column is connected to the lower pressure column to receive an argon and oxygen containing stream from the lower pressure column and thereby separate the argon and the oxygen and produce an oxygen containing liquid as a column bottoms and an argon-rich vapor column overhead; and

the argon column connected to the lower pressure column so that an oxygen containing stream composed of the oxygen containing liquid is introduced into the lower pressure column to increase the oxygen recovery.

24. The method of claim 22, wherein:

the motor is a variable speed motor;

a variable speed drive is connected to the motor to control speed of the motor and therefore, the cold compressor to enable the speed of the cold compressor to be reduced during a turndown operation of the apparatus when production of the oxygen product stream is reduced.

25. The apparatus of claim 23, wherein:

the condenser reboiler is connected to the higher pressure column so that a nitrogen-rich vapor stream composed of a column overhead produced in the higher pressure column is condensed within the condenser reboiler to produce a liquid nitrogen reflux stream and at least part of the liquid nitrogen reflux stream is introduced into the higher pressure column as reflux;

the higher pressure column is connected to the lower pressure column so that a nitrogen-rich liquid stream having a nitrogen concentration less than that of nitrogen-rich vapor is withdrawn from the higher pressure column and then introduced into the lower pressure column as reflux;

a subcooling heat exchanger is positioned between the higher pressure column and the lower pressure column and is configured so that the nitrogen-rich liquid stream is subcooled prior to introduction into the lower pressure column; and

an expansion valve is positioned between the subcooling heat exchanger and the lower pressure column so that the nitrogen-rich liquid stream is reduced in pressure to that of the lower pressure column prior to the introduction of the nitrogen-rich liquid stream into the lower pressure column.

26. The apparatus of claim 25, wherein:

the heat exchange system is a banked heat exchanger arrangement having a higher pressure heat exchanger and a lower pressure heat exchanger;

the lower pressure heat exchanger is connected to the higher pressure column to fully cool the first compressed air stream and to introduce the third compressed air stream, after having been fully cooled, into the higher pressure column;

the higher pressure heat exchanger is connected to the first booster compressor and the second booster compressor and the pump and has the first intermediate outlet, the second intermediate outlet and the intermediate inlet;

the higher and lower pressure heat exchanger are in flow communication with the lower pressure column to receive first and second nitrogen-rich vapor streams, made up, at least in part, of lower pressure nitrogen-rich vapor produced in the lower pressure column and to fully warm the first and second nitrogen-rich vapor streams; and

means for controlling flow rates of the first and second nitrogen-rich vapor streams such that cold end temperatures of the lower and higher pressure heat exchangers are balanced.

27. The apparatus of claim 26, wherein:

an argon condenser is connected to the argon column to condense argon reflux for the argon column, the argon condenser connected to the higher pressure column and also configured so that a crude liquid oxygen stream composed of a crude liquid oxygen column bottoms of the higher pressure column is partially vaporized in the argon condenser against condensing the argon reflux to the argon column;

the subcooling heat exchanger is also connected to the argon condenser and is also configured such that the crude liquid oxygen stream is subcooled prior to being partially vaporized in the argon condenser;

an additional expansion valve is positioned between the subcooling heat exchanger and the argon condenser to expand the crude liquid oxygen stream;

the subcooling heat exchanger is connected to the lower pressure column so that a waste nitrogen stream composed, at least in part, of the lower pressure nitrogen rich vapor produced as column overhead of the lower pressure column is divided into the first and second nitrogen-rich vapor streams and the first of the nitrogen-rich vapor streams is partially warmed in the subcooling heat exchanger; and

the argon condenser is also connected to the lower pressure column so that liquid and vapor phase streams, composed of liquid and vapor phases produced through the partial vaporization of the crude liquid oxygen stream, are introduced into the lower pressure column for further refinement of the crude liquid oxygen column bottoms.

28. The method of claim 27, wherein the lower pressure heat exchanger, the first booster compressor and the second booster compressor are connected so that a compressed main feed air stream composed of the compressed and purified air is divided into the first compressed air stream, the second compressed air stream and the third compressed air stream.