Air separation by adsorption

Claim 2

In an adiabatic pressure swing process for air separation by selectively adsorbing at least nitrogen alternately in at least two thermally isolated crystalline zeolitic molecular sieve adsortion beds of at least four Angstroms apparent pore size at ambient temperature by introducing feed air to the inlet end of a first adsorption bed at high pressure, discharging at least 60% oxygen from the discharge end, cocurrently depressurizing said first bed and terminating such cocurrent depressurization when the first bed is at lower pressure, and returning part of such oxygen from the cocurrent depressurization for repressurizaton of another purged adsorption bed, releasing waste gas from the first bed inlet end thereby countercurrently depressurizing same to a lowest pressure, introducing oxygen gas from another adsorption bed discharge end to the first bed discharge end as purge gas for desorption of the nitrogen adsorbate and discharging the adsorbate-containing purge gas from the first bed inlet end as waste gas, introducing oxygen gas from the discharge end of an other-than-first adsorption bed and at above said lowest pressure to the purged first bed for at least partial repressurization thereof, with the aforedescribed gas flows being such that a depressed temperature section is formed in the first bed inlet end wherein the coldest gas temperature is no warmer than 35° F. and the temperature difference between said coldest gas temperature and a warmest gas temperature within the first bed is at least 50° F.: the improvement comprising transferring heat to said inlet end by metal solid conduction from both the adsorbent inlet and the bed section downstream the inlet end at rate sufficient to maintain the gas flowing therethrough at temperature at least 20° F. warmer than such gas without such metal solid conduction heat transfer but less than 110° F.

Claim 3

An adiabatic pressure swing process according to claim 1 wherein heat is transferred to said inlet end at rate of 15 to 150 BTU/hr./sq. ft. bed cross-sectional area.

Claim 4

An adiabatic pressure swing process according to claim 1 wherein sufficient heat is transferred to said inlet end to maintain the gas flow therethrough at maximum temperature between 60° F. and 100° F.

Claim 5

In an adiabatic pressure swing process for air separation by selectively adsorbing at least nitrogen alternately in at least two thermally isolated crystalline zeolitic molecular sieve adsorption beds of at least four Angstroms apparent pore size at ambient temperature by introducing feed air at temperature less than 90° F. to the inlet end of a first adsorption bed at high pressure, discharging at least 60% oxygen from the discharge end, thereafter releasing additional oxygen from the first bed discharge end thereby cocurrently depressurizing said first bed and terminating such cocurrent depressurization when the first bed is at lower pressure, and returning part of said additional oxygen from the first bed for repressurization of another purged adsorption bed, releasing waste gas from the first bed inlet end thereby countercurrently depressurizing same to a lowest pressure, introducing oxygen gas from another adsorption bed discharge end to the first bed discharge end as purge gas for desorption of the nitrogen adsorbate and discharging the adsorbate-containing purge gas from the first bed inlet end as waste gas, introducing oxygen gas from the discharge end of an other-than-first adsorption bed and at above said lowest pressure to the purged first bed for at least partial repressurization thereof, with the aforedescribed gas flows being such that a depressed temperature section in the first bed inlet end wherein the coldest gas temperature is no warmer than 35° F. and the temperature difference between said coldest gas temperature and a warmest gas temperature within the first bed is at least 50° F.: the improvement comprising transferring heat to said inlet end by both an external heating source and also by metal solid conduction from both the adsorbent bed inlet and the bed section downstream the inlet end at rate sufficient to maintain the gas flowing therethrough at temperature at least 20° F. warmer than such gas without said external heating source and said metal solid conduction heat transfer but less than 110° F.

Claim 6

In an adiabatic pressure swing process for air separation by selectively adsorbing at least nitrogen alternately in at least two thermally isolated crystalline zeolitic molecular sieve adsorption beds of at least four Angstroms apparent pore size at ambient temperature by introducing feed air at temperature less than 90° F. to the inlet end of a first adsorption bed at high pressure, discharging at least 60% oxygen from the discharge end, thereafter releasing additional oxygen from the first bed discharge end thereby cocurrently depressurizing said first bed and terminating such cocurrent depressurization when the first bed is at lower pressure, and returning part of said additional oxygen from the first bed for repressurization of another purged adsorption bed, releasing waste gas from the first bed inlet end thereby countercurrently depressurizing same to a lowest pressure, introducing oxygen gas from another adsorption bed discharge end to the first bed discharge end as purge gas for desorption of the nitrogen adsorbate and discharging the adsorbate-containing purge gas from the first bed inlet end as waste gas, introducing oxygen gas from the discharge end of an other-than-first adsorption bed and at above said lowest pressure to the purged first bed for at least partial repressurization thereof, with the aforedescribed gas flows being such that a depressed temperature section in the first bed inlet end wherein the coldest gas temperature is no warmer than 35° F. and the temperature difference between said coldest gas temperature and a warmest gas temperature within the first bed is at least 50° F.: the improvement comprising transferring heat to said inlet end by both an external heating source and also by metal solid conduction from both the adsorbent bed inlet and the bed section downstream the inlet end at rate sufficient to maintain the gas flowing therethrough at temperature at least 20° F. warmer than such gas without said external heating source and said metal solid conduction heat transfer but less than 110° F.

Claim 7

An adiabatic pressure swing process according to claim 4 wherein the heat from an external source is supplied by introducing said feed air at temperature above ambient.

Claim 8

An adiabatic pressure swing process according to claim 5 wherein the feed air is compressed to said highest pressure and thereby warmed by the heat of compression, and thereafter partially recooled prior to inlet end introduction to remove only part of the compression heat.

Claim 9

An adiabatic pressure swing process according to claim 5 wherein the feed air is compressed to said highest pressure and thereby warmed by the heat of compression, the warmed compressed air is separated into a first part and a second part, and one of said parts is recooled to remove the compression heat and mixed with the unrecooled part prior to inlet end introduction.

Claim 10

An adiabatic pressure swing process according to claim 3 wherein the heat from an external source is by introducing external heating means to said inlet end.

Claim 11

In adiabatic pressure swing apparatus for air separation by selective adsorption of nitrogen comprising at least two thermally isolated zeolitic molecular sieve adsorbent beds of at least four Angstroms apparent pore size and at least 12 inches effective diameter circular cross-section, being arranged and conducted for alternate flow of feed air to the inlet end of each adsorbent bed at high pressure and discharge of at least 60% oxygen from the discharge end thereof: the improvement comprising a multiplicity of metallic elements in the form of aluminum 1/32 to 1/4 inch thick plates parallel to each other and equally spaced at 11/2 to 8 inch intervals across the adsorbent bed cross-section and extending from the inlet of each adsorbent bed at least one-third the distance toward said discharge end having a total cross-sectional area A of (X/K)(L/8) 2 where L is the adsorbent bed length (in feet), K is the thermal conductivity of said metallic elements (in BTU/hr. ft..sup. 2 °F/ft.), and X is the product KA for an 8 foot long adsorbent bed with values between 0.5 and 12, said metallic elements also being spaced across the adsorbent cross-sectional area such that the distance between each adsorbent particle and the closest metallic element is less than 7 inches.

Claim 12

In adiabatic pressure swing apparatus for air separation by selective adsorption of nitrogen comprising at least two thermally isolated zeolitic molecular sieve adsorbent beds of at least four Angstroms apparent pore size and at least 12 inches effective diameter circular cross-section, being arranged and conducted for alternate flow of feed air to the inlet end of each adsorbent bed at high pressure and discharge of at least 60% oxygen from the discharge end thereof: the improvement comprising a multiplicity of metallic elements in the form of aluminum 1/32 to 1/4 inch thick plates parallel to each other and equally spaced at 11/2 to 8 inch intervals across the adsorbent bed cross-section and extending from the inlet of each adsorbent bed at least one-third the distance toward said discharge end having a total cross-sectional area A of (X/K)(L/8) 2 where L is the adsorbent bed length (in feet), K is the thermal conductivity of said metallic elements (in BTU/hr. ft..sup. 2 °F/ft.), and X is the product KA for an 8 foot long adsorbent bed with values between 0.5 and 12, said metallic elements also being spaced across the adsorbent cross-sectional area such that the distance between each adsorbent particle and the closest metallic element is less than 7 inches.

Claim 13

Apparatus according to claim 9 wherein the aluminum plates are provided with a multiplicity of openings through each plate in the axial direction.

Claim 14

Apparatus according to claim 9 wherein the aluminum plates are radially disposed in the axial direction with outer edges equally spaced around the perimeter of such adsorbent beds.

Claim 15

In adiabatic pressure swing apparatus for air separation by selective adsorption of nitrogen comprising at least two thermally isolated zeolitic molecular sieve adsorbent beds of at least four Angstroms apparent pore size and at least 12 inches effective diameter arranged and conducted for alternate flow of feed air to the inlet end of each adsorbent bed at high pressure and discharge of at least 60% oxygen from the discharge end thereof: the improvement comprising a multiplicity of metallic elements in the form of aluminum rods of 1/4 to 1 inch diameter positioned parallel to each other and uniformly spaced across said adsorbent beds at 0.01 to 0.10 square foot total cross-sectioned area per square foot of adsorbent area and extending from the inlet of each adsorbent bed at least one-third the distance toward said discharge end having a total cross-sectional area A of (X/K) (L/8) 2 where L is the adsorbent bed length (in feet), K is the thermal conductivity of said metallic elements (in BTU/hr. ft. 2 °F/ft.), and X is the product KA for an 8 foot long adsorbent bed with values between 0.5 and 12, said metallic elements also being spaced across the adsorbent cross-sectional area such that the distance between each adsorbent particle and the closest metallic element is less than 7 inches.

Claim 16

In adiabatic pressure swing apparatus for air separation by selective adsorption of nitrogen comprising at least two thermally isolated zeolitic molecular sieve adsorbent beds of at least four Angstroms apparent pore size and at least 12 inches effective diameter arranged and conducted for alternate flow of feed air to the inlet end of each adsorbent bed at high pressure and discharge of at least 60% oxygen from the discharge end thereof: the improvement comprising a multiplicity of metallic elements in the form of aluminum rods of 1/4 to 1 inch diameter positioned parallel to each other and uniformly spaced across said adsorbent beds at 0.01 to 0.10 square foot total cross-sectioned area per square foot of adsorbent area and extending from the inlet of each adsorbent bed at least one-third the distance toward said discharge end having a total cross-sectional area A of (X/K) (L/8) 2 where L is the adsorbent bed length (in feet), K is the thermal conductivity of said metallic elements (in BTU/hr. ft. 2 °F/ft.), and X is the product KA for an 8 foot long adsorbent bed with values between 0.5 and 12, said metallic elements also being spaced across the adsorbent cross-sectional area such that the distance between each adsorbent particle and the closest metallic element is less than 7 inches.