Membrane separation system and process

Abstract

A membrane system is positioned within an insulated enclosure heated to maintain superheat conditions for the feed gas to the system, wherein individual membrane modules are not insulated. The feed gas compression heat is desirably used to supply the superheat to the feed gas within the insulated enclosure.

We claim: 
     
       1. An improved air separation process comprising: (a) compressing a feed air stream containing condensible water vapor to a desired feed air pressure;   (b) cooling .Iadd.the .Iaddend..[.said.]. compressed feed air stream to below the design operating temperature level of the air separation process, thereby supersaturating the feed air so that the feed air stream comprises .[.said.]. feed air saturated with condensible water vapor together with free water droplets;   (c) removing said free .[.liquid.]. .Iadd.water .Iaddend.droplets from the feed air stream;   (d) passing the compressed, cooled feed air stream, free of water droplets, into an insulated enclosure adpated to control and/or minimize the lose of heat therefrom, without superheat of said feed air stream prior to its passage into said insulated enclosure and without predrying said feed air stream to a temperature dew point lower than said design operating temperature prior to said passage of the feed air stream into the insulated enclosure;   (e) supplying sufficient heat within said insulated enclosure so as to superheat the feed air stream therein to a temperature where the saturation temperature thereof at the feed air pressure, said insulated enclosure serving to control and/or minimize the loss of heat therefrom such that any loss of heat is not greater than that being supplied within said insulated enclosure, so that the feed air within said insulated enclosure is mintained under superheat conditions at a temperature below its dew point to avoid undesired condensation of water present in the feed air within a permeable membrane system positioned within said insulated enclosure to effect the desired air separation;   (f) passing the .[.thus-.]. superheated feed air stream to said permeable membrane system positioned within said insulated enclosure, said permeable membrane system containing at least one membrane module capable of selectively permeating oxygen together with condensible water vapor, as a more permeable component of the feed air stream from nitrogen as a less readily permeable component thereof, said membrane module or modules not being individually insulated for the retention of heat therein;   (g) withdrawing nitrogen from the membrane system and from said insulated enclosure as non-permeate gas at essentially said feed air pressure; and   (h) separately withdrawing oxygen and condensible water vapor from the membrane system and from said insulated enclosure as permeate gas at a lower pressure, whereby condensation of water from the feed air stream within the membrane system is effectively precluded.     
     
     
       2. The process of claim 1 in which said heat is supplied within the insulated enclosure by passing heat generated external to the air separation process to said insulated enclosure. 
     
     
       3. The process of claim 2 in which said heat is supplied by the positioning of electric heater means within said insulated enclosure. 
     
     
       4. The process of claim 2 in which said heat is supplied by introducing steam to within said insulated enclosure. 
     
     
       5. The process of claim 1 in which the heat to superheat the feed air stream within the insulated enclosure is supplied by heat exchange means positioned within said insulated enclosure. 
     
     
       6. The process of claim 5 in which said heat exchange means is adapted to supply heat directly to said feed air stream. 
     
     
       7. The process of claim 6 in which the heat supplied to the feed air by said heat exchange means comprises heat recovered from the heat of compression generated upon compression of the feed air stream. 
     
     
       8. The process of claim 7 in which the feed air is compressed using an oil-flooded compressor, the heated oil from the compressor being passed to said heat exchange means to provide said heat required to superheat the feed air. 
     
     
       9. The process of claim 8 and including passing additional heat to the insulated enclosure, said additional heat comprising heat external to the air separation process. 
     
     
       10. An improved air separation system comprising: (a) a permeable membrane system containing at least one membrane module capable of selectively permeating oxygen, together with condensible water vapor, as a more readily permeable component of a feed air stream from nitrogen as a less readily permeable component thereof, said system including means for passing said feed air stream to the feed side of each said membrane module at a desired feed gas .[.prssure,.]. .Iadd.pressure, .Iaddend.and for separately withdrawing nitrogen at essentially .[.said.]. .Iadd.the .Iaddend.feed air pressure level and oxygen and condensible water vapor as permeate gas at a lower pressure from each said module, each membrane module not being individually insulated for the retention of heat therein;   (b) heat supply means suitable for supplying sufficient heat to the feed air stream so as to superheat said feed air stream to a temperature above the saturation temperature of the feed air at the feed air pressure prior to the passage of said feed air to the permeable membrane system;   (c) an insulated enclosure surround said membrane system and said heat supplied by said heat supply means, said enclosure being insulated to control and/or minimize the loss of heat therefrom such that any loss of heat therefrom is not greater than the heat being supplied by said heat supply means so that the feed air passed to the uninsulated membrane module(s) is maintained under superheat conditions at a temperature above its dew point to avoid undesired condensation of water present in the feed air within the membrane system, said insulated enclosure being sufficiently large to permit operating personnel access thereto for servicing of the membrane system of uninsulated individual module(s);   (d) compression means for compressing the feed air stream containing condensible water vapor to a desired feed air pressure;   (e) an air cooling zone suitable for cooling the compressed feed air stream to below the design operating temperature level of the membrane system, thereby supersaturating the feed air so that said feed air stream comprises .[.said.]. feed air saturated with condensible water vapor together with free water droplets;   (f) liquid separation means for removing said free water droplets from the feed air stream; and   (g) conduit means for passing the compressed, cooled feed air stream, free of water droplets, into said insulated enclosure without superheat of said feed air stream prior to its passage into said insulated enclosure containing membrane module(s) not individually insulated and without predrying of said feed air stream to a temperature dew point lower than .[.said.]. .Iadd.the .Iaddend.design operating temperature prior to said passage of the feed air stream into the insulated enclosure, whereby condensation of water from the feed air stream within the membrane system is effectively precluded.   
     
     
       11. The system of claim 10 in which said heat supply means for supplying heat generated external to the gas separation operation to said insulated enclosure. 
     
     
       12. The system of claim 11 in which said heat supply means comprises electric heater means positioned within said insulated enclosure. 
     
     
       13. The system of claim 11 in which said heat supply means comprises steam introduced to within said insulated enclosure. 
     
     
       14. The system of claim 10 in which said heat supply means comprises heat exchange means for supplying heat to said feed air stream within said insulated enclosure. 
     
     
       15. The system of claim .[.15.]. .Iadd.14 .Iaddend.in which said heat exchange means is adapted to supply heat directly to said feed air stream. 
     
     
       16. The system of claim 15 and including means for recovering the heat of compression generated upon compression of the feed air stream by the compression means of element (d) and passing said heat to the heat exchange means within said insulated enclosure. 
     
     
       17. The system of claim 16 in which said .[.compressor.]. .Iadd.compression .Iaddend.means comprises an oil-flooded compressor means, and including conduit means for passing oil heated in said compressor means to said heat exchange means. 
     
     
       18. The system of claim 17 and including control means for adjusting the amount of heated oil passed to said heat exchange means. .Iadd. 
     
     
       19.  An improved air separation process comprising: (a) compressing a feed air stream containing condensible water vapor to a desired feed air pressure in an oil-flooded compressor;   (b) cooling the compressed feed air stream to below the design operating temperature level of the air separation process, thereby supersaturating the feed air so that the feed air stream comprises feed air saturated with condensible water vapor together with free water droplets;   (c) removing said free water droplets from the feed air stream;   (d) supplying sufficient heat to said feed air stream to superheat the feed air stream to a temperature above the saturation temperature thereof at the feed gas pressure, the heat of compression of the feed air stream heating the oil in the oil-flooded compressor, the heated oil being passed to heat exchange means adapted to supply heat to the feed air stream for the superheating thereof;   (e) passing the superheated feed air stream to an insulated enclosure that serves to control and/or minimize the loss of heat therefrom so that the feed air stream within the insulated enclosure is maintained at superheat conditions at a temperature below its dew point to avoid undesired condensation of water present in the feed air within a permeable membrane system positioned within said insulated enclosure to effect the desired air separation, said heat exchange means being positioned outside and upstream of said insulated enclosure, the feed air stream not being predried to a temperature dew point lower than the design operating temperature prior to passage of the feed air stream into the insulated enclosure;   (f) passing the superheated feed air stream to said permeable membrane system positioned within said insulated enclosure, said permeable membrane system membrane system containing at least one membrane module capable of selectively permeating oxygen together with condensible water vapor, as a more readily permeable component of the feed air stream, from nitrogen as a less readily permeable component thereof, said membrane module or modules not being individually insulated for the retention of heat therein;   (g) withdrawing nitrogen from the membrane system and from said insulated enclosure as non-permeate gas at essentially the feed gas pressure; and   (h) separately withdrawing oxygen and condensible water vapor from the membrane system and from said insulated enclosure as permeate gas at a lower pressure,   whereby condensation of water from the feed air steam within the membrane system is effectively precluded. .Iaddend. .Iadd.       
     
     
       20.  The process of claim 19 and including passing additional heat to the insulated enclosure, said additional heat comprising heat generated external to the carrying out of the air separation process. .Iaddend. .Iadd.21. An improved air separation system comprising: (a) a permeable membrane system containing at least one membrane module capable of selectively permeating oxygen, together with condensible water vapor, as a more readily permeable component of a feed air stream from nitrogen as a less readily permeable component thereof, said system including means for passing said feed air stream to the feed side of each membrane module at a desired feed gas pressure, and for separately withdrawing nitrogen at essentially said feed air pressure level, and oxygen and condensible water vapor as permeate gas at a lower pressure from each said module, each module not being individually insulated for the retention of heat therein;   (b) oil-flooded compressor means for compressing the feed air stream containing condensible water vapor to a desired feed air pressure;   (c) an air cooling zone suitable for cooling the compressed feed air stream to below the design operating temperature level of the membrane system, thereby supersaturating the feed air so that the feed air stream comprises feed air saturated with condensible water vapor together with free water droplets;   (d) liquid separation means for removing said free water droplets from the feed air stream;   (e) heat exchange means adapted to supply heat to the cooled feed air stream, free of water droplets, for the superheating of the feed air stream to superheat conditions at a temperature above its dew point to avoid undesired condensation of water present in the feed air within the membrane system;   (f) an insulated enclosure surrounding said membrane system, said enclosure being insulated to control and/or minimize the loss of heat therefrom such that any loss of heat therefrom is not greater than the heat supplied for the superheating of the feed air stream so that the feed air passed to the uninsulated membrane module(s) is maintained under superheat conditions at a temperature above its dew point to avoid undesired condensation of water present in the feed air within the membrane system, the insulated enclosure being sufficiently large to permit operating personnel access thereto for servicing of the membrane system of uninsulated individual module(s), said heat exchange means being positioned outside and upstream of said insulated enclosure;   (g) conduit means for passing the compressed, cooled, superheated feed air stream, free of water droplets, into said insulated enclosure without predrying of said feed air stream to a temperature dew point lower than the design operating temperature prior to said passage of the feed air stream into the insulated enclosure; and   (h) conduit means for passing oil heating in said oil-flooded compressor   
     
     
        means to said heat exchange means. .Iaddend. .Iadd.22.  The system of claim 21 and including control means for adjusting the amount of heated oil passed to said heat exchange means. .Iaddend. .Iadd.23. The system of claim 21 and including means for passing additional heat generated external to the air separation operation to said insulated enclosure. .Iaddend.