Background:

Atmospheric air is compressed to around 5 bar, using centrifugal compressor. The heat
generated due to compression is removed by cooling the hot air a Direct Contact Cooler (DCC).
This cooler is a packed vessel, where the hot air comes in direct contact with the cooling water .
The cooling water is pumped from the top of the vessel, while the hot air enters the bottom of the
vessel.

The cooled air is sent for purification to remove impurities such as carbon di oxide, hydrocarbon
and moisture. The purification vessel is packed with alumina and molecular sieve which adsorb
the impurities. The out let air from the purification vessel, free from moisture, hydrocarbons and
carbon di oxide is sent for liquefaction of air and further fractional distillation to separate liquid
oxygen and nitrogen.

AIR COMPRESSOR MOTOR POWER: 3450 KW

CHILLED WATER PUMP MOTOR POWER: 22 KW
PARAMETERS: DESIGN (ACTUAL)

STREAM A B C D
Pressure (bar 5.7 5.65 7.44 (8.0) 5.7
abs)
Temp oC 41 19.78 16.80 (20.0) 35.0
Flow kg/hr 38227 38227 18902 19141
Kg mole/hr 1320 1320 1.049 1.062
Nm3/hr 29587 29587 23511 (20000) 23808
Vapour fraction 100 100 0 0
% mole
Enthalpy KW 157 -71 -83.58 -84.218

1. Water flow is less than the design and the chilled water inlet temp is more than the
design. What are the possible reasons for low water flow and higher water pressure?
2. What impact would this have in air flow if we need maintain the design of DCC outlet
air? How much less production is expected?
3. The constraint is to maintain the power consumption to the design level of 3540 KWH
for compressor and 22 KWH of chilled water pump. What are the possible reasons for
this less than design behavior of the pump?
4. Is there any other way of increasing the heat transfer efficiency of the tower to
compensate the under performance of the pump?

Design Parameters:
The compressor out let air temperature =120oC
The compressor outlet air flow :=174000 M3/hr
The pressure of air at the Direct Contact Cooler inlet = 5.2 bar
The cooler outlet air temperature = 15.5oC
The cooling water flow to the cooler = 85 M3/hr
Cooling water pump head = 9 bar

Actual ( observed ) parameters:

The compressor out let air temperature =118.5oC

The compressor outlet air flow :=160000 M3/hr
The pressure of air at the Direct Contact Cooler inlet = 5 bar
The cooler (DCC)outlet air temperature = 16.5oC
The cooling water flow to the cooler = 70 M3/hr
Cooling water pump head = 9 bar
The cooling water pump trips when the discharge pressure reaches 9 bar.
The purification vessel could not purify even at this lower flow, resulting in slippage of CO2 and
moisture which block the heat exchangers in the cryogenic distillation tower, resulting in either
lower production and lower capacity utilization of the plant.

So, the deviations from the design parameters result in the following:
1. Air flow could not be increased and hence the production capacity of the plant comes
down.
2. The higher compressor out let air increases the demand of the DCC.
3. The cooling water flow from the pump is less than the design and hence outlet air is
warmer than the design.
What are the modifications required and what would be the impact on the power consumption
and cost of production? Identify various options and suggest a optimal solution.