Pressure abnormalities are one of the most common issues in air separation units. During operation, system pressure may fluctuate due to compressor failures, pipeline leaks or blockages, or faulty pressure sensors. To address this, regular maintenance of compressors is required to ensure stable performance. Pipelines should be inspected and cleaned, with any leaks promptly repaired. In addition, pressure sensors should be periodically calibrated or replaced to maintain accurate control and stable system operation.

Failures in the cooling system can lead to unstable temperature control, affecting gas separation efficiency and product purity. This may be caused by poor cooling water circulation, icing or blockage in the cooler, or faulty temperature sensors. To resolve this, the cooling water system should be inspected and cleaned to ensure proper flow. Coolers should be regularly defrosted and maintained, and temperature sensors should be periodically calibrated or replaced to ensure accurate temperature control.

This issue may be caused by damaged packing or trays in the distillation column, improper operating parameters, or high impurity levels in the feed gas. Solutions include regularly inspecting and replacing internal column components, optimizing operating parameters to ensure optimal performance, and improving feed gas pretreatment to reduce impurities and maintain required purity levels.

Excessive energy consumption may result from equipment aging or reduced efficiency, non-optimized operating parameters, or system gas leakage. To address this, equipment should be regularly maintained and upgraded to improve efficiency. Operating parameters should be optimized to minimize unnecessary energy use, and the system should be routinely inspected to detect and repair leaks, ensuring proper sealing and efficient operation.

Failures in the control system may be caused by software or hardware issues, malfunctioning sensors or actuators, or loose or faulty electrical connections. To resolve this, control system software should be regularly updated and maintained to ensure stable operation. Faulty sensors and actuators should be inspected and replaced, and electrical connections should be routinely checked to ensure they are secure and reliable.