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Acetylene Plant


This acetylene plant from oxyplants is of an advanced design, incorporating several features not ordinarily found in other generators. This one is a fully automatic plant with twin hoppers (and needs an operators’ attention for only ten minutes in an hour).

All operations are performed by pneumatically controlled valves, assisted by highly sensitive sensors, integral with the temperature control instruments
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These in turn open the water inlet valve or residue drain valve etc. Two hydraulic pumps help to open and close the supply of calcium carbide. This is fed into the generator by screw feed conveyors. The screw feed mechanism and the agitators are operated by flame-proof motors and fittings.

The entire operation is perfectly synchronized to give maximum efficiency and simplicity in operation. Any failure, whether it is of power supply, water, instruments air, is signaled visually and also audibly when an alarm bell rings to alert the operator.

Only flame proof lights and electrical fittings according to IS21481-68 (Group II) or BSS-229 may be used in an acetylene plant building. Acetylene cylinders must be of specification IS: 7312: 1974 or ICC:8.

The design of the entire plant has been made with safety in mind. Flash back arrestors, high pressure reverse flow check valves, auto vent valves, non-return valves and flash back arrestors are also provided to make this plant absolutely safe to operate in all conditions.

Brief Process Description :-
‘Oxyplant’ acetylene generator is a stationary carbide to water automatic generator. Acetylene is generated as a result of the chemical reaction between calcium – carbide and water. The by-product is calcium-hydroxide (lime slurry) which is continuously discharged from the generator. The acetylene produced in the generator is at 0.5 kgs/cm2 and passed through coolers, driers, purifiers to achieve purity and compressed in a three stage water cooled compressor. The compressed acetylene gas is filled into the cylinder in the filling manifold at 15 bars and cooled by water spraying to achieve better absorption of gas in the acetone of the cylinder.

The gas produced is highly flammable and explosive, if mixed with air. Therefore various safety devices and automatic systems are incorporated to avert fire and/or explosion. These systems make the acetylene plant is highly sophisticated and safe equipment.

Acetylene Plants
1]. Carbide Hopper.
2]. Acetylene Generator .
3]. Condenser.
4]. L.P. Drier.
5]. Purifier.
6]. Scrubber.
7]. Acetylene Compressor.
8]. H.P. Drier.
9]. Filling Manifolds.

Acetylene Plant having the following Machineries and Equipments: Acetylene Plant Capacity



1.Acetylene Generator

The ‘oxyplants’ acetylene generator is horizontal cylindrical steel vessel with dish ends having agitator and its drive unit, carbide hoppers, screw feeders and its drive units, flash back arresters, safety valves, drain systems and the allied automatic control systems.

 

The generator tank is filled with water to high level and carbide is made drop in the water through the screw feeder system. When the carbide drops inside the generator tank the acetylene gas is generated due to the chemical reaction and passes through the flash back arrester to the other system in the plant.

 

 

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2. Cooler Condenser

The acetylene gas leaving the acetylene generator is cooled in cooler condenser and excess moisture is removed by condensation .The cooling water is circulated inside the jacket from bottom to top and acetylene gas passed through top to bottom.

 
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3. Low Pressure Drier

This is cylindrical vessel charged with anhydrous calcium chloride. This adsorbs the moisture in the gas and liquid calcium chloride collets at the bottom and can be drained periodically.
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4. Purifier

This is a large vertical cylindrical vessel divided into two sections by wire mesh frame work and charged with purifying mass. This mass absorbs gases like hydrogen sulphide, phosgene etc., from the gas .The purifying mass has to reactivated in every 125 working hours by exposing it to atmosphere.

 
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5. Ammonia Scrubber


This equipment is a vertical vessel fitted with level gauge, water make-up line and particular level as marked to be maintained at all the times .The acetylene gas is bubbled in water so that the water soluble impurities like ammonia will be scrubbed and gas becomes little wet to facilitate compression and further drying.

 
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6. Acetylene Compressor

This is 3 stage compressor driven by flame proof motor and lubricated by flash and forced lubrication system. The compressor along with interstage coils and purge vessels are immersed in a water filled tank to avoid in any pressurized acetylene to come in contact with air and also to make sure that all the components are continuously cooled. The third stage pressure is determined by the setting of backpressure regulating valve.
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7. High Pressure Drier


The high pressure drier consists of three columns .The first column is filled with mild steel chain packings to avoid any void and proper mixing. The second and third columns are fitted with two capsules each and are filled with anhydrous calcium chloride. Each column is fitted with drain valves to drain the moisture colleted at the bottom periodically.
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8. Filling Manifolds

The acetylene gas-filling manifold consists of two headers, each having provision for filling 30 cylinders at a time. Each header is individually fitted with non-return valves; flash back arresters, pressure gauges and manually isolating valves.

 

 
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We manufacture the acetylene plants a stationary, low pressure & medium pressure, carbide to water, with automatic controls and safety devices.

There are three Models of Generators

 

01.Oxyplant Acetylene – OPA.

Capacity :- 25 m3 /hr.
Model :- OPA – 25.
Purity :- 96 %.
Filling Pressure :- 15 Bar.
Cylinder filled in a Batch :- 40 nos.
Water requirements :-
a. Cylinder filling :- 180 liters. Per Cylinder
b. Cylinder cooling:- 50 liters.
Total :- 230 liters.
Power requirements:- 18 KW / 25 HP.

 

02.Oxyplant Acetylene – OPA.

Capacity :- 50 m3 /hr.
Model :- OPA – 50.
Purity :- 96 %.
Filling Pressure :- 15 Bar.
Cylinder filled in a Batch :- 60 nos.
Water requirements :-
a. Cylinder filling :- 180 liters. Per Cylinder
b. Cylinder cooling:- 50 liters.
Total :- 230 liters.
Power requirements:- 22 KW / 30 HP.

 

03.Oxyplant Acetylene –

OPACapacity :- 100 m3 /hr.
Model :- OPA – 100.
Purity :- 96 %.
Filling Pressure :- 15 Bar.
Cylinder filled in a Batch :- 120 nos.
Water requirements :-
a. Cylinder filling :- 180 liters. Per Cylinder
b. Cylinder cooling:- 50 liters.
Total :- 230 liters.
Power requirements:- 30 KW / 40 HP.

 

 

 
 
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