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Oxygen Plant

The process adopted to produce oxygen and nitrogen is called liquification and fractional distillation of air inside the air separation unit.

Air is expanded and liquefied in this process by expansion and cooling in an expansion engine and expansion valves in medium pressure. (40 kgs/cm2 to 50 kgs/cm2.). The expanded and cooled air from expansion engine and expansion valves will enter the lower part of the distillation column. The air as mostly in liquid state. The oxygen and nitrogen have different boiling points. Since nitrogen is more volatile is drawn out of the distillation column in vapour form and oxygen is less volatile will be collected in condenser. The liquid oxygen pumped at 150kgs/cm2 and filled in cylinders.

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The free atmospheric air is sucked in by a multi-stage air compressor through a filter and compressed to the working pressure. After each stage, intermediate coolers and water separators are provided. The compressed air then passes through the (evaporation) pre-cooler and then to the molecular sieve battery where the moisture and carbon dioxide are removed from the process air. It then passes through the exchanger No.1 where it is cooled by the out going waste nitrogen and product oxygen.

A part of this cold air then flows through an expansion machine and the balance through the heat exchanger No.2 the ratio of the air streams is controlled by an expansion valve, RI. Both these streams of air then unite in the lower column where it partially liquefies.

The liquid air (rich air) then passes through the expansion valve R2 to the upper column which is at a lower pressure than the lower column. Similarly the liquid nitrogen (poor liquid) travels from the lower column to the upper column through an expansion valve R3 where the separation of oxygen and nitrogen occurs. Nitrogen being more volatile passes out as a gas from the top of the column and this waste nitrogen flows through both the heat exchangers cooling the in-coming air. Similarly product oxygen is also passed through the two heat exchangers to cool the in-coming air and then to the filling manifold via a liquid pump. If a small amount of air is vented out from the upper column, higher purity nitrogen can also be obtained from this plant. R4 Valves is provided in order to fasten cooling during start-up.
The Oxygen plant having the following Machineries and Equipments: Oxygen Plant Capacity



1. Air Compressor

The air compressor is supplied 4 stroke type along with suitable motors, electrical starters, motor pulley, belts and inter stage coolers. The air compressed in this compressor to 40 to 50 kgs/cm2 depending the plant condition and requirements. Air compressor should be maintained properly as per manufactures manual to obtain the maximum output and efficiency.

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2. Water pump, cooling towers and water softeners

These are supplied as per compressor manufacturers instructions and to be maintained properly to achieve minimum shutdown and trouble - free operation of the compressor

Liquid Nitrogen Plant
  




3. After Cooler :

This is cylindrical tank fitted with air coils. The air is cooled after passing from compressor and cooled by circulating water.

4. Cascade Cooler:

This is elliptical tank fitted with air coils. These coils are half submerged in water, dry nitrogen bubbled through this water to become wet gas. As water vaporizes water gets cooled. The air inside the pipe will get cooled.

5. Moisture Separators:


Two numbers of moisture separators provided one after the after cooler and second one after chilling tank .The moisture condensed as water will be separated and drained regularly.

6. Chilling Tank and Chilling Unit:


Chilling tank is cylindrical tank fitted with air coil and refrigeration coils. The water is cooled by chilling unit and refrigeration coils. In this unit air is further cooled.

7. Oil Adsorber:


Oil adsorber is packed with activated alumina balls . Here the oil Vapour carried over by compressor will be removed. It is desirable to drain moisture from the bottom of the oil adsorber at regular intervals and also change the alumina after a specified period.

8. Molecular Seive Driers:


It is twin vessel driers both are filled with molecular sieves. As the process air passes through molecular sieves, the molecular sieves adsorb water vapour and carbon - di- oxide (Co2) from the air and make the air dry. After about 10 hours the molecular sieves become saturated and it will have to be regenerated by blowing hot air or nitrogen. Once the hot gas is blown through the saturated molecular sieves the CO2 and water vapour discharged and the drier is ready to use again.

9. Dust filter:


Dry air is filtered in this unit by a special material and prevents any dust particles entering the air separation unit.



10. Defrost Heater:


Despite purification and filtration of air some water vapour and CO2 will get past the molecular sieve driers and enter the Air separation unit and may be deposited in the tubes of heat exchangers, valves and L.O. pump filters. To remove this deposit, defrosting of the plant is carried out. For this dry air after heating in defrost heater passed inside the air separation unit and L.O. pump and deposits will be melted and removed.

 

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Oxygen Gas Plants India

 

11.Air separation Unit:


The process adopted to produce oxygen and nitrogen is called liquification and fractional distillation of air inside the Air separation unit.

Air is expanded and liquefied in this process by expansion and cooling in an expansion engine and expansion valves in medium pressure.(40 kgs/cm2 to 50 kgs/cm2.). The expanded and cooled air from expansion engine and expansion valves will enter the lower part of the distillation column. The air as mostly in liquid state. The oxygen and nitrogen have different boiling points. Since nitrogen is more volatile is drawn out of the distillation column in vapour form and oxygen is less volatile will be collected in condenser. The liquid oxygen pumped at 150kgs/cm2 and filled in cylinders
Air Separation Plant
  

 

12. Expansion Engine


This is a vertical single acting reciprocating type engine. This produces the cold required for operating the plant. The high pressure air enters through inlet valve at the start of downward stroke of the piston and expands .During upward stroke outlet valve opens and the expanded air pushed out side. The electric motor is used to start the engine initially, thereafter the engine is moved by the air pressure itself and the air gets cooled. This cooling is more than the expansion valves. The temperature drops in this engine in 50°C to 70°C depending on air pressure, temperature and inlet cam position.
Oxygen Gas Cylinders India
  


13. Liquid Oxygen Pump:

The liquid oxygen pump is a single stage, single acting piston pump. This is used for filling the oxygen into cylinders upto a pressure of 150 kg/cm2. The pump is designed for assembly in air separation unit that works by pumping liquid oxygen and gasifying the same in heat exchangers for final filling as gas, in cylinders.
Oxygen Gas Cylinders India
  


14. Filling Manifolds:

This are supplied for filling the high pressure gas oxygen into the cylinders at a pressure of 150 kgs/cm2 and provided with safety valves, isolating valves, cylinder filling valves pig tails with cylinder connection and pressure gauges.
Nitrogen Plants

 
 

15. Industrial and medical grade oxygen plants:

Range of Products

We manufacture oxygen / nitrogen plants from 20m3/hr to 800m3/hr for filling high pressure oxygen / nitrogen gas in cylinders and in the following combinations.

    1.Oxygen Gas Plants:

    Capacities ranging from 20M3/Hr to 800M3/Hr for filling high pressure cylinders upto 150 bar (200 bar optional), purity 99.6% (nitrogen gas available as by product).

    2. Oxygen Liquid Plants:

    Capacities ranging from 20 lts/hr upto 800lts, purity 99-99.6%, (nitrogen gas available as by product

    3. Nitrogen Gas Plants:

    Capacity ranging from 20M3/Hr to 800M3/Hr fot filling high pressure cylinders upto 150 bar (200 bar optional ), purity 99%-99.999%.

    4. Nitrogen Liquid Plants:

    Capacities ranging from 20lts/Hr upto 800lts/Hr, purity99-99.6%

    5. Oxygen & Nitrogen Plants:

    Capacities ranging from 20M3/Hr to 800M3/Hr oxygen and 100M3/Hr to 2000M3/Hr nitrogen gas by product

    6. Oxygen & Nitrogen Liquid Plants:

    Oxygen capacities ranging from 20lts/hr upto 800lts/hr, purity 99-99.6%  ( nitrogen gas available as by product ) . Simultaneously, nitrogen liquid production of purity 99-99.6%
 

Process Used: Latest Cryogenic

The process used is cryogenic which involves deep refrigeration/cooling of air below zero to minus 190 degree centigrade to liquid form and then air separation into liquid oxygen and liquid nitrogen. The process cycle is low pressure cycle and low power consumption and is proven technology all over the world.

Raw Material

Raw material used is free atmospheric air

Power Consumption

Power consumption is very low because of low pressure and high yield of oxygen/nitrogen.
 

We design, manufacture, erect, commission and run the Industrial Gas Plants. We are the leading manufacturers and exporter of Oxygen Plants ( gas & liquid or both) and Acetylene Plants.

01. Oxygen Gas Plant - OPG.

Capacity :- 20 m3 /hr to 800 m3/hr.
Model :- OPG – 20 to OPG – 800.
Purity :- 99.6 %.
Pressure :- 150 Bar to 250 Bar.(optional)

02. Oxygen Liquid Plant – OPL.

Capacity :- 20 m3 /hr to 800 m3/hr.
Model :- OPL – 20 to OPL – 800.
Purity :- 99.6 %.
Pressure :- 0.6 Kgs / Cm2.

03. Nitrogen Gas Plant – OPGN.

Capacity :- 20 m3 /hr to 800 m3/hr.
Model :- OPGN – 20 to OPGN – 800.
Purity :-
a) 99.6 %.
b) High Purity –99.9999 % –(2-5 ppm) –(optional) Pressure :- 150 Bar to 200 Bar (optional).

04.Nitrogen Liquid Plant – OPLN.

Capacity:- 20 m3 /hr to 800 m3/hr
Model :- OPLN – 20 to OPLN – 800
Purity :-
a) 99.6 %.
b) High Purity –99.9999 % –(2-5 ppm) –(optional)
Pressure :- 0.5 Bar

05.Oxygen / Nitrogen Plant - OPG- LNO.

Oxygen Gas Capacity:- 20 m3 /hr to 800 m3/hr – Gas.
Liquid Nitrogen and Liquid Oxygen taping facility will
be provided. ( optional)
Model :- OPG- LNO.
Oxygen Purity :- a) 99.6 %.
Nitrogen Purity :- a) 99.6 %.
Pressure :-a)Oxygen - 150 Bar.
b)Nitrogen Liquid – 0.6 Bar.
c)Oxygen Liquid - 0.6 Bar.
   
 
 
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