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Air Separation Plant Capacities: the Oxygen Plant Having the Following

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Air Separation Plant Capacities: the Oxygen Plant Having the Following Air Separation Plant Capacities: The Oxygen Plant Having The Following Machineries And Equipments: 1. Distillation Column The separation of air into its constituent parts at high purity requires a cryogenic distillation process. To achieve the low distillation temperatures a modern air separation unit requires a refrigeration cycle, and the cold equipment has to be kept within an insulated enclosure (commonly called a "cold box"). The cooling of the gases requires a large amount of energy to drive an air compressor to make this refrigeration cycle work. The air also has to be "clean" enough for cryogenic distillation, since water and carbon dioxide as well as other minor constituents of air can freeze in the cryogenic equipment. The process has the following main features: 2. Compression Atmospheric air is pre-filtered (to remove dust), and compressed to a pressure typically between 40 and 50 bar. Since the compressor heats up the air, it is cooled again in a heat exchanger to ambient temperatures. This can also achieve the removal of some ambient moisture. 3. Purification The process air is generally passed through a molecular sieve bed, which removes any remaining water vapour, as well as carbon dioxide, which would freeze in the cryogenic equipment. The molecular sieve is often designed to remove any gaseous hydrocarbons from the air, since these can be a problem in the subsequent air distillation. 4. Cooling & Distillation Process air is passed through an integrated heat exchanger (usually a copper coil exchanger) and cooled against product (and waste) cryogenic streams. The air is then cool enough to be distilled in a distillation column. The formation of liquid air in the cryogenic equipment requires some refrigeration and liquid is usually formed by Joule Thomson expansion of air across a valve or through an expansion engine, (a reverse compressor). The air is distilled in at least one and often two distillation columns, depending on the products required. cryogenic air separation units are built to provide one or both of nitrogen and oxygen. Liquid nitrogen "LIN", liquid oxygen "LOX” can be produced if sufficient refrigeration is provided for in the design. Finally the product gases are warmed against the incoming air to ambient temperatures. Product supply and storage The air gases are sometimes supplied by pipeline to large industrial users adjacent to or nearby to the production plant or stored as liquid. Unless a viable pipeline system exists, long distance transportation of products is usually done as a liquid product for large quantities or as dewar flasks or gas cylinders for small quantities. In addition to oxygen, nitrogen gas products may be produced - the only viable sources are from the distillation of air. Design and construction of air separation plants are part of Linde's traditional scope of activity, which led at the turn of the 19th century to the establishment of Linde's engineering division. The start-up of the world's first air separation plant in 1902 initiated the development of the cryogenic industry. Today, several hundred engineers and specialists work at Linde for the worldwide sale and contract execution of plants recovering the air components oxygen and nitrogen as well as the various rare gases. Quality, safety, health and environmental protection (QSE) have an outstanding importance in our work. Customers expect us to supply safe and economical plants according to latest technology. Linde Engineering stands for this, both at home and abroad. Air Separation Process Design and Development All air separation processes start with compression of air, and additional compressors may be used to boost the pressure of the nitrogen and / or oxygen products leaving the separation and purification process. Even more compression is required to produce large amounts of additional refrigeration when some or all of plant production from an air separation unit (ASU) is desired in liquid form. The cost of electricity is the largest single operating cost incurred in air separation plants. It is usually between one third and two thirds of the operating costs associated with producing gas and liquid products. Electric motors are used to drive the compression equipment, and are used in process heaters, instrumentation systems and cooling systems. Consequently, it is fair to say that electrical power is just as much a raw material as air for the manufacture of atmospheric industrial gas products. Small gaseous product plants may use hundreds of kilowatts (kW). Large liquid plants may have power demands measured in thousands and tens of thousands of kilowatts The Oxygen Plant Having The Following Machineries And Equipments: 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. 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 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 watervapour 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. 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 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. 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. 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. We design, manufacture, erect, commission and run the Air Separation Gas Plants. We are the leading manufacturers and exporter of Air Separation Plants (gas & liquid or both) and Acetylene Plants. AIR SEPARATION PLANTS 01.Air Separation Gas Plant -ASGP Capacity :- 20 m3 /hr to800 m3/hr. Model :- OPG – 20 to OPG – 600. Purity :- 99.6 %.
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