High Pressure Air Separation Gas Plants

Dryer & Heater
Purification Tower
Purification System
Expansion Engine
Cylinder filling Pump

High Pressure Air Separation Gas Plants

AIR SEPARATION PLANTS

OxyNitrotech is a leading Supplier & Exporter of Air Separation Gas Plants ranging from 30 M³/Hr to 800 M³/Hr and exports related Allied Equipment’s for these Plants, as well as High Pressure Seamless Cylinders for different types of Gases. Air Separation Gas Plants Manufactured by us of an Advanced Technology Design that works on Medium Pressure and is approved all over the world for its reliability, efficiency, operation and ease of use & incorporating several features not ordinarily found in other Plants like Low Operating Cost, Low Maintenance, Sturdy Design, Low Working Pressure, and mainly Complete ASU Column is of Stainless Steel 304, Skid Mounted System for Complete Purification System, Low Power Consumption per M³ gas produced. The Air Separation Gas Plants is Semiautomatic and needs an operator’s attention for only once in an hour.
MIDIUM SIZE OXYGEN SEPARETION PLANT
HIGHER CAPACITY AIR SEPARETION PLANT
Our Cryogenic Oxygen/Nitrogen Gas Plants are Designed, Manufactured and developed in accordance with ISO parameters 9001:2008 & as per international ASME standards & ISO 9000:2008.
Our Cryogenic Oxygen/Nitrogen Gas Plants are used in wide applications which include to the following industrial segments like Steel plants, Steel Rolling Mills, fabrication, Glass Industries, Hospitals, Chemical Industries, Petro-chemicals Industries, electronic and construction areas.
Our Air Separation Gas Plants are Designed, Manufactured and developed in accordance with ISO parameters 9001:2008 & as per international ASME standards.

Our Air Separation Gas Plants are used in wide applications which include to the following industrial segments like Steel plants, Steel Rolling Mills, fabrication, Glass Industries, Hospitals, Chemical Industries, Petro-chemicals Industries, electronic and construction areas.
Process Description: Cryogenic air separation is the preferred technology for producing very high purity oxygen and nitrogen. It is the most cost effective technology for high production rate plants. All plants producing liquefied industrial gas products utilize cryogenic technology.
Cryogenic air separation processes are routinely used in medium to large scale plants to produce oxygen, nitrogen, and argon as gases products.
Air separation is the most common process used to extract one or all of the main constituents of atmospheric air. The three main components are Nitrogen (78.1%), Oxygen (20.9%) and Argon (0.9%). The remaining gases in the air are in trace amounts and normally not recovered. In very large air separation units (ASU) Neon, Xenon and Krypton are recovered in small amounts.
Cryogenic air separation utilizes the diffrent condensing/boiling points of the components of air to enable separation by distillation at cryogenic temperatures. At atmospheric pressure the main components of air have the following condensing/boiling points:
  • Nitrogen -320F
  • Oxygen -297F
  • Argon -308F
Since air is a simple mixture, liquefying and distilling air provides a process to successfully separate the Nitrogen, Oxygen, and Argon. All ASU’s use this process.
The complexity of the cryogenic air separation process, the physical sizes of equipment, and the energy required to operate the process all vary with the number of gaseous and liquid products, required product purities, and required delivery pressures.
The process adopted to produce oxygen and nitrogen is called liquefaction and fractional distillation of air inside the air separation unit. Compressed & purified air is expanded and liquefied in this process of expansion and cooling in an expansion engine and expansion valves. The expanded and cooled air from expansion engine and expansion valves will enter the lower part of the distillation column in liquid form. 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 collected in condenser.
The Liquid Oxygen Compressed by Liquid Oxygen Pump & passed through Heat Exchangers, Gasified, filled at 150 Kg/Cm²g pressure to the Cylinders

 

 

 

SPECIAL FEATURES OF OUR OXYGEN/NITROGEN GAS PLANTS:

1.Equipments like Heat Exchangers, Column, Condenser Liquid vessels jackets & Inter connecting pipe lines are made of High Purity Stainless steel suitable for Cryogenic process. These are fabricated by special method of TIG & MIG welding. all the parts subjected to heat and cold transfer are fabricated of High Purity copper and Copper alloys. This will avoid internal leakages due to chemical corrosion, Age Hardening of the joining material like Led ALLOY.

  1. All the Equipment’s in the Cooling & Purification process are mounted on common metallic skid. This avoids individual foundation of these equipment at site, gives aesthetic look, and inter connecting pipe line are fabricated at our factory by X ray welders, tested, assembled, painted to provide good quality.
  2. For cooling incoming Air Two Chilling units are provided in case of failure of one unit another unit will take over the process and will not affect the production.
  3. Plant is designed in such a manner to retain maximum cold & the restarting time of plant is drastically reduced.
  4. We provide complete Erection, Testing, and Commissioning & Training of customer Plant Staff at your site for no extra cost.
  5. We provided Trunkey project (expect Civil, Earthing & Electrical up to our LT Panel).
  1. Cylinder capacity 6 to 7 cubic meter
  2. Cylinder filling Pressure 150 Kg/Cm²g
  3. Cylinder filling pressure can be provided up to 200 Kg/Cm²g on Request.
  4. Simulations Oxygen/Nitrogen production by cryogenic pumps up to pressure of 150 Kg/Cm²g.
  5. Liquid oxygen / liquid nitrogen Tapping Provisions are provided in plants above 100 M³/Hr and higher capacities.
  6. High purity Nitrogen of up to 1 PPM can also be produced simultaneously with a separate liquid Nitrogen pump in all plants on request.
  7. Nitrogen purity 98% and pressure 0.5 Kg/Cm²g is produced in all our plants Maximum up to 4 times of rated capacity of Oxygen production.

AIR SEPARATION GAS PLANT COMPONENTS & DESCRIPTION:

AIR COMPRESSOR 

Horizontal, Balanced Opposed, Reciprocating, Lubricated, Water Cooled, Double Acting, 4 Stage, Medium Pressure Air Compressor with Separate gauge panel, assembly consisting of Discharge pressure gauges for each stage with Stop Valve, water & Oil Pressure Gauge, Temperature gauges Oil Cut off Switch & fitted with suitable Electric motor.
We Use Ingersoll Rand Make Air Compressor which is World Class Compressors (www.ingersollrand.com) of Best technology & can be serviced anywhere in the world. The Ingersoll Rand reciprocating compressor family has earned worldwide recognition for reliable, trustworthy performance that saves money and enhances business success through:

  • Lower life cycle costs
  • An ability to thrive in punishing applications
  • Configurations that meet varying needs
  • Optimum solutions for greater efficiency

PROCESS SKID

It is Metallic Frame for mounting of After cooler, Moisture separators, cascade Cooler, Chilling Tank, Chillers, Carbon Filer, Alumina Filter, Ceramic Filters, Molecular Sieves battery, Drier Heater, Freon units.
This Metallic Frame is fitted with fourteen equipments as motioned above, all the inter-connecting pipe lines are fabricated, tested, Painted and assembled at Ex Works by Highly skilled , X-Ray Tested welders and supervised and inspected by qualified engineers this eliminates lot of Civil works, connecting & welding at site. This improves the quality and aesthetic look and occupies minimum space with access to maintenance and repairs.

MOLECULAR SIEVE BATTERY/DRIER (SKID MOUNTED)

this consists of 2 Nos. M.S. Vessels inter connected with pipelines of Nitrogen and Air, Electric Heater for Regeneration, Temperature Sensor, Temperature Indicators and this assist in the removal of moisture, Carbon-Di-Oxide, traces Acetylene and other Hydro-Carbons present in the process air. Along with Drier Control MSB Panel, fitted with DUST FILTER, ALUMINA FILTER, CERAMIC FILTER & HIGH EFFICIENCY CARBON FILTER.
  •  We use two columns with molecular sieves to ensure continuous production.
  • Dry compressed air is blown through a valve to the vessel where the pressure is built to reach 40 to 45 bar (g). Nitrogen is tied to a molecular sieve during the building of pressure, and the oxygen is allowed to pass through to the accumulation tank.
  • While pressure is build in one vessel, the second remains without pressure.
  • A part of the produced gas is used for regeneration of the molecular sieve.
For Oxygen, Zeolite type 13X is used. The molecular sieve is fully regenerative and has a life span on to 60.000 operation hours.

DEFROST HEATER

It is a Cylindrical Steel Vessel consisting of Air coil, Electric heater is immersed in Water to operate safely of defrosting Process of the air separation column.

EXPANSION ENGINE

It is a Vertical Single/Double acting, dry running with Hydraulic valve controlled, with safety devices, complete with Flywheel, Pressure Gauges, Motor Pulley, V-Belts, Belt –Guard, Drive Motor, Motor Slide Rails etc.

AIR SEPARATION UNIT (STAINLESS STEEL COLUMN)

Unit consists of lower and Upper Column with a condenser, Heat Exchangers, sub Coolers, Inter-Connected Pipe lines fabricated out of High Quality Stainless Steel by Argon Arc Welding. All these are housed in a steel box, duly insulated with special Quality Powder Perlite and fitted with Expansion Valves, Temperature Sensors and Liquid Level Indicators, Pressure gauges and Safety Relief Valves etc.

Equipments like Heat Exchangers, Column, Condenser Liquid vessels jackets & Inter connecting pipe lines are made of High Purity Stainless steel suitable for Cryogenic process. These are fabricated by special method of TIG & MIG welding. All the parts subjected to heat and cold transfer are fabricated of High Purity copper/stainless Steel. This will avoid internal leakages due to chemical corrosion, Age Hardening of the joining material like Led ALLOY.

LIQUID OXYGEN PUMP

Horizontal Type, Single Cylinder with Fly Wheel, Pressure Gauge, Motor Pulley, V- Belt, Belt Guard, Motor Rail, and Inter Connecting SS Pipes fitted with an electric motor to compress & fill O² gas into cylinders.

LIQUID NITROGEN PUMP

Horizontal Type, Single Cylinder with Fly Wheel, Pressure Gauge, Motor Pulley, V- Belt, Belt Guard, Motor Rail, and Inter Connecting SS Pipes fitted with an electric motor to compress & fill N2 gas into cylinders.

FILLING MANIFOLD for O2/N2

For filling high-pressure gas Oxygen/Nitrogen into gas Cylinders.

ORSAT APPARATUS/ONLINE PURITY ANALYZER

For measuring purity of Gaseous Industrial & Medical Oxygen & Nitrogen Gases.

WATER PUMP

For pumping the cooling water from water tank to cooling tower through Compressor & Other equipment’s of Plant.

COOLING TOWER

Induced Draft-Rotary Sprinkler type with Aluminum Casting Fan, FRP Body with suitable Electric Motor for maintaining the circulating water at minimum temperature for optimum performance of the Plant.

WATER SOFTENER

Used to remove hardness of water and to avoid scaling in Air Compressor Cylinder jacket, in the Coolers and water line.

MSB PANEL

For Controlling the Temperature of Molecular Sieve Battery during regeneration of the molecular sieves.

DISTRIBUTION ELECTRIC PANEL (L T Panel)

to control the electric distribution to different motors & heaters for complete plant.

We supply Electric Distribution Panel (Siemens /ABB) as per the Customers choice.

This new generation of Panel Board products represents the high level of engineering innovation expected. With flexibility and strength added to the existing rugged and durable Panel Board, Panel Boards are extremely easy to install. These newer designs also simplify wiring and reduce material requirements, saving additional installation time. new technology circuit breakers offer significant benefits and better coordination with upstream breakers that help meet 2011 NEC® Code requirements for selective coordination