ACETYLENE PLANTS

BDM Cryofusion & Mandressi ITALIA is one of the Leading Manufacturers of Air Separation Plants with Société Générale de Surveillance (SGS) quality approval and ISO 9001:2000 certification.

We are manufacturers of Latest Low Pressure Air Separation Plants of the Brand Cryofusion and Mandressi Italia and employ the latest Low Pressure Turbo Technology Series Air Separation Plants of Cryofusion and Mandressi operating at a working pressure of 6 to 8 bar.

Our company uses Rotary Screw type Air Compressors of Atlas Copco and a very efficient Air Separation Column (Cold Box) for achieving 99.9% yield to give a waste Nitrogen purity of nitrogen gas at the outlet of the cold box as low as 3 Parts per million.

We along with the team of cryogenic engineers of Cryofusion and Mandressi Italia have more than 50 years of experience in the field of Design, Manufacturing, Installation and Commissioning of all types of Oxygen - Nitrogen Air Separation Plants all over the world with a vast range capacities from 20 m3 per hour to 20,000 m3 per hour.

Acetylene (C2H2), a compound of carbon and hydrogen, is a colorless, highly flammable gas. It is slightly lighter than air and has a garlic-like odor. Acetylene is stored in high pressure cylinders filled with a porous material and contains acetone, into which the acetylene is dissolved.

Unless it is dissolved in a solvent, acetylene will dissociate at pressures above 15 psig and form lamp black and hydrogen. Heat is generated with dissociation, which in turn, produces a danger of explosion. Acetylene is manufactured by the reaction of water with calcium carbide. It is also manufactured by thermal cracking of hydrocarbons, or by partial combustion of methane and oxygen.


Acetylene has become increasingly prominent as a raw material for a whole series of organic compounds, among them Acetaldehyde, Acetic gas, and Acetic Anhydride. The remaining 20% of the acetylene production is principally used for oxy-acetylene cutting, heat treating, and welding.

The acetylene plant is fully automatic and all the operations are performed automatically by pneumatically controlled valves along with highly accurate sensors and temperature controller imported from USA.

Acetylene is generated as a result of the chemical reaction between the calcium carbide and water. The by-product calcium hydroxide is discharged automatically from the generator. Acetylene gas burns along with oxygen as a cutting & welding torch and it provides the highest temperature of any known oxygen gas mixture.

Acetylene has become increasingly prominent as a raw material for a whole series of organic compounds, among them Acetaldehyde, Acetic gas, and Acetic Anhydride. The remaining 20% of the acetylene production is principally used for oxy-acetylene cutting, heat treating, and welding.

The acetylene plant is fully automatic and all the operations are performed automatically by pneumatically controlled valves along with highly accurate sensors and temperature controller imported from USA.

Acetylene is generated as a result of the chemical reaction between the calcium carbide and water. The by-product calcium hydroxide is discharged automatically from the generator. Acetylene gas burns along with oxygen as a cutting & welding torch and it provides the highest temperature of any known oxygen gas mixture.

Process Description

Specification	For 15 Cu.m/Hr Acetylene Plant	For 25 Cu.m/Hr Acetylene Plant	For 50 Cu.m/hr Acetylene Plant	For 100 cu.m/hr Acetylene Plant
Capacity	15 Cum/Hr of Acetylene	For 25 Cum/hr of Acetylene	50 cu.m/Hr of Acetylene	100/Hr cu.m of Acetylene
Cylinders filled per batch	20	30	60 cylinders	120 cylinders
Carbide size	4-25mm	4-25mm	4-25 mm (or higher)	4-25mm (or Higher)
Hopper Capacity	75 Kg	100 Kg	150 kg	300 kg
Carbide required per batch	400 kg approx.(depending on carbide quality)	600 kg approx.(depending on carbide quality)	1,200 kg approx.(depending on carbide quality)	2700 kg approx. (depending on carbide quality)
Water required	10 liters per kg of Calcium Carbide used	10 liters per kg of Calcium Carbide used	10 liters per kg of Calcium Carbide used	10 liters per kg of Calcium Carbide used
Power required	10kw	12kw	18 KW	30 KW
Start up time	15 minutes	15 minutes	15 minutes	15 minutes
IIS/BS. Specifications Conforms to - Acetylene Generator" - Flame-proof motors	IS 8471-1977 IS 2148 (Group II-B)-1968 As amended	IS 8471-1977 IS 2148 (Group II-B)-1968 As amended	IS 8471-1977 IS 2148 (Group II-B)-1968 As amended	IS 8471-1977 IS 8471-1977 IS 2148 (Group IIB-1968 as amended)
Space Requirement 1. Process Area	50 Sq. M	70 Sq.M.	110 Sq.M	150 Sq.M
2. Carbide Storage Area	60 Sq. M	75 Sq.M.	112 Sq.M	175 Sq.M.
3. Cylinders filling Area	30 Sq.M	40 Sq.M.	60 Sq.M	100 Sq.M.
4. Cylinders storage area (depending upon cylinders inventory)	80 Sq.M	100 Sq.M.	160 Sq.M	200 Sq.M.
5. Lime slurry disposal area	80 Sq.M	100 Sq.M.	180 Sq.M	250 Sq.M.
6. Free space around the plant (on all sides)	15 M	16 M	18.5 M	20 M
7. Acetone godown	10 Sq.M	12 Sq.M.	20 Sq.M	30 Sq.M.

S No.	Qty.	Main Components	Description
1.	One	CARBIDE HOPPER	Fixed as a part of the Acetylene generator and used for carbide charging.
2.	One	ACETYLENE GENERATOR	Stationary medium pressure Generator
3.	One	CONDENSER	Used in the process as a part for the complete condensation of the flow mixture.
4.	One	PRE-COOLER	M. S. Vessel with tube arrangement for cooling Gas
5.	One	LOW PRESSURE DRIER:	Vertical M.S. Vessel fitted with Half Circle perforated M.S. Plates filled with one charge Hydrous Calcium Chloride
6.	One	ACETYLENE PURIFIER:	Large vessel divided into two section wire mesh frame work. The inside of vessel is coated with Chlorinated Rubber Paint as anti-corrosive measure. Each section is charged with f Purifying Mass to absorb gases like Hydrogen Sulphide, Phosgene, etc.
7.	One	AMMONIA WASHER:	Vertical vessel fitted with Level Gauge and Water Make Up Line. The Acetylene Gas is bubbled in the vessel to: to scrub water soluble impurities like Ammonia To facilitate compression of Acetylene Gas by making it wet.
8.	One	ACETYLENE COMPRESSOR	Compressor of rated capacity (Three Stage Type), Normal Reciprocating Piston Type, Oil Lubricated water submerged with Safety Valves, Pressure Gauges, Moisture Separators, Flame Proof Motor with Pulley, V-Belts and Belt Guard, Pneumatically Pressure Controlled). All three stages of the Compressor are provided with a Pressure Gauges to monitor the inter stage pressure.
9.	One	BATTERY OF HIGH PRESSURE DRIERS	It is filled with Anhydrous Calcium Chloride and with Non-return Valve and Pressure Regulating Valve & it consists of three columns. The First Column is fitted with M.S. chain Packing to avoid any void. The Second and Third Columns are fitted with two capsules each and are fitted with a Drain Valve to drain off moisture collected at the bottom periodically.

10.	One	ACETYLENE CYLINDER FILLING STATION	Manifold for filling cylinders each complete in all respects fitted with Filling Connections, Flash Back Arrestors, Pressure Gauge and Non-return Valves, Stainless Steel Braided Teflon loose connection with Brass Bull Nose and Brass Nut.
11.	One	MOTORIZED ACETONE PUMP:	Rotary Gear Pump made of Stainless Steel fitted with 0.5 HP flame Proof Motor for filling Acetone into Cylinders.
12.	One	ACETYLENE GAS LINES	Complete set as per our standard layout for Low and High Pressure with complete fittings. M. S. Seamless Sch. 40 Pipes for High Pressure Line Galvanized Iron ‘C’ Class heavy Duty Pipes for Low Pressure.