Introduction:
STAGE 1 – Compression of Air
The free saturated air is drawn from atmosphere through a highly efficient
dry-type Suction Filter into the first stage of the horizontally balanced opposed, lubricated reciprocating air compressor. The air is compressed over a multistage process to the desired air pressure (30-40 bar) and is then sent to the process skid for further use.
STAGE 2- Purification of Air
The compressed air is passed into an after cooler where the temperature is reduced to around 35 degree centigrade after which it is chilled in a
Chilling Unit to a temperature of 12 degree centigrade and then passed through a M
oisture Separator where the condensed moisture gets removed before entering into
Molecular Sieve Battery.
Before sending the air to the Molecular Sieve Battery, air is passed through an
Oil Adsorber where air becomes oil free. Chilled air passes through the Molecular Sieve Battery consisting of Twin Towers packed with
Molecular Sieves to remove moisture and Carbon dioxide present in the air.
Molecular Sieve Battery operates on Twin Tower System. When one tower is under production the, other tower is regenerated by passing waste Nitrogen gas at 200 degree Centigrade through a
Reactivation Heater.
After interval of 8 to 10 hours, the tower under production gets exhausted and is regenerated by similar process before use and thus the cycle continues. Any dust particles gets filtered in the Dust Filter before air enters the
Air Separation Column.
STAGE 3- Air Separation
Chilled, Oil-free and moisture free air enters into multi-pass
Heat Exchanger No. I where it gets cooled to (-80) Degree Centigrade by cold gained from outgoing waste Nitrogen and Oxygen.
A part of this air enters a multi-pass
Heat Exchanger No. II or
Liquefier made of special Alloy tubes. This air cools to (-170) Degree Centigrade before passing through an
Expansion Valve. Due to
Joule Thompson Effect, after the expansion valve, air gets further cooled down and gets liquefied before entering into
Bottom Column after which it comes to be known as
Rich Liquid.
The
Rich Liquid in the
Bottom Column enters into the feed tray of the
top column. Similarly the liquid nitrogen called
Poor Liquid enters into
Top
Column as a reflux & it takes away the heat of condensing Oxygen and gets vaporized whereas the liquid Oxygen flows down the trays of the
Top Column into the
Condenser and then passes through a
Sub-Cooler to a
Liquid Oxygen Pump.
STAGE 4- Gasified Oxygen
In
Gas Plants, the
L.O pump pumps liquid oxygen through
heat exchanger no. I & II, where liquid oxygen gets gasified before filling in
cylinders in the
Filling Manifold.
The pure bone dry oxygen gas at ambient temperature and high pressure is filled into Oxygen Cylinders through
manifold valves by means of the highly efficient reciprocating
Liquid Oxygen Pump.
In
Liquid Plants, the liquid oxygen or nitrogen is filled directly into a
Cryogenic Liquid Tank (capacity of 200 liters to 50,000 liters) where it is stored and used according to requirement.
STAGE 5- Nitrogen Production
Nitrogen can be produced both in gaseous as well as liquid form simultaneously without additional cost. Both commercial as well as technical grade can be produced.
Technical Specifications:
| SMALL CAPACITY |
| S.No. |
Model |
BDM-25 |
BDM-30 |
BDM-40 |
BDM-50 |
| 1 |
Capacity Oxygen |
25CuM/Hr. |
30 CuM/Hr. |
40 CuM/Hr. |
50 CuM/Hr. |
| 2 |
Nitrogen |
80 CuM/Hr. |
100 CuM/Hr. |
150 CuM/Hr. |
200 CuM/Hr. |
| 3 |
Purity
Oxygen
Nitrogen
(Optional up to 99.999%) |
99.6%
96%-96.6% |
99.6%
96%-96.6% |
9.6%
96%-96.6% |
99.6%
96%-96.6% |
| 4 |
Power Connected |
55 KW |
70 KW |
80 KW |
95 KW |
| 5 |
Power Consumed (abt.) |
40 KW |
45 KW |
60 KW |
70 KW |
| 6 |
Power Supply |
415 Volts |
415 Volts |
415 Volts |
415 Volts |
| 7 |
Air Capacity |
150 Cum/Hr |
200 Cum/Hr. |
250 Cum/Hr. |
300 Cum/Hr. |
| 8 |
Starting Pressure |
60 Kg/sq.cm. |
55 Kg/sq.cm. |
55 Kg/sq.cm. |
55 Kg/sq.cm. |
| 9 |
Working Pressure (abt) |
50 Kg/sq.cm. |
40Kg/sq.cm |
40Kg/sq.cm |
40Kg/sq.cm |
| 10 |
Starting Time (After Defrost) |
8 Hours |
8 Hours |
7 Hours |
7 Hours |
| 11 |
Starting Time (After Tripping) |
40 Mts. |
40 Mts. |
40 Mts. |
40 Mts. |
| 12 |
Areas Required |
6M x 8 M |
6 M x 10 M |
8 M x 10M |
8 M x 12 M |
| 13 |
Assembly Height |
7 M |
7 M |
7.5 M |
7.5 M |
| 14 |
Weight (About) |
14 Tons |
16 Tons |
18 Tons |
19 Tons |
| 15 |
Air Separation Column |
Type-BDM |
Type-BDM |
Type-BDM |
Type-BDM |
| MEDIUM CAPACITY |
| S.No. |
Model |
BDM-60 |
BDM-80 |
BDM-100 |
BDM-150 |
| 1 |
Capacity Oxygen |
60 CuM/Hr. |
80 CuM/Hr. |
100 Cum/Hr. |
150 Cum/Hr. |
| 2 |
Nitrogen |
200 CuM/Hr. |
250 CuM/Hr. |
300 Cum/Hr. |
500 Cum/Hr. |
| 3 |
Purity Oxygen |
99.6% |
99.6% |
99.6% |
99.6% |
| 4 |
Nitrogen
(Optional) |
96%-99.99% |
96%-99.99% |
96%-99.99% |
96%-99.99% |
| 5 |
Power Connected |
110 KW |
130 KW |
150 KW |
250 KW |
| 6 |
Power Consumed (abt.) |
88 KW |
95 KW |
105 KW |
165 KW |
| 7 |
Power Supply |
415 Volts |
415 Volts |
415 Volts |
415 Volts |
| 8 |
Air Capacity |
400 Cum/Hr |
400 Cum/Hr. |
600 Cum/Hr. |
900 Cum/Hr. |
| 9 |
Starting Pressure |
45 Kg/sq.cm. |
45 Kg/sq.cm. |
45 Kg/sq.cm. |
45 Kg/sq.cm. |
| 10 |
Working Pressure (abt) |
40 Kg/sq.cm. |
38 Kg/sq.cm |
36 Kg/sq.cm |
36 Kg/sq.cm |
| 11 |
Starting Time (After Defrost) |
8 Hours |
7Hours |
6 Hours |
6 Hours |
| 12 |
Starting Time (After Tripping) |
40 Mts. |
30 Mts. |
20 Mts. |
20 Mts. |
| 13 |
Areas Required |
12M x 15 M |
12 M x 15 M |
14 M x 15M |
14M x 15 M |
| 14 |
Assembly Height |
8.0 M |
9.0 M |
9.5 M |
9.5 M |
| 15 |
Weight (About) |
20 Tons |
25 Tons |
30 Tons |
40Tons |
| 16 |
Air Separation Column |
Type-BDM |
Type-BDM |
Type-BDM |
Type-BDM |
| HIGH CAPACITY |
| S.No. |
Model |
BDM-200 |
BDM-300 |
BDM-400 |
BDM-500 |
| 1 |
Capacity Oxygen |
200 CuM/Hr. |
300 CuM/Hr. |
400 Cum/Hr. |
500 Cum/Hr. |
| 2 |
Nitrogen |
800 CuM/Hr. |
1200 CuM/Hr. |
1400 Cum/Hr. |
2000 Cum/Hr. |
| 3 |
Purity Oxygen |
99.6% 96%- |
99.6% 96%- |
99.6% 96%- |
99.6% 96%- |
| 4 |
Nitrogen(Optional) |
9.99% |
99.99% |
99.99% |
99.99% |
| 5 |
Power Connected |
300 KW |
400 KW |
600 KW |
750 KW |
| 6 |
Power Consumed (abt.) |
220 KW |
330KW |
400 KW |
500KW |
| 7 |
Power Supply |
415 Volts |
415 Volts |
415 Volts |
415 Volts |
| 8 |
Air Capacity |
1200 Cum/Hr |
1800 Cum/Hr. |
2400 Cum/Hr. |
3000 Cum/Hr. |
| 9 |
Starting Pressure |
45 Kg/sq.cm. |
45 Kg/sq.cm. |
45 Kg/sq.cm. |
45 Kg/sq.cm. |
| 10 |
Working Pressure (abt) |
36Kg/sq.cm. |
36Kg/sq.cm |
30Kg/sq.cm |
30Kg/sq.cm |
| 11 |
Starting Time (After Defrost) |
6Hours |
5Hours |
5Hours |
5 Hours |
| 12 |
Starting Time (After Tripping) |
20 Mts. |
20 Mts. |
20 Mts. |
20 Mts. |
| 13 |
Areas Required |
14M x 15 M |
15M x 16 M |
15M x 18M |
18M x 20M |
| 14 |
Assembly Height |
9.5 M |
9.5 M |
10 M |
10 M |
| 15 |
Weight (About) |
50 Tons |
60 Tons |
70 Tons |
80Tons |
| 16 |
Air Separation Column |
Type-BDM |
Type-BDM |
Type-BDM |
Type-BDM |
Salient Features:
-
Available in Leak proof Argon Welded Column.
- Skid Mounted Version
- Low Pressure Technology
- Low Power Consumption
- 24 Hrs Continuous Duty Operation.
- Only One Operator Required To Run The Plant
- Heavy Duty Air Compressor (Water Cooled.)
- Built In Liquid Oxygen/Nitrogen Pump For High Pressure Oxygen/Nitrogen Filling.
- Built In Integral Gas Vaporizer.
- High Efficiency Trays for High Purity
- Extremely Safe To Use And Operate.
- Trouble Free Operation Due To Proven Design and Performance.
- Medical Grade Oxygen as Per American/European Pharmacopeias.
- Molecular Sieves of Zeochem Swiss of Special Grade for Total Carbon Dioxide,
- Moisture and Hydrocarbon Removal.
- Very Compact Design And Easy To Operate.
Scope of Supply:
Air Compressor
This is a multi stage, heavy duty water-cooled air compressor for 24 hours operation , horizontal type complete with fly wheel inter cooler,
foundation bolts, motor pulley, motor, v belt, guard and slide rails. This is used to compress atmospheric air.
Air Purifier/Process Skid
This consists of the following Parts:
- After cooler with tank
- Nitrogen cooler with tank
- Moisture separators
- Chilling units with Freon unit
- Oil absorber filled with alumina
- Molecular sieve batteries on skid
- Defrost heaters
- Gas/Air/water line as per standard layout on skid /platform prefabricated and ready for installation
- Water pump
- Inlet & outlet water lines
- Drain manifold complete with ball valves for draining moisture. All the above equipments are properly mounted on skid /platform complete with interconnecting piping and ready for installation.
Expansion Engine
Complete with branded motor/starter of Siemens / ABB world class quality. Expansion Engine is complete with hydraulic valve control, bursting disc for safety, complete with fly wheel pressure gauge, motor pulley V belt, Belt guard, slide rails inter connected pipes (inlet and outlet)
Air Separation Column - Cold Box
This consist of the complete cold box (outer steel casing) complete with top column, bottom column, condenser, sub-cooler, re-boiler, exchanger 1, exchanger 2, control panel, instruments, pressure gauges, digital automatic temperature scanner withpt-100 sensors, expansion valves, analysis valves, inlet & outlet, air oxygen and nitrogen, gas lines with control valves neatly mounted and firmly fixed on the cold box.
STAINLESS STEEL IS REQUIRED FOR HOSPITAL OXYGEN, FOOD GRADE QUALITY AND ALSO TO MAKE EXPLOSION PROOF.
NOTE: OLD TYPE OF COPPER VESSELS/COLUMNS/TRAYS LIKE CHINESE AND LOCAL TYPE DISCONTINUED 10 YEARS BACK.
Liquid Oxygen Pump
Horizontal single acting pump with Piston, Piston Rings - oil free - Teflon with guide ring, Safety Devices, Non-Return Valves, Motor with Pulley, V-Belts, Belt Guard, Inter Connecting Pipes with ducting to cold box suitable for filling Oxygen
High Pressure Filling Manifold
For filling high-pressure Oxygen to Cylinders. It consists of main High Pressure Isolation Valve and Pigtail filling connection with individual regulation Valve with Pressure Gauge and Safety Relief Valve.
ACCESSORIES (INCLUDED)
(i) Cooling Tower
Induced Draft-Rotary Sprinkler type with Aluminum Casting Fan, FRP Body with suitable Electric Motor for maintaining the circulating water temperature between the Hot well and Cold well for optimum performance of the Plant. Complete in all respects.
(ii) Electrical Panel
Electrical Panel for supply of electric power to individual motors with main MCCB, ampere and volt meter and bus bar. It has a bank of on/off switches and fuses. This enables the Operator to control all the Motors from one point (This can be supplied with remote control operation also).
WATER SOFTENER
Made of HDPE having single multi-port valve for different plant valve for different operations. Used to remove hardness of the water and to avoid scaling in Air Compressor Cylinder jacket and water line. Nacl/Regeneration. With min/max. Working pressure in 2.0/4.0 kgs/cm2. Complete in all respect.
WATER PUMP
Provided with the plant to be coupled with the Air compressor and the cooling tower.
ANALYZER
Oxygen Purity Apparatus will be provided along with to measure the purity of Oxygen.
Applications:
- Water Process
- Ferrous Metallurgy
- Non-ferrous Metal Refinery
- Coal mines
- Pharmacy
- Others: Chemical industry production, solid garbage burning, concrete production, glass manufacturing, medical oxygen, etc.
