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.
The Tonnage Series of Oxygen/Nitrogen Plants are designed for the applications that require large amount of oxygen and to replace bulk liquid oxygen storage vessels.
The output of Liquid Oxygen can be stored in a liquid oxygen tank. Liquid Nitrogen can be available as a by product simultaneously up to 99.999% (PPM GRADE) purity.
The plant is extremely versatile and all the possible product variants are possible You can either take 100% Liquid oxygen out put or 50% Liquid oxygen output directly into cylinders or 50% Liquid oxygen and 50% Liquid nitrogen.
Tonnage Plants can be designed for covered (standard) as well as outdoor installations.
These plants are PLC controlled, inclusive of oxygen analyzer.
Process Description
1. Compression of Air
This is done by the multistage highly efficient air compressor.
This is a water-cooled, balance opposed oil lubricated, heavy duty 24 hours continuously operating four stage machine.
It also composes of horizontal rugged inter-coolers to give normal discharge conditions.
The Compressor can be single frame primary as well as secondary equipment.
The multi Stage Composition improves the volumetric efficiency of the compressor and reduces B.H.P.
The inter stage temperature is low and therefore carbon formation is nil.
2. Purification of Air
This is done by the Process Skid.
The Process Skid comprises of the following components.
- After Cooler with Tank.
- Nitrogen Cooler with Tank.
- Moisture Separator (Purger).
- Chilling Unit with Freon Unit.
- Oil Absorber filled with Alumina.
- Molecular Sieve Battery on skid.
- Defrost Heater.
- Gas/Air Lines as per standard Layout on skid/platform.
- Water Pump.
- Drain Manifold complete with Ball Valves for draining moisture.
3. Cooling & Liquification of Air
This is done by a highly efficient expansion engine and also by a refrigeration unit (for 100% liquid output).
Expansion Engine
Single cylinder expansion engine, hydraulically operated with variable cam for automatic control of pressure and temperature, this is also equipped with ball type valve at inlet and outlet which is proof for trouble free operation for years together complete with electric motor.
4. Air Separation (Rectification)
This is done by the special AIR SEPARATION UNIT consisting of upper & lower column and special exchangers. The separation air is by the CRYOGENIC PROCESS. The final product from a liquid Oxygen/Nitrogen goes to the storage tank.
Air Separation Column (cold Box)
(Leak proof Stainless Column)
Supplied as packed unit consisting of the following components:
- Outer Steel Casing
- Main Heat Exchanger
- Bottom Column
- Top Column
- Liquid Oxygen & Nitrogen Filter
- Instrumentation
- Cold Pipe Lines
- Insulation Materials
5. Liquid Oxygen Pump
There is one liquid pump, namely for oxygen. The oxygen is being pumped in liquid form and thus eliminated unnecessary equipment such as gasholders and Oxygen compressor.
This pump has special design with SS jacket Argon welded with special jacket for insulation to avoid cold loss during pumping.
It has a special seal to prevent any oil carry over during operation. The oxygen purity is high and is bone-dry because this has been provided with special types of seals designed specially for this purpose complete with electric motor vee belts, fly wheel, pulley and guard.
6. Cryogenic Storage Tanks
Cryogenic Vessels are designed for storage and transport of liquid gases at sub-zero temperatures.
Manufacturing of such cryogenic tanks requires special technical know how and sophisticated fabrication techniques.
We have developed the necessary technology and have been manufacturing these cryogenic equipment like cryogenic vessels.
Technical Specifications
| Small Capacity Plants |
| S.No. |
Model |
BDM-T20 |
BDM-T30 |
BDM-T40 |
BDM-T50 |
| 1 |
Capacity |
|
|
|
|
| 2 |
Oxygen |
20 Ltr/Hr. |
30 Ltr/Hr. |
40 Ltr/Hr. |
50 Ltr/Hr. |
| 3 |
Nitrogen gas at outlet cold box |
80 Ltr/Hr. |
100 Lt r/Hr. |
150 Ltr/Hr. |
200 Ltr/Hr. |
| 4 |
Purity |
|
|
|
|
| 5 |
Oxygen |
99.6% |
99.6% |
99.6% |
99.6% |
| 6 |
Nitrogen (Optional) |
96% to 99.99% |
96% to 99.99% |
96% to 99.99% |
96% to
99.99% |
| 7 |
No. of Cylinders in a day |
60 |
100 |
150 |
200 |
| 8 |
Air Separation Column |
Type-BDM |
Type-BDM |
Type-BDM |
Type-BDM |
| Medium Capacity Plants |
| S.No. |
Model |
BDM-T60 |
BDM-T80 |
BDM-T100 |
BDM-T150 |
| 1 |
Capacity |
|
|
|
|
| 2 |
Oxygen |
60 Ltr/Hr. |
80 Ltr/Hr. |
100 Ltr/Hr. |
150 Ltr/Hr. |
| 1 |
Nitrogen gas at outlet cold box |
200 Ltr/Hr. |
250 Ltr/Hr. |
300 Ltr/Hr. |
500 Ltr/Hr. |
| 3 |
Purity |
|
|
|
|
| 4 |
Oxygen |
99.6% |
99.6% |
99.6% |
99.6% |
| 5 |
Nitrogen (Optional) |
96% to 99.99% |
96% to 99.99% |
96% to
99.99% |
96% to
99.99% |
| 6 |
No. of cylinders in a day |
240 |
300 |
400 |
600 |
| 7 |
Air Separation Column |
Type BDM |
Type BDM |
Type BDM |
Type BDM |
| Large Capacity Plant |
| S.No. |
Model |
BDM-T200 |
BDM-T300 |
BDM-T400 |
BDM-T500 |
| 1 |
Capacity (ltr/hr) |
|
|
|
|
| 2 |
Oxygen |
200 Ltr/Hr |
300 Ltr/Hr |
400 Ltr/Hr |
500 Ltr/Hr |
| 3 |
Nitrogen gas at outlet cold box |
800 Ltr/Hr |
1200 Ltr/Hr |
1400 Ltr/Hr |
2000 Ltr./Hr |
| 4 |
Purity |
|
|
|
|
| 5 |
Oxygen |
99.6%
|
99.6% |
99.6% |
99.6% |
| 6 |
Nitrogen liquid (Optional) |
96% to 99.99% |
96% to 99.99% |
96% to 99.99% |
96% to 99.99% |
| 7 |
Air Separation Column |
Type BDM |
Type-BDM |
Type-BDM |
Type-BDM |
Salient Features
Turbo expanders (Oil or Air Bearing) for trouble free operation..- All plants use “Oil free” rotary centrifugal oil compressor working between 0.6 to 1.0 mpa.
- Integrated Oxygen Analyzer.
- Electronic Auto Drains.
- Dew Point Analyzer.
- All Electrically sensitive equipment is individually fuse protected.
- Less stress on Molecular sieve due to internal screen design.
- Power surge protected.
- Superior Filtration Package.
- Air treatment Package mounted on a common skid for ease of installation.
- Electronic Capacitive Sensor is fitted to all filters.
- Purity of Oxygen produced from all plants is minimum 99.6% and Nitrogen Purity is available up to 99.99% (Depending upon requirement of the customer).
-
All plants incorporate Aluminum Brazed exchangers and packed columns for high efficiency.
-
All plants above “500” are supplied with automatic PLC control.
- All Filters have Liquid Level site glass and D/P Gauges.
- Electronic Liquid Moisture alarm fitted to PSA (Shutdown alarm).
- Smaller footprint and easier installation Dual PSA Skid makes for.
- Superior Stainless Steel valve design for lower maintenance.
- Superior Valve Actuators for lower maintenance.
- Easy access to components.
- Engineering support along with complete quality control is provided by our company.
-
We provide qualified engineers for Supervision, Installation and start up of all our plants as well as training of manpower at customers’ site.
-
Very low power consumption with proven performance and virtually Zero maintenance required for the machines.
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.
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.
