Our Oxygen/Nitrogen Plants are available in capacities from 30 to 1000m3/Hr suitable for producing industrial and medical oxygen upto 99.9% purity. Nitrogen is available as a second product from the oxygen plant in approximately four times the quantity of oxygen produced. Standard purity of nitrogen is 96% to 99.5% but are available upto 99.999% also.

Our OXYGEN/ NITROGEN plants are highly efficient Expansion engine and trouble free liquid oxygen pump, which make the plant work on low-pressure cycle resulting in very high efficiency and low power consumption.

Manufacturing Process

1. Compression Of Atmospheric Air By Air Compressor
The free saturated air is sucked from atmosphere through a highly efficient dry-type suction filter into the first stage of the horizontal balanced opposed, lubricated reciprocating air compressor. Compressed air is chilled to 12 degree centigrade in a chilling unit at a temperature of 12 degree centigrade to a moisture separator where the condensed moisture gets removed before entering into Molecular Sieve Battery. Before sending the air to MOLECULAR SIEVE BATTERY, air is passed through an OIL ABSORBER where air becomes oil free.

2. Purification of Air By Process Skid
Chilled air passes through the Molecular Sieve Battery consisting of Twin Tower 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 degC through a reactivation heater. After interval of 8 to 10 hours, the tower under production gets exhausted and 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.

3. Cooling Of Air By Expansion Engine (Expander)
The process air before liquefication in the air separation unit needs to be cooled to temperatures sub-zero (cryogenic). The main portion of the air after the process skid enters the expansion engine through the heat exchanger no. I after pre-cooling. The temperature of the air drops to around -165degC by the Expander which is a very highly efficient advanced design with Teflon piston rings and completely hydraulic mechanism with leakproof ball valves.

Conversion of Liquid Air Into Oxygen And Nitrogen By Air Separation Column
Chilled, Oil free and moisture free air enters into multi-pass HEAT EXCHANGER NO.I where it gets cooled to (-80) degC by cold gained from outgoing waste Nitrogen and Oxygen. A part of air this enters a multi-pass HEAT EXCHANGER NO. II or LIQUIFIER made of special Alloy tubes. This air cools to (-170) degC before passing through an expansion valve. Due to joule Thompson Effect, after the expansion valve, air gets further cooled down and gets liquified before entering into bottom column and is known as rich liquid.

The rich liquid in the bottom column enters into feed tray of top column enters into feed tray of top column. Similarly the liquid nitrogen called POOR LIQUID enters into top column as a reflux & it takes away the latest heat of condensing Oxygen and gets vapourised whereas the liquid Oxygen flows down the trays of the top column into the Condenser passes through a Sub-Cooler to a LO Pump.

4. Compression/Withdrawal And Filling Of Oxygen And Nitrogen
Liquid oxygen pump pumps Liquid Oxygen through heat exchanger no. II and I, 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 LO pump.

Scope of supply
Our oxygen/nitrogen plant has been supplied as a complete package including the following.
1. Suction Filter
High efficiency filter supplied with the compressor

2. Air Compressor
This is a multistage heavy duty water cooled air compressor with fly wheel inter cooler, foundation bolts, motor pulley, v belt, guard and slide rails and air filter. This is used to compress atmospheric air complete with motor and Starter.





3. Process Skid: Consisting of the following

After cooler with tank Nitrogen cooler with tank Moisture separator Chilling unit with freon unit Oil absorber filled with alumina Molecular sieve battery on skid Defrost heater

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

4. Expansion Engine
Complete with motor and starter with hydraulic valve control, bursting disc for safety, complete with flywheel pressure gauge, motor pulley v belt, belt guard, slide rails inter connected copper pipes (inlet and outlet) hydraulically operated high efficient engine with ball type of valves stainless steel liner vertical type of German Design.

5. Air Separation Unit (Cold Box)
This consists of outlet steel casing, main heat exchanger, liquefier, bottom column, top column, top column, condenser, sub cooler, liquid oxygen and nitrogen filter. Cooling pipe line, insulation material, digital electronic temperature indicator and scanner, PT 100 sensor, DP gauge manometer, expansion valve.

6. High Pressure Filling Manifold
For filling high-pressure oxygen to cylinders. It consists of main high pressure isolation Valve and Pigtail connection with individual industrial regulation valve with pressure gauge and Safety Relief Valve.

7. Liquid Oxygen Pump
Horizontal single acting pump with piston, piston rings, Safety devices, Non-Return Valves with Stainless Steel Head for long life, Motor and Starter with Pulley, V-Belts, Belt Guard, Inter connecting pipes with A.S.U. suitable for filling oxygen.

8. Cooling Tower
Induced Draft-Rotary Sprinkler type with Aluminium 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.

9. Electrical Panel
For supply of electricity to individual motors. With overall size of 1200W x 500D x 1550 Ht. It has a bank of on/off switches and fuses. This enables the Operator to control all the Motors from one point.

10. Water Softener (optional)
Made of HDPE having single multiport 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.

Note

1. Capacity of Cylinders: 5m3 and 6m3
2. The above product capacities are based on ambient conditions of 15degC temperature 760mm of Hg pressure and 50% relative humidity and 0.03% of Carbon Dioxide is allowed as impurity.

Optional

1. High purity of Nitrogen PPM grade can also be tapped simultaneously with additional liquid nitrogen pump
2. Higher capacities above 600 m3/hr can also be furnished upon request
3. Filling station for Nitrogen can also be provided at extra cost