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Dissolved Acetylene Gas Plant

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Dissolved Acetylene Gas Plant We manufacture Dissolved Acetylene Gas Plants in strict conformation to international quality norms and standards. The designs and drawings of the plants are pre-approved by the Chief Controller of Explosives. Our plants are developed under strict supervision of our experts and bear the ISI quality marking. We have equipped the plants with automatic controls for feeding water, maintaining temperatures and pressures. The slurry drains of the plants are carefully designed to make them fool-proof and highly efficient in accordance with international standards.

Special Features
  • No bulky gas holder required
  • Excellent absorption of gas in cylinders
  • No gas loss resulting in high yield
  • Simple and safe to operate
  • Low power consumption
  • Low maintenance cost
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The plant includes the following :
Acetylene Generator: The Acetylene Generator offered by us has gained appreciation for advanced design, fully automatic and superior features. The generator makes use of pneumatically controlled valves and highly sensitive sensors work in tandem with temperature control instruments to perform different operations. This results in opening of water inlet or residue drain valve. The supply of Calcium Carbide, fed into the generator b screw-feed conveyors is controlled by two hydraulic pumps. To ensure optimum safety and ease of operation, the screw-feed mechanism and agitators are operated by flame-proof motors and fittings. Perfect synchronization and simplicity of operation is essential to achieve excellent output and efficiency. The generator signals failure of power, water or air supply visually or through an alarm bell to alert the operator.

Requirements of the generator include:
  • An acetylene plant can only be fitted with flame proof lights & electrical fittings according to 152148-68 (group II) or 655-229
  • Acetylene cylinders must be of specification 15: 7312: 1974 or ICC: 8

Temperature Control : The Acetylene generator is equipped with temperature control system to enable the user to set and operate the plant at a specific temperature. This can be done regardless of the temperature of the cooling water and size of carbide used. To maintain a standard temperature, a sensor activates pneumatic control which adds water into the generator tank if the set temperature limit is exceeded. Owing to this, the generator is able to completely utilize Carbide which is an expensive raw material.

High Pressure Control : The gas pressure in the generator is bound to increase in case the compressor is of low capacity or the rate of production is faster than rate of absorption. If the gas pressure reaches a predetermined level of about 0.5 kg/cm2, the generator automatically cuts off carbide charging and stops the production process. Once the generator has been cleansed with Nitrogen, the generator will maintain a constant positive pressure and inhibit entering of air into the system. This also helps to reduce the pumping cost and make the plant extremely safe for the operator.

Water Level Control : In case the water level in the generator exceeds the high level mark, the water level control instrument will instantly discharge excessive water. The system gets activated when the level of water goes below or above the prescribed limits
No Loss-Carbide charge : To prevent loss of gas or wastage while the carbide is being charged, a high pressure hydraulic operated valve cuts off the section from the generator. This is an automatic procedure and does not require operator’s attention.

Condenser : Condenser performs the function of cooling the produced acetylene gas carrying water vapor and impurities. The condensation results in removal of excessive moisture and impurities. To perform this operation, the condenser has appropriate proportions suiting local conditions and efficient in order to assure complete cooling.

Low Pressure Drier : Low pressure drier is charged with Calcium Carbide to absorb the moisture in the generated gas. If the chemical purifier requires a certain amount of moisture to function effectively, a by-pass can be provided to allow direct admission of the generated gas partly or wholly.

Chemical Purifier : Chemical purifier utilizes two layers of regenerative chemicals for removing impurities. The purifying agent can be reactivated for re-use with the help of atmospheric air. Also, to ensure continuous operation an extra charge of chemicals can be kept in open wooden trolleys.

Water Scrubber : In order to remove impurities from the gas efficiently, water scrubber is installed between the chemical purifier and acetylene compressor.

Acetylene Compressor : The generator utilizes reciprocating, oil lubricated, multi-stage, water submerged with intercoolers and an I.R. made compressor for filling the cylinders. The compressor features safety relief valve for each stage and is driven by a 15 H.P flame proof motor which conforms to IS: 2148-68 (Gr.II-B).

High Pressure Drier : High pressure drier works on a battery of three high-pressure vessels. The first vessel is filled with Anhydrous Calcium Chloride, High Pressure Drier: High pressure drier works on a battery of three high-pressure vessels. The first vessel is filled with Anhydrous Calcium Chloride,

Filling Manifold : This consists of a battery of filling connections, which is used to connect to the gas cylinders. Also, non-return valves are used to adjoin various sections of the pipeline to the filling manifold.

To ensure optimum safe operation of the plant, these non-return valves should be checked from time to time. Also, the manifold should be periodically checked and cleaned to remove rust and scales which can prove to be a serious security hazard. The flexible hose pipes of the cylinders should also be regularly checked and cleaned to prevent them from bursting during the filling operation due to sudden discharge of Acetylene.

Instrument Air Compressor
Instrument Air Compressor is used in the flameproof motor with a buffer tank. Detailed specifications of the compressor are as follows:
BIS Specifications
A) Acetylene Generator IS 8471 (PT -4) 1977
B) Flame Proof Motors IS 2148 (Group II-B) -1968
Statutory requirement of distance as per Explosive Dept. Acetylene Plant and Carbide go down Should be: 9 meters from time pits. 15 meters from public road. 15 meters from Electricity room. 30 meters from any other bldg 90 meters !tom Oxygen Plant Air intake point Acetone go down of 2,500 Litres capacity should be 6 Meters from any other premises.
Power Supply 440 Volts/ 3 phase/50 hertz. (If your supply is different from this please specify.)

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