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Oxygen Gas Plant

Special Features Process Description Product Data Technical Specification Photo Gallery

We hold expertise in fabricating Oxygen Gas Plant. The Oxygen Gas Plants are carefully designed to produce pure Oxygen Gas concurrently with oxygen gas. The plants use an Expansion Engine and a special by-pass valve to enable rapid and adequate cooling. These features make the plants exceedingly stable and economically viable for the user. For full proof temperature indication, the plant uses electronic system scanner. Also, the system utilizes pressure differential gauges with stainless steel control panel to accurately indicate liquid level producing liquid oxygen gas. Further, the plant has been insulated by Perlite power to avoid cold losses. We have equipped our plants with 4-stage heavy duty air compressor, to utilize the power supplied by a diesel generator or normal power supply of 415/440 V-50 cycle. Our scope of supply also includes an industrial refrigerator/chilling plant with an air-cooling facility before and after the drier battery. To make the liquid pumps safe for pumping oxygen, the pumps come with non-lubricated cross head. Our plants have been appreciated for enabling minimum wastage of oxygen through waste nitrogen to ensure optimal production.

Special Features of Oxygen/Nitrogen Gas Plant
  • Low power consumption
  • Liquid Nitrogen withdrawal facility
  • Single pump for filling Oxygen as well as Nitrogen
  • Separate Nitrogen pump
  • No bulky gas holder required
  • Low maintenance cost
  • Safe and easy to operate
  • On-line oxygen purity analyzer
  • Facility for PPM grade of dry Nitrogen Gas
Oxygen Gas Plant
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Process Description of Oxygen/Nitrogen Gas Plant:

Oxygen and nitrogen can be separated from the atmospheric air because of different boiling points which enables easy distillation through fractional column. A multi-stage compressor sucks-in atmospheric air which is then compressed to a desired pressure. To remove CO2, hydrocarbons and moisture from the processed air, the compressed air is then passed through inter-coolers, industrial refrigerator, moisture separators, and molecular sieve battery. This purified air is then cooled by the Nitrogen and Oxygen in the 1st heat exchanger. Some of this cooled air is then passed through the expansion engine and other part goes through the heat exchanger. In both the places, the air is further cooled down to liquid state and released at the bottom of the column through an expansion valve.

The column has been segregated into two parts lower column and upper column along with a condenser in between. This condenser acts as a reflux for the lower column and a re-boiler for the upper. The liquid air in lower column separates through the trays producing crude oxygen and 90% pure nitrogen. The crude oxygen collected at the bottom is also called rich liquid and is then expanded using expansion valve. Due to difference in the boiling points, pure nitrogen boils and gets accumulated at the top of the upper column whereas oxygen collects at the bottom of the upper column.

To cool the incoming air, the released nitrogen and oxygen are removed through a separate path in the heat exchanger. The released oxygen is then compressed to a prescribed pressure by a liquid pump to be directly filled into cylinders. At the same time, Nitrogen is compressed to a pressure of almost O.5kg/cm2 which can then be compressed into cylinders using independent high-pressure compressors.

To fill Nitrogen into cylinders for commercial use, a change in the valve setting is made so as to make the mixed air chamber operative which in turn facilitates better control of the plant. The plant also facilitates filling and withdrawal of liquid Nitrogen gas (PPM Grade).

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List connected load for KVK Oxygen / Nitrogen gas Plants

  80 M3/Hr 100 M3/Hr 130 M3/Hr 170 M3/Hr 200 M3/Hr 300 M3/Hr
Name of the Unit Motor Capacities
Air Compressor Motor 150 HP 180 HP 180 HP 240 HP 300 HP 425 HP
Expansion Engine Motor 10 HP 10 HP 10 HP 20 HP 20 HP 20 HP
Chilling Plant Motor 3 HP 5 HP 5 HP 7.5 HP 7.5 HP 7.5 HP
Water Pump Motor 5 HP 5 HP 5 HP 7.5 HP 7.5 HP 10 HP
Cooling Tower Motor 3 HP 5 HP 5 HP 5 HP 7.5 HP 7.5 HP
Liquid Oxygen Pump Motor 3 HP 5 HP 5 HP 7.5 HP 7.5 HP 7.5 HP
Liquid Nitrogen Pump Motor (Optional) 3 HP 3 HP 3 HP 3 HP 3 HP 5 HP
Defrosting Heater 9 KW 9 KW 9 KW 9 KW 9 KW 9 KW
Molecular Battery Heater 15 KW 18 KW 18 KW 18 KW 30 KW 48 KW
Cooling Tank Water Pump .5 HP .5 HP .5 HP .5 HP 1 HP 1 HP
Nitrogen Blower 3 HP - - - - --

Hydrostatic Cylinder Testing Station

Essentially, the cylinders are made of a material that has a flexibility of expansion and contraction during pressurization. For various reasons this flexibility of expansion and contraction begins to deteriorate over a period of time. Similarly, on account of other conditions such as filling, handling, transportation and shop floor conditions, there a hydraulic testre chances of weight reduction over a period of time. It may also develop certain other defects normally rendering a cylinder unsafe for use. Globally such cylinders are required to be periodically tested for visual damages, weight loss and loss of elasticity.
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In view of the dimension of damage, which can be caused by a bad cylinder, being known, most people prefer to test these high-pressure cylinders periodically and is a mandatory requirement for safety.

We provide a complete set-up of equipment for conducting a dependable and assured Hydraulic test for such cylinders, with hydrostatic cylinder test systems.

Expansion Engine

Expansion Engine
The Expansion Engine is vertical, single acting, triple expansion engine, reciprocating type. This produces the cold required for the plant. High- pressure air enters through inlet valve at the start of downward stroke of the piston. On further downward motion, the inlet valve closes and entrapped Air expands. During upward stroke, outlet valve remains open and inlet valve remains closed. Therefore, in downward stroke Air enters the cylinder and expands. In the upward stroke the expanded air is pushed outside. The electric Motor is used to start the machine.
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Thereafter the Engine is moved by the Air pressure itself and during which time, the Engine motor retains the speed by acting as a brake. Since work is done by Air in rotating the flywheel, it loses itsexpansion engine manufacturer heat content (enthalpy), thus the Air gets cooled. This cooling is more than that of an expansion in an Expansion Valve.

An elementary factor for the function of an Expansion Engine is to use dry and carbon Dioxide free Air, as otherwise, ice and dry ice will form on valve seats, causing mal-function. The approx. temperature drop across Expansion Engine is 50 to 70°C, depending on inlet air pressure, temperature and inlet cam position.

The Expansion Engine manufacturer consists of three major units.
  • The drive unit
  • The cylinder unit for Air expansion
  • The Hydraulic system for operating the valves

The Hydraulic system is the control system. The Hydraulic oil is fed by a pump to:
  • Pressurized oil container for valve actuation.
  • Lubricate crankshaft and drive and drive unit parts .
  • Lubricate the rolled holders .

Technical Data
Specifications 80/100/130 M3/Hr Oxygen Plant 170/200 M3/Hr Oxygen Plant
Type of Expansion Engine Vertical Single Acting Vertical Single Acting
Diameter of cylinder bore 90 mm 80 mm each
No. Of Cylinders 1 2
Piston stroke 150 mm 125 mm
Speed of Engine 200 RPM 200 RPM
Inlet valve opening time cam setting 8 positions 8 positions
Electric Motor 10 HP / 1000 RPM (TEFC) 20 HP / 1000 RPM (TEFC)
Piston head clearance 1.2 /- 0.2 mm 1.2 /- 0.2 mm
Inlet valve pastel clearance 0.4 to 0.5 mm 0.4 to 0.5 mm
Inlet air pressure 60 kgs/cm2g 60 kgs/cm2g
Outlet air pressure 5 kgs/cm2g 5 kgs/cm2g
Throughput volume at 40 kgs/cm2 400 Nm3 / hr. 700-800 Nm3 /hr

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Special Features Process Description Product Data Technical Specification Photo Gallery

Product Range
Oxygen Gas Plant | Nitrogen Gas Plant | Dissolved Acetylene Gas Plant | Nitrous Oxide Plant
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