Universal is a certified ISO 9001:2000 organization and the latest achievement includes the successful approval for CE certification which makes our company the first in Asia to be certified for Cryogenic Pressure vessel exports to Europe and USA. Among our vast range of Products, the details for the small & medium & “Tonnage series” of oxygen nitrogen filling plants and cylinder filling oxygen nitrogen plants are given below. Turbo plants due to unique features incorporating low pressure machinery has no capacity limitations or restrictions like Medium & High pressure plants.

Capacities: Plants are available from 50m 3/hr upto 50,000m 3/hr Oxygen or nitrogen gas.

Cylinder filling: oxygen-nitrogen gas can be filled in the cylinders as per the cylinder filling chart given below

Model (O2/N2)	UBT -40 /50	UBT -60 /80	UBT -80 /100	UBT -100 /150	UBT -120 /150	UBT -130 /160	UBT -150 /200	UBT -170 /200	UBT -200 /220
Oxygen Capacity Nm3/hr	40	50	80	100	120	130	150	170	200
Nitrogen Capacity Nm3/hr	50	80	100	150	150	160	200	200	220
No of O2 cylinders per day (150 BAR*)	160	240	320	400	480	520	600	680	800
No of N2 cylinders per day (150 BAR*)	200	320	400	600	600	640	800	800	880

Model (O2/N2)	UBT- 220 /220	UBT- 300 /300	UBT- 350 /350	UBT- 400 /400	UBT- 500 /500	UBT- 600 /600	UBT- 800 /800	UBT- 1000 /1200
Oxygen Capacity Nm3/hr	220	300	350	400	500	600	800	1000
Nitrogen Capacity Nm3/hr	220	300	350	400	500	600	800	1200
No of O2 cylinders per day (150 BAR*)	880	1200	1400	1600	2000	2400	3200	4000
No of N2 cylinders per day (150 BAR*)	880	1200	1400	1600	2000	2400	3200	4800

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Universal Boschi(Italy) is a reputed manufacturer / exporter and supplier of Oxygen Nitrogen Filling Plants and Low Pressure Cylinder filling Oxygen Nitrogen Plants with a range of 20 cum/h to 50,000 cum/hr and following are the specifications for the same:

Models	UBT SERIES (CYLINDER FILLING PLANT) UBT40, UBT80, 100, 120, 150 , 180, 200, 220, 250, 300, 350, 400, 500, 600, 800 & 1000.
Oxygen production
Oxygen Output (cu. Mtr/hr)	40 TO 1000m3/hour
Oxygen Purity (%)	99.60%
Oxygen Pressure  (normal)	0.1BAR (0.01MPA)
in cylinders	150 Bar (15MPA)
Nitrogen production
Nitrogen Pressure out of Column (bar)	5 bar( UPTO 150 BAR OPT.)
Nitrogen Output (cu. Mtr/hr)	40 to 1000 m3/hr.*
Nitrogen Purity (ppm optional)	99.9% to 99.99/3ppm opt.
Nitrogen filling in cylinders(optional)	150 bar(kg/cm2)
Type
Operation Pressure (bar)	7 bar(kg/cm2)
Operation Period	24 hours -continuous
Air compressor	Rotary/screw - Oil free Piston - Centrifugal
Expander	turbo expander (turbine)
Downtime for repair	Very low due to screw compressor and low working pressure there are no leakages.
Air separation unit	High yield >99%
Exchanger efficiency(plate fin type)	Very high
Oxygen & nitrogen production	Simultaneous (no loss of oxygen)
Power
Connected	AS PER CAPACITY
Consumed( abt.)	AS PER MODEL
Specific power per m3 of oxygen	UPTO 0.6 UNITS DEPENDING ON CAPACITY
Specific power per m3 of oxygen +nitrogen(pure)	0.4kwh(units)
Voltage 3 phase**	380-415 50/60 hz

This is a multistage machine, balance opposed oil lubricated, water-cooled heavy duty designed for 24 hours continuous operation ,horizontal with rugged inter coolers to give normal discharge conditions. This can be single frame or a primary and secondary compressor. The increased no. Of stages improves the volumetric efficiency of the compressor and reduces B.H.P. The inter stage temperature are low and therefore no carbon formation.

Air Filter (Part of Air Compressor):
Dry type provided by the air compressor
manufacturer.

Process Skid Comprising Of The Following:

After Cooler with Tank:
Air coils with M.S. Tank to cool air after the Air Compressor

Nitrogen Cooler with Tank:
Air coils in two separate chambers in tankto Provides extra cooling by waste nitrogen

Moisture Separator (Purger):It consists of pressure vessels with drain valves for removing condensate from the process air at regular intervals of time.Two Nos. are provided.

Chilling Unit with Freon Unit:
This consists of shell and tube type system. The air is chilled by Freon evaporative coils or by the evaporative cooling of Nitrogen optionally.This system cools the process air to 12°C which is necessary for removal of moisture from the process air.

Oil Absorber filled with Alumina:
It consists of vessel packed with alumina balls with special filters at inlet and outlet. This is used to remove any oil traces from the process air.
Type :Aluminia G-80

Molecular Sieve Battery on skid:
Complete with 2 nos. vessels,Reactivation heater complete with Molecular Sieve designed for process skid mounting.

Cryogenic type completed with support and connected pipes and internal connections.
Supplied as packed units consists of:
Outer Steel Casing:
Manufactured with frame for mounting exchangers and separation column,control etc.

Main Heat Exchanger:
In air circuit in copper alloy coiled type-multi pass with high heat transfer coefficient.Argon welded stainless steel casing and tubes expanded for leak proof.

Liquefier:
In air circuit in copper alloy coiled type-multi pass with high heat transfer coefficient. Argon welded stainless steel casing and tubes expanded for leak proof.

Bottom Column:
Made out of Argon welded stainless steel with flanged ends for easy maintenance / repair with distillation trays of high efficiency with working pressure of 5 kg/cm2. The trays are dies fitted into the outer casing, which is Argon,welded.

Top Column:
Made out of Argon welded stainless steel with flanged ends for easy maintenance/repair with distillation trays of high efficiency with working pressure of 0.4 kg/cm2. Large inter space between trays for entertainment. The trays are dies fitted into the outer casing,which is Argon, welded.

Condenser & Sub-Cooler:

For liquid Nitrogen and liquid Oxygen made of special alloy.

Liquid Oxygen & Nitrogen Filter:

In stainless steel / copper alloy containing absorption material and fine mesh filter complete with connection for regeneration.

Instrumentation:

Complete instrumentation for control of liquid levels / pressure and analysis valves. The digital electronic temperature indicator with scanner, accurate PT-100 sensor. The expansion valves are manual control with long stem type with pointer and index. For liquid level measurement accurate DP Gauge Manometer, Panel Mounted is provided. Pressure gauges are German-Feibig.

Cold Pipe Lines:

All Coppers / SS alloy in interconnecting equipments inside cold box.

Insulation Materials:
The perlite is of sufficient quantity to insulate the cold box completely.

Basic Principle
The air separation plant is a plant recovering oxygen and nitrogen from air simultaneously. It advance low pressure technology process of Boschi Italy using Rotary screw compressor (or low oil free piston compressor)and turbo expander. The feed air entering the Molecular Sieve purification system employed to remove the moisture and Co2 from the process air. The air is liquefied by cryogenic cooling using latest plate and fin high efficiency heat exchangers and turbo expander. The liquid air separates into oxygen nitrogen and inert gases in the air separation column.

• Range : 40 TO 800M3/hr.
• Purity oxygen -99.6% .Nitrogen -99.99% or 3PPM
• Operating Air Pressure- 0.6 TO 0.7Mpa

Main Components
1.Air Compressor:

Rotary air compressors screw type can be used for smaller size plants upto 500m3/hr & 1000m3/hr. Centrifugal compressor can be used for higher size plants.

2. Air pre cooling system:
Air separation plants adopts chilling system in all air pre-cooling systems.

3. Air purification system:

This system beds of molecular sieve are used in the air purification system, it remove the Co2 & moisture for the process air at low-pressure

4. Rectification Column:

The unit in cold box are all low pressure technology. This unit employs the latest state of the art plate and fin exchanger, condenser and sub-coolers. The column is supplied as a packed unit complete with all the control systems including digital flow-meters, temperature, pressure available with high purity upto 2-3 ppm nitrogen as a second product without loss in oxygen production.

5. Turbo-expander:

Turbo-expander is used for giving cooling to the air for the liquification process and braked by booster, so as to reduce the expanded air column, stabilize the upper columns working condition and reduce power consumption. The turbine expander have complete trouble free working and long life and reliability.

6. Computer Control:

All the plants can be configured for automatic operation through a PC this will use a out switching valves of German or Japanese and motorized cryogenic valves on cold box.

Specifications for Small Capacity Plants :

Model (O2/N2)	UBT 40/ 50	UBT 60/ 80	UBT 80/ 100	UBT 100/ 150	UBT 120/ 150	UBT 130/ 160	UBT 150/ 200	UBT 170/ 200
Oxygen Capacity Nm3/hr	40	60	80	100	120	130	150	170
Oxygen Purity % O2	99.6	99.6	99.6	99.6	99.6	99.6	99.6	99.6
Nitrogen Capacity Nm3/hr	50	80	100	150	150	160	200	200
Nitrogen Purity	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM
No of O2 cylinders per day (150 BAR*)	160	240	320	400	480	520	600	680

Model (O2/N2)	UBT 200/ 220	UBT 220/ 220	UBT 300/ 300	UBT 350/ 350	UBT 400/ 400	UBT 500/ 500	UBT 600/ 600	UBT 800/ 800
Oxygen Capacity Nm3/hr	200	220	300	350	400	500	600	800
Oxygen Purity % O2	99.6	99.6	99.6	99.6	99.6	99.6	99.6	99.6
Nitrogen Capacity Nm3/hr	220	220	300	350	400	500	600	800
Nitrogen Purity	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM
No of O2 cylinders per day (150 BAR*)	800	880	1200	1400	1600	2000	2400	3200

• Range: 1,000 TO 10,000M3/hr.
• Purity oxygen-99.6% .Nitrogen-99.99% or 3PPM
• Operating Air Pressure- 0.6 TO 0.7Mpa

This air separation plant mainly includes:

• air filter system
• air compressor system
• air pre cooling system
• Molecular sieve purifying system
• rectifying column system, nitrogen & oxygen compress and storage system, instrument control system, electric control system. Etc.

Air filter and compression
Air enters the self cleaning air suction filter, after being removed of dust and other mechanical contaminants in it, then enters main air compressor, after compression air then enters the after cooler.

Air cooling and purifying
Air is cooled in the Pre-Cooling System before enters mole sieve adsorber, Air which enters the evaporator of the Pre-Cooling System is cooled by the refrigerant.

Mole sieve purifying system includes two mole sieve adsorber and Steam heater or Electric heater. The mole sieve adsorber adsorbs water, CO2 and some hydrocarbon in the air, one mole sieve adsorber is regeneration while another one is work.

Air rectification
Air from adsorber is divided two stream: one stream enter directly main heat exchange, then enter lower column after cooled, the second stream enter main heat exchanger to cool after compressed by booster end of the expander and cooled by after cooler, then enter upper column after expanded by the expander.

The content of nitrogen will increase through rising gas connect with the reflux. Needed reflux liquid nitrogen is from condensate evaporator in the top of lower column, oxygen will be evaporated and nitrogen will be condensed in here.

• Lower column production as following from the top down:
• Pure liquid nitrogen
• Poor oxygen liquid air with 20%O2
• Rich oxygen liquid air with 36.5%O2

All production in the lower column after sub cooler enter upper column as its reflux.Production of upper column as following from the top down:

• Waster nitrogen at the top.
• Liquid oxygen at the bottom

Direction which all production of upper column go Waster nitrogen is reheated to design temperature out of the cold box by main heat exchanger and sub cooler after drawn from the top of upper column, one steam is regenerated by molecular sieve absorber, the other is taken in water cool column to cool water.


Purity: Oxygen gas of 99.6% purity can be produced and *pure nitrogen of 99.9% upto 3ppm is produced.
without any los of the oxygen production. **voltage and frequency as per the country of installation.

Main Performance of the plant:

A. Oxygen purity 99.6% at 150-160 Bar(2200PSIG) for Oxygen cylinder filling
B. High purity Nitrogen 99.99%(ppm optional) or cylinder filling.

Universal Boschi (Italy) has a wide range of medium capacity low pressure cylinder filling plants which falls in the range of 1000 cum/hr to 10,000 cum/hr and the specifications are as follows :

Model (O2/N2)	UBT 1000 /1200 /30	UBT 1500/ 1500	UBT 2000/ 2000	UBT 2500/ 2200/ 70	UBT 1500/ 1500/ 45	UBT 3600/ 3600/ 100	UBT 6000/ 6000/ 200	UBT 10000/ 18000/ 380
Oxygen Capacity Nm3/hr (TPD)	32	48	64	80	50	115	190	320
Oxygen Purity % O2	99.6	99.6	99.6	99.6	99.6	99.6	99.6	99.6
Nitrogen Capacity Nm3/hr (TPD)	33	42	56	60	42	100	170	500
Nitrogen Purity	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM	(99.9- 99.99) % 3PPM
No of O2 cylinders per day (150 BAR*)	4000	N/A	N/A	N/A	N/A	N/A	N/A	N/A