Salient features of Gas pipeline supply Oxygen Nitrogen Plants, Oxygen Gas Plants, Oxygen Gas Filling Plants and Oxygen Nitrogen Gas Filling Plants (Low Pressure) :

• A few of the latest technological features incorporated into the Oxygen & Nitrogen plants are listed below.
• Purity of Oxygen produced from all plants is minimum 99.6% and Nitrogen Purity CAN BE available up to 1-3 PPM (Depending upon requirement of the customer).
• All plants use “Oil free” rotary screw /centrifugal oil compressor working between 5-7 BAR.
• All plants incorporate Aluminum Brazed exchangers and packed columns for high efficiency.
• Turbo expanders (GAS Bearing) for trouble free operation.
• All plants above “500M3/HOUR ” CAN supplied with automatic PLC control.
• 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.
• 100% reliability for oxygen gas quality for industrial & hospital use.

PROCESS DESCRIPTION for Oxygen Nitrogen low pressure Oxygen/Nitrogen plants:

1.COMPRESSION OF ATMOSPHERIC AIR
Air is compressed at a very pressure of 5-7 bar (kg/cm2). Air can be compressed at such low pressure by trouble free rotary compressor (Screw / Centrifugal Type/Oil free piston compressor of advanced technology are employed).

2. PRE COOLING SYSTEM
The second stage of the process uses a low pressure refrigerant for precooling the processed air to temperature around 12 deg C before it enters the purifier.

3. PURIFICATION OF AIR BY PURIFIER
The air enters a purifier consisting of twin Molecular Sieve driers, working alternatively. The Molecular Sieves remove the Carbon dioxide & moisture from the processed air before the air enters Air Separation Unit.

4. COOLING OF AIR BY turbo (EXPANDER)
The air has to be cooled to sub zero temperatures for liquification & the cryogenic refrigeration & the cooling is provided by highly efficient turbo expander, which cools the air to temperature almost below -165 to-170 deg C

5. SEPARATION IF LIQUID AIR INTO OXYGEN AND NITROGEN BY AIR SEPARATION COLUMN
Oil free, moisture free and Carbon Dioxide free air enters into low pressure fin type HEAT EXCHANGER where the air is cooled below sub zero temperatures by air expansion process in the turbo expander. Air gets liquefied when it enters the air separation column & gets separated into oxygen & nitrogen by the process of rectification.
Oxygen is available at the outlet of the ASU at a purity of 99.6%. Nitrogen is also available at the outlet as a second product at purity of 99.9% upto 3ppm simultaneously without loss of oxygen product.

6. COMPRESSION OF OXYGEN AND FILLING OF OXYGEN IN CYLINDERS
The final product in the form compressed Oxygen/Nitrogen goes to the high pressure oxygen cylinders at 150 bar or upto higher as required. This can be done by liquid oxygen pump is same models. We can use oil & water free compressor.

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(I) Air compressor: Screw/ low pressure- type:
We employ the most advanced compressor series available in the market. They have a unique combination, meeting customer requirements for low installation, operating and maintenance costs with high dependability and ease of use.

Screw type rotary compressors are one of the most advanced and trouble free.

Centrifugal Type Compressor: No other turbo type oil free compressor can match its efficiency and economy. This ensures a consistent and highly reliable source of air supply. Maintenance is extremely low.Oil free piston compressor are also very succesful due to V-Type configuration on very low working pressor.

(II) Pre – Cooling system:
The pre-cooling system is a highly efficient skid mounted equipment provided with the main purpose of cooling down the air to a temperature of 5 to 8 degrees Celsius and thus to discharge the condensed water. We are using highly reliable compressors of European origin.

(III) Universal Boschi Purifier:
The purifying system is the secondary process unit which is responsible for the removal of moisture, carbon dioxide, hydrocarbons as well as rare gases that are considered to be impurities in the process cycle of air separation. The structure essentially consists of double layered molecular sieves from “Zeochem” (Switzerland) along with alumina which acts as an adsorbent.

The process purifier is vital to the entire process and is greatly responsible for the purity of the final product i.e. Oxygen and Nitrogen in the Air separation Column. It consists of 2 skid mounted molecular sieve regeneration batteries that work on shifts and switch alternatively either manually or through a PLC control (optional).

(IV) Air separation Unit:
The Key to the entire Air separation Process lies within the Air Separation Unit (A.S.U). Here, the mixture of Oxygen and Nitrogen is separated by virtue of the difference in their liquefication temperatures.Liquefied air is sent to the lower and upper column using a double rectification process at temperatures below (– )180 deg centigrade.

The design and efficiency of the A.S.U determines the quality of the final product i.e. Oxygen and Nitrogen in terms of quantity and quality. The Boschi design A.S.U features highly efficient fin type aluminium heat exchangers and column, wherein the entire upper column is a packed column thus reducing the operational pressure and increasing the Oxygen, Nitrogen and Argon recovery.

Argon Recovery Plants

Argon is recovered ABOVE 1000M3/HOUR OXYGEN PLANTSby a revolutionary technique employing full rectification without using the Hydrogen and De-Oxo unit thus saving further on power costs, operational costs and investment. This makes the Boschi design machines highly versatile and economical thanks to all the research and development done over the years.

Features:

• All Aluminum Construction.
• Plate fin type exchanger
• Shelve type trays or packed type
• Low pressure
• Super efficient
• 100 to 50,000m3/hr oxygen/nitrogen/argon

Note: Check USA & Germany manufacturers for technology comparison.

(V) Turbo expander:

The Turbo expander is a gas bearing expansion refrigeration turbine that is much more efficient than any other expansion device.

It works on the technique of induced cooling via expansion due to which the operational pressure of the plant is further reduced and the performance of the distillation column is stabilized for constant production and high purity oil bearing turbine expander.

Universal turbo expanders test bed for 100% reliability and tested at 150,000 rpm at minus 190 degree centigrade. troublefree service for years.

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

Special Features:

A few of the latest technological features incorporated into the Oxygen & Nitrogen plants are listed below.

• All plants use “Oil free” rotary screw /centrifugal oil compressor working between 0.6 to 1.0 mpa.
• All plants incorporate Aluminum Brazed exchangers and packed columns for high efficiency.
• Turbo expanders (Oil or Air Bearing) for trouble free operation.
• All plants above “500” are supplied with automatic PLC control.
• 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.
• 100% reliability for oxygen gas quality for industrial & hospital use.

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 expanders.

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 expanders. The liquid air separates into oxygen nitrogen and inert gases in the air separation column.

Medium Capacity Liquid Plants(32 TPD TO 320 TPD)

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

Process Description

1. Air Compressor-Low Pressure
Air is compressed at a low pressure of 5-7 bar (0.5-0.7mpa). Air can be compressed at such low pressure by trouble free rotary compressor (Screw / Centrifugal Type advanced technology is employed in lieu of old bulky piston compressor).

2. Pre Cooling System
The second stage of the process uses a low pressure refrigerant for pre-coolingthe processed air to temperature around 12 deg C before it enters the purifier.

3. Purification of Air by Purifier
The air enters a purifier consisting of twin Molecular Sieve driers, working alternatively. The Molecular Sieves remove the Carbon dioxide & moisture from the process air before the air enters Air Separation Unit.

4. Cryogenic Cooling of Air by Turbo (Expander)
The air has to be cooled to sub zero temperatures for liquification & the cryogenic refrigeration & the cooling is provided by highly efficient turbo expander, which cools the air to temperature almost below -165 to-170 degC.

5. Separation of Liquid Air Into Oxygen and Nitrogen by Air Separation Column
Oil free, moisture free and Carbon Dioxide free air enters into low pressure plate fin type Heat exchanger where the air is cooled below sub zero temp, by air expansion process in the turbo expander.Due to the excellent thermal efficiency we can achieve a temperature difference delta t as low as 2 deg c at the warm end of these exchangers .

Air gets liquefied when it enters the air separation column & gets separated into oxygen & nitrogen by the process of rectification.

Liquid Oxygen is available at the outlet of the ASU at a purity of 99.6%.
Liquid Nitrogen is also available at the outlet as a alternate product at purity of 99.99%(upto 3ppm as required).Nitrogen gas will be available as a by product.

6. Compression of Oxygen filling in the Cylinder
The final product in the form compressed Oxygen/Nitrogen goes to the high pressure oxygen cylinders at 1 50 bar or upto higher as required.. Or for pipeline supply or captive consumption | Or for liquid plants to fill in cryogenic liquid tanks.

Large Capacity Liquid Plants (320 TPD TO 1600 TPD)

• Range: 10,000 TO 50,000M3/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 seperation 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 expanders 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.