WARNING ABOUT OXYGEN, NITROGEN, ACETYLENE GAS PLANTS:

Oil grease or similar substances must not be allowed to come into contact with compressed oxygen or liquid
oxygen. Contact of this substance with oxygen may result in an explosion. Personnel working in an area of
possible oxygen concentration, such as near an oxygen vent or a liquid oxygen spillage, or in a trench where
oxygen seepage and concentration might occur, must ensure that their clothing is free from contaminations of
oxygen before lighting a cigarette or approaching a naked flames. It is essential that the clothes be dries for at
least 15 minutes before approaching a flame after any such contamination.

The following precautions must be strictly observed Oxygen Gas Plant, Nitrogen Gas Plant, Acetylene
Gas Plant at all times:

1: Thoroughly wash all oxygen fittings, valves and parts with clean Tricolor Ethylene /
carbon tetra chloride (CTC) before installation. Never use petrol, kerosene or other
hydrocarbon solvents for this purpose. All tubing, lines valves etc. to be used in
oxygen service, must be of an approved type and must be thoroughly degreased
and blown out with clean oil-free compressed air or Nitrogen before being placed in
service.

2: Do not permit the release of Acetylene or other flammable gases in the vicinity of the plant air intake. A
concentration of Acetylene exceeding 5 parts per million in liquid oxygen may explode with extreme violence.
Strict supervision is essential to minimize the possibility of contamination.

3: The plant and the plant vicinity must be kept clean and free from abstractions at all times. Any oil leak within
the plant surrounding must be rectified without delay. Oil spillage must be cleaned up immediately using rag and
carbon Tetra Chloride.

4: Do not lubricate oxygen valves, regulators, gauges or fitting with oil or any other substance.

5: Ensure that insulation removed from the Air Separator jacket is not contaminated with oil or other inflammable
materials. Personnel carrying out maintenance on the Air Separation Plant equipment must wear clean overalls
and their hands and tools must be free of oil. This ensures that the insulation and equipment within the jacket is
not contaminated with oil. Should contamination take place the affected materials must be discarded and replaced
by clean new material?

6: Do not fasten electric conduits to the plant or its pipelines.

7: Do not use oxygen as a substitute for compressed air, spark present in an atmosphere of oxygen will
immediately burst into flame.

Our Company has patronized the technology of Boschi, Italy as it has been the most successful in the world
specially in Europe due to excellent design features and efficient process cycle.
The process of manufacture of oxygen and nitrogen from oxygen/nitrogen plants has been very much simplified by
Dr. Boschi of Italy with the following advantages.

Oxygen and nitrogen is made from atmospheric air.

The process of manufacture involves deep refrigeration/cooling of atmospheric air involving cryogenic
temperatures.
Oxygen and Nitrogen is made from the purest form that is liquid air which is separated by process of
rectification/distillation.
The oxygen and nitrogen can be drawn in liquid form or converted into gas upto 155/200 bar by a built in
liquid oxygen/nitrogen pump.
Oxygen purity upto 99.6% for industrial and medical grade is produced.
Nitrogen gas can be collected at 0.1bar at the outlet of the cold box and compressed as per requirement or
can be pumped by method of internal compression by a liquid nitrogen pump. The standard commercial
purity of nitrogen gas is 96-99% and upto ppm grade can be produced.
There is no requirement of raw materials and no recurring cost of chemicals.
The oxygen and nitrogen plants are designed for continuous duty and are automatic and can be operated
by just one person.
We have commenced the manufacture of the oxygen/nitrogen plants at New Delhi in 1985 under expert
supervision of the Italian Engineers with the ultimate goal to manufacture the same quality of plants
produced in Europe with a much cheaper labour cost.
We have been highly successful in exporting back to Italy to Ing L&A Boschi, Italy equipments and oxygen
plants for sale in Europe and other parts of the world.
Dr. Boschi himself took the trial and successful run of the first oxygen and nitrogen plant manufactured at
New Delhi in 1986 and certified ok for export to Italy and meeting international standards.
Now it has been over 20 years since we have been manufacturing oxygen and nitrogen plants at New Delhi
with the technology of Ing L&A Boschi, Italy as per the designs and drawings.
 We have skilled and trained technicians at our factory who have been manufacturing air separation plant,
oxygen plant, nitrogen plant, liquid nitrogen / oxygen plants and equipment since 1985 under supervision
of qualified engineers to meet inter-national specification.
Our Company is engaged as manufacturers and suppliers of air separation plant and gas plants in India.
We are producing the air separation plants, oxygen plant, nitrogen plant and acetylene plants of latest
technology of ING L&A BOSCHI, ITALY who have been the world leader in setting up
oxygen/nitrogen/acetylene plants, machine, factory and related machinery since 1930 in Italy along with
LINDE Germany. Our oxygen plants factory have been exported to all countries including South Africa,
Tanzania, Kenya, Congo, Liberia, Columbia, Congo, Libya, UAE, Saudi Arabia, Iraq, Iran, Europe, Italy,
Spain, Australia.
5 STEP BOSCHI PROCESS FOR MANUFACTURE OF OXYGEN & NITROGEN.
Step1
COMPRESSION OF ATMOSPHERIC AIR
Step2
PURIFICATION OF AIR
Step3
COOLING OF AIR
Step4
SEPARATION OF LIQUID AIR INTO OXYGEN AND NITROGEN
Step5
COMPRESSION/WITHDRAWAL AND FILLING OF OXYGEN AND NITROGEN

Process Description Acetylene Plant

ACETYLENE GENERATOR (MEDIUM PRESSURE):
It mainly consists of a twin Hooper that is:
Agiitator and its drive unit
Carbide Hooper screw feeder and its drive
Flash back arrestor
Safety relief valves drain system & the automatic
controls system.
SAFETY: The generator is fitted with five safety
valves. One is fitted on the gas outlet frame, one of
each of the flash arrestors and one on each of the
carbide Hooper. The bottom of the generator is fitted
with an air-operated drain valve which discharge
slurry in response to the slurry level is high. There is
a water inlet valve, which opens in response to the
temperature of the slurry.
Cooler condenser:
The cooler condenser cools the acetylene gas having
the generator, which is hot
and laden with moisture and other gaseous
impurities.
Low pressure Dryer:
This is a pressure vessel charged with solid
anhydrous carbide which absorbs the moisture in the
gas.
Purifier:
Acetylene compressor:
The acetylene compressor is a three stage machine
which is immersed in water filled tank to avoid any
pressurized gas to come in contact with air and also
to make sure that all the components are
continuously cooled. The compressor is drawn by
flame proof motor from outside the tank.
High Pressure Dryer:
The high pressure dryer consists of three columns.
The first column is filled with packing to avoid any
void and for proper mixing and the second and third
are filled with anhydrous calcium chloride.
Filling manifold:
The acetylene gas manifold consists of two headers
fitted with non-return valves, one flash back
arrestors, pressure gauge and manual isolation
valves.
Acetone Pump:
Acetone pump is supplied along with the plant for
charging acetone in cylinders.
• Automatic controls of acetylene
generator:

This is a large vessel provided with two sectors by Temperature cum water inlet control.
wire mesh frame network. Each sections by wire High temperature alarm.
mesh frame work. Each sectors are charged with Level cum slurry discharge control.
purifying mass which absorbs gases like hydrogen Level alarm.
sulphide, phosgene etc. Pressure controls.
Ammonia scrubber: Control of high temperature.
Control of high level.
This equipment has a vertical vessel filled with a
level gauge and water make-up line. A particular as
marked on the level indicator has to be maintained. • Level controls:
The ammonia scrubber all the water soluble
impurities like ammonia.
Level controller maintaining a particular level in the
generator. If the level is above normal, water can
enter the carbide hop.
• Level alarm:
The pressure inside the acetylene generator is
controlled by a meteoroid switch.
• Pressure alarm:
This is the important part for the safety of this plant.
A pressure switch is connected to the alarm system.

A C E T Y L E N E P LA N T L A Y O U T

Special precautions to be taken into account when making the Acetylene Plant Building:

• A safety zone of 15 m. all around the Acetylene Plant, from any other building should be provided, and a
minimum of 9 m. from any slurry pit.
• A separate Acetone storage should be constructed and must be provided with a 12 m. safety zone all
around.
• A distance of 90 m. must be maintained from any Oxygen Plant in the vicinity.
• All non-flame and explosion proof switches must be provided separately in an enclosure away from the
Acetylene Plant Building.
• No flammable material should be used for construction purposes of the Acetylene Plant Building.
• Both the Acetone go down and Calcium Carbide Store as well as the Acetylene Plant Building should be
well-ventilated with ventilators on the roof as well as ground level. All ventilators must be protected with
non-corrosive, galvanized non corrosive mesh, with a minimum gauge of 28 mesh to the linear inch. Covers
should be provided on the ventilators so that rain water may not enter through these openings.
• All electrical wiring should be of low voltage in the Acetylene Plant Premises. Electrical lines must not cross
any pipe conveying water or steam or acetylene.

PROCESS DESCRIPTION

In a Stationary Carbide to Water type Automatic Acetylene Generator acetylene is produced by reaction of calcium
carbide with water. Adequate quantity of water is held in the generator shell to which calcium carbide is fed from
top. The following reaction takes place:-

CaC2+2H2O = C2H2 + Ca(OH)2 + 27,000 Calories

The generated acetylene gas occupies the free volume inside the generator shell over the water level and pressure
of gas goes up till it reaches the set pressure level when by action of the pressure controller carbide feed motor is
cut-off. If the acetylene gas is taken out from the generator, the pressure inside the generator shell will go down
and by action of the pressure controller carbide feed motor will start and feed further carbide through the screw
feed mechanism from the hopper into the shell and further acetylene shall be generated. Thus the process shall
continue till the carbide filled in the hopper under operation is exhausted. At that stage change over takes place
and second hopper which was filled with carbide when first hopper was under operation now starts feeding carbide
into the generator shell and first hopper is filled with carbide.

As the process of acetylene generation is exothermic, there is a temperature rise of the generator. The generator
temperature cannot be allowed to go high because acetylene can catch fire. Moreover, generation of acetylene is
optimum at a particular temperature around 60ºC. Hence it is necessary to keep the generator temperature
around 60ºC. This is done automatically by the temperature controller which is preset at a temperature of 60ºC.
Since the generator has a tendency of increased temperature, the temperature controller acts on the water inlet
valve and opens the valve to bring in fresh process water which reduces temperature of the generator and thus
the generator temperature is kept at about a particular predetermined set point.
With inlet of fresh water to bring down the generator temperature the water level inside the generator goes up and
this water level is maintained between a high and low set point by pneumatically operated level controller. Slurry
discharge valve is made to open automatically by the level controller to discharge some quantity of slurry to lower
the waster level inside the generator when the water level tends to rise above the maximum level. As soon as the
level of water goes down the slurry discharge valve automatically closes. Thus only minimum quantity of slurry is
discharged at a time. Water inside the generator absorbs certain quantity of acetylene and hence this water
already saturated with acetylene should not be discharged continuously or in large volume but should be retained
inside the generator and thus prevent loss of acetylene with the slurry.

The Agitator is continuously driven when the carbide feed motor is running. However, when the generator is in
dormant state and there is no carbide feed, there is a tendency of the slurry to settle down and jam the agitator. A
timer controlled electric motor drive keeps the agitator under operation when the generator is in dormant state.
Thus slurry is always kept mixed with water without sedimentation. Agitator is a very important part of the
generator as it keeps the carbide and water intimately mixed for total reaction of the carbide and thus prevent loss
of carbide in the form of solids with the slurry.

Passage of acetylene gas from the generator to the carbide chamber (hopper) under filling is kept shut off by
hydraulically operated shut off device which operates automatically when the carbide in the hopper is exhausted
and screw feed motor is stopped.

The generated acetylene passes from the generator chamber through Wet Type Flash Back Arrestors and then
reaches Low Pressure Condenser where the temperature of gas is lowered by cooling water and part of the
moisture in the acetylene gas is taken out in the form of waster by condensation. Gas then passes through low
pressure dryer filled with calcium chloride to remove further quantities of moisture from acetylene gas before the
gas reaches purifying chamber. Gas then passed into purifying chamber with optimum quantity of moisture in the
gas (gas is not completely dry). Purifying chamber is filled with purifying chemicals to remove Phosphorus and
Sulphur compounds from the gas and if necessary to remove acidic fumes also. Thereafter gas passes to water
filled scrubber where acetylene gas is washed with water to remove particles of purifying chemicals which may be
carried over with the gas from purifying chamber. The wet gas then enters suction of acetylene compressor,
compressed and passed to high pressure dryer filled with mechanical devices and chemicals to remove lube oil
vapor and moisture from the gas. Gas after passing through the High Pressure Dryer is arrested by Back Pressure
Valve on the pipeline leading to the manifold. Back Pressure Valve is set at a pressure between 12 to 14 kg/cm2g
so that no gas till the pressure rises above the set pressure is allowed to pass on to the manifold. This ensures
efficient drying of acetylene gas in the high pressure dryer. Thereafter gas passes through Dry type Flash Back
Arrestor to manifold and then passes to the cylinders hooked on the manifold through Static Free Uni-flow Valves
meant for each cylinder.

Before hooking the cylinders on the manifold for filling they are weighed on a balance, loss of acetone if any
ascertained, loss is made up by filling acetone preferably by hand pump directly from acetone drum and then only
cylinders are made ready for connecting to the manifold for filling.

During filling continuous spray of cooling water is kept on the cylinders as there is a temperature rise of cylinder
during filling operation and absorption of gas in acetone is better when the gas is at a lower temperature. When
the cylinders are filled to the desired pressure as per temperature chart, filling is stopped and acetylene gas is
allowed to settle inside cylinders. There will be some drop in pressure and a second or 3rd filling may be necessary
to achieve the desired cylinder pressure. After filling cylinders are taken out by disconnecting the pigtails, cylinders
weighed on weighing machine and quantity of acetylene filled in the cylinders is ascertained from the weight of the
cylinders. Cylinders are tested for leaks and stored for distribution.

Cooling water is required at 3 points i.e. at condenser, for cooling of compressor and spray cooling of cylinders
under filling Industrial water is required in generator for reaction with carbide and in wet type Flash Back Arrestor
for topping up.

Water Meter is provided with each generator to check the water consumed by the generator in a given time and to
compare the ratio of carbide and water to determine the proper operation of the generator.

Hoist with skip and chain pulley block is provided to lift carbide from the ground to the generator hopper for filling
of hopper.

A small bank of 4 to 6 Nos. 6 M3 Nitrogen cylinders are kept in manifold with piping to various points for flushing
the various parts of the plant and inter-connecting pipelines.

Electrical lines are to be provided by customer from MCC located at a safe distance to feed carbide screw feed
motors, compressor motor controls and instrumentation.

Instrument Air Compressor is provided (pipeline is to be provided by customer) for operating the Pneumatic
Instruments. Apart from the instruments mounted on the generator, some of the control instruments are located
on a panel which is installed at a safe distance along with MCC.