OXYGEN / NITROGEN GAS PLANT

Special features of
KIGL Oxygen/Nitrogen gas plant
n KIGL plants incorporate design features which enable KIGL plants
to produce high quality nitrogen gas simultaneously with oxygen
gas production. This results in higher economical viability.
n KIGL plants are equipped with a highly efficient Expansion
Engine, which helps rapid and adequate cooling. On account of
this KIGL plant operation is exceedingly stable with a consistency
in gas purity.
n High standard of purity of gases.
n Low power consumption.
n A special bypass valve is provided for quick production and better
cooling. (R-4)
n Fool proof temperature indicating system-electronic scanner.
n International class pressure differential gauges are foolproof liquid
level indicators with stainless steel control panel.
n High quality insulation by Perlite power to prevent cold losses.
n Liquid Nitrogen withdrawal facility.
n Single pump for filling Oxygen as well as Nitrogen.
n Separate Nitrogen pump.
n Heavy duty air compressor (4 stage) suitable to operate with the
power supplied by a diesel generating set or normal power supply
of 415/440 V-50 cycle.
n No bulky gas holder required.
n An industrial refrigerator (chilling plant) with air-cooling facility
both before and after the drier battery is included in our scope of
supply.
n Low maintenance cost.
n Safe and easy to operate.
n Plants layout, foundation drawings for easy and economical
installation.
n On line oxygen purity analyzer.
n Liquid Pumps are with non-lubricated cross head and therefore
are hazard free for Oxygen pumping.
n Facility for PPM grade of dry Nitrogen Gas.
n Minimum percentage of Oxygen is lost through waste Nitrogen to
achieve optimum production.
Process Description
Atmospheric Air mainly consists of Oxygen and Nitrogen gases
along with small quantities of water vapour, Carbon Dioxide,
Argon, Helium, etc. Oxygen and Nitrogen from the Air are
separated due to difference in boiling points by distillation
through a fractional column.
Atmospheric Air is sucked in by a multi stage Compressor
through a filter and is compressed to the design pressure. The
compressed Air is then passed through inter-coolers, Industrial
Refrigerator, Moisture Separators, and then to the Molecular
Sieve Battery for removal of Carbon Dioxide, Hydrocarbons and
Moisture from the process Air. This pure Air then passes
through the 1st Heat Exchanger, where it is cooled by the out
going Nitrogen and Oxygen. Part of this cooled Air is passed
through Expansion Engine and the other part through the 2nd
Heat Exchanger. Both the Expansion Engine and 2nd Heat
Exchanger help in further cooling down the Air, which is finally
released to the bottom of the column through an expansion
valve. The Air becomes liquid at this stage.
The Column consists of two parts. The lower column and upper
column. In between the lower and upper columns there is a
condenser, which acts as a reflux for the lower column and as a
re-boiler for the upper column. The liquid Air at the bottom of
lower column separates through the trays to give crude Oxygen
at the bottom and approximately 90% pure Nitrogen at the top.
Crude Oxygen termed as rich liquid is then expanded through an
Expansion Valve from the lower column to the middle of the
upper column. Crude Nitrogen termed as poor liquid is expanded
through another Expansion Valve from the top of the lower
column to the top of the upper column. Due to difference in the
boiling points, the pure Nitrogen boils over and accumulates at
the top of the upper column and Oxygen which accumulates at
the bottom of the upper column.
Both Nitrogen and Oxygen are removed through separate paths
in Heat Exchangers, for cooling the incoming air. Oxygen is
compressed to a prescribed settled pressure by a liquid pump
and is directly filled into cylinders. Nitrogen is however available
at a pressure of approximately 0.5kg/cm2 and the same can be
compressed into cylinders with help of an independent high-
pressure compressor.
Normally the Nitrogen available is of 98.5% purity only and is
let out into the atmosphere as waste product. However, when
Nitrogen is to be filled, into the cylinders for commercial use,
the plant is controlled by a change in the valve setting to make
the mixed Air chamber operative to achieve the required
Nitrogen purity. (Facility of filling Nitrogen gas (PPM Grade) and
withdrawl of liquid Nitrogen is also possible, See P&I diagram.)
List of connected load for KIGL 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 – – – – –

Product Data in reference to 100 M3/Hr capacity plant

This plant can produce basically Oxygen and Nitrogen. However, the plant can be controlled to
produce these products in different standard modes as given below, based on standard operating
conditions :

DRY OXYGEN GASEOUS NITROGEN LIQUID NITROGEN

PRODUCT CYCLE REMARK
M3/HR PURITY M3/HR PURITY M3/HR PURITY

1 100 M3/HR 99.50% NIL 96-98% NIL

NITROGEN
2 93 M3/HR 99.50% 125 M3/HR 99.6-98% NIL COMPRESSOR
REQUIRED

3 93 M3/HR 99.50% NIL 15-18 LIT/HR 99.90%

USING TWO
4 70 M3/HR 99.50% 30 M3/HR 10 PPM NIL
SEPARATE PUMPS
Technical Data
Specifications 130 M3/Hr 170 M3/Hr 200 M3/Hr
Air Compressor Capacity 740 M3/Hr 950 M3/Hr 1150 M3/Hr
Starting Pressure 40 kg/cm2 40 kg/cm2 40 kg/cm2
Operating Pressure 30-35 kg/cm2 30-35 kg/cm2 30-35 kg/cm2
Starting time till production 7 Hrs 7 Hrs 7 Hrs
Defrosting time 4/6 Hrs 4/6 Hrs 4/6 Hrs
Defrosting cycle at normal condition 12 months 12 months 12 months
Power supply required 420V 220V 3Phase 50 Hz 420V 220V 3Phase 50 Hz 420V 220V 3Phase 50 Hz
Rate through put of liquid Oxygen Pump 130 M3/Hr 170 M3/Hr 200 M3/Hr
Delivery Pressure of pump 165 kg/cm2 165 kg/cm2 165 kg/cm2
Cylinder filling manifold 2 x 12 2 x 20 2 x 20
Cooling water requirement 40 M3/Hr (Re-circulated) 50 M3/Hr (Re-circulated) 70 M3/Hr (Re-circulated)
Make-up water requirement Approx. 0.5 M3/Hr Approx. 0.5 M3/Hr Approx. 1 M3/Hr
Max. Individual item weight 8.5 Tons 10 Tons 11 Tons
Gross Weight 20 Tons (approx.) 32 Tons (approx.) 40 Tons (approx.)
Insulation Perlite Perlite Perlite
Assembly Height 8.0 meters 9.2 meters 9.2 meters
Area required 200 sq. mtrs. 250 sq. mtrs. 350 sq. mtrs.
Material of construction Copper, Brass, Steel etc Copper, Brass, Steel etc Copper, Brass, Steel etc
Power consumption 1.2 units/M3 of Oxygen 1.0 units/M3 of Oxygen 1.0 units/M3 of Oxygen

Manufactured in India by :
INTERNATIONAL INDUSTRIAL GASES LIMITED
REGD. OFFICE : 146, ANDUL ROAD, HOWRAH-711 103
Telephone : 2668 4724 / 4725, Fax : +91 +33 +2668 4058
E-mail : cryodkg@cal.vsnl.net.in & iigascal@hotmail.com
Web site : http://www.iigas.com