Gas Plant Processing

8/19/2019 Gas Plant Processing

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Refd.web site link; http://www.industrialgasplants.com/cryogenic-oxygen-

plant.html#oxygen

Air Separation Plant

Air separation plants are gas plants producing different varieties of gases by the process of air separation.

Air separation plants produce the atmospheric industrial gases like oxygen, nitrogen, argon, helium,

methane using air and electrical power as raw materials.

Air Separation Technology

Though there are differences in process details displaying desired product mix and other factors, all air

separation plants make use one of the following two types of process technology:

• Cryogenic plants: The air separation technique used in cryogenic plants produce gas and liquid

products (liquid oxygen, liquid nitrogen etc. using very low temperature distillation which separates

air components and produce desired product purities.

• Non-cryogenic plants: The air separation technique used in non cryogenic plants produce

gaseous products with near!ambient temperature separation processes. They use differences in

properties like molecular structure, si"e and mass to produce oxygen or nitrogen.

All manufacturers and suppliers involved with air separation plants deal with the design, fabrication, and

construction of both cryogenic and non!cryogenic air separation plants. The main focus of the market in

today#s scenario is to supply independent operators of air separation systems with design, engineering, and

operations support. $n some cases this involve actual pro%ect work, and in some other it means providing

design, engineering and supervision.

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Capabilities of Air Separation Plants

&lant types offered by air separation plants include:

• 'xygen non cryogenic plant

• 'xygen cryogenic plant

• itrogen &)A plant

• itrogen cryogenic plant

• *odular liquid and gaseous cryogenic+non cryogenic nitrogen generators

• *odular liquid and gaseous cryogenic+non cryogenic oxygen generators

• arge gaseous cryogenic nitrogen generators+ oxygen generators

• iquid plants producing liquid oxygen, nitrogen and argon

Air Separation Plant Design

The basic elements considered in the design of an air separation plant are:

• Air &retreatment

• Air -ompression

• efrigeration

• /istillation

0esides that argon purification and+or product compression are also required. Air pretreatment systems

make use of either temperature swing or pressure swing adsorption technologies and usually efficient in

dealing with any environmental condition.

Buyer's Guide:Specifications of Air Separation Plants

Standard ype !ain "roducts Sec. "roducts pplications'xygen + itrogen 1as1enerating &lant

'xygen gas + 22.34itrogen gas + 22.22224

$i%uid nitrogen&

li%uid oxygen& argon&neon& krypton& xenon

$ron works, chemical,partial oxidation

ow &ressure iquid'xygen +iquid itrogen1enerating &lant

iquid 'xygen + 22.54iquid nitrogen + 22.22224

Argon $ndustrial gas sales

6igh &urity &ressuri"editrogen 1enerating &lant

itrogen gas + 22.22224 iquid nitrogen -hemical, petroleum,textiles, electronics industry

ses of Air Separation Plants

• Steel 'ndustries

• (on-steel !etal 'ndustries

• )lectronics

• "ower *enerating 'ndustries

• +hemical ,"etrochemical

• Semiconductor 'ndustries

• il , *as

• ood , e0erage

• !etals

• 1elding 'ndustries

• !ining

• *lass

• "ulp , "aper

• 'ndustrial gas

• )n0ironmental

• !edical

• Refrigeration

Cryogenic Liquid Plant


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-ryogenic iquid *anufacturing process 0enefits

7quipment equired 0uyers 1uide

-ryogenic liquid plants are gas plants producing liquid oxygen or liquid nitrogen in the cryogenic process.

-ryogenic process is one of the most popular technique used in many large scale gas plants for producing

purified oxygen or purified nitrogen. The output of liquid oxygen produced from the plant can be stored in a

liquid oxygen tank. iquid nitrogen is produced as a by product simultaneously upto 22.2224 purity. Thecryogenic plants are extremely versatile, safe and easy to operate and all the possible product variants that

are produced can be taken as either 8994 liquid oxygen out put or 94 liquid oxygen output directly into

cylinders or 94 liquid nitrogen and 94 liquid oxygen.

!hat is Cryogenic "i#uid$

A refrigerated, severely cold (!39;- to !


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• Copression of air: This is accomplished by multistage highly efficient air compressor.

• Purification of air: &urification of air is dome by an important component of the gas plant known

as process skid.

• Cooling ( li#uification of air: A highly efficient expansion engine and a refrigeration unit (for

8994 liquid output are used for cooling and liquification.

• Air separation )rectification*: Air separation is done in an air separation unit consisting of

upper ? lower column and special exchangers. The separation air is done by the cryogenic process

and the final output whether a liquid oxygen or liquid nitrogen or both goes to the storage tank.

Benefits of Cryogenic "i#uid Plants

0esides producing pure liquid oxygen and nitrogen, cryogenic liquid plants are used directly in other

processes:

• 6ydrogen recovery

• 6ydrogen purification

• iquid petroleum gas (&1 recovery from refinery off gas

• 7thane and ethylene recovery

• &urification of carbon monoxide

• itrogen purification of ammonia syngas

• atural gas processing for recovering 1 and helium

+#uipent re#uired in Cryogenic "i#uid Plants

• )uction filter

• Air compressor

• &rocess skid

o After cooler with tank

o itrogen cooler with tank

o *oisture separatoro -hilling unit

o 'il absorber

o *olecular sieve battery

o /efrost heater

o 1as+Air+water line as per standard layout on skid

o @ater pump

o $nlet ? outlet water lines

• 7xpansion engine

• Air separation unit

• iquid oxygen pump

• -ooling tower

• @ater softener

Buyer's Guide: Technical specifications

• -apacity (&roduct 'ptions:

o 'xygen liquid 8994, itrogen gas

o 'xygen liquid 94, 'xygen gas 94, itrogen gas

o 'xygen gas at 94, itrogen liquid 94, itrogen gas

• &urity : 'xygen, nitrogen (optional upto 22.2224

• &ower connected


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• &ower consumed (abt.: 94 gas 94 liquid, 8994 liquid

• &ower supply

• Air capacity

• )tarting pressure

• @orking pressure (abt: 94 gas 94 liquid, 8994 liquid

• )tarting time (after defrost

• )tarting time (after tripping

• Areas required

• Assembly height

• @eight (about

• Air separation column

Cryogenic Nitrogen Plant

)pecifications &rocess

Applications

-ryogenic nitrogen plants are gas plants generating nitrogen using the cryogenic process. -ryogenic plants

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using cryogenic temperature are used for production of liquid and gaseous nitrogen from atmospheric air.

@hile the cryogenic oxygen plants produce oxygen as the final product, nitrogen is also produced as a by

product in the process. 6owever, there are independent gas plants producing nitrogen alone. $n other words,

the cryogenic air separation units can produce both high purity nitrogen gas as a second product with

oxygen and as a prime product in nitrogen generators, where gas is the final output. 0eing a relative inert

gas, cryogenic nitrogen is used as a protective atmosphere to prevent oxidation.

-ryogenic nitrogen plants represent highly efficient equipment for large!scale nitrogen production with the

nitrogen purity of up to 2!224 pure nitrogen. $n most cases the cryogenic technology of nitrogen production

proves economically feasible and are always considered more advantageous than membrane and

adsorption systems.

Specifications of Cryogenic Nitrogen Plants

A typical cryogenic plant has two modules!a cold box and an warm end container. The cold box consists of a

condenser, the rectification column and heat exchangers. The warm end container is usually equipped with

an air pre!treatment unit, an air compressor, electrical devices and a control system.

Typical specifications for a cryogenic nitrogen plant that a buyer should know without additional purification

and compression are:

• -apacity: 'utput capacity

• &urity: itrogen purity

• &ressure

• Ambient temperature during operation and storage

The Cryogenic Process and Technology

The cryogenic process separates air by using means of rectification. This makes use of the different

evaporation temperatures of the air components. There are inlet filters in the pants which remove dust andother impurities from the air before it enters the air compressor. 6ere the air is compressed to the required

process pressure. $t is then pre!cooled. After moving through a moisture separator, the air enters one of two

molecular adsorbers, where impurities are removed. 6ere, one adsorber is always effective while the other

is being regenerated by residual gas from the separation process.

The processed air is then cooled at a liquefaction temperature in the main heat exchanger and then fed into

the bottom of the rectification column. The pure nitrogen fraction is removed from the top column, then fed

into the product line. -old is supplied in the form of liquid nitrogen ($ from the back!up system. This is

regenerated with an expansion turbine. The pure nitrogen is stored in cylinders or storage tanks and then

distributed.

,lo diagra


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Applications of Cryogenic Nitrogen Plants

• -hemical and petrochemical industry

o $nerting+purging

o -atalyst regeneration

• 0lanketing

o *etallurgy+1lass industry

o 6eat treatment

o efining

o &urging

o $nerting

• 7lectronic industry

o &urging

o $nerting

o &ackaging

o Air /rying

• ood $ndustry

o packaging

o $nerting

• 'il and gas industry

o itrogen fire fighting

o &ipe!lines blowing

o Air drying

o &ressure testing

o Technological tanks cleaning

o

Cryogenic Oxygen Plant

-ryogenic 'xygen The process 'xygen 1rades

Applications 0uyers 1uide

-ryogenic oxygen plants are oxygen generating plants in the cryogenic process. @e all know that there are

basically two processes used in gas plants to produce pure oxygen!one is the cryogenic process and the

other is the non cryogenic process.

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@hile the cryogenic process is suitable for large scale gas plants as well small si"ed gas plants, the non

cryogenic process involving the &)A technique is more suitable for small si"ed plants. -ryogenic gas plants

are suitable for producing oxygen for industrial and medical uses and available in large, bulky si"es and also

small si"ed cylinders. $n other words, cryogenic oxygen plants are available in low purity which is

approximately 24 and high purity which is almost 22.3B4. There are oxygen!only plants, and multi!product

configurations like oxygen, nitrogen, argon etc.

!hat is Cryogenic ./ygen$

-ryogenic oxygen is oxygen in liquid state and it is very cold. $n cryogenic oxygen plants, oxygen is

produced, stored and maintained in a liquid state at a substantially constant pressure.

The Cryogenic Process

-ommercial oxygen produced in cryogenic gas plants use the cryogenic distillation process originally

developed in 852. This cryogenic process produces oxygen that is 22B4 pure. The steps involved are as

follows:

Copression

• The air is compressed using a multi!stage compressor, which is then passed through a water!

cooled after cooler to condense any water. 0efore compression, air is pretreated to remove

impurities. 'nce the impurities are removed, the air is submitted to fractional distillation, where the

components are separated in several stages. $n the cryogenic process, a cryogenic section is

required to provide the low temperatures required to liquefy the gas components. 'nce the liquid

oxygen is separated, it is purified and stored.

• The air passes through a molecular sieve adsorber, containing "eolite and silica gel!type

adsorbents. These adsorbents adsorbs the carbon dioxide, heavier hydrocarbons, and any

remaining traces of water vapor.

Separating

• Air is separated into its ma%or components in this step. The portion of the pretreated air is diverted

through a compressor, where its pressure is cooled and allowed to expand to nearly atmospheric

pressure. This expansion rapidly cools the air using the cryogenic technique.


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• The air stream which is part liquid and part gas enters the base of the high!pressure fractionating or

distillation column. As the air moves up the column, it loses additional heat. The oxygen continues

to liquefy, leading to the formation of oxygen!rich mixture in the bottom of the column, and other

gases like nitrogen and argon flow to the top as a vapor. The oxygen at the top is the liquid oxygen

mixture, also known as crude liquid oxygen, which is almost 22.4.

Purifying

The oxygen at the bottom is about 22.4 pure. ewer cryogenic distillation units are used to recover more

of the argon+nitrogen from the low!pressure distillation column, and this improves the oxygen purity to about

22.54. $f higher purity is needed, additional fractionating columns may be added to further refine the oxygen

product.

Distributing

The purified cryogenic oxygen produced is distributed to the end users in gas pipelines from nearby air

separation plants or transported in cylinders and storage tanks to specified destinations. $t is transported in

large, insulated tanks, usually made of two shells and the air is evacuated between the inner and outer shell

to obstruct heat loss.

Diagraatic representation

./ygen Grades at Cryogenic ./ygen Plants

The -ompressed 1as Association, formed in >)A with the intention to work for the development and

promotion of safety standards and safe practices in the industrial gas industry, establishes grading

standards for both gaseous oxygen and liquid oxygen. These standards are based on the amount and type

of impurities present.

1as grades are called Type $ and range from A to . The grade A stands for 22.94 pure and grade stands

for 22.224 pure. iquid grades are called Type $$. These also range from A to . 6owever, the types and

amounts of impurities in liquid grades are different from the gas grades. The most commonly produced

grades of oxygen are Type $ 1rade 0 and 1rade - and Type $$ 1rade - which is 22.4 pure. They are used

in steel making and in the manufacture of synthetic chemicals.

Applications of Cryogenic ./ygen

• -ombustion

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• 1lass industry

• *etal fabrication

• &ulp and paper industry

• -hemical industry

• *edical

• @aste water treatment.

+#uipent re#uired in cryogenic o/ygen plants

• )uction ilter

• Air -ompressor

• After -ooler

• -hilling >nit

• 'il Absorber

• *oisture )eparator

• *olecular )ieve 0attery

• 7xpansion 7ngine

• Air )eparation -olumn

• iquid 'xygen &umps

Buyer's guide

• Si2e: $arge& !edium& Small&

"ortable

• +apacity

• "urity

• ir +apacity

• "ower +onnected

• "ower +onsumed

• "ower Supply

• Starting pressure

• 1orking "ressure

• reas Re%uired

• ssembly 3eight

• 1eight

• ir Separation +olumn

Hydrogen Plants

*anufacturing &rocess 6ydrogen from ossil uels 6ydrogen from enewables

0iological &rocess Ammonia -racking Applications

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0uyer#s 1uide

0ound in organic matter and in water, hydrogen constitutes almost =4 of the earth#s surface and hence the

most abundant of all the chemical elements. 6ydrogen gas plants, available in small as well as in large

tonnage si"es, are hydrogen generating systems, used widely as a fuel and in various industrial purposes.

or many manufacturers and suppliers dealing with gas plants, supplying hydrogen gas plants involveconceptual design, procurement, detailed engineering, fabrication, construction, start!up, including

distribution and operator training.

%anufacturing Process of 0ydrogen

There are a wide range of sources by which hydrogen in produced in gas plants, which we are discussing

below:

0ydrogen fro ,ossil ,uels

• Stea 1eforing:

A very common method of producing hydrogen, steam reforming implied the use of thermal energy

which helps in separating hydrogen from the carbon components in methane and methanol. $n other

words a hydrocarbon gas like methane (-6C is combined with steam at high temperatures and

pressures in the presence of a catalyst which in turn produces hydrogen and -'<

The hydrogen produced is used in the manufacturing of fertili"ers, chemicals and also in the

improvement of the quality of petroleum products. This is considered to be the most cost effective

method of producing hydrogen.

• Partial ./idation:

Another process of producing hydrogen from fossil fuels is by the process of reaction of heavier

hydrocarbons like coal, oil, and some biomass products with steam.

0ydrogen fro 1eneables

@hen we talk about renewable energy, it implies the energy derived from energy sources like wave, wind,

solar, tidal etc. which is naturally replenished and cannot be exhausted. /ifferent processes used in

renewable energy to produce hydrogen is discussed below:

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• +lectrolysis

0y separating the elements of water!6 and oxygen ('!by charging water with an electrical current

is referred to as electrolysis and this is one popular method of producing hydrogen. Adding an

electrolyte like salt helps in making better the conductivity of the water and increases the efficiency

of the process. The chemical bond between the hydrogen and oxygen breaks with the electric

charge and separates the atomic components, which create charged particles called ions. The ions

are of two types!the anode, which is positively charged, and the cathode, which is negatively

charged. The anode attracts oxygen and hydrogen gathers at the cathode.

• Stea +lectrolysis

A variation of the conventional electrolysis process, in steam electrolysis, instead of electricity the

energy needed to split the water is added as heat. At


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Aonia Crac2ing

Another method used for the production of hydrogen is ammonia cracking process. This process is highly

recommendable in conditions where ammonia is used as a raw material, nitrogen does not function as an

impurity ? hydrogen is used as a reducing atmosphere

Applications of 0ydrogen Gas Plants

• 1efinery ( Petrocheicals: &etroleum and petrochemical manufacturers require a reliable

supply of high!quality hydrogen for their operations.

• .ils 0ydrogenation: 6ydrogenation of sugars, natural oils is very important in the production of

a variety of consumer goods like cooking oils, sweeteners, and cleaning products.

• %etals 0eat Treating: A hydrogen!containing atmosphere is required in many metals heat

treating processes require to produce a high quality finished part.

• Glass %anufacturing: $t is very essential to have a stable and consistent hydrogen supply in

meeting the strict product quality standards in the float glass industry.

• +lectronics:/ue to the sensitivity in electronics manufacturing, on!site gas plants producing

hydrogen provides several benefits over alternative solutions.

• Transportation 1efueling: As the demand for alternative energy sources increases, the ability

to produce hydrogen fuel economically is becoming increasingly important.

• !elding: 6ydrogen gas is required for welding and cutting.

• Cheical 3ndustry: 6ydrogen gas acts as synthesis gas for ammonia synthesis in the chemical

$ndustry.

• Paper ( Te/tiles

• Steel 3ndustry

• ,uel Cells

Buyer's Guide

Things to know before purchasing hydrogen gas plants are

• 3ydrogen purity

• +apacity

• "roduced gas pressure

• ire ha2ard

• "lant si2e

• "rocess description

• "lant description

• "lant control instruments

• "lant performances

Nitrogen Plant

-ryogenic &rocess on cryogenic process 7quipment

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Types 0uyers 1uide

itrogen gas plants are nitrogen generating system which can be small, portable si"e to large tonnage gas

plants, like oxygen plants, used for refining, chemical processing and other applications. $nfact, in almost all

oxygen plants, nitrogen is also produced at the same time.

itrogen (


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liquid is about 394 nitrogen and C94 oxygen and known as the Fich iquidF. As nitrogen is more

volatile it rises to top of the lower column and it becomes liquefied because of the cold it gets from

the condenser.

• Air Separation: inal separation is attained in the upper column. As the rich liquid entering the

middle of the upper column flows down, nitrogen evaporates and oxygen continues as liquid. The

liquid nitrogen which is also known as the poor liquid enters the top of the column and while flowingdown, it comes in contact with any evaporating 'xygen and condenses the same into liquid.

itrogen being volatile becomes a gas. The entire gaseous nitrogen is piped out through heat

exchangers from the top of the column. 1enerally the purity of 'xygen will be 22.4 and itrogen

about 234, when the plant is operated exclusively for oxygen production.

• ,illing of "i#uid 5Gas Nitrogen: The last step is the filling of purified nitrogen into pumps and

cylinders .

Non Cryogenic %anufacturing Process

PSA Process

>sing molecular sieves separation technique, the nitrogen generator produces nitrogen gas from

atmospheric air. The &)A process for nitrogen generation is similar to that of oxygen but carbon molecular

sieve (-*) is used instead of "eolite molecular sieve (G*). /ue to the adsorption properties of -*), it is

possible to produce nitrogen by charging two adsorber vessels with compressed air one after the other.@hile one vessel adsorbs, the other vessel is used in regenerating by pressure reduction. $n other words,

when compressed air is passed, nitrogen comes out as product gas from one vessel while the other vessel

is simultaneously regenerated by de!pressurisation to atmospheric pressure.

%ebrane Nitrogen Syste

0y using membrane technology, compressed air is provided from air compressor to separate nitrogen from

air. A feed air cleaning system is available in the membrane separator to provide clean air, free from solid

particles, oil and water droplets. The clean air will lead to higher efficiency nitrogen production and ensure

long life of the membranes.

+#uipent re#uired in Nitrogen Plants

• ir compressor system

• !oisture separator

• (4 Separation !embrane !odules

• (4 *as anks

• ir filter

• dsorber

• )xpander

• (itrogen pressure and flow regulator

Standard Applications of Nitrogen Gas Plants

• -hemical *anufacturing (*aterial Transfer, 0lanketing

• 7lectronics ()torage, @ave )oldering, urnace Application


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• ood &rocessing

• ood &ackaging

• aser -utting

• Tire illing

• &lastics ($n%ection *olding

• &harmaceuticals (&ackaging, 0lanketing

• 6eat Treatment (errous ? on!errous *etals

Types of Nitrogen Plants

/epending on the manufacturing process, nitrogen plants can be classified as follows:

• %ebrane Nitrogen Plants: The most automated gas plants designed for production of

nitrogen from atmospheric air.

• Adsorption Nitrogen Plants: Automated systems designed for gaseous nitrogen production

from air.

• Cryogenic Nitrogen Plants: These are cryogenic temperatures based plants designed for

production of liquid and gaseous nitrogen from atmospheric air.

• %obile Nitrogen Stations: *obile stations used for air!to!nitrogen production are specially

designed for operation in various climatic "ones. H *obile nitrogen compressor stations: These are

self!operated and carried nitrogen compressor stations for high!pressure nitrogen recovery.

Buyer's guide

Technical specifications to consider for purchasing nitrogen gas plants are

• Si2e: $arge& !edium& Small& "ortable

• +apacity: "ressure

• "urity

• "ower +onsumed• "ower Supply

• "ower +onnected

• Starting pressure


• ir +apacity

• Starting ime 5fter 6efrost7

• Starting ime 5fter ripping7

• reas Re%uired• ssembly 3eight

• 1eight


Oxygen Plant


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-ryogenic &rocess &)A process 7quipment

Types Applications 0uyers 1uide

'xygen plants are cost effective and safe oxygen producing system that range from small portable units to

large si"ed gas plants. The main purpose of oxygen plants is to produce industrial and medical oxygen up to

22.24 purity. The oxygen gas plants are used to serving markets for bottling cylinders, bra"ing of metals,

industrial gas cutting of steel, production of steel glass and ampule industry, used in petrochemical industry,

oil ? gas industry, animal husbandry and used for fabrication.

The oxygen plant units commonly operate according to cryogenic technology which is the preferred

technique for large si"ed plants or through non cryogenic technology!&)A+E&)A+E)A (&ressure swing

adsorption+Eacuum pressure swing adsorption+Eacuum swing adsorption, preferable for small and medium

si"ed plants. 6owever, it is basically the specifics of the application which decide which technology will be

most economical. The oxygen plant can also be used to produce nitrogen and argon from the air at the

same time. These oxygen plants can be designed as per their application requirements or as per thespecifications of customers.

%anufacturing Process )Cryogenic Process*

The process of producing oxygen in oxygen gas plants involves the following steps:

Step 6: Copression of atospheric air

$n the first stage of the production process, the free saturated air is sucked from atmosphere with the help of

a highly efficient dry!type suction filter or an air compressor.

Step 7: Purification of air

The next step involves the cleaning of air by removing moisture, oil traces, carbondioxide and other impure

products in the process air. $n the cryogenic technology, the compressed air is chilled in a chilling unit and

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transfered to a moisture separator where the condensed moisture gets separated before entering into

*olecular )ieve 0attery. 0efore that the air is passed through an oil absorber to remove oil.

Step 8: Cooling of air

The process air before liquefication in the gas plant is cooled to below!"ero temperature (cryogenic. After

pre cooling, the main portion of the process air enters the expansion engine through the heat exchanger .

The temperature of the air further drops down, somewhere about !83 deg - by the expander. est of air

enters into a highly efficient expansion engine, where the air is cooled further down to (!89 deg - before

entering into bottom column. The liquefied air collected at the bottom column from both these streams is

known as Frich liquidF.

Step 9: Separation of air

After the colling, the air enters the air separation unit where the air is converted into liquid air by deep

cooling at low or cryogenic temperatures and is separated into liquid oxygen and nitrogen.

Step : ,illing of o/ygen

The final stage in the process is the transport of liquid oxygen from the condenser to the cryogenic liquid

oxygen pump for filling gas cylinders.

%anufacturing process )PSA process*

&)A technology is another technique used in producing oxygen but it is preferred for small si"ed or portable

plants. The technique is based on the selective adsorption process of gas molecules under pressure on the

surface of highly porous and efficient adsorbent, usually "eolite based molecular sieve. $n &)A )ystem,

when compressed air is passed through "eolite based molecular sieve, the molecules of oxygen, moisture ?

other impure gases are adsorbed on the surface and oxygen which is not adsorbed comes out.

+#uipent 1e#uired in ./ygen Plants

• *olecular 0attery

• &urger

• &ressure )kid

• 7xpander

• -hilling >nit

• 'il Adsorber


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• 1as -ompressor

Types of ./ygen Plants

/epending on the manufacturing process, oxygen plants can be classified as follows:

• Adsorption ./ygen Plants: 6igh!performance gas plants developed for oxygen production

from atmospheric air and cylinder filling.

• %ebrane ./ygen Plants: ully automated membrane gas plants specially developed for air

oxygenation.

• Cryogenic ./ygen Plants: 1as plants for deep air free"ing specially designed to produce both

liquid and gaseous oxygen from air.

• %obile ./ygen Stations: These are transportable gas stations used to deploy a complete

oxygen production cycle with the cylinder filling option.

Application of ./ygen Plant

The basic property of oxygen is that it makes combustion possible, and it is this property which makes it

highly usable in various industrial applications. 0eing the largest volume industrial gas, oxygen plants are

used in the following industries :

• &etroleum ecovery and efining

• -hemical $ndustry

• )teel *anufacturing $ndustry

• &ulp and &aper $ndustry

• 1lass *anufacturing

• abrication industry

• *edical industry

Buyer's Guide

Technical specifications to consider for purchasing oxygen gas plants are:

• Si2e: $arge& !edium& Small&

"ortable• +apacity: xygen "ressure 5upto7

• "urity

• "ower +onnected

• "ower +onsumed

• "ower Supply

• ir +apacity


• Starting ime 5fter 6efrost7

• Starting ime 5fter

ripping7

• reas Re%uired

• ssembly 3eight

• 1eight



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PSA Oxygen Gas Plant

&rocess eatures E&)A unit

0enefits Applications

&)A oxygen gas plants are plants producing oxygen using the &)A process. 'xygen is used for various

industrial applications and hence needs to be produced in large volumes. There are usually two methods to

do this: cryogenic process and the &)A process. The &)A technology has today emerged as a very popular

technique for the production of commercial production of oxygen gas and suited for both small and mediumsi"ed units. The &)A process is very useful for small applications like oxygen production for asthma

patients.

!hat is PSA$

&)A stands for pressure swing adsorption. $t is dependent on air being filtered through aluminosilicate

minerals, called as "eolites. $n the &)A process, nitrogen gas is adsorbed into the "eolites and oxygen (and

argon pass through. $t is a technology in which some gas species are separated from a mixture of gases

under pressure. The &)A technique is very environment friendly and can also remove other gases such as

carbon dioxide from industrial waste gas streams.

The process

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• Copression of feed air and conditioning: >sing an air compressor, the ambient air gets

compresses, dried by an air dryer and then filtered before entering the process vessels.

• Adsorption: The next step in the &)A process of producing oxygen is the adsorption process.

The process removes impurities and produces almost 8994 pure oxygen. The pre!treated air

passes through a vessel filled with Geolite *olecular )ieve (G*). 6ere nitrogen and other gases

gets adsorbed and most of the oxygen pass and this continues till G*) is fully exhausted.

• Desorption: The saturated G*) is regenerated. This is done by pressure reduction, using a

simple pressure release system. This is after the adsorption process. The waste stream moves into

atmosphere. @hile regenerated adsorbent is purged with oxygen. This is again used for the

generation of oxygen.

• 1ecei4er: The adsorption and desorption process take place at equal time intervals, and there is

continuous generation of oxygen. 0y using a connected oxygen receiver, a constant product flow

and purity is maintained, which can store the oxygen with purities up to 24. inally, the plant

produces a constant flow of on!site produced oxygen.

,eatures of PSA ./ygen Plants

>sually the design of &)A oxygen plants rely on many factors like:

• Geolite bed packing

• 0ed length

• /iameter

• ate of infeed air

$n medical oxygen &)A plants, power efficiency is not given much preference compared to robustness,

process stability and oxygen purity. $n large si"ed &)A plants, the &)A process is only cost effective while

operating at maximum separation efficiency.

;PSA ./ygen Plant nit

>sing E&)A (vacuum pressure swing adsorption, oxygen is produced in small demands for various

applications. A typical E&)A unit is shown below:

Benefits of Psa Plants

-ompared to other processes used in gas plants, the &)A process has certain benefits:

• 6igh operational efficiency

• owers power costs

• ull safety


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• o ha"ards involved as with bulky gas cylinders

• ow pressure drops

• 6igh output pressures

• $ndependent on!site production

Applications of PSA ./ygen Plants

• )teel industry

• &ulp and paper industry

• 1lass and enamel industry

• /rinking water supply

• -hemical industry

• 0iotechnology industry

• @aste water treatment and waste disposal ind

What is cryogenic gas

-ryogenic gas plants have today emerged in the current market scenario as the most efficient and cost

effective technology of producing and distributing pure gases like oxygen and nitrogen. The technology is

perfect for large si"ed gas plants. The best feature of these gas plants is that they can produce liquid

products.

-ryogenic gases are liquefied gases at standard temperature and pressure. They are kept in their liquid

state at very low temperatures. The word FcryogenicsF in 7nglish means Fthe production of icy coldF.

-ryogenics in physics means the study of the production of extremely low temperatures (below !89 I-,

!


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• A little quantity of liquid can expand into very large volumes of gas.

-ryogenic gases are very popular and they are used as fuels, oxidi"ers and refrigerants. These gases are to

be stored properly to get their maximum usage. $n poorly insulated containers, it is very likely that some

cryogenic gases actually condense the surrounding air, forming a liquid air mixture. That is the reason they

should be held in special containers like /ewar flasks, which are generally about 8.5 m (3 feet tall and 28.cm (D feet in diameter. or commercial applications they are stored in giant tanks. $n museums, cryogenic

gas is stored in smaller vacuum flasks fitted in a protective casing. There are cryogenic transfer pumps used

on 1 piers. These pumps are used to transfer iquefied atural 1as from 1 -arriers to 1 storage

tanks.

-ryogenic gas also has some ha"ards associated with it like as they may be flammable, as in 6ydrogen,

&1 or they may be oxidi"ers, as in luorine, 'xygen and hence they must be carefully used.

A quick recap • +ryogenic gas is a gas formed at 0ery low temperature 5below 89+7.

• +ommonly used cryogenic materials is li%uid nitrogen and li%uid helium.

• he gas is produced through a process of compression and cooling.

•


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"i#uid ./ygen

-omprising sed primarily in

the aerospace, submarine and gas industry, liquid oxygen ('K is the liquid form of oxygen, which is pale

blue in color and extremely cold. iquid oxygen has a boiling point of !


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• =rypton

• >enon

• 3ydrogen

• $"*

• cetylene

• $i%uid oxygen

Storing of Cryogenic Gas

-ryogenic gases are needed to be stored in special containers, which are usually thermally insulated

containers, specifically designed to bear rapid temperature changes and extreme differences in temperature.

>sually the containers are designed in such a way so that they have few of the features as given in the

figure below:

Storage containers

)ome of the popular storage containers of cryogenic gases are as follows:

Dear flas2s

/ewar flask, named after its inventor )ir Lames /ewar in 852


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dispensing the cryogenic liquid. As a backup protection these cylinders also have pressure!control valves

with a frangible or bursting disk.

There are three main types of cryogenic liquid cylinders which are designed for storing:

• 'nly liquid

• 'nly gas

• iquid or gas

"i#uid cylinders ha4e to priary ad4antages:

• At relatively low pressure compared to compressed gas cylinders, these cryogenic cylinders can

hold a large volume of gas.

• These cylinders are an easy source of cryogenic liquid that can be easily handled.

Cryogenic products that are stored in li#uid cylinders are:

• (itrogen

• rgon

• xygen

• 3elium

• 3ydrogen

• (itrous oxide

• +arbon dioxide

• =rypton

• !ethane

• >enon

• (eon

@hile nitrogen, argon, oxygen, helium, hydrogen are stored in their liquid states, nitrous oxide and carbon

dioxide are kept as refrigerated liquids, but at higher temperature and pressure. These cylinders are well

insulated but at times the extremely low temperatures of the cryogenic liquids can lead to constant heat leak

and vapori"ation. The cryogenic product when not used will lead to pressure in the cylinder and often vent

via the container#s pressure relief device. 6owever, this is a normal and safe function of the cylinder.

Tan2s

Tanks are large double!walled, insulated storage tank, spherical or cylindrical in shape used for storing

cryogenic liquids or gases. Tanks are large storing containers for cryogenic gases, capacities ranging from

approximately hundreds of gallons to thousands of barrels. They are designed in such a way so that they

can be easily mounted in fixed locations as stationary vessels or on truck chassis or railroad car for easy

transportation. The pressure inside the tank is kept normal. The space between inner and outer surface is

vacuum and there are safety relief valves to protect the tanks.

Soe useful tips to consider for storing and transporting cryogenic li#uids:


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• 7nsure that all incoming containers are not damaged before storing.

• Always use the correct name for all products. or instance, you should never call Fliquid oxygenF as

Fliquid airF. 'r if the oxygen is in a mixture of other gases, refer to it as Foxygen mixtureF or

Fmedium purity liquid oxygenF.

• /ewar flasks should always be kept covered with a loose fitting cap. This helps in preventing air or

moisture from entering the container and at the same time allows pressure to escape.

• *ake use of only the plug or stopper supplied with the container.

• 1lass dewar flasks should not be used to store combustible or oxidi"ing cryogenic liquids.

• ever let ice form in the neck of flasks.

• /o not store containers in those areas where they have a chance to come in contact with moisture.

7nsure that storing vessels are insulated from any sources of heat.

• /o not store liquid oxygen containers on asphalt, oil soaked gravel or wood.

• $t is better to use concrete or clean gravel under storage areas.

• )tore all cryogenic liquid containers in well!ventilated areas.

• 6andle liquid cylinders carefully by avoiding rolling, dropping or tipping them on their sides.

• @hen transferring cryogenic liquids from one flask to another, always cool the receiving dewar flask

before filling it.

• )tart filling liquids slowly so as to allow the vapori"ation to chill the receiving container. After the

liquid boiling and vapori"ation have declined, fill the container at the normal rate.

• >se an appropriate filling device when pouring cryogenic liquids.

• ill storage containers only with liquids they are designed to hold.

A quick recap

ll cryogenic products must be properly stored and transported.he containers should bedesigned in such a way so that they can bear rapid temperature changes and also

differences in temperature. hat is why most containers are thermally insulated. Some of

the popular storage containers used for storing cryogenic gases are as follows:

• $i%uid dewar flasks

• $aboratory li%uid dewar flasks

• $i%uid cylinders

• anks

Cryogenic Air Separation


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-ryogenic Air )eperation &rocess low diagram Air )eparation )teps A quick recap

-ryogenic air separation process is one of the most popular air separation process, used frequently in

medium to large scale plants. $t is the most preferred technology for producing nitrogen, oxygen, and argon

as gases and+ or liquid products and supposed to be the most cost effective technology for high production

rate plants. $n today#s market scenario, all liquefied industrial gas production plants make use of cryogenic

technology to produce liquid products.

!hat is cryogenic air separation process$

-ryogenic air separation is a process to produce highly purified gases or liquids and it is done by taking

large volumes of air from the atmosphere, which is then compressed, cooled, liquefied. This is thenseparated into its ma%or components by distillation. After the air is compressed, impurities must be removed.

There are different variations arising from differences in user requirements in the cryogenic air separation

cycles to produce industrial gas products. The cycle of processing depends on:

• 6ow many products are required (whether simply oxygen or nitrogen, both oxygen and nitrogen, or

nitrogen, oxygen and argon.

• equired purities of the products.

• 1aseous product delivery pressures.

• astly whether the products need to be stored in liquid form.

$n the cryogenic gas processing, various equipment is used like the distillation columns, heat exchangers,

cold interconnecting piping etc. which operate at very low temperatures and hence must be well insulated.

These items are located inside sealed Fcold boxesF. -old boxes are tall structures with either round or

rectangular cross section. /epending on plant type, si"e and capacity, cold boxes may have a height of 8

to 39 meters and < to C meters on a side.

Cryogenic air separation flo diagra

The cryogenic air separation flow diagram given below does not represent any particular plant and shows in

a general way many of the important steps involved in producing oxygen, nitrogen, and argon as both gas

and liquid products.

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Steps in Cryogenic Air Separation

• ,irst Step: The first step in any cryogenic air separation plant is filtering and compressing air.

After filtration the compressed air is cooled to reach approximately ambient temperature by passing

through air!cooled or water!cooled heat exchangers. $n some cases it is cooled in a mechanical

refrigeration system to a much lower temperature. This leads to a better impurity removal, and also

minimi"ing power consumption, causing less variation in plant performance due to changes in

atmospheric temperature seasonally. After each stage of cooling and compression, condensed

water is removed from the air.

• Second Step: The second step is removing the remaining carbon dioxide and water vapor, which

must always be removed to satisfy product quality specifications. They are to be removed before

the air enters the distillation portion of the plant. The portion is that where the very low temperature

can make the water and carbon dioxide to free"e which can be deposited on the surfaces within the

process equipment. There are two basic methods to get rid of water vapor and carbon dioxide !

molecular sieve units and reversing exchangers.

• Third Step: The third step in the cryogenic air separation is the transfer of additional heat against

product and waste gas so as to bring the air feed to cryogenic temperature. The cooling is usually

done in bra"ed aluminum heat exchangers. They let the heat exchange between the incoming air

feed and cold product and waste gas streams leave the air separation process. The very cold

temperatures required for distillation of cryogenic products are formed by a refrigeration process

comprising expansion of one or more elevated pressure process streams.

• ,ourth Step: This step involves the use of distillation columns to separate the air into desired

products. or example, the distillation system for oxygen has both FhighF and FlowF pressure

columns. itrogen plants can have one or two column. @hile oxygen leaves from the bottom of the

distillation column, nitrogen leaves from the top. Argon has a boiling point similar to that of oxygen

and it stays with oxygen. $f however high purity oxygen is needed, it is necessary that at an

intermediate point argon must be removed from the distillation system. $mpure oxygen produced in

the higher pressure distillation column is further purified in the lower pressure column. &lants which

produce high purity oxygen, nitrogen or other cryogenic gases require more distillation stages.

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• ,ifth Step: The fifth step involves refrigeration which is formed at cryogenic temperature levels.

efrigerations compensate for imperfect heat exchange and for heat leak into the cold equipment.

The refrigeration cycle is almost similar like the one used in home and automobile air conditioning

systems. 'ne or more elevated pressure streams are reduced in pressure, which chills the stream.

To maximi"e chilling, the pressure expansion or reduction takes place inside an expander. 1aseous

products usually come out from the plant at relatively low pressures. $n general, the lower thedelivery pressure, the higher the plant efficiency. $t is always cost effective to produce the cryogenic

gas at low pressure and use a blower or compressor to achieve required delivery and gaseous

storage pressures.

A quick recap

+ryogenic air separation process depends in boiling points differences to separate and purify products. ll cryogenic processes include these steps:

• iltering and compressing air.

• Remo0ing the contaminants.

• +ooling the air to 0ery low temperature.

• 6istilling the air to produce desired products.

• 1arming in heat exchangers gaseous products and waste streams that also cool

the incoming air stream

Cryogenic Gas Haards

0ealth ha


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cryogenic gases are considered to be of low toxicity, but still they can lead to specific health

problems. )ome gases like carbon monoxide, fluorine, and nitrous oxide are toxic and hence it is

advisable to check the properties of the gases that are being used. or example, liquid carbon

monoxide can generate large quantities of carbon monoxide gas, which can cause death almost

immediately.

,laability5+/plosion ha


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$f this confined fluid is released all of a sudden, a significant thrust is experienced. 'ver!

pressuri"ation of cryogenic gas occurs when during the phase of change from liquid to gas is not

vented properly. The vapori"ation of cryogenic fluids produce large volumes of gas. A container

with inadequate pressure relief will lead to accumulation of pressure till the container ruptures,

which leads to serious in%ury.

• %aterials and construction ha


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0o to pre4ent ha


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cylinders are allowed for liquid hydrogen. ever allow any spilling of hydrogen it can create a flammable

cloud.

A quick recap o a0oid unnecessary ha2ards while handling or storing cryogenic li%uids& some handy

tips are gi0e below:

• lways wear personal protecti0e e%uipment while handling cryogenic gases.

• nly trained and %ualified personal should be allowed to handle& transport or

storing cryogenic gases.

• "roper storage is essential for such gases.

• +ylinders should not be dragged or carried.

• +ontainers should not be used for other purposes except for storing the specified

gas.

• !agnets should not be used for lifting cylinders.

• bser0e containers for loss of insulated 0acuum.

• ll cryogenic storage e%uipment must ha0e proper pressure relief 0ent system so

as to a0oid explosion or o0er pressuri2ation etc

Non!cryogenic Air Separation

1as processing or air separation is a very old technology of science involving the separation of air and the

identification of oxygen as an atmospheric component. )uch a process owes its origin with the origin of


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chemistry. There are basically two basic technologies of air separation: -ryogenic air separation and on

cryogenic air separation.

@hile the cryogenic technique is a traditional method, the non!cryogenic air separation is however a very

new technology. on cryogenic air separation was developed during the 82=9s. @hile cryogenic gas

separation requires large si"ed plants for its processing, the non cryogenic process is considered to be aconvenient, efficient, and economical method to buying gas in high pressure cylinders or for purchasing bulk

liquid products to be vapori"ed. This process is preferable for many small scale users of oxygen or nitrogen.

!hat e/actly is Non Cryogenic Separation$

The traditional method of producing nitrogen and oxygen gases is cryogenic air separation which involves

the process of cooling air in large si"ed plants to several hundred degrees below "ero in order to separate

the component gases. on!cryogenic air separation is however a very new technology that requires air to

force through through special materials that selectively pass or retain the oxygen or nitrogen. The physical

properties of the gases other than the temperature like molecular si"e and mass are exploited in non

cryogenic air separation process to produce discrete and refine elements of air at close!to!atmospheric

temperature. 'perating at near!ambient temperature, these are then used to produce commercially valuable

gaseous products like oxygen and nitrogen.

There are three main technologies involved in non cryogenic process. They are

• &ressure )wing Adsorption (&)A used in nitrogen and oxygen generators

• Eacuum!&ressure )wing Adsorption (E&)A used in oxygen generators and

• *embrane )eparation, used to produce nitrogen gas.

@e will discuss in details the three processes in the section:

•

Types of non!cryogenic air separation

Ad4antages of Non Cryogenic Separation Processes

• The non cryogenic technique is much smaller in si"e than cryogenic plants

• The basic advantage is that it can be placed directly on the customer#s site

• They are efficient and economical choices when demand is relatively small and when very high

product purity is not required

• They are compact

• They can operate at near!ambient temperature and pressure

• 'nce installed, they can be brought on!line in less than D9 minutes.

Conclusion

on cryogenic gas processing is growing up in recent years though it has not been able to completely

displace other existing technologies. The process is gradually gaining market share in those applications

where it has a clear economic or technical advantage. 0oth technology!push and market!pull factors have

contributed to the running of non separation process centered on &)A, E&)A or membrane technology. or

many manufacturers and suppliers, these non!cryogenic gas separations must play against the long

established cryogenic separations involved in bulk gas business.

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on!cryogenic gas processes are on the way to altering the economics of certain processes and expanding

the markets, applications, and uses of gases. The separation of air into oxygen, nitrogen, natural gas

purification, hydrogen recovery will become increasingly important across a wide spectrum of very specific

applications. >sing non!cryogenic separations all types of gas streams can be processed. According to

recent report, the present and future markets for non!cryogenic gas separations include the following:• Air )eparation !!nitrogen and oxygen enriched air

• atural 1as -lean up

• 6ydrocarbon -lean!up

• 6ydrogen )eparations

• 6ydrogen recovery from off!gases

• *iscellaneous !!rare gases, drying

Gas Plant Processing

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