Low Pressure Liquid Oxygen Nitrogen Plants
Universal
IN COLLABORATION WITH ING. L&A Boschi (Italy) Manufactures and supplies Premium Quality low pressure Air separation plants of all sizes ranging from
50 m3/hour to 50,000 m3/hour including Cryogenic Tonnage gas plants and liquid plants. Univesal Boschi wth its state-of-the-art technology has established itself as the leading exporter of air separation plants with the most varied capacity range.
With manufacturing facilities spread out in various locations all over India &Asia and sales located in New Corporate Region of Delhi, the Italy based company is dedicated to supplying the latest in Cryogenic Technology constantly striving to improve its products through continuous research and development.
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 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
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.
Process description for Oxygen – Nitrogen Low pressure gas plants:
1. COMPRESSION OF ATMOSPHERIC AIR BY AIR COMPRESSOR
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 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 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 OF 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 t the outlet as a second product at purity of 99.9% upto 3ppm simultaneously without loss of oxygen product.
6. Compression of Oxygen & filling it 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..
Main Equipments :
(I) Air Compressor: Screw/low pressure- type : (or Oil free Piston or Centrifugal types)
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 : 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.
(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.
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 is recovered by 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.
(V) Turbo expander:
The Turbo expander is a gas or oil 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.
Universal Turbo Expanders
Test bed for 100% reliability and tested at 150,000 rpm at minus 190 degree centigrade.
Troublefree service for years!
Technical Specification :
Universal Boschi (Italy) is a reputed manufacturer/exporter and supplier of Liquid Oxygen Plants, Liquid Oxygen Nitrogen Plants(Low Pressure) and Liquid Filling Oxygen Nitrogen Plants starting from 40 cum/hr and following are the specifications for the same :
| Models |
UBTL SERIES UBT40, UBT80, 100, 120, 150 , 180, 200, 220, 250, 300, 350, 400, 500, 600, 800 & 1000. 2000, 3000, upto 40.000 |
| Oxygen production |
Liquid Oxygen (LOX) 40 to 40,000m3/hr |
| Oxygen Output (cu. Mtr/hr) |
40 TO 50,000m3/hour Liquid |
| Oxygen Purity (%) |
99.6% (03 Bar) |
| Liquid Oxygen Pressure in cylinders |
0.03 MPA (0.3Bar) |
| |
| Nitrogen production |
Liquid Nitrogen (LIN) - 40 to 40,000m3/hr |
| Nitrogen Pressure out of Column (bar) |
|
| Nitrogen Output (cu. Mtr/hr) |
99.9% to 99.99/3ppm opt. |
| Nitrogen Purity (ppm optional) |
150 bar(kg/cm2) |
| Nitrogen filling in cylinders(optional) |
150 bar(kg/cm2) |
| Argon Production |
Argon recovery unit can be filled for argon production above 1000,3/hr |
| |
| Type |
| Operation Pressure (bar) |
7 bar(kg/cm2) |
| Operation Period |
24 hours -continuous |
| Air compressor |
Rotary/screw |
| Expander |
turbo |
| 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) |
0.2 to0.4kwh(units) |
| Voltage 3 phase** |
380-415 50/60 hz or as per country |
1. Small Capacity Liquid Oxygen Nitrogen (Low Pressure) Plants :
- Range : 20 TO 1000M3/Hr.
- Purity : Oxygen - 99.6% and Nitrogen -99.99% or 3PPM
- Operating Air Pressure : 0.6 TO 0.7Mpa
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 expanders. The liquid air separates into oxygen nitrogen and inert gases in the air separation column.
Technical Specifications for Small Capacity Plants :
Universal Boschi (Italy) is a reputed manufacturer/exporter and supplier of Small capacity Liquid Oxygen Nitrogen Plants (Low Pressure)in the range of 20 cum/hr - 1000 cum/hr and following are the specifications for the same :
| Model (O2/N2*/Ar) |
LOX Capacity Nm3/h |
LOX Capacity L/Hr |
GO2 Purity
% O2 |
GN2 Capaity Nm3/h |
LIN Capacity Nm3/h |
| UBTL-20/20 |
20 |
24 |
99.60% |
20 |
20 |
| UBTL-30/30 |
30 |
36 |
99.60% |
30 |
30 |
| UBTL-40/50 |
40 |
48 |
99.60% |
50 |
40 |
| UBTL-60/80 |
60 |
72 |
99.60% |
80 |
60 |
| UBTL-80/100 |
80 |
96 |
99.60% |
100 |
80 |
| UBTL-100/150 |
100 |
120 |
99.60% |
150 |
100 |
| UBTL-120/150 |
120 |
144 |
99.60% |
150 |
120 |
| UBTL-150/200 |
150 |
180 |
99.60% |
200 |
150 |
| UBTL-170/200 |
170 |
204 |
99.60% |
200 |
170 |
| UBTL-200/220 |
200 |
240 |
99.60% |
220 |
200 |
| Model (O2/N2*/Ar) |
LOX Capacity Nm3/h |
LOX Capacity L/Hr |
GO2 Purity
% O2 |
GN2 Capaity Nm3/h |
LIN Capacity Nm3/h |
| UBTL-220/220 |
220 |
264 |
99.60% |
220 |
220 |
| UBTL-250/250 |
250 |
300 |
99.60% |
250 |
250 |
| UBTL-300/300 |
300 |
360 |
99.60% |
300 |
300 |
| UBTL-LOX/350LIN/350 GAN |
350 |
420 |
99.60% |
- |
350 |
| UBTL-350/350 |
350 |
420 |
99.60% |
350 |
350 |
| UBTL-400/400 |
400 |
480 |
99.60% |
400 |
400 |
| UBTL-500/500 |
500 |
600 |
99.60% |
500 |
500 |
| UBTL-600/600 |
600 |
720 |
99.60% |
600 |
600 |
| UBTL-800/800 |
800 |
960 |
99.60% |
800 |
800 |
2. Medium Capacity Liquid Oxygen Nitrogen (Low Pressure) Plants :
Medium Capacity Liquid Plants(32 TPD TO 320 TPD)
- Range: 1,000 TO 10,000M3/hr.
- Purity : Oxygen - 99.6% and 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-cooling 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 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 and filling it 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.
Technical Specifications for Medium Capacty Plants :
Universal Boschi (Italy) is a reputed manufacturer/exporter and supplier of Medium capacity Liquid Oxygen Nitrogen Plants (Low Pressure) in the range of 1000 cum/hr - 10,000 cum/hr and following are the specifications for the same :
| Model (O2/N2*/Ar) |
LOX Capacity Nm3/h |
LOX Capacity L/Hr |
GO2 Purity % O2 |
GN2 Capaity Nm3/h |
LIN Capacity Nm3/h |
| UBTL-1000(LOX/LIN)1000 |
1000 |
1200 |
99.60% |
- |
1000 |
| UBTL-1000(LOX)/1000(LIN) |
1000 |
1200 |
99.60% |
- |
1000 |
| LOX/4450 GOX/100LIN/100GAN/LAR70 |
450 |
540 |
99.60% |
1000 |
100 |
| UBTL-1000/800 |
1000 |
1200 |
99.60% |
800 |
1320 |
| UBTL-1500/1500 |
1500 |
1800 |
99.60% |
1500 |
1980 |
| UBTL-2000/2000 |
2000 |
2400 |
99.60% |
2000 |
2640 |
| UBTL Ar-1500/1500/45 |
1500 |
1800 |
99.60% |
1500 |
1980 |
| UBTL Ar-3600/3600/100 |
3600 |
4320 |
99.60% |
3600 |
4752 |
| UBTL Ar-6000/13000/200 |
6000 |
7200 |
99.60% |
13000 |
7920 |
3. Large Capacity Liquid Oxygen Nitrogen (Low Pressure) Plants :
Large Capacity Liquid Plants (320 TPD TO 1600 TPD)
- Range : 10,000 TO 50,000M3/hr
- Purity : Oxygen - 99.6% and 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.
Technical Specifications for Large Capacity Plants :
Universal Boschi (Italy) is a reputed manufacturer/exporter and supplier of Large capacity Liquid Oxygen Nitrogen Plants (Low Pressure) in the range of 10,000 cum/hr - 50,000 cum/hr and following are the specifications for the same :
| Model (O2/N2*/Ar) |
LOX Capacity Nm3/h |
LOX Capacity L/Hr |
GO2 Purity % O2 |
GN2 Capaity Nm3/h |
LIN Capacity Nm3/h |
| UBTL Ar-10000/18000/380 |
10000 |
12000 |
99.60% |
18000 |
13200 |
| UBTL Ar-15000/13000/450 |
15000 |
18000 |
99.60% |
18000 |
15000 |
| UBTL-15000/10000 |
15000 |
18000 |
99.60% |
10000 |
19800 |
| UBTL-18000/15000 |
18000 |
21600 |
99.60% |
15000 |
23760 |
| UBTL-20000/20000 |
20000 |
30000 |
99.60% |
20000 |
33000 |
| UBTL-25000/25000 |
25000 |
36000 |
99.60% |
20000 |
39600 |
| UBTL-30000/25000 |
30000 |
36000 |
99.60% |
25000 |
39600 |
| UBTL-40000/30000 |
40000 |
48000 |
99.60% |
30000 |
52800 |
| UBTL-50000/50000 |
50000 |
60000 |
99.60% |
50000 |
50000 |
