Setup Oxygen & Nitrogen Plant Factory Project-Universal Boschi Industrial Plants

We are world class manufacturer and exporter of acetylene gas plant for oxy acetylene gas welding and cutting applications. Automatic standard acetylene generation plant is used for producing ac..

Specification

Capacity : 15 m3/hour to 200 m3/hour
Applications : Oxy-Acetylene Welding and Cutting
Technology : ING L.&A. BOSCHI, ITALY (Since 1930)
Uses : Welding, Cutting and Heat Treatin

How an Acetylene Gas Plant Works

The process for producing acetylene gas involves a chemical reaction between calcium carbide and water. Raw materials used in the reaction are water and calcium carbide, which is popular for commercial production of acetylene. CaC2 (chemical formula for calcium carbide) is made by a mixture of line and coke in a blast furnace. The reaction between water and Cac2 is formulated as CaC2 + 2H2O -> C2H2 + Ca(OH)2 The reaction generates C2H2 (acetylene), calcium hydroxide and heat. Very less moisture content is generated during the reaction.

Detailed Technical Process for Acetylene Production

The process for generation of acetylene gas is described in detail below. We use the standard size of calcium carbide during the testing of acetylene gas plants. However, you can use the CaC2 of varying sizes which will have impact on the performance.

Components Used in the Acetylene Plant

Acetylene generator
Condenser
Low pressure dryer
The LP purifier
Ammonia Scrubber
Acetylene compressor
High Pressure Drier
Cylinders filling manifold
Flame proof level controller
Instrument Control Panel

Our Competitive Advantages

Low working pressure
Low operating cost
Sturdy design
User friendly
Fully automatic
Low maintenance
Trouble free operation
Latest and high quality
High pressure and low pressure safety cut off
External lubricator placed
Pressure gauges from Wika German
CE approved valves
Inter-stage moisture separators for moisture drain by centralized drain valve station
Latest antistatic v belts

What are the main uses of Acetylene Gas

Acetylene is one of the most popular fuel gases, which is used in wide range industrial applications. It is used in combination with oxygen for generating high flame temperatures. Some of the industrial applications are given below:

Welding
Cutting
Heating
Brazing
Portable Lighting
Plastics and Acrylic Acid Derivatives
Production of Chemicals

TECHNICAL SPECIFICATIONS OF ACETYLENE PLANT

S.NO	Description		UA-15	UA-25	UA-50	UA-100	UA-200
1.	Capacity Cubic Meter per hour		16	27.5	55	110	220
2.	RAW MATERIAL REQUIRED
	Raw Material	Calcium Carbide (kg/m3 of gas) Main Raw Material -cac2- Carbide quality 5mm to 25 mm specify	3.3	3.3	3.3	3.3	3.3
	Power	Power (average requirement)	10kw	12kw	15kw	28kw	40kw
	Water	Cooling water make-up (liters/N.cubic meter of gas)	10	10	10	10	10
3.	CHEMICAL & CONSUMABLES IN SMALLER QUANTITIES FOR PURIFYING PROCESS
	Calcium Chloride (gms/N.cubic meter of gas) (one charge supplied inside LP drier)		50	50	50	50	50
	Purifying mass (gas plus acid absorbtion mix per cum of gas)		15gms/N.Cum+4gms	15gms/N.Cum+4gms	15gms/N.Cum+4gms	15gms/N.Cum+4gms	15gms/N.Cum+4gms
4.	CYLINDER FILLING
	Acetone in cylinders pumped through acetone pump		As Required	As Required	As Required	As Required	As Required
	Space Required (approx.)		As Required	As Required	As Required	As Required	As Required
	Process Area		50 Sq.M	70 Sq.M	110 Sq.M	150 Sq.M	200 Sq.M
	Carbide Area		60 Sq.M	75 Sq.M	112 Sq.M	175 Sq.M	250 Sq.M
	Cylinder Filling Area		30 Sq.M	40 Sq.M	60 Sq.M	100 Sq.M	150 Sq.M
	Cylinder Storage Area (Depending upon cylinder inventory)		80 Sq.M	100 Sq.M	160 Sq.M	200 Sq.M	400 Sq.M
	Lime Slurry disposal area		80 Sq.M	100 Sq.M	180 Sq.M	250 Sq.M	300 Sq.M
	Free Space around the plant (on all sides)		15 M	16 M	18.5 M	20 M	20 M
	Acetone Godown		10 Sq.M	12 Sq.M	20 Sq.M	30 Sq.M	40 Sq.M

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Oxygen Cylinder Filling Plant

UNIVERSAL BOSCHI is a global manufacturer and exporter of Oxygen/Nitrogen Gas Plant with Latest Cryogenic Technology Stainless Steel Column and Atlas Copco Air Compressor. We are manufact..

Specification

Capacity : 50 to 1,000 m3/hour
Output : 200 to 4,000 Cylinders/Day
Purity : OXYGEN - 99.7% & NITROGEN - 99.999%
Pressure : 150 - 200 Bar

Universal Boschi is a leading manufacturer and supplier of cylinder filling oxygen plant. Our plants are designed and developed by using the latest technology in order to make them perform as per the plants of international standard. With the technical collaboration of ING. L. & A. BOSCHI of Italy, our company develops and designs automatic and efficient plants. Our association with Dr. Boschi of Italy has helped immensely to manufacture the plants which are in compliance with the international standards and CE certification. Our cylinder filling oxygen plant is unmatched in the industry.

Basic Principle

Our cylinder filling oxygen plant is a plant recovering oxygen and nitrogen from air simultaneously. It employs low pressure technology process of Boschi Italy along with Rotary screw compressor (or low oil free piston compressor) and turbo expanders. The feed air entering the Molecular Sieve purification system used to disappear 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 gets separated into oxygen nitrogen and inert gases in the air separation column.

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 latest rotary compressor (Screw/Centrifugal Type latest technology is used in place 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 goes inside the purifier.

3. Purification of Air by Purifier

The air goes inside purifier holding twin Molecular Sieve driers, working alternatively. The Molecular Sieves remove the Carbon dioxide & moisture from the process air before the air gets into the Air Separation Unit.

4. Cryogenic Cooling of Air by Turbo (Expander)

The air must be cooled to sub zero temperatures for liquification & the cryogenic refrigeration & the cooling is provided by highly efficient turbo expander, which cools the air to temperature almost below -165 to-170 deg C.

5. Separation If Liquid Air into Oxygen and Nitrogen by Air Separation Column

Oil free, moisture free and Carbon Dioxide free air goes inside the low pressure plate fin type Heat exchanger where the air is cooled below sub zero temperatures by air expansion process in the turbo expander. Owing 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 reaches at the air separation column & gets separated into oxygen & nitrogen by the process of rectification.

6. Compression of Oxygen filling in the Cylinder

The final product in the form compressed oxygen/nitrogen goes to the high pressure oxygen cylinders at 150 bar or upto higher as required. It is required for pipeline supply, captive consumption or for liquid plants to fill in cryogenic liquid tanks.

TECHNICAL SPECIFICATION

NAME OF MODELS	UBP-50	UBP-100	UBP-130	UBP-170	UBP-200	UBP-300	UBP-400	UBP-500	UBP-1000
CAPACITIES (CUBIC METER/HR.)	50	100	500	700	200	300	400	500	1000
NO. OF CYLINDERS IN A DAY (OXYGEN/NITROGEN)	200	400	500	700	800	1200	1600	2000	4000

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Medical Oxygen Plant

We are leaders in manufacturing and supplying skid mounted portable mobile oxygen plant. Our oxygen containerized systems are designed for installation in a shipping container. It can be easily s..

Specification

Capacity : 25 to 500 m3/hour
Output :100 to 2,000 Cylinders/Day
Purity : OXYGEN - 99.7%
Pressure : 150 - 200 Bar

Main Features

Ready to start SKID Mounted in ISO FRAME
PLUG AND PLAY
Zero headaches of site work piping wiring etc
Suitable for outdoor installation
ZERO maintenance Atlas Copco air compressors.
All plants fully tested for full production and purity before factory delivery
Very low power consumption. (Saving up to 30% power and zero maintenance)
Saving of water as air compressor is air cooled.
100% stainless steel construction column as per ASME standards.
Cryogenic type for high purity 99.7% industrial and medical versions
High purity Oxygen for medical/hospital use.
No concrete foundations as all machinery is skid/floor mounted.

Advantages of SKID MOUNTED System

Maintenance-Free Operation
EASY TO INSTALL
Easy to Move
FACTORY FITTED AND TESTED PLANT
High Return on Investment

Specification Table for Skid Mounted Oxygen Plant

MODEL	CAPACITY IN M3/HOUR	NUMBER OF CYLINDERS PER DAY	PURITY OF OXYGEN PRODUCED	PRESSURE OF OXYGEN IN CYLINDERS
UBPM-25	25	100	99.7%	150-200 BAR
UBPM-50	50	200	99.7%	150-200 BAR
UBPM-80	80	300	99.7%	150-200 BAR
UBPM-100	100	400	99.7%	150-200 BAR
UBPM-150	150	600	99.7%	150-200 BAR
UBPM-200	200	800	99.7%	150-200 BAR
UBPM-300	300	1200	99.7%	150-200 BAR
UBPM-400	400	1600	99.7%	150-200 BAR
UBPM-500	500	2000	99.7%	150-200 BAR

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Liquid Nitrogen Plants

We are leading manufacturer of liquid nitrogen plants that are designed and developed using high quality technology. Our liquid nitrogen plant generates liquid nitrogen with high purity up to 99.99%. ..

Specification

Capacity : 50 to 1,000 m3/hour
Output : 50 to 1000 Liter/Day (Liquid Nitrogen Optional)
Purity : OXYGEN - 99.7% & NITROGEN - 99.999%
Pressure : 2 - 4 Bar

Key Points of LOX-LIN Plants

100% stainless steel column as per ASME standards.
Low Power Consumption. No downtime as liquid Nitrogen stored in Tank.
Low pressure Rotary air compressor by ATLAS COPCO which are the best in the world.
New Technology with 100% stainless steel vacuum insulated condenser
New Design 100% stainless steel head and cold parts of the cryogenic expander.
New Technology liquid pump with 100% super insulated stainless steel cold end.
High purity output upto 99.99%.

MODEL	PRODUCTION IN M3/HR	PRODUCTION LITERS/HOUR	PURITY
UBTLN-50	50	73	99.9 To 99.99999%
UBTLN-100	100	145	99.9 To 99.99999%
UBTLN-200	200	218	99.9 To 99.99999%
UBTLN-300	300	435	99.9 To 99.99999%
UBTLN-400	400	578	99.9 To 99.99999%
UBTLN-500	500	724	99.9 To 99.99999%
UBTLN-1000	1000	1440	99.9 To 99.99999%
UBTLN-1500	1500	2171	99.9 To 99.99999%
UBTLN-2000	2000	2894	99.9 To 99.99999%
UBTLN-3000	3000	4341	99.9 To 99.99999%
UBTLN-4000	4000	5788	99.9 To 99.99999%
UBTLN-5000	5000	7235	99.9 To 99.99999%

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Liquid Oxygen Plants

We are trusted manufacturer and exporter of liquid oxygen plants with precision designing, ASME/CE quality materials and cryogenic low pressure technology. Moreover, our company has acquired the techn..

Specification

Capacity : 50 to 1,000 m3/hour
Output : 50 to 1000 Liter/Day (Liquid Nitrogen Optional)
Purity : OXYGEN - 99.7% & NITROGEN - 99.999%
Pressure : 2 - 4 Bar

Key Features of UBTL Series LOX Plants

100% stainless steel column as per ASME standards.
Low Power Consumption. No downtime as liquid oxygen stored in Tank.
Low pressure Rotary air compressor by ATLAS COPCO which are the best in the world.
New Technology with 100% stainless steel vacuum insulated condenser
New Design 100% stainless steel head and cold parts of the cryogenic expander.
New Technology liquid pump with 100% super insulated stainless steel cold end.
High purity output upto 99.7%.

Model & Capacity Table of Liquid Oxygen Plants

Production	UBTL-50	UBTL-100	UBTL-200	UBTL-300	UBTL-400	UBTL-500	UBTL-1000
Liquid Oxygen Output (liters per hour)	60	120	235	350	470	590	1172
Purity Oxygen (%)	99.799.7	99.7	99.7	99.7	99.7	99.7	99.7
Liquid Nitrogen Output (liters per hour)	73	144	290	435	578	700	1440
Purity Nitrogen (%)	99% to 99.999% or ppm	99% to 99.999% or ppm	99% to 99.999% or ppm	99% to 99.999% or ppm	99% to 99.999% or ppm	99% to 99.999% or ppm	99% to 99.999% or ppm

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Oxygen Nitrogen Plants

We are manufacturing and exporting of Oxygen/Nitrogen Gas Plants, which are technologically very advanced. Our oxygen/nitrogen gas plants are being manufactured and supplied as per the latest technolo..

Specification

Capacity : 30 to 2000 m3/hour
Output :120 to 8,000 Cylinders/Day
Purity : OXYGEN - 99.7% & NITROGEN -99.99%
Pressure : 150 - 200 Bar

Salient Features of UBP Series New Technology Oxygen Plant

High Purity Oxygen for Industrial and Medical grade.
Rotary Automatic Air compressor (Air cooled - Hence Heavy saving of Water)
Skid mounted & easy to install.
100% cryogenic grade stainless steel; hence oxygen produced is 100% medical oxygen suitable as per American/European pharmacopeia & industrial uses like cutting/welding etc.
Liquid oxygen pump technology for filling high purity oxygen in cylinders at 150 to 200 Bar.
Low Power consumption
Quick start system ensures faster production after power tripping.

MODEL	CAPACITY IN M3/HOUR	NUMBER OF CYLINDERS PER DAY	PURITY OF OXYGEN	PRESSURE
UBP-30	30	120	99.7%	150-200 BAR
UBP-50	50	200	99.7%	150-200 BAR
UBP-80	80	300	99.7%	150-200 BAR
UBP-100	100	400	99.7%	150-200 BAR
UBP-130	130	500	99.7%	150-200 BAR
UBP-150	150	600	99.7%	150-200 BAR
UBP-170	170	700	99.7%	150-200 BAR
UBP-300	300	1200	99.7%	150-200 BAR
UBP-400	400	1600	99.7%	150-200 BAR
UBP-500	500	2000	99.7%	150-200 BAR
UBP-600	600	2400	99.7%	150-200 BAR
UBP-1000	1000	4000	99.7%	150-200 BAR
UBP-1500	1500	6000	99.7%	150-200 BAR

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Air Separation Plant

Cryogenic Air Separation Plant World class manufacturer and exporter of cryogenic gas air separation plant. we have manufactured over 500 AIR SEPARATION PLANTS & EQUIPMENTS since 1985..

Specification

Capacity : 50 to 2,000 m3/hour
Output : 200 to 8,000 Cylinders/Day
Purity : OXYGEN - 99.7% & NITROGEN - 99.999%
Pressure : 150 - 200 Bar

Key Features

100% stainless steel column as per ASME standards.
Low Power Consumption. No downtime as liquid Nitrogen stored in Tank.
Low pressure Rotary air compressor by ATLAS COPCO which are the best in the world.
New Technology with 100% stainless steel vacuum insulated condenser
New Design 100% stainless steel head and cold parts of the cryogenic expander.
New Technology liquid pump with 100% super insulated stainless steel cold end.
High purity output upto 99.99%.

TECHNICAL SPECIFICATION

PRODUCTION	UBT-50	UBT-100	UBT-200	UBT-250	UBT-300	UBT-400	UBT-500	UBT-600	UBT-800	UBT-1000	UBT-2000
OXYGEN / NITROGEN CYLINDERS FILLING PER DAY	200	400	800	1000	1200	1600	2000	2400	3200	4000	8000
OXYGEN PURITY(%)	99.7	99.7	99.7	99.7	99.7	99.7	99.7	99.7	99.7	99.7	99.7
NITROGEN PURITY(%)	99.9	99.9	99.9	99.9	99.9	99.9	99.9	99.9	99.9	99.9	99.9

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Oxygen Gas Plants

We are an esteemed company for manufacturing and supplying pure nitrogen plants made in technical collaboration with ING. L. & A. Boschi of Italy. With state of the art designs, technology from Eu..

Specification

Capacity: UBP- 50 M3/Hour to 2000 M3/Hour
Output: 200 to 8000 Cylinder Filling/Day
Purity: OXYGEN- 99.7%
Applications: Medicals, Hospitals and Laboratory, HealthCare Industry.

Scope and Supply

Air Compressor : Rotary air compressor screw type can be employed for smaller size plants upto 50 m3/hr to 1000m3/hr.
Air Pre Cooling System : Air separation plants adopt chilling system in all air pre-Cooling systems.
Air Purification System : In this system, molecular sieve are used in the air purification system to remove the CO2 & moisture for the process air at low- Pressure.
Rectification Column : The unit in cold box is all low pressure technology. This unit employs the latest state of the art plate & 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.
Turbo-Expander : Turbo - Expander is employed for giving cooling to the air for the liqefication process and braked by booster, so as to diminish the expanded air volume, stabilize the upper columns working condition and reduce power consumption. The turbine expanders have complete trouble free working and long life and reliability.
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 SPECIFICATION

NAME OF MODELS	UBP-50	UBP-100	UBP-130	UBP-170	UBP-200	UBP-300	UBP-400	UBP-500	UBP-1000
CAPACITIES (CUBIC METER/HR.)	50	100	500	700	200	300	400	500	1000
NO. OF CYLINDERS IN A DAY (OXYGEN/NITROGEN)	200	400	500	700	800	1200	1600	2000	4000

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Oxygen Plant Installed in Haiti

UNIVERSAL BOSCHI Successfully Installed Oxygen Plant in Haiti. Setup onsite Liquid & Gaseous Oxygen Production Plant with Liquid Storage Tanks and Oxygen Cylinder Filling Station. Are Iif You..

Specification

Capacity : 150 m3/hour
Output :150 Liter/Hour
Purity : OXYGEN - 99.7% & NITROGEN -99.99%
Pressure : 150 - 200 Bar

Salient Features of UBPL Series Liquid Oxygen Nitrogen Plant

High Purity Oxygen for Industrial and Medical grade.
Rotary Automatic Air compressor (Air cooled - Hence Heavy saving of Water)
Skid mounted & easy to install.
100% cryogenic grade stainless steel; hence oxygen produced is 100% medical oxygen suitable as per American/European pharmacopeia & industrial uses like cutting/welding etc.
Liquid oxygen pump technology for filling high purity oxygen in cylinders at 150 to 200 Bar.
Low Power consumption
Quick start system ensures faster production after power tripping.