Low Pressure Cylinder Filling Oxygen Nitrogen Plants

---

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

*pure nitrogen of 99.9% upto 3ppm is produced without any los of the oxygen production.
**voltage and freqwuency as per the country of installation.

Main Performance of the plant:

A. Oxygen purity 99.6% at 150-160 Bar(2200PSIG) for Oxygen cylinder filling
B. High purity Nitrogen 99.99%(ppm optional) or cylinder filling.
NOTE: There is no loss of oxygen Production when producing high purity nitrogen.

Air separation is CRYOGENIC TYPE with low-pressure cycle of 7 Kg/cm2 with air separation by liquification. This cycle utilize an Expansion TURBINE to give the cold calories at (-)1 80° C. The cold box is supplied as a complete package unit with control panel and insulation.

Process Description:

Process Description
This air separation plant mainly includes:
• air filter system
• air compressor system
• air pre cooling system
• Molecular sieve purifying system
• rectifying column system, nitrogen & oxygen compress and storage system, instrument control system, electric control system. Etc.

Air filter and compression
Air enters the self cleaning air suction filter, after being removed of dust and other mechanical contaminants in it, then enters main air compressor, after compression air then enters the after cooler.

Air cooling and purifying
Air is cooled in the Pre-Cooling System before enters mole sieve adsorber, Air which enters the evaporator of the Pre-Cooling System is cooled by the refrigerant.

Mole sieve purifying system includes two mole sieve adsorber and Steam heater or Electric heater. The mole sieve adsorber adsorbs water, CO2 and some hydrocarbon in the air, one mole sieve adsorber is regeneration while another one is work.

Air rectification
Air from adsorber is divided two stream: one stream enter directly main heat exchange, then enter lower column after cooled, the second stream enter main heat exchanger to cool after compressed by booster end of the expander and cooled by after cooler, then enter upper column after expanded by the expander.

The content of nitrogen will increase through rising gas connect with the reflux. Needed reflux liquid nitrogen is from condensate evaporator in the top of lower column, oxygen will be evaporated and nitrogen will be condensed in here.
• Lower column production as following from the top down:
• Pure liquid nitrogen
• Poor oxygen liquid air with 20%O₂
• Rich oxygen liquid air with 36.5%O₂

All production in the lower column after sub cooler enter upper column as its reflux.Production of upper column as following from the top down:
• Waster nitrogen at the top.
• Liquid oxygen at the bottom

Direction which all production of upper column go Waster nitrogen is reheated to design temperature out of the cold box by main heat exchanger and sub cooler after drawn from the top of upper column, one steam is regenerated by molecular sieve absorber, the other is taken in water cool column to cool water.
• It is compressed to 150 BAR for filling oxygen cylinders by a oxygen booster in the cylinder filling manifold.

Scope of Supply:

The oxygen plant UBT SERIES consist of the following equipments
1. AIR COMPRESSOR
Filter system with steel structure and supports elements.
Dedust system with valve, collecting machine, spray equipment, automatic clean and control system.
Send the pressure difference signals to PLC by pressure differential transmitter.
Instrument and electric control system              :1set

2. Air purification unit:
• Air Refrigerant compressor including special motor
 - One condenser
 - One evaporator / water cooler
 - One set of Piping and valves
 - Instrumentation
 - Water Separato

• Molecular Sieve Battery on skid
Complete with 2 nos. vessels, Reactivation heater complete with Molecular Sieve designed for process skid mounting.

• Defrost Heater
Consist of heating coils and heating element 5 kW.

• Gas/Air Lines as per standard Layout
All pipelines for process air, Nitrogen and Oxygen line, HP line upto manifold along with short bend, elbow, socket and other necessary fitting as per our standard layout drawing.

3. Air Sepration Column (Cold Box):
Cryogenic type completed with support and connected pipes and internal

4. Turbo expander:
The turbo expander is a rotary machine running on gas bearing. This is used to provide cooling for the liquefication of air at minus 180 to (-)190degrees centigrade.
including:
1. Expansion turbine body 
2. Ventricular joint                   
3. Inlet filter                            
4. Silencer                               
5. Bearing & sealed gas system     
   - Instrument gas filter        
   - ET bearing and sealed gas system 
 
5. Oxygen Cylinder Filling System:
The oxygen is filled into cylinders by an oxygen filling SYSTEM ( PUMP/BOOSTER) .

6. Filling Mainfold Cylinder Filling Station for Filling Oxygen Gas:
Complete with control valves pressure gauge safety valve & pigtail connections points each.

7. Purity Testing Analyser:
Digital automatic purity analyzer.

Technical Specification

Models	UBT SERIES (CYLINDER FILLING PLANT) UBT40, UBT80, 100, 120, 150 , 180, 200, 220, 250, 300, 350, 400, 500, 600, 800 & 1000.
Oxygen production
Oxygen Output (cu. Mtr/hr)	40 TO 1000m3/hour
Oxygen Purity (%)	99.6%
Oxygen Pressure  in cylinders	150 bar(kg/cm2)
Nitrogen production
Nitrogen Pressure out of Column (bar)	5 bar( UPTO 150 BAR OPT.)
Nitrogen Output (cu. Mtr/hr)	40 to 1000 m3/hr.*
Nitrogen Purity (ppm optional)	99.9% to 99.99/3ppm opt.
Nitrogen filling in cylinders(optional)	150 bar(kg/cm2)
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)	0.4kwh(units)
Voltage 3 phase**	380-415 50/60 hz