Process Description

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Our Company has patronized the technology ofs Boschi, Italy as it has been the most successful in the world specially in Europe due to excellent design features and efficient process cycle.

The process of manufacture of oxygen and nitrogen from oxygen/nitrogen plants has been very much simplified by Dr. Boschi of Italy with the following advantages.

•	Oxygen and nitrogen is made from atmospheric air.
•	The process of manufacture involves deep refrigeration/cooling of atmospheric air involving cryogenic temperatures.
•	Oxygen and Nitrogen is made from the purest form that is liquid air which is separated by process of rectification/distillation.
•	The oxygen and nitrogen can be drawn in liquid form or converted into gas upto 155/200 bar by a built in liquid oxygen/nitrogen pump.
•	Oxygen purity upto 99.6% for industrial and medical grade is produced.
•	Nitrogen gas can be collected at 0.1bar at the outlet of the cold box and compressed as per requirement or can be pumped by method of internal compression by a liquid nitrogen pump. The standard commercial purity of nitrogen gas is 96-99% and upto ppm grade can be produced.
•	There is no requirement of raw materials and no recurring cost of chemicals.
•	The oxygen and nitrogen plants are designed for continuous duty and are automatic and can be operated by just one person.
•	We have commenced the manufacture of the oxygen/nitrogen plants at New Delhi in 1985 under expert supervision of the Italian Engineers with the ultimate goal to manufacture the same quality of plants produced in Europe with a much cheaper labour cost.
•	We have been highly successful in exporting back to Italy to Ing L&A Boschi, Italy equipments and oxygen plants for sale in Europe and other parts of the world.
•	Dr. Boschi himself took the trial and successful run of the first oxygen and nitrogen plant manufactured at New Delhi in 1986 and certified ok for export to Italy and meeting international standards.
•	Now it has been over 20 years since we have been manufacturing oxygen and nitrogen plants at New Delhi with the technology of Ing L&A Boschi, Italy as per the designs and drawings.
•	We have skilled and trained technicians at our factory who have been manufacturing air separation plant, oxygen plant, nitrogen plant, liquid nitrogen / oxygen plants and equipment since 1985 under supervision of qualified engineers to meet inter-national specification.
•	Our Company is engaged as manufacturers and suppliers of air separation plant and gas plants in India. We are producing the air separation plants, oxygen plant, nitrogen plant and acetylene plants of latest technology of ING L&A BOSCHI, ITALY who have been the world leader in setting up oxygen/nitrogen/acetylene plants, machine, factory and related machinery since 1930 in Italy along with LINDE Germany. Our oxygen plants factory have been exported to all countries including South Africa, Tanzania, Kenya, Congo, Liberia, Columbia, Congo, Libya, UAE, Saudi Arabia, Iraq, Iran, Europe, Italy, Spain, Australia.

5 STEP BOSCHI PROCESS FOR MANUFACTURE OF OXYGEN & NITROGEN.

Step 1: Air Compressor
The free saturated air is sucked from atmosphere through a highly efficient dry-type suction filter into the first stage of the horizontally balanced opposed, lubricated reciprocating air compressor.

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Step 2: Purification of Air (Process Skid)
This consists of purification of the air by removing moisture, oil traces and carbon-dioxide in the process air.
Compressed air is chilled to 12°C in a chilling unit and evaporation cooler, compressed air passes through the coils of the chilling unit at a temperature of 12°C to a moisture separator, where the condensed moisture gets removed before entering into Molecular Sieve Battery. Before sending the air to MOLECULAR SIEVE BATTERY, air is passed through an OIL ABSORBER where air becomes oil free.

Chilled air passes through the Molecular Sieve Battery consisting of Twin Tower packed with molecular sieves to remove moisture and carbon dioxide present in the air.

Molecular Sieve Battery operates on Twin Tower System, when one tower is under production the other tower is regenerated by passing waste nitrogen gas at 200°C through a REACTIVATION HEATER. After interval of 8 to 10 hours, the tower under production gets exhausted and regenerated by similar process before use and, thus the cycle continues. Any dust particle gets filtered in the DUST FILTER before air enters the AIR SEPARATION COLUMN All the equipments are mounted on process skid.

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Step 3: Expander (Expansion Engine)
The process air before liquefication in the air separation unit needs to be cooled to temperatures sub-zero (cryogenic). The main portion of the air after the process skid enters the expansion engine through the heat exchanger no. I after pre-cooling. The temperature of the air drops to around -165degC by the Expander which is a very highly efficient advanced design with Teflon piston rings and completely hydraulic mechanism with leakproof ball valves.

Rest of air at (-80) deg C from Heat Exchanger No. I enters into a highly efficient EXPANSION ENGINE, where the air further gets cooled down to (-150) deg C before entering into bottom column. The liquefied air from both these streams collected at the BOTTOM COLUMN is known as RICH LIQUID

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Step 4: Air Separation Unit
After the process skid, the air enters the air separation unit (cold box) where the air converts into liquid air by deep cooling at cryogenic (low temperatures) and is separated into liquid oxygen and nitrogen.

Chilled, Oil-free and moisture-free air enters into multi-pass HEAT EXCHANGER No. 1 where it gets cooled to (-80) deg C by cold gained from outgoing waste nitrogen and oxygen.

A part of air, this enters a multi-pass HEAT EXCHANGER NO. II or LIQUEFIER made of special alloy tubes. This air cools to (-170) deg C before passing through an expansion valve. Due to Joule Thompson Effect, after the expansion valve, air gets further cooled down and gets liquefied before entering into Bottom Column.

The RICH LIQUID in the BOTTOM COLUMN enters into feed tray of top column. Similarly the liquid nitrogen called POOR LIQUID enters into top column as a reflux & it takes away the latent heat of condensing oxygen and gets vaporized whereas the liquid oxygen flows down the trays of the TOP COLUMN into the Condenser. Liquid Oxygen from CONDENSER passes through a SUB-COOLER to a LIQUID OXYGEN PUMP.

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Step 5: Cylinder Filling Station
Liquid Oxygen & Nitrogen passes from the condenser to the cryogenic liquid oxygen pump for filling gas into cylinders.
A. Capacity from 20 cubic Meter / hour to 500cubic Meter/ hour
B. Pressure (150 kg/cm2) upto 300 kg/cm2