(336).Start a Industrial Gas Plant
Industrial gas is a group of gases that are commercially manufactured and sold for use in industrial processes, such as steelmaking,oil refining, medical applications, fertilizer, semiconductors, etc.,. They may be both organic and inorganic, are produced by extraction from the air by a process of separation or are produced by chemical synthesis, and will take various forms such as compressed, liquid, or solid.
The most common industrial gases are:air gases - oxygen (O2), nitrogen (N2) and argon (Ar) rare gases - such as helium (He), krypton (Kr), xenon (Xe) and neon (Ne) and other gases like hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2) and nitrous oxide (N2O) ,chlorine (Cl2), hydrogen chloride (HCl) and sulphur dioxide (SO2) ,acetylene (C2H2), methane (CH4) and propane (C3H8).
In addition, there are many different mixtures of these and other gases to meet the needs of specific applications. The industrial and medical gases industry serves a very large number of customers in the whole community. Industrial gases are essential for almost all manufacturing. Large quantities of oxygen, nitrogen and argon are used in the steel and metal industry. Shipyards and the automotive industry use acetylene, propane, mixtures of fuel gases and oxygen for cutting and welding. Liquid nitrogen is vital in recycling plastics, packaging and scrap tyres. The chemical industry employs all major industrial gases as a raw material or for inerting. The other smaller market segment consists of cylinder gas and mixtures.
According to the Freedonia group, inc., a Cleveland-based industry research firm, world demand for industrial gases is forecast to increase 6.9% annually to $36.8 billion in 2011, with volume exceeding 300-bcm (billion cubic meters). Asia/pacific is the largest consuming region because of rapid growth in developing industrial markets, especially those of china and India.
Coming back to India, there are presently over 300 small & medium size plants and approximately 25 large tonnage plants all over the country. These gases are supplied through pipelines to captive customers in adjacent factories; in cryogenic transport tanks for bulk deliveries to long distance customers; or filled in cylinders.
The present annual turnover of the gas industry, excluding captive production is about Rs. 3,000 crores ($650 million). With increased industrialization, the demand pattern of industrial gases is also changing fast. Modern application in the food processing industry, agro industries, healthcare and technology are growing at a tremendous pace. This has driven the industry to adopt stringent quality control systems and an efficient distribution network.
Major players in India include BOC India, INOX Air Products Ltd., Jindal Praxair Oxygen Co. Ltd., Air Liquide India Holding P.Ltd., Aims Industries Ltd etc.
The Indian gas industry is growing at an average rate of 12 per cent per annum during the last couple of years, with the industrial oxygen growing consistently at 15-17 per cent per annum. The growth of industrial gas industry can be easily forecast on the basis of projections of the steel and other metallurgical industry. Steel demand is seen rising by 10% in the fiscal year to march 2011, helped by higher spending on infrastructure will continue to drive growth of the gas industry. Natural gas comprises 9 % of India's primary energy consumption and it will be 14% of energy mix by 2010. Demand for natural gas is also likely to increase at an average annual growth rate of 7.3%.Metals production and fabrication will continue to be the largest market for industrial gases, accounting for 31% of total demand in value terms in coming years. The second largest market will be the chemical processing/petroleum refining segment. The medical/healthcare market, though smaller in size, will be the fastest growing and record gains from the expansion of healthcare services in developing nations and rapidly increasing use of home healthcare respiratory therapies in advanced economics. Hydrogen is gaining prominence and most companies are striving to develop technologies that can efficiently exploit the potential of hydrogen. Increased use of natural gas will create an opportunity for higher production of argon and carbon dioxide. The Industrial gas industry has a very bright future in the coming years.
- The global market for the industrial gas business was worth $63 billion in 2008. It decreased to an estimated $59 billion in 2009, but is projected to increase at a compound annual growth rate (CAGR) of 5.2% to $76 billion in 2014.
- Sales in the chemicals and refining-related processing market amounted to $22.7 billion in 2008, and decreased slightly to $22.4 billion in 2009, but are expected to reach $27.5 billion in 2014, for a 5-year (CAGR) of 4.1%
- The second-largest segment of the market, metal manufacturing and fabrication, was estimated to be worth $17 billion in 2008 and was expected to decrease to $14.5 billion in 2009. It’s projected to grow to more than $20 billion in 2014, for a 5-year CAGR of 6.7%.
Nitrogen Gas Plant
Nitrogen plant/generator operating on PSA technology, consists of twin tower system filled with special grade of carbon molecular sieves (C.M.S). At a time, one tower keeps in production cycle and other in regeneration cycle. When compressed air passed through C.M.S. bed, the molecules of oxygen, moisture & other unwanted gases are adsorbed on surface of C.M.S. And the nitrogen which is not adsorbed by C.M.S comes out of adsorption tower and is collected in a surge vessel. For continuous generation of nitrogen, two adsorption towers are provided which are interconnected with auto change over valves controlled by a sequence programmer. When one tower saturates with oxygen the process automatically changes over to another tower and thus the nitrogen production is continuous.
Flow Scheme for PSA Nitrogen Gas Generator
Our gas generators are of optimum quality, durable and easy to handle. Our on site PSA nitrogen generators are custom made and can be adjusted to give the desired nitrogen quality for your process and application.
Purity of Nitrogen
If you want pure Nitrogen, what you need is to select our PSA nitrogen gas generator. Nitrogen purity in the range of 99% to 99.9999% can be achieved through our nitrogen gas generators. Our PSA nitrogen gas generator produces raw nitrogen of 99% to 99.99% purity. By adding purification modules to this unit, nitrogen of 99.9999% purity can be achieved. Following are the generator models to produce different nitrogen purities:
Pressure Swing Adsorption (PSA) technology relies on the selective adsorption phenomena of gas molecules under pressure on the surface of highly porous and efficient adsorbent. Here in oxygen generation, the adsorbent is zeolite based molecular sieve (Z.M.S).
Process of PSA Oxygen Gas Generators
In this system, when compressed air is passed through a adsorption tower field with Z.M.S, the molecules of oxygen, moisture & other unwanted gases are adsorbed on surface of Z.M.S and oxygen which is not adsorbed by Z.M.S comes out of adsorption tower. This oxygen is collected in a surge vessel. Two adsorption towers are used for continuous generation of oxygen gas, which are interconnected with autochange over valves controlled by Programmable Control Panel (PLC) in the control panel. After saturation of one tower with oxygen, the process automatically changes over to another tower resulting into the continuous production of oxygen gas for long.
In the first molecular bed, compressed air is fed in which nitrogen is trapped and oxygen flows out.
When the first bed is filled with nitrogen, air flows into the second bed.
When the second bed separates oxygen from nitrogen, nitrogen is vented out in the atmosphere in the first bed.
Again the compressed air flow in to the first bed, the process continues and there is a constant flow of oxygen.
In fact, the productivity of a PSA oxygen generator depends upon the requirement of oxygen purity. With a relatively small increase in feed air these generators can produce significantly more oxygen at 90% purity than it can at 95.4%. By means of a PLC or some other micro processor based controller, on larger generators it is practical for the users to change the swing cycles on timely basis. In fact, the purity and flow levels can also be selected and optimized based on changing demand variables.