Acetylene Plant

Acetylene Gas Plant Generator

Our fully automatic Acetylene plants are available in capacities from 25m3/hr to 200m3/Hr. In a Stationary Carbide to Water type Automatic Acetylene Generator acetylene is produced by reaction of calcium carbide with water. Adequate quantity of water is held in the generator shell to which calcium carbide is fed from top. The following reaction takes place:-

CaC2+2H2O = C2H2 + Ca(OH)2 + 27,000 Calories (heat generated)
The design of the entire plant has been made with safety in mind. Flash Back Arrestors, High Pressure Reverse Flow check valves, safety valves and complete gauging help protect both equipment and personnel. Various auto controls, safety valves, auto vent valves, non-return valves and Flash Back Arrestors are also provided to make this plant absolutely safe to operate in all conditions.

Salient Features of our Acetylene Plant

  • No bulky gasholder required
  • Automatic Controls for feeding water.
  • Maintaining temperatures, pressures, and slurry drain are full proof, efficient and are of international standard.
  • Excellent absorption of gas in cylinders
  • No gas loss and high yield.
  • Very simple and safe to operate
  • Lower power consumption
  • Low maintenance cost.

Scope Of Supply of Acetylene Plants Generator


Our Acetylene plant has been supplied as a complete package including the following.

1. MEDIUM PRESSURE STATIONERY ACETYLENE GENERATOR:

Carbide to water type along with the accessories with hopper for feeding the calcium carbide
[Note: The Acetylene Generator is part of the Acetylene Plant and is not supplied separately.]

It mainly consists of a twin Hooper that is

  • Agitator and its drive unit
  • Carbide Hooper screw feeder and its drive
  • Flash back arrestor
  • Safety relief valves drain system & the automatic controls system

Acetylene Generator can be set to operate at any given temperature, regardless of the size of carbide used or temperature of the cooling water

Acetylene Generator
Acetylene Generator under installation


2. INSTRUMENTS

Instruments - Temperature and Pressure

[Note: The Instrument Air Compressor is part of the Acetylene Plant and is not supplied separately.]

A flameproof motor with a buffer tank drives the instrument air compressor


3. PRE-COOLER

M. S. Vessel with tube arrangement for cooling Gas

[Note: The Cooler Condenser is part of the Acetylene Plant and is not supplied separately.]

Cooler Condenser:
Removes lime particles and condenses while cooling the acetylene


4. LOW PRESSURE DRIER:

Vertical M.S. Vessel fitted with Half Circle perforated M.S. Plates filled with one charge Hydrous Calcium Chloride

[Note: The LP Drier is part of the Acetylene Plant and is not supplied separately.]

Maintain the proper acetylene moisture content for purification and filled with Calcium Chloride


5. ACETYLENE PURIFIER:

Large vessel divided into two section wire mesh frame work. The inside of vessel is coated with Chlorinated Rubber Paint as anti-corrosive measure. Each section is charged with f Purifying Mass to absorb gases like Hydrogen Sulphide, Phosgene, etc.

[Note: The Acetylene Generator is part of the Acetylene Plant and is not supplied separately.]

This consists of two layers of regenerative chemicals, which remove additional impurities. The purifying agent may be reactivated for re-use by the atmosphere air. For continuous operation one extra charge of chemicals can be kept in open wooden trolley. This inside of vessel is coated with chlorinated Rubber Paint as anti corrosive measure. Each section is charged with purified Rubber Paint as anti corrosive measure. each section is charged with purified mass to absorb gases like H2S (Hydrogen Sulphide) and PH3 (Phosphene), etc to obtain high purity 99.6%. There will be 2 purifier that will be connected in series. The inside of the vessel is coated with chlorinated rubber paint as anti corrosive measure.

Acetylene Gas Filling Plants Manufacturers India
Chemical Purifier


6. AMMONIA WASHER:

Vertical vessel fitted with Level Gauge and Water Make Up Line. The Acetylene Gas is bubbled in the vessel to: a) to scrub water soluble impurities like Ammonia b) To facilitate compression of Acetylene Gas by making it wet.

[Note: The Ammonia Water/Washer Scrubber is part of the Acetylene Plant and is not supplied separately.]

The vertical vessel fitted with level gauge and water make up line to remove ammonia from acetylene to maintain high purity. The equipment is installed between the chemical purifier and the high-pressure compressor which helps to remove additional impurities from the gas if any


7. ACETYLENE PLANT COMPRESSOR:

ACETYLENE COMPRESSOR of rated capacity (Three Stage Type), Normal Reciprocating Piston Type, Oil Lubricated water submerged with Safety Valves, Pressure Gauges, Moisture Separators, Flame Proof Motor with Pulley, V-Belts and Belt Guard, Pneumatically Pressure Controlled). All three stages of the Compressor are provided with a Pressure Gauges to monitor the inter stage pressure

[Note: The Acetylene Compressor is part of the Acetylene Plant and is not supplied separately.]

Normal reciprocating Piston Type Oil lubricated water submerged with safety valve, flame arrestor, pressure gauge. All three stages of the compressor have a pressure gauge to monitor the interstage pressure.

The acetylene compressor is a three-stage machine which is immersed in water filled tank to avoid any pressurized gas to come in contact with air and also to make sure that all the components are continuously cooled. The compressor is drawn by flame proof motor from outside the tank.

Acetylene Plants Compressor
Acetylene Compressor


8. BATTERY OF HIGH PRESSURE DRIERS

Filled with Anhydrous Calcium Chloride and with Non-return Valve and Pressure Regulating Valve. It consists of three columns. The First Column is fitted with M.S. chain Packing to avoid any void. The Second and Third Columns are fitted with two capsules each and are fitted with a Drain Valve to drain off moisture collected at the bottom periodically.

[Note: The High Pressure Dryer is part of the Acetylene Plant and is not supplied separately.]

3 mounted on the compressor for easy access. A flame arrestor for safety and a back pressure valve which maintain a minimum of 14 bars to remove the oil and water vapors from the acetylene after compressor. This consists of a battery of three high-pressure vessels. The first is filled with metal filler, while the second and third are filled with anhydrous calcium chloride. It is very important that the high pressure dryer is fully filled up with Calcium Chloride, as any voids in high pressure area are against the required safety.


9. ACETYLENE FILLING MANIFOLD

ACETYLENE FILLING MANIFOLD for filling cylinders each complete in all respects fitted with Filling Connections, Flash Back Arrestors, Pressure Gauge and Non-return Valves, Stainless Steel Braided Teflon loose connection with Brass Bull Nose and Brass Nut.

[Note: The Hilling Manifold is part of the Acetylene Plant and is not supplied separately.]

140 cylinder manifold and each manifold is protected with flame arrestors on each side of the shutoff valve. Each cylinder connection includes an “o” ring style handwheel connection to the cylinder.
The acetylene gas manifold consists of two headers fitted with non-return valves, one flash back arrestors, pressure gauge and manual isolation valves.


10. MOTORIZED ACETONE PUMP:

Rotary Gear Pump made of Stainless Steel fitted with 0.5 HP flame Proof Motor for filling Acetone into Cylinders.

[Note: The Acetone Pump is part of the Acetylene Plant and is not supplied separately.]

It is a geared motor pump coupled with motor by love-joy coupling. The pump has two parts mainly suction port and the discharge port. The suction port is provided with extended pipe and foot value to reach the bottom of the acetone drum. Acetone pump is supplied along with the plant for charging acetone in cylinders.


11. Complete set of ACETYLENE GAS LINES

Complete set of ACETYLENE GAS LINES as per our standard layout for Low and High Pressure with complete fittings. M. S. Seamless Sch. 40 Pipes for High Pressure Line Galvanized Iron 'C' Class heavy Duty Pipes for Low Pressure.

[Note: The Acetylene Gas Line is part of the Acetylene Plant and is not supplied separately.]

We shall also provide with a complete set of acetylene gas line for low and high pressure piping with complete fitting M.S. seamless schedule 40 for high pressure line galvanized Iron “C” class heavy duty pipes for low pressure.


12. NO LOSS CARBIDE CHARGE

[Note: The No Loss Carbide Charge is part of the Acetylene Plant and is not supplied separately.]

No gas is lost or wasted while charging the carbide because that section is completely sealed off from the generator by a high pressure hydraulically operated valve. All the above controls are automatic and require no attention from the operator. There is a further safety device, in terms of an alarm bell, which will ring continuously till the fault is corrected


13. LEVEL CONTROLS

[Note: The Level Controls are part of the Acetylene Plant and is not supplied separately.]

Level controller maintaining a particular level in the generator. If the level is above normal, water can enter the carbide hop.


14. LEVEL ALARM

[Note: The Level Alarm is part of the Acetylene Plant and is not supplied separately.]

The pressure inside the acetylene generator is controlled by a meteoroid switch.


15. PRESSURE ALARM

[Note: The Pressure Alarm is part of the Acetylene Plant and is not supplied separately.]

It is a geared motor pump coupled with motor by love-joy coupling. The pump has two parts mainly suction port and the discharge port. The suction port is provided with extended pipe and foot value to reach the bottom of the acetone drum. Acetone pump is supplied along with the plant for charging acetone in cylinders. This is the important part for the safety of this plant. A pressure switch is connected to the alarm system.


16. SCALE CYLINDER WEIGHT

[Note: The Scale Cylinder Weight is part of the Acetylene Plant and is not supplied separately.]

Includes stand for simplifying acetone additions and weighing cylinders.



Acetylene Plants Purifier   Acetylene Plant Compressor
Purifier Acetylene Compressor
Acetylene Plants cylinder filling arrangements   Acetylene Plant Generator
Acetylene cylinder filling arrangements
Acetylene Generator

17. DRAIN BACK MANIFOLDS

[Note: The Drain Back Manifolds is part of the Acetylene Plant and is not supplied separately.]

Safely recovers the acetylene gas from problems cylinders.




Acetylene Plant HP Driers   Acetylene Plants LP Drier
HP Driers
LP Drier Purifier & Ammonia Washer
Condenser & Generator   Generator Platform
Condenser & Generator
Generator Platform

Acetylene Plants Technical Specification

TECHNICAL SPECIFICATION
S. No. Description BA - 25 BA - 50 BA - 100
1. Capacity (acetylene with purity as per IS-30B) Cubic Meter per hour 25 50 100
2. Process water required (liters/kg of calcium carbide processed) 8 -10 8 -10 8 -10
3. Calcium carbide required (kg/N.cubic meter of gas) 4 4 4
4. Calcium chloride required (gms/N.cubic meter of gas) 50 50 50
5. Cooling water make-up required (liters/N.cubic meter of gas) 10 10 10
6. Power required (average requirement) 12kw 15kw 28kw
7. Purifying mass required (gas plus acid absorption mix per cum of gas) 15 gms/N.Cum + 4 gms 15 gms/N.Cum + 4 gms 15 gms/N.Cum + 4 gms
8. Instrument/Process air 70 liters/minute 70 liters/minute 70 liters/minute
9. Acetone As required As required As required
10. Hydraulic oil required (for screw feed system) Equivalent to SAE - 30 Equivalent to SAE - 30 Equivalent to SAE - 30
11. Lubricating oil required (for compressor) Hylube HDX-40 Hylube HDX-40 Hylube HDX-40
12. Power Supply 440 Volts/3 phase/50 hertz 440 Volts/3 phase/50 hertz 440 Volts/3 phase/50 hertz
EQUIPMENT SCHEDULE
S. NO Description S. NO Description
1 CARBIDE HOPPER 11 GAS LINES
2. ACETYLENE GENERATOR 12. CONDENSER
3. L.P. DRYER 13 AUTOMATIC SCREW FEED
4. PURIFIER 14. AGITATOR
5. AMMONIA SCRUBBER 15. TEMPERATURE CONTROLLER
6. ACETYLENE COMPRESSOR 16 PRESSURE CONTROLLER
7 H.P. DRYER 17 LEVEL CONTROLLER
8. CYLINDER FILLING MANIFOLD 18 SLURRY DISCH ARGE CONTROL