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ACETYLENE PLANTS AND GAS

 

Our Acetylene Plants are of indigenous manufacture. Every part has been carefully designed by experienced engineers. These parts are made of the best material. Every part has been accurately made and carefully inspected before assembly. Each unit, after assembly is charged and worked continuously to check its performance. You are, therefore, assured of an efficient and dependable D.A Plant. 

This Acetylene Plant is of an advanced design, incorporating several features not ordinarily found in other generators, this able us to attain the highest efficiency in the world of 99.8%. This one is a fully automatic plant with twin hoppers (and needs an operators' attention for only ten minutes in an hour).

All operations are performed by pneumatically controlled valves, assisted by highly sensitive sensors, integral with the temperature control instruments. These in turn open the water inlet valve or residue drain valve etc. Two hydraulic pumps help to open and close the supply of calcium carbide. This is fed into the generator by screw feed conveyors. The screw feed mechanism and the agitator are operated by flame-proof motors and fittings. The entire operation is perfectly synchronized to give maximum efficiency and simplicity in operation. Any failure, whether it is of power supply, water, instruments air, is signaled visually and also audibly when an alarm bell rings to alert the operator.

Only flame proof lights and electrical fittings according to IS2148-68 (Group II) or BSS-229 may be used in an acetylene plant building. Acetylene cylinders must be of specification IS: 7312: 1974 or ICC:8.

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.
High Pressure Acetylene Generator Acetylene Generator Specially designed high pressure generator, to be operated with dust or lump size carbide at efficiency of more than 98%. The generator is manufactured in accordance with Section 8 of the ASME Code and produces acetylene gas at less than 0.6 bar (8 psig) pressure. Hoppers are used to provide an uninterrupted flow. The simplicity of operation allows the generator to be run only when acetylene is required.

The generator will provide enough acetylene to supply Five IIGL compressors when the proper modification to the screw-feed systems are made.
Our one of the few innovation in Acetylene Generation. Acetylene Generator Acetylene Compressor Designed to Customer Needs.
Acetylene plant in assembly stage just before a performance check in made. Acetylene plant in assembly stage after a performance check in made. Acetylene Compressor in assembly line
H-TYPE ACETYLENE GENERATOR  Specially designed to be used on off-shore sites or areas where space is a constraint This is one of the long range of  water to carbide  type of Acetylene Generators .The design allows it to operate to a maximum working pressure of 1.5 kg/cm2 with a constant flow rate 3.25 cum /hr  the approx quantity of calcium carbide that each tray would hold is 12.5 kg. This generator  contains  two gas producing chambers, each containing a carbide tray and also a built-in-filters at the top.
ACETYLENE GENERATOR SPECIFICATIONS:

Specifications

KIGL-DA-25 KIGL-DA-45 KIGL-DA-100 KIGL-DA-200
Capacity 15 to 30 cubic meter/hr of Acetylene 31-50 cubic meter/hr of Acetylene 51-100 cubic meter/hr of Acetylene 101 to 200 cubic meter/hr of Acetylene
Cylinders filled per batch  60 Cylinders 60 Cylinders 120 Cylinders 120 Cylinders
Carbide Size 4-50 mm 4-80 mm 4-80 mm 4-80 mm
Maximum Operating Pressure 1.5 kg/cm2 1.5 kg/cm2 1.5 kg/cm2 1.5 kg/cm2

Hopper Capacity

250 Kg 400 Kg 500 Kg 900 Kg
Minimum Guaranteed Efficiency 92% 92% 92% 92%
Water required

6 to10 liters. per kg of Calcium Carbide used

6 to10 liters. per kg of Calcium Carbide used 6 to10 liters. per kg of Calcium Carbide used 6 to10 liters. per kg of Calcium Carbide used
Connected load 8 KW 8 KW 18 KW 18 KW
Start up time 15 minutes 15 minutes 15 minutes 15 minutes
Conforming specifications 

IS 8471

UL-408T

RAC-203

NFPA-51A

IS 8471

UL-408T

RAC-203

NFPA-51A

IS 8471

UL-408T

RAC-203

NFPA-51A

IS 8471

UL-408T

RAC-203

NFPA-51A

Power Supply 380 ~ 440 Volts / 3 phase / 50 hertz
(if your supply is different from this please specify to enable us quote accordingly)
380 ~ 440 Volts / 3 phase / 50 hertz
(if your supply is different from this please specify to enable us quote accordingly)
380 ~ 440 Volts / 3 phase / 50 hertz
(if your supply is different from this please specify to enable us quote accordingly)
380 ~ 440 Volts / 3 phase / 50 hertz
(if your supply is different from this please specify to enable us quote accordingly)

    

SOME SPECIAL FEATURES OF OUR ACETYLENE PLANTS

  • NO NEED OF A GAS HOLDER

  • CONTINUOUS OR INTERMITTENT SERVICE

  • AUTOMATIC CONTROLS TEND TO FAIL SAFE

  • RESIDUE KEPT IN SUSPENSION AUTOMATICALLY

  • REMARKABLY EASY TO OPERATE AND MAINTAIN

  • SCREW FEED MECHANISM OPERATES AUTOMATICALLY

  • AUTOMATIC THERMOSTATIC WATER INLET RESIDUE OUTLET

  • NO VENTING OF ACETYLENE FROM THE TANK TO THE ATMOSPHERE

 

A C E T Y L E N E  P LA N T  L A Y O U T

Special precautions to be taken into account when making the Acetylene Plant Building:

  • A safety zone of 15 m. all around the Acetylene Plant, from any other building should be provided, and a minimum of 9 m. from any slurry pit.
  • A separate Acetone storage should be constructed and must be provided with a 12 m. safety zone all around.
  • A distance of 90 m. must be maintained from any Oxygen Plant in the vicinity.
  • All non-flame and explosion proof switches must be provided separately in an enclosure away from the Acetylene Plant Building.
  • No flammable material should be used for construction purposes of the Acetylene Plant Building.
  • Both the Acetone go down and Calcium Carbide Store as well as the Acetylene Plant Building should be well-ventilated with ventilators on the roof as well as ground level. All ventilators must be protected with non-corrosive, galvanized non corrosive mesh, with a minimum gauge of 28 mesh to the linear inch. Covers should be provided on the ventilators so that rain water may not enter through these openings.
  • All electrical wiring should be of low voltage in the Acetylene Plant Premises. Electrical lines must not cross any pipe conveying water or steam or acetylene.

 

PROCESS DESCRIPTION

 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

The generated acetylene gas occupies the free volume inside the generator shell over the water level and pressure of gas goes up till it reaches the set pressure level when by action of the pressure controller carbide feed motor is cut-off. If the acetylene gas is taken out from the generator, the pressure inside the generator shell will go down and by action of the pressure controller carbide feed motor will start and feed further carbide through the screw feed mechanism from the hopper into the shell and further acetylene shall be generated. Thus the process shall continue till the carbide filled in the hopper under operation is exhausted. At that stage change over takes place and second hopper which was filled with carbide when first hopper was under operation now starts feeding carbide into the generator shell and first hopper is filled with carbide.

As the process of acetylene generation is exothermic, there is a temperature rise of the generator. The generator temperature cannot be allowed to go high because acetylene can catch fire. Moreover, generation of acetylene is optimum at a particular temperature around 60ºC. Hence it is necessary to keep the generator temperature around 60ºC. This is done automatically by the temperature controller which is preset at a temperature of 60ºC. Since the generator has a tendency of increased temperature, the temperature controller acts on the water inlet valve and opens the valve to bring in fresh process water which reduces temperature of the generator and thus the generator temperature is kept at about a particular predetermined set point.

With inlet of fresh water to bring down the generator temperature the water level inside the generator goes up and this water level is maintained between a high and low set point by pneumatically operated level controller. Slurry discharge valve is made to open automatically by the level controller to discharge some quantity of slurry to lower the waster level inside the generator when the water level tends to rise above the maximum level. As soon as the level of water goes down the slurry discharge valve automatically closes. Thus only minimum quantity of slurry is discharged at a time. Water inside the generator absorbs certain quantity of acetylene and hence this water already saturated with acetylene should not be discharged continuously or in large volume but should be retained inside the generator and thus prevent loss of acetylene with the slurry.

The Agitator is continuously driven when the carbide feed motor is running. However, when the generator is in dormant state and there is no carbide feed, there is a tendency of the slurry to settle down and jam the agitator. A timer controlled electric motor drive keeps the agitator under operation when the generator is in dormant state. Thus slurry is always kept mixed with water without sedimentation. Agitator is a very important part of the generator as it keeps the carbide and water intimately mixed for total reaction of the carbide and thus prevent loss of carbide in the form of solids with the slurry.

Passage of acetylene gas from the generator to the carbide chamber (hopper) under filling is kept shut off by hydraulically operated shut off device which operates automatically when the carbide in the hopper is exhausted and screw feed motor is stopped.

The generated acetylene passes from the generator chamber through Wet Type Flash Back Arrestors and then reaches Low Pressure Condenser where the temperature of gas is lowered by cooling water and part of the moisture in the acetylene gas is taken out in the form of waster by condensation. Gas then passes through low pressure dryer filled with calcium chloride to remove further quantities of moisture from acetylene gas before the gas reaches purifying chamber. Gas then passed into purifying chamber with optimum quantity of moisture in the gas (gas is not completely dry). Purifying chamber is filled with purifying chemicals to remove Phosphorus and Sulphur compounds from the gas and if necessary to remove acidic fumes also. Thereafter gas passes to water filled scrubber where acetylene gas is washed with water to remove particles of purifying chemicals which may be carried over with the gas from purifying chamber. The wet gas then enters suction of acetylene compressor, compressed and passed to high pressure dryer filled with mechanical devices and chemicals to remove lube oil vapor and moisture from the gas. Gas after passing through the High Pressure Dryer is arrested by Back Pressure Valve on the pipeline leading to the manifold. Back Pressure Valve is set at a pressure between 12 to 14 kg/cm2g so that no gas till the pressure rises above the set pressure is allowed to pass on to the manifold. This ensures efficient drying of acetylene gas in the high pressure dryer. Thereafter gas passes through Dry type Flash Back Arrestor to manifold and then passes to the cylinders hooked on the manifold through Static Free Uni-flow Valves meant for each cylinder.

Before hooking the cylinders on the manifold for filling they are weighed on a balance, loss of acetone if any ascertained, loss is made up by filling acetone preferably by hand pump directly from acetone drum and then only cylinders are made ready for connecting to the manifold for filling.

During filling continuous spray of cooling water is kept on the cylinders as there is a temperature rise of cylinder during filling operation and absorption of gas in acetone is better when the gas is at a lower temperature. When the cylinders are filled to the desired pressure as per temperature chart, filling is stopped and acetylene gas is allowed to settle inside cylinders. There will be some drop in pressure and a second or 3rd filling may be necessary to achieve the desired cylinder pressure. After filling cylinders are taken out by disconnecting the pigtails, cylinders weighed on weighing machine and quantity of acetylene filled in the cylinders is ascertained from the weight of the cylinders. Cylinders are tested for leaks and stored for distribution.

Cooling water is required at 3 points i.e. at condenser, for cooling of compressor and spray cooling of cylinders under filling Industrial water is required in generator for reaction with carbide and in wet type Flash Back Arrestor for topping up.

Water Meter is provided with each generator to check the water consumed by the generator in a given time and to compare the ratio of carbide and water to determine the proper operation of the generator.

Hoist with skip and chain pulley block is provided to lift carbide from the ground to the generator hopper for filling of hopper.

A small bank of 4 to 6 Nos. 6 M3 Nitrogen cylinders are kept in manifold with piping to various points for flushing the various parts of the plant and inter-connecting pipelines.

Electrical lines are to be provided by customer from MCC located at a safe distance to feed carbide screw feed motors, compressor motor controls and instrumentation.

Instrument Air Compressor is provided (pipeline is to be provided by customer) for operating the Pneumatic Instruments. Apart from the instruments mounted on the generator, some of the control instruments are located on a panel which is installed at a safe distance along with MCC.

  “B” TYPE

 

 “B” TYPE ACETYLENE GENERATOR

This is an excellent acetylene Generator for remote installation as several operators can draw supply simultaneously. A single carbide chamber is employed in both cases, as a greater gas output is obtainable than is possible when a small carbide charge is split-up into two chambers.  Our experience of over several decades shows that the advantages claimed for two chambers cannot be substantiated with a generator of less than 30 lbs. Carbide capacity.  Very small chambers merely lead to excessive labour in charging, and as in many makes the feed will not automatically change from chamber No.2 back to No.1, the supposed advantage of continuity of gas supply is not attained.  All our Generators approved by the Government of India and conforming to      IS 8471, UL 408, TRAC-203 & NFPA-51A. 

SALIENT FEATURES: - • Compact  • No installation required

   No maintenance cost      • Any size of calcium carbide used.

PARTICULARS

MODEL NO

B-0

B-1

B-2

CARBIDE CHARGE IN EACH CHAMBER (kg)

3.2

5.5

6.8

MAXIMUM OUT PUT PER HOUR (litres)

608

1094.

2432

TOTAL OUT PUT PER HOUR (litres)

851

1459.

3648

NUMBER OF CARBIDE CHAMBER

1 No.

1 No.

2 No.

GAS HOLDER CAPACITY (litres)

76

110

322

GAS OUT PUT LINE  (mm)

15

20

25

 

“S” TYPE

“S” TYPE ACETYLENE GENERATOR

PARTICULARS

MODEL NO

S-10

S-20

S-30

CARBIDE CHARGE (kg)

4.53

9.00

14.00

MAXIMUM OUT PUT PER CHARGE (litres)

1095

2190

3283

WEIGHT & DIMENSIONS

MODEL NO

S-10

S-20

S-30

WEIGHT EMPTY  (kg)

68

91

159

SHIPPING DIMENSION (mm)

762X762X1372

819X819X1524

1067X1067X1981

DIA (mm)

457

508

762

OVERALL ASSEMBLED HEIGHT (mm)

1210

1372

1829

 All dimensions and specifications  shall change from time to time.

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