Universal Industrial Plants
Gas Pipeline Supply Air Separation Plants-Low Pressure

Universal Boschi Technical COLLABORATION WITH ING. L. A. Boschi (Italy) is the leading Manufacturer and supplier Premium Quality low pressure( 5-7 bar only) Air separation OXYGEN – NITROGEN plants of all sizes ranging from 50 m3/hour to 50,000 m3/hour including Cryogenic Tonnage OXYGEN – NITROGEN air separation plants and liquid plants.

With manufacturing facilities & Oems spread out in various locations all over India & Asia and sales located in New Corporate Region of Delhi WITH WAREHOUSING FACILITIES IN DUBAI AND SINGAPORE the Italy based company is dedicated to supplying the latest in Cryogenic Technology constantly striving to improve its products through continuous research and development.

Quality:


Universal is a certified ISO 9001:2000 organization and the latest achievement includes the successful approval for CE certification and SGS()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 ( HAVING BULKY PISTON COMPRESSORS WHICH CAN GO UPTO ONLY 600M3/HR (Practicaly)



Main performance of the plant:

Range Oxygen (cu. Mtr/hr) : 40 TO 50.000m3/hr
Nitrogen Pressure out of Column (bar) : 7 bar

Product Outputs

A.
Oxygen purity GAS 99.6% at 150-160 Bar(2200PSIG) or upto 200/300 bar as required for Oxygen cylinder filling .
B. high purity Nitrogen 99.99%(3ppm optional) or cylinder filling.

NOTE: There is no loss of oxygen production when producing high purity nitrogen.


Pure Nitrogen Plants
pure nitrogen plant pure nitrogen plants

Special Features:•


A few of the latest technological features incorporated into the Oxygen & Nitrogen plants are listed below.
• Purity of Oxygen produced from all plants is minimum 99.6% and Nitrogen Purity CAN BE    available up to 1-3 PPM (Depending upon  requirement of the customer).
• All plants use “Oil free” rotary screw /centrifugal oil compressor working between 5-7    BAR.
• All plants incorporate Aluminum Brazed exchangers and packed columns for high    efficiency.
• Turbo expanders (GAS Bearing) for trouble free operation.
• All plants above “500M3/HOUR ” CAN supplied with automatic PLC control.
• Engineering support along with complete quality control is provided by our company.
• We provide qualified engineers for Supervision, Installation and start up of all our plants    as well as training of
  manpower at customers’ site.
• Very low power consumption with proven performance and virtually Zero maintenance    required for the machines.
• 100% reliability for oxygen gas quality for industrial & hospital use.


      Process for turbo low pressure oxygen
      – nitrogen plants( upto 50.000m3/hr)
flow charts

Process description for Oxygen – Nitrogen low pressure Oxygen/Nitrogen plants:

1.Compression Of Atmospheric Air

Air is compressed at a very pressure of 5-7 bar (kg/cm2). Air can be compressed at such low pressure by trouble free rotary compressor (Screw / Centrifugal Type/Oil free piston compressor of advanced technology are employed).

2. Pre Cooling System

The second stage of the process uses a low pressure refrigerant for precooling the processed air to temperature around 12 deg C before it enters the purifier.

3. Purification Of Air By Purifier

The air enters a purifier consisting of twin Molecular Sieve driers, working alternatively. The Molecular Sieves remove the Carbon dioxide & moisture from the processed air before the air enters Air Separation Unit.

4. Cooling Of Air By turbo (EXPANDER)

The air has to be cooled to sub zero temperatures for liquification & the cryogenic refrigeration & the cooling is provided by highly efficient turbo expander, which cools the air to temperature almost below -165 to-170 deg C

5. Seperation If Liquid Air Into Oxygen & Nitrogen By Air Seperation Coloumn

Oil free, moisture free and Carbon Dioxide free air enters into low pressure fin type HEAT EXCHANGER where the air is cooled below sub zero temperatures by air expansion process in the turbo expander.
Air gets liquefied when it enters the air separation column & gets separated into oxygen & nitrogen by the process of rectification.
Oxygen is available at the outlet of the ASU at a purity of 99.6%. Nitrogen is also available t the outlet as a second product at purity of 99.9% upto 3ppm simultaneously without loss of oxygen product.

6. Compression of oxygen & filling of in cylinders

The final product in the form compressed Oxygen/Nitrogen goes to the high pressure oxygen cylinders at 150 bar or upto higher as required. This can be done by liquid oxygen pump is same models. We can use oil & water free compressor.

Main Equipments

(I) Air compressor: Screw/ low pressure- type:

We employ the most advanced compressor series available in the market. They have a unique combination, meeting customer requirements for low installation, operating and maintenance costs with high dependability and ease of use.

Screw type rotary compressors are one of the most advanced and trouble free.

Centrifugal Type Compressor:

No other turbo type oil free compressor can match its efficiency and economy. This ensures a consistent and highly reliable source of air supply. Maintenance is extremely low.Oil free piston compressor are also very succesful due to V-Type configuration on very low working pressor.

pre cooling system
(II) Pre – Cooling system:

The pre-cooling system is a highly efficient skid mounted equipment provided with the main purpose of cooling down the air to a temperature of 5 to 8 degrees Celsius and thus to discharge the condensed water. We are using highly reliable compressors of European origin.

(III) Universal Boschi Purifier:

The purifying system is the secondary process unit which is responsible for the removal of moisture, carbon dioxide, hydrocarbons as well as rare gases that are considered to be impurities in the process cycle of air separation. The structure essentially consists of double layered molecular sieves from “Zeochem” (Switzerland) along with alumina which acts as an adsorbent.

The process purifier is vital to the entire process and is greatly responsible for the purity of the final product i.e. Oxygen and Nitrogen in the Air separation Column. It consists of 2 skid mounted molecular sieve regeneration batteries that work on shifts and switch alternatively either manually or through a PLC control (optional).

Air Seperation units
(IV) Air separation Unit:

The Key to the entire Air separation Process lies within the Air Separation Unit (A.S.U). Here, the mixture of Oxygen and Nitrogen is separated by virtue of the difference in their liquefication temperatures.Liquefied air is sent to the lower and upper column using a double rectification process at temperatures below (– )180 deg centigrade.

The design and efficiency of the A.S.U determines the quality of the final product i.e. Oxygen and Nitrogen in terms of quantity and quality. The Boschi design A.S.U features highly efficient fin type aluminium heat exchangers and column, wherein the entire upper column is a packed column thus reducing the operational pressure and increasing the Oxygen, Nitrogen and Argon recovery.

Argon Recovery Plants

Argon is recovered ABOVE 1000M3/HOUR OXYGEN PLANTSby a revolutionary technique employing full rectification without using the Hydrogen and De-Oxo unit thus saving further on power costs, operational costs and investment. This makes the Boschi design machines highly versatile and economical thanks to all the research and development done over the years.

Features

  • All Aluminium Construction.
  • Plate fin type exchanger
  • Sleve type trays or packed type
  • Low pressure
  • Super efficient
  • 100 to 50,000m3/hr oxygen/nitrogen/argon


  • Note: Check USA & Germay manufacturers for technology comparision.

    turbo expanders (V) Turbo expander:

    The Turbo expander is a gas bearing expansion refrigeration turbine that is much more efficient than any other expansion device.

    It works on the technique of induced cooling via expansion due to which the operational pressure of the plant is further reduced and the performance of the distillation column is stabilized for constant production and high purity oil bearing turbine expander.

    universal turbo expanders
    test bed for 100% reliability and tested at 150,000 rpm at minus 190 degree centigrade.
    troublefree service for years!






    Technical Specification

    Models UBT SERIES:- UBT40, UBT80, 100, 120, 150 , 180, 200, 220, 250, 300, 350, 400, 500, 600, 800 & 1000 upto 50,000 m3/hr
    Oxygen production
    Oxygen Output (cu. Mtr/hr) 40 TO 50,000m3/hour
    Oxygen Purity (%) 99.6% at 0.1BAR/0.01MPA
    Oxygen Pressure in cylinders 10 Bar to 150 bar(kg/cm2) Oxygen filling booster available.
    200 optional
    Nitragen gas is available as a second products also.
    Nitrogen production
    Nitrogen Pressure out of Column (bar)

    40 to 50,000 m3/hr.* at 5 BAR

    Nitrogen Output (cu. Mtr/hr)

    40 to 50.000m3/hr

    Nitrogen Purity (ppm optional)

    99.9% to 99.99% 3PPM opt.

    Nitrogen filling in cylinders (optional) 10 bar to 150bar(kg/cm2) Nitrogen filling booster available.
     
    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) 0.2 to0.4kwh(units)
    Voltage 3 phase** 380-415 50/60 hz or as per country