General
Design 1
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1. Introduction The Manual Nitrogen Generation Plant is a self-contained system designed to produce high-purity nitrogen gas for cylinder filling, industrial processes, and laboratory applications. Combining a diesel‐driven air compressor, air‐drying unit, Pressure Swing Adsorption (PSA) module, and a hydraulically driven booster, this plant offers on‐site, reliable nitrogen generation up to 200 bar. Its modular design ensures portability and ease of operation in environments lacking stable electrical infrastructure. 2. Key Features • Integrated Diesel Engine & Air Compressor: - Diesel engine (Graeves Cotton G-1510, 9 HP @ 3000 RPM) directly powers an 8.8 CFM, 2‐stage air compressor, delivering clean compressed air at 12 kg/cm2 (approximately 7 bar). - Air‐cooled, single‐cylinder design ensures efficient operation in ambient temperatures up to 50 °C. • High‐Efficiency Air Drying & Filtration: - Activated carbon filter (15 kg) and ceramic candle pre‐filter (1 μm) remove oil, moisture, and particulates from compressed air before entering the PSA module. - Heatless regenerative air dryer (IS 2825 compliance) maintains dew point below –60°C, safeguarding molecular sieve beds. • PSA Nitrogen Generation Module: - Twin‐tower PSA unit (150 mm × 1000 mm, 16 L each) equipped with Carbon Molecular Sieves (CMS) produces nitrogen at up to 99.9% purity. - Adjustable flow rate of 0.5–5 Nm3/hr (rotameter calibrated to 0.5–5 Nm3/hr range; typical operation at 2 Nm3/hr). - Surge tank (600 mm × 1250 mm, 60 L) buffers nitrogen output to maintain steady pressure. • Hydraulic Booster Assembly: - Single‐stage, single‐acting hydraulic booster delivers nitrogen from PSA module pressure (approx. 5.8 kg/cm2) up to 200 bar, enabling direct filling of high‐pressure cylinders. - Bronze piston (Ø 70 mm) within an Italian‐honed barrel ensures minimal leakage and consistent performance. - Inlet and outlet check valves (SSCH series) prevent reverse flow, protecting PSA beds and ensuring safety. • Robust Hydraulic Power Pack: - Dowty gear pump (40 L/min, 132 bar max) driven by a 3 HP electric motor (220VAC), providing hydraulic power for booster operation. - EPE 10 μm filter and 100 μm strainer protect hydraulic components from contamination. - Mild steel tank (250 L capacity) with integrated Rexroth DC solenoid valve (4/2 way) controls hydraulic flow. • Comprehensive Instrumentation & Controls: - Six SS 304 pressure gauges (0–10 kg/cm2, 4′′ dia) and two Bourdon‐type pressure switches monitor air and nitrogen stages. - Nine solenoid valves (12 V DC, 1⁄4′′ porting) automate air dryer regeneration, PSA switching, and venting cycles. - Siemens PLC (12 DI/8 DO) provides sequence control for startup, shutdown, and changeover operations. • Portable & Field‐Ready Design: - Self‐contained skid with forklift pockets and lifting points for easy transport. - Modular arrangement of engine, compressor, cooler, PSA towers, surge tank, and booster allows straightforward maintenance. - Fuel tank (5.5 L) and oil sump (1.75 L) integrated into engine base for compact footprint. 3. Working Principle 3.1. Air Compression & Pre‐Treatment: - The diesel engine (G-1510) is started via rope pull (or optional 12 V electric start). It drives the two‐stage air compressor, which compresses ambient air to approximately 7 bar. - Compressed air enters the pre‐filter (ceramic candle) to remove particulates above 1μm. Next, it passes through the activated carbon filter (12 L volume) to eliminate oil vapor and hydrocarbon contaminants. 3.2. Air Drying & Storage: - The filtered air is directed into a regenerative heatless dryer. Two alternately switching towers filled with Zeolite Molecular Sieves (ZMS) adsorb moisture, ensuring the dew point is maintained at or below –60 °C. - Dried air is collected in the Dry Air Receiver (250 mm × 1200 mm, 60 L), where it is held at 7 bar until the PSA module is activated. 3.3. Pressure Swing Adsorption (PSA) Nitrogen Generation: - Upon reaching the required air pressure (7 ± 0.5 kg/cm2), the PLC energizes solenoid valves to route air to one of the two CMS‐filled absorber towers. Under pressure, oxygen and trace gases are adsorbed onto the CMS bed, allowing high‐purity nitrogen to exit at the bottom of the active tower. - The opposite tower undergoes regeneration (depressurization and ambient venting) to purge adsorbed oxygen, preparing it for the next adsorption cycle. - Nitrogen flows through a final quality control stage, passing a rotameter (0.5–5 Nm3/hr) set to 2 Nm3/hr. After 10 minutes of vent‐purge, pure nitrogen is ready at approximately 5.8 bar. 3.4. Hydraulic Boosting & Cylinder Filling: - Once the Surge Tank pressure stabilizes at ~5.8 kg/cm2, manual valve operation opens the inlet to the hydraulic booster. The diesel‐driven hydraulic booster piston, powered by the hydraulic power pack, compresses nitrogen from PSA pressure up to 200 bar. - Integrated check valves at the booster inlet and outlet prevent backflow into the PSA module and ensure one‐directional high‐pressure discharge. - High‐pressure nitrogen is routed through safety valves and pipelines to fill storage cylinders directly via the bottom outlet needle valve. 4. Component Details 4.1 Diesel Engine (Graeves Cotton G-1510) • Type: Vertical, single‐cylinder, air‐cooled, cold start, compression ignition, four‐stroke • Rated Power: 9 HP @ 3000 RPM (Centrifugal governor; reflection‐type silencer) • Displacement: 510 cm3 (Bore 85 mm × Stroke 90 mm) • Fuel Tank Capacity: 5.5 L • Lubrication: Forced lubrication utilizing 15W-40 API CH-4 oil (e.g., Greaves Maxtherm) • Start Method: Rope start (standard); Optional 12 V electric start available • Dry Weight: 62 kg (involute crankcase design) • Maintenance: First oil change after 1000 km, then per schedule; daily oil level checks; monthly filter checks 4.2 Air Compressor • Output: 8.8 CFM @ 12 kg/cm2 (7 bar) • Tank: Integral 160 L ASME‐rated air receiver with safety relief valve • Construction: Deep‐finned cast iron cylinders, aluminum cooler tubes, forged steel crankshaft, belt‐driven by the diesel engine • Cooling: Aero‐dynamically designed fan ensures heat dissipation up to 50 °C ambient • Safety: Pressure relief after each compression stage; fully enclosed belt guard conforming to Euro norms • Filter: Oil bath type air filter (engine‐mounted), stainless steel compressor valves, oil sight glass for visual lubrication check 4.3 Air Drying & Filtration • Ceramic Candle Filter: - Rating: 1 μm particulate removal - Design Code: IS 2825 - Operating Pressure: Up to 8 kg/cm2; Volume: 1 candle, 100 mm × 600 mm • Activated Carbon Filter: - Volume: 12 L of granular activated carbon (Oriental Carbon, 50 mesh) - Removes oil vapor and hydrocarbon traces before drying stage • Heatless Air Dryer (ADU): - Two absorber vessels (100 mm × 1000 mm, 8 L each) filled with ZMS (CECA, 2–3 mm balls) - Design Pressure: 8 kg/cm2; Hydrotest Pressure: 12 kg/cm2; Shell MOC: IS 2062 - Automatic cycling via 3 diaphragm‐type changeover valves (1/2′′, 10 kg/cm2) and 3 solenoid valves (12 V DC) 4.4 PSA Nitrogen Generator • PSA Towers: - Two vessels (150 mm × 1000 mm, 16 L each), carbon molecular sieves (CECA, 1.6mm pellets, 18 kg total) - Operating Pressure: 7 kg/cm2; Design Pressure: 8 kg/cm2; Shell MOC: IS 2062 - Cycle controlled by PLC toggling 8 automatic valves and 5 solenoids • N2 Surge Tank: - Vessel Size: 600 mm × 1250 mm, 60 L (IS 2825) - Buffers PSA output, stabilizing nitrogen flow prior to boosting 4.5 Hydraulic Boosting System • Booster: - Single‐stage, single‐acting hydraulic cylinder; - Barrel: Italian‐honed tube; Bronze piston Ø 70 mm; Hydraulic bore Ø 140 mm - Max Outlet Pressure: 200 bar; Check Valves: SSCH series (1⁄2′′ MNPT, cracking 1 psi, working 250 bar) - Piston Seal: K03‐P (58 × 70 × 7.8 mm HCOPUR); O‐Ring Cord (Ø 3 mm, length ~198.9 mm) • Hydraulic Power Pack: - Dowty gear pump (40 L/min, 132 bar max), 3 HP, 220 VAC motor - Reservoir: MS tank 250 L (aminimal capacity to allow fluid expansion) - Filtration: EPE 10 μm filter, 100 μm strainer - Control Valve: Rexroth DC 4/2 solenoid valve, 12 V DC 4.6 Instrumentation & Controls • Pressure Gauges: Six SS 304, 4′′ dial, 0–10 kg/cm2 (3/8′′ NPT) • Pressure Switches: Two Bourdon type, 0–10 kg/cm2, 1⁄4′′ connection • Solenoid Valves: Nine total (2‐way, 3‐port), five normally closed (NC) and four normally open (NO), 1⁄4′′ ports, 12 V DC • Rotameter: 1⁄2′′ connection, 0.5–5 Nm3/hr range, calibrated at 5.5 kg/cm2 • PLC: Siemens unit with 12 digital inputs (DI) and 8 digital outputs (DO), 12 V DC supply 5. Technical Specifications
