Acknowledgement

Group D extends hearty gratitude to Gyan Bahadur Tamang, faculty, Operations Management, Nepal Commerce Campus for his special encouragement and facilitation for the project. This group is very grateful to college as well. Foremost, we extend our sincere gratitude the industrial union of Balaju who gave us the permission to conduct our project well. Furthermore, we also express our thanks to the operation manager of Om Oxygen manufacturer Pvt. Ltd. for giving us the opportunity to study the production of Oxygen gas in large scale level. Without their contribution our plan would have been incomplete and out of touch with the industrial reality. It was a great fun & informative to us to conduct this project. During the course of the project we gained the valuable insight into Oxygen industry. We believe this project had added experience and knowledge among us to conduct the similar type of project in our near future. Finally, we share our warm gratitude to all staffs of Oxygen industry who have helped us in preparing this plan.

Group Members
Bikram Limbu Mukesh Tamang Lil B. Kc. Rajesh Shrestha Prabin Kc. Amrit Pandit Santosh Nepal

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Oxygen
Oxygen, O2, is a colorless odorless gaseous main group element which belongs to Group VIb of the periodic table.
y y y y y

Atomic Number : 8 Atomic Mass : 15.9994 Melting Point : -214 degC Boiling Point : -183 degC Density : 1.429

Atmospheric oxygen is of vital importance for all aerobic organisms. For industrial purposes, oxygen is obtained by fractional distillation of liquid air. It is used in metallurgical processes, in high-temperature flames and in breathing apparatus

Uses
Oxygen is essential for life and it takes part in processes of combustion, its biological functions in respiration make it important. Oxygen gas is used with hydrogen or coal gas in blowpipes and with acetylene in the oxy-acetylene torch for welding and cutting metals. Oxygen gas is also used in a number of industrial processes. Medicinally, oxygen gas is used in the treatment of pneumonia and gas poisoning, and it is used as an anesthetic when mixed with nitrous oxide, ether vapour, etc. Carbon Dioxide is often mixed with the oxygen as this stimulates breathing, and this mixture is also used in cases of poisoning and collapse for restoring respiration. Liquid oxygen mixed with powdered charcoal has been used as an explosive.

Inputs
For the production of oxygen gas in large quantity the manufacturer uses the air from free atmosphere for production. In order to obtain the desired output i.e. oxygen gas following inputs are required: y y y y y air, water, Electricity. Labour force, Machinery equipment,
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Industrial preparation of Oxygen gas

Capital etc.

Transformation Process

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Air Compressor and Chilling Unit

The free saturated air is sucked from atmosphere through a highly efficient dry-type suction filter into the first stage of the horizontally balanced opposed, lubricated reciprocating air compressor. Compressed air is chilled to 12C in a chilling unit or evaporation cooler, compressed air passes through the coils of the chilling unit at a temperature of 12C to a moisture separator, where the condensed moisture gets removed before entering into Molecular Sieve Battery. Before sending the air to MOLECULAR SIEVE BATTERY, air is passed through an OIL ABSORBER where air becomes oil free.

Purification of Air
Chilled air passes through the Molecular Sieve Battery packed with molecular sieves to remove moisture and carbon dioxide present in the air. Molecular Sieve Battery operates on Twin Tower System, when one tower is under production the other tower is regenerated by passing waste nitrogen gas at 200C through a REACTIVATION HEATER. After interval of 8 to 10 hours, the tower under production gets exhausted and regenerated by similar process before use and, thus the cycle continues. Any dust particle gets filtered in the DUST FILTER before air enters the AIR SEPARATION COLUMN All the equipments are mounted on process skid. (See our Catalog)

Air Separation
Chilled, Oil-free and moisture-free air enters into multi-pass HEAT EXCHANGER No. 1 where it gets cooled to (-80) deg C by cold gained from outgoing waste nitrogen and oxygen. A part of air, this enters a multi-pass HEAT EXCHANGER or LIQUEFIER. This air cools before passing through an expansion valve air gets further cooled down and gets liquefied before entering into Bottom Column. Rest of air at enters into a highly efficient EXPANSION ENGINE, where the air further gets cooled before entering into bottom column. The liquefied air from both these streams collected at the BOTTOM COLUMN is known as RICH LIQUID. Inside view of a air separation unit (Cold Box) in stainless steel

The RICH LIQUID in the BOTTOM COLUMN enters into feed tray of top column. Similarly the liquid nitrogen called POOR LIQUID enters into top column as a reflux & it takes away the latent heat of condensing oxygen and gets vaporized whereas the liquid oxygen flows down the trays of the TOP COLUMN into the Condenser. Liquid Oxygen from CONDENSER passes through a SUB-COOLER to a LIQUID OXYGEN PUMP.

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Cylinder filling station

Cylinder Filling Station

Liquid Oxygen from the condenser to the cryogenic liquid oxygen pump for filling gas into cylinders. A. Capacity from 20 cubic Meter / hour to 500cubic Meter/ hour B. Pressure (150 kg/cm2) upto 300 kg/cm2

Random Fluctuation
Random fluctuation is the undesired disturbances that affect output. There arise various types of disturbances during the transformation process that affects the quality of the desired output. Such disturbances are even more in our country. Such disturbing factors are: y y y y y y Load- shedding hampers the process of electrolysis, Breakdown of machinery also equally hampers the transformation process, Lack of raw materials, Lack of skilled manpower, Labour Union interference in the industry, Strikes of labour and employees, etc.

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Random Fluctuation:
y y y y Load shedding, Break down of machinery, Strikes of labour, Lack of raw materials, etc.

Monitor output: Adjustment Needed?

y Automatic gadgets are used to check the quality of O2 gas.

Inputs
y y y y Air Water Electricity Labour equipments,

Conversion Process:
y y Electrolysis of water Separation of Oxygen and Hydrogen gas

Out puts:
y Oxygen gas

y Machines and y Capital, etc.

Comparison/feed back:
y Purity of oxygen is checked and made sure that no other gas is present there

Production and Operation System

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CONCLUSION:

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