KDON-165 oxygen production plant and oxygen plant for hospital

General Performance

Description	Output	Purity	Pressure out of cold box
Gas oxygen	165Nm3/hr	99.6% O2	15Mpa.G

1.0 Technical highlights

1.1 Main air compressor

Use screw compressors manufactured by world famous brand ATLAS, etc.

ATLAS

Oil lubrication for cylinder

1.2 Air pre cooler

Freonair heat exchanging pre-cooling system:

Skid closed structure with little area occupation

Installed indoor for convenient operation and maintenance

Equipped with Germany Bitzer double Freon compressor for two state high efficiency and reliable running

Refrigeration loading adjustable with 3 modes: 50%, 75%, 100%

350%, 75%, 100%

Equipped with water separator to remove free water after air temperature down, thus to decrease working loading of air purifying system

Decrease the air temperature to be 8-15C which is best for air purifying system working.

8-15C

1.3 Air purification system

Remove dangerous impurities contained in the air before entering the cold box and brings complete safety for a long operating time without any necessary defrosting

With Temperature Swing Adsorption system the total air flow is treated on alumina layer for water elimination and then on the molecular sieve which stop carbon dioxide (CO2), moisture (H2O), acetylene, (C2H2).

(CO2),  (H2O), (C2H2)

Use double layer system because of major advantage:

The activated alumina layer, located upstream, very effectively protects the layer of the molecular sieve as:

First it completely stops the water. The water, even when pure, relatively quickly downgrades the efficiency of the molecular sieve in relation to the CO2. Unlike the molecular sieve, activated alumina is the ideal adsorbent to stop water. Its mechanical strength is almost unaffected by the presence of liquid water.

CO2

Furthermore, when acid gases are present in the air, it is essential for the long term durability of the molecular sieve that these gases do not penetrate alumina layer at the same time as the water. Such acids create mechanical deterioration of the molecular sieve. Compared to molecular sieve, activated alumina has a much higher chemical resistance to acid.

1.4 Air separation system (cold box)

Use complete rectifying process to produce gasliquid nitrogen as per plant design and customers requirements

Low working pressure(column 1.0MPa.G)

1.0MPa.G

Use convective sieve tray(with China National patent, No. ZL 2006 2 0073335.7) to upgrade fractionation efficiency and recovery rate

No. ZL 2006 2 0073335.7)

1.5 Turbine expander (air bearing)

WT have over 30 years design and manufacturing experience by cooperation with cryogenic institute of China Xian Jiaotong University(www.xjtu.edu.cn), and have been awarded several China national patents and prizes (i.e. Patent No. ZL 2006 2 0073333.8, ZL 95 2 45209.X)

WT30(www.xjtu.edu.cn) No. ZL 2006 2 0073333.8, ZL 95 2 45209.X)

Helium Turbine expander for China space industry is awarded as national key new product No. 20013200005 by P.R. China Economic & Trade Committee.

No. 20013200005

With high rotation speed (maximum 250, 000 rpm, normally 40,000-60,000 rpm) and adiabatic efficiency (normally 80-85%)

250, 000 rpm,40,000-60,000 rpm 80-85%

Skid structure and small size for easy mount, transportation, and repair

Rotor and bearing(key parts) can be conveniently changed without dismounting whole expander and taking out insulation perlite

1.6 Instrumental control system (PLC control)PLC

Use Siemens S7-300, computer and printer for main data collection, display, interlock, record, print, etc.

Siemens S7-300,

Main operation(switch of air purifying system, etc.) can be finished on computer

1.7 Main design and fabrication software and hardware

Design:

Use advanced ASPEN and HYSYS software for process simulation and calculation

ASPEN HYSYS

Use SW6-98 software package for design of pressure vessel

SW6-98

Use Auto CAD, KM CAD, I-DEAS6.0, CAXA for 2D drawing making

Auto CAD, KM CAD, I-DEAS6.0, CAXA for 2D

Use ProEngineer and Solid Works for 3D piping design and stress analysis(i.e. inside piping of cold box)

ProEngineer Solid Works3D

Use MUSE and HYSYS for aluminum plate fin heat exchanger design

MUSE  HYSYS

Use ProII, Excel, HYSYS for turbine expander design

ProII, Excel, HYSYS

Fabrication:

Use USA HAAS 5 coordinate processing center to manufacture impeller and rotor

USA HAAS

Use large vacuum braze welding furnace to manufacture aluminum plate fin heat exchanger

Test equipments: XY-2515, XX-2005, XXH-3005, XXQ-3005 X-ray machine, CTS-22,CTS-26 UT facility, JCD-900, CYE-2A, CY-1000A MT

XY-2515, XX-2005, XXH-3005, XXQ-3005 X-ray machine, CTS-22,CTS-26 UT facility, JCD-900, CYE-2A, CY-1000A MT

Welding equipments: Submerged Arc auto welding machine, Gas shielded welding machine

Use Schenck dynamic balance test equipments for rotor assembly of turbine expander

Schenck

Planing machine

Auto(half-auto) cutting machine

Sand blast equipment

2.0 Performance data

2.1 Design basis

2.1.1 Units

Flows: Nm3h (normal conditions, i.e. 0C 1.013 bar)

Nm3h (, i.e. 0C 1.013 bar)

PressureMPa gauge, unless otherwise stated.

MPa

Temperature: degree Celsius (C), unless otherwise stated.

(C)

Concentration and impurities: vpm (volume part per million) , or % volume.

vpm () ,  % .

Other measurement and data will be specified in the International Metric System (S.I.), unless otherwise stated.

(S.I.)

2.1.2 Ambient conditions

Air temperature    Design    30C

Maximum      40C

Minimum      -28C

Relative humidity  Design    70%

Atmospheric pressure  Design    0.1013 MPa.A

Site elevation Design    100m

2.1.3 Air compositions

Impurities Chemical formula Basis of design

Carbon Dioxide    CO2 <400 ppm

Methane       CH4 5 ppm

Ethylene       C2H4     0.1 ppm

Ethane   C2H6     0.1 ppm

Propane        C3H8     0.05 ppm

Acetylene      C2H2    0.3 ppm

Propylene     C3H6     0.2 ppm

Hydrocarbons      C4+       < 0.05 ppm each

Carbon Monoxide       CO 0.6 ppm

Hydrogen     H2  0.7 ppm

Ammonia      NH3 0.01 ppm

Hydrogen Sulphide     H2S       0.001 ppm

Chloride        Cl2  0.1 ppm

Total Strong Acids       HCl + HNO3 0.05 ppm

Dust            0.5 mgNM3

Sulfur Dioxide      SO2       0.1 mgNM3

Nitrous Oxide      N2O      0.35 ppm

Nitrogen Oxides   NOx      0.1 ppm

Ozone   O3  0.2 ppm

Note:

If, during lifetime of the plant, there are variations in the environment conditions, which affect or could affect the safe operation of the plant, and in particular any variations in the air quality figures mentioned here-above. Buyer shall inform Contractor immediately of any such variations, Contractor shall inform the Buyer of the consequences (if any) of these variations including cost impact for modification (if any). In case of peaks for CnHm in air, which might exceed the limits indicated here-above, it could be necessary to shut down the plant depending on the actual operating conditions (CnHm concentration in LOX vaporizer). Contractor shall not be held responsible for any consequences or damages (including shut down) which are due to the existence of different air quality figures than those mentioned here-above. The Buyer shall hold Contractor harmless from any consequences of damages of any kind in this case.

CnHmLOXCnHm

2.1.4 Site conditions

The construction criteria to be considered for the mechanical design of the elements of the plant are as follows.

Maximum wind speed 30 msec

Earthquake   IX by MSK-64 (EMS-98)

Yearly rainfall       300 mmy

Snow load     150 Kgm2

2.1.5 Utilities (supplied by Buyer)

2.1.5.1 Electricity

LV-1      380V +- 5%, 3 phases, 50HZ+- 1HZ

the neutral system is direct to earth.

LV-2      220V+- 5%, AC, 50HZ

2.1.5.2 Coolant

Air

2.2 Product parameters of ASU

Product

Output

Purity

Pressure at cold box outlet

Mode I

GOX       165NM3hr    99.7%     15MPa.G

Note:

The above parameters are based on design conditions.

2.3 Utilities consumption of ASU

2.3.1 Power consumption (preliminary for reference only, to be finalized at order stage)

SN

Equipment

Power(LV-1)

KW  Power  (LV-2)

KW

1     Main air compressor

275

2     Air pre-cooling system

7.5

3     Air purification system

48

4     Control system

3

5     Total(installed power)

333.5

2.3.2Operation of ASU

Running time

ASU is designed for a continuous running time 24 hours a day.

The shut down for inspection and scheduled maintenance of the whole plant shall be once every two years.

24

3.0 Process as per following flow diagram

4.0 Equipments main parameters

SN   Parameter description  Value

4.1  Main air compressor    1 set

Model    ZT275

Type       Screw, oil free

Medium Air

Coolant  air

Flow 40M3min

Inlet pressure 0.098 MPa.A

Outlet pressure     1.0 MPa.G

Outlet temperature      40C

Main material Carbon steel, stainless steel

Motor protection level IP55

Manufacturer Atlas Copco

4.2  Air refrigeration system       1set

Model    BAYL-215010

Air flow  2150NM3hr

Working pressure 1.0MPa.G

Coolant  air

Inlet air temperature    ~40C

Outlet air temperature ~10C

Refrigerant    407C

Refrigerant compressor       Germany Bitzer or French Befmar

Main material Carbon steel, stainless steel

Manufacturer Suzhou Bainian

4.3  Air purification system  1set

Model    HXK-215010

Air flow  2150NM3hr

Working pressure 1.0MPa.G

Adsorbent     13X APG molecular sieve+alumina

Air after purification     H20<1ppm

CO2<1ppm

Switch way    Automatic

Switch cycle   6hours

Reactivation gas flow   ~400NM3hr

Reactivation gas heater 1set

Main material Q345, OCr18Ni9

Manufacturer WT

4.4  Air separation system (cold box) 1set

Model    FO-165

Column Working pressure   ~0.92MPa.G

Rectifying column type Sieve tray

Main heat exchanger   Plate fin type

High pressure heat exchanger

Condenservaporizer     Plate fin type

Main material 3003, 5052, 5083, Q235-A, 0Cr18Ni9

Disposal evaporator     1 set

Manufacturer WT

4.5  Liquid oxygen pump 2 sets (one use one standby)

Flow 165NM3hr

outlet pressure     15MPa.G

Manufacturer Xinya or equivalent

4.6  Turbine expander 11    1set

Bearing  air

Booster end

Flow 1330NM3hr

Inletoutlet pressure      1.1331.281 MPa.A

Inlet temperature  31.3 deg C

Adiabatic efficiency      72%

Expansion end

Flow 720NM3hr

Inletoutlet pressure      0.760.135 MPa.A

Inlet temperature  131K

Adiabatic efficiency      76%

Bearing  air

Manufacturer WT

4.7  Turbine expander 22    1set

Bearing  air

Booster end

Flow 1330NM3hr

Inletoutlet pressure      1.031.133 MPa.A

Inlet temperature  20deg C

Adiabatic efficiency      72%

Expansion end

Flow 1040NM3hr

Inletoutlet pressure      0.2690.12 MPa.A

Inlet temperature  113K

Adiabatic efficiency      76%

Bearing  Air

Manufacturer WT

4.8  Control way   Automatic

Configuration Software Seimens PLC S7-300

Operator stationincluding computer and operation system software   1set

Engineer stationincluding computer and operation system software    1set

Printer    1 set(HP or CANON)

UPS 10KVA

Pressure transmitter     China make

Differential pressure transmitter China make

Solenoid valve      SMC,ASCO, or CKD

Butterfly valve       Neles or Hangyang, Sanfang, or equivalent

Thermometer Pt100

Pressure gauge     Spring type

Expander rotation probe     Shanghai  brand

Local pressuretemperature indicator Shanghai

Cryogenic valve    KOSO, Sanfang or equivalent

Analyzers, including

Produt O2  analyzeronline Beijing

CO2 analyzer Beijing

Dew point analyzer     Beijing

Bearing air cabinet       1set

4.9  GOX filler       1set

Model    GC-40

Filling head    40 pc

Manufacturer WT

4.10 Electrical control system      1set

Including

Electrical control cabinet(purifier) ()    1set

4.11 Unit internal valves and gauges on Sellers PID drawing (including mate flanges, bolts, nuts, etc.)PID() 1set

4.12 Unit external valves and gauges on Sellers PID drawingPID   1set