acetylene plant for continuous process applications

Acetylene Plant for Continuous process Applications is mainly used in chemical industry of the production of ethylene or various chemical processes and designed for maximum carbide yield and high efficiency.

The rated plant capacity is from 5 to 50 kg per hour depends on model selected. The acetylene plant is constructed and inspected with a best practice policy that meets the intent of design principles and manufacturing practices from Section VIII of the ASME codes. It is also designed to NFPA 51A: “Standards for Acetylene Charging Plants 2006”. Equipped with all of the safety features found only in Hi-Tech’s plants, The Plant is optimized for low building and installation costs. This acetylene plant is skid mounted with the generator mounted on one skid and the process equipment installed on a second skid.

The medium pressure generator is the highly efficient “SCREW FEED” type capable of using calcium carbide of graded size from 4 mm up to 50 mm with a maximum dust content of 15%. The recommended carbide size is 15 X 25 mm. The generator has automatic water inlet, residue agitation and residue discharge. The generator comes complete with a double 100 kg capacity hoppers which is recharged by exposing only the hopper to atmospheric pressure. The balance of the system remains sealed, permitting fast recharging with calcium chloride and a quick return to charging cylinders.
The process skid consists of equipment to cool the acetylene and to produce acetylene that is 99.6% pure. Laboratory grade acetylene purity is based on USA/UK grade calcium carbide or the equivalent being used.

Acetylene storage tank is provided with master valves, flame arresters and check valves. tank is filled with monolithic calcium mass for preventaion of formation of dangerious pockets, Acetylene is stored at a working pressure of 2.5 bars and drawn for use directly to process plant.

with the help of mass flow controller, calculated amount of acetylene is dosed to process plant.

A motor control center is used to control all automated processes of the acetylene plant. Also having facility of remote controlling by local area connection

The Main Parts of Acetylene Generator


The Generator has all the safety features- temperature safety instrument, water inlet control, high water shutoff, low water level alarm, automatic carbide feeding, automatic residue discharge, and over pressurization safety relief valves. A Double hopper of approximately 100 kg feeds the carbide as needed, producing approximately 50 to 280 m3 of acetylene per charge depends on model selected.

 Cooler Condenser

The acetylene gas passes through a cooler condenser to lower the temperature with help of recirculated cross flow cooling water.

Low Pressure Drier

The acetylene gas passes through a low pressure drier to remove water particles that gets evaporated during carbide reaction.


The gas travels through a purifier to remove impurities that otherwise would collect in the cylinders, reducing the acetylene absorbing capability. The purifier and scrubber also assist in removing impurities like Hydrogen sulphide and phosgene etc. that build up in the flame arresters, causing blocking and check valve malfunctions.

Ammonia Scrubber

The ammonia scrubber removes 99% of the ammonia that develops during the acetylene generating process. Removing ammonia prevents amines from forming and clogging flame arresters and cylinders.


A 3 stage compressor increases the acetylene pressure from 0.4 bars(6 psig) to 24 bars maximum (350 psig). Cooling coils and condensate traps are located at each stage, and the entire assembly of the compressor, with its coils and traps, is submerged in water for maximum cooling of the acetylene gas

Medium Pressure Drier

A medium pressure drier is included for additional drying due to climatic conditions.

High Pressure Driers

The high pressure driers remove moisture and oil picked up during compression. The acetylene then flows through a special filter, flame arrester, and a back pressure valve before going to the manifold, where every station valve is protected with a flame arrester on each side. A flame arrester, reverse flow check valves, and handwheel connections are on the end of the lead (pigtail) at the cylinder.

Storage Tank

Storage tank act as accumdator for acetylene gas that is drawn for use to chnimcal industry, fitted with pressure sensors, temprature sensors, pressure gauges, shure shot safety relief valves, flash back assesors and check valves

Electrical Controls

Electrical controls include a weather-proof panel with a main disconnect switch, individual motor starters, PLC and disconnect switches. An air compressor is included to supply air for the generator controls, acetone pump, and to reactivate the purifying material.

Throughout the entire process, safety devices monitor all operations because safe operation is one of the most important features of the plant. All other plant instructions are included in the “Installation, Operation and Maintenance” manual. Exceeding all competitive models, the plants are extremely safe and highly efficient, obtaining the maximum yield from calcium carbide. In fact, increases in carbide yield have been up to 11% over low pressure plants – even new plants. Yields could be even greater when the Hi-Tech used to replace outdated plants.

Acetylene Generator

acetylene generator

Plant Unique Features

  • Completely Pre-Piped & Skid Mounted.
  • Containerized Shipments right from factory.
  • Critical process parameters monitored and recorded and recorded every 500 milliseconds.
  • Automatic shutdown for in case of high Temperature,High Pressure,High Water level etc.
  • Designed in accordance with local standards.
  • Automatic and unattended operation.
  • On-site start-up Training and assistance by Hi-tech’s Engineered Solutions technicians anywhere in the world.

General Layout Installation View of Acetylene Plant for Continuous Process Application

acetylene plant for continuous process application installation

The Advantages

Hi-Tech’s Acetylene Plants can be opearted and maintained without extensive technical knowledge or training.our easy to follow manuals,drawings,videos and on-site training will enable your staff to properly calibrate and maintain the whole system.routine maintenance is limited to normal compressor up-keep and periodic cleaning and replacement of filter elements only.

  1. ModernPlant is designed with standard Safety practice from NFPA,CSB,FDA etc.
  2. EconomicalHigher Acetylene Gas Yields with small plant foot-print and lower initial costs.
  3. CompactThe plant Doesn’t required any bulky gas holder system & consumes very less space.
  4. Efficient-compact design with PLC Operation controls all plant parameters.
  5. Easy Installation-The Plant arrives on pre-piped skids for minimum on-site assembly & installation.
  6. Safe-The Plant operation and critical points like Level,temperature & Pressure is controlled by an intelligent industrial grade PLC,Hence Provides an Un-equalled protection to acetylene filling plants.

Technical Details

A full line of Acetylene Plants available for continuous process applications, use the following table to determine which model is most suitable for your application

HTA-C-5 HTA-C-10 HTA-T-20 HTA-T-30 HTA-T-40 HTA-T-50
Capacity 5 kg/hr 10 kg/hr 20 kg/hr 30 kg/hr 40 kg/hr 50 kg/hr
Operating Pressure 0.5 Bar 0.5 Bar 0.5 Bar 0.5 Bar 0.5 Bar 0.5 Bar
*Purity 99.6% V/V 99.6% V/V 99.6% V/V 99.6% V/V 99.6% V/V 99.6% V/V
Startup Time 5 Minutes 5 Minutes 5 Minutes 5 Minutes 5 Minutes 5 Minutes
Carbide Size 15-25mm 15-25mm 15-25mm 15-25mm 15-25mm 15-25mm
Tank capacity 0.2 m3 0.3m3 0.6m3 1.2m3 1.5m3 1.8m3
Power requirement 4 KW 6 KW 8 KW 11 KW 13 KW 15 KW

*using USA/UK grade Calcium carbide having Max 15% Dust Concentration;

Note- Custom built models also available, Specifications are subject to change without prior notice.