Small / Transportable Acetylene Cylinder Filling Plants

The Small / Transportable Acetylene Cylinder Filling Plants is designed for maximum carbide yield and high efficiency. The rated plant capacity is from 5kg/hr to 20 Kg/hr using USA/UK grade calcium carbide depends on model selected. The Hi-Tech 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”.

The transportable/small acetylene plant is skid mounted with All equipment mounted on one 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 comes complete with a single 120 kg capacity hopper. Acetylene is generated only when needed.

Two 10 to 20 cylinder manifold come with Main Isolation valve, flame arresters and flexible cylinder filling leads that have non-return check valves. Hand wheels with nipples that use o-rings to seal make the connection of cylinders quicker.

A motor control center is provided to control all automated processes of the acetylene plant.

The Main Parts of Acetylene Generator

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 Single hopper of approximately 100 kg feeds the carbide as needed, producing approximately 20 to 60 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.

Purifier

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.

Compressor

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.

Charging

Charging of the cylinders can be accomplished in 8-10 hours.

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.

General Layout Installation View of Transportable Acetylene Plant

Technical Details

A Full Line of Small Capacity / Transportable type acetylene generators available

our generators provide from 2 to 20 kg per hour of acetylene, use the following table to determine which model is most suitable for your application-

Specifications ? Model ?	HTA-T 2	HTA-T-5	HTA-T-10	HTA-T-15	HTA-T-20
Capacity	2 Kg/Hr	5 Kg/Hr	10 Kg/Hr	15 Kg/Hr	20 Kg/Hr
Operating   Pressure	0.5 Bars G	0.5 Bars G	0.5 Bars G	0.5 Bars G	0.5 Bars G
Purity*	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
Carbide Size	0-7 mm	7-15 mm	7-15mm	15-25mm	15-25 mm
Cylinders Filled per Batch**	3	6	12	18	24
Connected Power	3 KW	5 KW	8 KW	12 KW	16 KW

*using USA/UK grade Calcium carbide having Max 15% Dust Concentration; ** A batch is of 8 Hours and Cylinders having 7 kg acetylene capacity.

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