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Acetylene
Generator
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Special features of Better Deal Machine Dissolved Acetylene Gas
Plant
- No bulky gasholder required.
- Automatic control for feeding water, maintaining temperatures,
pressures, and slurry drain are, fool proof, efficient and are of
international standard.
- Excellent absorption of gas in cylinders.
- No gas loss and high yield.
- Very simple and safe to operate.
- Low power consumption.
- Low maintenance cost.
- Manufactured as per Designs and Drawings approved by The Chief
Controllers of Explosives.
- Manufactured under ISI quality marking.
| Specification |
For 15 Cum/Hr Acetylene Plant |
For 25 Cum/Hr Acetylene Plant |
For 50 Cum/hr Acetylene Plant |
For 100 cum/hr Acetylene Plant |
| Capacity |
15 Cum/Hr of Acetylene |
For 25 Cum/hr of Acetylene |
50 cu.m/Hr of Acetylene |
100/Hr cu.m of Acetylene |
| Cylinders filled per batch |
20 |
30 |
60 cylinders |
120 cylinders |
| Carbide size |
4-25mm |
4-25mm |
4-25 mm (or higher) |
4-25mm (or Higher) |
| Hopper Capacity |
75 Kg |
100 Kg |
150 kg |
300 kg |
| Carbide required per batch |
400 kg approx.(depending on carbide
quality) |
600 kg approx.(depending on carbide
quality) |
1,200 kg approx.(depending on
carbide quality) |
2700 kg approx. (depending on
carbide quality) |
| Water required |
10 liters per kg of Calcium Carbide
used |
10 liters per kg of Calcium Carbide
used |
10 liters per kg of Calcium Carbide
used |
10 liters per kg of Calcium Carbide
used |
| Power required |
10kw |
12kw |
18 KW |
30 KW |
| Start up time |
15 minutes |
15 minutes |
15 minutes |
15 minutes |
II S/BS. Specifications conforms to
- Acetylene Generator"
- Flame-proof motors |
IS 8471-1977 IS 2148 (Group
II-B)-1968 As amended |
IS 8471-1977 IS 2148 (Group
II-B)-1968 As amended |
IS 8471-1977 IS 2148 (Group
II-B)-1968 As amended |
IS 8471-1977 IS 8471-1977 IS 2148
(Group IIB-1968 as amended) |
Space Requirement
1. Process Area |
50 Sq. M |
70 Sq.M. |
110 Sq.M |
150 Sq.M |
| 2. Carbide Storage Area |
60 Sq. M |
75 Sq.M. |
112 Sq.M |
175 Sq.M. |
| 3. Cylinders filling Area |
30 Sq.M |
40 Sq.M. |
60 Sq.M |
100 Sq.M. |
| 4. Cylinders storage area
(depending upon cylinders inventory) |
80 Sq.M |
100 Sq.M. |
160 Sq.M |
200 Sq.M. |
| 5. Lime slurry disposal area |
80 Sq.M |
100 Sq.M. |
180 Sq.M |
250 Sq.M. |
| 6. Free space around the plant (on
all sides) |
15 M |
16 M |
18.5 M |
20 M |
| 7. Acetone godown |
10 Sq.M |
12 Sq.M. |
20 Sq.M |
30 Sq.M. |
Process description
Acetyle Generator
The Better Deal Machine Acetylene Generator is of an advanced design,
incorporating several features not ordinary found in other generators. The
BDM Acetylene generator is a fully automatic plant.
Pneumatically controlled valves and highly sensitive sensors, integral with
the temperature control instruments, perform all operations. These in turn
open the water inlet valve or residue drain valve etc. Two hydraulic pumps
help to open and close the supply of calcium carbide, which is fed into the
generator by screwfeed conveyors. The screw feed mechanism and the agitators
are operated by flameproof motors and fittings. The entire operation is
perfectly synchronized to give maximum efficiency and simplicity in
operation. Any failure, whether it is of power supply, water or air is
signaled visually and also audibly when an alarm bell rings to alert the
operator.
Only flame proof lights & electrical fittings according to IS2148-68
(group II) or BSS -229 may be used in an acetylene plant building. Acetylene
cylinders must be of specification IS: 7312:1974 or ICC:8.
Temperature Control
The BDM Acetylene Generator can be set to operate at any given temperature,
regardless of the size of carbide used or temperature of the cooling water,
A sensitive sensor actuates a pneumatic control that adds water into the
generator tank when the temperature exceeds the set limit, thus maintaining
a given standard temperature. This helps in complete utilization of carbide,
which is a very expensive raw material.
High Pressure Control
If all the gas generated cannot be drawn in by the compressor and passed on
the filling manifold, either due to low capacity of the compressor or fast
generation, gas pressure will gradually build in the generator. When the gas
pressure reaches a predetermined level (about 0.5kg/cm²) carbide will
be cut off automatically and further generation of gas is stopped.
There is no expensive gas holder with the BDM Acetylene Generator. This
item alone will reduce the investment on such a plant. Further, as the gas
generated is always at a positive pressure, the pumping cost is also
reduced. Since the generator is constantly at a positive pressure, (once the
plant has been purged with Nitrogen) no air can enter the system, and it is
this feature which makes the "BDM" Plant inherently very safe.
Water Level Control
If excessive water enters the generator to cool it and the water level goes
above the high level mark, the water-level control instrument will
immediately discharge the excessive water thus maintaining the water between
the acceptable high and low level marks.
No loss-Carbide charge
No gass is lost or wasted while charging the carbide because that section
is completely sealed off from the generator by a high pressure hydraulically
operated valve.
All the above controls are automatic and require no attention from the
operator. There is a further safety device, in terms of an alarm bell, which
will ring continuously till the fault is corrected.
Condenser
The Acetylene gas leaving the generator is hot and carriers with it some
water vapour and other impurities. The condenser will cool the gas, thereby
condensing the excessive moisture in preparation for its subsequent removal.
The condenser is of ample proportion to suit local conditions and ensures
complete cooling, provided that sufficient water supply is maintained.
Low Pressure Drier
The drier is charged with calcium chloride. The absorbs the moisture in the
gas. In case a certain amount of moisture is necessary to enable the
chemical purifier to function effectively, a by-pass is provided to allow
part or whole of the gas to be directly admitted into the chemical purifier.
Chemical Purifier
This consists of two layers of regenerative chemicals, which remove
additional impurities. The purifying agent may be reactivated for re-use by
the atmosphere air. For continuous operation one extra charge of chemicals
can be kept in open wooden trolley.
Water Scrubber
The equipment is installed between the chemical purifier and the
high-pressure compressor, which helps to remove additional impurities from
the gas if any.
Acetylene Compressor
For filling of the cylinders an I.R. make reciprocating, oil lubricated,
multi-stage, Water submerged compressor with intercoolers, safety relief
valve for each stage, driven by a 15 H.P. Flame Proof Motor confirming to
IS:2148-68 (Gr.II-B) is provided.
High Pressure Drier
This consists of a battery of three high-pressure vessels. The first is
filled with metal filler, while the second and third are filled with
anhydrous calcium chloride. It is very important that the high pressure
drier is fully filled up with Calcium Chloride, as any voids in
high-pressure area are against the required safety.
Filling Manifold
This consists of a battery of 60 filling connections to connect to the gas
cylinders. Non-return valves are extremely important for the safe operation
of the plant and should be periodically examined. The manifold should also
be periodically cleaned to remove rust and scales, (iron rust rushing though
the pipeline at high speed could generate a spark and cause fire). The
cylinders filling pig tails (flexible hose pipes) should also be
periodically cleaned to ensure that they: do not burst during filling
operation, (if they do burst, a fire would ensure due to sudden discharge of
Acetylene).
Instrument Air Compressor
A flameproof motor with a buffer tank drives the instrument air compressor.