Cable industry is of the biggest industries using nitrogen on a large scale. Wire manufacturing and cable industry are industries which require constant supply of nitrogen. This industries use N2 gas for smooth running of their production processes. No doubt, use of nitrogen plant and generators in the cable industry is extensive. There is no more reliable source of obtaining industrial nitrogen than installing an onsite nitrogen plant.

And, nitrogen is one of the most abundantly found elements comprising 78% of earth’s atmosphere. As mentioned earlier, the inert gas is used wide variety of commercial applications. However, many companies are now finding it more beneficial to install their own nitrogen gas plants than sourcing the non-reactive gas from third-party suppliers.

Why wire makers and cable industry need nitrogen?

During the manufacturing of cables, it is but natural that air, humidity and oxygen molecules will go into the coating material and the wire upon coating. So the nitrogen gas is introduced in the coating material and the wire. This creates a closed nitrogen atmosphere thereby preventing oxidation.

We know that high tension cables (33 KV-210 KV) are made with the help of a process called nitrogen atmosphere curing. Better Deal Machineries Pvt. Ltd. is one of the leading nitrogen plant manufacturing companies supplying nitrogen plants. We have supplied nitrogen plants to various companies manufacturing cables in South America, Asia, Africa and Middle-East.

Earlier, the cable industry used steam curing of electrical cables. In this process there was no way to remove moisture completely.  As a result, the cable insulation was of poor quality because some moisture was always left inside the coating.

 Then, steam curing gave way to the dry nitrogen curing. Now we have hundreds of cable companies using nitrogen for manufacturing of high tension cables. However, this kind of curing requires constant supply of nitrogen at 12-18 bar pressure. Better Deal Machinery has been manufacturing and supplying high pressure nitrogen generators for over 35 years for catering to such needs.

 Nitrogen plants for cable industry are manufactured with the latest cryogenic technology. The plants can be set for generating nitrogen at a required pressure. And, the nitrogen gas generated in the nitrogen plant/generator is stored in high pressure tanks.

The storage tank is used for taking nitrogen for curing through an advanced pressure reducing valve. The tank will take care of fluctuating nitrogen requirements. And, it also provides high pressure nitrogen flow during purging. This application requires nitrogen to have purity of 99.9%. This level of N2 purity is deal for achieving perfect insulation.  We will discuss important aspects of curing of cables in the following sections:

Tempering of Copper wires

Manufacturing of copper wires needs tempering. It is required for increasing flexibility and resistance. The process uses nitrogen for tempering process. The inert gas is put inside the stove for stopping oxidation at high temperatures. No doubt nitrogen completely stops oxidation.

Cooling and heating

Nitrogen is used for cooling and heating.  Air conditioners and industrial cooling devices use copper pipes. For usage of copper wires, these devices must go through a leakage test in which we use nitrogen.

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Moreover, cryogenic liquids have boiling points below -150 degree Celsius and they are gases under normal temperature and pressures.  However, it is important to note that these gases turn into gases under different conditions of temperature and pressure.

And, all these gases have one common property that they are very cold and they can grow into very large volumes of gas. Liquid oxygen plants use cryogenic distillation process for generating LOX.  

Liquid oxygen applications

 LOX is molecular oxygen frozen to cryogenic temperature. It is used in various industries including aerospace, submarine and gas industries. Liquid oxygen was used as an oxidizer in the first liquid fueled rocket in 1926.

It is used in various hospitals as it is store liquid oxygen at very low temperature. Liquid oxygen can be stored in vessels and tanks.  Liquid oxygen is converted into medical oxygen gas at normal temperature for the patients to breathe. In the hospitals, the converted medical oxygen is moved around through a gas pipeline.     

Amongst the applications of liquid oxygen, we see that LOX is used in basic oxygen process (BOP). Firstly, LOX is turned into a gas with a liquid oxygen pump. Then, we pour pure oxygen into a bath of molten blast-furnace iron and scrap.  

With the help of oxygen, a series of heat-releasing reactions are set into motion. Moreover, it also causes oxidation of impurities such as silicon, phosphorous and carbon.

 Liquid oxygen safety tips

Liquid oxygen can cause a variety of hazards including the following:

• Extreme cold
• Asphyxiation
• Toxicity
• Adhesion
• Physical Hazard
• Flammability

For handling liquid oxygen you must follow standards safety tip provided in a manual for liquid oxygen plant.  Firstly, you must ensure that your cryogenic systems come fitted with pressure-relief devices. It is imperative that you should not use a system without the pressure-relief device.

And, you must observe precaution using cryogenic liquids in well-ventilated areas to prevent vapor accumulation.

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Advantage of getting oxygen plant feasibility report

There are many advantages of getting an oxygen plant feasibility study as it will equip you with the specialized know-how of oxygen business and market. The detailed project report (DPR) of oxygen plant will provide you with customized and actionable information regarding the status of the current market , process of O2 generation, technology, investment and oxygen plant project budget/cost.  DPR is full of insightful analysis of the industry with detailed evaluation of every factor.

The DPR will also include O2 plant capacity, land and building specifications, machinery description, and flow sheet diagram, raw materials details with list of reputed suppliers, total investment with detailed information on rate of return, profit margins and break-even period. It also explains the projected size of the market in the next 5 years and CAGR of the industrial gas industry and oxygen in particular.

Leverage oxygen business with DPR

It is the best tool for quickly leveraging oxygen plant business with the insight provided by the DPR. However, the report must be accessed from a reputed business consultancy. It will help you to identify market growth drivers. It is essential that you are aware of the factors that handicap the growth of the oxygen industry.  The depth of information provided in the analysis of the industry will give you competitive advantage over your competitors.

Armed with such effective information, you would be working in tandem with the current market trends. Knowledge of the market structure will act as stepping-stone for leveraging your oxygen business in the industry.  Analysis of the current market trends and technological developments will keep you updated and geared for future growth.

Market growth drivers

• Factors limiting market growth
• Current market trends
• Market structure

Key highlights

Overview of key market forces propelling and restraining market growth:

• Up-to-date analyses of market trends and technological improvements
• Pin-point analyses of market competition dynamics to offer you a competitive edge major competitors
• An array of graphics, BEP analysis of major industry segments
• Detailed analyses of industry trends
• A well-defined technological growth with an impact-analysis

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BDM has entered into an exclusive technological partnership with an acclaimed Italian company for getting their state-of-the-art designs and cryogenic technology for fabrication of industrial gas plants. The firm has one of the largest manufacturing and testing facilities in Delhi NCR region.

Superior technology and designs

BDM is always focused on delivering high quality oxygen and nitrogen gas plants. Our centre for testing and manufacturing is fully equipped with all modern facilities and technology. Our engineers and designers are highly skilled in the fabrication of world-class plants.

Designing is decided after studying the market trends and requirements of clients. The latest developments in technology are imbibed in the designing. Built with the latest technology, BDM air separation plants are able to generate oxygen with purity up to 99.7% and nitrogen with purity up to 99.9%, which is sufficient all kinds of applications including medical.

High quality air separation column and other components

Air separation column is the most important part of the plant. Separation of gases through liquefaction and distillation takes place in the column. You know why we call it the heart of air separation process. It is no wonder that the column contributes around 60% of the costing of the plant.

In order to achieve high quality, fabrication of the column is accomplished with cryogenic grade stainless steel. We use argon welding for achieving seamless joining. It is the efficient and seamless type of welding.  Only a few reputed air separation plant manufacturers use this type of welding.

High quality standards

BDM places high premium on the quality of its industrial gas plants. Our clients world-wide know us as the leading oxygen nitrogen gas plant engineering company that uses internationally approved standards.

Maintenance of international standards requires use of only ASME certified materials. Withstanding extreme temperature and pressure needs materials of high quality. Use of sub-standard material would compromise durability, reliability and performance. For BDM, the trust our customers place in our ability to manufacture and supply world-class is absolute. The entire edifice of our business depends on delivering quality products.

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Oxygen is known as a life-sustaining element of the atmosphere. The gas constitutes 21% of the air we breathe.  It is one of the most commonly found elements on the planet earth.  It is a highly reactive element that combines with all elements except noble gases to form compounds. 

On the planet earth it is found bound in compounds such as silicates, oxides and water. The reactive element is also present in lakes, oceans and rivers. However, it is worthwhile to remember that in its molecular form oxygen occurs only in the atmosphere.

Role of oxygen in steelmaking

As mentioned earlier, the non-metallic gas is very important in the steel making. In order to sustain burning process, we require oxygen in a large in the steel manufacturing process. Generally, the steel companies oxygen in its liquefied form.

Liquid oxygen can be effectively transported and easily stored in large volumes. However, it is vaporized when it is time to use it in applications the liquid oxygen is vaporized into the gaseous form. Any material will burn ferociously in the presence of oxygen.  It is combined with a fuel gas for use in cutting, welding and brazing.

And, use of oxygen also increases the fuel temperature. Steel is cut using a jet of gaseous oxygen from oxy-fuel, plasma or laser processes. It is used in a process called thermal lancing which is highly effective in cutting though concrete materials and metals.  

 Use of oxygen in blast furnace iron making

O2 is widely used in the primary steel making with basic oxygen furnace and electric arc furnace. It is also used in the secondary processes.  Oxygen is used for enriching blast air during the process. It also proves handy in lancing clogged tap hole in the furnace.

For cutting of cast products use of the non-metallic gas is extensive. The casting machines needs to be fed with continuous supply of oxygen.  

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The industries prefer the cryogenic technology, notwithstanding the cost, because it is the most cutting-edge and generating liquid oxygen (LOX) has many advantages which are not available if you choose other technologies such as pressure swing adsorption even though it is cheaper. Cryogenic process is considered the most efficient technology and can generate oxygen in both liquid and gaseous forms. Moreover, storing and transporting LOX is easy besides it is less likely to leak compared to gaseous oxygen.

How costing of an oxygen plant is decided?

Oxygen plant manufactured with the cryogenic technology is built with the high quality materials and components. Air separation unit (ASU) is the most important part of the cryogenic based plants which contributing around 60% of the cost. ASU is the heart of the O2 plant as generation of high purity oxygen depends on its performance.

High grade stainless steel is used for manufacturing and fabricating the column since the very operation of the plant machinery is dependent on. Oxygen plant cost is mainly dependent on the ASU and air compressor. Moreover, the performance of the plant would definitely depend on the quality of the air separation column and the air compressor.  

The plant is fully automated with the world-class PLC system. All the processes of air separation are automatic requiring little no manual inputs. It is equipped with a high quality self-diagnostic system that sounds an alarm when something goes wrong within the plant machinery. The operator sitting in the control room notices it and sets it right.

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For food businesses, it costs them money if their food deteriorates as it will fetch lower prices. Worse still, customers might not be willing buy food which has become rancid. Use of nitrogen is the only way to stop or slow down the deterioration of food and increase the integrity and freshness of food. Food-grade nitrogen is used in the food industry for food preservation.  Many nitrogen plants for snack food packaging are working incredibly for preserving the food from getting spoiled.

What is nitrogen food packaging?  

Packaging of food requires use of gaseous nitrogen with high purity up to 99.0%, which is considered ideal packaging.  It is used for keeping the food fresh with its freshness, integrity and taste remaining intact. There are other conditions as well that must be observed for ensuring effective nitrogen food packaging which are described hereunder:

• Oxygen concentration must never exceed 1%
• Carbon monoxide concentration must always remain below 10ppm and concentration of carbon dioxide must never exceed 300ppm.
• Moisture content must remain below 56ppm

 Why nitrogen is used in food packaging?

Nitrogen has got just the right chemical and physical properties making it perfect for processing for food.  It is the right gas because being inert it does not react with the food materials which can affect aroma, integrity and taste of the food. And it is effective because it can displace oxygen and prevent oxidation stopping moisture and bacterial growth responsible for breakdown of food.

How nitrogen packaging system works?

Nitrogen food packaging works by using nitrogen for displacing oxygen from within the packing.  The process is also called MAP (modified atmosphere packaging). The food to be preserved must be placed in an unsealed wrapping with nitrogen introduced into it. This drives out oxygen –rich air and moisture present in the air.   Afterwards, the packaging is completely sealed trapping nitrogen inside making it oxidant poor so food would achieve longer shelf life.

How to get food grade nitrogen?

There are two ways of getting nitrogen supply either through subscribing nitrogen cylinders or by installing onsite nitrogen plant. Getting the supplies through cylinders also does the work for you but it costs you extra and delivery is erratic. On the other hand, installation of the N2 plant will give you access to uninterrupted supply of nitrogen some of which you would store for later use. It is most effective solution for ensuring constant supply of oxygen.

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How oxygen can be generated at home?

There are many chemical processes via which one can generate oxygen but they are not suitable for practical applications. For example, O2 can be produced by electrolysis of water those who studied chemistry in Senior Secondary School must know. However, the setup for generating oxygen through this process requires intricate electrical setup with mains AC current. It is a risky method if you are not adept in handling electric equipment. Moreover, there is no way you could store the gas generated through this process.

Production of oxygen with concentrator

However, there is a way for generating oxygen gas which can be used for consumption for undergoing oxygen therapy.  This could be best done by using an oxygen concentrator.  It is a small and portable device that takes atmospheric air which is then enriched to oxygen with purity between 90-95%.  It is the best equipment for generating oxygen at home for personal consumption. Moreover, it is easy to operate and maintain and is affordable.

The process of oxygen generation is also very simple. It is takes room air which is compressed and purified inside the concentrator. It is made up of motor and compressor, heat exchanger, surge tank, four way solenoid valve, molecular sieve beds and product tank with pressure regulator and flow meter adjusting valve.

Working principle of oxygen concentrators

The room air after being compressed is filtered into the concentrator directing the air in an uninterrupted stream.  After compression, the air moves into sieve bed filters where nitrogen is removed from the air. Sieve bed is filled with Zeolite which is a six-sided microscopic cube with holes on each side and helps to remove nitrogen from the air.  There are two sieve beds and air is directed into the first bed moving oxygen into the product tank. When the first bed is saturated with nitrogen the compressed air is moved into the 2^nd sieve bed generating oxygen and moving it into the product tank.

Two sieve beds are located in the concentrator. After air is first compressed in the concentrator, it is forced into the first sieve bed. Oxygen is sent into the product tank. The first sieve bed then gets filled up with nitrogen. Next, the gas flow is switched, and the compressed air is moved to the second sieve bed. The first sieve bed’s compressor is sent to the outside room, and the air from the product tank goes back into the first sieve bed.

The drop in pressure from the first sieve bed and the weakening of oxygen makes the Zeolite release nitrogen. The Oxygen and Nitrogen come back together and are released in the room as regular air. The air is then compressed and sent to the second sieve where Oxygen is moved through it to the Product Tank. The whole cycle starts over again with the first sieve after a few seconds.

Other important parts are the cooling system that keeps the portable oxygen concentrator from overheating, and the nasal cannula that delivers the purified oxygen after the oxygen has been passed through all the sieve bed filters. The cannula helps improve oxygen absorption.

If you want to produce high purity oxygen on large scale you can install oxygen plant.

Know more about oxygen plant visit:

www.betterdealmachinery.com/blog/how-oxygen-plant-produces-pure-oxygen/

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PSA plant oxygen production

PSA oxygen plant uses the adsorption technology using twin towers filled with adsorbent material Zeolites. The PSA plant is made up of the following components: adsorbent containers, oxygen analyzer, PLC, valves and a tank.  When the ambient air goes through one of the towers containing molecular sieves filled with Zeolites where nitrogen and carbon dioxide gets adsorbed allowing oxygen to pass through and is collected as a product gas.  At fixed intervals of time, the active tower is switched to regeneration mode evaporating the adsorbed gas back into the atmosphere. In this PSA process, oxygen purity is monitored.  

Cryogenic oxygen plant

In the cryogenic process the ambient air is taken into the air separation unit where it is filtered and compressed. Then, the air is passed into purification unit where the impurities present in the air such as carbon dioxide, moisture and hydrocarbons are removed. Afterwards, the process air is moved through a series of heat exchangers cooling it to cryogenic temperature. After the liquefaction of the air, it is passed through high pressure distillation column separates oxygen from nitrogen and other gases based on their boiling points. Now the separated gas, oxygen is sent into a lower distillation column where it is distilled to required purification level.

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