Talk on Oxygen Plant and

other Utility Departments

Necessity of Oxygen Plant in Steel making
Pressure at
Peak Flow
battery
Product User Rate Remarks
limit (Min)
Nm3/hr
kg/cm2 (g)
BOF Shop 2 pipelines
Oxygen each designed for 76500 20 Cyclic
100% peak flow
Blast furnace (Blast Continuous,
Oxygen 20000 9
enrichment) Uniform
Fluctuations in
Oxygen General purpose 4000 16
narrow range
Nitrogen BOF, BOF-GCP 13000 31 Continuous
CCD, CDCP, BF &
Nitrogen 18000 16 Continuous
Misc
Argon BOF, CCP 3050 16 Cyclic
 Production of each ASU
Oxygen Plant Mixed mode Gas mode
Products (NM3/hr) (NM3/hr)
Oxygen
Gaseous Oxygen 21000 (720 TPD) 22000 (750 TPD)
Liquid Oxygen (Gas 1000 (34.2 TPD)
Eq.)
Nitrogen
Gaseous Nitrogen 15500 (465 TPD) 15500 (465 TPD)
Liquid Nitrogen 500 (15 TPD)
Liquid Argon 790 (33.85 TPD) 790 (33.85 TPD)
 Production Parameters of each ASU
Flow rate, Nm3/hr Pressure
Product Purity Mixed Gas Kg/cm2
Mode Mode (g)
Gaseous Oxygen 99.5% 11000 12000 40
Gaseous Oxygen 99.5% 10000 10000 20
Liquid Oxygen (Gaseous
99.5% 1000 -
equivalent)
Gaseous Nitrogen < 5 PPM O2 6500 6500 31
Gaseous Nitrogen < 5 PPM O2 9000 9000 16
Liquid Nitrogen
< 5 PPM O2 500 -
(Gaseous equivalent)

Liquid Argon < 5 PPM O2 &

790 790
(Gaseous equivalent) N2 combined
 OXYGEN PLANT from
“PROCESS” point of view
 Raw Materials required for
Oxygen Plant
 Power : 32,125 KWh/Hr (Guaranteed Power
consumption for Mixed mode Operation)

 Emergency Power for Liquid Backup system : 325KVA

 Makeup water : 180 M3/ Hr @ 1 Kg/cm2

 Fire water: From USM Pumping station for Spray &

Hydrant systems
 Variation of Boiling Points

Boiling Point
1 ATMA 5 ATMA
Water 100˚C 152˚C
Oxygen -183˚C -164˚C
Nitrogen -196˚C -179˚C
Argon -186˚C -167˚C
 Basic Cycle Steps in Air Separation

1 2 3/4 5 6

1) Compression
To Provide Energy for the Separation Process
2) Cleaning
To Remove Impurities
(a) Water/CO2 - which would freeze and cause blockages
(b) Hydrocarbons - which would be dangerous in oxygen rich environments
3) Heat Exchange
To cool air to cryogenic temperature
4) Cold Production
Required to provide refrigeration for liquid streams + losses
5) Separation
Of air into oxygen, nitrogen and argon of required purities and flow rates
6) Heat Exchange
To warm products to ambient conditions
 Process Overview
Product Gas
Compression

Liquid
Compression Purification Expansion Products
Air

Filtration Cooling Heat Exchange Separation

between into O2 , N2
incoming hot and Argon
air & outgoing through
cold products Distillation
 GRAPHICAL REPRESENTATION OF PROCESS
Waste
Nitrogen
Process from MHE
Air to
MHE
Regeneration
Heater

MSA1 MSA2

To ATM

MAC: Main Air Compressor

DCAC: Direct Contact Air Cooler
EVC: Evaporation Cooler
MSA: Molecular Sieve Adsorber
D E
MAC C V
Process Air:
Waste Nitrogen: A Chilled
C
Cooling Water:
C Water Pump

Process
Air from Main Air Water Pump
Cooling Water
ATM Filter from CWS
Cooling Water to
CWS
 GRAPHICAL REPRESENTATION OF PROCESS

Process HPGOX PGOX HPGAN SEALGAS PGAN LIN LAR LOX

Air TANK TANK TANK
from
PPU
Waste Nitrogen

MAIN HEAT EXCHANGER

A
L C
P
PC: Pressure Column C
LPC: Low Pressure Column
AC: Argon Column
P
Process Air: C
Oxygen:
Nitrogen:
Waste Nitrogen:
Oxygen Rich Liquid:
Argon:
PFD - Main Plant
 Drive Unit Driven Unit
Synchronous Motor Compressor
10 MW, 11 KV, 50 Hz, 534 A 3 Stage, Centrifugal Type
4 Pole, Salient Type Flow rate : 111700 Nm3/Hr
Brushless Excitation System Suction Pressure : 0.993 bar a
Starting Method : DOL Discharge Pressure : 5.6 bar a
Make : ABB Sweden Make : Atlas Copco, Germany
 Drive Unit Driven Unit
Synchronous Motor Compressor
6.8 MW, 11 KV, 50 Hz, 363 A 6 Stage, Centrifugal Type
4 Pole, Salient Type Flow rate : 62660 Nm3/Hr
Brushless Excitation System Suction Pressure : 5.3 bar a
Starting Method : DOL Discharge Pressure : 58 bar a
Make : ABB Sweden Make : Atlas Copco, Germany
 Drive Unit Driven Unit
Impulse Turbine Induction Generator
Flow rate : 25800 Nm3/Hr
Suction Pressure : 32.3 bar a
Discharge Pressure : 5.3 bar a
Inlet Temperature : -109◦ C
Outlet Temperature : -173◦ C Make : Atlas Copco, Germany
Make : Cryostar, France
Oxygen Ignition
Pressure
Particle Impact Source
Contamination
Temperature
Heat of Compression
Concentration
Friction

All materials in contact with oxygen

Fuel
 Gas Volumetric Composition
( %)
Oxygen 21.95
Nitrogen 78.1
Argon 0.93
• Atmospheric gases are non-toxic but alterations in their concentrations
- especially that of Oxygen – have an effect upon life and combustion
processes.

• If good practice is not observed accidents may happen as changes in

concentration cannot be easily detected by the human senses.

• Oxygen is not flammable but it does support combustion.

• Nitrogen and Argon inhibit combustion.

• When these gases are in the liquid state it is necessary to bear in mind
the very low temperatures involved (below -180°C). They can rapidly
cause cold burns and make certain materials sufficiently brittle to lead
to structural failure.
Fire Hazards : Oxygen reacts with most elements. The initiation, speed
and the extent of these reactions depend in particular upon:
- concentration, temperature and pressure of the reactants
- ignition energy
- mode of ignition

Combustibility of materials : Oxygen enrichment of the atmosphere,

even by a few percent, considerably increases the risk of fire.
Sparks which would normally be regarded as harmless can
cause fires. Materials which do not burn in air, including fireproofing
materials, may burn vigorously or even spontaneously in oxygen-
enriched air.

Oil and grease : Oil and grease are particularly hazardous in the
presence of oxygen as they can ignite spontaneously and burn with
explosive violence.
They should never be used to lubricate oxygen or enriched-air
equipment. Special lubricants which are compatible with oxygen must
be used under certain conditions.
Nitrogen makes up 78% of the air we breath; because of this it is often
assumed that nitrogen is not hazardous.

However, nitrogen is safe to breath only if it is mixed with an

appropriate amount of oxygen.

Nitrogen is used commercially as an inert agent to keep

material free of contaminants (including oxygen) that may corrode
equipment, present a fire hazard, or be toxic.

A lower oxygen concentration (e.g., caused by an increased

amount of nitrogen) can have a range of effects on the human body and
can be fatal if it falls below 10%. This is called “asphyxiation”.
Atmospheric O2
Concentration Possible Results due to enrichment of N2 in Air
(%)
20.9 Normal
19.0 Some unnoticeable adverse physiological effect.
Increased pulse and breathing rate, impaired
16.0
thinking and attention, reduced coordination.
Abnormal fatigue upon exertion, emotional upset,
14.0
faulty coordination, poor judgment.
Very poor judgment and coordination, impaired
12.5 respiration that may cause permanent heart damage,
nausea, and vomiting.
Inability to move, loss of consciousness, convulsions,
< 10.0
death.
Routes of exposure: The substance can be absorbed into the body by
inhalation.

Inhalation risk: On loss of containment this liquid evaporates very

quickly causing super saturation of the air with serious risk of
suffocation when in confined areas.

Effects of Inhalation: This gas is inert and is classified as a simple

Asphyxiant. Inhalation in excessive concentrations can result in
dizziness, nausea, vomiting, loss of consciousness, and death. Death
may result from errors in judgment, confusion, or loss of consciousness
which prevent self-rescue. At low oxygen concentrations,
unconsciousness and death may occur in seconds without warning.
Fire Hazard :

Liquid oxygen contains 4,000 times more oxygen by volume than normal
air. Materials that are usually considered non-combustible, (such as carbon
and stainless steels, cast iron, aluminum, zinc and Teflon (PTFE),) may
burn in the presence of liquid oxygen. Many organic materials can react
explosively, especially if a flammable mixture is produced. Clothing
splashed or soaked with liquid oxygen can remain highly flammable for
hours.
Extreme Cold Hazard :

Cryogenic liquids and their associated cold vapours and gases can produce
effects on the skin similar to a thermal burn. Brief exposures that would not
affect skin on the face or hands can damage delicate tissues such as the
eyes. Prolonged exposure of the skin or contact with cold surfaces can
cause frostbite. The skin appears waxy yellow. There is no initial pain, but
there is intense pain when frozen tissue thaws.

Unprotected skin can stick to metal that is cooled by cryogenic

liquids. The skin can then tear when pulled away. Even non-metallic
materials are dangerous to touch at low temperatures. Prolonged breathing
of extremely cold air may damage the lungs.
 Person exposed to over oxygenated atmosphere must make sure
that his/ her clothes are ventilated before he/ she approaches
any flame/ spark

 Never use tools meant for general purpose use on oxygen

handling equipment.

 Never use oxygen as substitute for compressed air or Nitrogen.

 Never use any hose pipe used for some other purpose of oxygen.

 High pressure oxygen valves should be opened slowly and

carefully.

 Never use any oil of grease on any Oxygen handling equipment

 Person working in oxygen rich area should wear clean clothes(free
from traces of oil of grease).

 Never wear any shoes with metallic spikes while working in

oxygen rich area

 There should not be any source of flame or spark or smoke within

15 meter from outer limit of oxygen rich area

 No painting is to be carried out around any oxygen producing/

handling unit when the system is in operation.

 Only pressure gauges marked “OXYGEN SERVICE” are to be

used for oxygen service and on no account are these gauges to
be used on other services.