Process
Description
Acetylene Gas Generator: The KVK Acetylene Gas Generator is of an
advanced design, incorporating several features not ordinarily found in
other generators. The KVK Acetylene Gas generator and Acetylene Gas Cylinder
are fully automatic.
The KVK Acetylene Generator and Acetylene Gas Cylinder are advanced design,
incorporating several features not ordinarily found in other generators and
cylinders. The KVK Acetylene generator is fully automatic. 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 screw feed conveyors. The screw feed mechanism and the
agitators are operated by flameproof motors and fittings. The entire
operation is perfectly synchronized to achieve 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 152148-68
(group II) or 655-229 may be used in an Acetylene plant building. Acetylene
cylinders must be of specification 15: 7312: 1974 or ICC: 8.)
Temperature Control: The KVK Acetylene Generator can be set to
operate at a 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 0.5 kg/cm2) carbide charging will be cut off automatically and
further generation of gas is stopped. There is no expensive gas holder with
the KVK 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 "KVK" 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 level between the acceptable high and low level marks.
No loss -Carbide charge: No gas is lost or wasted while charging the
carbide because one 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.
Condenser :The Acetylene gas leaving the generator is hot and
carries 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. This
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 trolleys.
Water Scrubber :The equipment is installed between the chemical
purifier and Acetylene compressor, which helps to remove 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 void in high-pressure area is against the required safety.
Filling Manifold :This consists of a battery of filling connections
to connect to the gas cylinders. Non-return valves are provided in various
sections of the pipeline to the filling manifold. These 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 cylinder 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 could
occur due to sudden discharge of Acetylene).
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