Complete Technology Handbook on Industrial Gases with Manufacturing Process, Machinery Equipments and Project Profiles

Welcome to the "Complete Technology Handbook on Industrial Gases with Manufacturing Process, Machinery Equipments and Project Profiles". This comprehensive guide delves into the fascinating world of industrial gases, offering a detailed exploration of their production processes, machinery, equipment, and project profiles. Whether you're an entrepreneur seeking opportunities in the industrial gas sector, a manufacturer looking to expand your operations, or simply curious about the essential role of these gases in various industries, this book is your definitive resource.

In this handbook, we navigate through the complexities of industrial gases, providing you with in-depth knowledge about their manufacturing methods, applications across diverse industries, and the machinery and equipment involved in their production. The content is thoughtfully organized to help you grasp the intricacies of this vital field.

Our primary aim is to equip you with a comprehensive understanding of industrial gases, from their origins to their manifold applications. Whether you are interested in the intricacies of gas separation, the uses of different industrial gases, or the economic aspects of gas production, you will find it all here.

What You'll Discover:

• Detailed Manufacturing Processes: Explore the intricacies of gas production, including technologies such as cryogenic distillation, fractional distillation, electrolysis, and more.
  
• Machinery and Equipment: Gain insights into the machinery and equipment used in gas production, from air separation units to purification systems.
• Industrial Gas Applications: Learn about the wide-ranging applications of industrial gases in sectors such as metallurgy, healthcare, energy production, and beyond.
• Project Profiles: Discover valuable project profiles that offer insights into setting up your own gas production facilities.

Whether you're an industry professional, an aspiring entrepreneur, or a student of chemical engineering, this guide is designed to cater to your needs. You can delve into specific chapters that pique your interest, or you can explore the entire book to gain a comprehensive overview of the industrial gas landscape. The chapters are systematically organized to facilitate easy navigation and reference.

We hope this handbook serves as an invaluable companion on your journey through the intricate world of industrial gases. May it inspire innovation, fuel curiosity, and empower you to harness the potential of these gases in diverse applications. Together, let's embark on this enlightening exploration of industrial gases and their profound impact on our modern world.

Chapter 1

Industrial Gases - Introduction

What defines an industrial gas

Which gases are classified as industrial?

Gas processing and LNG

Gas processing 

Gas production technology 

Gases

Other common industrial gases 

Important liquefied gases 

Industrial gas applications 

Chapter 2

Different Types of Industrial Gases and its Uses

Industrial Gases: Details 

Examples of industries concerned 

Aeronautics 

Contents-cum-Index Nitrogen

Food Packaging 

Light Bulb Production 

Chemical Plants

Tire Inflation 

Electronics 

Stainless Steel Manufacturing 

Pollution Control 

Pharmaceuticals 

Mining  

BTP – Construction  

Inert gases, what gases are and what they are used for?  

Active gases, what gases are and what they are used for? 

Argon industrial gas 

Carbon dioxide industrial gas

Oxygen Industrial gas 

Uses 

Oxidizers 

Oxidizer Process Description 

Flammable Gases 

Propane 

Hydrogen 

Butane 

Methane  

Ethylene  

Acetylene 

Ammonia 

Ethane 

Silane 

Inert Gases 

Characteristic of Noble gas 

Atomic radii 

Ionization enthalpy 

Electron gain enthalpy 

Applications of Inert Gases 

Helium 

Neon 

Argon 

Krypton 

Xenon

Radon 

Industrial Gases - Supply Chain 

Production process 

Air extraction 

Pressure management 

Gas compression and expansion 

Gas laws 

Effect of pressure 

Liquefaction of Gases

Combustion or burning 

The Fuel gases  

Carbon 

Acetylene C2H2 

Compressed gases and safety

Compressed gas cylinders 

Dissolved Acetylene 

LP-Gas 

Oxygen 

Precautions in handling compressed gases 

Oxygen

Nitrogen  

Nitrous Oxide 

Carbon Dioxide 

Carbon Monoxide 

Hydrogen 

Dissolved Acetylene 

Ethylene  

Joining metals 

Soldering 

Brazing 

Welding 

Braze welding 

Failure of adhesion 

Chapter 3

Acetylene Gas 

Odor 

Vapor Density 

Vapor Pressure 

Toxicity Data  

Major Hazards 

Properties of Acetylene –C2H2 

Acetylene Uses 

Production of Acetylene 

Health Hazards 

Toxicity 

Flammability and Explosibility 

Reactivity and Incompatibility 

Storage and Handling 

Accidents

Disposal 

Chapter 4

Ozone Gas

Ozone Layer Depletion 

What is Ozone Layer Depletion?

Causes of Ozone Layer Depletion 

Chlorofluorocarbons

Unregulated Rocket Launches 

Nitrogenous Compounds

Natural Causes 

Effects of Ozone Layer Depletion 

Effects on Human Health 

Effects on Animals 

Effects on the Environment 

Effects on Marine Life 

Solutions to Ozone Layer Depletion 

Avoid Using ODS 

Minimise the Use of Vehicles 

Use Eco-friendly Cleaning Products 

Use of Nitrous Oxide should be Prohibited 

Ozone location 

Ozone abundance 

Ozone Gas-Generating Equipment 

Ozone Generator Rooms 

Piping, Valves, and Fittings 

Secondary Containment 

Materials 

Identification 

Automatic Shutdown 

Manual Shutdown 

How are people exposed to ozone? 

How does ozone react in the respiratory tract? 

What are ozone’s acute physiological and symptom effects? 

What effects does ozone have at the cellular level? 

How does response vary among individuals? 

Chapter 5

Air Gases Technology viz Nitrogen, Oxygen and Argon

Components of air 

Oxygen 

Nitrogen 

Carbon dioxide 

Smoke and dust particles 

Composition of Air 

Main Components of Air 

Oxygen 

Carbon Dioxide 

Nitrogen 

Argon 

Water Vapour

Dust Particles 

Nitrogen, Argon & Oxygen Gas Uses In Metallurgy Engineering

Oxygen

Nitrogen

Argon

Chapter 6

Noble Gases Technology viz Neon, Krypton and Xenon

Members of the Inert Gas Family

Non-Metallic Behaviour of Inert Gases

Uses of Noble Gases

How were the Inert Gases Discovered?

Neon

Physical Properties

Chemical Properties of Neon

Uses of Neon 

Krypton

Element Properties 

Properties of the element

Compounds 

Uses of Krypton

Applications 

Precautions 

Xenon

Chemical Properties of Xenon 

Physical properties of Xenon 

Applications and effects of Xenon 

Optics and illumination  

Medicine 

Interesting Facts about Xenon 

Applications 

Precautions 

Health effects of xenon 

Effects of xenon on the environment 

Chapter 7

The Noble Gas Helium 

Element Properties 

Abundance and isotopes 

Properties 

Production and uses 

Helium Gas Cryogenic Purifiers 

ExtractionHydrogen Gas Cryogenic Purifiers 

Product Highlights: 

Why get your purifier from AET? 

Examples uses of High-Grade Helium Gas 

Chapter 8

Technology of Synthesis Gases viz. Hydrogen and Carbon Monoxide

Steam Methane Reforming (SMR) 

Membrane 

Cold Box 

Pressure Swing Adsorption (PSA) Unit 

Auto Thermal Reformer (ATR) 

Membrane

Cold Box 

Pressure Swing Adsorption (PSA) Unit 

Gasification (E-Gas™ and E-Gas Plus®) 

Hydrogen 

Properties 

Combustion 0:29

Flame

Reactants 

Electron energy levels 

Spin isomers 

Ortho-hydrogen and parahydrogen 

Reactivity of hydrogen 

Hydrogen bond 

Isotopes of hydrogen 

Production and applications of hydrogen 

Analysis

Carbon Monoxide 

Sources of Carbon Monoxide 

Health Effects Associated with Carbon Monoxide 

Chapter 9

Carbon Dioxide Gas Technology 

Chemical and physical properties  

Carbon Cycle 

The Primary Sources of CO2 

Natural CO2 Sources 

Anthropogenic CO2 Sources 

Technology of Carbon Dioxide Separation from Flue Gases 

CO2 Separation Technologies 

Absorption 

Solvents 

Different Cycles for CO2 Adsorption 

Cryogenic Distillation 

Membrane Separation 

Inorganic Membranes 

Polymeric Membranes 

Mixed Matrix Membranes 

Hollow Fiber Membrane 

Chapter 10

Natural Gas and Technology 

Advances in the Exploration and Production Sector 

Offshore Production – NASA of the Sea 

Liquefied Natural Gas 

LNG Delivery Facility with Tanker 

Natural Gas Fuel Cells 

How a Fuel Cell Works 

Natural Gas Technology Resources 

Natural Gas Technologies R&D 

Future trends in natural gas technology 

Intelligent Utility Distribution Networks 

Radio Frequency Identification (RFID)

Zero-Emissions Power Plants 

Benefits, Uses, Importance, Limitations 

Natural Gas Benefits 

Natural Gas Importance 

Natural Gas Usage Limitations 

Chemical Composition of Natural Gas 

Isomers 

Olefin hydrocarbons 

Cyclic or Ring Hydrocarbons 

Gases 

Liquid 

Solid 

Chapter 11

Fuel Gases Technology 

Types 

Manufactured fuel gas 

Well or mine extracted fuel gases 

Uses

Decantation Management System work

Benefits 

Stationary Fuel Tank Management System 

Benefits 

High-Speed Bowser Fuel & Fastfill System for Efficient Refueling 

Benefits 

Mobile Fuel Management - Never Run Out of Fuel 

Need for Mobile Fuel Management System 

How does Mobile Fuel Management System work? 

Benefits 

Turnkey Fuel Management 

Need for Turnkey Fuel Management Solution 

How does a Turnkey Fuel Management System work?

Benefits 

Chapter 12

Special Gases 

Hydrogen 

Sources of hydrogen 

Recovery of Hydrogen 

Hydrogen use in petroleum refineries 

Refinery in-house recovery of hydrogen 

Recovery from coke oven gas 

Hydrogen generation plants 

Electrolysis of Water 

Thermal Cracking of Ammonia 

Treatment of Hydro carbon Feedstock for Hydrogen Recovery 

Small Steam Reforming Plants 

(a) Reform ing stage 

(b) Shift stage 

Large Hydrogen Generation Plants 

Synthesis Gas, Partial Oxidation 

History 

Partial Oxidation Process 

Ammonia Synthesis 

Hydrogen Recovery from Ammonia Synthesis Plants

Other Uses for Synthesis Gas

Fuel Cells 

Carbon Monoxide 

Sources 

Carbon Monoxide Recovery 

General 

General process of recovery 

Basic Cryogenic Recovery Processes 

Methane Wash Cryogenic Recovery 

Compression and conversion machinery for carbon monoxide

Requirements for a Liquid CO Pump

Safety of LCO Transport 

Safety equipment in general 

High-purity nitrogen 

General characteristics 

Revovery

Applications for inertness

Nitrogen as a Preservative

Nitrogen as an Emissions Controller 

Nitrogen Use in Sparging

Nitrogen for Pressure Transferring

Liquid Nitrogen for Vapor Recovery 

Liquid Nitrogen Makes Worn Rubber Tires Profitable

Process and equipment options 

Cryogenic Process Cycle

Permeable Membrane Separation Process 

Pressure Swing Adsorption 

Ultrahigh-purity nitrogen 

Removal of Outside Impurities 

Chapter 13

Gases Applications in Medicine

Introduction 

Oxygen (O2) 

Storage and transport of liquid nitrous oxide 

Uses in Respiratory Care 

Manufacturing

Carbon Dioxide

Uses in Respiratory Care 

Manufacturing 

Helium 

Uses in Respiratory Care 

Manufacturing

Compressed Air 

Uses in Respiratory Care 

Manufacturing 

Nitrogen

Uses in Respiratory Care

Manufacturing 

Nitric Oxide 

Uses in Respiratory Care

Manufacturing 

Nitrous oxide (N2o) 

Uses in Respiratory Care  

Manufacturing 

Medical air 4 bar

Medical air 7bar 

Medical vacuum 

System components

Sources 

Bulky systems 

Manifold systems 

Medical air treatment systems

Vacuum pumps 

Piping networks

Valves 

Warning and alarm systems 

Outlets and inlets 

Secondary equipment 

Design principles

Design keys 

Number of stations 

Flow rates

Operation

Storage and transport of liquid oxygen 

Storage and transport of liquid nitrous oxide

Chapter 14

Air Separation Technology

Air Separation Overview

Basic Air Separation Unit (ASU) Components 

Main Air Compressor (MAC)

Front End Clean Up

Coldbox 

Expander 

Liquid Argon System 

Different Types of Air Separation Units (ASU)

All gaseous product 

Linde’s first fractionation machine 

Distillation and Fractionation

Fractionation

Stripping

Rectification

Theoretical considerations of fractionation

Evaporation and Condensation

Separation Techniques: Obtaining Gases from Air

Step 1:Conversion of air into liquid air

Step 2:Fractional Distillation 

Cryogenic Process of Air Separation

Steps in the cryogenic process of air separation 

Production of argon 

Production of liquid products 

Chapter 15

Front-End Purification Systems 

Processes and materials used in front-end purification systems 

Original Prepurification 

Adsorbents 

General 

Introduction of Activated Alumina 

Activated Alumina 

Regeneration of Activated Alumina 

Zeolites (Molecular Sieves) 

Chemical Formula 

Types of Molecular Sieves 

Silica Gel 

Design of current front-end purification systems 

General Background 

Equipment Used 

Precooling Units Upstream of Adsorption 

Direct Contact Aftercooler 

Evaporative Water Chiller 

Mech anical Refrigerat ion Unit 

Adsorber Unit 

Standard Design 

Multiple Vertical Vessels 

Horizontal Vessels 

Radial or Concentric Design

Process Operation 

Isolation Valve Downstream of FEP 

Adsorption Kinetics

Regeneration Concerns 

Warning Against Excessive Heat During Regeneration 

High-Pressure Vessel Regeneration 

Regeneration Options For FEP Units 

General 

Chapter 16

Industrial Processes of Gas

Introduction 

Industrial processes in Gas Processing Centers 

Sweetening 

Regeneration 

Sulfur recovery 

Residual gas cleaning

Incineration 

Gas sweetening 

Liquid sweetening 

Sulfur recovery 

Cryogenic process 

Absorption process 

Fractionation 

Nitrogen Rejection Unit (NRU) 

Chapter 17

Photographs of Plant and Machinery  

Acetylene Production Plant 

Advantages of our acetylene plant 

Air Separation Gas Plant 

Main Features 

Main equipments of oxygen gas plant 

Reactor equipment 

Types of Reactors 

Batch Reactor 

Continuous reactors 

Types of continuous reactors 

Continuous stirred-tank reactor model (CSTR) 

Continuous tubular reactor or Plug flow reactor model (PFR)

Fixed bed reactors 

Semibatch reactor 

Tubular furnace 

Boiler Equipment 

Auxiliary equipment 

Pumping equipment 

Types of pumps 

Centrifugal pumps 

Oil pumps

Positive displacement pumps

Oil transfer pumps 

Diaphragm pumps

Thight Electric pumps

Petrochemical pumps

Pipeline connecting Accessories 

Non-return valves for oil and gas pipelines 

Types of check valves 

Diaphragm check valve 

Stop check valve

Lift check valve 

In-line check valve

Shut off and control valves 

Dust collectors 

Water Treatment and Purification before disposal 

Chapter 18

Manufacture of Pure Gases

What are Pure Gases? 

Examples of pure gases

Acetylene 

Applications of Acetylene 

Production of Acetylene 

Oxygen 

Manufacture of Oxygen 

Generation of Oxygen through Photosynthesis 

Generation of Oxygen through Cryogenic Distillation Method 

Pre-treatment 

Heat Transfer and Cooling the Air 

Air Distillation 

Coal Gas

Development or Production of Coal Oil and Gas 

Manufacturing Process 

Industrial Use of Coal Gas

Domestic Heating 

Chapter 19

Plants and Machinery

Oxygen Cylinder Filling Plant 

Usage in the Industry 

Uses in Medicine and Health 

Oxygen Filling Plant Specifications 

Plant Design 

CO2 Purification & Liquefaction Process

Vacuum Insulated Cryogenic Storage Tank

Features 

Other Details 

Specifications:

PSA Nitrogen Gas Plants

Salient Features

Technology

Chapter 20

Plant Economics of Dissolved Acetylene Gas And Bottling Plant of Industrial Compressed Oxygen, Medical Oxygen, Argon, CO2 and Nitrogen

Process Description of DA [Dissolved Acetylene] Gas

Operation condition: site condition

Technical details of acetylene manufacture 

Chemical Reaction and Raw Materials 

Process of manufacture of acetylene

Raw Material Requirements

Process Description

Wet Process

Dry Process

Equipment Used

Purity, Yield Storage

Process of compressed gas bottling plant

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 21

Plant Economics of Hydrogen Production (99.9% Pure) and Oxygen as By-Product

Introduction

Details of Electrolysis for Hydrogen Production

Polymer Electrolyte Membrane Electrolyzers

Alkaline Electrolyzers

Solid Oxide Electrolyzers

Production of hydrogen using different feed stock

Hydrogen from fossil fuels

Production from natural gas

Production from coal

Hydrogen from Splitting of Water

Water electrolysis

Alkaline Electrolysis

Polymer electrolyte membrane (PEM) electrolysis

High-temperature electrolysis

Photo-electrolysis (photolysis)

Photo-biological production (biophotolysis)

High-temperature decomposition

Thermo-chemical water splitting

Electrolysis for H2 production

Alkaline Water Electrolysis

Alkaline water electrolyser

Inside a water electrolyser

Alkaline Membrane Cells

Steam electrolysis at 1000°C

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 22

Plant Economics of Industrial Gases Bottling Plant with Various Gas Mixtures

Process of manufacture of oxygen, carbon dioxide and argon

Oxygen and nitrogen gas

Other details of oxygen and nitrogen separation from air

Distributions

Filling

Cylinders

Liquid Oxygen

Argon Gas

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital 

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 23

Plant Economics of Liquid Oxygen Bottling Plant

Raw Materials

Manufacturing Process of Liquid Oxygen

Liquid Oxygen

Shipping Methods of Oxygen

Container’s and Regulation

Adsorption principle

Temperature and pressure influence

Pressure swing adsorption

Adsorption oxygen plants

Membrane technology

Innovation technology available today

Membrane operation principle

Membrane cartridge 

Compressor and vacuum technologies

Process in Details

Pretreating

Separating

Purifying

Distributing

Manufacture of oxygen from high temperature steam

Method

Plant Economics

Land & Building

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month

Total Capital Investment 

Turn Over/Annum 

Chapter 24

Plant Economics of Oxygen Plant [Cryogenic] Air Separation Method

Gas Production Technology

Fractional distillation of air

Liquefaction

Fractional distillation

Cylinder Filling

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital 

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 25

Plant Economics of Small Oxygen Plant

Manufacturing process of liquid oxygen

Liquid Oxygen

Shipping Methods of Oxygen

Container’s and Regulation

Process in details

Pretreating

Separating

Purifying 

Distributing 

Plant Economics

Land & Building 

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum