PROCESS DESCRIPTION DOC No.

:GAIL/CONT-XXXX/PR-00X
Sheet no. 1 of 4
Project Cryogenic Nitrogen Generator
Owner GAIL, PATA
Consultant Engineers India Limited(EIL)
BOCI job No XXXX

PROCESS DESCRIPTION

Air suction and compressor:

Air is drawn into the plant through the Air Suction Filter (127-GN-101A/B/C/D) and compressed to the required
operating pressure in Main Air Compressors (127-KC-101A/B/C/D). These are four Nos. Centrifugal compressors.
Three will be on continuously running and one on standby.

Air precooling:
Direct contact air-water system (127-VV-101) with Evaporation cooler (127-VV-102) is employed to cool the air.
The air –water direct contact tower will cool air in single stage with the Chilled water from the Evaporation cooler.
The outlet temp from the direct contact air-water tower will around 12-15 degC. The Direct contact air –water
tower has an in built moisture separator which separates heavy particles and the heavy droplets recovered in the
tower. The chilled water from Evaporation cooler will be taken to direct contact air-water system by the chilled
water pumps(127-PC-101A/B).

Drying
The chilled air at a temperature of 12-15 C is then passed to adsorber vessels (127-VV-103A/B) where the
saturated moisture & carbon dioxide are removed from the process air by using Alumina and Molecular Sieves
respectively. The carbon dioxide & Moisture content in the process air is monitored with the help of an on-line CO2
& Moisture analyzers located at the exit of after filter. After 4 hrs of operation, the on-line adsorbent vessel is
taken off-line in order to regenerate the saturated adsorbents at a temperature of around 170 deg C. This is
achieved by switching the air & regeneration gas streams by means of automatic on/off control valves. The
regeneration stream that is waste air from the cold box is heated to the required regeneration temperature by a
regeneration gas Electric Heater (127-EZ-101). The hot gas passes down through Molecular Sieves and
Activated Alumina layers, removing CO2 & Moisture from saturated adsorbents before venting to atmosphere. The
adsorbent material is then brought back to its on stream operating temperature by passing the cold waste air
through the bed.

This specification and the copyright therein are the property of BOC INDIA LIMITED and all information which it contains is confidential. The
specification must not be produced or disclosed, nor must any information therefrom be disclosed without the prior consent in writing of
BOC INDIA LIMITED
Rev No. 0 4 5 6 7
Date 01.11.11
Prepared by SM
Checked by SM
Approved by JR
PROJECT ENGINEERING DIVISION Issued for Information
BOC INDIA LIMITED, KOLKATA
 PROCESS DESCRIPTION DOC No. :GAIL/CONT-XXXX/PR-00X
Sheet no. 2 of 4
Project Cryogenic Nitrogen Generator
Owner GAIL, PATA
Consultant Engineers India Limited(EIL)
BOCI job No XXXX

Occasionally a small amount of dry air is used as ‘Thawing air’ for thawing of cold box (recommended biennially).

Air cooling
The purified air is cooled down to saturation temperature of around –167deg C by the return gases from the HP
Column (127-CC-101) in the main heat exchanger (127-EP-101) & feed directly to High pressure column (DA
38301(25)). The cold air from 127-EP-101 is rectified in the column, where oxygen-rich liquid (RL) and gaseous
nitrogen (GAN) with the purity of < 3 PPM O2 are obtained respectively at the bottom and at the top of the
Distillation column. The rich liquid drawn from the bottom of column is throttled and The throttled liquid is
vaporized in the Bath type Reboiler/condenser (127-EP-102) by the condensation of gaseous nitrogen drawn
from column top, thus obtaining liquid nitrogen & Reflux for the column
The waste gas from the condensor –reboiler is cooled in 127-EP-101 and then expanded in a Turbine (127-LZ-
101) to achieve the desired refrigeration of the plant. This waste air at ~4.7barA is expanded to a pressure of ~
1.4 BarA which cools the LIN product from distillation column in a subcooler(127-EP-103) and then gets warmed
up in 127-EP-101 before leaving the cold box. A part of it sent to an electric regeneration heater as regenerating
gas for molecular sieve & alumina & is vented to the atmosphere through a Waste nitrogen silencer. While, the
rest is utilized to produce chilled water in Evaporation cooler.

GAN and LIN products:

The gaseous nitrogen drawn from the top of column, a part of this is warmed close to ambient temperature in the
main heat exchanger (127-EP-101) and is delivered as a product, while the other is condensed in the
Reboiler/condenser (127-EP-102). Thus the Liquid nitrogen obtained, its one part is refluxed back in the column
another part will be routed directly to LP storage tank(127-TT-401) through a flash separator(127-VV-105).

This specification and the copyright therein are the property of BOC INDIA LIMITED and all information which it contains is confidential. The
specification must not be produced or disclosed, nor must any information therefrom be disclosed without the prior consent in writing of
BOC INDIA LIMITED
Rev No. 0 4 5 6 7
Date 01.11.11
Prepared by SM
Checked by SM
Approved by JR
PROJECT ENGINEERING DIVISION Issued for Information
BOC INDIA LIMITED, KOLKATA
 PROCESS DESCRIPTION DOC No. :GAIL/CONT-XXXX/PR-00X
Sheet no. 3 of 4
Project Cryogenic Nitrogen Generator
Owner GAIL, PATA
Consultant Engineers India Limited(EIL)
BOCI job No XXXX

Back up system and Distribution:

Liquid Nitrogen from the Low-pressure storage tank (127-TT-401) is pumped with the Transfer pumps (127-PC-
402A/B) through a steam vaporizer (127-EP-401A/B) bath to sustain supplies to GAN consumers at 7.0kg/cm2g
pressure during back up or peak demands.

The nitrogen from nitrogen plant and backup will be supplied to LLDPE /HDPE units at 7 kg/cm2G and other units
at 6.8 kg/cm2G. An hookup provided from existing nitrogen vaporiser to the line of nitrogen to other units with
appropiate controls when pressure falls at this line during high demands.

Plant air and IA system :

The specified Air flow rate required for the Instrument air is taken from the 3rd stage discharge of the compressor
and used in a HOC type drier . Plant air is taken from Air compressor discharge header after after cooler and sent
to the LP Air receiver and from there to consumers. The drier unit is a fully packaged local control unit is based on
HOC principle and dry air at minus 40 degC dew point is achieved. This is a self contained fully automatic system
.The IA for the consumers is controlled by a down stream pressure control back up by the High pressure Air
receiver.
For emergency and peak IA demand, the dried air is compressed in a reciprocating air compressor(existing, not in
present plant scope) and filled in the high pressure vessel to a pressure of 31 kg/cm2 g . The down stream control
system of the HP Instrument air receiver facilitates withdrawal of peak IA requirement.

Scope of supply
Following equipment shall be supplied for the plant to meet the requirement of the proposed nitrogen plant:
CRYOGENIC NITROGEN PLANT
1. Main Air Compressor Units 127-KC-101A/B/C/D
2. Suction Air Filters 127-GN-101A/B/C/D
3. Direct contact Air-water system 127-VV-101
4. Evaporation cooler 127-VV-102
5. Pre-Purification Unit Adsorbers 127-VV-103A/B

This specification and the copyright therein are the property of BOC INDIA LIMITED and all information which it contains is confidential. The
specification must not be produced or disclosed, nor must any information therefrom be disclosed without the prior consent in writing of
BOC INDIA LIMITED
Rev No. 0 4 5 6 7
Date 01.11.11
Prepared by SM
Checked by SM
Approved by JR
PROJECT ENGINEERING DIVISION Issued for Information
BOC INDIA LIMITED, KOLKATA
 PROCESS DESCRIPTION DOC No. :GAIL/CONT-XXXX/PR-00X
Sheet no. 4 of 4
Project Cryogenic Nitrogen Generator
Owner GAIL, PATA
Consultant Engineers India Limited(EIL)
BOCI job No XXXX

6. PPU Regeneration Heater 127-EZ-101

7. Thawing Heater 127-EZ-102
8. Nitrogen Generator Cold Box
9. Main Exchanger 127-EP-101
10. Distillation Column 127-CC-101
11. Reboiler/Condenser 127-EP-102
12. Subcooler 127-EP-103
13. Expansion Turbine with generator brake 127-LZ-101
14. Waste Disposal Unit 127-VV-104
15. LIN Atmospheric storage tank 127-TT-401
16. Tank Pressure Building coil –127-EA-401
17. Liquid Nitrogen steam bath Vaporizers 127-EA-401A/B
18. Liquid Nitrogen transfer pump 127-PC-402A/B
19. Flash separator 127-VV-105

20. Silencers:
a) Air Compressor Blow Off Silencer (127-WL-101 A/B/C/D)
b) Waste Air Silencer (127-WL-103)
c) Nitrogen product Silencer (127-WL-104)
d) PPU Depressurization silencer (127-WL-102 )
21 Chilled Water pumps for Air – water tower 127-PC-101A/B
IA/PA SYSTEM
1. LP and HP buffer vessel for IA system 127-VV-001, 127-VV-002
2. IA drier packaged drier 127-LJ-001A/B

This specification and the copyright therein are the property of BOC INDIA LIMITED and all information which it contains is confidential. The
specification must not be produced or disclosed, nor must any information therefrom be disclosed without the prior consent in writing of
BOC INDIA LIMITED
Rev No. 0 4 5 6 7
Date 01.11.11
Prepared by SM
Checked by SM
Approved by JR
PROJECT ENGINEERING DIVISION Issued for Information
BOC INDIA LIMITED, KOLKATA
 PROCESS DESCRIPTION DOC No. :GAIL/CONT-XXXX/PR-00X
Sheet no. 5 of 4
Project Cryogenic Nitrogen Generator
Owner GAIL, PATA
Consultant Engineers India Limited(EIL)
BOCI job No XXXX

22. Water chilling unit GC-38301 (15)

23.Flash separator (FA-38303)

This specification and the copyright therein are the property of BOC INDIA LIMITED and all information which it contains is confidential. The
specification must not be produced or disclosed, nor must any information therefrom be disclosed without the prior consent in writing of
BOC INDIA LIMITED
Rev No. 0 4 5 6 7
Date 01.11.11
Prepared by SM
Checked by SM
Approved by JR
PROJECT ENGINEERING DIVISION Issued for Information
BOC INDIA LIMITED, KOLKATA