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