Compact Cryogenic Air Separation Units

Demand for small, flexible Cryogenic Air Separation Units is rising in India and Southeast Asia, especially in regions where regular cylinder or truck deliveries over long distances can be challenging. Regional operators face stiff competitive pressures. Hence, they are looking for cost-effective, reliable and flexible solutions that can be deployed quickly and easily. In addition, these air separation units must be designed for ease of operation and low maintenance over a long service life.

PED is now bringing its technological excellence and its unique insights to the compact segment.

A modular design standardizes all the main plant components for maximum cost efficiencies and ease of deployment. These modules are pre-fabricated at and PED’s workshop in India and workshops of Linde Engineering (LE) in Germany to the maximum possible extent. PED’s manufacturing workshop in Kolkata is responsible for most of the packaged components, with LE Schalchen, Germany handling all the engineering. The successful combination of German engineering excellence and local production capabilities enables us to provide the best of both worlds.

Plant designs are created using advanced process simulation tools as well as sophisticated engineering design tools. A proven control concept with cutting-edge software ensures reliable, convenient, and economical plant operation. The control equipment is supplied in a plug-and-play container for easy installation.

Key components for compact cryogenic plants such as the air compressor, molecular sieve valves, turbine and coldbox are delivered completely pre-packaged and tested. The exchangers and columns are installed in self-supporting coldboxes. In addition, the sizes of the coldboxes are designed for road transportation, which also eases on-site installation. Other modules such as the valves and pumps are installed in skids to the maximum degree possible for prefabrication and testing. Electrical and instrumentation equipment is delivered in plug-and-play containers. The plant control system together with the operator station(s) and analysis equipment comes in an air-conditioned container, ready-cabled and shop-tested, with the DCS preconfigured for rapid start-up. A separate shop-assembled container is supplied for all electrical medium-voltage switchgear, transformers and low-voltage switchgear, including VFDs for pumps and other electrical equipment. All of these modules and skids are equipped with remote I/O modules for an easy bus connection. This pre-assembled, packaged design minimises on-site erection timelines.

At Linde, we are firmly committed to the highest safety, health, environmental and quality (SHEQ) standards. You expect us to supply safe and economical plants equipped with the latest technology and we deliver on that expectation – worldwide. In addition, sophisticated interlock functions protect our ASUs against any unforeseen failures or maloperation. They also ensure the plant remains in a safe condition even in the event of a power failure. Protective measures are applied wherever the safety of operating personnel may be jeopardized by the process, rotating machinery or exposure to extreme temperatures.

All of our projects are executed to the following rigorous standards to ensure the highest levels of quality:

• Local Indian legislation and norms 
• EN ISO 9000 : 2000 
• ISO 9001 
• ISO 14001 
• PED 97/23/EC 
• OHSAS 18001 
• ASME code, (U Stamp) 
• SCC checklist 
• Work safety and environmental protection legislation

Our packaged plants are designed to minimise the total cost of ownership over the entire lifecycle. This starts with the cost efficiencies of local production, backed by the technology leadership of our German-engineered coldboxes. Local manufacturing of the heat exchangers, columns, coldboxes, skids and electrical and instrumentation containers allows us to combine the benefits of competitive costing with high-quality standards. Aluminium and/or stainless steel are used for piping and columns.

Our new compact plants are designed for ease of operation. Made by internationally renowned manufacturers, all instruments are engineered to the highest standards of quality and reliability. The instrumentation panel is connected to a safe and sophisticated process control system, using the latest proven digital control technologies for optimum reliability. Advanced control functions can support fully unattended operation, automatic start-up from cold conditions, automatic load changes, and production adaptations. Ease of operation and remote-control functionality contribute to the lowest possible total cost of ownership.

Leveraging German Engineering at its core, supported by local manufacturing helps PED achieve the optimal balance between quality and cost.