INDUSTRIAL GASES: ACETYLENE oxygen, a process referred to as "thermal

PRODUCTION cracking" or "pyrolysis" of hydrocarbons.

HISTORY RAW MATERIALS IN ACETYLENE

• Ancient times - Acetylene's origins trace PRODUCTION
back to ancient times, Throughout
history, acetylene was unintentionally • Calcium carbide +H2O - The primary
generated during the burning of organic method for producing acetylene involves
substances like wood. reacting calcium carbide (CaC2) with
• 1836 - Acetylene's initial discovery is water.
attributed to Edmund Davy, observed a • Hydrocarbons and electric arc -
novel gas formation during water passing a hydrocarbon (such as
electrolysis, dubbing it methane) through an electric arc. The
"OXYHYDROGEN." This gas comprised intense heat of the arc breaks down the
a mixture of hydrogen and oxygen, hydrocarbon molecules, resulting in the
capable of reacting to produce acetylene formation of acetylene.
under specific conditions. • Partially combusting methane -
• 1860 - Acetylene was rediscovered in partially combusting methane (CH4) with
1860 by French chemist Marcellin air or oxygen. In this method, methane is
Berthelot, who introduced the term not completely burned, leading to the
"acétylène" to describe it. formation of acetylene.
• 1862 - German chemist Friedrich Wöhler
achieved the synthesis of acetylene by MANUFACTURING PROCESS
combining calcium carbide with water—
groundwork for industrial-scale acetylene
production.
• 1892 - Pioneering development of a
practical method for producing
commercial - scale acetylene is credited
to Thomas L. Willson.
• 1895 - Canadian inventor Thomas L.
Willson (Father of Carbide)
independently devised a cost-effective
technique for manufacturing calcium
carbide, a breakthrough that
revolutionized the industrial production of
acetylene.
• Early 20th century - Acetylene GENERATION - Calcium Carbide is loaded to the
experienced widespread adoption in acetylene generator using the hopper filling cart.
various industrial sectors The calcium carbide is mixed with water, instantly
• 1920 - Cellulose acetate was employed producing acetylene. This reaction is facilitated
for the production of synthetic fibers and by a carbide feed mechanism, which operates by
video films. Concurrently, Julius sensing the pressure inside the generator body.
Nieuwland's synthesis of vinyl acetylene As the pressure drops after the carbide is added,
additional carbide is introduced to sustain the
• Mid to late 20th century –
reaction and ensure a continuous flow of
WORLD WAR 1 - acetylene served as a
acetylene in the process stream.
precursor for the creation of butadiene,
Unit Equipment Involved: Acetylene Generator
serving as a substitute for natural rubber.
Advancements in Chemical Engineering
PURIFICATION –
and industrial processes spurred the
The Acetylene is cooled down in the cooler
emergence of new methods for acetylene
condenser and moisture is
production.
extracted in the L.P Drier.
• Modern day - Presently, the primary
1.Cooling and Drying
method for acetylene synthesis involves
- The gas produced in the process is
the partial combustion of methane with
passed through the cooler condenser,
 which uses pipes surrounded by water to
cool the acetylene stream.
- The low pressure drier is then used to
extract moisture until the correct amount
needed for the purification process is left.
Unit Equipment Involved: Cooler Condensor,
Low Pressure Drier
The Acetylene is passed through a Purifier to
remove its impurities and remove the ammonia
by a scrubber.
2. Purifying and Ammonia Scrubbing
- The dried acetylene is passed through
the acetylene purifier, where impurities
such as phosphine, arsine, H2S are
removed from the gas. If industrial
acetylene is needed the purification
process can be bypassed.
- The ammonia scrubber uses water to
remove 99% ammonia in the acetylene
stream.
Unit Equipment Involved: Purifier, Ammonia
Scrubber
COMPRESSION - Acetylene enters compressor
to boost the gas up to cylinder filling pressure and
remove left moisture by H.P. Driers.
Compression and Moisture Removal
- The acetylene then enters the
compressor and is raised from inlet
pressure to desired final cylinder.
- The High Pressure Driers removes any
left moisture and filter out particles.
Unit Equipment Involved: Acetylene
Compressor, High Pressure Driers
CYLINDER FILLING - Acetylene is filled directly
to the cylinders.
- The acetylene is compressed into a
cylinder that has liquid acetone and a
porous monolithic mass filler.
Unit Equipment Involved: Cylinder Filling Ramp
USES OF ACETYLENE
• Welding and Cutting
• Flame Heating and
• Brazing
• Chemical Synthesis
• Thermal Spraying
• Carbon Nanotube Synthesis
• PVC plastic synthesis
• Ripening Agent
• Carbide Lamps
WASTE TREATMENT
Treating Carbide Lime Involves Different
Methods:
1.)Drying
2.)Neutralization
3.)Stabilization
4.)Solidification
5.)Lime Pods
6.) Decanting
7.)Membrane Filtration/Filtration
8.)Centrifugal Action
In acetylene plants, carbide lime is generated as
a byproduct. Carbide lime is further processed to
make it useful in other industries or be safe for
disposal.
Regardless of the treatment method used, it's
essential to ensure that the treated carbide lime
meets regulatory requirements for disposal or
reuse. This may involve testing the material for
various parameters such as pH, heavy metal
content, and leaching potential.
PLACES CARBIDE LIME CAN BE DISPOSED:
Landfill Disposal: Carbide lime can be disposed
of in properly permitted landfills designed to
handle non-hazardous industrial waste. Before
disposing of carbide lime in a landfill, it's essential
to check with local authorities to ensure
compliance with waste disposal regulations and
to verify that the landfill accepts this type of waste.
Specialized Disposal Facilities: Certain
specialized facilities may accept carbide lime for
disposal, particularly if it contains hazardous
contaminants or requires specific treatment
methods. These facilities may include hazardous
waste treatment plants or facilities equipped to
handle specific types of industrial waste.
OXYGEN PRODUCTION
HISTORY
• 1774 - The English chemist Joseph
Priestley made an independent
discovery of oxygen by heating
mercuric oxide and observing the
emergence of a gas which he termed
"dephlogisticated air."
• 1777 - French chemist Antoine
Lavoisier, in his research, identified
oxygen as a unique element and
designated it "oxygen," derived from
Greek terms signifying "acid-former."
• 1800 - William Nicholson and Anthony
Carlisle made the groundbreaking
discovery of electrolysis, a PRESSURE SWING ADSORPTION
phenomenon wherein water could be
decomposed into hydrogen and
oxygen through the application of an
electric current.
• 1801 - John Dalton, an English
scientist, formulated the atomic theory,
offering a theoretical framework crucial
for comprehending the composition of
gases, including oxygen.
• 1809 - Humphry Davy pioneered the
initial practical technique for oxygen
production by subjecting a blend of
mercury oxide and mercuric nitrate to
heat.
• 1810 - Louis Jacques Thénard and
Joseph Louis Gay-Lussac developed
an improved method for producing
oxygen by heating potassium chlorate.
• 1874 - Carl von Linde developed a
method for liquefying air, which allowed
for the separation of oxygen from other
components of air.
• WORLD WAR 1 - Oxygen became
increasingly important for medical and
industrial applications, leading to
further advancements in oxygen
production technology.
• Mid to late 20th century - In the mid-
20th century, with the development of
advanced technologies such as
pressure swing adsorption (PSA) and
membrane separation.
• Modern Era - Oxygen production
continues to evolve with advancements
in materials science, engineering, and
sustainability.
RAW MATERIALS IN OXYGEN
PRODUCTION
1. NATURAL OXYGEN PRODUCTION
Photosynthesis – OXYGEN
2. INDUSTRIAL OXYGEN
PRODUCTION
CRYOGENIC SEPARATION PROCESS
RAW AIR - consisting mainly of
nitrogen, oxygen, and trace amounts of
other gases.
REFRIGERANTS - Liquid nitrogen or
liquid helium is used to cool the air to
very low temperatures, enabling the
separation of oxygen from nitrogen
through distillation.
ADSORBENTS - Zeolite or Carbon
Molecular Sieves are used as
adsorbents to selectively capture
nitrogen from air while allowing oxygen
to pass through.
COMPRESED AIR - Atmospheric air is
compressed and fed into the PSA unit.
MEMBRANE SEPARATION
POLYMER MEMBRANES - These
membranes have selective
permeability, allowing oxygen
molecules to pass through while
blocking other gases like nitrogen.
COMPRESED AIR - Similar to PSA,
compressed air is used as the
feedstock for membrane separation.
OXYGEN MANUFACTURING
PROCESS
COMPRESSION - Air is filtered and
compressed up to 5.5 - 6 bar pressure.
 - Air from the atmosphere is suctioned OXYGEN CYLINDER FILLING - Oxygen will
and filtered using filters to remove dust be converted to gas using vaporizer coils and
and particles and hard impurities. distributed using cylinders.
- Air is compressed in a compressor, up - Oxygen is compressed to a prescribed
to 5.5 bar pressure, to make the air flow settled pressure by a liquid pump and
from the start to end process. is directly filled into cylinders.
Unit Equipment Involved: Air Compressor - Oxygen will be converted to gas using
vaporizer coils and distributed in
PURIFICATION - Air is cooled down then is cylinders.
passed through the purification units to
remove water, hydrocarbons, and CO2.
- The high pressure air is cooled in the
pre-cooling system to 10 degrees
Celsius using refrigerated water.
- Water, hydrocarbons, and CO2 are
removed in the purification units using
molecular sieves and activated
alumina.
Unit Equipment Involved: Direct Contact Air
Cooler, Chiller Pump, Purification Units

EXPANSION - The high pressure air is USES OF OXYGEN

expanded in an expansion turbine and a Joule
Thompson valve. MEDICAL USES:
- The adiabatic expansion results in a Respiratory Support
drastic drop from 10 deg to -120deg C. Anesthesia and Surgery
- The expanded air is passed to the Hyperbaric Oxygen Therapy
fractional distillation column through
heat exchangers. INDUSTRIAL PROCESSES:
- Air is further reduced to -165degC. At Metal cutting and Welding
this temp. The oxygen in the column Glass Making
will get liquified with 40% oxygen Steel Making
content (rich liquid).
Unit Equipment Involved: Expansion Environmental Applications
Turbine, Joule Thompson Valve Wastewater Treatment
Aquaculture
DISTILLATION - Air is liquified then is further Bioremedation
separated into its components. Liquified Aerospace
oxygen is accumulated at the bottom. Life Support System
- In between the lower and upper Combustion
column, there is a condenser which
acts as a reflux for the lower column WASTE TREATMENT
and as a re-boiler for the upper column.
- Due to differences in the boiling points, Carbon Dioxide (CO2) Removal: Carbon
the pure Nitrogen boils over and dioxide is separated from the air during the
accumulates at the top of the upper initial stages of the oxygen production process.
column and oxygen accumulates at the After the carbon dioxide is captured it can now
bottom of the upper column. either be stored or utilized.
Unit Equipment Involved: Distillation
Column, Heat Exchanger
 CCS AND CCU
CARBON CAPTURE AND STORAGE
Carbon Capture and Storage (CCS): CCS
involves capturing CO2 emissions from
industrial sources, such as power plants or
cement factories, and storing them
underground or in geological formations to
prevent their release into the atmosphere.
While not strictly a form of recycling, CCS helps
reduce CO2 emissions by capturing and
permanently storing them, thereby mitigating
their impact on climate change.
The collected condensate may undergo further
treatment before disposal or reuse, depending
on regulatory requirements and environmental
considerations.
Reverse Osmosis (RO) Treatment:
Reverse osmosis is a water treatment process
that utilizes a semipermeable membrane to
remove contaminants and impurities from
water.

CARBON CAPTURE AND UTILIZATION

Carbonation: CO2 can react with minerals,
such as magnesium or calcium silicates, to
form stable carbonate minerals. This process,
known as mineral carbonation, permanently
sequesters CO2 while producing useful
materials for construction or other applications.

HYDROCARBON TREATMENT

The treatment of hydrocarbon waste often

involves processes such as oxidation,
biodegradation, or chemical conversion to less
harmful substances. Oxidation processes
involve burning the hydrocarbons in controlled
conditions to convert them into carbon
dioxide and water. Biodegradation utilizes
microorganisms to break down the
hydrocarbons into simpler, less harmful
compounds.

Once treated, the hydrocarbon waste can be

disposed of safely according to environmental
regulations or recycled if possible. Recycling
may involve reusing the hydrocarbons as fuel
or feedstock for other industrial processes.

WATER TREATMENT

In many oxygen production processes, such as

cryogenic distillation or pressure swing
adsorption (PSA), air is compressed and
cooled to remove moisture and other impurities
before the oxygen is separated from nitrogen.
During this cooling process, water vapor in the
air condenses into liquid form, which is then
separated from the purified air stream.