Hi-Tech Gas Plants designs and manufactures acetylene cylinder filling plants for industrial gas producers and businesses requiring reliable acetylene generation and cylinder charging solutions. Our plants integrate acetylene generation, gas cooling, purification, compression and cylinder filling equipment into a coordinated system.
With model options for different production requirements, our acetylene gas plants feature automated process controls, integrated safety devices and a compact skid-mounted design. We provide solutions tailored to your required production capacity, site conditions and applicable safety standards.
Industrial Acetylene Gas Generation and Cylinder Filling
Our acetylene cylinder filling plant is designed to generate acetylene from calcium carbide and water, followed by gas treatment and preparation for cylinder charging. The integrated process equipment helps manage gas quality and moisture removal before compression and distribution to the filling manifolds.
The plant configuration can be selected according to production capacity, cylinder filling demand and installation requirements. This makes it suitable for industrial gas businesses looking for an integrated acetylene generation and cylinder filling solution.
Why Hi-Tech Gas Plants
Generator
The Generator has all the safety features- temperature safety instrument, water inlet control, high water shut off, low water level alarm, automatic carbide feeding, automatic residue discharge, and over pressurization safety relief valves. A Double hopper of approximately 110 kg feeds the carbide as needed, producing approximately 50 to 280 m3 of acetylene per charge depends on model selected.
Cooler Condenser
The acetylene gas passes through a cooler condenser to lower the temperature with help of recirculated cross flow cooling water.
Low Pressure Drier
The acetylene gas passes through a low pressure drier to remove water particles that gets evaporated during carbide reaction.
Purifier
The gas travels through a purifier to remove impurities that otherwise would collect in the cylinders, reducing the acetylene absorbing capability. The purifier and scrubber also assist in removing impurities like Hydrogen sulphide and phosgene etc. that build up in the flame arresters, causing blocking and check valve malfunctions.
Ammonia Scrubber
The ammonia scrubber removes 99% of the ammonia that develops during the acetylene generating process. Removing ammonia prevents amines from
forming and clogging flame arresters and cylinders.
Compressor
A 3 stage compressor increases the acetylene pressure from 0.4 bars(6 psig) to 24 bars maximum (350 psig). Cooling coils and condensate traps are located at each stage, and the entire assembly of the compressor, with its coils and traps, is submerged in water for maximum cooling of the acetylene gas
Medium Pressure Drier
A medium pressure drier is included for additional drying due to climatic conditions.
High Pressure Driers
The high pressure driers remove moisture and oil picked up during compression. The acetylene then flows through a special filter, flame arrester,
and a back pressure valve before going to the manifold, where every station valve is protected with a flame arrester on each side. A flame arrester, reverse flow check valves, and handwheel connections are on the end of the lead (pigtail) at the cylinder.
Charging
Charging of the cylinders can be accomplished in 8-10 hours.
Electrical Controls
Electrical controls include a weather-proof panel with a main disconnect switch, individual motor starters, PLC and disconnect switches. An air compressor is included to supply air for the generator controls, acetone pump, and to reactivate the purifying material. Throughout the entire process, safety devices monitor all operations because safe operation is one of the most important features of the plant. All other plant instructions are included in the “Installation, Operation and Maintenance” manual. Exceeding all competitive models, the plants are extremely safe and highly efficient, obtaining the maximum yield from calcium carbide. In fact, increases in carbide yield have been up to 11% over low pressure plants – even new plants. Yields could be even greater when the Hi-Tech used to replace outdated plants.
- Modern–Plant is designed with standard Safety practice from NFPA,CSB,FDA etc.
- Economical–Higher Acetylene Gas Yields with small plant foot-print and lower initial costs.
- Compact–The plant Doesn’t required any bulky gas holder system & consumes very less space.
- Efficient–compact design with PLC Operation controls all plant parameters.
- Easy Installation–The Plant arrives on pre-piped skids for minimum on-site assembly & installation.
- Safe–The Plant operation and critical points like Level,temperature & Pressure is controlled by an intelligent industrial grade PLC,Hence Provides an Un-equalled protection to acetylene filling plants.
- Completely Pre-Piped & Skid Mounted.
- Containerized Shipments right from factory.
- Critical process parameters monitored and recorded and recorded every 500 milliseconds.
- Automatic shutdown for in case of high Temperature,High Pressure,High Water level etc.
- Designed in accordance with local standards.
- Automatic and unattended operation.
- On-site start-up Training and assistance by Hi-tech’s Engineered Solutions technicians anywhere in the world.
our generators provide from 20 to 200 kg per hour of acetylene, use the following table to determine which model is most suitable for your application-
| Specifications? Model? | HTA-20 | HTA-50 | HTA-100 | HTA-150 | HTA-200 |
| Capacity | 20 Kg/Hr | 50 Kg/Hr | 100 Kg/Hr | 150 Kg/Hr | 200 Kg/Hr |
| Operating Pressure | 0.5 Bars G | 0.5 Bars G | 0.5 Bars G | 0.5 Bars G | 0.5 Bars G |
| Purity* | 99.6% V/V | 99.6% V/V | 99.6% V/V | 99.6% V/V | 99.6% V/V |
| Startup Time | 5 Minutes | 5 Minutes | 5 Minutes | 5 Minutes | 5 Minutes |
| Carbide Size | 17-15 | 15-25 mm | 15-25 mm | 15-25mm | 25-50 mm |
| Cylinders Filled per Batch** | 24 | 58 | 116 | 174 | 232 |
| Connected Power | 10 KW | 15 KW | 35 KW | 50 KW | 65 KW |
*using USA/UK grade Calcium carbide having Max 15% Dust Concentration; ** A batch is of 8 Hours and Cylinders having 7 kg acetylene capacity.
Note- Custom built models also available, Specifications are subject to change without prior notice.
General Layout Installation View of Acetylene Plant
