Key features The Bellelli Engineering Nitrogen Generator is a well-proven unit built to internationally acceptable codes and standards. Key features include: * Modular Design Major plant modules are supplied as pre-assembled, skid mounted packages and include ready mounted instrumentation, electric wiring and pre-fabricated pipe-work. The result is a proven product requiring minimal re-engineering, available on a short delivery and packaged to reduce installation time. * Proven Reliability Bellelli Engineering designed more than 20 air separation units worldwide which provide valuable performance feedback for continual improvement. * Turn Down Capacity The proposed system has the capacity to run at 50% of the full performance design with low energy consumption and maintaining the best efficiency. This is specific design and own Know-How of Bellelli Engineering. * Unattended Operation Day to day running of the plant is automatically controlled so that it can operate totally unattended for extended periods of time whilst maintaining product purity and continuity of supply. Bellelli Engineering Air Separation Unit are designed for maximum reliability achieving on-stream factors in excess of 99%. * Engineering and Manufacturing Quality Bellelli Engineering is certified at both its engineering and manufacturing facilities within the European Quality Assurance Standard ISO9001:2000. The quality assurance and standard will be guaranteed by the continuous day by day quality check of all production phases and process. Process After filtration the compressed air is cooled to reach approximately ambient temperature (or lower) by passing through a mechanical refrigeration system (chiller). This leads to a better impurity removal, and also minimizing power consumption, causing less variation in plant performance due to changes in atmospheric temperature seasonally. After each stage of cooling and compression, condensed water is removed from the air. Then, the remaining carbon dioxide and water vapor must always be removed to satisfy product quality specifications. They are to be removed before the air enters the distillation portion of the plant. The portion is that where the very low temperature can make the water and carbon dioxide to freeze which can be deposited on the surfaces within the process equipment. There are two basic methods to get rid of water vapor and carbon dioxide - molecular sieve units and reversing exchangers. Next step in the cryogenic air separation is the transfer of additional heat against product and waste gas so as to bring the air feed to cryogenic temperature. The cooling is usually done in brazed aluminum heat exchanger. It let the heat exchange between the incoming air feed and cold product and waste gas streams leave the air separation process. The very cold temperatures required for distillation of cryogenic products are formed by a refrigeration process comprising expansion of one or more elevated pressure process streams. This step involves the use of distillation columns to separate the air into desired products. While oxygen leaves from the bottom of the distillation column, nitrogen leaves from the top. Argon has a boiling point similar to that of oxygen and it stays with oxygen. If however high purity oxygen is needed, it is necessary that at an intermediate point argon must be removed from the distillation system. Impure oxygen produced in the higher pressure distillation column can be purified in an lower pressure column. Plants which produce high purity oxygen, nitrogen or other cryogenic gases require more distillation stages. At the end, one or more elevated pressure streams are reduced in pressure, which chills the stream. To maximize chilling, the pressure expansion or reduction takes place inside an expander. Gaseous products usually come out from the plant at relatively low pressures. In general, the lower the delivery pressure, the higher the plant efficiency. It is always cost effective to produce the cryogenic gas at low pressure and use a blower or compressor to achieve required delivery and gaseous storage pressures. Service * Training Bellelli Engineering can supply training courses, individually designed to suit particular Customer needs, in all aspects of plant operation, maintenance, safety and efficiency. These courses are run by specialist Bellelli Engineering engineers, and can be held at our headquarters in Italy, or at site, depending on the individual requirement. * Plant Audits Bellelli Engineering recommends that air separation plants should undergo an annual safety and process check to ensure it is kept in optimum working condition, and any deterioration is reduced to a minimum by early identification of problems and physical defects. The plant check can include; . Analysis of power consumption versus product production, . Inspection of the pressure, temperature and vibration instruments on the machinery, . Vibration analysis and cooler efficiency checks, . Checks of the integrity and effectiveness of all the functions of the control instrumentation, . Pressure drop and mass balance surveys to check the process efficiency and . Analysis of the cold box purge to check for leaks in the cold box. Following the inspection, our engineers will produce a report detailing our findings, together with assessments and recommendations for plant modifications and improvements, where appropriate. * Plant Safety Bellelli Engineering regards safety of air separation plants as the highest priority. Our safety officers can carry out physical inspections of plants and their safety procedures, reporting all findings to the plant manager, as well as giving presentations to operational and maintenance staff an all aspects of plant safety. * Other Services As a plant operator in an ever-changing industrial environment, Bellelli Engineering has used the opportunities available for innovation and increased flexibility to develop many new operational and maintenance procedures. Such services, successfully implemented in our own plants and now available to our Customers, include: . On-line computer monitoring, . Plant overhaul to increase plant capacity, . Production optimisation for revised operating modes, . Cold Box modifications in order to recover additional gases, . Periodic inspection and testing of pressure systems and . Inventory checks of spare part holding.