What Size Acetylene Plant is Right for Me?

Acetylene (C2H2) is a highly flammable gas; it is colorless and has a peculiar odor. Acetylene gas plants are units where acetylene gas production is carried out. At the plant, acetylene is produced either through a chemical reaction or cracking process. Acetylene has a number of applications across industries, especially in sectors such as chemical, oil & gas, and polymer. But there are a number of factors you consider before you install a plant on your site. One of them is deciding the size of the plant based on your application. There are certain pointers you consider when choosing the size of the acetylene gas and cylinder filling plant and this blog discusses the same. Here we focus on three acetylene plants— Model 301, Model 925, and ATX Series.

Questions to Answer When Choosing the Size of the Acetylene Plant

The size of the plant largely depends on the application. Here are a few questions a prospective customer should answer to determine the right size of the plant:

1. What is the intended use of the equipment?
   1. Cylinder filling:
      1. Approximate number of cylinders to be filled per month
      2. Cylinder Connection (CGA #, DIN, Other connection)
2. 1. Pipeline:
      1. Distance from generator to point of use
3. Are there standards that the plant is to be built to: (NFPA, EIGA, Other?)
4. Is a HAZOP study required as part of the project?
5. Has a budget been established for the project?
6. Has a site been selected and/or approved?
7. What is the target startup date for this project?

About Acetylene Plants

Over the years, acetylene gas plant designs have changed and evolved with the incorporation of technology and automation. With the need to mitigate risk and prevent hazards, they are deigned to meet the required safety standards and certifications such as NPFA. Acetylene cylinders use acetone in the porous mass to store 25 times more acetylene gas in them (known as acetoning acetylene gas). If the acetylene is removed from the cylinder too fast acetone will be removed with the gas. Therefore, the acetone will have to be checked after each use, when returned to the filler. In general, you can run up to three batches of acetylene production in a plant on a daily basis, with one batch of about eight hours.

Here are the details of our three innovative plant models:

1. Model 301– 8.5 m³/hr – Acetylene Cylinder Filling Plant

This acetylene plant is designed for maximum carbide yield and high efficiency. The rated plant capacity is 8.5 m³ per hour using USA grade calcium carbide. This plant complies with the design principles and manufacturing practices mentioned in the section VIII of the ASME Codes and NFPA 51A: “Standards for Acetylene Charging Plants 2006”.

This plant is skid mounted and the entire equipment is mounted on this single skid. One 20 cylinder manifold comes with a master valve, station flame arresters, and flexible cylinder filling leads that have non-return check valves. Cylinders can be quickly connected through hand wheels with nipples that use O-rings for sealing. A motor control center is used to control all automated processes of the acetylene plant. The generator has a capacity hopper of 136 kg. Acetylene is generated on a need basis.

2. Model 925– 25 m³/hr – Acetylene Cylinder Filling Plant

The Rexarc 925 Acetylene Cylinder Filling Plant is designed for maximum carbide yield and high efficiency. The rated plant capacity is 25 m³ per hour, and charges 40 cylinders at one time. It complies with the design principles and manufacturing practices mentioned in the section VIII of the ASME Codes. This model is cost effective in terms of construction and installation. It is skid mounted with the generator on one skid and the process equipment on the other. Two 40 cylinder manifolds come with master valves, station flame arresters and flexible cylinder filling leads that have non-return check valves. Cylinders can be quickly connected through hand wheels with nipples that use O-rings for sealing. A motor control center is used to control all automated processes of the acetylene plant.

3. ATX Series – 50 to 250 m³/hr Acetylene Cylinder Filling Plant

The Rexarc ATX Series plant is available is sizes from 50 to 250 m³/hr. Its design complies with the section VIII of the ASME Codes and NFPA 51A: “Standards for Acetylene Cylinder Charging Plants”. It comes with a very thorough user manual with installation drawings and instructions regarding installation, operation, and maintenance in English and other languages. The amazing point is that with this plant, you get all the spare parts required for one year.

If you need to find out the right size of acetylene plant for your application, you can contact Rexarc for assistance. Rexarc is the leading producer of acetylene gas plants, apparatus, and complete gas control systems; and has clients across the globe.