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Large Scale Air Separation Unit for Reliable Industrial Gas Supply

The Large Scale Air Separation Unit (ASU) is a high-capacity industrial cryogenic facility engineered for the continuous separation of atmospheric air into high-purity gaseous and liquid oxygen, nitrogen, and argon.

Utilizing cryogenic fractional distillation, these systems serve as utility plants for industrial sectors including integrated steelmaking, coal gasification, and petrochemical synthesis.

Internal Compression Process Air Separation Equipment
Internal Compression Air Separation Equipment (ASU) produces high-pressure gaseous oxygen (GOX), nitrogen (GAN), and liquid co-products without external high-pressure gaseous oxygen compressors....
Full Distillation Argon Air Separation Equipment
This full distillation cryogenic air separation plant is engineered for industrial gas producers, EPC contractors, and heavy industry end users requiring simultaneous, high-purity production of...
Large-scale Air Separation Unit for Steel Mill
Large-scale Air Separation Units (ASUs) for steel mill applications are cryogenic industrial gas plants designed to produce high-purity oxygen, nitrogen, and argon through low-temperature air...
Oversized Air Separation Unit for Coal Chemical
The Large-Scale Air Separation Unit for Coal Chemical Applications is a high-capacity cryogenic air separation system engineered to deliver continuous gaseous oxygen, nitrogen, and liquid...

Specifications

Parameter	Baseline Configuration A	Baseline Configuration B	Baseline Configuration C
Simultaneous Design Mode	Full simultaneous GOX + GAN baseline	Full simultaneous GOX + GAN baseline	Full simultaneous GOX + GAN baseline
Gaseous Oxygen (GOX) Output	10,000 Nm³/h (≈ 343 t/d)	30,000 Nm³/h (≈ 1,028 t/d)	60,000 Nm³/h (≈ 2,057 t/d)
GOX Purity & Nominal Outlet Pressure	≥ 99.6% O₂; 0.1 MPa(g) baseline, up to 3.0 MPa(g) via internal compression	≥ 99.6% O₂; 0.1 MPa(g) baseline, up to 5.0 MPa(g) via internal compression	≥ 99.6% O₂; 0.1 MPa(g) baseline, up to 8.0 MPa(g) via internal compression
Specific Power Consumption (at 0.1 MPa(g) GOX)	0.46–0.52 kWh/Nm³ O₂	0.42–0.48 kWh/Nm³ O₂	0.40–0.45 kWh/Nm³ O₂
Gaseous Nitrogen (GAN) Output	Up to 30,000 Nm³/h	Up to 90,000 Nm³/h	Up to 180,000 Nm³/h
GAN Purity & Nominal Outlet Pressure	≤ 10 ppm O₂; 0.1 MPa(g) baseline, up to 3.0 MPa(g) via product compressor	≤ 5 ppm O₂; 0.1 MPa(g) baseline, up to 3.0 MPa(g) via product compressor	≤ 1 ppm O₂; 0.1 MPa(g) baseline, up to 5.0 MPa(g) via product compressor
Refined Argon (GAR) Output	300–350 Nm³/h (optional argon recovery module required)	950–1,050 Nm³/h (optional argon recovery module required)	1,900–2,100 Nm³/h (optional argon recovery module required)
GAR Purity	≥ 99.999% Ar; ≤ 2 ppm O₂, ≤ 3 ppm N₂	≥ 99.999% Ar; ≤ 1 ppm O₂, ≤ 2 ppm N₂	≥ 99.999% Ar; ≤ 1 ppm O₂, ≤ 2 ppm N₂
Total Liquid Co-product Extraction	Combined LOX/LIN/LAR: 3–5% of feed air mass at rated load	Combined LOX/LIN/LAR: 3–8% of feed air mass at rated load	Combined LOX/LIN/LAR: 3–10% of feed air mass at rated load
Design Ambient Conditions	20°C, 1.013 bar(a), 65% RH	20°C, 1.013 bar(a), 65% RH	20°C, 1.013 bar(a), 65% RH

Technical Note

Volumetric flows are referenced to 0°C and 1.01325 bar(a). Mass conversions assume a pure oxygen density of 1.429 kg/Nm³. Specific power consumption is measured at the plant battery limit for the stated co-production case, including the main air compressor, booster compressors, and cooling water system, at the design ambient conditions. Internal compression and liquid co-production increase this value, and the guaranteed figure is fixed in the contract.

Output Configuration

Full Distillation Argon Air Separation Equipment

Simultaneous Mass Balance

Rated GOX, GAN, and GAR outputs represent defined co-production cases. MAC flow is matched to the distillation column's heat and mass balance for each design case.

Large-scale Air Separation Unit for Steel Mill

Gas–Liquid Trade-off

Liquid oxygen (LOX), liquid nitrogen (LIN), and liquid argon (LAR) production consume refrigeration capacity, reducing gaseous output or increasing specific energy consumption.

Oversized Air Separation Unit for Coal Chemical

Argon Recovery

Packed rectification columns recover crude argon from the low-pressure distillation column. With an integrated argon recovery module, the target is 78–82% of the theoretical argon in the incoming air.

Product Grade Selection

Distillation parameters are set during front-end engineering to meet the needs of blast furnace oxygen enrichment (93–95% O₂) or high-purity chemical oxidation (≥ 99.8% O₂).

Process & Technology

01.

Air Compression and Pre-cooling

Multi-stage centrifugal compressors raise feed air pressure, with interstage cooling. A direct-contact water cooling tower then removes heat and reduces the moisture load.

02.

Molecular Sieve Purification

Dual-bed switching adsorbers remove water vapor, CO₂, acetylene, and hydrocarbons to prevent freezing and accumulation in the cold box heat exchangers.

03.

Heat Exchange and Refrigeration

Aluminum plate-fin heat exchangers transfer heat between incoming air and returning cold streams. Cryogenic turboexpanders provide the required process refrigeration.

04.

Dual-Column Distillation

The feed air is separated into nitrogen, oxygen, and crude argon in a structured-packing column system housed in a perlite-insulated cold box.

Site & Utility Customization

Intake filtration, compressor impeller selection, and cooling tower sizing are tailored to site elevation and ambient temperatures.

Power Grid Integration

Motors, high-voltage switchgear, and control systems are configured for local requirements, including 3.3, 6.6, 10, or 11 kV and 50 or 60 Hz.

Plant Layout

Cold box modules can be supplied as shop-fabricated, preassembled vertical frames to reduce site welding, or designed for field erection where plot space is limited.

Site Data Requirements

Engineering requires site-specific data, including historical temperature extremes, barometric pressure, raw water quality, and available electrical capacity.

Safety & Reliability

Hydrocarbon control

The main condenser-reboiler operates with a continuous liquid oxygen purge to prevent hydrocarbon and acetylene accumulation, and online analyzers monitor total hydrocarbons and acetylene with alarm and interlock settings.

Feed air protection

Molecular sieve breakthrough monitoring and intake air quality checks guard against contaminants such as acetylene entering the cold box.

Internal Compression Process Air Separation Equipment

Safety interlocks

Automatic shutdown logic covers high hydrocarbon levels, low liquid level in the main condenser, rotating equipment faults, and loss of utilities.

Equipment protection

Compressors and turboexpanders are monitored for vibration and bearing temperature, with remote DCS access available for trend analysis and troubleshooting.

Engineering Support

Engineering Deliverables

Include foundation load data, P&IDs, electrical single-line diagrams, piping general arrangement (GA) drawings, and battery-limit interface schedules.

Factory Testing

Covers non-destructive testing (NDT), hydrostatic testing, helium leak testing of cold box aluminum heat exchangers, and factory acceptance testing (FAT) for major rotating equipment.

Pressure Equipment Codes

Pressure vessels are manufactured to ASME Section VIII, Division 1, or applicable GB codes, as identified on their nameplates. Process piping follows ASME B31.3 or applicable regional standards. Equipment destined for Europe is addressed under the PED 2014/68/EU framework, as applicable.

FAQ

Q: Which main components are manufactured in-house, and which come from OEMs?

A: We fabricate the cold box, distillation columns, and process piping in-house. The main air compressor, turboexpander, and plate-fin heat exchangers are supplied by named OEMs.

Q: What performance guarantees do you provide?

A: We guarantee product flow, purity, and specific power consumption. The typical power tolerance is +3% of the guaranteed value. Performance is verified through a 72-hour site test.

Q: How long does it take from contract signing to first oxygen?

A: For a 30,000 Nm³/h plant, equipment delivery typically takes 14–18 months, followed by 6–9 months for installation and 2–3 months for commissioning.

Q: How is a large cold box shipped?

A: A 30,000 Nm³/h cold box is typically divided into modules approximately 4 m wide and 20–35 m long. Modules are shipped as break-bulk cargo or on special trailers.

Q: How long does a cold start take?

A: A cold start from ambient conditions to on-spec oxygen typically takes 24–48 hours.

Q: What service life can I expect?

A: Molecular sieve beds generally last 5–8 years, while the aluminum cold box has a design life of 25–30 years.

Q: Why do the three configurations specify different nitrogen purities?

A: Higher nitrogen purity requires more distillation trays and a higher reflux ratio. This typically increases power consumption by 1–3% and requires a taller column. The required purity is set during front-end engineering.

Q: How much plot area does a 30,000 Nm³/h ASU require?

A: A complete plant, including the cold box, compressor house, cooling tower, and purification system, typically requires 12,000–20,000 m². The final area depends on the cold-box design and site layout.

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