What period can you operate the plant for in a safe manner ?
The Acetylene plant can be safely operated continuously in batches of 7 - 8 hours each. Up to 3 batches can be conducted daily hence the plant can be run continuously 24 hours a day.
During filling of cylinders, how much acetylene is filled and also how much acetone do you add ? What is the capacity of the cylinders ?
In a new cylinder the approximate amount of Acetylene filled will be around 6 Kg and 3 - 4 Kg (approx) of Acetone is added per fill. The amount of Acetone varies depending upon the tier weight of Cylinder.
How much calcium chloride is put in the driers, and how long does it last?
300 KG of calcium chloride will be required to be Filled inside the Low Pressure (LP) drier and it will last quite long for over 10-12 batch (wherein 1 batch is for 7-8 hours each)
Take example of the 50 m3/hrAcetylene plant. This plant fillshow many cylinders after 8 hours?
Kindly note that in one batch of 7 - 8 hours 100 m3/hr plant can fill in around 60 - 65 cylinders.
What happens to the acetone after acetylene has been used. Do we have to refill 4kg every time the acetylene is filled?
While using Acetylene gas, the Acetone also gets evaporated along with the acetylene gas. Yes, refilling of Acetone will be done every time Acetylene is filled.
Please understand that acetylene is an unstable gas in naturally occurring form and starts decomposing while generating a lot of heat and pressure due to which it cannot be safely pressurized as a pure compound. By mixing the Acetone in the acetylene gas as a solvent, the acetylene can be safely transported and stored in an economical way.
Kindly note that every Acetylene cylinder has its unique Tier weight mentioned on the Cylinder, Thus, before refilling Acetone into a cylinder we have to weigh every cylinder and we need to fill acetone accordingly to match up the tire weight of cylinder. In a standard 40 Liter acetylene cylinder the Acetone required is around 3 - 4 Kg per cylinder of acetylene gas.
Does the calcium carbide regenerate itself? How long does it take to regenerate? How many times can it be regenerated/re used?
Calcium carbide reacts with water to form Acetylene as per the following reaction :
CaC2 + 2H2O = C2H2 + Ca(OH)2 + 27,000 Calories
As you may see from the above reaction, The Calcium Carbide (CaC2) breaks down upon contacting with water molecules (2H2O) to form Acetylene gas (C2H2 ) with Calcium Hydroxide (Ca(OH)2 referred to as slurry discharge) and this process releases heat as a result of the reaction. Any production process based on this reaction will not allow for the Calcium Carbide to regenerate.
What is the expected water quality to be used in the process? Do we need a water treatment plant for feed water into generator?
You will require about 8 - 10 liter of water for each KG of carbide processed. You will not require a water treatment plant due to the nature of the reaction.
What happens to the water after the reaction? Can it be reused?
The water (2H2O) mixes with Calcium Hydroxide Ca(OH)2 to become slurry (Ca(OH)2) which cannot be reused and need to be discharged in the form of waste.