Production line of Nitrous Oxide- DSW Manufacturer
Nitrous oxide (N₂O) plants are facilities that produce this gas, which is commonly known as laughing gas.
DSW is one of the leading manufacturers and exporters of nitrous oxide plants or n2o factories from China.
Our Nitrous Oxide plant is very safe and economical, with an efficient Generation system that reduces power consumption and adds to safety.
Separated elements mean that the plant units have fixed dimensions, but the layout of the complete plant is roughly free, owing to the different lengths and shapes of the connection tubes between the teams.
The installation and start-up process requires more time; some connections are only finished on the Customer’s site.
The Main Parts of the N2O Plant
- Melter & Reactor
The production process begins by heating ammonium nitrate in a reactor. At 210°C, ammonium nitrate begins decomposing, and this process is accelerated to a thermal set point of 255°C. The temperature is carefully maintained at approximately 240°C to prevent unwanted reactions, ensuring that N₂O is efficiently produced with minimal impurities. - N₂O Condenser
The gas leaving the reactor is saturated and directed to a condenser, which removes water. This condensate contains ammonium nitrate and nitric acid, which are reclaimed and purified to minimize waste and enhance efficiency. - Scrubber Systems
DSW’s production line includes water, sodium hydroxide, and acid scrubbers. These systems remove impurities, mainly by-products, from ammonium nitrate decomposition. This purification occurs in a closed-loop absorption tower, ensuring that only pure nitrous oxide progresses to the next stage. - Moisture Separator
A moisture separator removes any remaining condensate water in the gas, further refining the nitrous oxide before it progresses to compression. - Nitrous Oxide Compressor
The purified gas is compressed in a three-stage, non-lubricated reciprocating compressor. Cooling coils and condensate collectors in each stage allow efficient cooling, with the entire assembly immersed in water to optimize gas temperature for high efficiency and stability. - Drying Units
In these units, adsorption removes water vapour from the compressed gas. This step ensures consistent dryness and purity, which is particularly important for high-grade applications. - High-Pressure Buffer Storage
The dried gas is stored in six pressure vessels at 15 bar, buffering it before the liquefaction phase. This storage system also provides stability to maintain continuous production and supply. - Liquefaction Unit
The buffer-stored gas is liquefied in a specialized refrigerant unit that cools nitrous oxide to temperatures as low as -20°C. This liquefaction process is crucial for long-term storage and efficient transportation. - Cylinder Filling Ramp
DSW’s filling ramp allows customization for user requirements, providing flexibility in cylinder sizes from 200L to 20,000L. Safety mechanisms, including tailpipes and pressure relief systems, are installed to ensure secure filling and handling.
Nitrous Oxide Plant
The primary industrial process for producing nitrous oxide involves the thermal decomposition of ammonium nitrate. However, other methods are also available, such as direct oxidation of ammonia or purifying off-gas from polyamide chain production to create it.
Purity Levels and Quality Control
- Industrial Grade (99.9%): Suitable for general industrial applications where high but non-critical purity is acceptable.
- Electronic Grade (99.999%): Ultra-high purity N₂O is necessary for the electronics and LED manufacturing industries. DSW’s quality assurance protocols eliminate even minute impurities, achieving this rigorous standard.
- Food and Medical Grade: DSW adheres to specific regulatory standards to produce food- and medical-grade N₂O. This involves additional purification steps and quality checks to ensure suitability for sensitive applications like food foaming and anaesthesia.
Each batch undergoes stringent testing to ensure compliance with industry-specific requirements, such as ISO standards, making DSW a trusted provider across different market segments.
Nitrous Oxide Production Processing
In the Melters, Ammonium Nitrate decomposes to produce a mixture of Nitrous Oxide and superheated steam. Ammonium Nitrate fumes, Nitrogen, and other Nitrogen oxides are also produced. Moisture and impurities can be removed using sulphuric, acidic, and caustic soda. Nitrogen traces are removed after compression with a compressor by bleeding the tops of storage vessels that store Nitrous Oxide.
Ammonium nitrate is melted in a melter. The molten ammonium nitrate flows into a combustion pot, decomposing ammonium nitrate according to the following reaction.
The reaction is a touchy one and must be controlled. The formation of N2O is prevented if the temperature is allowed to exceed a certain level. We have achieved a reaction efficiency of 95% in our plant. However, in practice, N2O combustion can also produce other impurities. Ammonium nitrate fumes and undecomposed ammonium are present. The primary scrubber recovers these gases. In the first water scrubber, the steam from the hot gas condenses, and the moisture and ammonium nitrate entrained in it are separated in the mist separator. The caustic cleaner removes residual ammonium, carbon dioxide, and other nitrogen oxides.
Application
Nitrous oxide has a wide array of uses across various industries. Here are some primary applications:
- Food Industry: As a food-grade aerosol propellant, N₂O is used in whipped cream and other culinary applications to enhance foaming, texture, and stability.
- Medical Field: Medical-grade N₂O is a mild anaesthetic and analgesic, requiring stringent purity standards to ensure safety and efficacy in healthcare settings.
- Electronics and LED Manufacturing: Due to its stable reactivity, ultra-high-purity nitrous oxide is essential in the etching processes used in electronics and LED manufacturing.
- Consumer Products: N₂O also finds applications in cosmetics (such as perfumes and sprays), household products, and even aerosols like engine starting boosters.
