Phone : +91-8374485833, mail: sravani@consultant.com
Phone : +91-8374485833
Moil : sravani@consultant.com
WISDOM
WISDOM ENGINEERING
Storage Tank design consultancy services
Bulk oxygen storage system design services
at such a large scale (example 2,000 m³)
Storing bulk oxygen at such a large scale (example 1,60,000 m³) requires careful planning and adherence to safety standards due to oxygen’s reactive nature, particularly in large volumes. Here are a few common methods for bulk oxygen storage:
Liquid Oxygen Storage
Liquid oxygen (LOX) is one of the most efficient methods for storing large volumes of oxygen because it has highly reduced volume in liquid stage.
Storage Tanks: Cryogenic storage tanks are used to store liquid oxygen at extremely low temperatures (around -183°C or -297°F). These tanks are typically double-walled, with insulation between the inner and outer layers to maintain the low temperature.
Capacity: The size of the tank required would depend on the exact volume and the duration for which the oxygen needs to be stored.
Safety Considerations: Due to the extremely low temperatures, cryogenic tanks need to be equipped with pressure relief valves, safety sensors, and relief venting systems to prevent over-pressurization and catastrophic failure
High-Pressure Gas Storage
Oxygen can also be stored in large high-pressure gas cylinders or pressure vessels. This method is common for applications where oxygen is stored in its gaseous form but under high pressure.
Pressure Vessels: These large cylinders or vessels store oxygen at pressures ranging from 150 bar (2200 psi) to 300 bar (4500 psi), depending on the design.
To store 1,60,000 m³ of oxygen at 150 bar pressure, you'd require approximately 1,067 large cylinders require.
Safety Considerations: Storage systems need to be designed with multiple safety features, such as pressure relief devices, fire suppression systems, and structural integrity assessments. Oxygen-rich environments can cause accelerated corrosion in certain materials, so the storage tanks must be made of compatible materials, such as stainless steel.
Oxygen Generation and Storage Systems
Some industries prefer to generate oxygen on-site via an oxygen generator (PSA or VPSA) and store the generated oxygen in bulk tanks for continuous use.
Pressure Swing Adsorption (PSA) and Vacuum Pressure Swing Adsorption (VPSA) are common technologies used to produce oxygen from ambient air. These systems are energy-efficient, and the oxygen produced can be stored in liquid or gas form depending on the setup.
Storage: After generation, oxygen can be compressed and stored in high-pressure vessels, or cooled and stored as liquid oxygen. For very large quantities like 1,60,000 m³,
Bulk Oxygen Tankers
Another option is to use bulk oxygen tankers or cryogenic tankers for transportation and storage. These tankers can hold large amounts of liquid oxygen and can be refilled as needed.
Mobile Storage: These tanks can be placed at strategic locations or be used for distribution purposes, especially when the facility is not able to handle such a large volume on-site continuously.
Safety Considerations
Ventilation and Fire Safety: Oxygen is a strong oxidizer, and high oxygen concentrations increase the risk of fire. Storage areas must be well-ventilated to avoid the accumulation of oxygen-enriched air. Fire-resistant materials should be used for tanks and pipelines.
Leak Detection: Continuous leak detection systems should be installed to ensure that any leaks are detected immediately.
Case Study: Oxygen 700m³ Bulk Storage System Design for Mangla Steel Pvt Ltd.
Client: Mangla Steel Pvt Ltd., Noida (U.P)
Consultant: Sandhya Design Consultancy
Year: 2024
Project Scope: Design & Engineering of Oxygen Bulk Storage System
Number of Tanks: 28 tanks (25KL each)
System Type: Cryogenic Double-Wall Tanks for Liquid Oxygen (LOX) Storage and Distribution
Project Overview
Mangla Steel Pvt Ltd., a leading steel manufacturer in Noida, U.P., required a state-of-the-art oxygen bulk storage and supply system to support their industrial operations. The system was designed to provide a reliable and efficient source of liquid oxygen (LOX) for their steel manufacturing processes. Sandhya Design Consultancy was entrusted with the comprehensive design and engineering of the oxygen storage facility, including tanks, vaporizers, safety devices, and associated infrastructure.
Objectives
To design a scalable and efficient oxygen storage system capable of handling 700m³ of oxygen storage.
To ensure safety compliance with industry standards, including ASME Boiler and Pressure Vessel Code, Section VIII, for unfired pressure vessels.
To integrate a cryogenic double-wall storage tank system, vaporization, and pressure regulation for continuous oxygen supply.
To optimize plant layout and engineering for seamless installation and operation.
Key Features of the Design
Cryogenic Double-Wall Storage Tanks
Tank Specifications:
28 tanks, each with a storage capacity of 25KL (25,000 liters)
Designed for storing Liquid Oxygen (LOX) at cryogenic temperatures
Double-wall design for improved insulation and safety, minimizing heat transfer
Conversion to LOX:
Tanks were designed with the flexibility to convert gaseous oxygen to liquid oxygen (LOX), optimizing storage and distribution efficiency.
Tanks feature advanced insulation and safety mechanisms, including vacuum-insulated liners.
Plant Layout
The plant layout was carefully designed to optimize space and ensure safe operation. The design integrated oxygen storage tanks, a pump house, regasification plant, and other auxiliary systems into a cohesive facility layout.
Clear and easy access was provided for maintenance, with safety zones and separation distances observed between key equipment.
New Pump House & Regasification Plant
A new pump house was designed to house the liquid oxygen pumps, ensuring reliable transfer of LOX from storage to the distribution system.
The regasification plant converts liquid oxygen (LOX) to gaseous oxygen (GOX) for delivery to the steel plant’s manufacturing process. The plant includes high-efficiency vaporizers and pressure regulators to ensure the oxygen supply meets demand without fluctuations.
Oxygen Storage Containers
In addition to the primary LOX storage tanks, auxiliary containers were designed to store gaseous oxygen for short-term backup. These containers are strategically placed throughout the facility for redundancy.
Pressure Regulators & Safety Devices
The system includes advanced pressure regulators to maintain consistent pressure throughout the storage and distribution network.
Safety relief devices were incorporated to ensure that overpressure situations do not lead to tank rupture or other hazards. These safety devices comply with industry standards and ASME Section VIII requirements.
Vaporizers & Manifolds
Vaporizers: Cryogenic vaporizers were designed to efficiently convert liquid oxygen to gaseous oxygen. The system features both ambient air vaporizers and heated vaporizers for efficient operation during varying weather conditions.
Manifolds: Multi-tank manifolds were incorporated to ensure smooth distribution and the ability to isolate individual tanks for maintenance or in the event of a system fault.
Interconnecting Piping
A detailed piping layout was developed to connect the tanks, vaporization systems, manifolds, and other components. Materials were carefully selected for their ability to withstand the low temperatures and high pressures associated with LOX storage.
The piping network includes both insulated and uninsulated segments depending on the system’s operational requirements.
Foundations and Supports
Foundations for the cryogenic tanks and supporting structures were designed to handle the weight and thermal expansion associated with LOX storage.
Supports were designed to ensure stability, with allowances for temperature-induced stress and vibration during operation.
P&ID (Piping and Instrumentation Diagram)
A detailed P&ID was developed to document the flow of fluids, control systems, and instrumentation for monitoring and maintaining optimal performance. This diagram provides a visual reference for system operation and troubleshooting.
Compliance with Industry Codes
The design adheres to the ASME Boiler and Pressure Vessel Code, Section VIII—Unfired Pressure Vessels for all pressure-containing equipment and safety components.
All piping, tubing, and fittings were specified to meet the highest quality standards, ensuring long-term reliability and safety.
Insulation and Safety Relief Devices
The oxygen storage tanks were equipped with advanced insulation to minimize heat ingress and maximize storage efficiency.
Safety relief valves and venting systems were incorporated to manage pressure surges and avoid catastrophic failures.
Testing and Commissioning
Comprehensive testing was conducted to ensure all components, including tanks, piping, vaporizers, and safety devices, met performance and safety standards.
Pressure testing, leak testing, and functional testing were carried out during the commissioning phase to ensure the integrity of the entire system.
Challenges and Solutions
Temperature Management: The cryogenic nature of liquid oxygen posed a significant challenge in terms of insulation and safe handling. The design included high-performance thermal insulation and heat-tracing systems to maintain the appropriate temperatures.
Safety Considerations: Given the hazardous nature of liquid oxygen, the design focused heavily on safety, incorporating robust pressure relief devices, emergency venting, and fail-safe mechanisms throughout the system.
Space Constraints: The limited space at the Mangla Steel facility required careful planning of the layout to ensure that all components fit within the available area while still adhering to safety and operational standards.
Regulatory Compliance: Sandhya Design Consultancy worked closely with local authorities and safety regulators to ensure that the design met all relevant standards, including the ASME Boiler and Pressure Vessel Code and other safety and environmental regulations.
Results and Impact
The successful implementation of this oxygen bulk storage system has enabled Mangla Steel Pvt Ltd. to enhance its production capabilities by ensuring a steady and reliable supply of oxygen. The cryogenic storage system provides both efficiency and safety, with significant improvements in the plant's operational reliability. The new system also offers redundancy and scalability, allowing for future expansion as the company's needs grow.
The project has strengthened the client's operational capabilities while ensuring safety and compliance with industry standards. By optimizing the oxygen supply chain, Mangla Steel is positioned to meet the growing demand for its products in the competitive steel industry.
Conclusion
The design and engineering services provided by Sandhya Design Consultancy have resulted in the successful creation of a state-of-the-art oxygen bulk storage and supply system for Mangla Steel Pvt Ltd. The project exemplifies the application of advanced engineering techniques in cryogenic tank design, system integration, and safety compliance, all while meeting the specific needs of the client.
This facility sets a new standard for oxygen storage in industrial applications, providing Mangla Steel with a robust, scalable, and efficient solution for its oxygen supply needs.
For more information, please contact Sandhya Design Consultancy.