SVKM’s NMIMS

Mukesh Patel School of Technology Management and Engineering

INTERIM REPORT

ON

PRESSURE SWING ADSORPTION OXYGEN GENERATOR

By

PRASOON TAYLOR

Roll Number: N275

SAP Number: 70471117086

Faculty Mentor

Mrs. ALAKNANDA LONARE

Industry Mentor

Mr. MOHANLAL BHATI

1
 A REPORT

ON

PRESSURE SWING ADSORPTION OXYGEN GENERATOR

By

PRASOON TAYLOR

Roll Number: N275

SAP Number: 70471117086

A report submitted in partial fulfillment of the

requirements of 5 years Integrated MBA Tech Program of

Mukesh Patel School of Technology Management &

Engineering, Narsee Monjee Institute of Management

Studies (NMIMS) (Deemed to be University), Mumbai

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 SVKM’s NMIMS (Deemed to be University)

Mukesh Patel School of Technology Management & Engineering

Vile Parle (W), Mumbai 400 056

MANAGEMENT INTERNSHIP REPORT Semester IX MBA (Tech)

Submitted in Partial Fulfillment of the Requirements for Management Project/Training for Semester IX

MBA (Tech)

Name of the Student: - Prasoon Taylor

Roll No & Batch: - N275 2017-2022

Academic Year: - 2020 - 2021

Name of the Discipline: - MBA Tech

Name and Address of the Company: - Mayo Vessels & Machines Pvt. Ltd.

Training Period: From June 14, 2020 to September 14, 2020

THIS IS TO CERTIFY THAT

Mr. /Ms. Prasoon Taylor has Satisfactorily Completed her Training/Project Work, submitted the training
report and appeared for the Presentation & VIVA as required.

External Examiner Internal Examiner Faculty Mentor

Date:

Place:

Seal of University:

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 Completion Certificate
This is to certify that,

Mr. /Ms. Prasoon Taylor

Has completed the training and project as a part of Management Internship in our company as mentioned below
and has also submitted the report

(i) Project Title: - Pressure Swing Adsorption Oxygen Generator

(ii) Date of Joining: - 14/06/2021

(ii) Date of Completion: - 14/09/2021

In partial fulfillment of 9th semester Management Internship for MBA Tech program of Mukesh Patel School of
Technology Management and Engineering, Narsee Monjee Institute of Management Studies (NMIMS) (Deemed to be
University), Mumbai

Industry Mentor’s Signature & Seal

Date: - September 11, 2021

Place: - Aurangabad, Maharashtra

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 Table of Content
Sr. No. Topic Name Page
Number
1 Acknowledgment 6
2 List of Illustrations 7
3 About the Company 8
Project Title: PSA Oxygen Plant
4 Introduction 8
5 Purpose 8
6 Scope 8
7 Benefits of Project 9
8 Applications of Project 10
9 Concepts considered 11
10 Project Working Principle 14
11 Technical Specifications 17
12 Comparison Analysis 22
13 Description of Processing of Plant 24
14 Phases of the Project Completion 26
15 Costing of Project 28
16 Risks & Conclusion 30
17 Appendix 31

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 Acknowledgments

I gratefully acknowledge for the assistance, cooperation, guidance and clarification provided by Mr. Mohanlal Bhati
during the development of the Pressure Swing Adsorption Oxygen Generator. My extreme gratitude to Mr. Mohanlal
Bhati and his team who guided me throughout the project. Without his willing disposition, spirit accommodation,
frankness, timely clarification and above all faith in me, this project and the assignment could not have completed in
due time. His readiness to help me out in the busy schedule must have special attention. I would also like to thank
the faculty mentor from the college Mrs. Alaknanda Lonare for the cooperation and the important support. I will
also thank all the teaching staff that taught me with the concepts that helped me in completing the project
successfully.

Finally my deepest gratitude to my parents who have given me much needed comfort, support, encouragement
and inspiring to complete the project.

I perceive as this opportunity as a big milestone in my career development. I will strive to use the gained skills
and knowledge in the best possible way and will continue to work on their improvement, in order to attain desired
career objectives. Hope to continue cooperation with all of you in the future.

Sincerely,

Prasoon Taylor

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 List of Illustrations

Sr. No. Figure Name Page

Number
1 Fig.1: Phases of the project 12
2 Fig. 2: A generalised view of the whole system 14
3 Fig. 3: Adsorption Process 15
4 Fig. 4: Equilisation Process 16

5 Fig. 5: Regeneration Process 16

6 Fig. 6: Technical Specification Table 1 17

7 Fig. 7: Technical Specification Table 2 18

8 Fig. 8: Comparison Analysis of Products 1 22

9 Fig. 9: Comparison Analysis of Products 2 22

10 Fig. 10: Comparison Analysis of Products 3 23

11 Fig. 11: Comparison Analysis of Products 4 23

12 Fig. 12: A detailed view of system 26

13 Fig. 13: Air Receiver Design finalised 31

14 Fig. 14: Vent Silencer design 32

15 Fig. 15: The Valve Connection Design with modifications from normal structure 33

16 Fig. 16: PSA Tank design 34

17 Fig. 17: The complete system design by the company 35

18 Fig. 18: Storage Vessel Design 36

Tables
1 Table 1: Average Man Hour Costing 28
2 Table 2: Labor Cost of Equipment 29

3 Table 3: Material Cost 29

4 Table 4: Consumable Cost 29

5 Table 5: Total Project Cost 30

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About the company: -

Mayo Vessels & Machines is a firm of Multidiscipline as a Technocrat with VAST earned experienced after testing
and installation of various configuration of M.S.W integrated Facility in INDIA ABROAD & OFF SHORE present Fast
Development of India created enormous WASTE generation due to rapid growth of Population, Mechanization &
Urbanization with a result hazardous dumping Waste generated Methane in Dumping Yard is much Dangerous than
even CO2 gas emission for global warming disease. MAYO'S Best utilization of earned perfect Engineering
application of Civil, Mechanical, Electrical, Hydraulic, Pneumatic Thermodynamic & BIO TECHNOLOGY have
developed Environ save system i.e. M.S.W INTEGRATED MANAGEMENT SYSTEM to take care of mounted Dump
Yard on different contour of Panchayat, Municipal Council and Corporation level by taking TOTAL CARE of M.S.W.
rule 2000 & WORLD NORMS.

PROJECT: PSA Oxygen Generator Plant

Introduction:
Gas is a group of gases that are commercially manufactured and sold for uses in other applications. The most
common industrial gases are: air gases - Oxygen (O2), Nitrogen (N2) and Argon (Ar) rare gases - such as Helium
(He), Krypton (Kr), Xenon (Xe) and Neon (Ne)and other gases like hydrogen (H2), Carbon Monoxide (CO), Carbon
Dioxide (CO2) and NitrousOxide (N2O), Chlorine (Cl2), Hydrogen Chloride (HCl) and Sulphur Dioxide (SO2),
Acetylene (C2H2), Methane (CH4) and Propane (C3H8). In addition, there are many different mixtures of these and
other gases to meet the needs of specific applications.

Purpose of the project:

The project was initiated upon the circumstances that arose due to the corona virus pandemic. 5-6 months earlier
when there was a severe need of oxygen due to the second wave hit in the country, we observed that there was
allot impatience regarding the oxygen. Due to this need, the company decided to start setting up its own oxygen
plants across the nation and accordingly anyone in need to purchase and set, will have the opportunity as well to
purchase from us and set as per their choice.

Scope:
Usage in the Industry:
The industrial and medical gases industry serves a very large number of customers in the whole community.
Industrial gases are essential for almost all manufacturing. Large quantities of oxygen, nitrogen and argon are used
in the basic and infrastructural [Link] and the automotive industry use acetylene, propane, mixtures
of fuel gases and oxygen for cutting and welding. Liquid nitrogen is vital in recycling plastics, packaging and scrap
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tyres. The chemical industry employs all major industrial gases as a raw material or forinerting. The other smaller
market segment consists of cylinder gas and mixtures.

Market Outlook
In India, there are presently over 300 small & medium size plants and approximately 25 largetonnage plants all over
the country. These gases are supplied through pipelines to captive customers in adjacent factories; in cryogenic
transport tanks for bulk deliveries to long distance customers; or filled in cylinders. The present annual turnover of
the gas industry, excluding captive production is about Rs. 3,000 crores ($650 million). With increased
industrialization, the demand pattern of industrial gases is also changing fast. Modern application in the food
processing industry, agro industries, healthcare and technology are growing at a tremendous pace. This has driven
the industry to adopt stringent quality control systems and an efficient distribution network. Major players in India
include BOC India, INOXAir Products Ltd., Jindal Praxair Oxygen Co. Ltd., Air Liquide India Holding [Link]. Aims
Industries Ltd etc.

The Indian gas industry is growing at an average rate of 12 per cent per annum duringthe last couple of years, with
the industrial oxygen growing consistently at 15-17 per cent per annum. The growth of industrial gas industry can be
easily forecast on the basis of projectionsof the steel and other metallurgical industry. Steel demand is seen rising by
10% in the fiscal year to march 2011, helped by higherspending on infrastructure will continue to drive growth of
the gas industry. Natural gas comprises 9 % of India's primary energy consumption and it will be 14% of energy mix
by 2010. Demand for natural gas is also likely to increase at an average annual growth rate of 7.3%.Metals
production and fabrication will continue to be the largest market for industrial gases, accounting for 31% of total
demand in value terms in coming years. The second largestmarket will be the chemical processing/petroleum
refining segment. The medical/healthcaremarket, though smaller in size, will be the fastest growing and record
gains from the expansion of healthcare services in developing nations and rapidly increasing use of home healthcare
respiratory therapies in advanced economics. Hydrogen is gaining prominence andmost companies are striving to
develop technologies that can efficiently exploit the potentialof hydrogen. Increased use of natural gas will create an
opportunity for higher production ofargon and carbon dioxide. The Industrial gas industry has a very bright future
in the coming years.

The benefits of setting up of this project:

o High Reliability: Low gas speeds through the molecular sieve beds, first-class components,stainless
steel valve bodies and instrument air tubing, heavy-duty industrial PLC manufactured to work always.

o Lowest Energy Consumption; Energy cost is your major expense, not depreciation. Fast pay-back assured.

o Easy Integration: Easy installation and integration with existing equipment: All system tie-in pointsare on one
side.

o Safe: Heavy-duty adsorption vessels designed and certified for an unlimited number ofcyclic loads.

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o Customization: An extended list of options allows you to define your specific Trident Twin-TowerPSA Oxygen
Generator adjusted to your individual need.

Applications:

Fish Forming

• Fish production can be increased as long as sufficientoxygen, fresh water and food are provided.
• Rise in stock density by maintaining a higher level ofDissolved Oxygen.
• Preventing ice formation during winters.
• Increase in the oxygen content as compared to atypical air-fed aerating system.
• Uniform Dissolved Oxygen levels throughout

Sewage Treatment
In the biological treatment of waste-water, the useof oxygen instead of air permits increased capacity in existing
treatment plants. Injecting oxygen into sewers reduces hydrogen sulfide formation, which results in reduced
corrosion and odor.

Welding, Brazing and cutting

Oxygen is used with fuel gases in gas welding, gas cutting, oxygen scarfing, flame cleaning, flame hardening, and
flame straightening. In gas cutting, the oxygen must be of high quality to ensure a high cutting speed and a clean
cut.

Pulp and Paper

Oxygen is increasingly important as a bleaching chemical. In the manufacture of high-quality bleached pulp, the
lignin in the pulp must be removed in a bleaching process. Chlorine has been used for this purpose but new
processes using oxygen reduce water pollution. Oxygen plus caustic soda can replace hypochlorite and chlorine
dioxide in the bleachingprocess, resulting in lower costs.

In a chemical pulp mill, oxygen added to the combustion air increases the production capacity of the soda
recovery boiler and the lime re-burning kiln. The use of oxygen in black liquor oxidation reduces the discharge of
sulfur pollutants into the atmosphere.

Medical

In medicine, oxygen is used during surgery, intensive care treatment, inhalation therapy, etc. High standards of
purity and handling must be maintained. Oxygen is typically supplied to hospitals though bulk liquid deliveries,
then distributed to usagepoints. It assists with respiratory problems, saving lives and increasing patient comfort.
Larger scale units using which also use non- cryogenic air separation technology are being utilized in small

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and/or remote hospitals where demand is high enough to make cylinder deliveries a logistical problem but
where liquid deliveries are unavailable or very costly. These units typically producing 90 to 93% purity oxygen,
which is adequate for most medical uses.

Miscellaneous Uses:
• Oxygen has many uses in breathing apparatus, such as those for underwaterwork and refinery and
chemical plant self-contained breathing apparatus.
• Liquid oxygen is used in liquid-fueled rockets as the oxidizer for fuels such ashydrogen and liquid methane.
• Metal Spraying
• Bead Making, Lamp Working, Glass Blowing
• Mining & Gold Processing
• Battery Manufacturing
• Cement And Lime Kilns
• Melting
• Chemical Oxidation Fermentation

The whole internship was in general a Project Management Internship which consisted almost every of the
management features we have learnt. The main concept was based on Operations and Supply Chain Management
that included the product selection and logistics, in addition to which the optimize use and best possible analytics
of our project with the competitor‘s similar project could be made.

Concepts considered during the whole course.

Pre-process and Post-process

While one is considered as the part of the pre-process, product development comes under the part of post-
processing. Product selection is done on the basis of various criterions and hence the decision is influenced through
such factors, whereas Product development takes place once the product is already been selected and is in the
market. Product development mostly focus on the various approaches to improve the quality of the product,
enhance and increase the effectiveness, leading to improvement ad more sales for the business

Research and Development

Of course, product selection requires research, market surveys, and trial and error method but Product
development requires extensive research and various processing. The definition of product development is to
enhance and evolve the product further, which is why the Research and development would be on a larger scale for
Product development, compared to Product selection.
Let’s take an example here, for a car brand owner, selecting the model, the logo, the design and product comes
under Product selection but improving the model, changing the design and evolving the product into a different and
enhanced version comes under the scope of Product development.

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Expectations and Results

It is not possible to judge or expect the results or outcome of your business just by selecting the right product. The
demand of a consumer keeps on changing, with the changing seasons, and hence there always lies a possibility of
failure. However, under the concept of product development and the processing, you have some results from the
trial and error method and can predict the expectations of your consumer or the target audience.

Product selection and designing

Have you ever looked at a blueprint of a building before it is built? Architects entrust their plan, their vision into a
single piece of paper, which they call a blueprint and the then structure is built with necessary resources, process
and development. Similarly, selecting a product is a blueprint, designing and developing the product, processing it
through various resources and methods is a part of building a structure brick by brick for every business.

Fig.1: Phases of the project

Expertise

Selecting a product by considering the various criterions available just requires vision and understanding about the
future of your business, however, the product development part includes various technical and complex processing
which requires professional expertise, every step of the way. As we looked at the earlier point, the designing is
done, brick by brick and hence the area and the level of expertise differ at each part.

Significance

Now the term significance here does not mean the difference in the level of importance between Product selection
and development. Rather, it means the level of significance it holds on the final result, that is the profit. Planning
about a product is one thing, but the significance or the key is in product development or the designing, most of the
time it does not match with the expected results derived from product designing.

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Time & Money invested

A business is launched once the product is at its end-stage or in the finished process. However, most of the time and
even the investment is not spent on selecting a product but on the development of the product. This explains to us
how much should we emphasize in each of the categories. Product development would require a lot of time
and a lot of money to be invested while indulging in the processing. As any particular development process can help
evolve or enhance your product and increase your sales.
To make sure there are healthy and well maintained operation strategies, I focused upon:
• Planning: I at every stage constantly worked to forecast, plan, and adjust to optimize processes based on
conditions.
• Process: Production of goods or services requires having strong, repeatable processes.
• Efficiency: I had to regularly maintain troubleshoot bottlenecks, inadequate resources, and downtimes to
create optimal efficiency.
• Cost Control: Production is typically a major part of a company’s cost structure, and I worked to manage it
wisely.
• Quality: Good quality control is necessary to maintain customer satisfaction and the company’s reputation.
Companies can greatly suffer without it.
• Continuous Improvement: To remain competitive, I had the vision that company for this project need to have
processes in place to consistently seek better ways of doing things.
• Technology: Underlying all of these foundations is technology. Well-used technology helped keeping the
company ahead of the curve.
• Profitability: Executed properly, all of the above foundations lead to a strong bottom line.

To estimate the cost of the project:

A cost estimate is a summation of all the costs involved in successfully finishing a project, from inception to
completion (project duration). These project costs can be categorized in a number of ways and levels of detail, but
the simplest classification divides costs into two main categories: direct costs and indirect costs.
• Direct costs are broadly classified as those directly associated with a single area (such as a department or
a project). In project management, direct costs are expenses billed exclusively to a specific project. They
can include project team wages, the costs of resources to produce physical products, fuel for equipment,
and money spent to address any project-specific risks.
• Indirect costs, on the other hand, cannot be associated with a specific cost center and are instead incurred
by a number of projects simultaneously, sometimes in varying amounts. In project management, quality
control, security costs, and utilities are usually classified as indirect costs since they are shared across a
number of projects and are not directly billable to any one project.

A cost estimate is more than a simple list of costs, however: it also outlines the assumptions underlying each cost.
These assumptions (along with estimates of cost accuracy) are compiled into a report called the basis of estimate,

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which also details cost exclusions and inclusions. The basis of estimate report allows project stakeholders to
interpret project costs and to understand how and where actual costs might differ from approximated costs.
Beyond the broad classifications of direct and indirect costs, project expenses fall into more specific categories.

Common types of expenses include:

• Labor: The cost of human effort expended towards project objectives.
• Materials: The cost of resources needed to create products.
• Equipment: The cost of buying and maintaining equipment used in project work.
• Services: The cost of external work that a company seeks for any given project (vendors, contractors, etc.).
• Software: Non-physical computer resources.
• Hardware: Physical computer resources.
• Facilities: The cost of renting or using specialized equipment, services, or locations.
• Contingency costs: Costs added to the project budget to address specific risks.

Project Working Principle:

Oxygen PSA process can be described with following steps.

The PSA process starts as clean and dry compressed air enters the first cylinder (left). The
unwanted gas is adsorbed by the pellets at high pressure, but the molecules you want pass
through the sieves. The resulting high-purity gas is stored in the buffer tank.

Compression, drying and filtering of input air:

The ambient air is compressed by an air compressor. Before entering the PSA process the compressed air
is dried and filtered.

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 Fig. 2: A generalised view of the whole system

Oxygen adsorption on ZMS bed:

Our PSA units have two cylinders filled with Zeolite Molecular Sieve (ZMS). Compressed and
purified air is conducted to one of these cylinders. As the air flows through the cylinder, the
Zeolite bed adsorbs nitrogen, while oxygen passes through to the oxygen accumulation tank.
The adsorption process is interrupted before the ZMS becomes saturated with nitrogen by
diverting the input air to the secondcylinder, which at this point starts producing oxygen.
During this step of the cycle, the second cylinder (right) iscleaned.

Fig. 3: Adsorption Process

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Next, the pressure between the two cylinders is equalized.

Fig. 4: Equilisation Process

Nitrogen desorption and Zeolite bed regeneration:

The ZMS of the first cylinder (now saturated with nitrogen) is regenerated by reducing
pressure in the cylinder below that of the adsorption step. The adsorbed nitrogen is released
and vented into atmosphere. The regenerated adsorbent is then purged with oxygen from the
second cylinder. After this step it is again ready for another cycle.

Fig. 5: Regeneration Process

Oxygen accumulation in storage tank:

Adsorption and desorption steps are repeated in the Zeolite tanks at equal time intervals. A
constant flow of oxygen is conducted to oxygen storage tank, which can store the oxygen to
pressures up to 5-6 bars. The oxygen purities reached with our systems are 93 ± 3%.

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The technical specifications for the PSA Oxygen Plant are:

Fig. 6: Technical Specification Table 1

17
 Fig. 7: Technical Specification Table 2

Note: Due to company policies, images are placed instead of editable content.

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Since, the technical specifications together with the main technique upon which the project
works, we come to the point where all the products description as per their utilization in the
project is given below:

Adsorbent Towers
Mayo’s PSA oxygen plant has 2 adsorber towers and which contains the Zeolite Molecular Sieves along with
Activated alumina. This mixed desiccant bed adsorbs nitrogen, and concentrates oxygen from the air during
drying cycle. Pressure gauges are fitted on these towers to indicate the tower pressure and there is provision
for refilling the desiccant.

Air dryer
Moisture in compressed air used in oxygen plant causes problems in the operation of the desiccant beds as
well as solenoid valves and can adversely affect the process and product being manufactured. In order to avoid
the above said problem and to supply the dry air an air dryer is required in this plant. We used Ingersoll Rand’s
refrigeration dryer eliminates any water vapor remaining in the compressed air coming at the outlet of the
compressor house. The dryers have been designed for nominal standard inlet conditions as per ISO 7183 in
order to obtain a dew point under pressure of +3oC to +7oC.

Air receiver
Air receiver is connected in between the Air dryer and Adsorbent towers. This air receiver acts as an
accumulator and the air supplied to this receiver must be dry air.

Fine filter
This filter avoids dust, dirt, foreign materials and moisture before entering into the molecular sieves bed and
damaging the working. Trident make fine-filter (1micron) is used in this plant.

Carbon filter
This filter is used to remove oil and hydrocarbon vapor from the compressed air stream before get into the
desiccant bed. Trident make carbon filter (0.01micron) is used in this plant.

After filter
This filter avoids the desiccant particles from the adsorbent towers coming with the oxygen after production.
Trident make fine-filter (1micron) is used in this plant.

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Inlet feed air solenoid pilot valves
This valves allows the inlet feed air between the two adsorbent towers during drying phase. Controls signals
for valve operation is taken from the control panel and the pilot air required for this valve is taken from the air
receiver.

Electronic control valve

These valves open for a period of when the absorber is pressurized to deliver oxygen to the oxygen receiver for
use.

Mufflers
Mufflers are used for reducing the amount of noise emitted by the exhaust of the waste gases coming out from
the adsorbent towers during regeneration phase.

Electronic auto drain valves

Electronic auto drain valve (EDV) automatically removes condensate from the filters.

Pressure equalization valve

After pressurization cycle on one of the absorbers, the purge valve will open for a period and pressure
equalization between the adsorber towers will take place.

Pressure regulators
The air pressure regulator controls the inlet air pressure before entering into the adsorber tower in the inlet
side and control the delivery oxygen pressure at delivery side.

Pressure gauges
These gauges indicates the air pressure inside the adsorbent towers and receiver.

Non return valves

These valves prevents the back flow of oxygen into the adsorbent towers.

Oxygen sensor
This sensor is used to indicate the product purity in terms of %of oxygen from the oxygen generator.

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Ball valves
These valves are used to open and shut off the inlet and product outlet from the receivers based on the
requirement.

Exhaust solenoid pilot valves

This valves allows the waste air from the two adsorbent towers during regenerating phase. Controls signals for
the valve operation is taken from the control panel and the pilot air required for this valve is taken from the air
receiver.

PLC Control panel

The PLC (Programmable Logic Controller) process the inputs and outputs ) to and fromthe system components
and communicates with the touch screen.

Pressure relief valve

This valve is in place to ensure that the pressure in the vessels does not exceed safe system working pressure.
It will only open in the event of a serious malfunction. It is fitted in all vessels.

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Considering the operations and supply chain management concept, we looked towards variety
of suppliers regarding the product requirement we needed, and as per a detailed comparison,
we selected the best possible product range with price as minimal as possible which could help
us bring the optimal final results. Below is the comparison graphs of the 4 suppliers we
selected out of which we selected the final ones:

Fig. 8: Comparison Analysis of Products 1

Fig. 9: Comparison Analysis of Products 2

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Fig. 10: Comparison Analysis of Products 3

Fig. 11: Comparison Analysis of Products 4

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Description of Processing of Plant

The oxygen generator works on the PSA system as stated above. The mixed bed desiccant
adsorbs moisture and Nitrogen from the compressed air for generating the oxygen. For
proper removal of moisture and Nitrogen from the wet air regeneration of the desiccant is
required. Regeneration is achieved by means of allowing a part of the the oxygen from the
supply outlet.

Cycle of Operations:
The oxygen generator works based on the following phases,
➔ Drying
➔ Pressure Equalization
➔ Depressurization
➔ Regeneration
➔ Re-pressurization

Drying cycle
The compressed wet air flows through the pre filter. The water particles get filtered by the
filter. The filtered air flows in to the adsorber tower filled with activated alumina where it
loses all the moisture to the alumina. Purified (Moisture and oil free) air further passing
through the Molecular Sieves (Zeolite type). The sieves selectively adsorb nitrogen, allowing
oxygen to pass through at the desired purity level.

Pressure Equalization cycle

At the end of drying cycle the second adsorber tower is ready for the next drying cycle so in
order to re-pressurize the tower to drying pressure by means of inlet air it take so much
time to save that energy the air in the tower 1 is fed in to the second tower and the
pressures are equalized.

Depressurization
After drying for the preset cycle time, the desiccant bed will be saturated with moisture and
nitrogen. For successful removal of moisture and nitrogen in the next cycle, this moisture
and nitrogen is to be removed from the desiccant. This removal of moisture cycle starts with
depressurization. In this cycle air inside the tower is vent out by the depressurization valve.
The pressure is expanded to atmospheric pressure. The sudden depressurization brings out
nitrogen molecules trapped in the sieves pores to the surface of the beads

Regeneration Cycle
In order to remove the moisture and nitrogen during regeneration cycle. Small portion of
oxygen from the drying tower is passes over the sieves through the regeneration orifice.
This results in complete regeneration of Molecular Sieves and ready for the next cycle.

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Re-pressurization cycle
At the end of drying cycle the second adsorber tower is ready for the next drying cycle so re-
pressurization of the tower2 to drying pressure is necessary this is achieved by allowing
the inlet feed air to the adsobent tower.

WORKING

✗ Wet dirt atmospheric air is compressed in the compressor.

✗ The air coming from the compressor is first fed into the inlet Pre-Filter, here the
impurities present itself and water particles are removed.
✗ After that in order to remove the water vapor present in the air it is allowed to flow
through the refrigerant air dryer, where 2 to 7 deg C, pressure dew point is
achieved.
✗ This dry air is stored in the air receiver under pressure.
✗ On the first cycle drying phase dry air is allowed to adsorbent tower by means of
inlet valve through the fine filter and carbon filter, Where the foreign materials and
carbon particles are removed from the air.
✗ The compressed dry air flowing through mixed bed tower 1 is selectively adsorbs
the nitrogen and delivers the oxygen enriched air to the oxygen receiver.
✗ Where the oxygen is stored under pressure.
✗ At this time the tower-2 is in regeneration phase.
✗ A small portion of the oxygen enriched air is expanded to near atmospheric pressure
by passing through the purge orifice. Expansion of this oxygen gas to near- atmospheric
pressure increases the ability of the purge air to strip the previously adsorbed
nitrogen from desiccant bed in tower- 2. The absorbed gases exhauststhrough the
opened two-way purge valve.
✗ From the oxygen receiver the oxygen is taken to the user end through the after
filterand bacterial filter.

The automatic cycling of the adsorption and desorption between the two beds enablesthe
continuous production of oxygen.

A failure alarm system is also included in the project which will start working if the following
conditions are observed:
• The oxygen purity is rated below the required purity level.
• The pressure in any of the vessels is rated below the working pressure.

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Above all contains the working principles and terminologies upon which the project is made.
Now, below is mentioned all the phases that made the completion of the project successful.

The project consists of 5 phases which are already mentioned below:

1. The Ideation phase

2. Screening Phase
3. Design
4. Test
5. Launch

The Ideation Phase: This was the period when all the possible ideas that could be applied in the project by
observing the already set similar projects and possible future advancements as theory in the project were
gathered. To get more help, I even visited various similar plant manufactures and asked them what they were
thinking about the new advancements that could be included in the plant. Gathering all the inputs from my
research and their end a list of possibilities were made which was then going to be thoroughly screened in the
next phase. A generalized design was also made during the time of idea gathering.
Here is a design that was made as the base of whole project:

Fig. 12: A detailed view of system

The Screening Phase: During this, all the ideas that were gathered earlier were brought together on one table
and were thoroughly checked by making which combinations were better and which were not and on this basis
we refrained from selecting any wrong combination. During this phase only we prepared the requirement sheet
and as per that which products were required for pre-process and which were post-process were bifurcated. The
whole market analysis for the final stage selling purpose together with logistical and financial support decisions
were made during this phase. An estimated project cost was also made during this period as per the budget
allocated by the company authorities.

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As a project head, I divided which products were needed to be manufactured by the company and which were
needed to be purchased from the market were decided and upon this, the design phase was initiated. The
products that were to be manufactured are:
1. Air Receiver
2. PSA Tanks
3. Storage Tank
4. Vent Silencer
5. Junction Box
6. Flanges for Tanks
7. Lifting Hook
8. Balances
9. Frame
The products that were meant to be purchased are:
1. Flanges for connection with Tanks
2. SS Pipes
3. Valves
4. Nuts
5. Bolts
6. Washers
7. Connectors
8. Couplings
9. Rotameter
10. Panel Board
11. Glasswool
12. Hose Pipe
13. Air Compressor
14. Air Dryer
15. Filters
16. Teflon Tape
17. Teflon Gasket
18. Bends, etc.

The Design Phase: In this particular phase, checking all the Indian and American Standards which help in
checking the corrosive nature along with decay period and other technical requirements (mentioned above), the
design for everything[designs in appendix] to be manufactured were made. As per the per-hour capacity of the
generator, the tank capacity along with the thickness were jotted into design software and drawn and finished by
the technician.

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As the manufacturing started, the purchase order was made for all the requirements that were to be purchased
from the market at minimum cost. The test certificates along with proper bills payment procedures were made
sure to be available at time of order receiving. The circuit diagram of the panel board was also finalised during
this. At last in the design phase, when all the technicalities were finalised by the company authorities along with
manufacturing, the lookout for Zeolite Molecular Sieves were taken into consideration.

After the designs were finalised and the manufacturing began with the purchased materials received at our end,
manufactured and purchased products were initiated to assemble as a whole. The whole plant was manufactured,
assembled and tested within 30 days after the whole design and procurement of materials of the project which
was around 25 to 30 days. Thus, the initial 1st month of the project included the Ideation and Screening Phase.
The next month consisted of the Design Phase. The current project status is under the Testing Phase.

The Test Phase: As the products are getting assembled, the testing of the whole unit needs to start. So, in the
terminal period of the internship the PSA tanks were filled with Zeolite and the whole system test run was
initialized. Approximately of 7 to 8 tests are to be made out of which 2 tests are made successful. The whole
mindset of the test phase is to achieve the desired purity. This test certificate which will be arrived after the 3rd
party test will be used in the marketing of the whole plant by the company’s marketing unit. In the meantime, the
marketing unit has begun their work in which they are currently looking forward to making a list of all potential
clients in accordance with the ongoing Govt. Tenders in this field. Brochures along with presentations will be
made, so that at times of conferences, the company officials could use it in their talk.

The Launch Phase: This is the phase which will include launching of the plant under the banner of Mayo Vessels
& Machines Pvt. Ltd. Together with it, the PSA Oxygen Generator will be out for sale and as per the client’s
requirements and needs further modifications will be done.

Costing of the Project:

Table 1: Average Man Hour Costing

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Table 2: Labor Cost of Equipment

Table 3: Material Cost

Table 4: Consumable Cost

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 Table 5: Total Project Cost

The risks that could have occurred:

• Goal of this section is to predict profit if the scenario occurs that less consumers purchase the
product.

• Consumer utility maximization could have predicted wrong.

• Copycats may enter market or oxygen prices may drop limiting market.

Conclusions:

1. It is now possible to deliver 95% pure oxygen to patients in a hospital, and to those who want
to enjoy a life without the restriction of bulky liquid oxygen bottles.

2. This technology would change the lives of millions of patients and those needing oxygen
around the world for years to come.

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Appendix:

Fig. 13: Air Receiver Design finalised

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Fig. 14: Vent Silencer design

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Fig. 15: The Valve Connection Design with modifications from normal structure

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Fig. 16: PSA Tank design

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Fig. 17: The complete system design by the company

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Fig. 18: Storage Vessel Design

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