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Mellcon Engineers Private Limited

New Delhi, Delhi

| GST  07AAACM2229E1ZX

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Mellcon Engineers Pvt. Ltd. is a closely held company. It has its head office in Okhla Industrial Area Phase - I, New Delhi. manufacturing a Wide range of AIR DRYERS , GAS DRYERS , moisture removal and control equipments including Refrigerated Dryers, Air / Gas Dryers, CNG Gas Dryers a range of Water Chillers and Chilling Machines Liquid carbon dioxide storage Tanks .Okhla Industrial Area is the premier Industrial Location in Delhi infrastructural well served and with good communication facilities attached. The company is professionally managed and the Chief Executive is assisted by top level professionals. The company lays maximum emphasis on consistent high quality for its products and has a well laid out quality systems with back-up of a well trained work force to ensure quality. The company has an active R & D programme to improve further the Quality of present products and develop new products. In fact all the present products of the company are the result of in-house R & D efforts. DESIGN FACILITIES
All the design facilities are available in-house. The hardware consists of a bank of computers with associated peripherals connected in LAN with internet, with own in-house developed design software and is personally looked after by the company CEO. The design group has access to a well equipped library. MANUFACTURING FACILITIES
The works has adequate handling facilities for receiving incoming materials including plate material and for stacking them. Required equipment for material preparation manipulation and fabrication are also available. QUALITY ASSURANCE AND CONTROL
The company lays maximum emphasis on quality and has a well laid out quality system with complete traceability. Quality is everybody's responsibility and specifically that of the QA department which functions independently under quality Assurance Manager who directly reports to the Managing Director. INSPECTION AND TESTING
Welding being the major fabrication process, is paid special attention. Welding procedure specifications are available for all materials and combinations in various thicknesses and the procedure / welders are properly qualified under 3rd party inspections. These record are available for client perusal. ACCEPTANCE
MEPL Products have found wide acceptance in Industry and also approved by Major consultants and Public Sector Organization Like EIL , NTPC. BHEL. JCE. DALAL, IOCL, BPCL ETC. The Company has also been certified as an ISO 9001-2000 compliant by BSI.
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Nature of Business

Manufacturer

Total Number of Employees

101 to 500 People

Year of Establishment

1985

Legal Status of Firm

Limited Company (Ltd./Pvt.Ltd.)

Annual Turnover

Rs. 10 - 25 Crore

GST Number

07AAACM2229E1ZX

PSA Nitrogen Gas Generators
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PSA Nitrogen (N2) Gas Generator plant is an Inertisation Gas Atmosphere Generator ... enabling a permanent source of onsite NITROGEN Gas , with minimum energy consumption. PSA Nitrogen ( N2 ) Gas Generator Equipment is an Inert Gas Atmosphere Generator &  incorporates Two sets of columns filled with Carbon Molecular Sieves CMS. Under Pressure these columns retain all Active Molecules compounds present in air like (Oxygen, Carbon Dioxide and Water) with the exception of the inert gases like Nitrogen & Argon.. The N2 Gas can be produced onsite for direct use or can be stored in Nitrogen storage tanks / Cylinders  for intermittent use.
( Nitrogen and Argon ). This process is referred as PSA ( Pressure Swing Adsorption ).

Mellcon is the world leader in gas separation technology, providing on-site, non-cryogenic Industrial Nitrogen Gas Generators and Oxygen Gas Generation Systems . Mellcon  Offers NITROLINE a  line of robust, reliable and modular Nitrogen Gas  generators, based on Pressure Swing Adsorption (PSA) technology incorporating state-of-the-art Carbon Molecular Sieves (CMS) Adsorbents to deliver dry Dry Nitrogen Gas (N2) onsite..

Mellcon Engineers Manufactures PSA Nitrogen Gas Generators (Inert Gas) which produce high purity Nitrogen from compressed air, allowing continuous availability at a very competitive cost, compared to alternative supply with Nitrogen Gas cylinders or cryogenic Liquid N2 Storage  tank. Each Nitrogen system can be equipped with a Nitrogen Gas Analyser to monitor the purity of of N2 Gas continuously.

NITROGEN N2 Gas Generator plant  eliminates all disadvantages associated to the purchase and operation costs of high- pressure N2 cylinder systems or cryogenic nitrogen gas storage  tanks, enabling a permanent source of onsite NITROGEN, with minimum energy consumption and maintenance requirements. PSA NITROGEN Gas Plant  is designed to be easily installed in any indoor facility. requiring only a compressed air line and a power connection.

With purities up to 99.9999% of N2, NITROGEN Gas can be connected to an external buffer allowing a reserve or a delay of production/consumption in accordance to the needs of each application.

Standard system design
  Automatic Pressure control
  Automatic Flow control
  Automatic Purity control
  Alarms available for visual, audible or output contacts

 Custom designed systems to meet customer requirements
   Integrated Compressor packages
   Redundant components for service
   Receiver tank integration
   High pressure systems
   Customer special control systems
   System integration to customer component

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Inertization System For Cement industry
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Inertization of Coal Mill, Silos & Bag Filters in the Cement Industry

For inertization applications in various industries, traditionally many have opted for fuel based inert gas systems. While this technology was dominant in the past, it has very quickly been replaced by the cleaner, cost effective and much more efficient Nitrogen systems.

So, we look at the two systems and provide a comparison of their features.

Characteristic

PSA Nitrogen Generator

Fuel based Inert gas Generator

Start up time

Start Up Time is Only 5 Minutes

It Takes Arround 30 minutes for heat up of refractory and stablizing the gas composition

Operation

It is fully automatic and does not require any operator.

This require Continuous attention and monitering of different parameters to correct combustion conditions and to get soot free combustion

Cost of Operation

For 150 nm3/hr capacity plant running cost is only Rs.350 /- per hour.

For 150 nm3/hr capacity plant running cost is arround 1000 /- per hour. due to high cost of kerosene / Diesel fuel.

Inertization quality

Density of Nitrogen Gas is same as that of Co2 + N2 inert gas.

It gives no better Inertization as Co2 + N2 gas density is more or less same as of N2 Gas.

Gas Composition

As Nitrogen is Generated from atmospheric air,it is free from Co,Co2,hydrogen and Other hydrocarbons.

As this is a combustion process, inert gas contains CO and other hydro carbons which are not desirable in inert gas.

Dew Point/Dryness

Nitrogen Gas is very dry and the dew point is (-) 40 degree C.

Inert gas is moist, so there is always moisture condensation in the pipeline and water droplets reach the consumption points giving problems.

Life of equipments

Life of equipment is arround 15 - year. No corrosion takes place.

Due to sulfur present in kerosene / diesel fuel,equipment of inert gas generator get corroded fast. Life of Equipments is generally 5 to 7 Years Only.

List of Components

Nitrogen Generator is maintenance free. Life of carbon molecular sieve is around 10 years.So maintenence cost is negligible.It is a lifelong lasting equipment.

Combustion based inert gas has corrosive So2 gas, water droplets and soot particles, Thease give more wear and tear and of gas compressor internal valves and maintenence is frequent and expensive.

 

 

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Membrane Nitrogen Generators
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Standart membrane nitrogen production system consists of four main parts. Air compressor, air treatment, air seperation and nitrogen control system.

 

Air compressor

Air is the raw material of the nitrogen generator. Air compressor pressurize the air absorbed from the atmosphere to the ideal pressure and supply it to the nitrogen generator. Oil injected screw compressors or oil free compressors are convenient type of air compressors.

 

Air treatment

Quality of compressed air is essential in

preserving the performance of membrane nitrogen generators. Water, oil, dust particals and steam of water and oil must be kept away from air

treatment system. Nitron nitrogen generators include basic air treatment within the skid.

 

Air seperation system

 

 

Compressed   air        which   passed            through            air treatment system reaches to air seperation system and  at this stage nitrogen and air are seperated from   each   other.   In   membrane-type   nitrogen generators, air seperation process works in such a

principle where oxygen molecules skip from the membrane surface and nitrogen molecules stay in the membrane inner surface.

Membrane is a polimar material produced in the form of hollow fiber and in parallel modules.

 

Nitrogen control system

Purity of the nitrogen produced in the air seperation system can be adjusted according to the application field.

 

Oxygen in the product nitrogen is continiously measured. If oxygen concentration in product gas is higher then preset value, product valve is automatically closed and off-spec valve open till product purity is reached to preset value. In critical applications, off-spec / product valve system is very important for quality assurance.

 

 

 

Adjustable product purity option can be added if different product purity is required. In that case operators will be able to set maximum oxygen concentration in product line. In those plants higher producy purity can be achived by lower product flowrate which is the general rule of nitrogen generators.

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Heatless Compressed Air Dryer
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Mellcon Engineers are the manufacturers of complete range of Heatless Compressed Air Dryer system (drier) and gas dryer system,These Compressed gas and air dryers (driers) find use in majority of Industrial compressed air system and applications. These air and gas dryer (drier) are also offered for High Pressure gas and air drying system and applications. Following is a brief description of the working of these compressed air dryer and gas dryer systems.. A Heatless compressed air dryer (drier) is the simplest form of dessicant type gas or air dryer (drier) for achieving a dew point of -40C for compressed air systems and other gas and air dryer (drier) applications . Process- Wet incoming Compressed air after passing through prefilter passes through the slide piston valve assembly and is directed towards chamber I where the compressed air passes upward through the desiccant bed (Activated Alumina or Molecular Sieves ). Compressed Air drying takes place by adsorption. Dry Compressed air from chamber I then passes through the Check valve assembly and then through the after-filter to the application or work area. While Compressed air is drying in chamber I the dessiccant in chamber II where the desiccant has been wetted in the previous cycle is being simultaneously regenerated. The chamber II is depressurised to atmosphere through the purge valve in the downward direction. A portion of the dry compressed air passes through the needle valve / orifice plate through the desiccant and flushes out the desorbed moisture. When the regeneration is complete, the purge valve is closed and the tower is slowly repressurised to line pressure for a smooth changeover. A drying period of 5 minutes provides an efficient dew point of -40C or better (at atmospheric pressure ). In regeneration process approximately 60 seconds are required for repressurisation.

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Refrigerated  Air Dryer
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Refrigerated Air Dryer

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A refrigerated air dryer is the most commonly used. type of compressed air dryer / Gas Dryer for most plant applications for the drying of plant air and other utility gases like Seal gas , hydrogen gas for generator cooling , nitrogen Gas drying etc. where a dew point of (+2) Deg. C. at line pressure i.e. (-22 )Deg. C. at atmospheric pressure) is an acceptable norm. This Type of dryer finds application in Fly ash conveying , Seal gas Drying . General plant air , hydrogen gas dryer used in generator cooling application & Pneumatic tools operation. As much as 2300 gallons of moisture can be removed from a100 cfm pneumatic system operating at 100 psi in 12 months of 3 shift operation, moisture which without a refrigerant air dryer, would have passed through the delicate pneumatic equipments & instruments FEATURES OF REFRIGERATED AIR DRYER A full range of aircooled as well as water cooled refrigerant air dryers are available for moisture removal & to provide dry clean air to any size and type of compressed air & pneumatic systems ENERGY EFFICIENT HEAT EXCHANGER Power consumption reduced by upto 10% over conventional refrigerated dryer system. ADVANCED DESIGN Moisture Dirt and oil contamination is removed by either impaction or integral filtration-ensures maximum protection for pneumatic compressed air equipment at all times CONTAMINANT REMOVAL DOWN TO 1 MICRON Minimal additional filtration is required after the refrigerated dryer for most applications. TRIED AND TESTED CONTROL SYSTEM Ensures maximum reliability of the refrigerated air dryer at all times. DEW POINT INDICATOR (AT LINE PR.) At - a - glance monitoring of dryer performance thru an online digital dew point temperature indicator. LOW NOISE LEVELS- 60 DB (A) Suitable for location in indoor working environment Wet Compressed air undermines efficiency of smallest to the largest pneumatic system. Therefore, moisture removal in compressed air system installation is a must.

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Internal Heater Dryer
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Internal Heater Dryer

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This dryer provides an efficient, economical and easy to maintain method of drying compressed air and gases. The drying medium (Silica gel or Activated Alumina ) is contained in two carbon steel pressure vessels. While chamber I is drying, air is passed over an electrical heater embedded in chamber II and carries out the desorbed moisture of this chamber. This type of system utilizes about 2-3% of the gas as a purge. It is an ideal system for gases requiring ultra low drying like dew points upto (-80C). Each column remains in line for about 6 hours. For regeneration, the desiccant is heated for about 3 hours and then cooled for another 3 hours before changeover. The operation is fully automatic.

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Heat of Compression Air Dryer
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Energy Conservation by Heat of Compression type compressed air dryer is a breakthrough in compressed air drying technology. The hot air from the oil-free air Compressor at 120C or higher temp, is used directly for regeneration of the desiccant bed in the compressed air dryer. After regeneration, this air is cooled down to 40C in the water cooled after cooler and then it is dried in second tower. Thus the use of heaters is eliminated. For eg. in the 6 + 6 Hrs. Cycle the hot air is fed for regeneration of desiccant bed for 4 Hrs. and for balance 2 Hr. a changeover takes place where the air is first cooled in an after cooler, then dried and before going to the outlet, cools the regenerated desiccant bed, thus bringing it down to ambient temperature. This cycle is reversed for the next 6 Hrs. where the Adsorber drying the air in the previous cycle goes for regeneration and vice versa. There is considerable power saving in these type of Compressed Air Dryers and the dew point is also better than the Refrigerated type of Compressed Air Dryers . Main Advantage of Heat of Compression Type Compressed air dryer is the energy conservation and heat recovery achieved which is being wasted in After cooler in the conventional air dryers is now used to reactivate the desiccant.

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High Pressure Air-Gas Dryer
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MELLCON High Pressure Air / Gas are available in operating pressure ranges i.e. 60 Bar g (900 psig) to 400 Bar g 6000 psig) and in flows ranging. from 50 to 500 M3 per hour (30 to 300 SCFM) for compressed air and process gases. The unique high pressure design provides unparalleled reliability, easy maintenance and safety from dangerous high pressure leaks. Integrated pre-filter and after filters with differential pressure gauges and manual drains are provided as standard equipment making installation an easy and quick job. Suitable controls for offshore or hazardous duty applications are available upon request. Activated Carbon Filters are also incorporated to remove Oil vapors upto 99.99 percent efficiency. An optional Dew Point meter can also be offered as an integral Unit. For various industrial applications where air / gas at high pressure in dry form is required, Mellcon offers High Pressure Air / Gas Dryers. It is suitable for such application and is one of the best choice. High Pressure Air / Gas Dryers are mainly used in Marine & Defense applications. Some of the other High Pressure industrial applications are. :- Air Circuit Breakers High Pressure Generator Starting High Pressure Air for Aircraft Engine Starting Scuba diving and breathing air applications High Pressure Gas Filling High Pressure H2 for Turbine cooling High Pressure Testing High Pressure Process Gas Applications etc. SPECIAL FEATURES Fully Automatic and Ready to Install Outlet Dew Point upto (-) 80 deg. C or better Operating voltage - 24 V - 220 V AC / DC Operating Pressure Up to 400 Bar g. For cost comparison of operating of a Heat of Compression Type Air Dryers Vs. Heated Type/Heatless/Refrigerated Type Air Dryers please click here.

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Dew Point
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Dew Point

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Mellcon dew Point Apparatus is the most economical, simple, errorless system for the spot checking of Dew Point temperature of any compressed Air / Gases. This consists of a closed cylindrical glass with two chrome Plated tubes, a low range thermometer (-50+40 Deg.C) and a dry Ice Maker. Air / Gas enters to cylindrical glass through one chrome Plated tube and Exhausts. The other chrome plated tube is centrally placed in the cylindrical glass and thermometer is placed in it. Make dry ice (Solid C02 ) with the help of dry ice maker & a CO2 Gas cylinder. Pour some ether / acetone in the chrome plated tube having thermometer, And slowly put dry ice pieces into this liquid to reduce the wall temperature of the chrome plated tube. At a particular temperature the dew / frost will start forming on the walls of the tube and the same temperature can be noted from the thermometer. This is the dew Point temperature of that particular Air / Gas.

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Auto Drain Trap
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Auto Drain Trap

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Mellcon Auto Drains are most economical, simple & maintenance free systems. The compressed Air / Gas contains Inherent moisture which will condense in receiver tanks, filters and pipelines, which requires regular draining systems. Auto Drains are available in two options namely: 1) ELECTRONIC TIMER DRAIN. 2) LEVEL BASED ZERO LOSS CONDENSATE DRAIN Electronic Timer Based Auto Drain Traps ( Model No: ACDT - 6 ) Mellcon Auto Drain Trap Model ACDT - 6 is 2/2 way pilot operated. Fully automatic, Maintenance free, easy to install and suitable to drain condensate from compressed air system like Dryer, Receiver, Moisture Separator etc.

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Water Cooled Afer Cooler
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Water Cooled Afer Cooler

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Mellcon compressed air aftercoolers are high performance shell and tube heat exchangers coolers connected to a moisture separator and a drain trap. All after coolers are individually stage wise inspected as per IS-2825/ASME/TEMA standards. The tubes used are high quality copper / cupro nickel/SS/ carbon steel as per user's requirement. All flanges and tube sheets conform to ANSI B 16.5 standards. The capacity of the after coolers are ranging from 10 CFM to 10,000 CFM working pressure up to 150 kg/cm (g) which will be ready for installation with air/gas inlet/outlets and water inlet/outlet nozzles.

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Split Flow-No Purge Loss Dryer
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The wet Air / Gas stream is split at the air dryer inlet through a differential distributor valve. Part of this air / gas stream is passed through an external heater and heated to a regeneration temperature of 160-180C, then it is fed to the Adsorber desiccant tower A containing Silica gel or activated Alumina / Molecular Sieves under regeneration thus removing out the moisture from the desiccant bed. A water cooled / air cooled aftercooler condenses the desorbed moisture which is discharged regularly through the automatic drain trap . after condensation This Air/ Gas stream joins the main incoming air stream and goes for drying to the other tower B under drying. Normally a Cycle time of 8+8 hrs is utilized to complete one cycle of operation. After each operation the changeover is effected automatically. This type of dryer provides an outlet Dew Point of -40 deg C. The Air dryer can be supplied with standard accessorize like simplex / duplex Prefilters / Afterfilters, Flowmeters, dew point meters etc. The system is fully automatic / semi automatic , with Timer / PLC controls with feedbeck to/ from main DCS. APPLICATIONS -- - Instrument air dryers for power plants Refineries & Petrochemicals , chemical & fertilizer plants etc. - CNG Compressed Natural Gas Drying & conditioning plants , Gas Drayers. - Hydrogen Gas Drier for generator Cooling Application.

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Air Cooled Water Chiller
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Air Cooled Water Chiller

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Welcome to MELLCON ENGINEERS - The premier industrial resource for energy efficient air cooled & water cooled Chillers. We supply a broad range of water chillers including standard package water chillers, refrigeration cooled and portable water chillers. industrial water chillers, as well as custom and temperature controlled water chillers. Should you do a cost analysis, you would be pleasantly surprised to realize how quickly a chiller ends up paying for itself and then saving you money from there on out, for years to come. Mellcon Engineers New Delhi are the manufacturers of industrial energy efficient aircooled water chiller plants and water chilling plants ranging from 1 TR. to 40 TR. nominal cooling capacity for industrial applications like laser chiller, medical chillers ,process chiller, machine cooling, aquarium chiller etc. Mellcon range of Air Cooled recirculating Water chiller system represents the ideal solution for the water cooling of Industrial process Water chiller Systems & designed to facilitate quick installation for all packaged chilled water system requirements .

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Water Cooled Water Chiller
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Welcome to MELLCON ENGINEERS the premier industrial resource for Energy efficient industrial & sea Water Chillers. We supply a broad range of water cooled chillers including standard package water chillers, specialty, refrigerated, cooled and portable water chillers. industrial water chillers, brine chiller, glycol chiller as well as custom and temperature controlled water chillers and chilled water plants. Should you do a cost analysis, you would be pleasantly surprised to realize how quickly a chilling machine ends up paying for itself and then saving you money from there on out, for years to come. INCREASED PRODUCTION The speed and accuracy of production will increase as you maintain a constant and proper cooling temperature in your equipment. A chilled water machine will reduce the number of rejected parts while increasing the number of parts produced per hour. You may ask yourself: "Does my equipment shut down during summer months" -- "Are there periods where our rejection rate increases" A COOLING TOWER may provide adequate cooling during winter months, but fail during the hotter periods of the year. A water chiller will immediately eliminate this problem. Why a Chiller for Equipment Protection The most compelling reason for a chiller is the protection it provides to your valuable process equipment-- such as laser machines , spot welders, injection molding equipment, and other applications. A chiller commonly represents a small fraction of the cost of the processing equipment, yet it provides solid protection of your investment, 24 hours a day, 7 days a week for years and years to come. Sizing a Chiller Correctly - calculate cooling load of water chiller - how to size chillers Simple instructions to Assure Proper Cooling The importance of selecting a correctly sized chiller cannot be downplayed. An undersized chiller will always be a problem-- never able to properly cool the process equipment. An oversize chiller will never be able to run at

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Cold Room Small and Medium
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The need - Food poisoning is generally caused by lack of hygiene, or preparation storage, transport and pathogens such as Salmonella, E. Coil and spore are present in variety of raw food from poultry to eggs and pork to vegetables. Food preparation at incorrect temperatures can cause infectious pathogens and mold toxins, main sources of even fatal poisoning. The modern society with its want for diversity, eating-out and ready-made need has created an intricate food chain that often spans continents! This has in turn made it indispensable to keep temperatures under close scrutiny. Because freezing keeps food safe indefinitely Storing food properly in your walkin cooler will prevent. cross-contamination that can lead to Food borne Illness Mellcon Engineers are the manufacturers of complete range of Industrial Modular Cold Rooms and Refrigeration units for the small and medium cold rooms , walk in refrigerators Walk in Coolers comprising of Machine made prefabricated PUF insulated Panels of different thickness from 60mm to150mm. thk PUF insulation and are covered with precoated GI sheet / SS sheet on both side or a combination of both. The Walk-In-Coolers are ready to assemble with the help of Cam locking arrangement provided inside the PUF panels and no need of any angle iron structure is required. We pride ourselves on our unique ability to custom design any Walk In Cooler or Freezer application as well as insulated panel systems The advanced design Control panel is fully automatic and provided with all necessary controls for precise operation of the equipment. All models are fitted with remote electronic control panel which is adjustable to suit most requirements. WALK IN COOLERS AND WALK IN FREEZERS FOR CONVENIENCE STORES, RESTAURANTS, FLORISTS AND INDUSTRY

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Liquid CO2  Storage Tank
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Liquid CO2 Storage Tank

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'MELLCON' the premier ISO - 9000 organization in the manufacturing of pressure vessels and approved by all major consultants in India now offer Skid mounted pre-engineered tankage for LIQUID CO2 STORAGE TANKS ( Carbon dioxide gas Storage Tanks ) having the storage capacity range from 3,000 kgs to 50,000 kgs of liquid carbon dioxide duly approved by Chief Controller of Explosives as per SMPV Rules. (pdf) . These are designed as per the recommendations in IS-2825 / ASME Sec Vlll DlV - 1 codes and the material of construction are SA-516/ IS-2062/ IS-2002/SS-304 or as per the specific requirement of the customer meeting al the Requirements . The vessel can be horizontally and vertically. mounted with 175 mm thick Insulation and aluminum cladding. The surfaces are wire brushed and sand blasted before painting. The painting is done with 2 coats of zinc chromate primer followed by 2 coats of enamel paint.The vessels are stage wise inspected by our Inspection engineers as per the recommendations of the relevant code and the Chief controller of explosives norms. All welding are performed by qualified welders only. Finally it is hydro tested and de-hydrated with dry nitrogen. MELLCON also offers these tanks under any third party inspection according to customers specific requirement. These storage tanks are equipped with all standard instruments and controls like safety valves, Pr. gauges, Pump, Valves, Piping, Drains, Pr. Regulators, Control panel and optional accessories like Refrigerated vapor recovery systems, Vaporizers , Pressure reducing Station etc.etc. Optionally a Digital weighing scale can also be supplied as an integral part.

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Hot Air Blowing Equipment
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Mellcon Engineers are specialized manufacturers of Industrial Hot Air Blowers & Air Heaters equipments for Bus Ducts dehydration & moisture removal technology during long shut down periods. We have supplied large number of Hot Air Blowing Equipments to various projects e.g. Neyveli Lignite Corporation, NALCO Angul, GMDC Ahmedabad, NTPC Rihand, Panipat Thermal Project, DVC Mejia, Pendent Cement Bhutan etc. Inspection was carried by leading consultants like MECON, M.N Dastur, DCL, Desein, Tata Projects etc. Mellcon make Hot Air blowing Heaters are equipped with Digital Temperature Indicating Controller (TIC), Blind Temperature Controller (BTC). TIC and BTC are having individual set points, by which the temperature of the Air Heater can be controlled. Set temperature of TIC is at outlet temperature can b maintained as required, So that this will maintain the temperature of heater at this temperature by energizing & de energizing the Heater according to the temperature. BTC which is provided as extra safety device is set at 10 degree C above desired outlet temperature.This will cut off the heater if the temperature increases more than its set temperature and alert the operator by an audio alarm so that the temperature will not increase beyond control.

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Inert Gas Generators
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Inert Gas Generators

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PSA Nitrogen (N2) Gas Generator plant is an Inertisation Gas Atmosphere Generator ... enabling a permanent source of onsite NITROGEN Gas , with minimum energy consumption. PSA Nitrogen ( N2 ) Gas Generator Equipment is an Inert Gas Atmosphere Generator &  incorporates Two sets of columns filled with Carbon Molecular Sieves CMS. Under Pressure these columns retain all Active Molecules compounds present in air like (Oxygen, Carbon Dioxide and Water) with the exception of the inert gases like Nitrogen & Argon.. The N2 Gas can be produced onsite for direct use or can be stored in Nitrogen storage tanks / Cylinders  for intermittent use.
( Nitrogen and Argon ). This process is referred as PSA ( Pressure Swing Adsorption ).

Mining Application
The use of Nitrogen Gas for fighting underground fires was based on the experience with the use of carbon dioxide. Many countries have used nitrogen Gas successfully in their mining industry. For more then last 50 years, nitrogen has been used most widely in the mining industries of the Czech Republic, later in the Great Britain, Russia, Germany, France, Poland, Romania, Slovakia, China, Canada, Bulgaria, India, Australia and in other countries with a modern coal mining industry.


Description
 Mellcon is the world leader in gas separation technology, providing on-site, non-cryogenic Industrial Nitrogen Gas Generators and Oxygen Gas Generation Systems . Mellcon  Offers NITROLINE
a  line of robust, reliable and modular Nitrogen Gas  generators, based on Pressure Swing Adsorption (PSA) technology incorporating state-of-the-art Carbon Molecular Sieves (CMS) Adsorbents to deliver dry Dry Nitrogen Gas (N2) onsite..

Mellcon Engineers Manufactures PSA Nitrogen Gas Generators (Inert Gas) which produce high purity Nitrogen from compressed air, allowing continuous availability at a very competitive cost, compared to alternative supply with Nitrogen Gas cylinders or cryogenic Liquid N2 Storage  tank. Each Nitrogen system can be equipped with a Nitrogen Gas Analyser to monitor the purity of of N2 Gas continuously.

NITROGEN N2 Gas Generator plant  eliminates all disadvantages associated to the purchase and operation costs of high- pressure N2 cylinder systems or cryogenic nitrogen gas storage  tanks, enabling a permanent source of onsite NITROGEN, with minimum energy consumption and maintenance requirements. PSA NITROGEN Gas Plant  is designed to be easily installed in any indoor facility. requiring only a compressed air line and a power connection.

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Liquid Co2 Storage Tanks
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Liquid Co2 Storage Tanks

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'MELLCON' the premier ISO - 9000 organization in the manufacturing of pressure vessels and approved by all major consultants in India now offer Skid mounted pre-engineered tankage for   LIQUID CO2  STORAGE TANKS ( Carbon dioxide gas Storage Tanks ) having the storage capacity range from 3,000 kgs to 50,000 kgs of liquid carbon dioxide duly approved by Chief Controller of Explosives as per SMPV Rules.

These are designed as per the recommendations in IS-2825 / ASME Sec Vlll DlV - 1 codes and the material of construction are SA-516/ IS-2062/ IS-2002/SS-304 or as per the specific requirement of the customer meeting al the  Requirements .
The vessel can be horizontally and vertically. mounted with 175 mm thick Insulation and aluminum cladding. The surfaces are wire brushed and sand blasted before painting. The painting is done with 2 coats of zinc chromate primer followed by 2 coats of enamel paint.

The vessels are stage wise inspected by our Inspection engineers as per the recommendations of the relevant code and the Chief controller of explosives norms. All welding are performed by qualified welders only. Finally it is hydro tested and de-hydrated with dry nitrogen. MELLCON also offers these tanks under any third party inspection according to customers specific requirement.

These storage tanks are equipped with all standard instruments and controls like safety valves, Pr. gauges, Pump, Valves, Piping, Drains, Pr. Regulators, Control panel and optional accessories like Refrigerated vapor recovery systems, Vaporizers , Pressure reducing Station etc.etc. Optionally a Digital weighing scale can also be supplied as an integral part.

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Hydrogen Gas Dryer
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Hydrogen Gas Dryer

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MELLCON make Hydrogen Gas Dryer (Refrigerated Type) is a reliable and economical way of eliminating the moisture.  In this system the Compressed Hydrogen Gas, saturated with Water Vapour, enters Dryer inlet and is pre-cooled by outgoing Refrigerated Gas in Heat Exchanger Assemble / PHE, a smooth surface, non-fouling,  gas to gas Heat Exchanger.  Pre-cooling removes some of the heat load from the incoming Hydrogen Gas allowing the use of a more efficient refrigeration condensing section, where it is cooled to 2 Deg. C.  The pre-cooled Hydrogen Gas then passes through the Moisture Separator, where the water is separated and discharged regularly through the Drain Valves. The cold gas then exits at outlet, after it has passed through the other side of Heat Exchanger Assembly / PHE, where it is warmed by the incoming hot gas.  This re-heating increases the gas's effective volume (enabling it to do more work) and prevents pipe sweating downstream.  Gas stream, does not fall below the temperature to which it was chilled in the gas-to-refrigerant heat exchanger  (referred to as dew point temperature) and hence no more water vapor will condense into trouble-some liquid.  Removing the water allows you to keep pipe lines, gas tools, valves and cylinders, spray guns, pneumatic instruments and any gas operated device clean and dry. 

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Air Pressurisation Equipment
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MELLCON offers Bus Duct Pressurisation System, which maintain constant positive pressure in all bus ducts connected to it by releasing compressed dry air into the bus duct. The system mainly comprised of three parts.

(a)            Compressed Air Supply Unit

(b)            Heatless Air Dryer Unit

(c)            Pressurisation Unit 

COMPRESSED AIR SUPPLY UNIT 

Equipment is given with one working and one stand by system. Any of the Compressor can be selected by Selector Switch “SW” provided on Control Panel.

 

Option-1 of “SW” for making Compressor-I as main working (master) and Compressor-II as standby. 

Option-2 of “SW” for making Compressor-II as main working (master) and Compressor-I as standby.

 

One Auto Drain Valve is provided with Air Receiver Vessel, which operate periodically to drain the water whenever any one compressor out of two starts filling of air in the receiver.

HEATLESS AIR DRYER UNIT

 The unit ensures that the compressed air released to bus ducts is dry and free form dust etc. The functioning of Air Dryer Unit is as follows. Wet incoming air at rated pressure and temperature enters pre-filter in line, where all the liquid particles are entrained, Pre-filter is fitted with automatic drain valves that operate periodically to drain the water. An electronic timer controls the operation of auto drain. The liquid and dust free air from the pre-filter outlet enters the Activated Carbon Filter, where all the oil vapour contaminants are removed. Now the air passes through Adsorber Towr-1, where the drying of air takes place by adsorption. Dry air from Adsorber-1 passes through the Check Valve Assembly and then through the After Filter in line before reaching the pressurisation panel. Pre-filter, Activated Carbon Filter and After Filter are provided with standby components.

PRESSURISATION UNIT

 

Pressurisation Units controls & maintains the air pressure inside the bus ducts by releasing required quantity of air, further air supply will be controlled by Pressure Switch “PS-3”. The Pressure Switch sends signal to Solenoid Valve “SV-9” for releasing or closing the air supply to bus ducts. The pressurisation panel has an alarm system (Hooter) to alert the operators in case of bus duct pressure is high or low. The pressurisation line is also fitted with a Safety Relief Valve “SFV” which releases the excess air to atmosphere in case of high pressure in bus ducts. The inputs for these safety alarm are obtained from a Pressure Transmitter, which senses the bus duct pressure and in turn send signal to the Pressure Indicator. The pressure indicator actuates the alarm in abnormal conditions.

 

The Pressurisation System is fully automatic, complete with Control Panel Cubicle with Fault Indication & Hooter. Two Nos. Pressure Regulator Valve “PRV-1” & “PRV-2” are provide in bus duct pressurization line before Pressure Switch “PS3”. Air supply is given in a controlled way from “PRV-1” & PRV-2”. Set Points of “PRV-1” is 1.5 KG/Cm2 (g) & PRV-2 is 10 mBar.. The Control Panel has the following indications on the front panel apart from annunciator apart from other indication signals.

 

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Refrigerated Dryer

Refrigerated Dryer

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Split Flow No Purge Loss Air Dryers
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Water Chiller

Water Chiller

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Cold Room

Cold Room

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Packaged Dry Air Plant
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Packaged Dry Air Plant

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MELLCON offers packaged Dry Air Plant in which complete assembly is mounted on a common skid. Assembly includes Air Compressor, After Cooler, Air Receiver and Air Dryer. The system is ready to install type just requiring power connection, water connection and air inlet/outlet connection. Packaged Dry Air Plants are offered upto a capacity of 100CFM. The basic scheme of the system is shown below:- Air Compressor compresses the atmospheric air thereby raising its temperature & humidity. This hot air is cooled in Water Cooled After Cooler to a temperature of 400 C and in the process moisture condenses & drained out. This air is stored in air receiver and then passes through the Air Dryer where air is dried to a a desired Dew Point. This fully dry air is sent for the pneumatic/process application .

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Recovery System
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Recovery System

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Mellcon offers fully automatic and effective ready to use effective refrigerant recovery system with power range from 120 watts to 800 watts. It has a volumetric capacity range from 4-6KG/HR to 40-45KG/HR. To start the unit connect the service hose to the lower side of the refrigeration system and press the start button. The unit will start operating and the refrigerant gas gets extracted and distilled. It will turn off automatically after all the gas is removed. It will pull a 10 degree vacuum and if a positive pressure is sensed the unit will start automatically. The recovery system is equipped with unique features that includes: The heavy-duty compressor with service fittings Suction and delivery gauges and temperature cut off circuits to assure the safety of the equipment. An hour meter for determining when the maintenance is required. Control panel to monitor the automatic operation.

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