When to Use Nitrogen Gas Generator Manufacturer？

The air we breathe contains two gases that are extremely useful in industry: oxygen (about 21%) and nitrogen (about 78%). Adding oxygen to a process enables better control of heating patterns, higher furnace efficiencies (for lower fuel consumption) and reduction in particulate and NOx emissions. It’s used with fuel gases to enhance processes including gas welding, gas cutting, oxygen scarfing, flame cleaning, flame hardening and flame straightening. Oxygen is a raw material in many oxidation processes and to regenerate catalysts. Nitrogen gas is used for purposes ranging from inerting and purging to flushing and sterilizing to product transfer and packaging. Many such processes remove undesirable oxygen from a manufacturing process or environment, preventing oxidation that can damage metal parts and sensitive electronics. Nitrogen is also used in refining and gas separation processes. Since oxygen and nitrogen occur together in the air, they must be separated before they can be used. The right tool for the job is an oxygen generator or a nitrogen generator.

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Oxygen molecules are separated from the other molecules within a clean, dry compressed air stream. Pressure Swing Adsorption (PSA) is a simple, reliable and cost-effective technology that enables continuous, high-capacity oxygen flow at the desired level of purity (90% to 95%). Adsorption happens when atoms, ions or molecules from a substance (compressed air in this case) adhere to a surface of an adsorbent. PSA technology isolates oxygen molecules from other molecules (nitrogen, CO2, water vapor and trace gases) to leave high purity oxygen at the outlet of the generator. The process takes place in two separate pressure vessels (tower A and tower B), each filled with a carbon molecular sieve, that switch between a separation process and a regeneration process. Here’s how it works.

Nitrogen molecules are separated from other molecules within a clean, dry compressed air stream. Pressure Swing Adsorption technology is used here as well, to isolate nitrogen molecules from other molecules in compressed air to leave nitrogen at the desired purity at the outlet of the generator. For some applications, such as tire inflation and fire prevention, relatively low purity levels (between 90% and 97%) are required. Other applications, such as food/beverage processing and plastic molding, require higher levels of purity (from 97% to 99.999%).

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About 80% of nitrogen end uses require nitrogen as a gas, not as a liquid. That being said, many companies use bottled liquified nitrogen. The primary reason nitrogen is liquified is for ease of transportation. However, generating liquid nitrogen requires a tremendous amount of energy.

Shifting to in-house generation of nitrogen gas can help manufacturers achieve significant cost savings, usually from 40-80%. This depends on current liquid nitrogen market prices. In addition, this transition offers a rapid payback period of typically less than 2 years. Business owners typically recover the initial investment in nitrogen generation systems in a remarkably short amount of time. 

In-house generation of nitrogen gas also frees up space otherwise needed to store nitrogen bottles (both full and empty), further enhancing operational efficiency and reducing overhead costs.  

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