From small labs to large industrial plants, numerous organisations rely on nitrogen gas, making on-site generation a game-changing solution. For these companies, reliance on liquid nitrogen deliveries presents various issues, inconveniences, and increased expenses over dependable alternatives.
On-site nitrogen generation offers significant cost savings, a safer workplace for employees, and an improved environmental rating. Businesses typically realise a 50% to 70% reduction in nitrogen costs when producing nitrogen on-site compared to purchasing and transporting nitrogen supplies.
Here at J LL Leach & Co Ltd, we can provide a detailed analysis and estimate for the provision and installation of Atlas Copco Nitrogen Generators. In this article, we highlight the benefits of on-site nitrogen generation and why it is helpful to your business.
Cost-Effectiveness
On-site nitrogen generation offers substantial savings by transforming ongoing nitrogen supply costs into a one-time capital investment. Typically, businesses achieve a return on investment within 12 to 24 months. Pressure swing adsorption (PSA) and membrane nitrogen generators enable companies to meet their nitrogen needs on-site, lowering operational costs while improving efficiency.
Eliminating Delivery and Storage Costs
Relying on bottled nitrogen or cylinders requires storage space and incurs additional rental fees. On-site nitrogen generation eliminates these costs by producing nitrogen gas on demand, whether through a membrane nitrogen generator or a PSA system. This minimises dependency on nitrogen storage tanks, reduces logistical challenges, and simplifies operations.
Stability and Custom Purity Levels
Purchasing nitrogen is subject to market price fluctuations, making budgeting unpredictable. On-site nitrogen systems stabilise costs and allow businesses to produce the exact purity required. Nitrogen generators can adjust purity levels from 90% to 99.999%, ensuring applications like laser cutting or food packaging are optimised without incurring unnecessary expenses for higher purity.
Reducing Losses and Improving Efficiency
Delivered nitrogen is often supplied as a liquid, requiring energy-intensive processes to convert it back to gas. This conversion can result in up to 10% loss, with additional losses during storage. On-site nitrogen generation eliminates these inefficiencies. The production process directly supplies gaseous nitrogen as needed, enhancing operational efficiency while reducing waste.
Reliability and Convenience
Reliance on regular nitrogen deliveries creates vulnerabilities in supply chains. Delays due to strikes, roadworks, or adverse weather can disrupt production schedules. On-site nitrogen generators eliminate this dependency, ensuring an uninterrupted supply tailored to your operations.
Modern systems have advanced control features that maintain consistent purity levels, flow rates, and gas quality. Real-time monitoring and diagnostics provide immediate alerts for any irregularities, improving reliability.
Extended contracts lock businesses into long-term commitments with a single nitrogen supplier. Sometimes, multiple producers are sought, but this is often against your best interests.
Alternatively, switching to on-site nitrogen production processes and using gas generators allows operators to produce nitrogen on demand. The purity levels, gas quality, and flow rate are precisely maintained and constantly monitored using sophisticated control systems.
In an age of labour strikes, long-term roadworks, and other potential obstacles to reliable gas deliveries, on-site gas generation is convenient and reliable.
Environmental Benefits
Environmental regulations continue to set a higher standard for what is expected of businesses. Companies must maintain vigilance over their carbon footprint and it is highly recommended to take active steps to reduce their environmental impact. Moving away from gas deliveries supports a reduction in both direct and indirect carbon emissions.
Producing nitrogen instead of relying on deliveries gets trucks off the road. Fewer road-related emissions, plus avoidance of diesel or petrol fuel usage, ensure your company is greener.
Nitrogen delivered by truck is made available in liquid form. Converting liquid nitrogen back to a gaseous state requires excessive amounts of electricity. This requirement is entirely removed when nitrogen deliveries are no longer received.
Modern equipment creates nitrogen in a more energy-efficient manner. Producing gas as needed prevents gas wastage and unintended volume losses, resulting in environmental benefits.
Additionally, the energy-intensive process of liquefying nitrogen for transport is no longer required. Producing on-site nitrogen reduces direct and indirect emissions, aligning with sustainability initiatives and ISO 14001 standards.
Safety Improvements
Handling liquid nitrogen stored at -196°C introduces risks such as frostbite and dangerous leaks during pressurisation. On-site nitrogen generation eliminates the need for cryogenic liquids, significantly reducing these hazards.
Businesses reduce reliance on high-pressure nitrogen cylinders by using PSA nitrogen generators or other nitrogen gas systems, minimising the risks of leaks and accidents. These systems provide built-in safety features and real-time monitoring, ensuring safer, more reliable operations.
On-site nitrogen gas production also reduces contamination risks, as purified nitrogen is generated in a controlled environment, ensuring higher gas purity – critical for industries like food processing.
By using PSA or membrane nitrogen generators, businesses reduce the reliance on high-pressure cylinders, minimising risks of leaks and accidents. Built-in safety features and real-time monitoring ensure safer operations. This is especially critical in food processing and healthcare, where safety standards are stringent.
Purity and Quality Control
Gas purity levels are important, whether too high or too low.
Depending on the equipment, such as pneumatic or welding, a minimum purity level is required to produce professional outcomes. Otherwise, the result is inferior welds that do not hold, inefficient air tool operations, and other potential issues.
When you purchase nitrogen, it is usually provided at a 97% gas purity level or higher. Your manufacturing equipment may only require a 90% or 95% purity. The difference has an enormous bearing on your business’s total nitrogen expenses.
A steady supply of nitrogen sometimes comes with other gas purity concerns. Unpredictable purity levels are another factor that plays havoc with expensive equipment. When under a long-term contract, this is troublesome to resolve.
Gas quality is another consideration. It refers to the cleanliness of the nitrogen gas. When produced using less clean pressurised air, the lower gas quality introduces problems for machinery reliant on it. As a result, equipment may break down more frequently.
Nitrogen generators work highly efficiently. Subsequently, nitrogen purity is precisely managed, giving you more control. This ensures it is consistent at the required flow rate. Similarly, gas quality is maintained as needed.
Unpredictable purity from delivered nitrogen is eliminated, reducing wear and tear on expensive equipment and enhancing operational efficiency.
Customisation and Scalability
At J LL Leach, we assess the nitrogen requirements of our customers’ operations. We understand that each use case and need is unique. We create custom nitrogen generator systems that match current and future demand.
Correctly sizing these systems ensures optimal efficiency and reduced waste. Systems can be easily scaled to meet future demands, providing flexibility for business growth.
Contact us today to discuss your on-site nitrogen generation needs.
FAQ
What are the advantages of on-site nitrogen generation?
On-site nitrogen generation enables businesses to produce nitrogen gas as needed, eliminating the dependency on nitrogen gas cylinder deliveries. This approach provides greater control over purity levels, reduces nitrogen consumption, and ensures a reliable nitrogen supply without the risk of running out. Additionally, it helps lower costs and enhances safety by eliminating the need to handle cryogenic liquids.
How does a PSA system work in nitrogen gas generation?
A PSA system separates nitrogen molecules from compressed air to produce high-purity nitrogen gas. This process allows industries to generate nitrogen on-site at the required purity levels for specific applications, such as creating an inert atmosphere in manufacturing or food processing. PSA systems are highly efficient, minimising nitrogen losses and ensuring a steady supply.
What are the installation requirements for nitrogen gas generators?
Installing a nitrogen generator typically involves connecting the system to a compressed air supply and ensuring the necessary infrastructure for gas production is in place. A range of nitrogen generators, including PSA and membrane technology options, can be customised to meet specific nitrogen consumption needs. These systems are designed to be reliable and scalable, ensuring they can grow with the business while maintaining consistent nitrogen production.
