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. Typically, businesses realise a 50% or greater reduction in nitrogen costs when producing gas instead of purchasing 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.
Table of Contents
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, significantly reducing long-term nitrogen expenses.
Eliminating Delivery and Storage Costs
Relying on bottled nitrogen or cylinders requires storage space and incurs additional rental fees. On-site nitrogen generation, whether through a membrane nitrogen generator or a pressure swing adsorption (PSA) system, eliminates these costs by producing nitrogen gas on demand, minimising the need for nitrogen storage tanks and reducing logistical challenges.
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, avoiding overpaying for high-purity nitrogen that may not be necessary for applications such as food processing or laser cutting.
Reducing Losses and Improving Efficiency
With delivered nitrogen, the conversion from liquid to gas results in up to 10% loss, and additional nitrogen is lost during storage. On-site nitrogen generation produces gaseous nitrogen as needed, preventing losses and improving operational efficiency.
Reliability and Convenience
Business operations, with a need for nitrogen and a dependence on regular supplies, create a single point of failure. Suppliers sometimes suffer shortages because of unforeseen circumstances leading to delayed deliveries. This introduces potential downtime for production facilities.
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.
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.
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.
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 nitrogen systems ensures that the machinery meets all requirements without any issues. It operates more efficiently with less waste or unnecessary energy usage. Subsequently, nitrogen-related expenses are reduced.
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.
