Investing in an on-site Pressure Swing Adsorption (PSA) Nitrogen Generator is a smart decision for companies that use air compressors and need a constant flow of nitrogen. By producing nitrogen right where it's needed, businesses can cut ties with outside nitrogen providers. This move saves money on shipping and handling and ensures that there's always enough nitrogen available.
The PSA Nitrogen Generators are advantageous because they save costs and offer dependable operation. They use a sophisticated method called Pressure Swing Adsorption (PSA) to create nitrogen gas whenever it's required.
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How does a PSA nitrogen generator work?
Pressure Swing Adsorption (PSA) technology is the powerhouse behind PSA Nitrogen Generators, making them a top choice for a wide variety of industries that require a steady, high-quality nitrogen gas supply.
At the core of the generator system, the PSA Nitrogen Generator employs a Carbon Molecular Sieve (CMS), which plays a pivotal role in separating nitrogen molecules from the compressed air and gas mixture. The compressed air is funneled at high pressure into a vessel filled with CMS. These carbon molecular sieves are adept at selectively absorbing oxygen and other gases, allowing the nitrogen molecules to be harvested as the end product.
The operation of the gas generator is based on a cyclical process. While one chamber is in the adsorption phase, trapping gases under high pressure, the other is regenerating at a lower pressure, releasing the trapped gases to get ready for the next round. This pressure 'swing' between chambers is what gives PSA Nitrogen Generators their name and ensures a constant flow rate of nitrogen gas.
Adding PSA Nitrogen Generator to an installation system can greatly reduce the cost of ownership when compared to relying on high-pressure cylinders. The system's adept use of the air supply and its on-site production capability mean that businesses no longer depend on external delivery, which translates into cost savings and a reliable flow of nitrogen gas.
Nitrogen Purity Requirements
To produce your own nitrogen, you need to first figure out the required purity for your use. Clean, dry air is essential when feeding it into a nitrogen generator, as it ensures high-quality nitrogen and protects the CMS from moisture damage. Keep the intake air temperature between 10 and 25 degrees Celsius and the pressure from 4 to 13 bar. A dryer should be in place after the compressor and before the generator to treat the air.
If using an oil-lubed compressor, an oil coalescing and carbon filter are necessary to remove impurities before the air reaches the nitrogen generator. Most systems designs have built-in sensors to monitor air quality and protect the PSA system.
The air factor is a big deal in system design for nitrogen generation, indicating how much compressed air is needed for a certain nitrogen output. It's a measure of efficiency: the lower the air factor, the more efficient and cost-effective the generator is
Advantages of PSA Nitrogen Generators
High-Quality Nitrogen Gas Production
Nitrogen generators capture and convert the air around us into nitrogen with purity levels as high as 99.9995%, depending on the system's capabilities. Generators provide a steady stream of high-purity nitrogen, maintaining both flow and pressure as needed.
Round-the-Clock Reliability and Minimized Downtime
Offering uninterrupted operations 24/7, these generators ensure a constant flow of nitrogen gas, ready whenever required.The on-demand nitrogen supply means operations can continue without interruption, reducing idle time.
Supply Flexibility
The nitrogen output can be quickly adjusted to meet different needs. As long as the generator's flow and purity match the task, switching applications is straightforward and hassle-free.
Cost-Effective Ownership and Substantial Cost Savings
By replacing outdated cylinder technology, the cost of producing nitrogen on-site is significantly lower, slashing expenses by over 50% for many lab setups compared to bottled or liquid nitrogen. After the initial investment, the long-term savings can reach up to 90%, making the payback period worthwhile.
Robust and Convenient Design
Built to withstand vibrations and impacts, and not affected by oils or moisture, these generators, with regular annual maintenance, can reliably function for a decade or more. Their compact design means they take up less room, which makes them an ideal suite for tight spaces.
Applications & Industries
Nitrogen generation is relied on by many industries for their manufacturing processes. They include, but are not limited to:
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Food & Beverage
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Oil & Gas
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Mining Industry
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Pharmaceutical, Chemical & Petrochemical Industry
Choosing Between a PSA Generator and a Membrane Generator
PSA and membrane systems each offer unique features and benefits. In general, membrane technology is better suited to low purity applications while PSA technology is best suited for higher purity applications.
|
Specification |
PSA Generator |
Membrane Generator |
|
Achievable Purity |
Higher Purity |
High Purity |
|
Efficiency |
Higher |
High |
|
Differential Pressure |
1.5~2 bar |
1~1.5 bar |
|
Flow Stability |
Fluctuating in/on/outlet |
Stable |
|
Buffer tank required |
Surge air receiver and nitrogen mixing vessel required |
No |
|
Noise |
High (blow-off peaks) |
Low Noise Operation |
|
Control Type |
PLC, Auto control |
PLC, Auto Control |
|
Inlet Temperature |
Operation up to 60°C |
Operation up to 60°C |
|
Start-up time |
Minutes / hours |
Seconds |
|
Weight |
Medium |
Low |
|
Maintenance |
Low |
Lower |
|
Moving Parts |
Frequent change-over of valves |
No required |