Get the best nitrogen generator for your facility! If you use nitrogen in your industrial processes, an onsite nitrogen generator can save a lot of money and ensure that you never run out of the nitrogen you need. But there are a few things you should know about nitrogen generators before you buy.
With competitive price and timely delivery, SUNCENTER sincerely hope to be your supplier and partner.
What Is Nitrogen Used For?
Nitrogen gas (N2) is used for a variety of industrial and research applications. Nitrogen is a colorless and odorless gas that makes up 78% of the Earth's atmosphere. It is also an inert gas, meaning it does not support combustion and does not react chemically with most substances. These properties make nitrogen gas extremely useful for a number of applications that require shielding or prevention of oxidation reactions such as combustion, corrosion, or spoilage.
Some industrial applications of nitrogen include:
- Controlled atmosphere storage of fruits, vegetables, and other food products (to prevent oxidation and spoilage)
- Food processing (especially inerting/blanketing for the production of wine, oils, soft drinks, and dairy products)
- Modified-atmosphere packaging (MAP) for meats, dairy products, wine, pre-cooked foods, and pharmaceutical products
- Electronics production
- Laser cutting and welding (as a shielding gas)
- Gas-assisted injection molding (GAIM)
- Foamed rubbers, plastics, and elastomers
- Explosive applications (to provide a protective atmosphere)
- Chemical production
- Aerosol can propellant
How Pure Does Nitrogen Need to Be?
Different applications have varying levels of purity requirements. For example, electronics manufacturing and pharmaceutical applications often require very high purity nitrogen (up to 99.999%), whereas food packaging or tire inflation might require lower purity levels (around 95% to 99.5%).
Issues to consider when determining purity requirements for nitrogen:
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Consider how sensitive your process or product is to impurities. Processes that are highly sensitive to oxygen, moisture, or other contaminants will require higher-purity nitrogen to prevent quality issues.
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Many industries have established standards that specify the required purity levels for various processes. Reviewing these standards can provide a clear benchmark for what you need.
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If you're unsure about the specific purity level needed for your application, consulting with nitrogen generator suppliers or industry experts can provide valuable guidance.
Typical Nitrogen Purity Requirements by Application*
Application
Nitrogen Purity (%)
Food Packaging
99.0 - 99.5
Pharmaceuticals
99.95 - 99.99
Electronics Manufacturing
99.99 - 99.999
Metal Processing
99.5 - 99.9
Chemical Industry
99.9 - 99.99
Laboratory & Research
99.99 - 99.999
Laser Cutting
99.95 - 99.99
Pipeline Purging
95.0 - 99.5
Inerting/Blanketing
99.0 - 99.5
*Based on typical industry guidelines; always refer to relevant standards, regulations, and application requirements for your specific application.
Argon may be left behind in the nitrogen separation process. Argon is also an inert gas and is naturally present in the atmosphere, though at much smaller levels than nitrogen and oxygen. Residual argon is generally less than 1.5% by mass in the final purified nitrogen product. Because argon is also inert, this is not a problem for the majority of applications; argon will provide the same shielding and inerting functions as nitrogen gas. The best onsite nitrogen generators can produce total inert gas with a purity of 99.999% or higher.
Choosing the Best Nitrogen Generator
Choosing the right nitrogen generator depends on your specific needs regarding nitrogen purity, flow rate, and cost considerations. Selecting the appropriate nitrogen generation technology for your application is essential to achieve the desired balance between nitrogen purity, efficiency, and operational cost. Tailoring the system to the application needs, the operating environment, and other requirements will ensure optimal system performance and maximize cost-effectiveness.
Types of Nitrogen Generators
There are two different technologies in use for onsite nitrogen generation:
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Membrane nitrogen generators: Work by separating nitrogen from other gasses in the air through a membrane filter. Air is pushed through this membrane, and due to the different sizes of gas molecules, nitrogen is separated from the rest. This type of generator is known for its simplicity, reliability, and low maintenance. They are best suited for applications that require nitrogen gas at lower purities (95% to 99.5%).
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PSA nitrogen generators: Use a process called Pressure Swing Adsorption. This method involves passing compressed air through a vessel filled with a carbon molecular sieve (CMS). Under pressure, CMS adsorbs oxygen and other gasses, allowing nitrogen to pass through as a purified product. Once the sieve becomes saturated with oxygen, the system switches to another vessel, allowing the saturated sieve to regenerate by releasing the adsorbed gasses. PSA generators are capable of producing high-purity nitrogen (up to 99.%) and are suitable for applications requiring high purity levels.
Membrane vs. PSA Nitrogen Generation: Features, Benefits and Applications
Membrane
Pressure Swing Adsorption (PSA)
Advantages
Lower initial cost
Simpler design
Low maintenance requirements
Safe for explosive environments (no electrical components)
Modular & field scalable
Suitable for remote deployment
High purity levels
Continuous production
Suitable for high flow/high purity applications
Disadvantages
Lower purity
Susceptible to oil contamination
Efficiency affected by ambient conditions
Higher initial investment
Requires periodic replacement of adsorbent material
More moving parts (e.g., valves) requiring maintenance
Purity Levels
95% to 99.5%
Up to 99.999%
Flow Rates
Up to 15,000 cubic feet per hour (depending on purity)
Up to 130,000+ cubic feet per hour/+ cubic feet per minute (depending on purity)
Common Applications
Tire inflation (esp. in aviation)
Oil & gas pipeline purging and well stimulation
Fire prevention & suppression
Manufacturing and food & beverage applications with lower purity requirements
Laser cutting
Metal processing/heat treating
Welding & soldering
Food packaging and preservation
Pharmaceuticals
Inerting/blanketing
Laboratories & research facilities
Factors to Consider When Selecting a Nitrogen Generator
When selecting a nitrogen generator, there are several key factors to consider to ensure you choose the right system for your needs.
These factors will help you evaluate different nitrogen generators based on your specific requirements to ensure operational efficiency and cost-effectiveness:
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Purity requirements: The first and foremost factor is the purity level of nitrogen required by your application. Different processes need different purity levels, ranging from 95% to 99.999%. Higher purity levels may require more sophisticated and expensive systems. PSA gas generators can deliver higher purity than membrane systems.
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Flow rate: Consider the volume of nitrogen your operation will consume. The flow rate, usually measured in standard cubic feet per minute (SCFM) or standard cubic feet per hour (SCFH), should match your consumption to avoid inefficiencies or shortfalls. PSA nitrogen generators have much higher flow capacity than membrane N2 generators.
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Operating environment: Ambient temperature, humidity, and cleanliness can affect the performance of the nitrogen generator, particularly membrane systems. On the other hand, the simple operation and low maintenance requirements of membrane N2 generators make them a better choice for remote or rugged conditions.
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Pressure requirements: Different applications may require nitrogen at different pressures. Ensure the generator you select can deliver nitrogen at the required pressure for your processes. If higher-pressure nitrogen is needed, a booster compressor may be needed to reach the required PSI.
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Cost of ownership: Look beyond the initial purchase price to understand the total cost of ownership, which includes maintenance, operating costs, and potential downtime. Energy efficiency plays a significant role in ongoing costs for nitrogen generation.
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Maintenance needs: Different generators have varying maintenance requirements. Consider how often maintenance is needed, the complexity of maintenance tasks, and the availability of service and parts. Membrane systems are generally lower maintenance than PSA systems.
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Reliability and durability: The reliability of the nitrogen generator is critical to avoid production downtimes. Look for systems with a proven track record of durability and reliability in similar applications.
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Size and space considerations: Consider the physical size of the nitrogen generator and the space available in your facility. Ensure that there is adequate space for installation, maintenance, and potential future expansion.
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Scalability: Consider whether the nitrogen generator can be scaled up to meet future growth or changes in demand. Some systems offer modular expansions, while others may require a complete replacement. If you are anticipating growth in the future, look for a model that is field-expandable and scalable.
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Manufacturer reputation and support: Finally, consider the reputation of the manufacturer and the level of support they offer. Good after-sales support, warranty terms, and accessibility of technical assistance can significantly affect your experience and the system's uptime.
Flow vs. Purity
When selecting a nitrogen generator, the most important questions to ask are:
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What is the volume of nitrogen I need to produce each hour, shift, or day? If your nitrogen consumption is variable, look at your peak demand.
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What is the nitrogen purity (or total inert gas purity) required by your application?
The tradeoff between flow rate and purity is a fundamental aspect of nitrogen generation systems. The higher the desired purity level of nitrogen gas, the longer the process takes and the lower the flow rate. This is because achieving higher purity requires the gas to spend more time in contact with the separation medium, whether that's the adsorbent material in PSA systems or the membrane in membrane systems.
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In PSA technology, increasing purity levels might require slower cycling or a larger bed of adsorbent material to ensure that more oxygen and other undesired gasses are removed from the air.
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For membrane technologies, achieving higher purity levels involves adjusting the flow rate to allow more time for oxygen and other gasses to permeate through the membrane, leaving a higher concentration of nitrogen.
In other words, the same nitrogen generator can deliver much higher flow at lower purities (e.g., 95%-96%) than at higher purities. Delivering ultra-high purity nitrogen at 99.999% will severely curtail the flow rate. System specifications for nitrogen generators will provide the maximum flow rate for each purity level.
Nitrogen Generation System Components
Whether membrane or PSA, a nitrogen generator is part of a complete system that includes air compressors, piping, filtration, and other elements.
Components of a nitrogen generation system include:
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Air compressor: An industrial air compressor is an essential element of a nitrogen generation system to compress atmospheric air to the required pressure for nitrogen generation, typically between 100 and 150 PSI. Rotary screws, rotary vane, or reciprocating air compressors can all be used in nitrogen generation applications.
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Air receiver tank: An air receiver tank placed after the compressor cools the compressed air, allowing excess moisture to condense and drop out. It also ensures a consistent flow and pressure for the nitrogen generation process.
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Air dryer: Air dryers are essential to reduce the moisture content in the compressed air before it goes into the nitrogen generator. Removing moisture before nitrogen separation reduces strain on the system and helps to achieve higher nitrogen purity. Either refrigerated or desiccant dryers can be used; desiccant dryers may be recommended for applications requiring ultra-high-purity nitrogen.
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Pre-filtration: Inline filtration is used to remove oil and particulate matter from the air stream before nitrogen generation. The pre-filtration stage may include a combination of coalescing filters, particulate filters, and water separators.
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Nitrogen generator: At the core of the system, the nitrogen generator separates nitrogen from other air components using membrane or PSA technology.
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Booster compressor (optional): Output pressure for nitrogen systems is usually between 100-150 PSI, depending on technology type and inlet pressures. A booster compressor is sometimes used to raise the PSI of nitrogen for efficient storage or specific application needs. A multi-stage reciprocating compressor is capable of elevating pressure to 600 PSI or higher.
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Nitrogen buffer tank: Another tank is located after the nitrogen generator to store the generated nitrogen gas. This ensures a consistent supply of nitrogen and smooths out production fluctuations while maintaining consistent pressure and flow.
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Post-filtration (optional): Depending on the application and purity requirements, another bank of inline filters may be used after the nitrogen generator to remove any remaining impurities.
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Piping and distribution system: A piping system is needed to transport compressed air from the compressor to the nitrogen generator and deliver the nitrogen gas from the generator to the point of use. Piping for nitrogen systems must be rated for high-pressure applications. PneuTech prefers the Unipipe system for nitrogen applications.
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Control system: Control systems for nitrogen generators play a pivotal role in managing the operation and efficiency of the entire nitrogen generation process. These systems can range from simple manual controls to sophisticated automated solutions, allowing for precise regulation of pressure, flow rate, and purity of the produced nitrogen gas.
Components of a Membrane Nitrogen Generator
Membrane nitrogen generators are simple systems with no moving parts. Instead, they use hollow fiber membranes to allow passive diffusion of gas.
The core components of a membrane nitrogen generator are:
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Membrane module: The heart of the generator, this module contains hollow fiber membranes that selectively separate nitrogen from other gasses in the air based on molecular size and diffusion rates.
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Vent: Oxygen, carbon dioxide, water molecules, and other non-target gasses are vented back into the atmosphere.
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Purity adjustment system: A series of valves and controls designed to adjust the flow of air through the membrane module, enabling the operator to fine-tune the purity level of the nitrogen produced.
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Post-filtration: Some models come with integrated post-filtration to remove any remaining impurities from the nitrogen stream.
Components of a PSA Nitrogen Generator
PSA nitrogen generators are more complex in their operation.
The core components of a PSA twin-tower nitrogen generator include:
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Adsorption towers: Typically, two or more towers are filled with carbon molecular sieve (CMS) material, which adsorbs oxygen and other impurities under pressure, allowing nitrogen to pass through as a purified product.
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Pressure vessels: The adsorption towers are housed in durable pressure vessels to withstand the cycling pressures of the adsorption and regeneration phases, critical for the PSA process.
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Valves and control system: A network of valves controlled by an automated system that regulates the flow of air into the adsorption towers and directs the flow of purified nitrogen. This system also manages the pressure swing process, alternating between adsorption and regeneration phases to ensure continuous nitrogen production.
Nitrogen Generators from PneuTech
Proudly made in the USA, PneuTech nitrogen generators meet the highest possible standards for quality and performance.
PneuTech offers a range of system options and sizes for any nitrogen application:
Want more information on high pressure nitrogen gas compressor suppliers? Feel free to contact us.
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TNX series membrane nitrogen generators: A modular, field-scalable membrane system with low maintenance requirements, a small footprint, and integrated post-filtration and purity control.
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TN2 total: Our most popular membrane nitrogen production solution includes filtration, temperature, pressure, and flow control packages along with the membrane module(s).
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NGN series twin tower PSA: A high-performance twin tower PSA system capable of purities up to 99.999% and flow rates up to SCFM. Featuring generously sized adsorption towers for even and consistent N2 production and oversized pipes for low-pressure drop and energy efficiency.
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NGU UltraN2 high-purity series PSA: When the ultimate nitrogen purity is needed, the UltraN2 system delivers with purity beyond 99.999%. These systems deliver highly purified N2 rated to 50 ppm or 10 ppm oxygen content.
All PneuTech nitrogen generators are backed by PneuTech's 5-year Pneu-Assure warranty:
- Five-year warranty on pressure vessels
- Two-year bumper-to-bumper warranty on the entire unit
- Guaranteed after-sales support
- Industry-leading technical expertise
If you're ready to get started with onsite nitrogen generation, talk to the experts at PneuTech. Our nitrogen team will help you determine which type of nitrogen generator is right for you and design a total system that meets your application requirements.
Contact PneuTech for all of your nitrogen generation needs.
Various industries and applications often use compressed air as an energy source. Compressed air is essential in numerous processes and equipment, from manufacturing plants to dental offices and automotive workshops. Despite its extensive use, misconceptions and gaps in knowledge make it harder for people to know how to find the right compressor for their needs. However, you can easily choose the right industrial compressor with this buyer's guide.
What Is Compressed Air?
Compressed air involves compressing atmospheric air to increase its pressure for various applications. This process typically requires an air compressor that intakes atmospheric air and pressurizes it for use in different tools or systems. Once compressed, you can store the air in tanks or directly use them to power devices and equipment. The ability to store and transport energy makes compressed air a versatile and valuable resource in many settings.
Why Do People Use Compressed Air?
Compressed air serves diverse purposes, including powering pneumatic tools and machinery, controlling valves and actuators, and providing clean air for breathing purposes. Its versatility and adaptability make it a popular choice in various sectors, such as manufacturing, construction, healthcare, and transportation. Industries often prefer pneumatic systems powered by compressed air due to their reliability, safety, and ease of maintenance.
How Do You Measure Compressed Air?
Measuring the pressure of compressed air means using units such as pounds per square inch (psi) or kilopascal (kPa). Meanwhile, you can gauge the volume of compressed air using cubic feet per minute (cfm) or liters per minute (L/min). These measurements are crucial for selecting the appropriate compressor size and type for different applications to ensure efficient operation and energy use.
Understand Your Company's Needs
Buyers must have a clear understanding of what their company needs before purchasing an air compressor. Start by identifying the scope of your purchasing responsibilities, which may include everything from office supplies to high-value technology. Determine specific requirements for each purchase, such as quantity, quality standards, and delivery timelines.
Knowledge of your company's objectives, such as enhancing productivity or reducing costs, along with budget constraints and strategic goals, will help you make the right purchasing decision. Select suppliers that align with the company's immediate needs and long-term goals. This understanding is the foundation of your role, ensuring that every purchase supports broader company objectives.
Research Potential Suppliers
Conduct thorough research into potential suppliers to ensure they are reliable, reputable, and capable of meeting your company's requirements. Begin by assessing their history, including their past performance in terms of delivery accuracy and adherence to quality standards. Review their quality control processes to understand how they maintain product standards.
Also, analyze their pricing strategies to ensure competitive rates and evaluate their delivery capabilities to meet your timelines. Considering their financial stability, ethical practices, and customer reviews will also help you build a comprehensive profile so you can know what you're buying.
Build Relationships With Suppliers
Developing strong relationships with suppliers is crucial to successful purchasing. By building trust and open communication channels, you can negotiate better deals, receive priority service, and create long-term partnerships that benefit both parties. Hosting quarterly or monthly meetings and consistent communication through emails or video calls can foster a collaborative environment. Strong relationships can also result in mutual growth, as your success can lead to increased business for your suppliers.
Keep Track of Market Trends
Stay updated on market trends, including changes in supplier prices or the availability of certain products or services. This information can help you make informed purchasing decisions and anticipate potential supply chain disruptions, such as shortages or increased lead times. Understanding these trends can also provide a competitive advantage, allowing your company to adapt quickly to market conditions. Regularly reviewing industry reports, attending trade shows, and networking with peers can also help you stay on top of the market and keep your company ahead of the curve.
Negotiate Effectively
Effective negotiation skills are essential for buyers to ensure cost-effective purchasing. Be confident in communicating your company's needs and expectations while being open to compromise. Approach negotiations with a clear understanding of your objectives and the supplier's perspective. Aim for a win-win situation where both parties feel satisfied with the agreement.
Monitor Supplier Performance
Monitoring supplier performance is crucial to ensure they meet the agreed-upon terms and quality standards. Keep track of delivery times, checking for promptness and reliability, as well as product quality, to ensure everything meets your expectations. Also, evaluate customer service levels to promptly identify any issues.
Regular performance reviews, such as quarterly evaluations and feedback sessions, can also help you maintain high standards and foster continuous improvement in your business. Thankfully, when you address concerns early, you can work with suppliers and find the air compressor that helps you prevent future disruptions.
Review Contracts Carefully
Review the supplier's contract before signing to ensure all terms are fair and favorable for your company. Pay attention to key components such as:
- Delivery schedules
- Payment terms
- Confidentiality clauses
- Legal obligations
Make sure the terms regarding penalties for non-compliance or late deliveries are clear. Seeking legal advice will help you avoid potential risks or loopholes that could negatively impact your company. A thorough review safeguards your company's interests and establishes a strong relationship with your suppliers.
Communicate Clearly
Effective communication is a cornerstone of the purchasing process. Make sure you clearly communicate your company's needs, expectations, and any changes in requirements or deadlines to suppliers to avoid misunderstandings. This communication involves sending emails and making calls while building strong relationships with suppliers through regular updates and feedback sessions. Developing strong communication skills can also boost collaboration, foster trust, and lead to more successful outcomes for your business.
Continuously Improve
Always strive for continuous improvement in your processes and decision-making. Seek feedback from suppliers and colleagues to identify areas of improvement and implement necessary changes to enhance your performance. Embracing new technologies, methodologies, and best practices will also help you stay ahead in the purchasing field. This continuous improvement might involve:
- Adopting innovative procurement software
- Attending professional development courses
- Participating in industry forums
Learning more about air compressors and the market can help you navigate the purchase process with confidence.
Choosing the right industrial compressor isn't always easy, but with this buyer's guide, it can be. Ensure you're getting the air compressor that's right for your industry by understanding its uses and what your company needs one for'and U.S. Air Compressor can help if you're unsure. Our selection of industrial air compressors can help you cut costs and improve efficiency. Don't hesitate to work with us if those benefits sound good to you!
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