One of the primary considerations when choosing nitrogen generators is the cost. This is often the most significant expense, especially if a facility needs to run a compressor. However, this cost is usually small, and over the long term, the financial benefit of nitrogen generation is the greatest advantage too. Compared to the cost of never-ending tank deliveries, the initial cost of nitrogen generation is minimal. Nitrogen Generation representatives can help you calculate the long-term cost of using nitrogen generators.
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The cost of nitrogen generators varies depending on the equipment and location you plan to install them. You should also consider the maintenance costs, as running an air compressor can be expensive. In addition, you will need to pay for electricity and gas for the unit. Finally, it would help if you also considered how much time it will take for your nitrogen generator to pay for itself. The return on your investment will vary, but it is usually within nine to 24 months.
One of the main benefits of nitrogen generators is that they are more affordable than cylinders. The cost of cylinders is high, and many costs are associated, including delivery and admin fees. Also, cylinders are challenging to move and leak, causing your nitrogen supply to run out during a critical operation. Additionally, you will need to worry about the logistics of changing canisters and reloading cylinders, which can be time-consuming and messy.
The demand for nitrogen is increasing, driving the development of nitrogen generators. Traditional nitrogen supplies are in cylinders or liquid form and are produced at an air separation plant through an electrically intensive process known as fractional distillation. To produce nitrogen, air must be chilled below -200 deg C, and the process requires large amounts of energy. It also needs a large-scale operation to be economically viable.
Nitrogen generators can be designed to operate at different levels of efficiency. For example, CompAir nitrogen generators use pre-treated air from a standard industrial compressor. This air is treated to remove oxygen and trace gases, and only nitrogen is allowed to pass through to the application. This is not a novel concept, but modern nitrogen generators use radical PSA designs and control systems to maximize efficiency. The energy savings from nitrogen generators are so significant that they will pay for themselves in a few years.
One of the most critical aspects of nitrogen generators is their logistics. Having nitrogen in stock is essential for critical operations. The shortage of nitrogen can lead to product damage and loss, which can result in massive costs. Additionally, storing nitrogen is costly, requiring additional floor space and fire protection. Furthermore, many businesses have rental agreements for cylinders and tanks, which increases the cost of nitrogen. Fortunately, several solutions can help you reduce your costly maintaining a constant nitrogen supply.
One of the most cost-effective methods of nitrogen generation is on-site nitrogen generation. It is much more affordable than buying nitrogen from a vendor. But membrane nitrogen generators are not without their logistical problems, so it is crucial to work with a professional team and a trucking company to ensure that all the necessary nitrogen is delivered correctly. Industrial operators may also need to install storage facilities for nitrogen to meet regulatory requirements. Additionally, the storage facility must comply with specific temperature standards, as fluctuating temperatures can cause product loss in transit.
Due to its inert nature, gaseous nitrogen can be used in various purging, blanketing, and flushing operations. Depending on the process involved, different grades of nitrogen purity are needed to fulfill unique manufacturing needs.
This article discusses the categories of nitrogen gas for industrial use and their appropriateness for different manufacturing processes.
Nitrogen purity refers to the proportion of nitrogen gas present in a sample taken from its stream compared to impurities present. Nitrogen gas can be categorized as high purity or low purity depending on the ratio of pure gas to contaminants like oxygen, water vapor, carbon monoxide, and carbon dioxide.
This categorization based on nitrogen concentration plays a key role in determining the suitability of nitrogen for any industrial process.
The purity of a sample of nitrogen gas is determined by the percentage/concentration of pure nitrogen in it. For gas to be classified as high purity, it must possess at least 99.998 percent nitrogen while lower purity nitrogen gas usually contains a higher proportion of impurities.
High-Purity Nitrogen Gas
Gaseous nitrogen with concentrations above 99.998% is considered a high-purity fraction. High nitrogen purity can be graded in different ways by different manufacturers; however, it is mostly considered to be a 'zero-grade' fraction. Zero-grade nitrogen purity is categorized as such because it contains less than 0.5 parts per million of hydrocarbon impurities.
Other key characteristics of high-purity nitrogen gas are:
Low-Purity Nitrogen Gas
Nitrogen gas ranging between 90 to just under 99.9% is considered to be low-purity. Common low-purity nitrogen gas brands include:
Contact us to discuss your requirements of Ultra High Purity Nitrogen Generator. Our experienced sales team can help you identify the options that best suit your needs.
Nitrogen gas manufacturers name their products differently; there are no standardized naming conventions. As a result, a low-purity gas from one producer might be mistaken for a high-purity gas by another based on its name alone. The only definitive way to determine a gas rating is to check the manufacturer's guide on their unique gas concentrations.
Classifying pure nitrogen gas is done with the grading system using digits within each minimum purity rating. The first digit of each grade refers to the number of 'nines' present in it while the second digit represents the number following the last nine. For example, grade N3.0 is equal to 99.9% nitrogen purity and is a pure grade gas purity classification (no second digit attachment).
Pure grade nitrogen classifications include N2.0, N3.0, N4.0, N5.0, N6.0, and N7.0.
Ultra-high nitrogen purity levels refer to a nitrogen gas concentration of 99.999% with negligible impurities. UHP nitrogen specifications are strict with variations rendering the classification invalid.
The oxygen content of UHP gas can be no greater than 2 parts per million by volume (ppmv), total hydrocarbons cannot exceed 0.5 parts per million by volume, and moisture no greater than 1 part per million by volume). UHP nitrogen gas is typically used in scientific applications.
Oxygen-free nitrogen is defined as gaseous nitrogen containing no more than 0.5 parts per million of oxygen. OFN gas is typically maintained at 99.998% nitrogen purity. This grade of nitrogen gas is useful in scientific research and calibration processes where oxygen impurities might alter outcomes or cause incorrect results.
As mentioned above, the concentration of nitrogen required in different industrial processes varies greatly. The key consideration in choosing a grade of nitrogen is the effect of impurities on the selected application. Sensitivity to moisture, oxygen, and other contaminants are critical factors to consider
Pharmaceutical manufacturing processes require high nitrogen purity levels to prevent contamination and alteration of their final products. Many drugs require high-grade nitrogen with a purity between 97-99.99%. This high to ultra-high purity nitrogen is used for nitrogen blanketing storage tanks, receptacles, and other equipment used in drug manufacturing.
High-purity nitrogen is also used in drug packaging to help retain freshness and keep active ingredients from deteriorating.
Gaseous nitrogen with purity levels ranging from 95-99% is useful in the oil and gas industry to reduce the risk of fires and explosions in associated processes. Chemical storage tank inerting and pipeline purging with gaseous nitrogen help minimize the risk of sudden combustion of their contents.
Pipeline maintenance services frequently use pressurized nitrogen for pipeline cleaning and pipeline decommissioning processes.
Nitrogen is commonly used in different steps of food/beverage production, packaging, and storage. Nitrogen in food packaging and processing is used to preserve the shelf life of processed food/drinks by eliminating food oxidants, preserving flavor, and preventing rancidity. Food-grade nitrogen gas requirements typically fall between 98-99.5% purity.
Understanding the nitrogen grade requirements for each application is essential for selecting the appropriate nitrogen supply source and ensuring optimal performance and reliability. Some industrial applications and their nitrogen-grade requirements are outlined below.
At NiGen, we specialize in supplying and maintaining efficient onsite nitrogen generators tailored to meet the diverse needs of various industrial manufacturing processes. With our extensive range of products and services, we ensure that all nitrogen requirements are fulfilled at every stage of your production cycle.
Contact us online today for a quote or to learn more about our services and nitrogen generators.
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