Details
The Neometrix PSA Nitrogen Generation Plant is an advanced on-site nitrogen production system designed for industrial applications requiring high-purity nitrogen. Using Pressure Swing Adsorption (PSA) technology, it efficiently separates nitrogen from atmospheric air through Carbon Molecular Sieve (CMS) adsorption, ensuring a continuous, cost-effective, and reliable nitrogen supply. With purity levels ranging from 95% to 99.99%, this system eliminates the need for nitrogen cylinders or liquid nitrogen storage, significantly reducing operational costs. Equipped with automated PLC controls, safety mechanisms, and energy-efficient components, it is ideal for industries such as food packaging, pharmaceuticals, electronics, metal processing, oil & gas, and aerospace. The modular design allows for easy installation, scalability, and low maintenance, making it a superior alternative to conventional nitrogen sources. The PSA Nitrogen Generation Plant, manufactured by Neometrix Group, is a state-of-the-art on-site nitrogen production system designed to deliver a continuous and high-purity nitrogen supply. Operating on Pressure Swing Adsorption (PSA) technology, it efficiently separates nitrogen from atmospheric air using Carbon Molecular Sieve (CMS). This eliminates the need for nitrogen cylinders or liquid nitrogen storage, significantly reducing operational costs and dependency on external suppliers. This nitrogen generator is engineered to meet the demands of industrial, medical, pharmaceutical, chemical, aerospace, food processing, and electronics sectors, ensuring high efficiency, reliability, and minimal maintenance. Technology and Working Principle The system is based on the Pressure Swing Adsorption (PSA) principle, which utilizes selective adsorption to separate nitrogen from compressed air. The process is fully automated and cyclic, ensuring a constant supply of high-purity nitrogen. 1. Air Compression, Drying, and Filtration: Ambient air is compressed using an air compressor, then passed through refrigerant or desiccant dryers to remove moisture. Pre-filters and fine filters remove dust, oil, and contaminants before the air enters the PSA unit. 2. Selective Oxygen Adsorption on CMS Beds: The system consists of two adsorption towers filled with Carbon Molecular Sieve (CMS). When dry compressed air enters the first tower, CMS selectively adsorbs oxygen, carbon dioxide, and other trace gases, allowing nitrogen to pass through as the product gas. 3. Automatic Tower Switching and Pressure Equalization: Before the CMS in the first tower becomes fully saturated, the system automatically switches to the second tower. Simultaneously, a pressure equalization step occurs, reducing energy consumption and enhancing efficiency. 4. Oxygen Desorption and Regeneration: The CMS in the first tower is regenerated by depressurization, releasing the adsorbed oxygen and waste gases into the atmosphere. The tower is then ready for the next cycle. 5. Nitrogen Storage and Delivery: The purified nitrogen gas is collected in a nitrogen buffer tank at the required purity and pressure, ensuring a stable supply to downstream applications. Technical Specifications The PSA Nitrogen Generation Plant is designed to meet a variety of industrial needs. Below are the key technical specifications: • Nitrogen Purity Range: 95% to 99.99% (depending on application requirements) • Rated Operating Pressure: 7 bar (g) • Maximum Working Pressure: 9 bar (g) • Air Inlet Temperature: Up to 104°F (40°C) • Operating Temperature Range: 5°C to 43°C • Dew Point of Outlet Nitrogen: Up to -40°C (depending on air dryer selection) • Voltage Requirement: 100-240V AC, 50/60 Hz, Single Phase • Noise Level: ≤ 75 dB(A) • Flow Rate Capacity: 10 Nm3/hr (customizable based on demand) • Air Consumption: Typically 4-5 times the nitrogen output, depending on purity level • Power Consumption: Low-energy design to minimize operational costs • Control System: PLC-based control with HMI interface • Regeneration Type: Automatic pressure swing adsorption (PSA) • Safety Features: Overpressure protection, emergency stop, and automatic fault alarms Outstanding Features and Advantages 1. High Reliability and Durability: • Constructed with high-quality stainless steel components and industrial-grade PLC controls. • Designed for continuous 24/7 operation with minimal wear and tear. 2. Energy Efficiency and Cost Savings: • Uses low-energy PSA technology to significantly reduce nitrogen production costs. • Eliminates the need for expensive nitrogen cylinders and liquid nitrogen storage. 3. Customizable and Scalable Design: • Available in multiple capacity ranges, with purity and pressure adjustable as per customer needs. • Modular design allows for future expansion without major system modifications. 4. Easy Installation and Integration: • Pre-assembled and factory-tested for quick setup. • Compact footprint for easy integration into existing facilities. 5. Advanced Automation and Monitoring: • User-friendly PLC control panel with touchscreen HMI for real-time monitoring of nitrogen purity, pressure, and system status. • Automated alarms and notifications for maintenance and troubleshooting. 6. Safety and Compliance: • Equipped with pressure relief valves, automatic emergency shutdown, and gas purity monitoring sensors. • Meets ISO 8573 Class 4 air quality standards for safe and clean nitrogen production. 7. Low Maintenance Requirements: • No moving parts in the adsorption system, reducing wear and maintenance costs. • CMS bed lifespan of 8-10 years with proper usage and maintenance. Applications The PSA Nitrogen Generation Plant is widely used in multiple industries due to its efficiency, reliability, and high purity output. Key applications include: • Food and Beverage Industry: Used for modified atmosphere packaging (MAP) to prevent oxidation and extend product shelf life. • Pharmaceutical and Medical: Ensures a sterile, inert atmosphere for drug manufacturing, preservation, and laboratory research. • Electronics and Semiconductor Industry: Provides ultra-pure nitrogen for soldering, circuit board assembly, and cleanroom operations. • Chemical and Petrochemical: Used in blanketing, purging, and inerting to prevent hazardous reactions. • Metal Processing and Heat Treatment: Supports annealing, sintering, and welding processes by eliminating oxidation. • Aerospace and Automotive: Provides controlled environments for fuel tank blanketing and component testing. • Oil and Gas Industry: Used in well drilling, pipeline purging, and tank blanketing. System Components and Description The PSA Nitrogen Generator consists of the following key components: 1. Adsorption Towers (Two Towers): These contain Carbon Molecular Sieve (CMS), which selectively removes oxygen and impurities while allowing nitrogen to pass. 2. Air Dryer: Removes residual moisture from the compressed air, preventing contamination and improving efficiency. 3. Pre-Filters and Fine Filters: Ensures clean and dry compressed air before entering the PSA system. 4. Electronic Control Valves: High-performance solenoid valves regulate adsorption, equalization, and regeneration cycles. 5. Pressure Regulators and Gauges: Monitors and controls nitrogen pressure levels for safe operation. 6. Nitrogen Purity Analyzer: Real-time nitrogen purity monitoring system ensures product gas meets the required specifications. 7. Silencer and Auto Drain Valves: Reduces noise emissions and removes excess condensate from the system. 8. Control Panel with HMI and PLC: Fully automated operation with real-time monitoring and alarm notifications. Operation and Maintenance Startup Procedure: • Turn on the power supply and set the desired nitrogen purity. • Open the air supply valve and allow the system to stabilize. • The adsorption cycle will begin automatically, and nitrogen will start accumulating in the storage tank. • Once the system achieves the required purity, nitrogen is ready for use. Shutdown Procedure: • Close the nitrogen outlet valve to maintain system pressure. • Turn off the power supply and depressurize the towers. • Drain any accumulated moisture and contaminants. Maintenance Schedule: • Daily: Check system pressure, inspect for leaks, and monitor nitrogen purity. • Monthly: Inspect and clean filters, check silencers, and verify automation settings. • Six-Monthly: Replace pre-filters, fine filters, and moisture separators. • Annually: Inspect solenoid valves, check CMS bed condition, and calibrate purity sensors. • Every Three Years: Replace Carbon Molecular Sieve (CMS) for peak efficiency. Conclusion The Neometrix PSA Nitrogen Generation Plant is a high-performance, cost-effective, and low-maintenance solution for industries requiring a reliable nitrogen supply. With advanced automation, modular scalability, and energy-efficient design, it is an ideal alternative to traditional nitrogen sources, offering a quick return on investment and long-term operational benefits.
