Benefits of On Site Nitrogen Generation

Tired of relying on unreliable deliveries and skyrocketing nitrogen costs? On-site nitrogen generation could be the game-changer you’ve been waiting for. This innovative technology isn’t just a futuristic dream; it’s been quietly revolutionising industries like food processing, pharmaceuticals, and laser cutting for years.

Imagine:

• Slashing nitrogen expenses by up to 70% compared to traditional tank deliveries.
• Boosting operational efficiency with instant, on-demand nitrogen supply.
• Ditching the delivery headaches and enjoying complete control over your nitrogen needs.
• Minimising environmental impact with a reduced carbon footprint.

In this comprehensive article, we delve into the benefits of on-site nitrogen generation systems. Whether you are deliberating the viability of investing in such a system or seeking in-depth knowledge about its advantages, our detailed guide will offer you a clear perspective.

We, at Control Gear, leverage our expertise in on-site nitrogen generators and compressed air solutions to show how these systems could revolutionise your operational efficiency and significantly cut costs.

Understanding On Site Nitrogen Generation

Nitrogen is used in many industries, from food packaging and electronics manufacturing to chemical plants and pharmaceuticals. Traditionally, businesses relied on bottled nitrogen or bulk liquid gas, but these methods can be costly, unreliable, and difficult to budget. Generating nitrogen on site provides a more efficient, cost-effective, and reliable nitrogen supply, reducing dependence on third-party suppliers.

How Do Nitrogen Generators Work?

On-site nitrogen gas generators produce nitrogen by extracting it from compressed air. Since nitrogen is produced directly on demand, there is no risk of running out of supply or dealing with expensive pressurised bottles. The two main technologies used are:

• Membrane Nitrogen Generators – separate oxygen and moisture from compressed air using semi-permeable membranes, delivering high-purity nitrogen (95–99.5%). Ideal for food preservation, modified atmosphere packaging, and industrial applications requiring moderate nitrogen levels.
• Pressure Swing Adsorption (PSA) Generators – use carbon molecular sieves (CMS) to absorb oxygen, producing high-purity nitrogen (up to 99.999%). Essential for electronics manufacturing, chemical plants, and laser cutting, where precise nitrogen levels are critical.

Why Choose On-Site Nitrogen Generation?

✔ Lower Costs – avoid costly bottled nitrogen, bulk liquid deliveries, and rental fees, maximising return on investment.
✔ No Waste – produces nitrogen as needed, eliminating waste from unused gas in nitrogen storage tanks.
✔ Reliable Supply – maintains a steady nitrogen flow without the risk of delivery delays or shortages.
✔ Improved Safety – no high-pressure cylinders or liquid gas handling, reducing workplace hazards.
✔ Eco-Friendly – lowers carbon footprint by removing transport emissions and ongoing nitrogen waste.

Seamless Integration for Maximum Efficiency

Modern nitrogen generator installations, like those from Atlas Copco, integrate smoothly with air compressors and packaging processes. This ensures freshness in perishable food and reliability in electronic component production. Switching to on-site nitrogen generation means greater control, efficiency, and long-term savings.

Benefits of On-Site Nitrogen Generation

On-site nitrogen generation offers a multitude of advantages over traditional bottled or liquid nitrogen delivery. From cost savings and enhanced safety to improved process control, these systems bring a new level of efficiency to industries that rely on nitrogen.

Let’s delve into the specific benefits that make on-site nitrogen generation a compelling choice for many businesses.

Reduce Costs and Improve Gas Supply

One of the most significant benefits of choosing an onsite nitrogen generation system is its cost-effective solution compared to having to pay for liquid nitrogen to be delivered.

The reason generating nitrogen yourself is cheaper is because it can be made to your specific gas purity levels rather than having to pay for over-specified gaseous nitrogen that is more expensive and then kept in a storage tank for continuous usage when you need it.

It’s also a great way to reduce the number of ongoing contracts and tank rental fees you have to pay regularly, helping you streamline your nitrogen costs and stop being overcharged for long-term nitrogen gas contracts.

Here’s a simple ROI analysis:

Scenario: A food processing plant currently consumes 10,000 cubic feet (CF) of liquid nitrogen per week, at a cost of $5.00 per CF. This translates to annual expenses of $260,000.

On-Site Nitrogen Generation Solution: Investing in a system capable of producing 10,000 CF of nitrogen weekly incurs an upfront cost of approximately $50,000. However, the operating cost per CF of self-generated nitrogen is roughly $1.50, resulting in annual production expenses of $78,000.

Calculating the ROI:

• Cost Savings: $260,000 (traditional cost) – $78,000 (on-site generation cost) = $182,000
• Payback Period: $50,000 (upfront investment) / $182,000 (annual savings) = approximately 0.27 years, or 3.3 months

In this scenario, the on-site nitrogen generation system pays for itself in just over three months! And the savings keep rolling in year after year, potentially reaching millions of dollars over the system’s lifespan.

Moreover, integrating such systems often reduces indirect costs, including logistical complexities and time lost due to delayed deliveries.

In short, when you choose to process your own nitrogen gas, you can look forward to stable and cost-effective production processes that work hard for you!

Less Nitrogen Gas Waste

When you order nitrogen gas cylinders and other gases, you must estimate how much gas you need, plus the exact pressure required for your applications. Too much or too little nitrogen can often be delivered as a result.

Excess nitrogen leads to unnecessary costs and handling efforts, while insufficient supply disrupts operations. On-site production eliminates this issue entirely, ensuring optimal consumption while significantly reducing wastage by as much as 40%.

The problem with too much nitrogen is that it will end up being wasted, which requires more man-hours to deal with. Plus, an unnecessary expenditure.

Reliability and Control

The third main benefit of being in charge of your own nitrogen production list is that it will be reliable and ensure that you are in complete control of your supply at all times.

An on-site nitrogen generator can work to provide a continuous and uninterrupted supply of nitrogen when you need it. In other words, nitrogen supply issues will no longer be a problem, and you can produce the quality and amount of nitrogen you need to suit your own schedule.

The other great thing about nitrogen systems is that you can set up your nitrogen generators to provide the right purity and flow rate level for your nitrogen consumption requirements.

In essence, whether you choose Atlas Copco nitrogen generators or a different brand, having the ability to enjoy central control of your gas supply means that even distribution is easier than ever before. Centralised control systems integrated with IoT can also enhance monitoring capabilities, ensuring operational precision.

On-site Air Compressors Are Safer

Gas production via a generator will involve several safety issues that must be carefully considered. First, if you do not have on-site nitrogen generators, you will need to purchase nitrogen cylinders.

Nitrogen cylinders pose a risk of explosion or leaks, which can put your business in danger. Even when your cylinders are empty, storing and moving them is difficult, as they are heavy and can cause injury.

It is also important to remember that nitrogen gas is turned into liquid nitrogen for transportation, or the pressure levels are increased up to 300 bar (g)/4350 psi. While you are not responsible for this transportation, you will need to think about unloading it when it arrives. This, of course, poses additional safety concerns.

When you produce nitrogen, you can eliminate the risks with cylinder delivery by only making enough nitrogen for your needs, including the right purity level. This also removes the need for high-pressure handling, significantly reducing workplace risks.

Space Efficiency

Modern nitrogen generator machines have been designed to be compact and easy to move around for optimal on-site generation. You have more control over where you process your nitrogen and can effortlessly get your generator working where and when you need it.

When your nitrogen generator is not in use, it is easy to store without fear of safety problems or without the worry of your team getting injured while working with it.

In addition to having a smaller generator working to provide a steady supply of nitrogen for your use, you will also be able to free up more valuable storage space on your premises as you no longer need to store the cylinders.

This flexibility makes these systems particularly advantageous for facilities with dynamic spatial needs or evolving operational layouts.

Environmental Impact

Being aware of your carbon footprint and ensuring environmentally friendly practices is easier with nitrogen generators; you are responsible for all production and purity. This means that you can work to reduce your carbon dioxide emissions and make your business a healthier place to be without reducing your own workflow capabilities.

Moving towards a more environmentally friendly work also means better use of capital purchase as you will be more efficient with your purchases and able to reduce the levels of waste that you are currently producing.

Taking responsibility for your carbon footprint is not just great for your business in terms of hitting targets, but it will also make you more attractive to clients who are keen to work in the most environmentally friendly way. The cumulative impact on environmental sustainability can also provide a significant competitive edge in industries prioritising green practices.

Applications of an On-Site Nitrogen Generation System

Even when you are clear on using an on-site nitrogen generator, you may wonder whether it is suitable for your industry or needs. Take a look at some of the most common applications of an on-site nitrogen generation system below:

• Offshore Drilling – getting nitrogen cylinders delivered to offshore drilling sites is not simple, so a generator can support the needs instead. This makes it easy to get a constant supply and enables you to change purity levels as and when needed. Atlas Copco’s PSA nitrogen generators are particularly suited for such remote operations due to their high reliability and ease of maintenance​​.
• Food Packing – modifying the packing area is important as too much oxygen can cause food to expire quicker, putting pressure on the company. By installing a nitrogen generator, you can create a nitrogen-rich environment, reduce oxygen, and get the best life span from your food production. Atlas Copco offers Class 0 oil-free solutions for the food and beverage industry to ensure that nitrogen remains contamination-free, enhancing product quality and safety​​.
• Electronics – electronics manufacturing requires a controlled environment, and PSA nitrogen generators can help provide the gas needed for soldering. The nitrogen molecules help improve the soldering quality, making the components more trustworthy and longer lasting. High-purity nitrogen provided by PSA systems, up to 99.9995%, is ideal for maintaining the precision needed in electronics manufacturing​.
• Manufacturing – laser cutting is a big part of the manufacturing industry, and having access to free-flowing nitrogen ensures that you oversee the production of high-purity gas that will move oxygen and stop oxidation during laser cutting.  Atlas Copco’s PSA nitrogen generators offer high flow rates and customisable purity levels, making them a perfect match for laser applications​​.
• Chemical Handling – when it comes to chemicals, a generator can help to create an inert atmosphere in a storage tank, helping to reduce risk, and prevent fire and unplanned chemical reactions. Nitrogen inerting, supported by Atlas Copco generators, is critical in chemical and petrochemical industries to maintain safety standards​.

PSA Nitrogen Generators Vs Membrane Technology

Before investing in a generator delivery, you will need to decide which type is best for you. There are two choices, Pressure Swing Adsorption (PSA) or Membrane Nitrogen Generation (MNG). 

A PSA system is like a high-tech sieve for air. PSA generators employ carbon molecular sieves (CMS) that selectively absorb oxygen from compressed air, leaving behind purified nitrogen. This technology excels in:

• High Purity: PSA delivers nitrogen purity levels up to 99.9995%, essential for applications like pharmaceutical production, electronics manufacturing, and medical uses​​.
• Production Strength: PSA systems offer high flow rates, making them suitable for large-scale industrial requirements.
• Long Lifespan: Robust CMS materials ensure reliable operation for years to come.

But, PSAs have limitations and drawbacks:

• Higher Upfront Cost: PSA systems generally require a larger initial investment compared to MNG
  
• Maintenance Needs: Regular maintenance of the CMS is crucial for optimal performance.
  
• Energy Consumption: PSA systems typically consume more energy than MNG due to the compressed air requirement.
  

On the other corner, an MNG system is a microscopic filter that separates air’s components. MNG systems utilise semi-permeable membranes that allow nitrogen to pass through while blocking other gases like oxygen. This technology shines in:

• Cost-Effectiveness: MNG systems are more affordable to install and operate, ideal for smaller operations or temporary setups.
  
• Portability: MNG systems are often compact and lightweight, ideal for smaller spaces or temporary needs.
  
• Low Maintenance: MNG requires minimal maintenance, making it a low-touch solution.
  

Likewise, MNG’s weaknesses are the opposite of PSA’s strengths:

• Lower Purity: Nitrogen purity typically ranges between 95–99.5%, which is insufficient for some high-precision applications.
• Limited Production Strength: MNG systems generally have lower flow rates compared to PSA, making them less suitable for large-scale demands.
• Membrane Replacement: Membranes eventually degrade and require periodic replacement, adding to ongoing costs.

Ultimately, the best technology depends on your specific needs and priorities. Consider these factors:

• Required Nitrogen Purity: Do you need ultra-high purity for sensitive applications, or is a lower range sufficient?
• Production Volume: How much nitrogen do you require daily or weekly?
• Budget and Investment Horizon: Can you afford the initial investment and ongoing maintenance costs?
• Space and Portability: Do you have space constraints or need a mobile solution?

Atlas Copco offers a range of PSA and MNG solutions tailored for various industries, ensuring you achieve cost-effective and high-performance nitrogen generation​​.

By understanding the strengths and limitations of PSA and MNG, you can make an informed decision that optimises your nitrogen generation needs and empowers your business success.

The Benefits of On-Site Nitrogen Generation with Control Gear 

There’s no denying that having access to nitrogen gas on-site can help you to streamline your business offer and improve efficiency, reduce safety issues and environmental impact, all while improving reliability, control and offering cost savings.

Explore Atlas Copco’s on-site nitrogen generators to find the perfect fit for your business needs. Contact our experts to optimise your compressed air and nitrogen solutions for maximum performance and sustainability​.

Explore our range of Atlas Copco on-site nitrogen generators and find the perfect fit for your business needs.

FAQ

Why is on-site nitrogen generation better than using bottled nitrogen?

On-site gas generation eliminates the pitfalls of relying on external suppliers, such as delivery delays, fluctuating costs, and handling high-pressure cylinders. Businesses that produce high-purity nitrogen benefit from greater control, lower costs, and improved safety. This ensures a consistent supply that meets the total demand for nitrogen gas without waste or inefficiencies.

How does on-site nitrogen generation improve product shelf life?

Nitrogen gas is essential in industries like food packaging and pharmaceuticals, where controlling oxygen exposure is critical. By producing high-purity nitrogen on demand, businesses can maintain precise nitrogen levels. This prevents oxidation, spoilage, and contamination, ultimately extending shelf life and ensuring product integrity.

Is nitrogen gas generation safe for industrial use?

Yes. On-site gas generation eliminates risks associated with high-pressure cylinders and bulk liquid storage. Since nitrogen is an inert gas, it is used for many applications, from fire prevention to chemical processing, without creating combustion risks. Generating nitrogen on-site reduces handling hazards, making it a safer and more efficient alternative to traditional supply methods.