Modular Nitrogen Generators Replace Twin Tower For a Win

“You can’t manage what you don’t measure” is an adage we live and die by.  In a world of data and analytics, there is no excuse for subjective compromise in a highly technical industry.  We conducted a comprehensive engineering study of the existing nitrogen generation system to tackle all three objectives.  We also measured the supplementary liquid nitrogen supply to ensure total nitrogen demand visibility.  Our engineering team also analyzed how the nitrogen was used on the production floor.

Engineering Study Results

Once we collected the data and completed the engineering study, the baseline report revealed that the current nitrogen system was undersized by approximately 75%, relative to the plant’s peak demand.  All nitrogen requirements above 26% of peak production were supplemented by expensive liquid nitrogen from a third party.

With the new peak demand numbers identified, we determined that installing a larger twin tower nitrogen generator would not be possible without significant construction (and cost) to the building.  The client would require a modern and dynamic system design to utilize the existing room.

Lastly, we determined that the twin tower nitrogen generator was inefficient as production fluctuated.  We identified that the equipment was running as efficiently as specified under full load conditions (100% capacity utilization).  However, during part load (99% utilization and under), the target compressed air to nitrogen ratio would fall drastically, and the system was using far more energy than required.  Some days, the nitrogen generator was using twice the electricity needed because the twin tower design could not scale its energy usage when not utilized to its full potential.  The inefficiency of the nitrogen generator was simply due to its design, which is better suited for applications with a stable and unvarying flow profile.

Next Steps

Using the study, the Purity Gas Engineering team developed a performance model that separated a single large twin tower nitrogen generator into an agile system consisting of 6 modular nitrogen generators that would work as a cohesive unit during peak production and anywhere in-between.  The comparative data showed that as a result, the entire system (four times larger!) could be installed in the same overcrowded room that was currently housing the undersized twin tower system.  In addition, we designed the 6 module system so that modules would activate and deactivate to scale with production demands.  This design philosophy ensures that energy is conserved and never wasted during low-demand periods.  Unneeded nitrogen generator modules would enter an energy-saving economy mode and stop using power when not required.  As production and flow requirements increased, the modules would awaken independently to join the system for duty, ensuring optimum system efficiency.

Additional Incentives for Modular Nitrogen Generators

Our performance model showed significant energy savings by switching to modular design theory that it became eligible for a considerable energy reduction incentive through the local electricity provider.  An independent engineering firm specializing in industrial energy management completed the stringent measurement and verification process before and after the system replacement to validate the savings and claims.  This process provided a secondary analysis of the project to substantiate the gains and provide a financial incentive for using less energy.  It was a pioneering validation for modular nitrogen generation and the first energy reduction incentive of its kind.