psa nitrogen generation
DESCRIPTION
The generation of Nitrogen via the pressure swing method is explained by this presentationTRANSCRIPT
IntroductionPressure Swing Adsorption (PSA) is a nitrogen gas generation method with a specially designed adsorbent. This adsorbent is
called a Carbon Molecular Sieve (CMS) having micro pores in its surface to adsorb O2, CO2 and H2O molecules when under a
certain pressure. After the adsorption process, the adsorbent is regenerated by depressurizing the vessel containing the
adsorbent. PSA can produce the nitrogen gas continuously by repeating above adsorption and regeneration.
The use of the PSA process has seen immense growth during the last few decades, mainly due to its simplicity and low operating
costs. Major applications outside of nitrogen have been the recovery of high purity hydrogen, methane and carbon dioxide and
oxygen.
The number and size of the CMS will dictate the purity of the nitrogen produced and the flow rates possible. PSA has been
successfully used to produce nitrogen from a rate of 5,000 CFH to 60,000 CFH with purities ranging from 95% - 99.9995%.
When to Use PSAThere different options of nitrogen production, such as permeation membrane systems and cryogenic distillation. This means it is
important to first establish if PSA is the most efficient and economic method for your application. In order to do this you will need
to determine the day to day use of nitrogen that is anticipated and the purity of the nitrogen that is required. Figure 1 shows the
areas where PSA is likely to be a good option (Adsorption onsite generation).
Figure 1 – Map of areas covered by different methods1
When to Use PSAPSA can produce nitrogen in a range of purities as shown in figure 1. However, figure 1 does not take into account the financial
aspect (i.e. the cost of production). Figure 2 can give an idea of the general trend of how costs change with increasing levels of
purity and increasing flow rates. It is not always necessary to produce highly pure nitrogen. For example blanketing vegetable oils
can be done with purities of around 99.5%.
Figure 2 – Effect of Purity on cost1
The purity of nitrogen required to blanket a
flammable material is determined by the material’s
Limiting Oxygen Concentration (LOC) or Lower
Flammability Limit (LFL). These values can be
obtained from the National Fire Protection
Association’s (NFPA) NFPA 69: Standard on
Explosion Prevention Systems. In this guideline it
can be seen that sometimes the purity required can
be below 95%.
During the course of a day the demand for nitrogen
can vary. This is bad news for PSA as PSA works
most efficiently when working at its full design
capacity.
When to Use PSAIn order to gain the maximum economic benefits from an on site PSA system it is incredibly important to ensure that it is working
at maximum capacity for as long as possible. To allow this to be done it is vital to establish the flow pattern on a daily basis that is
required. As well as knowing figures like the number of hours of operation during a day, it is just as important to know the
fluctuations in the load during the day. If fluctuations are present in the load, it will be the nature of these fluctuations that will
determine the size of the PSA system, and the buffer tank if required.
PSA systems are outstanding when it comes to supplying a steady flow pattern. This kind of flow pattern allows the unit to be
sized very easily and constantly work at full capacity. When the loading pattern contains instantaneous peaks and troughs a PSA
system will struggle. Sizing for the lower demand will mean that a buffer tank will be required and sizing for peak demand will
mean the PSA system is working at part capacity or idle, bringing high operating costs. An erratic flow pattern can usually be
handled by a combination of a PSA system and liquid nitrogen supplements. PSA systems are usually aimed at having a utilisation
of 90% or higher.
Figure 3 –
Possible nitrogen
flow patterns. 1
How Does PSA WorkPSA systems are actually very easy to understand in concept. The basic description would be that air is taken from the
atmosphere, filtered to remove solids (dust particles etc.), compressed to achieve the required pressure by the PSA system, put
through the absorbent at high pressure and then either collected in a tank or distributed around the network. Figure 4 shows the
general system schematic for a PSA system.
Figure 4 - Basic Schematic for PSA system2
How Does PSA WorkLooking in more detail at the PSA system (the nitrogen generator module in figure 4) the process used by PSA can be condensed
into 6 steps. The PSA system in general is constructed of two vessels containing an absorbent. The absorbent is there to remove
Oxygen, Carbon Dioxide and other gases found in air, apart from Nitrogen, which will pass straight through the absorbent
unaffected. Only one of the vessels is in operation at any given time, while the other is regenerating.
For the purpose of explanation and clarity, from figure 5
the vessel on the left will be referred to as vessel 1 and the
vessel on the left will be referred to as vessel 2. The first
step of the process will involve pressurising vessel 1 and
depressurising vessel 2. This will allow vessel 1 to be
prepared for adsorption and vessel 2 to be ready for
regeneration. The pressure required for pressurisation can
vary from system to system, and the 8 bar indicated in
figure 5 is not compulsory.
In figure 5 the green particles are nitrogen while the red
are other gases present in air. In between the two vessels
there is a release to the atmosphere. Figure 5 – Repressurisation/Depressurisation3
How Does PSA WorkThe next step of the process is shown in figure 6. This step is
called adsorption and regeneration. Vessel 1 is now pressurised
and compressed air is being passed through it and the
absorbent is active. So at the exit point of vessel 1 pure
nitrogen is emitted. Some of the nitrogen emitted is sent to
vessel 2. Vessel 2 is depressurised so passing a nitrogen
through it will remove any absorbed gases from the absorbent
and then this is released to the atmosphere.
Figure 6 -
Adsorption and
Regeneration3
Step 3 is known as Equalisation. As the name suggests all
that is happening during this time is that the pressure in
vessels 1 and 2 are being equalised. During this step no
nitrogen is produced and no gases from regeneration are
released to the atmosphere as regeneration and absorption
will have ceased. After this step the whole cycle is
repeated but with vessel 2 doing the adsorption and vessel
1 doing the regeneration.
Figure 7 -
Equalisation3
Safety ConsiderationsDuring operation Nitrogen generators such as PSA system can produce oxygen rich and nitrogen rich atmospheres. This is
particularly dangerous when the system is housed within a building. It is important that the area the system is housed in is well
ventilated and provided with adequate fire protection. This is because if an oxygen rich atmosphere is produced there is a
significantly increased risk of fire. It is recommended that the oxygen concentration within the building should not exceed 23.5%.
As there is also a possibility of nitrogen rich atmospheres being produced, hence a reduction in the oxygen level, the oxygen level
should be monitored to ensure it stays above 19.5% as lower than this constitutes hazardous working conditions.
When installing the PSA it is vital to install proper ventilation, always ensure the nitrogen exhaust and the waste gases are piped
out of the building. Sensors for the oxygen level should also be linked in with an alarm system, and signs should be posted to warn
personnel of a possible oxygen deficient area.
An important note would be to consider having an oxygen level alarm in rooms where tools
are powered by gases other than oxygen, as leakages from pipes and tools can also result in
an oxygen deficient area.
If it is not possible to maintain an oxygen level that is adequate then the correct breathing
apparatus should be provided. As previously mentioned that it is possible to have an oxygen
enriched area, in which fire hazards are increased, it is recommended that personnel working
in the building where the PSA is housed should wear flame retardant clothing such as NOMEX,
and that the building and directly surrounding area be kept free of hydrocarbons and other
combustible materials.
Installation 1The first part of installation is site selection. One of the primary factors in site selection is the quality of air. Many PSA systems are
located in or near industrial areas, resulting in the air quality be fairly low. It is likely the air will be contaminated with
hydrocarbons, acid gases and particulate matter. This will have a negative affect on the operation of the PSA system and in the
case of hydrocarbons and other flammable particles could have a serious impact on the safety of the operation of the PSA system.
In industrial areas some level of contamination is to be expected, and the manufacturer should be consulted to determine
acceptable levels of contamination.
When selecting a site, survey of the surrounding area should be performed. The survey should include but not be limited to,
looking at how future development might affect the air quality and investigations into potential fire hazards. It is important to
ensure that around the PSV there will be enough space for other operations and maintenance to continue.
As noted in the ‘Safety Considerations’ section the ventilation of the building that
houses the PSA is of paramount importance. It is recommended that a minimum of 6
air changes an hour are performed. The release of the oxygen rich waste gas should
be funnelled away from any possible sources of ignition (i.e. road traffic).
Materials used for the construction of the PSA and interconnecting pipework are
usually carbon steel or copper. When selecting materials the presence of high velocity,
oxygen rich gases should be considered. Any non – metallic material will react with
oxygen, so when routing exhaust gases, contact the manufacturer for suitable materials
of seals and gaskets are required.
Installation 2Before the installation is completed and the PSA turned on, pipework needs to be cleaned,
especially in the waste gas routing. The removal of rust, dirt, weld slag and oils is vital for
minimising the fire risk and maximising the life and performance of the PSA. Under EN60079
Nitrogen generators are not thought to be a hazard to electrical equipment, so it is acceptable
to use general purpose wiring depending on if the location in in or out doors. All equipment
must be grounded.
The fire protection that would need to be installed for the PSA system is very simple. A
large, readily available supply of water is usually sufficient if in the form of a number of fire hydrants or hoses. The fire protection
system should allow the fire to be approached from all angles. It common practice to have an emergency shut down system on a
PSA, and on larger installation there may be more than one place to trigger the system.
Something that is sometimes overlooked is the noise produced by compressors and high gas velocities, this should be considered if
placing near a residential area. Also the venting of the building should be directed away from personnel and exhaust from pressure
relief valve should directed away from personnel. Waste gases from nitrogen generators are typically high in water content, so
drainage and freezing protection should be considered.
When reviewing hazards with in PSA supplier ‘dusting’ (deterioration of the adsorbent) should be taken into account. The particle
produced are not normally hazardous but are frequently a low level irritant and the particle can cause measuring instruments to
provide inaccurate readings.
Installation 3
PSA systems will have air compression systems that will
generate water condensation via processes such as drying. The
condensate stream do sometimes contain small quantities of
oil, glycol and molecular sieve dust. Provisions should be made
for the disposal of such solids or fluids, that comply with all
national and local environmental practices.
Finally before installation is started, a hazard review should be
performed to reduce any possible hazards. It is preferable that
more than one person performs this.
Storage – Cryogenic LiquidEach site will have their own issues with the storage of nitrogen. This is due to the fact that sites across the world all have
different environments to cater for. Therefore every storage system needs to be designed with the on site environment
considered. The characteristics of nitrogen that can it to be a hazard when stored in large quantities are that it is colourless,
odourless, tasteless and more importantly does not support life.
Nitrogen can be stored on site as a cryogenic liquid in a tank. Usually this is only an option when the amount of nitrogen to be
stored is quite high. EIGA DOC 127/13 will provide good guidance for the storage of cryogenic nitrogen for up to 125,000 litres. for
To reduce the dangers on handling stored cryogenic liquids (in this case nitrogen) it is important to undertake a risk assessment in
accordance with the Confined Spaces Regulations (SI 1997 No. 1713). Refer to BCGA Code of Practice 36 for information on the
design of cryogenic gas storage on site.
When considering small quantities of nitrogen (50 litres or less) the use of dewars is appropriate. BCGA COP 30 is able to give
good advise on storing cryogenic nitrogen on a small scale in dewars. Before choosing the option of storing small quantities
cryogenically, it is important that cost implications are considered.
Storage - GaseousAs mentioned in the Cryogenic storage section nitrogen is only
a treat to life because it is a gas that does not support life. This
means when storing nitrogen on site in cylinders, as gas form,
the treats are that it may be compressed in a cylinder,
therefore likely to explode when heated and it is an asphyxiant
stored in a high concentration.
This means it is important to keep the nitrogen cylinders in a
cool, well ventilated area. The cylinders should not be allowed
to reach temperatures above 50oC. The cylinders should be
stored in a vertical orientation and should be secured to
prevent them from falling over. Frequent inspections of
cylinders should be performed to check for leaks and the area
they are stored in should preferably be away from sources of
heat and ignition. For further advice see BOC Doc 8347.
Piping and Distribution 1Care should be always be taken when designing piping and
distribution for nitrogen. Consideration of local temperatures
and pressures involved should be taken into account. When
pumping large quantities of nitrogen around a large network, it
may be suitable to have pressure reducing stations outside of
workshops or any other site where the nitrogen is to be used,
This is to reduce the pressure of the nitrogen to the correct
pressure for use. The pressure reducing station should have a
Pressure Reducing Device (PRD) on the low pressure side of the
pressure reducing station as a back up if the station should fail.
The components of the pipework system itself should have
isolation valves where necessary to allow for testing and
maintenance.
Piping and Distribution 2When piping pressurised nitrogen above ground it is important
to keep piping away from sources of heat, and to design the
distribution network with expansion and contraction due to
heat in mind. Other things to bare in mind are sources of
damage and vibration.
Underground pipework should also have consideration of how
temperature changes will expand and contract the pipework.
All underground pipework must not have threaded or flanged
connections in order to prevent gas from leaking and cathodic
protection should be used to prevent corrosion. When
underground pipes are to go under load bearing roads or
paths, it is best to encase them in pipe sleeves that are then
vented to atmosphere.
Refer to EIGA Doc 149/10 section 8 for more guidance.
Operation of the PSAFor the operation of the PSA to be done in a safe manner it is
generally a case of getting the correct practices and procedures
in place. The creation of operation checklists and log sheets
should be created for the start-up and operation of a generator
and all of its components. The log sheets are there to monitor
temperatures, pressures, vibrations, power and capacity.
Keeping a log sheet will help to diagnose any problems early
and adjust any characteristics to optimise performance.
The actual operation of the PSA should be performed by a
properly qualified persons, who will have developed a list of
procedures to cover different failures of the PSA. For example
what should be done in case of a fire in the compressor. For
further guidance see EIGA Doc 149/10 section 9.
MaintenancePerforming maintenance on these system can be very dangerous. The tanks containing the adsorbent are usually stored in
cabinets. This means the creation of a nitrogen or oxygen enriched atmosphere is likely in these areas. Also it means that work
may have to carried out in confined areas.
If repairs are necessary and require piping or vessel to be opened or have hot repairs done, the pipe work or vessels concerned
should be purged with clean air until an oxygen concentration of 19.5% - 23.5% is achieved and can be maintained. After new
equipment has been installed, before restarting the PSA a good cleaning process to remove any contaminants should be
performed. For further guidance see EIGA Doc 149/10 section 10.
References1) http://www.airproducts.com/~/media/Files/PDF/products/producing-nitrogen-via-psa-CEP-Article_20120638.pdf [online] Accessed 12/09/2013
2) http://www.gastec.com.my/Nitrogen/N2%20PSA/GasTec%20PSA%20N2%20Gen%20Systems%20Presentation.pdf [online] Accessed 13/09/2013
3) http://www.atlascopco.com/nitrogenus/products/nitrogen_generators/psa_nitrogen/ [online] Accessed 13/09/2013
Useful Documents1)BCGA CODE OF PRACTICE CP362)BCGA CODE OF PRACTICE CP303)BCGA CODE OF PRACTICE CP254)BULK LIQUID OXYGEN, NITROGEN AND ARGON STORAGE SYSTEMS AT PRODUCTION SITES IGC Doc 127/13/E 5)BOC gases Datasheet (Nitrogen – oxygen free)6)SAFE INSTALLATION AND OPERATION OF PSA AND MEMBRANE OXYGEN AND NITROGEN GENERATORS IGC Document 149/10/E7)BULK LIQUID OXYGEN, NITROGEN AND ARGON STORAGE SYSTEMS AT PRODUCTION SITES AIGA 031/06