Nitrogen Generation Using PSA Technology
Nitrogen is one of the key gases in modern industrial processes. This inert and non-flammable gas constitutes approximately 78% of dry atmospheric air and, due to its specific physical and chemical properties, is widely used in industries such as petrochemical, pharmaceutical, metallurgy, and food packaging.
In the following sections, the scientific principles of nitrogen separation from air are examined, and the structure and operation of PSA nitrogen generators are analyzed in accordance with industrial standards and the proprietary engineering designs of Fidar Faraz Fartak.
Definition of Nitrogen and Its Physical Properties
Nitrogen is a colorless, odorless gas with a density of approximately 1.25 g/L at standard conditions and a boiling point of −196 °C.
At ambient temperature, nitrogen exhibits very low chemical reactivity, making it ideal for applications requiring an inert atmosphere. From a thermodynamic perspective, nitrogen’s high specific heat capacity contributes to its stability in thermal processes.
Atmospheric Air Composition and the Importance of Gas Separation
Ambient air consists of approximately 78% nitrogen, 21% oxygen, and less than 1% noble gases and CO₂.
For industrial applications, oxygen and moisture must be removed from the air stream to produce nitrogen at the required purity levels, typically ranging from 95% to 99.999%.
Main Methods for Nitrogen Separation from Air
1. Cryogenic Separation
In this method, air is cooled to extremely low temperatures, allowing its components to be separated based on their respective boiling points. This technology is suitable for very large capacities; however, it involves high capital investment and significant energy consumption.
2. Membrane Separation
This system utilizes polymeric membranes with higher permeability to oxygen, allowing selective oxygen removal. While this method offers compact design and operational simplicity, nitrogen purity typically does not exceed 98%.
3. Pressure Swing Adsorption (PSA)
In PSA technology, separation is based on the difference in adsorption affinity of gases on a solid adsorbent. Under elevated pressure, oxygen and CO₂ are preferentially adsorbed by Carbon Molecular Sieve (CMS), while nitrogen—being non-adsorbed—exits the adsorption column as the product gas.
During pressure reduction, the adsorbent is regenerated and the cycle is repeated. Compared to other methods, PSA offers lower operating costs, high reliability, and on-site generation capability.
Structure and Components of a PSA Nitrogen Generator
The industrial PSA nitrogen generation package developed by Fidar Faraz Fartak consists of fully engineered components, each playing a critical role in nitrogen production:
1. Air Compressor
Supplies compressed air at a typical operating pressure of 7 to 10 bar.
The compressor type (oil-injected screw, oil-free, single-stage, or two-stage) is selected based on nitrogen purity requirements and application sensitivity.
2. Air Treatment Unit (Filtration and Dryer System)
In accordance with ISO 8573-1 Class 1.4.1, solid particles, oil vapor, and moisture must be removed to protect the PSA adsorbent.
(Moisture is considered a critical impurity alongside oxygen and other gases; improved moisture removal directly enhances nitrogen purity.)
This section typically includes particulate filters, carbon filters, and either refrigerated or desiccant air dryers.
3. Compressed Air Receiver
Stabilizes inlet pressure and minimizes flow fluctuations entering the PSA towers, thereby extending valve life and ensuring stable adsorption cycles.
4. Adsorption Columns (PSA Towers)
Two vessels filled with Carbon Molecular Sieve (CMS) sourced from reputable international suppliers. The towers alternately perform adsorption and regeneration cycles. Valve switching sequences are controlled by a PLC system to maintain stable nitrogen purity.
5. Nitrogen Storage Tank
Ensures outlet pressure stability and provides continuous supply during sudden demand fluctuations (peak flow conditions).
6. Electrical Panel and PLC Control System
Fidar Faraz designs utilize intelligent industrial controllers that continuously monitor pressure, tower temperature, and nitrogen purity. These systems support remote monitoring and fully automated control of adsorption and regeneration cycles.
Proprietary Design and Engineering Technology of Fidar Faraz Fartak
The design of Fidar Faraz PSA towers incorporates Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) to optimize flow distribution, minimize pressure drop, and determine optimal regeneration timing.
Technical Proposal and Engineering Services
For each industrial project, the Fidar Faraz Fartak engineering team provides a customized technical proposal, including:
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Comparative analysis of PSA, membrane, and cryogenic technologies
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Evaluation of ambient conditions and compressed air quality
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Piping layout design and optimal line sizing
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Development of a Preventive Maintenance Plan (PMP)
During the operational phase, 24/7 technical support and guaranteed supply of original consumable parts are provided.
Conclusion
PSA nitrogen generators manufactured by Fidar Faraz Fartak represent a combination of precise engineering design, high-quality international adsorbents, and advanced control technology.
With low operating costs, stable performance, and high efficiency, these systems are considered the optimal solution for on-site nitrogen generation.
For technical consultation, system design, and economic evaluation tailored to your project requirements, Fidar Faraz specialists are ready to assist.