1) Rubber / Tire Manufacturing
Nitrogen in the tire manufacturing field is one of the most important assets - tire curing presses in the process of curing. Curing is used to give a tire its final shape and tread pattern. It involves the chemical cross-linking of rubber and vulcanizing agents, resulting in an elastomeric tire. Nitrogen is applied for the same purpose for rubber manufacture.
Nitrogen as a flexible inert gas keeps the system pressure at the desired level. In addition, operators of nitrogen-based tire presses can select the system pressure independently of the curing temperature.
Mentis onsite PSA nitrogen generator delivers high purity nitrogen with adjustable pressure. The cost-effective system completely replaces your daily reliance on liquid nitrogen supply and it overrides transportation limitations.
Advantages of Mentis onsite PSA nitrogen generator for rubber or tire manufacture
Um productivity and reliability at user spot
Reduction of purchasing and delivery costs of bulk nitrogen supply
Better pressure stability and independent pressure setting
Up to 100% extension of bladder lifetime
Improved quality for reduced scrap costs
The nitrogen generator is based on the principle of PSA, using high-quality CMS as an adsorbent, and nitrogen is separated from air under a certain pressure. The purified and dried compressed air is subjected to pressure adsorption and decompression desorption in an adsorber. Due to the kinetic effect, the diffusion rate of oxygen molecular in micropores of the CMS is much larger than nitrogen molecular. When adsorption does not reach equilibrium, the nitrogen is enriched and collected in the gas phase as product nitrogen. Then, the pressure is reduced to normal pressure, and the adsorbent desorbs impurities, such as adsorbed oxygen to regenerate. Generally, two adsorption towers are in the system, one tower adsorbs and the other desorbs and regenerates, and the two programs are alternately cycled and repeated by automatic control of the PLC program, so as to achieve continuous production flow of high-quality nitrogen.
The pharmaceutical industry, to improve the quality of drugs, whether it is the production of large infusions, water needles, powder needles, lyophilized,s or oral solutions, the nitrogen-filling process is required. At the same time, the economic choice of nitrogen introduction and compliance with GMP requirements have been the focus of pharmaceutical production. In the past, most of the nitrogen used in pharmaceuticals came from industrial nitrogen or liquid gas in cylinders to be vaporized into gaseous nitrogen.
Nitrogen generator has a wide range of uses in the pharmaceutical industry such as in synthetic drugs. It is isolated by pure nitrogen in bioengineering. It is filled with ammonia in the preparation products, such as large infusion, water needle, powder needle, lyophilizer, oral liquid, etc., where nitrogen could be used directly. So there is a great demand for nitrogen supply in pharmaceutical production.
The purity of nitrogen is required to be high, generally 99.999% or higher.
Nitrogen is required to be free of dust, bacterial, or odor and can be used for packages of injections.
It is required that nitrogen maintain constant pressure during the production processes to ensure continuous normal production. The quality of nitrogen directly affects the quality of the drug. According to the GMP regulations and the industry standards, the nitrogen generator should ensure the safety and reliability of onsite nitrogen supply on the basis of providing qualified nitrogen - dry, clean, pressurized, and high purity. Mentis provides you to produce high-quality nitrogen.
3) Petrochemical Industries
Nitrogen gas has vital importance in the chemical-petrochemical industry due to inert gas properties - creating an inert atmosphere in processing, storage, and transfer of flammable materials, eliminating undesired poisonous and flammable gases.
Nitrogen gas offers a wide range of capabilities to the oil, gas, and petrochemical industries, and is used predominantly during plant commissioning, maintenance, shutdown and start-up preparations, nitrogen purging, blanketing and subsequent nitrogen leak testing forming a critical path to the success of any project.
Nitrogen availability for both project work and ongoing operations has, therefore, become critically important. As many oil and gas projects are based in remote locations, deliveries of nitrogen to the point-of-use is a major undertaking. With the advent of low-cost and reliable nitrogen gas production using air separation in the gaseous phase many oil and gas projects have opted for in-situ nitrogen generation.
Nitrogen has various applications in the oil and gas and petrochemical industry, including those described below.
Blanketing of tanks and tankers
Many hydrocarbons and chemicals are volatile and extremely reactive with oxygen. While processing, storing, and transporting these liquids, it is necessary to displace any atmospheric oxygen in the headspace by blanketing with an inert gas such as nitrogen.
Nitrogen purging is an industry-standard technique for the replacement of a hazardous or undesirable atmosphere with an inert dry atmosphere. The two most common methods of purging are displacement and dilution. The geometry of the processing system determines which method is used. For simple systems, displacement purging is often more effective in terms of time and costs. While for complex systems, dilution purging is applied for the same purposes.
When hydrostatic testing is impossible, components or systems are tested with nitrogen. However, system design specifications must be reviewed and detailed risk analysis completed before testing with the compressible medium.
Nitrogen is used in good applications to reduce the weight of fluid in the wellbore. Nitrogen is pumped through coiled tubing (or gas lift tubing) and discharged at good perforations. As the nitrogen gas flows up the production casing, it expands and reduces the weight of fluid in the column, allowing the well to flow.
Cooling of catalyst
During refinery shut down, it is desirable to reduce the temperature of process catalysts as quickly as possible. Large volumes of nitrogen can be pumped by pumping equipment to assist in the cooling process and in this way valuable hours of shutdown time will be saved.
4) Laser Cutting
Cutting is an intuitive application of laser devices. When converging a beam of photons onto a small spot, the resulted high energy density can easily vaporize materials. Thus, by moving the beam along a designed path, the workpiece can be separated into individual parts.
Laser cutting techniques have now evolved into multiple forms, including vaporization cutting, fusion cutting, reactive fusion cutting, thermal stress cracking, scribing, and cold cutting. Each one of them involves different operating modes, energy levels, and utilization of an assist gas.
The choice of the optimal cutting depends on material physical properties, light sources, and other factors. Today, laser cutting has become the most common laser manufacturing technology.
Nitrogen used for Laser cutters relies on non-reactive (inert) gases as the assist gas. Nitrogen would be the typical choice in the process of cutting stainless steels, aluminum and its alloys.
Cutting with non-reactive gases often refers to clean cutting or high-pressure cutting. Here, the material is melted solely by laser power and blown out of the cutting kerf by the kinetic energy of the gas jet - typically by nitrogen.
With the onsite Mentis PSA nitrogen system, all direct and indirect costs from transport and delivery of nitrogen, as well as nitrogen cylinder and tank rental, are omitted. As the associated CO2 emission stopped, this technology is also a real contribution to the environment.
5) Storage Control (Fruits, Vegetables & Grains)
Fruit and vegetable
Fruit and vegetable air conditioning storage applied in commercial storage keeps developing for over 70 years worldwide. It is more advanced fruit and vegetable preservation facilities which not only adjust the temperature & humidity inside the warehouse but also control the oxygen content, CO2 content, and so on to put the fruits & vegetables in a dormant state, which keeps the original quality of the fruits and vegetables even after EX-warehouse, makes the storage time longer, contributes to better preservation effect, extends their shelf lives, meets all standards as it is green storage and there is no contamination.
Atmosphere modifying equipment including nitrogen generators, CO2 scrubbers, ethylene removal equipment, humidifying device, gas analyzers, temperature, humidity and gas composition automatic controlling & monitoring devices, as well as a specialty cold storage warehouse, in which nitrogen generator utilization rate is the highest. Generally, the nitrogen purity required by controlled atmosphere technology is 99%.
6) Food & Beverage Industr??es
Nitrogen gas is the multipurpose and key factor in food and beverage industries - Beverage Mixing/Dispensing, Bacteria Eliminations, Bottling, Coffee Processing/Making & Packing, Health and Beauty Aids, Packaging, Vertical Form Fill Machines, Wine & Beer Making, Processing/Making/Storage/Packing of Drinks, Snacks, Milk Powder, Jam, Juice, Sauce, etc...
Bacteria as well as worms and insects are detrimental to all kinds of foods or beverages and need to be removed to avoid spoilage and infection - by replacing oxygen with nitrogen. No bacteria means no mold or mildew. Hence the basic requirements on Hygiene Grade and Food Grade of foods and beverages can be met.
As an inert gas, nitrogen is applied in the processing of foods & beverages to keep away oxidization, corruption, or metamorphism as well as contamination, by which the original quality, taste, and flavor are protected and kept. For raw material processing & storage, nitrogen is also applied for the same purpose.
To get better flavor and taste, nitrogen is also used as an additive in some foods or beverages, such as soft drinks and beer. More and more nitrogen is used for the same purpose in the processing of various foods and beverages.
While at a certain level, nitrogen is mostly used in the packaging, bottling, and shelf storage processes to replace and insulate oxygen for a longer shelf life of foods and beverages. In such cases, nitrogen consumption is higher.
Sometimes transportation of bulk raw material and finished products also require nitrogen gas.
In recent years, the required nitrogen purity is increased from 95% to 99.9% or even higher in the applications above - one of the reasons is that manufacturers care more about quality and it also contributes to longer shelf life to avoid food safety incidents to cut their expense of public relations, on the other hand, new technologies, “new” foods and beverages are developed requiring nitrogen with higher purity.
Specify your nitrogen needs to Mentis and you will get complete solutions for your own nitrogen production and get turn-key solutions.
7) Metal and Heat Treatment
Nitrogen generator application in Metallurgy, Metal processing as annealing protective gas, sintering protective gas, nitride treatment, washing furnace and purging gas, nitrogen is widely used in metal heat treatment, powder metallurgy, magnetic materials, copper processing, wire mesh, galvanizing wire, semiconductor, powder reduction, and other fields. Some of these industries require nitrogen with purity ≥99.5%, while others require high-quality nitrogen with purity ≥99.9995% and dew point below -65 °C.
Metal production and processing: manufacturing steel, iron, copper, aluminum products annealing, carbonization, high-temperature furnace protection, low-temperature assembly of metal parts and plasma cutting. Metal heat treatment requires protective gas and safety gas for industrial furnaces during heat treatment processes, such as bright annealing and bright quenching to prevent oxidation of products.
Nitrogen is a good source for heat treatment such as bright quenching, bright annealing, nitride, nitrocarburizing, soft carbonization, welding, and protective gas during powder metallurgy sintering.
Metal heat treatment: alloy steel, high carbon steel annealing protection atmosphere, metal powder sintering protection atmosphere, nitride treatment, washing furnace and purging gas, etc., and the high-quality nitrogen gas are produced by CAN GAS System. The purity is greater than 99.9995% with a dew point below -65 °C.
Heat treatment in a nitrogen-based atmosphere with a basic nitrogen content is a new technology and process for energy-saving, safety, avoiding environmental pollution and full utilization of natural resources. It has been shown that almost all heat treatment processes, including quenching, annealing, carburizing, carbonitriding, soft nitride and carbon re-carbonation can be carried out using a nitrogen-based atmosphere, and the metal parts treated can be same as the traditional endothermic atmosphere treatment.
Aluminum processing industry: Aluminum products, aluminum profile processing, aluminium thin rolling, and other gas protection.
Powder metallurgy: Powder sintering, nitrogen protection in the sintering of magnetic materials.
Synthetic fiber: Nitrogen-filled pressed material, drawing anti-oxidation.
Nitrogen-filled lead-free soldering: used for reflow oven and wave soldering.
Metallurgical industry: Continuous casting, continuous rolling, steel annealing protective gas; converter top and bottom compound blowing nitrogen steel, converter steelmaking sealing, blast furnace top sealing, blast furnace ironmaking pulverized coal injection gas.
Metal deep processing: nitrogen in steel is mainly used as a protective gas. For example, rolling steel, galvanizing, chrome plating, continuous casting, etc., nitrogen gas is used as a shielding gas, and the purity of nitrogen is required to be 99.99% or more. Mentis Nitrogen generator constant nitrogen gas is provided for this purpose. With a gas solution, the purity of nitrogen can reach 99.9995%.
The medium and high voltage cable generation: The process of inert gas cross-linking is performed by using nitrogen gas. The polyethylene insulating material with the peroxy compound cross-linking agent is used to complete the extrusion of the conductor shielding layer through the three-layer co-extrusion-insulation layer-insulation shielding layer. Thereafter, the cross-linking process is completed continuously and uniformly through a sealed cross-linking tube filled with high-temperature, high-pressure nitrogen. The heat transfer medium is nitrogen (inert gas), and the cross-linked polyethylene has excellent electrical performance and the product range can reach 500KV.