Generon | Pioneering Gas Solutions®: On site Nitrogen Generation

Industry Veterans in the know turn to GENERON® membrane separators when they need a reliable high purity nitrogen supply that’s mobile, low maintenance and customized to volume and size. GENERON delivers safe, efficient, custom solutions to the following industries:

AIRCRAFT INDUSTRY

NDUSTRIAL & COMMERCIAL MARKETS
Tires and Struts, Cart Support, Inflation of Evacuation Slides, Bottle Filling Stations.
• Technical Nitrogen Type I, Grade A, Class 1
• Double purity hollow-fiber membrane nitrogen generator
• Medium pressure nitrogen booster for pressures up to 60 barg / 850 psig
• High pressure nitrogen booster for pressures up to 300 barg / 4,350 psig
• Medium-pressure nitrogen storage tank with downstream pressure regulator
• Technical Nitrogen Type I, Grade B, Class 1

AIRCRAFT FUEL TANK INERTING

INDUSTRIAL & COMMERCIAL MARKETS
TYPICAL PURITIES:

  • 95 – 99.999% N2

It’s necessary to inert the vapor filled space in fuel tanks and bladders on commercial and military aircraft in order to mitigate the risk of fuel vapor combustion. Working with key sources in the commercial airline industry, GENERON®developed and designed a custom system module to meet the demanding environments and needs required for this type of system. GENERON was selected and proud to provide:

OBIGGS – On Board Inert Gas Generating System, – GENERON has been selected to provide On Board Inert Gas Generating System filters for use on Commercial Aircraft flown within the United States. These filters use engine bleed air to produce nitrogen for blanketing fuel tanks on aircraft. Working with key sources within the commercial airline industry, a custom module was designed to meet the demanding and harsh environments that the module must perform in.

For information on GENERON Products that are utilized for these applications, please click on the Product links below:

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AIR-DRIVEN TOOLS / MACHINERY

INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Using gaseous Nitrogen to power tools rather than compressed air provides a cleaner drive. Gaseous Nitrogen at approximately -40F dew point will severely reduce the possibility of corrosion and shorten the life of the power tool.

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AGRICULTURE

INDUSTRIAL & COMMERCIAL MARKETS

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ALGAE AND SPARGING

ENVIRONMENTAL, INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Injecting Nitrogen at purity levels above 95% into liquid sparging or bubbling processes, reduces oxygen content to a level where most biological and botanicals cannot exist, consequently preventing algae and bacterial growth. GENERON’s® patented high efficiency membrane units make installation and retro-fitting easy. Our engineers provide safe cost efficient designs that specifically address your application.

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AUTOCLAVE

AUTOCLAVE

– heat treat, bonding, composite fiber, aircraft fuselage, bladders

INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999%

Curing facilities using autoclaves and ovens for meal, Kevlar, high strength fiber, and carbon fibers are perfect for introducing Nitrogen. With purity requirements ranging from 95% to 99.999%, the lower oxygen content and drier air provide the most ideal curing conditions. Benefits include no metal oxidation, faster curing times; higher quality product and increased production.

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BACTERIA ELIMINATION

INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999%

Oxygen supports life even at microscopic levels. When you remove the oxygen and replace it with nitrogen purity as low as 95% you stop the growth of bacteria. By blanketing, or sparging nitrogen into the system, the need to add chemicals or organic material to eliminate food spoilage, mildew, and mold is eliminated. N2 not only prevents the growth of bacteria in powder, liquid, or bulk food storage containers but provides an eco-friendly alternative to chemicals. GENERON® patented high efficiency m
embranes provide a constant flow in small foot prints and 10 year plus service life.

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BALLASTING

MARINE, OIL & GAS, PETROCHEMICAL & COMMERCIAL INDUSTRIES

TYPICAL PURITIES:

  • 95 – 99.999% N2

The composition of some LNG imports do not meet UK natural gas specifications, consequently requiring nitrogen ballasting. Please contact GENERON for assistance in sizing your nitrogen generator.

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BLANKETING FOR ADHESIVE CURING

INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Blanketing purges furnaces of oxygen where the adhesive compounds are applied to tape. Purging the furnace with nitrogen, allow materials the ability to bond better.

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BOILER

INDUSTRIAL & COMMERCIAL MARKETS

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BRIGHT ANNEALING

INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

With oven temperatures reaching 1,500°F or higher, oxidation on the finished product is always a concern. Bright annealing requires a high purity of nitrogen (99% to 99.995%) to insure high quality product during the oven curing process. During the cool down period, a higher SCFH flow rate is used, but typically at a lower purity of nitrogen (95% to 99%). The GENERON® NS- series can provide 95% to 99.999% purity levels.

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CARBON FIBER CURING

INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

As in normal autoclave applications the curing of polymer resin carbon fibers and Kevlar are enhanced. Temperatures above 1,000 degrees C are used in a nitrogen environment. Carbon fibers yield is about 92% with increased strength. Products cure faster; finishes are bubble free and have higher strength fibers.

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CHEMICAL PLANTS

PETROCHEMICAL, OIL & GAS, AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

GENERON® Nitrogen Generators are used in chemical plants for production, storage and chemical handling. Nitrogen protects against the danger of fire, moisture contamination and discoloration, and product degradation.

BLANKETING

INDUSTRIAL & COMMERCIAL MARKETS

Blanketing has a fairly constant nitrogen demand with low flows and volume requirements. Surges in the demand for nitrogen occur when there is a drop in temperature or a transfer from the vessel, making for a larger “head space”.

PRESSURE TRANSFER / UNLOADING

Higher flows of nitrogen are needed for a short time during these operations, depending on the amount and distance of material moved. Unloading a tanker truck to a storage vessel requires a moderate flow. Loading a barge from a storage tank takes high flows and volumes. Pressure unloading can require pressures greater than 100 psig, depending on the line pressure needed and the time allowed for the transfer.

PIPELINE AND VESSEL PURGING

Purging is necessary to clear lines and vessels of liquids or reduce oxygen levels. Several purge cycles may be required, depending on the purity of nitrogen and the desired oxygen content. Flow and volume requirements are generally quite large. To successfully purge a vessel or pipeline, 4-8 volume turnovers of 95%-98% purity nitrogen are typically required.

REACTOR SPARGING

Reactor sparging removes impurities, usually water or oxygen, from hindering reactions or producing unwanted by-products. Depending on the process, batch or continuous, then the need for nitrogen is occasional or constant. The inert gas flows and volumes are low to moderate.

PIGGING

When transporting more than one type of chemical through a line at the same time, a “pig” is used to physically separate the materials. Pigs also ensure the line is free from obstruction. The amount of nitrogen needed depends on the volume of the line and the time allotted for completing the operation. Many CPI operations have erratic nitrogen demand patterns; therefore, a surge tank may be necessary to buffer the nitrogen. A low pressure (200 psig) vessel is generally adequate. Non-cryogenic nitrogen can be recompressed to higher delivery pressures by conventional compressors.

DRYING

Some chemicals and processes are adversely affected by moisture and must be kept extremely dry. GENERON® membranes produce extremely dry nitrogen, down to 5 ppm or less water vapor by volume. The nitrogen can be heated to improve drying effectiveness.

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CURING

INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Nitrogen helps maintain an atmosphere free of oxygen and moisture, preventing oxidation on metals.

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ELECTRONICS

INDUSTRIAL & COMMERCIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Ships Atmosphere, Reflow soldering of PCBs, Wave soldering of PCBs Selective soldering of PCBs, lead-free solder pastes, atmosphere storage of SMD components.

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ETHANOL PRODUCTION / BIO-FUELS

OIL, GAS AND PETROCHEMICAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

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FIRE SUPPRESSION

COMMERCIAL, INDUSTRIAL, OIL, GAS, ENVIRONMENTAL, AND PETROCHEMICAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

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FOOD AND BEVERAGE

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 90 – 95% N2

Food is harvested and package throughout the year around the world. Nitrogen keeps it fresh and tasty until purchased and consumed. This allows valuable time for food and beverage distributors to get products to consumers.

Beverage Dispensers, Casino’s, Wine packaging, snack packaging, candy & coffee packaging, Blanketing of storage tanks, Controlled atmosphere (CA) transport and storage, fluffing of fats and mayonnaise, modified atmosphere packaging (MAP), sparging of edible oils, baby foods and beverages, Wine bottling, Beer

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GAS BLANKETING

OIL, GAS, ENVIRONMENTAL, AND PETROCHEMICAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.9% N2

The use of inert gas to control corrosion of the internal surface of plant equipment can be an effective method. Inert gases can only be utilized in systems that maintain a sealed pressurized environment for the duration of the idle period. Nitrogen is the most common gas used with very little oxygen and zero moisture. For complete corrosion control, oxygen content must be less than 1%. Prior to the introduction of nitrogen, all components and interior spaces of the system must be dry and free of sediments, deposits and accumulations that could hold moisture.

Once the system is dried and cleaned, the system must be restored to tight conditions. Inert gas requires that the system to be sealed and capable of maintaining the positive pressure of the gas. The presence of gas should be monitored through pressure instrumentation. All entry points must be labeled cautioning against personnel entry for protection against asphyxiation in low oxygen concentration spaces.

The corrosion control mechanism provided by the nitrogen is not a conversion of the existing atmosphere but rather maintenance of the cleaned atmosphere condition. This is achieved by the elimination of oxygen, a key component to most corrosion cells. Several strains of microbiological organisms do not need oxygen to survive and could therefore flourish. Where conditions have been poorly prepared, corrosion could initiate and remain active. Effective oxygen exclusion requires purging of the original atmosphere by repeated pressurization with nitrogen, followed by venting until the oxygen concentration is less than 1%.

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INERTING

COMMERCIAL, INDUSTRIAL, OIL, GAS, ENVIRONMENTAL, AND PETROCHEMICAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

The drying of process systems, either post-construction, subsequent or turnaround hydrostatic testing, is a critical operation. Failure to ensure systems are free of moisture, or to a specific dew point, can have serious production or safety implications. Hydrate formation, pipework blockage, product impurity and the formation of corrosive chemicals can be caused by improper protocols. A process system that’s been “drained” of water can be dried by injecting or blowing air or gaseous nitrogen. Nitrogen has a very low dew-point and will absorb moisture readily.

GENERON has a wide range of equipment suited to system drying, particularly for moisture sensitive petrochemical plants.

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INJECTION MOLDING

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Used to improve quality and production, nitrogen injection molding (known as GAIM-Gas Assist Injection Molding) uses nitrogen with purities from 95% to 99.995%. The purity of the nitrogen depends on the type of polymer, the percentage of oxidation, and the product melt temperatures. Nitrogen eliminates any moisture in the process and allows molten product to be pushed from a smaller cavity compartment into large cavity. Nitrogen reduces warping, distortion, and surface blemishes.

REACTION INJECTION MOLDING

The manufacture of parts by Reaction Injection Molding (RIM), consumes large quantities of nitrogen. Nitrogen protects isocyanates and polyols from oxygen and moisture degradation during storage. Nitrogen is also used as a means of reducing the specific gravity of the polyol / catalyst / chain extender mixture prior to reaction with the isocyanate.

GENERON® nitrogen generators provide a low oxygen, low moisture gas with their reactants in storage and as a means of nucleation without the expense of liquid nitrogen. In addition GENERON® nitrogen generators offer the manufacturer freedom from price increase and storage tank rental fees.

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JEWELRY MANUFACTURING

COMMERCIAL AND INDUSTRIAL MARKETS

Nitrogen systems are used for Vacuum casting, Induction smelters and hot waxing. GENERON® PSA or Membrane systems do not require an added pressure boosting system. These applications have a nitrogen product pressure of 30 to 100 psig. Eliminating oxidation and moisture free processing ensures a safe work environment.

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KILN / GRAIN DRYING

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Nitrogen is used to reduce the potential explosive hazard and keep dew points up to -50°F. The removal of moisture and high purity nitrogen prevent organic growth during the drying process.

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LABORATORY

TYPICAL PURITIES:

  • 95 – 99.999% N2

GENERON will assist you with the definition of the specific MOC (Maximum Oxygen Content) for safe handling and storage of your product. We also can simulate the exact residual oxygen presence in your tank / reactor / storage room at varying purities of the supplied nitrogen with our in-house developed software. Additionally, we will do a detailed simulation and analysis of the nitrogen consumption profile including peak consumptions.

Blanketing, padding of products sensitive to oxidation, Dry-seal Inerting, Explosion prevention, Monomer storage, Pipeline purging, Pneumatic transport of powders, Polymer drying, Pressure transfer of liquids and Chroma Photography.

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LABORATORY N2

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

In most laboratories today, nitrogen is used in controlled atmosphere storage units, glove boxes, gas chromatograph/IRD, and refractive indicator and detector/RID units.

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LEAK CHECK

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Leak detection on process systems using helium and nitrogen gas is the most accurate and quantifiable method. On an offshore production platform, or within a petrochemical complex, the elimination of hydrocarbon leakage is an operational priority. Such containment loss can lead to hazardous situations, environmental impact and huge financial loss.

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METALLURGY

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Metal extruding, heat treat, braising application, aluminum extrusion, De-gassing of aluminum, Isocure and Isoset process for casting core manufacturing, slag splashing in steel furnaces, wire galvanizing.

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MINING

OIL, GAS, PETROCHEMICAL, AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Extinguishing coal mine fires, Inerting sulfuric acid plants for heap leaching, Inerting worked over or abandoned mines, Purging of LPG lines in copper/nickel/uranium mines.

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MODIFIED ATMOSPHERE PACKAGING

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Nitrogen is a cost-effective, eco-friendly and organic way to stop bacterial growth, reduce oxidation, preserve product taste and texture, improve the visual appeal of freshness and extend product shelf life.

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NITROGEN AS A PROPELLANT

OIL, GAS, PETROCHEMICAL, AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Whether you’re performing major maintenance or remedial treatments on your pipeline, using nitrogen as an inert propellant for moving “pigs” through your pipeline mitigates risk and liability. Nitrogen is the gas of choice to displace oxygen, retard oxidation, break the “fire triangle” and prevent explosions.

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OIL & GAS MARKET

OIL, GAS, PETROCHEMICAL, INDUSTRIAL AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Oil exploration & production and transportation often times involve working in close proximity to flammable materials. Nitrogen gas mitigates the possibility of explosion and creates a safer working environment. Thousands of GENERON® systems are used worldwide in Onshore and Offshore Industries. Check out our Video: Nitrogen Applications for the Oil & Gas Market:

  • Heave Compensation
  • Coiled Tubing for Well Servicing
  • Emergency High Pressure Bottle Filling
  • General Rig Inerting
  • Well Injection Pressure Maintenance
  • BOP Enclosure System
  • Flare Tower Inerting
  • Platform Instrument Air
  • Buffer Gas Seals
  • Cement Foam Injection
  • Export Line Commissioning
  • Underbalanced Drilling

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PHARMACEUTICALS

COMMERCIAL AND INDUSTRIAL MARKETS
TYPICAL PURITIES:

  • 95 – 99.999% N2

The purity of gases necessary for many pharmaceutical manufacturing processes is often higher than the application requires. Nitrogen purity of 99.999% or better may be necessary for an application where oxygen sensitivity or reactivity is acute; however this same purity may not be required to blanket the flammable solvents and powders used. Most flammable solvents and powders can be exposed to oxygen concentrations in the range of 8-12% before the potential for explosion exists. Therefore a purity of 99.999% is unnecessary and costly.

BLANKETING
Blanketing prevents combustion of chemicals and powders and removes reactive gases from your process. GENERON® Membrane Generated Nitrogen is the most cost effective and efficient way to ensure proper blanketing atmosphere.

MAXIMUM PERMISSIBLE OXYGEN CONTENT TO PREVENT IGNITION BY SPARK OF COMBUSTIBLE DUSTS USING ENRICHED NITROGEN AS THE ATMOSPHERIC DILUTENT
Dust Oxygen
Cellulose 10.6%
Cornstarch 8%
Dextrin 11.9%
Salicylic Acid 15.8%
Starch 9.3%
Sucrose 11.9%

Data in this table is from NFPA 69-1978, which in turn are from the US Bureau of Mines Report of Inv. 6543. The data was obtained by laboratory experiments conducted at room temperature and pressure using a 24 watt continuous spark as the ignition source. In the absence of reliable data, the US Bureau of Mines or another recognized authority should be consulted.

In pharmaceutical applications, our GENERON® Membrane and Nitrogen Pressure Swing Adsorption (PSA) systems are used to prevent combustion of chemicals and powders and for the removal of reactive process gases. Many materials react to and become unstable in environments having even the smallest amounts of oxygen. Our PSA and Membrane systems are used to displace this oxygen, therefore, preventing potential explosive situations.

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PIPELINE DRYING

OIL, GAS, PETROCHEMICAL, INDUSTRIAL AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Drying process systems, either post-construction, subsequent or turnaround hydrostatic testing, is a critical operation. Failure to ensure systems are free of moisture, or to a specific dew point, can have serious production or safety implications. Hydrate formation, pipework blockage, product impurity, and the formation of corrosive chemicals can be caused by improper protocols. A process system that’s been “drained” of water can be dried by injecting or blowing air or gaseous nitrogen.

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PIPELINE INERTING

OIL, GAS, PETROCHEMICAL, INDUSTRIAL AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Nitrogen is the gas of choice to displace oxygen, retard oxidation, break the “fire triangle” and prevent explosions.

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PIPELINE PIGGING

OIL, GAS, PETROCHEMICAL, INDUSTRIAL AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Whether you’re performing major maintenance or remedial treatments on your pipeline, using nitrogen as an inert propellant for moving “pigs” through your pipeline mitigates risk and liability. Nitrogen is the gas of choice to displace oxygen, retard oxidation, break the “fire triangle” and prevent explosions.

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PLASMA & LASER CUTTING

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

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PLASTICS

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

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REFINERIES

Refinery

OIL, GAS, PETROCHEMICAL, INDUSTRIAL AND ENVIRONMENTAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Nitrogen is used in refineries for Inerting, Blanketing, and Purging, which suppresses flammability by reducing oxygen levels below possible combustion.

TYPICAL APPLICATIONS FOR REFINERIES ARE:

REACTOR SPARGING

– removes impurities, usually water or oxygen, that hinder reactions or produce unwanted by-products. If the process is batch or continuous, then the need for nitrogen is occasional or constant. The inert gas flows and volumes are low to moderate.

BLANKETING

has a fairly constant nitrogen demand with low flows and volume requirements. Surges in the demand for nitrogen occur when there is a drop in temperature or a transfer from the vessel, making for a larger “head space”.

DRYING:

Some chemicals and processes are adversely affected by moisture and must be kept extremely dry. GENERON® membranes produce extremely dry nitrogen, down to 5 ppm or less water vapor by volume. The nitrogen can also be heated to improve its drying effectiveness.

PURGING

N2 gas is used for cooling and removal of combustible gases from process units during maintenance shut-downs.

CATALYST REGENERATION:

Catalytic reformers, hydrocrackers, hydro treaters and H2 plants require N2 for heating & cooling and as a carrier gas for chemicals.

GENERON® Nitrogen systems offer a wide range of flow rates and purities up to 99.999 % and well suited for Refinery / CPI applications.

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SAUNTERING: WAVE & ELECTRONICS

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

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SEMI-CONDUCTORS

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

High purity N2 is used by component level manufacturers and producers as a carrier gas for overall protection against impurities and oxidation in semiconductor and soldering processes.

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SHIPBOARD INERTING

MARINE MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

Transportation of flammable, explosive or oxidizing cargos requires Inerting solution to prevent fire and explosion within the cargo spaces mitigating large scale damage and loss of life. Inert gases are commonly used to fill cargo tanks and void spaces, as well as to maintain a low oxygen content during voyage.

GENERON® Maritime Nitrogen Systems offer Membrane and PSA Type Turn Key packages with a track record of 1,900 + installations on board Chemical / Product and LNG carries providing flow rates from 100 m3/h up to 5,000 m3/h.

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TIRE MANUFACTURING

COMMERCIAL AND INDUSTRIAL MARKETS

TYPICAL PURITIES:

  • 95 – 99.999% N2

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