Scaling Up High-Purity Nitrogen for Advanced Laser Cutting
Project Overview
A highly valued, rapidly expanding customer recently partnered with Design Air once again to upgrade their utility infrastructure. Experiencing a significant surge in production, the client required a substantial increase in their high-purity nitrogen supply to feed a growing fleet of laser cutters across their facility.
We were tasked with expanding their existing generation capabilities to meet this new peak demand efficiently and reliably.
The Challenge: Meeting Surging Demand Without Escalating Costs
As the client’s manufacturing output grew, so did their reliance on nitrogen for precision laser cutting. While they were already utilising on-site generation, their expansion meant they risked falling short of required volumes. Reverting to the traditional approach of buying and renting supplementary high-pressure nitrogen bottle banks would introduce logistical bottlenecks and unsustainable operational expenses.
The challenge was to scale their independent nitrogen supply securely, eliminating any dependency on external deliveries while drastically reducing long-term overheads.
The Solution: An Additional Atlas Copco HPN2 Skid
Having previously experienced the massive benefits of on-site generation, the client trusted our engineering team to expand their existing setup seamlessly. We specified, supplied, and integrated an additional Atlas Copco HPN2 Nitrogen generation skid into their facility’s infrastructure.
Combined Production Power
With the new skid integrated alongside their existing system, the site can now produce a combined volume of up to 38m³/hr of nitrogen.
Exceptional Purity
The Atlas Copco HPN2 system guarantees a continuous supply of nitrogen at a 99.99% purity level. This ultra-high purity is strictly required to achieve flawless, oxidation-free edges during the laser cutting process.
High-Pressure Storage
To ensure immediate availability at the exact pressure required for all cutting applications, the high-purity nitrogen is compressed and safely stored in multiple 300-bar bottle banks. This setup creates a robust, on-site buffer that handles peak production demands effortlessly without starving the laser cutters.
The Results: Staggering ROI and Absolute Autonomy
The strategic decision to expand their on-site nitrogen generation delivered immediate, transformative results for the client’s bottom line and operational workflow:
- Staggering Cost Savings: When compared to the traditional manner of buying and renting external bottle banks, the financial savings of running these nitrogen generation skids are staggering. The cost per cubic metre of gas is now a fraction of market delivery rates.
- Uninterrupted Production: The combination of continuous generation and 300-bar storage ensures the site has an immediate, on-demand supply of nitrogen 24/7. This completely removes the risk of costly machine downtime caused by delayed external gas deliveries.
- Scalable Success: The modular nature of the Atlas Copco equipment means the system has grown seamlessly alongside the customer’s business, proving that on-site generation is a future-proof investment.
The Design Air Standard
At Design Air, we do more than just supply equipment; we engineer total utility independence. From the initial operational analysis to full system design, specification, installation, and ongoing maintenance, we provide a complete, end-to-end partnership.
If you are currently buying or renting nitrogen bottles, the potential cost savings of generating your own supply on-site are significant. Get in touch with Design Air today for expert advice and an accurate assessment of your potential return on investment.