Eliminating Bottled Gas Costs with On-Site Nitrogen Generation for Laser Cutting
Project Overview
A manufacturing facility recently partnered with Design Air to replace their bottled nitrogen supply. The client required a dependable source of high-pressure nitrogen for their laser cutting operations.
We commissioned an Atlas Copco HPN2 Skid 9 Nitrogen Generation Skid to meet their exact specifications. At Design Air, we conduct a complete feasibility study to determine average nitrogen usage, required purity, and pressure needs.
We use this data to design a suitable nitrogen generation package and estimate the return on investment.
The Challenge: Delivered Gas Costs vs. On-Site Control
The primary challenge was the high ongoing expense of buying Manifold Cylinder Pallets (MCPs) and topping up bulk storage liquid tanks. Laser cutting requires instantaneous high flow at high pressure.
Relying on external suppliers involves continuous costs for the gas, bottle rental, and delivery transport. The client needed a cost-effective solution that provided an independent gas supply without interrupting their production schedule.
The Solution: A Fully Integrated Atlas Copco System
Our engineering team designed and installed an on-site nitrogen generation system to handle the specific demands of laser cutting.
Atlas Copco HPN2 Skid 9
The energy-efficient heart of the operation, matching its motor speed to the exact air demand of the plant and scaling seamlessly with production shifts.
High-Pressure Storage
The system boosts the generated nitrogen up to 280 bar(g) and stores it in a 12x60L MCP. These all-in-one skids contain the necessary compressor, dryer, filters, generator, and booster for high-pressure applications like laser cutting.
Strategic Operation
The skid operates overnight using cheaper energy rates. This ensures a full MCP of high-purity nitrogen is ready by morning to cover the daily shift.
The Results: Savings From Day One
The installation of the on-site generator delivered immediate financial and operational benefits.
- Reduced Operational Costs: The monthly cost of purchasing and running the on-site system is significantly lower than buying in MCPs or liquid nitrogen.
- Immediate Return: By utilising our flexible finance packages, the client started saving on running costs from the first day of operation.
- Reliable Supply: The stored MCP facilitates the instantaneous high flow and high pressure required for the laser cutting process.
The Design Air Standard
We act as a dedicated partner to ensure your system meets your operational goals. A nitrogen generator is part of an integrated pressure system, and we ensure the installation complies with UK law, including the Pressure Systems Safety Regulations 2000 (PSSR). We provide exact calculations for flow rate and purity so you never pay for over-specified gas.
Do you use nitrogen gas in your process? Contact Design Air today for a free consultation visit and discover how much you could save with on-site generation.