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The industrial uses of Oxygen Generators

Air is about 78 percent nitrogen and 21 percent oxygen, with other molecules including carbon dioxide, argon and water. The oxygen from Air is very useful because of its high reactivity and is extracted for various industrial uses. It’s the second largest gas, by volume, used in industrial processes worldwide.

Around 55% of artificially produced oxygen is used in the manufacturing of steel where enriching the air with oxygen increases reaction rates. Oxygen is used in metal refining, fabrication, chemical and petroleum processing, pharmaceutical manufacture, glass and ceramic manufacture, paper manufacture, medicine and healthcare. Oxygen is also combined with other gases and used in gas welding, gas cutting, flame cleaning, flame hardening and flame straightening. And the source of all this oxygen is either Oxygen tanks or an on-site Oxygen Generator.

How Oxygen Generators work

Oxygen Generators and Oxygen Concentrators use a similar working principle - Pressure Swing Adsorption. In Pressure Swing Adsorption the oxygen is separated from a compressed air stream by trapping nitrogen using adsorption.

Pressure swing adsorption relies on a characteristic of gases where, under high pressure, gases tend to get stuck to solid surfaces. They are "adsorbed" by the solid surface. More pressure means more gas is adsorbed by the surface. And if the pressure is decreased then the gas is released or desorbed.

The solid surface is called an adsorbent material, and certain adsorbent materials attract some gas components more strongly than others. In an oxygen generator system air is first compressed and passed through filters that remove any oil, water and other contaminants. The purified air is then passed into two adsorption towers which both have an adsorbent material called a zeolite bed.

Zeolite beds trap nitrogen molecules and allow oxygen molecules to stream through. At high pressure, the zeolite adsorbs nitrogen in large quantities. In the first half of the pressure swing cycle the first adsorption tower receives compressed air from the inlet. The cycle lasts about 3 seconds. The pressure in the first adsorption tower rises above atmospheric pressure and the zeolite traps nitrogen, gradually becoming saturated with it. Once the air passing the zeolite reaches near 100% pure oxygen the valve at the oxygen output opens and the oxygen-rich gas flows into another holding tank or system for productive use or further processing. By this time the zeolite bed has reached its maximum capacity to adsorb nitrogen. It’s capacity is regenerated however because when the pressure in the tower drops the adsorbed nitrogen is released.

The second half cycle begins as the valve to the first tower closes and the valve to the second tower opens. The first half of the cycle ends as the pressure in the first tower drops and nitrogen is desorbed.

The second half of the cycle takes place in the second tower but the process works in exactly the same way. This gives the adsorbent zeolite material in the first tower time to regenerate.

Excess nitrogen is vented through the exhaust to ensure that the oxygen purity at the output end stays above 90%.

Why you should buy on-site Oxygen Generators

Let’s compare having an on-site Oxygen Generator with the common practice of renting tanks from an oxygen tank supplier. Here’s what you need to consider:

You’re paying rent for a minimum of three oxygen tanks all times. One is being used, the second is a replacement and the third is the empty tank waiting to be collected.

Oxygen tanks take up a large amount of valuable floor space as they sit in their racks. And they need to be kept in an area that won’t create a health hazard.

They are also very heavy to maneuver and require special equipment and time to handle correctly.

Contamination inside the oxygen tank can occur over time when the pressure drops below 34 bar g. This creates an estimated 14% wastage of gas when you rent from a oxygen tank supplier.

Most of our customers started off by renting from oxygen tank suppliers. When they started looking into purchasing an oxygen generator it was usually because they had increased capacity needs and the amount of tank they needed to rent became difficult to manage.

For some of them their high oxygen gas requirements meant that their tanks could be consumed in a matter of days. Switching tanks also reduced their overall up-time, which can add up over the course of a year. Then there’s the issue of contaminants and inconsistent purity levels that they discovered when dealing with rented cylinders. They chose to invest in on-site Oxygen Generators because they wanted greater control over purity, cost-efficiency, and a continuous uninterrupted supply of oxygen for their work.

The Atlas Copco PSA oxygen generator

On-site, high-purity oxygen is ideal for applications such as: wastewater treatment, ozone production, health care and glass industry. The OGP series of oxygen generators delivers capacities from 0.6 to 56 l/s and flows between 2 and 200 Nm³/h. Your generator is delivered ready to use, you only need a supply of dry compressed air. This low installation cost is not the only way you save money: PSA technology is reliable and highly efficient, so running costs are low. Last but not least, on-site oxygen is significantly cheaper than using bottles or bulk deliveries.

Features and Benefits

Ready to Use

Only requires a supply of dry compressed air
Plug-and-play
No specialist installation or commissioning
Fully automated and monitored including oxygen sensor as standard
Performance guaranteed independent from temperature

Cost Savings

Low installation and running cost – highly efficient technology
No additional costs such as order processing, refills and delivery charges
Virtually service free

Exceptional Convenience

Continuous availability (24 hours a day, 7 days a week)
Risk of production breakdown due to gas running out is eliminated

Desired Purity

Oxygen supply according to your need: from 90% to 95% purity
Very easy to set up the device for other purity levels

High Flow Capacity

The wide product range and nitrogen flows up to 200 Nm³/h make the new OGP series ideal for applications such as waste water treatment, ozone production, health care, glass and many more

You don’t have to buy it right away. Lease it first!

Atlas Copco has put together a special “Lease to Own” program for customers in the UAE.

The program is designed to support you need to make smart financial decisions for your business.

When you lease one of our oxygen generators you benefit because:

The terms are flexible
The monthly payments are low
We offer an optional full service solution combined with 5 years warranty

Take a look at how on-site gas generation stacks up against renting from a nitrogen/oxygen gas supplier.

Installment	Cost of leasing bottles (AED)	Running cost of on-site gas generation (AED)	Cash flow (AED)
Quarter 1	75,000	68,500	6,500
Quarter 2	75,000	68,500	6,500
Quarter 3	75,000	68,500	6,500
Quarter 4	75,000	68,500	6,500
Quarter 5	75,000	68,500	6,500
Quarter 6	75,000	68,500	6,500
Quarter 7	75,000	10,000	65,000
Quarter 8	75,000	10,000	65,000
Total	600,000	431,000	169,000