How to Size a Nitrogen Generation System for Your Facility

Getting the sizing of a nitrogen generation system right from the start determines whether the system delivers reliable, consistent nitrogen across every application it serves or creates operational problems that are expensive to correct after installation. Undersized systems run out of capacity during peak demand. Oversized systems consume more energy and capital than necessary. Presscon.com works with every customer to size and specify a system that matches actual demand, integrates with existing infrastructure and scales with future production requirements.

Defining Nitrogen Demand

Flow rate and peak consumption

The starting point for any system sizing is establishing how much nitrogen the facility actually consumes. Presscon analyses nitrogen consumption across every application in the facility, mapping both average flow rates and peak demand periods. Peak consumption is the critical parameter: the system must be capable of supplying the maximum flow rate the facility requires at any given moment, not just the average. A laser cutting facility running multiple high-power machines simultaneously, for example, consumes nitrogen at a substantially higher rate during full production than during single-machine operation, and the system must be sized for the former rather than the latter.

Purity level

Different applications require different nitrogen purity levels, and purity has a direct effect on system sizing. Higher purity requires more compressed air per cubic metre of nitrogen produced, which increases both the generator capacity and the compressed air supply needed to feed it. Presscon establishes the purity requirement for each application in the facility and sizes the system to meet the most demanding specification while identifying where lower purity is acceptable to avoid over-engineering the supply to applications that do not require it.

Operating pressure

The delivery pressure required at each point of use determines the system pressure at which the generator and buffer vessel must operate. Laser cutting applications typically require higher delivery pressures than inerting or blanketing applications. Presscon maps the pressure requirements of every application and designs the distribution system accordingly, ensuring that each connection point receives nitrogen at the correct pressure without over-pressurising the system as a whole.

Assessing the Compressed Air Supply

A nitrogen generator produces nitrogen from compressed air, making the quality and capacity of that supply a fundamental input to system performance. Presscon assesses the existing compressor infrastructure at each facility to determine whether it can supply the generator at the required flow rate, pressure and air quality. Moisture, oil contamination and particulate levels all affect Carbon Molecular Sieve performance and service life. Where the existing supply does not meet quality requirements, Presscon identifies the filtration and drying equipment needed before the generator is installed.

Sizing the Generator and Buffer Vessel

With demand, purity, pressure and compressed air quality established, Presscon sizes the generator and buffer vessel to match the specific requirements of the facility. The generator is sized for peak demand at the required purity and pressure. The buffer vessel absorbs demand peaks and smooths flow variations, ensuring stable delivery pressure at all points of use. The N-Gen modular design means capacity is built from individual modules rather than a single fixed unit, allowing precise sizing for current demand with a clear path to additional capacity as production grows.

Building in Redundancy and Future Capacity

Presscon builds redundancy into every system where production continuity requires it. In facilities where a nitrogen supply interruption would cause a production stoppage or a safety system failure, the system is configured so that required output is maintained even when one module is isolated for maintenance. Future capacity is addressed during initial sizing by designing the buffer vessel, distribution pipework and compressed air supply to accommodate additional modules beyond those installed at commissioning, avoiding the need to replace the system when production demand grows. 

How Presscon Sizes and Specifies Every System

Presscon does not size nitrogen generation systems from catalogue specifications or standard configurations. Every system begins with a detailed assessment of the facility, covering current nitrogen consumption across all applications, compressed air supply quality and capacity, delivery pressure requirements, redundancy needs and projected future demand. This assessment produces a system specification that is specific to the facility and verifiable against actual operating conditions rather than estimated from general industry parameters.

The sizing assessment includes a detailed cost model comparing the total cost of on-site generation against the current cost of cylinder or bulk liquid supply, giving operations and financial managers a clear and specific basis for evaluating the investment. All systems are designed and built in-house at Presscon’s production facility in Honselersdijk, with 24/7 service support available from commissioning through the full operational life of the installation.