Saudi Aramco's Guide to Nitrogen and Inert Gas Systems

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Nitrogen/Inert Gas Systems
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Process
File Reference: CHE10710
For additional information on this subject, contact

R. A. Al-Husseini on 874-2792
Process
CONTENTS
PAGES
INFORMATION
TYPES OF NITROGEN AND INERT GAS GENERATION ..............................................................1
Cryogenic Nitrogen Generation ..............................................................................................1
Combustion Inert-Gas Generation ..........................................................................................1
Pressure-Swing Adsorption Nitrogen Generation ...................................................................6
Polymeric Membrane Inert Gas Generation ............................................................................8
NITROGEN/INERT GAS REQUIREMENTS ...................................................................................10
Allowable Concentrations.....................................................................................................10
PURGE REQUIREMENT CALCULATIONS ...................................................................................11
Pressure/Depressure Cycle....................................................................................................11
Purge Through ......................................................................................................................12
Tank or Vessel Blanketing....................................................................................................13
PURIFICATION-GAS QUALITIES FROM VARIOUS GENERATORS .........................................14
Purification Processes ...........................................................................................................14
DISTRIBUTION SYSTEM ................................................................................................................15
DESIGN CONSIDERATIONS...........................................................................................................16
PROCESS SELECTION ....................................................................................................................17
STORAGE..........................................................................................................................................18
SAFETY CONSIDERATIONS ..........................................................................................................19
Process
WORK AID
WORK AID 1:ALLOWABLE CONCENTRATIONS OF OXYGEN................................................20
WORK AID 2: PURGE CALCULATIONS-PRESSURE/DEPRESSURE CYCLE ..........................21
WORK AID 3: PURGE CALCULATIONS - PURGE THROUGH CYCLE ....................................22
WORK AID 4: CONTAMINANT CONCENTRATION FROM VARIOUS INERT GAS
GENERATORS .................................................................................................23
WORK AID 5: NITROGEN GENERATION RELATIVE COST VERSUS PURITY......................24
WORK AID 6: CRITICAL OXYGEN CONCENTRATIONS ..........................................................25
WORK AID 7: EXPLOSIVE LIMITS (SADP-J-503) .......................................................................26
GLOSSARY
GLOSSARY .......................................................................................................................................27
REFERENCE
REFERENCES ...................................................................................................................................28
Saudi Aramco Standards.......................................................................................................28
Saudi Aramco Design Practices ............................................................................................28
Exxon Basic Practices...........................................................................................................28
ii
Process
LIST OF FIGURES
Figure 1.
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Linde Dual-Pressure Liquefaction System .........................................................................................2

Linde Double-Column Air Separator (Cont'd) ...................................................................................3
Combustion Inert-Gas System ...........................................................................................................4
Inert Gas Generator ............................................................................................................................5
Inert Gas Generator (Compressor and Dryer on Skid Mounting) ......................................................5
Pressure-Swing Adsorption Nitrogen Generator ................................................................................6
Adsorber Tower for Nitrogen Generator ............................................................................................7
Adsorber Tower (Skid Mounted) .......................................................................................................8
Membrane Inert Gas System ..............................................................................................................9
iii
Process
TYPES OF NITROGEN AND INERT GAS GENERATION

Four main processes are used for the generation of nitrogen or inert gas: cryogenic, combustion, pressure-swing
adsorption, and more recently, polymeric membrane processes.
Cryogenic Nitrogen Generation

In Saudi Aramco, there is a large cryogenic nitrogen generator at Qurayyah. Nitrogen produced there is
shipped to the areas in Saudi Aramco.
Cryogenic nitrogen generators are made to produce all-liquid nitrogen, all-nitrogen gas, or a mixture of liquid
and gas.
Typical sizes of cryogenic generators start at about 4,000 SCFH for all-liquid generators. Smaller all-liquid and
very large all-gas sizes are available. Air products and Chemicals is a typical supplier of cryogenic nitrogen
generators.
Auxiliaries required for cryogenic nitrogen generators include vaporizers for the liquid nitrogen and
compressors for the nitrogen gas.
Storage can be in the liquid form in refrigerated storage vessels or as a gas in pressure storage.
Schematics of a Linde cryogenic air liquefaction process and an air separator are shown on Figure 1.
Combustion Inert-Gas Generation

There are two main types of combustion inert-gas generators, direct water cooled and indirect cooled. Indirect
cooling can be either by air or water. Several fuels can be used. Natural gas is the most common. However,
liquid fuels and even some wastes can be used. The combustion inert-gas generators can also be dual-fuel fired
with liquid and gas.
Typical sizes range from 800 to 150,000 SCFH.
Process
With permission from D. Van Nostrand
Figure 1. Linde Dual-Pressure Liquefaction System
Process
Figure 1. Linde Double-Column Air Separator (Cont'd)
Process
Auxiliaries required for combustion inert-gas generators include an air blower, a dryer similar to a compressed
air dryer, a compressor, and storage. Storage is often similar to a large compressed air receiver.
A schematic of a combustion inert gas generator is shown on Figure 2.
With permission from Permea
Figure 2. Combustion Inert-Gas System
Process
Figure 3 shows a combustion inert gas generator alone and Figure 4 shows it with a compressor and dryer on
the same skid mounting.
With permission from Permea, a Monsanto Company
Figure 3. Inert Gas Generator
Figure 4. Inert Gas Generator (Compressor and Dryer on Skid

Mounting)
Process
Pressure-Swing Adsorption Nitrogen Generation

The front end of a pressure-swing adsorption nitrogen generator is essentially the same as a combustion inertgas generator. This is followed by one or two dual-tower molecular sieve adsorbers. The adsorbers operate on
a pressure/depressure cycle. They adsorb carbon dioxide and other contaminants
Aftercoolers and oil and water filters are usually installed between the gas generator and the adsorbers.
An ultrasorber or second adsorber can be added to increase the purity of the nitrogen. If very dry air is
required, an additional dryer can also be added.
Pressure storage is most common for this type of nitrogen generator.
Typical sizes range from 500 to 50,000 SCFH.
Figure 5 shows a pressure-swing adsorption nitrogen generator with compressor and two pairs of adsorber
towers.
"3 " Molecular

Sieve Adsorber
"1 "
Combustion
Unit
"2 "
Compressor
System
Figure 5. Pressure-Swing Adsorption Nitrogen Generator
Process
Figure 6 shows a single pair of adsorber towers rated at 12,000 SCFH at 85 psig. Figure 7 is a skid-mounted
pressure-swing adsorption nitrogen generator. The combustion unit, compressor, and adsorber towers are on
the same frame. This unit produces 750 SCFH of nitrogen.
Figure 6. Adsorber Tower
Process
MSC-0.75 producing 750 cubic feet per hour of nitrogen. Small capacity
generators are shipped with combustion unit, compressor, and
adsorption system on one steel frame.
Figure 7. Adsorber Tower (Skid Mounted)
Polymeric Membrane Inert Gas Generation

Polymeric membrane inert gas generators are a recent development. The heart of the generator is Monsanto's
PrismR separator. This separator selectively removes oxygen, water, and carbon dioxide from compressed air
by permeation through hollow fiber membranes.
The equipment required includes an air compressor, the polymeric membrane separator, and storage.
The separators operate at pressures between 100 and 1,450 psig. A typical operating pressure is 435 psig.
Process
Typical sizes range from 3,500 to 20,000 SCFH. Higher capacities are available using multiple units.
Monsanto and Maritime Protection A/S are contacts for anyone interested in this equipment.
A schematic of a membrane inert gas generator is shown on Figure 8.
Figure 8. Membrane Inert Gas System
Process
NITROGEN/INERT GAS REQUIREMENTS

Nitrogen and inert gas are used in the following service:
Equipment purging
Tank or vessel blanketing
Feed to some processes
Solids conveying
Seal gas
Backup to compressed air systems
Others
Allowable Concentrations (Also in Work Aid 1)

A maximum of 0.5% of oxygen in inert gas is allowed to eliminate a possible explosion hazard.
To prevent combustion, oxygen should be kept below 2% in hydrogen-rich atmospheres and below 5% in
hydrocarbon-rich atmospheres.
Various chemical or process blanketing uses may have other limitations on such contaminants as carbon
monoxide, carbon dioxide, hydrogen sulfide, and others.
10
Process
PURGE REQUIREMENT CALCULATIONS

One of the most frequent uses of nitrogen or inert gas is to purge equipment of explosive or hazardous vapors
before maintenance. This can be done by using a pressure and depressure cycle or by continuous purging.
Pressure/Depressure Cycle (Also in Work Aid 2)

You can use the following equation to determine the number of cycles of pressure and depressure required to
lower the oxygen concentration in a space.
C1 C o
N
= P2 P1
C2 C o
Co = % O2 in purge gas
C1
= % O2 initially in purged space
C2
= % O2 finally in purged space
P1
= Low (minimum) pressure in atm
P2
= High (maximum) pressure in atm
= Number of pressure/depressure cycles
For example, assume a vessel at 1-atm pressure has an initial oxygen concentration of 19%. This concentration
must be lowered to 5% to stay below the critical oxygen concentration of a hydrocarbon (see Work Aid 6).
Inert gas with 0.5% oxygen is available for purging at 100 psig.
Co = 0.5%
C1
= 19%
C2
= 5%
P1
= 1 atm
P2
= 100/14.7 + 1 = 7.8 atm
11
Process
Thus:
19 0.5 = 7.8 1 N
]
5 0.5 [
7.8 N = 4.11
N = 0.688 cycle (less than 1 full cycle )
In this case, one cycle is adequate. To check:
[ ]
19 0.5 = 7.8
C 2 0.5
1
18.5 +
C2 =
0.5
7.8
C 2 = 2.87% O 2 after 1 cycle
One cycle would require 6.8 times the vessel volume of inert gas. This would lower the vessel oxygen
concentration to 3.87%.
Purge Through (Also in Work Aid 3)

The following equation can be used to calculate the quantity of inert gas or nitrogen required to purge a vessel
to reduce the oxygen concentration.
C C
C 2 = 1 V o + Co
e
V = Ratio of purge gas volume to space volume

Using the same example as before:
5 = 19 V0.5 + 0. 5
e
e V = 18.5 = 4.11
4.5
V = 1.415
In this case 1.415 times the vessel volume of inert gas would lower the vessel concentration to 5%.
12
Process
Tank or Vessel Blanketing

The quantity of inert gas required for tank or vessel blanketing depends upon the maximum withdrawal of
liquid or vapor from the vessel. The purge gas volume in must equal the liquid or vapor volume out.
13
Process
PURIFICATION-GAS QUALITIES FROM VARIOUS GENERATORS (Also in

Work Aid 4)
The table below lists the typical concentrations of impurities that might be found in the gas produced by various
types of nitrogen and inert gas generators.
Contaminant %
Generator Type
CO2
CO
H2
O2
Combustion-nonreducing
11.4-15
0-0.1
0-0.1
0.1-0.6
Combustion-reducing
11.4-15
0.1-0.6
0.1-0.6
0-0.1
Adsorption
0.002-0.1
0.1-3.0
0.1-3.0
0.12-0.001(1)
Polymeric membrane
<5
0.5-10
(1) 0.1% of CO and H2 is consistent with 0.12% O2

3.0% of CO and H2 is consistent with 0.001% O2
Purification Processes
Several processes are available for further purifying the inert gas or nitrogen.
An MEA absorber will remove 99.5% of the CO2 and H2S in inert gas.
A caustic absorber will remove all CO2 and SO2.
A catalytic purifier can reduce the concentration of O 2 to 2 ppm, NOx to 1 ppm, and CO to 20
ppm.
14
Process
DISTRIBUTION SYSTEM
The pressure of an inert gas or nitrogen system depends upon the use of the gas. The required pressure for tank
blanketing is usually very low. For purging or for backup to a compressed air system, typical pressures range
from 60 psig to 100 psig. For solids conveying, the pressure frequently used is about 15 psig. However, higher
and lower pressures are also used.
Pressure drop in distribution piping is similar to pressure drop in a compressed air system. The average
pressure drop is normally kept below 0.2 psi per 100 ft of equivalent length.
Check valves or non-return valves are usually installed at every unit battery limit and at each consumer to
prevent the backup of contaminants into the inert gas or nitrogen system.
Breakaway connections are used for all consumers except for continuous or very frequent users.
At utility stations, a connection different from air, steam, and water connections should be used to ensure
against incorrect connections.
15
Process
DESIGN CONSIDERATIONS
In determining the system demand, you need to consider all users. You should also include: process feed, if
any, tank blanketing, conveying, and purging. Be sure that you determine the maximum simultaneous loads for
all consumers.
The quality of inert gas or nitrogen used is very dependent upon its final use. For safety reasons, the oxygen
content should be below 50% of the critical oxygen concentrations of materials frequently encountered are
listed in Work Aid 6. Explosive limits for some commonly encountered gases are listed in Work Aid 7.
For process feed or other uses where chemical contamination is a concern, the inert gas specification required
purity of the gas.
16
Process
PROCESS SELECTION (ALSO IN WORK AID 5)

The type of inert gas or nitrogen generator must be selected by balancing the cost of generation versus the
required purity of the gas.
The following table gives you relative capital costs of nitrogen generation systems versus the gas purity.
Generation Process
CO2
Contaminant (ppm)
H2Q
O2
Relative
Capital Cost(1)
1,000
10
25
1.0
1,000
10
10
1.04
1,000
10
1.07
1,000
10
1.12
500
25
1.12
20
1.40
(1)Based on 10,000 SCFH

Cryogenic nitrogen costs about five times as much as combustion inert gas.
Waste heat recovery is possible with a combustion inert gas generator. A 20,000 SCFH inert gas plant can
supply about 1.8 million Btu per hour to a 125 psig steam generator.
17
Process
STORAGE
Cryogenic liquid generators require cold storage. At atmospheric pressure, storage must be at minus 320F.
Vapor storage is similar to storage for compressed air.
As a general rule, C.M. Kemp recommends 25 to 50 ft 3 of storage for each 1,000 SCFH of consumption.
18
Process
SAFETY CONSIDERATIONS
To avoid an explosive atmosphere, base your designs to stay below 50% of the critical oxygen concentrations
of hazardous material given in Work Aid 6. For a hydrogen-rich atmosphere, you should design for less than
2% O2.
For a hydrocarbon atmosphere, you should design for less than 5% O 2. You should keep the inert gas
concentration below 0.5% O2.
A list of gases, with their lower and upper explosives limits is contained in Work Aid 7.
To ensure against asphyxiation or danger to breathing, you should keep the oxygen concentration above 19%
O2 in areas where personnel can be present. Remember that nitrogen is odorless. It is usually impossible to
detect excess nitrogen, therefore the lack of oxygen, by smell.
19
Process
WORK AID 1: ALLOWABLE CONCENTRATIONS OF OXYGEN

O2 should be limited to 0.5% or less in inert gas to eliminate the possibility of explosion.
To prevent combustion, O2 should be limited to the following:
2% in hydrogen-rich atmospheres
5% in hydrocarbon-rich atmospheres
20
Process
WORK AID 2: PURGE CALCULATIONS-PRESSURE/DEPRESSURE CYCLE

The following equation can be used to determine the number of pressuring and depressuring cycles that will be
required to reduce the oxygen percentage in a space.
C1 C o
N
= [P 2 P 1 ]
C2 C o
Co = % O2 in purge gas
C1 = % O2 initially in purged space
C2 = % O2 finally in purged space
P1
= Low (min) pressure, atm
P2
= High (max) pressure, atm
= Number of pressure/depressure cycles
21
Process
WORK AID 3: PURGE CALCULATIONS - PURGE THROUGH CYCLE

The following equation can be used to determine the amount of purge gas required in a once-through purge.
C2 =
C 1 Co
+ Co
eV
Ratio of purge gas volume to space volume
Co
% O2 in purge gas
C1
% O2 initially in purged space
C2
% O2 finally in purged space
22
Process
WORK AID 4: CONTAMINANT CONCENTRATION FROM VARIOUS INERT

GAS GENERATORS
The following table lists ranges of various contaminants that may be expected in the effluent gas from various
types of inert gas generators.
Inert Gas
Generator Type
Contaminant Concentration
CO2
CO
H2
O2
Combustion-nonreducing
11.4-15
0-0.1
0-0.1
0.1-0.6
Combustion-reducing
11.4-15
0.1-0.6
0.1-0.6
0-0.1
Adsorption
0.002-0.1
0.1-3.0
0.1-3.0
0.12-0.001
Polymeric membrane
<5
0.5-10
23
Process
WORK AID 5: NITROGEN GENERATION RELATIVE COST VERSUS PURITY
CO2
Contaminant Level (ppm)

H2O
O2
Relative
Capital Cost(1)
1,000
10
25
1.0
1,000
10
10
1.04
1,000
10
1.07
1,000
10
1.12
500
25
1.12
20
1.40
(1)Based on 10,000 SCFH

Cryogenic nitrogen cost is about five times the cost of combustion inert gas.
24
Process
WORK AID 6: CRITICAL OXYGEN CONCENTRATIONS

LIST OF TYPICAL CRITICAL OXYGEN CONCENTRATIONS (%) (1)
Acetaldehyde
12
Acetone
11.6
Allyl chloride
12.6
Ammonia
15
Benzene
11.2
1, 3 Butadiene
10.4
Butane
12.1
1-Butene
11.4
Ethane
11
Ethanol
10.6
Ethylene
10
Gasoline (octane 100)
11.6
Heptane
11.6
Hexane
11.9
Isobutane
12
Methane
12.1
Methanol
9.7
Pentane
12.1
Propane
11.4
Vinyl chloride
(1) Critical oxygen concentration (COC) is the minimum level of oxygen to

sustain combustion. A mixture of flammable vapor and oxygen
containing less than the COC of oxygen will not sustain combustion.
Ref. "Combustion, Flames and Explosions of Gases," Bernard Lewis and Guenthe Von Elbe, Academic Press,
Inc., NY, NY, 1961, Appendix
25
Process
WORK AID 7: EXPLOSIVE LIMITS (SADP-J-503)

For a given gas, the explosive limit is that volume percent of the gas present in air that will produce an
explosive mixture. Upper and lower explosive limits define the explosive range.
Lower Explosive
Limit (LEL)
Vol. %
Upper Explosive
Limit (UEL)
Vol. %
Methane
5.0
15.0
Ethane
3.0
12.5
Propane
2.2
9.5
Butane
1.9
8.5
Hydrogen Sulfide
4.0
44.0
Hydrogen
4.0
75.0
Ammonia
15.0
28.0
Methyl Alcohol
7.4
36.0
Gasoline(1)
1.4
7.6
Naphtha(1)
0.8
5.0
Kerosene(1)
0.7
5.0
Gas
(1)Typical Values
Reference conditions: 15C at 101.325 kPA (60F at 14.7 psia)
26
Process
GLOSSARY
blanketing
combustible
critical oxygen concentration
(COC)
explosive gas
flash point
ignition temperature
lower explosive limit (LEL)
purge
upper explosive limit (UEL)
Maintaining a desired vapor concentration in a contained space such as in

the vapor space of a process vessel or storage tank. A space could be
inert-gas-blanketed, or it could be hydrocarbon-blanketed.
Capable of being ignited with resultant burning or explosion.
(Interchangeable with flammable.)
The minimum level of oxygen to sustain combustion.
Any combustible gas capable of being ignited and burned under certain
conditions of quantity and/or confinement; normally used as a synonym
for flammable gas.
The minimum temperature at which a liquid gives off sufficient vapor to
form an ignitable mixture with the air near the surface of the liquid or
within the vessel used.
The minimum temperature required for a substance, whether solid, liquid
or gaseous, to initiate or cause self-sustained combustion independent of
the heating or heated element.
The minimum concentration of vapor or gas in air or oxygen below which
propagation of a flame does not occur on contact with a source of
ignition.
Replacing vapor in a container or space with other vapor such as inert gas.
The maximum concentration of vapor or gas in air or oxygen, above
which propagation of a flame does not occur on contact with a source of
ignition.
27
Process
REFERENCES
Saudi Aramco Standards
SAES-J-503
Combustion Gas Monitoring Systems
Saudi Aramco Design Practices
SADP-J-503
Combustion Gas Monitoring Systems
Exxon Basic Practices
BP12-1-1
Inert Gas Generators
28

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Nitrogen/Inert Gas Systems

For additional information on this subject, contact

Saudi Aramco DeskTop Standards

Saudi Aramco DeskTop Standards

Linde Dual-Pressure Liquefaction System .........................................................................................2

Saudi Aramco DeskTop Standards

TYPES OF NITROGEN AND INERT GAS GENERATION

Cryogenic Nitrogen Generation

Combustion Inert-Gas Generation

Saudi Aramco DeskTop Standards

With permission from D. Van Nostrand

Figure 1. Linde Dual-Pressure Liquefaction System

Saudi Aramco DeskTop Standards

Figure 1. Linde Double-Column Air Separator (Cont'd)

Saudi Aramco DeskTop Standards

With permission from Permea

Figure 2. Combustion Inert-Gas System

Saudi Aramco DeskTop Standards

With permission from Permea, a Monsanto Company

Figure 3. Inert Gas Generator

With permission from Permea, a Monsanto Company

Figure 4. Inert Gas Generator (Compressor and Dryer on Skid

Saudi Aramco DeskTop Standards

Pressure-Swing Adsorption Nitrogen Generation

"3 " Molecular

Figure 5. Pressure-Swing Adsorption Nitrogen Generator

Saudi Aramco DeskTop Standards

With permission from Permea

Figure 6. Adsorber Tower

Saudi Aramco DeskTop Standards

Figure 7. Adsorber Tower (Skid Mounted)

Polymeric Membrane Inert Gas Generation

Saudi Aramco DeskTop Standards

With permission from Permea, a Monsanto Company

Figure 8. Membrane Inert Gas System

Saudi Aramco DeskTop Standards

NITROGEN/INERT GAS REQUIREMENTS

Tank or vessel blanketing

Feed to some processes

Backup to compressed air systems

Allowable Concentrations (Also in Work Aid 1)

Saudi Aramco DeskTop Standards

PURGE REQUIREMENT CALCULATIONS

Pressure/Depressure Cycle (Also in Work Aid 2)

= % O2 initially in purged space

= % O2 finally in purged space

= Low (minimum) pressure in atm

= High (maximum) pressure in atm

= Number of pressure/depressure cycles

= 100/14.7 + 1 = 7.8 atm

Saudi Aramco DeskTop Standards

In this case, one cycle is adequate. To check:

Purge Through (Also in Work Aid 3)

V = Ratio of purge gas volume to space volume

Saudi Aramco DeskTop Standards

Tank or Vessel Blanketing

Saudi Aramco DeskTop Standards

PURIFICATION-GAS QUALITIES FROM VARIOUS GENERATORS (Also in

(1) 0.1% of CO and H2 is consistent with 0.12% O2

A caustic absorber will remove all CO2 and SO2.