Compressed Air and Nitrogen Generation for Ultrafine Powders
In the production of ultrafine powder new materials, the stability and cleanliness of the gas source, as well as the effectiveness of nitrogen protection, directly determine product quality and production efficiency. Powder oxidation, moisture and oil in the gas source, high air usage costs, and unstable equipment leading to shutdowns are common pain points in the industry.
In the production of ultrafine powder new materials, the stability and cleanliness of the gas source, as well as the effectiveness of nitrogen protection, directly determine product quality and production efficiency. Powder oxidation, moisture and oil in the gas source, high air usage costs, and unstable equipment leading to shutdowns are common pain points in the industry.
Project Implementation and Operating Results
In the production of ultrafine powder new materials, the stability and cleanliness of the gas source, as well as the effectiveness of nitrogen protection, directly determine product quality and production efficiency. Powder oxidation, moisture and oil in the gas source, high air usage costs, and unstable equipment leading to shutdowns are common pain points in the industry.
1. Project Background
For the high-load, continuous, and high-cleanliness production requirements of a new materials company's annual production project of 500,000 tonnes of ultra-fine powder new materials, the BOSAN tailor-made customized dual-stage compression screw air compressor and nitrogen generator combination machine solution was designed to solve the production gas needs in one stop, laying a solid gas source foundation for large-scale mass production.
2. Core Pain Points of the Project
With an annual production of 500,000 tonnes at full capacity, the equipment requires 7 × 24 hours of continuous and stable gas supply, and pressure fluctuations directly affect the uniformity of the powder particle size.
Ultrafine powder is extremely prone to oxidation, moisture absorption, and contamination, and has very high requirements for the cleanliness of the air source and nitrogen protection.
The traditional externally purchased liquid nitrogen model is costly and supply is unstable, making it unsuitable for large-scale production.
Ordinary air compressors have high energy consumption and large no-load losses, resulting in long-term production cost pressure.
3. BOSAN Customized Combination Solution
Combining the full-process conditions of powder crushing, pneumatic conveying, classification and sorting, and silo inerting protection, the BOSAN adopts an integrated dual-stage compression permanent-magnet variable-speed screw air compressor and PSA nitrogen generator solution.
01. Two-stage PM VSD Screw Air Compressor
Adopting an efficient two-stage compression structure and a high-efficiency screw air end, the energy-saving advantage is significant; the permanent-magnet variable-speed self-adaptive load regulation matches the workshop air usage fluctuations, greatly reducing no-load energy consumption. Equipped with a multi-stage precision purification system, it controls moisture, particles, and residual oil through supporting dryers and filtration systems, ensuring stable operation throughout air flow crushing, pneumatic conveying, and automated valve groups, reducing powder contamination and defective product risks. The equipment supports full-load operation around the clock, adapting to the continuous production rhythm of the factory.
02.PSA Nitrogen Generator
Relying on on-site nitrogen generation using clean compressed air, the nitrogen purity can be precisely adjusted according to the characteristics of the materials, fully covering scenarios such as powder crushing chamber inerting, pipeline purging, silo sealing, and finished product protection. This reduces dependence on purchased liquid nitrogen, significantly lowers long-term gas costs, and eliminates reliance on external supply.
03. Integrated Intelligent Management and Control
The entire set of equipment is intelligently interconnected, monitoring pressure, flow, nitrogen purity, and equipment operation status in real time. It supports fault warnings, remote maintenance, balanced operation of multiple units, significantly reducing manual maintenance costs, making the management of the air compression station more efficient and worry-free.
4. Project Implementation Results
Stable quality: The air source is clean and stable, reducing issues such as powder oxidation, moisture absorption, and contamination, and steadily improving the pass rate of finished products.
Low energy consumption: Dual-stage compression and frequency conversion energy-saving technology effectively reduce the electricity consumption of the factory, providing a direct cost-saving effect.
Sufficient production capacity: 24/7 operation provides uninterrupted and stable gas supply, meeting the scaled production demand of 500,000 tonnes per year.
Cost saving: On-site nitrogen generation replaces liquid nitrogen procurement, significantly optimizing long-term operating costs.
Customer Review
"The 500,000-tonne ultra-fine powder project has strong production continuity, and the air source is the core foundation of production. The BOSAN integrated air compressor and nitrogen generator solution not only solves the supply of compressed air but also achieves on-site self-production of protective nitrogen. The equipment runs stably, energy consumption control meets expectations, and it safeguards the smooth production launch of our new materials project."
5. Conclusion
Having been deeply involved in the new materials powder industry for many years, BOSAN, relying on its core advantages of 'comprehensive product range, high power, ultra energy-saving, and customization,' focuses on providing integrated air supply solutions—including air compressors, nitrogen generators, purification systems, and complete station customization—for companies in ultra-fine powders, functional powders, and new energy materials. With professional equipment and tailored solutions, it helps new materials enterprises improve quality, reduce costs, and increase efficiency!
The figures apply to this project and its specific operating conditions, not guaranteed results for other projects or the entire product series. Configuration and performance are subject to the project technical agreement.