Atlas Copco nitrogen generation solutions
The benefits:
- Plug-and-play.
- No specialist installation or commissioning.
- Fully automated and monitored including oxygen sensor as standard.
Wide range of applications:
- Food & beverage (storage & packaging), Pharmaceutical applications, Plastic injection molding, Electronics.
- Laser cutting, Semiconductor manufacturing, Chemical applications, Metal heat treatment, Cable & optical fiber industries, Glass industries and more.
The benchmark: Temmler Ireland
Temmler Ireland is a Bulk Pharmaceutical Solid Oral Dose manufacturing facility based in Killorglin, Co. Kerry for nearly 50 years. Temmler are part of the Aenova Group which is Europe’s largest CDMO entity. The site produces bulk Hard Gelatine Capsules containing sustained release pellets which are distributed to customers throughout the world. One of the Site’s core products, Diclofenac Sodium, a non-steroidal anti-inflammatory, is marketed in Ireland under the brand name Difene.
In August 2020, they installed the Atlas Copco NGP450+ nitrogen generator, complemented by a best-in-class oil-injected rotary screw GA132VSD+ compressor. We view this application as a benchmark for Atlas Copco’s gas generation solutions at their best.
Atlas Copco NGP450+ nitrogen generator in action in Co. Kerry
Temmler has always been environmentally conscious and has been generating their own supply of Nitrogen for over 30 years. Their previous PSA Plant (not Atlas Copco) was designed to produce 500 Nm³/hr and fed by three Atlas Copco GA110(kW) compressors. "When it came time to replace this equipment, we were given the opportunity to propose and quote a complete Atlas Copco system. The NGP450+ provided produces over 600 Nm³/hr of nitrogen while being fed by a single GA132(kW)VSD+ compressor, this equates to an energy cost of 2.2cent per m3 of Nitrogen for this system
Atlas Copco Ireland
Atlas Copco offered us a cost-effective package system which was effectively a “Plug & Play” for us. This meant that we were able to get the new PSA Plant installed, tested and qualified within our tight summer shutdown window. We were up and running seamlessly when production resumed after the break. "Nitrogen is used as a blanketing medium in several process steps within the production train. Hence, it is a critical utility which ensures the safe operation of the site. A nitrogen purity of > 99% is required for this purpose.
Temmler Ireland
As proven in the savings achieved by Temmler Ireland, Atlas Copco’s gas generation solutions are the ultimate cost and energy savers, along with offering complete control over your nitrogen production. This is an all-in-one solution with exceptional reliability and efficiency.
Prior to receiving the order for this system, we carry out a sizing and cost saving analysis with the aid of compressor data logging and site supplied N2 recordings. The system has met, and even exceeded our estimates. "With combined savings (Energy & Liquid Nitrogen) of over €60,000 per year based on just 50hrs per week operation, increased Nitrogen purity and more available N₂ flow. The site is now also able to reduce the use of Liquid Nitrogen which originally covered peaks in demand as well as being a backup supply.
Atlas Copco Ireland
The installation has led to significant energy savings from using one GA132 kW VSD compressor versus three 110 kW fixed speed units. The NGP450+ offered additional inherent savings as it has a significantly lower air-to-nitrogen ratio. "Furthermore, we are using significantly less liquid nitrogen top-up when site demand is high because the new system has a 30% greater output. We decided to retain two of the old GA110 machines as emergency back-up to the GA132 VSD unit and also to a 90kW VSD which supplies the site’s compressed air requirements.
Temmler Ireland
Atlas Copco NGP+ technology
Our NGP+ premium nitrogen generators offer the completest scope of nitrogen supply at the highest energy efficiency. On-site gas generators allow you to produce your own nitrogen and oxygen, using only a supply of dry compressed air. Generating gases on-site reduce the cost of using bottles or bulk deliveries.
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