Inert Gas Generators

Our range of inert gas generators deliver the highest level of efficiency in diverse applications. These generators range from exo-gas generators to endo gas generators and ammonia crackers. These inert gas generators deliver the highest standards of performance at all times.

Exo gas produces protective layer for heat treatment furnaces. There are two different types of exo gas which can be produced. One is Lean exo-gas and other one is Rich exo gas. Just changing the air/fuel ratio produces both these gases. Lean exo gas is suitable for non-ferrous metals heat treatment. In case of steel/brazing/annealing applications, we use Rich exo gas.

Dew Point
By applying refrigerated dryer after gas generator, the dew point of (+) 5^oC is achieved. Molecular Sieves dryer is provided for implementing (-) 60⁰C Dew point.

Burner
These exo gas generators are fitted with a specially designed swirl flame burner. These burners offers soot free combustion and oxygen free exo-gas. The burner is ignited by the spark plug and UV-flame scanner continuously monitors the flame.

Safety Interlocks
Fuel supply to the burner stops automatically. Due to any problem related to low combustion air pressure, flame failure, low water flow or low fuel pressure - the gas generator shuts down safely giving audio-visual alarm.

Gas Composition	Lean Exo	Rich Exo
CO2	11 to 13%	5 to 6%
CO	0.5 to 1.5%	11 to 12%
H2	0.5 to 2%	12 to 13%
N2	Balance	Balance
Fuel	Natural gas/LPG/Kerosene or Diesel
Capacities	10 Nm3/hr to 5000 Nm3/hr

The Endothermic gas generator operates on LPG or Natural gas. When reaction of air and fuel takes place on Nickel catalyst at 1050^oC, endothermic gas composition is produced.

This endothermic process requires external heat. Electrical heaters or fuel burning around the retort provides this heat. The retort is made of heat resistant alloy, which is suitable for 1150^oC temperature. The life of the retort is around 5-years.

Some carbon deposits takes place on catalyst due to the cracking of fuel. Later onwards this fuel is burnt-off after every 30-days by regeneration process. This process regains catalyst activity. The catalyst life is around 2- years.

CO	28 to 30%
H2	20 to 25%
CO2	0.1 to 0.5%
N2	Balance
Dew point	(-) 5oC
Fuels	LPG or Natural gas.
Capacities	5Nm3/hr to 100 Nm3/hr

The Ammonia Cracker we offer produce a mixture of hydrogen and nitrogen. These cracked ammonia is widely applied in heat treatment furnaces. The ammonia cracking takes place on nickel catalyst at a temperature of 850^oC. This gas contains around 100-ppm uncracked ammonia impurity. The dew point of this is only (-) 30^oC.

Ammonia cracking is an endothermic reaction and it requires a lot of heat from outside. We offer electrical heating furnace upto 100Nm3/hr capacity.

Molecular Sieves Purifier
For reducing residual Ammonia content and to get dry gas, a molecular sieve purifier is provided. It reduces Ammonia down to 1-ppm level and dries gas upto (-) 80^oC dew point.

Some of the Features Of Cracked Ammonia

• Fully automatic, skid mounted units.
• Catalyst retort is made of heat resistant alloy. It withstands upto 1150^oC operating temperature. The retort life of this catalyst is around 10 years.
• Furnace has ceramic fiber insulation and a full size hinged door for easy maintenance and easy inspection.

Ammonia Gas Generator	Without Molecular Sieves Purifier	With Molecular Sieves Purifier
Hydrogen	75%	75%
Nitrogen	25%	25%
Oxygen	Nil	Nil
Residual ammonia	100-ppm (max)	1-ppm (max)
Dew Point	(-) 30oC	Upto(-) 80oC
Capacities	1 Nm3/Hr to 1000 Nm3/Hr.

As alternative to Endo Gas, Methanol cracking has become widely acceptable. "It is used for furnace atmospheres base." It is used in various applications like carburizing, carbo nitriding, annealing and hardening.

Keeping in mind the safety purpose the dissociated methanol is used with nitrogen gas. In this process nitrogen gas is used as a carrier, which reduces the consumption of methanol. The solution cracking process takes place at a temperature above 750^oC as under:

CH3OH=2H2 + CO

5 ltrs. Of Methanol and 10 Nm3 Nitrogen is mixed together (e.g. Methanol 5 liters & Nitrogen 10 Nm3) into furnace to create the exact gas composition equivalent to Endo-gas

99.5% pure nitrogen gas is used from cylinders or from a captive PSA-Nitrogen generator. The methanol, which is used, should be free from moisture to avoid getting poor dew point in the furnace.


Carburizing / Carbo-nitriding : PSA Nitrogen and Methanol creates a process gas for carburizing and carbonitriding
Annealing : Annealing temperature depends on Nitrogen and Methanol content
Hardening : The Nitrogen solution hardens the products maintaining the tensile strength

CO2	0.5% (max)
CO	20%
H2	40%
N2	Balance
Dew point	(-) 40oC
Capacities	5 Nm3/hr to 100 Nm3/hr Protective gas.