Inert Gas Control Techniques

FOR THE REDUCTION OF VOC EMISSIONS & THE PREVENTION OF

FIRES AND EXPLOSIONS IN CHEMICAL PROCESSES.
APPLICATION FOR OXYGEN ANALYSIS.
A COMPARISON OF THREE TYPICAL METHODS

General
Flammable solvents and highly combustible powders are essential ingredients of many
industrial- manufacturing processes. Such combinations of ingredients raise the possibility of
flash fires or explosions within those processes. No flammable process is immune to this threat.
At Ntron, we believe protection from industrial fires and their catastrophic results is possible.
Thousands of incidents each year can and have been completely eliminated by using our systems
designed for Oxygen analysis based Inerting Control.
Combustion needs only three ingredients: an ignition source, fuel, and oxygen. However, the
successful elimination or absolute control of just one of these ingredients removes the possibility
of a fire or explosion.
Ignition
Whenever flammable liquids and dry powdersare pumped, mixed, filtered, agitated or kept in

motion during the manufacturing process, static electricity is created. Static sparks and an
adequate oxygen supply, are the most common sources of ignition in chemical and
pharmaceutical plant fires.

Fuel
Elements such as dusts, flammable liquids or gases become fuel under certain conditions within
a process.
In the manufacturing process, the danger of combustion becomes a reality when the temperature
of flammable liquids rises above their flash point. Vapor concentrations between the LEL (lower
Explosive Limit) and the UEL (Upper Explosive Limit) provide the necessary fuel conditions for
combustion.
Oxygen
By displacing oxygen with an inert gas, the risk of fire can be completely eliminated even if both
the ignition source and fuel are present. Most solvents and powders in typical manufacturing
processes require 10 to 15% oxygen for combustion at ambient temperature and pressure. As
long as oxygen is controlled to levels below the MOC (Minimum Oxygen Concentration for
combustion), combustion cannot take place.
Inerting:
Absolute Oxygen Control Inerting is a method that decreases the oxygen concentration within a
process vessel to a level where combustion cannot take place. This is achieved by the addition of
an inert gas such as Nitrogen, Carbon Dioxide, or steam. Inerting is one of the safest, most
reliable methods for fire and explosion prevention within a process. Most importantly, unlike
fire suppression systems or explosion venting devices, Inerting is a PREVENTATIVE technique
that keeps businesses operating and employees safe. Historically, Process engineers have relied
on two methods for Inerting Processes.
Pressurization method:
In this method, a continuous positive pressure is maintained on the process. This is usually
accomplished using a pressure regulator with pressure sensor for confirmation. The concept is
that once the vessel has been initially purged of oxygen, a positive pressure will prevent oxygen
(in the form of air), from entering the process. This method generally results in maintaining a
near 0.0% of oxygen in the vessel. Additionally, when manual ingredient additions are made to
the vessel, the pressure regulator is unable to maintain sufficient pressure. Actual consumption
of nitrogen in an atmospheric pressure based process using this method requires approximately

5-7 volume exchanges plus additional nitrogen consumption during manual ingredient additions.
Typical oxygen concentration in the vessel ranges from 0.0 to 1% when no manual additions are
made. Inert gas is wasted and there is no assurance that the oxygen value is at a safe level.
Timed Volume Method:
This method is based on volume exchanges to get the oxygen concentration to a safe level. The
vessel is completely flushed with inert gas before operation. This initial purge is designed to
bring the oxygen concentration to a safe value. Once completed, additional inert gas is added at
a calculated flow rate for the rest of the process. A safe level of oxygen is assumed to be present
in the vessel. This continuous purge is usually at a higher flow rate than needed. This technique
does not account for the changes that can occur in modern complex manufacturing processes.
Actual consumption of nitrogen in a typical process using this method requires approximately 45 volume exchanges plus additional nitrogen consumption during manual ingredient additions.
The vessel atmosphere will hover around 1% O2 when no manual additions of ingredients are
made. Inert gas is wasted and there is no assurance that the % O2 is at a safe level.

TYPICAL INSTALLATION OF SINGLE CHANNEL OXYTRON SYSTEM

ON THE ELEVATED TEMPERATURE OF A CHEMICAL REACTOR
ATMOSPHERE OR MIXER
(Ambient temperature process does not contain acid vapors)

1. Coalescing Sample Prefilter to remove particulates and catch condensing process solvent
vapors.
2. Automatic Drain to remove filter condensate while maintaining eductor vacuum.
3. Sample Conditioning Package extracts & cleans gas sample before directing it to the
oxygen and loss of sample flow sensors.
4. Oxytron Analyzer monitors and controls the oxygen level of the elevated temperature of
the chemical reactor atmosphere.
5. Safety Barriers maintain the Intrinsic Safety of the Sample Conditioning Package.
6. Inerting Control Solenoid Valve allows inreactor atmosphere on demand.