Oxygen Concentrator – Introduction
Oxygen concentrator systems are a vital component in industries requiring a continuous and reliable supply of high-purity oxygen. Unlike smaller bedside units designed for personal use (sometimes called oxygen generators), large oxygen concentrators are engineered for facilities, often housed in dedicated plant rooms or containerised solutions, and are designed for longevity and reliability. These oxygen concentrators span the range from about 50 to 7500 litres per minute of oxygen (100kg/day to 15 000kg/day) production and are critical in manufacturing, healthcare, water treatment, mining, and other sectors that depend on a steady oxygen source.
How Industrial Oxygen Concentrators Work
Industrial oxygen machines utilise Pressure Swing Adsorption (PSA) technology to extract oxygen from ambient air. This process involves:
Raw product input
Atmospheric air is drawn into the system, compressed and filtered to an ISO 8573-1 class 1:4:1. This class defines the contamination in compressed air in three class ratings: solids, humidity/liquid water and oil. Filtration components and dryers are used to remove most of the oil and solid contaminants, and much of the water is condensed during air compression. The clean compressed air is typically stored in an air receiver. The air quality should monitored and maintained within the definition of the specification above to ensure the oxygen plant’s longevity.
Oxygen concentrator or PSA
The compressed air is passed through a PSA (pressure swing adsorption) device, which separates the oxygen from the air passing through it. The technology was developed in the 1960s by Dr Skarstrom, and the operation cycle is still referred to as the Skarstrom cycle. The cycle includes the following four steps:
- Pressurisation: The adsorbent bed is pressurised with the gas mixture to be separated.
- Adsorption: In oxygen PSA’s, zeolite is used and nitrogen gas is trapped, leaving the oxygen to be captured.
- Depressurisation: The pressure in the bed is reduced, causing the adsorbed gas to desorb.
- Purge: The desorbed gas is purged from the bed, leaving behind the desired separated gas.
- Oxygen Collection & Delivery: The purified oxygen is stored.
The Product – Oxygen
Oxygen product purity is typically monitored continually and should be between 90 and 96% at optimal performance. Some Nitrogen remains in the product (4-9%) as well as Argon (0.9-1%) and potentially traces of other rare gases.
For medical use, the oxygen product should be measured continuously against the specified requirements of “Oxygen 93” as defined in the pharmacopeia. Sensing of the oxygen composition is handled by a suite of electronic sensors, which are used to accurately profile the gas as it is produced.
WHO Standards and Compliance
For medical applications, oxygen purity must align with WHO’s “Oxygen 93” standards, ensuring compliance with safety and quality regulations. WHO also mandates adherence to ISO 80601-2-69 for users of single patient bedside concentrators. This standard highlights the need for proper monitoring, maintenance, and backup power solutions to ensure patient safety and operational reliability. In South Africa, PSA manufacturers must be registered to manufacture a medical device with the local authority, SAHPRA (South African Health Products Regulatory Authority).
Oxygen Concentrator – Key Advantages
- Cost Efficiency: Reduces reliance on bulk oxygen deliveries and associated logistical expenses.
- Continuous Supply: Ensures an uninterrupted oxygen flow, which is crucial for operations requiring 24/7 availability.
- Scalability: Systems can be customised to meet specific flow and purity requirements.
- Environmental Benefits: Reduces carbon footprint compared to liquid oxygen transportation and storage.
- Control Of Supply: Your plant gives you full control of your oxygen supply.
Containerised vs. Plant Room Installations
Industrial oxygen concentrators can be installed in dedicated plant rooms or housed within modular shipping containers, each offering unique benefits:
- Plant Room Installations: Ideal for facilities with existing infrastructure, allowing seamless integration into oxygen distribution networks.
- Containerised Solutions: Prefabricated mobile units suitable for remote locations, disaster relief, and temporary setups.
Cylinder Filling Capabilities for Seamless Integration
One of the most significant advantages of large-scale oxygen concentrators is their ability to incorporate cylinder filling functionality. Large PSA systems typically supply oxygen at about 300kPa to 500kPa to maintain the highest process efficiency. Oxygen booster compressors are used to boost the pressure of oxygen produced from 300kPa to 20,000kPa (cylinder pressure). Foxolution cylinder filling plants are capable of filling different size cylinders that can be used for different purposes, typically these include three sizes. This feature enables industries to:
- Refill Oxygen Cylinders On-Site: Reducing dependency on external suppliers.
- Maintain Backup Supply: Ensuring emergency reserves are always available.
- Support Multiple Applications: Serving various departments within a facility simultaneously.
Industries Benefiting from Industrial Oxygen Concentrators
- Manufacturing & Metal Cutting: Enhancing efficiency in welding, brazing, and cutting operations.
- Water & Wastewater Treatment: Supporting oxidation processes for purification.
- Mining & Chemical Processing: Facilitating combustion and material processing applications.
Conclusion
Large oxygen concentrators offer a reliable, cost-effective, and scalable solution for businesses requiring a continuous oxygen supply. Whether installed in plant rooms or within containerised units, these systems provide a seamless and efficient alternative to traditional oxygen procurement methods. With the added advantage of on-site cylinder filling, companies can further streamline operations and enhance self-sufficiency in oxygen management.
Please call Foxolution to discuss your oxygen concentrator application or to define an innovative solution that makes an immediate impact on what matters most to you.