TECHNICAL RESOURCES

Pressure Swing Adsorption (PSA) separates gases by taking advantage of the different adsorption characteristics of gas molecules under pressure. As compressed gas enters an adsorbent vessel, unwanted components are retained on the adsorbent while the desired product gas passes through.When the adsorbent becomes saturated, the vessel is depressurized to release the captured gases and regenerate the adsorbent. Multiple vessels operate in sequence so that purification and regeneration occur simultaneously, providing a continuous supply of high-purity gas.

Clean, dry compressed air enters adsorption vessels filled with adsorbent material. Under pressure, the adsorbent captures unwanted gases while nitrogen flows to the buffer tank. The vessels continuously alternate between adsorption and regeneration, ensuring an uninterrupted nitrogen supply.

A PSA system automatically regulates pressure, cycle timing, and gas flow to achieve the required purity and production rate. Modern PLC-based control systems continuously monitor operating conditions and adjust the cycle parameters to maintain stable performance despite changes in demand and inlet biogas composition

PSA Nitrogen generators typically deliver purities ranging from 95% to 99.999%, covering applications from general inerting to highly oxygen-sensitive processes such as heat treatment, electronics manufacturing, and fine chemicals.

Higher or customised purity levels can be evaluated together with the Sysadvance engineering team.

Turndown refers to the range over which a PSA can reduce its production while maintaining the specified gas quality. Depending on the process design, many PSA systems can operate efficiently across a wide flow range without compromising product purity.

For virtually all small- and medium-scale applications—including continuous 24/7 operation, variable demand profiles, and fast start-up requirements—PSA technology offers lower capital investment, lower cost per cubic metre, and easier plant integration.

Cryogenic plants are generally reserved for very high flow rates or projects requiring the simultaneous production of multiple industrial gases.

Gas purity depends on feed gas composition, pressure, temperature, flow rate, and adsorption cycle timing. Once commissioned, the PSA is optimized for its design conditions, but operating parameters are self-adjusted if process conditions change.

Producing Nitrogen on-site eliminates recurring costs associated with cylinder filling, rental, transportation, delivery charges, and evaporation losses from cryogenic tanks.

It also gives manufacturers full control over their gas production costs while reducing dependence on external suppliers and logistics.

An additional benefit is a significant reduction in carbon emissions by minimising road transport and storage-related losses.

The adsorbent material depends entirely on the application. Common materials include activated alumina, silica gel, molecular sieves (zeolites), and activated carbon. The selection is based on the target gas separation, contaminant levels, and operating conditions.

For the vast majority of industrial applications, PSA systems provide higher energy efficiency, greater flexibility, and lower lifetime operating costs than membrane technology.

Under normal operating conditions, PSA adsorbents typically provide many years of reliable service. Their lifetime depends largely on feed gas quality and correct operation. Exposure to liquid contaminants, excessive particulate loading, or operation outside design limits can reduce adsorbent performance. On average, if no serious contamination occurs, adsorbent is expected to last more than 10yrs.

The generator is supplied with clean, dry compressed air and is typically installed downstream of the existing compressor, air receiver, dryer, and filtration system, requiring minimal modifications to the plant's compressed air network.

PSA technology is widely recognized for its high reliability because it contains relatively few moving parts. With routine preventive maintenance and correct operating conditions, plant availability typically exceeds 99%, making PSA suitable for continuous industrial operation.

Nitrogen generators can be supplied as skid-mounted or containerised plug-and-play systems.

Outdoor installation is possible in most cases, provided that temperature limits, ventilation requirements, and maintenance access are properly considered.

Commissioning time depends on system size and complexity. Smaller packaged systems are often operational within a few days, while larger industrial installations generally require one to two weeks, including testing, optimization, and operator training.

Maintenance mainly focuses on the compressed air treatment system (filters, drains, and dryers), together with periodic inspection of valves and instrumentation.

With properly treated compressed air, the adsorbent can maintain its performance for many years.

The main operating costs are electricity for compressors and controls, routine maintenance, and periodic replacement of filters or consumable components. Since PSA systems require no chemical regenerants, operating costs are generally predictable and comparatively low.

A well-designed and properly maintained PSA nitrogen generator typically has a service life of 15–20 years or more.

Routine maintenance generally includes replacing filter elements, inspecting valves and instrumentation, checking control systems, and performing scheduled servicing of rotating equipment where applicable. Following the manufacturer's maintenance schedule helps ensure long-term reliability.

Systems can include online oxygen analysers, data logging, and remote communication, allowing continuous monitoring of Nitrogen purity, flow rate, pressure, dew point, and other key operating parameters, with automatic alarms in case of deviations.

Electrical requirements vary depending on system size and customer standards. PSA systems are available for a wide range of international voltages and frequencies and can be integrated with existing plant electrical infrastructure.

Industrial Nitrogen case studies commonly show total gas cost reductions between 30% and 90%, depending on consumption profile, local gas prices, electricity costs, and the customer's starting point.

Payback periods of less than one to two years are frequently achieved.

Yes. Many PSA systems allow cycle parameters to be adjusted to accommodate moderate variations in feed gas composition, pressure, or required product purity. Significant process changes may require re-optimization by the equipment supplier.

Nitrogen is used across almost every industrial sector—from food and beverage packaging to electronics manufacturing, metal processing, heat treatment, pharmaceuticals, chemicals, plastics, energy, and many other applications.

For a detailed overview, please visit our Applications section.

Residual oxygen can create safety risks, increase corrosion and prevent compliance with gas grid specifications. METHAGEN VPSA directly removes oxygen without requiring a separate deoxygenation unit.

An industrial PSA Oxygen generator produces oxygen (O₂) from compressed air using Pressure Swing Adsorption (PSA) technology. The adsorbent selectively retains Nitrogen while Oxygen passes through as the product gas.

Depending on the application, oxygen levels as low as 0.2% can be achieved without additional DEOXO equipment.

Filtered and dried compressed air enters adsorption vessels containing molecular sieves. Nitrogen is adsorbed under pressure while Oxygen is delivered to the buffer tank. The vessels alternate automatically between adsorption and regeneration, ensuring a continuous Oxygen supply.

Direct oxygen removal avoids additional deoxygenation equipment, reducing CAPEX, maintenance and OPEX, as well as to allow Oxygen injection in Biogas for H2S reduction.

Industrial PSA oxygen generators typically provide Oxygen purities between 90% and 95%, covering a wide range of industrial applications including wastewater treatment, glass production, metal cutting, combustion enhancement, aquaculture, and ozone generation.

Higher purity requirements should be evaluated on a case-by-case basis by the SYSADVANCE engineering team.

Yes. Oxygen may be injected upstream in the digestor or HsS filter system to improve H₂S removal while VPSA removes residual oxygen before grid injection, increasing efficiency in H2S reduction and decreasing costs associated with H2S pre-treatment.

PSA technology is generally the most economical solution for low- and medium-capacity Oxygen demand, offering lower investment costs, reduced operating complexity, fast start-up, and excellent flexibility for varying production requirements.

Cryogenic plants remain the preferred solution for very large Oxygen consumption or multi-gas production facilities.

Nitrogen reduces biomethane calorific value and may prevent compliance with pipeline specifications.

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On-site Oxygen production removes recurring delivery, rental, transportation, and storage costs while ensuring continuous gas availability.

It also reduces dependency on external suppliers and lowers the environmental impact associated with transporting industrial gases.

Yes. The METHAGEN LF VPSA process is specifically designed for efficient nitrogen removal up to 20% Nitrogen.

The generator is installed downstream of the existing compressed air treatment system and integrates easily with standard industrial compressor installations.

Membranes separate CO₂ efficiently but have limited methane/nitrogen selectivity, thus not allowing for the removal of Nitrogen in Biogas..

PSA Oxygen generators are available as skid-mounted or containerised systems suitable for indoor or outdoor installation, provided environmental and maintenance requirements are respected.

No. It is effective but generally requires higher energy consumption and more complex and costly equipment.

Routine maintenance mainly involves servicing the compressed air treatment equipment and periodically inspecting valves, analysers, and instrumentation.

With adequate air quality, the adsorbent provides reliable long-term performance.

Automatic control adjusts cycle time and feed flow to maintain stable product quality.

A correctly sized and properly maintained PSA Oxygen generator commonly operates for 15–20 years or longer.

Yes. Continuous process control maintains biomethane quality, independently from volatility in Biogas inlet composition.

Systems can be equipped with online Oxygen analysers, pressure, flow, and dew point monitoring, data logging, remote diagnostics, and alarm management to ensure continuous performance verification.

VPSA is generally more tolerant of temporary contaminant excursions than membrane systems.

Industrial Oxygen users frequently achieve 30% to 90% reductions in total gas costs, depending on consumption patterns and local market conditions.

Many projects achieve return on investment within one to two years.

Siloxanes, VOCs, ammonia, liquid water, compressor oil and particulates.

PSA Oxygen is widely used in wastewater treatment, glass manufacturing, metal fabrication, combustion enhancement, aquaculture, ozone generation, pulp and paper, mining, chemical processing, and numerous other industrial applications.

For more detailed information, please visit our Applications section.

VPSA is less likely to suffer permanent damage than membrane systems after temporary upsets.

An industrial VSA (Vacuum Swing Adsorption) oxygen generator produces Oxygen (O₂) directly from ambient air using adsorption technology. Instead of relying on compressed air, VSA systems use low-pressure blowers and vacuum pumps to separate Oxygen from Nitrogen, delivering high-efficiency on-site Oxygen production.

Lower energy consumption reduces lifetime operating costs.

Ambient air is drawn into the system by a blower and passes through adsorption vessels filled with molecular sieve. Nitrogen is selectively adsorbed while oxygen passes through to the product buffer tank. The adsorbent is then regenerated under vacuum before the cycle repeats, providing a continuous oxygen supply.

Specific energy consumption can be as low as approximately 0.18 kWh/Nm³ under suitable conditions.

Industrial VSA Oxygen generators typically produce Oxygen with purities between 90% and 95%, making them suitable for applications such as wastewater treatment, glass manufacturing, combustion enhancement, mining, aquaculture, pulp and paper, and chemical processing.

Higher purity requirements should be evaluated together with the SYSADVANCE engineering team.

Reduced electricity consumption lowers OPEX throughout the project lifetime.

VSA technology becomes particularly advantageous for higher oxygen flow rates, where it can significantly reduce energy consumption compared with PSA systems.

Because VSA operates at low pressure and regenerates the adsorbent under vacuum, it typically offers lower specific power consumption, especially in continuous large-scale industrial applications.

Typically after around 10 years or longer under normal operating conditions.

For medium- to high-capacity oxygen demand, VSA often provides the lowest total cost of ownership, combining relatively low capital investment with low operating costs and rapid installation.

Cryogenic plants remain the preferred solution for very large Oxygen production capacities or when multiple industrial gases are required simultaneously.

VPSA generally requires fewer replacement interventions, reducing lifecycle costs.

Producing Oxygen on-site eliminates recurring costs associated with gas deliveries, cylinder rental, liquid oxygen storage, transportation, and supplier dependency.

It also improves supply security while reducing the carbon footprint associated with industrial gas logistics.

No. It is a dry adsorption process.

Both technologies produce Oxygen on-site, but each has its strengths:

PSA is generally preferred for lower flow rates and where compressed air is already available.

VSA is typically the most energy-efficient solution for medium and high oxygen demands, thanks to its low-pressure operating principle.

The optimal choice depends on flow rate, purity, operating profile, available utilities, and overall project economics.

Yes, subject to local gas quality specifications, up to 99% CH4 concentration.

Unlike PSA systems, VSA generators do not require a compressed air system. Instead, they operate using low-pressure blowers, vacuum pumps, and filtration equipment, simplifying installation where compressed air capacity is limited.

Yes. It builds on SYSADVANCE's extensive PSA installation base.

VSA Oxygen generators are available as skid-mounted or containerised plug-and-play systems suitable for indoor or outdoor installation.

Adequate ventilation, ambient temperature control, and sufficient maintenance access should be considered during system design.

Approximately 165 to 5,000 Nm³/h in modular configurations.

Routine maintenance includes servicing the blower, vacuum pump, filters, valves, and instrumentation.

With proper preventive maintenance, the molecular sieve maintains stable performance for many years.

A PSA can be integrated into a plant control system using standard industrial communication protocols and conventional digital or analog I/O. The exact signal list depends on the level of automation and customer requirements.

A correctly designed and maintained VSA Oxygen generator typically provides a service life of 15–20 years or more, with many installations operating reliably beyond this period.

Most PSA systems reach operating pressure within minutes and begin producing gas shortly afterward. Full design purity is typically achieved once the adsorption cycle has stabilized.

VSA systems can incorporate online Oxygen analysers, flow meters, pressure transmitters, data logging, remote monitoring, and predictive maintenance features, allowing continuous supervision of system performance and automatic alarms if operating parameters deviate from specification.

During an emergency stop, feed gas is isolated and the adsorption cycle stops safely. Once the cause has been resolved, the system can normally be restarted following the standard operating procedure. Extended shutdowns may require depressurization before restart.

Compared with purchased Oxygen, VSA installations frequently achieve 30% to 90% reductions in total gas costs, depending on local electricity prices, Oxygen consumption, and the existing supply method.

For medium and high Oxygen demand, VSA often delivers the lowest cost per cubic metre of Oxygen, with many projects achieving payback periods of less than one to two years.

Yes. Industrial PSA systems are commonly designed for outdoor installation and can be supplied with weather protection, insulation, heat tracing, or other environmental features to suit local climate conditions.

VSA oxygen generators are widely used in industries requiring medium to large volumes of oxygen, including:

Wastewater treatment

Glass manufacturing

Steel and non-ferrous metallurgy

Mining

Pulp and paper

Chemical processing

Ozone generation

Aquaculture

Combustion enhancement

Cement and lime production

Energy and environmental applications

For more detailed information, please visit our Applications section.

Higher feed pressure generally improves adsorption efficiency and reduces equipment size, provided the system operates within its design limits. The optimum operating pressure depends on the gas composition and the required product specifications.

HELISYS is an advanced Helium recovery and purification system designed to continuously recover, purify and recirculate helium within industrial leak testing and process applications. By maintaining a constant helium purity level, HELISYS minimizes helium losses, reduces operating costs and improves overall process stability.

Conventional Helium recovery systems gradually accumulate atmospheric contaminants such as Nitrogen, Oxygen and moisture. As contamination increases, Helium purity decreases, forcing operators to periodically vent contaminated gas and replace it with fresh helium.

HELISYS eliminates this limitation by continuously removing contaminants, maintaining stable helium purity and significantly reducing helium consumption.

The "Purge Trap" is the recurring cycle in conventional helium recovery systems where contaminated Helium must be vented and replaced once impurity levels exceed acceptable limits. This results in:

Helium losses

Increased operating costs

Production interruptions

Reduced process consistency

HELISYS eliminates this cycle through continuous Helium purification.

Conventional recovery systems primarily collect Helium and remove particulate matter and limited amounts of moisture. However, they cannot continuously remove atmospheric contamination entering the recovery loop.

HELISYS incorporates Vacuum Pressure Swing Adsorption (VPSA) technology to continuously remove contaminants from the recovered helium stream, maintaining constant Helium purity without periodic gas replacement.

HELISYS uses Vacuum Pressure Swing Adsorption (VPSA) technology to selectively adsorb contaminants while allowing helium to pass through. The system continuously removes Nitrogen (N₂), Oxygen (O₂), Argon (Ar), Carbon dioxide (CO₂) and water vapour (H₂O), ensuring a stable supply of high-purity Helium.

HELISYS continuously removes:

Nitrogen (N₂)

Oxygen (O₂)

Argon (Ar)

Carbon dioxide (CO₂)

Water vapour (H₂O)

This ensures consistent Helium purity while protecting sensitive equipment and improving process reliability.

Depending on the application and system configuration, HELISYS maintains Helium purity levels of up to 99.99%.

HELISYS can recover up to 98% of the Helium used within the process, substantially reducing helium consumption and operating costs.

HELISYS delivers a constant pressure dew point below −40°C, providing ultra-dry Helium that protects sensitive instrumentation and downstream equipment.

Yes. HELISYS is designed to handle varying inlet gas compositions, including low Helium concentrations and mixed gas streams such as Helium/Nitrogen (He/N₂).

Continuous removal of air ingress allows leak testing systems to operate with reduced evacuation requirements, shortening cycle times and increasing production throughput.

In conventional systems, deep vacuum levels are required to minimize contamination entering the Helium recovery loop.

Since HELISYS continuously removes atmospheric contamination, the required vacuum level can often be reduced, significantly decreasing evacuation time and enabling higher testing capacity.

No. HELISYS integrates with existing leak testing processes while maintaining stable Helium purity.

Consistent gas quality reduces sensitivity drift, minimizes false failures and ensures repeatable leak detection performance.

HELISYS continuously restores Helium purity, eliminating the need for periodic gas purging. Fresh Helium is only required to compensate for unavoidable process losses rather than contamination buildup.

Yes. HELISYS is designed for seamless integration with existing Helium recovery installations, improving system performance without requiring major process modifications.

HELISYS is typically installed downstream of the Helium compressor (6–9 barg) and upstream of the high-pressure Helium boosters.

This installation arrangement:

Purifies helium at the optimal operating pressure

Supplies clean, dry Helium to the booster system

Extends the service life of compressors, boosters and high-pressure valves

By supplying ultra-dry, high-purity Helium, HELISYS helps protect:

Mass spectrometers

Vacuum pumps

High-pressure boosters

Precision valves

Leak testing fixtures

Sensitive components under test

The removal of moisture and carbon dioxide reduces corrosion, contamination and maintenance requirements while extending equipment lifetime.