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RJ Engineering Systems designs and builds Nitrogen Generation Packages using polymeric membrane systems from Air Liquide MEDAL. The hollow fiber membranes from MEDAL offers one of the most efficient and durable nitrogen generation sys-tems on the market. The Nitrogen Generator packages can be configured with equip-ment for compressed air generation, pretreatment, membrane modules and down-stream pressure boosting, as required by customers. The operating pressure range of different membranes in combination with capacities and pressure ranges of compressors available allows for a wide selection of package models. Units offered in modular design provide the required flexibility in operation per customer requirements. Specifications, standards, metallurgy and requirements laid down by industry associations, major end users, engineering consulting companies and inspection authorities are incorporated according to customer demands.

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Nitrogen Generators Membrane Type

MEDAL hollow fiber nitrogen membranes are the most advanced in the world. The superior performance of MEDAL nitrogen membranes is derived from their high selectivity and high productivity, which are a result of the ability to produce nitrogen membranes with an extremely thin, defect free separating layer. The range of MEDAL membranes available have an output range of 5 to 5000 l/min and purities of 95 to 99.95%, dry and CO2 free . Nitrogen Generators using MEDAL membrane separators are typically of the composite type and are more compact in size than those utilizing alternate technologies. This is a result of higher nitrogen production per unit volume of membrane module. After aging of the membranes, the nitrogen recovery ratio remains the same, with drop in production volume per membrane, at the same time contributing to reduction in pressure drop across the membrane. The packaged units are always sized to accommodate for the reduction in production volume after aging. Membranes from MEDAL can tolerate high water content in the feed air. The membrane separator performance will not decline permanently should water condense on the membrane surface. Their performance reverts to 100% once the condensed water has dried. The high H2O and CO2 permeability of the membranes ensures a very dry (-70 C pressure dew point) nitrogen product, depleted of CO2. Membranes separate gases by the principle of selective permeation across the membrane wall. For polymeric membranes, the rate of permeation of each gas is determined by its solubility in the membrane material, and the rate of diffusion through the molecular free volume in the membrane wall. Gases that exhibit high solubility in the membrane and gases that are small in molecular size, permeate faster than larger, less soluble gases.

"Fast" gases permeate through the membrane wall faster or more readily than "slow" gases, thus separating the original gas mixture into two streams. The purity of the desired streams can be adjusted by changing the operating conditions. The ability of a membrane to separate two gases is determined by its "selectivity", which is the ratio of permeability of the two gases. The higher the selectivity, the more efficient the separation and less energy is needed to run the system. Based on operating pressures, the membranes are categorized as follows: Low Pressure Membranes: For inlet pressures up to 15.0 barg/219 psig High Pressure Membranes: For inlet pressures up to 36.0 barg/523 psig

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Relative Permeation Rates H2O He H2 NH3 CO2 H2S CH3OH CO Ar N2 CH4 C2H6 C3H8 Fast > > > > > > > > > > > Slow

Hollow Fiber Membrane SeparatorsTechnology:

Compressed air supply to the Nitrogen generator is pretreated through a customized train, depending on the quality of the compressed air. Wet compressed air from Oil flooded or lubricated compressors go through a bulk coalescing filter to remove free water and oil droplets, followed by a preheater to stabilize the relative humidity to 90% or less, to avoid wetting of the downstream equipment. The heater is also designed to maintain an optimum process temperature conducive to maximum recovery rates and flow capacity. An Activated carbon bed filter removes oil aerosols and vapor, with a 0.1 micron particulate filter downstream of heater to ensure long uninterrupted life of the membranes. Pretreatment systems for compressed air supplied from oil free compressors can be limited to a coalescing filter and heater. Activated carbon filters are not needed unless ingress of hydrocarbon vapors are anticipated. In Low Pressure Membranes, the cleaned, superheated compressed air enters one end of the membrane bundles with sealed off inter fiber voids, the gas flow is through the inside or bore of the hollow fibers. Permeates or rejects consisting of O2, CO2 and water vapor permeate to the outside of the membranes and are exhausted to the atmosphere, through side vents. Nitrogen at purity as controlled is delivered at the other end of the membrane bundles through the bores.

In High Pressure Membranes, the flow pattern is the opposite, with the gas flow on the outside of the hollow fibers, with the permeates travelling to the bore of the fibers. Nitrogen is delivered through a channel at the center of the bundle on the same side as the inlet. Permeates are directed from the cores to a vent port on the opposite side to be vented to atmosphere. This ar-rangement provides for very low pressure drops, which are critical for high pressure operations.

Overall, MEDAL membranes offer very little pressure drop due to design of the fibers; the pressure drops reduces further as the membranes age over time. In high purity flows, the pressure drop can be as low as 0.06 bar/0.9 psi to 0.4 bar/5.5 psi, depending on the membrane model selected. Nitrogen purity and flow is controlled by a pneumatic flow control system comprising of an intelligent back pressure control valve with a positioner, with an override based on the output from the Oxygen analyzer. This arrangement allows for continuous operation of the system without any manual adjustment of the back pressure valve , when process variables change due to variations in ambient conditions, process demand or upstream equipment performance.

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Membrane Type Nitrogen Generators-Process Description:

Membrane Type Nitrogen Generators are designed to operate continuously at maximum design rate but can seamlessly adapt to fluctuating demands across the full range. If the demand goes down, the system shuts off the inlet gas flow at an adjustable discharge pressure set point until the demand picks up again; the nitrogen supply resumes immediately on demand. The modular construction allows modifying the capacity of the system by isolation of one or more membrane bundles, if needed to adjust the real time size of the unit. This feature allows online replacement of the bundles as well, without affecting production. The unique dual blowdown system in the design of the package allows automatic streamlining of the nitrogen generator during startups and resets, without any deterioration of purity of nitrogen in the downstream storage or piping. The system adds the safety feature of instantaneous evacuation of the membranes, in case of upstream upsets like malfunction of compressor after cooler or heaters.

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Membranes housings are available from a select choice of materials: Aluminum, Carbon steel or Stainless steel. The carbon steel and stainless steel housings are designed to ASME Sec VIII Div 1 and certified.

Piping is designed as per applicable piping standards including ASME B 31.3. Stainless steel or Carbon steel piping, valves and vessels are available as per installation locations and operating conditions. Vessels are designed to ASME Sec VIII Div 1 and certified.

Heater element sheaths in Incoloy 800H, SS 321 & SS316L

Radiography, Ultrasonic & Dye Penetrant Inspection available for all components

Full traceability and Certification to EN 10204 2.2, 3.1 or 3.2 as required.

Membrane Type Generators-Design & Operation Flexibility:

Membrane Housings, Vessels and Piping-Construction & Materials:

Special Features :

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Intelligent and Flexible Control Systems

Microprocessor based programmable control systems with Graphic interfaces, with flexibility to allow user programming and full remote connectivity.

Programmable Logic Controllers which form the core of the controls can integrate upstream and downstream equipment for total package control.

Standard construction has Stainless steel panels- NEMA 4X/IP 66 protection with touchscreen HMI. The HMIs have full onscreen diagnostic capability and energy buffering for data security.

The panels are suitable for locating in harsh envi-ronments, with basic units supplied with UL Class 1 Div 2 or ATEX Zone 2 and 22 approvals.

SCR Controlled Heaters

Electric air pre-heaters use SCR power controllers with dedicated heater panels, as standard. The heater panels come standard with safety features like Shorted SCR detection, Flange temperature cutouts, Element temperature cutouts and Panel temperature cutouts.

Standard diagnostic features include individual Current, Voltage and Power measurements, Partial load detection and Earth leakage detection.

Heater designs incorporate two options: Hairpin type elements for compact installations and Straight cartridge elements which allow online maintenance and change-outs with 100% redundant element sets.

Integrated Packages

The large range of air compressors and boost-er compressor options from RJ Engineering portfolio makes integrated packages with upstream and downstream compressors possible.

Apart from reduced capital costs due to consolidated engineering and manufacturing, this allows single point monitoring of operation by global controls. An integrated package can contribute towards considerable savings in operating costs, especially in cases with fluctuating demands.

Interactive sizing of components and capacity control by variable speed are some of the ways integrated packages offers energy savings.

Customization options :

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Hazardous area classification

Units are configured to meet hazardous area classification requirements to fit project spec-ifications.

Heaters, Instruments, Cables, Glands & Panels are selected to meet requirements of NEC, NFPA 70/IEC 60079/ATEX Directive 94/9/EC explosion proof and intrinsically safe classes, zones, categories, gas groups and temperature classes, beyond the Class 1 Div 2 & Zone 2 and 22 standard approvals.

When Integrated packages are offered, Electric motors and local starter panels including variable Frequency Drives can also be area classified. Heater SCR panels can also be customized with explosion proof purge units, if located in the field.

Outdoor units-Weather protection & Portability

Weather proof enclosures and construction for all- weather outdoor operation is another special-ty offered across all units. The package would be enclosed in a portable weatherproof container with all- weather insulation and HVAC for equip-ment protection and personnel comfort. Typical all weather units are designed to operate between average low (-32C/-25F) to average high (46C/115F) and protected against rain, snow, sleet and dust.

Portable units can be designed to be self con-tained, with air pre-heaters & space heaters utilizing engine jacket water as the heating medium.

Special metallurgy for components

Custom material grades and specialty coating are available on all components, for harsh operating environments like offshore, coastal, humid and dusty locations. Stainless steel piping and vessels are offered with internal and external grit blasting, polishing or special coating, depending on the loca-tion and service.

Instrument wetted parts in Hastelloy C & Monel 400, Stainless Steel 904L or Inconel 625 tubing, Stainless steel cable glands, fittings & explosion proof panels are some of the unique metallurgical requirements addressed in custom packages.

XNML&H1/2/3/4-****-9950/9900/9800/9700/9500: Membrane Module Packages

TECHNICAL SPECIFICATIONSINDIVIDUAL MEMBRANE MODULES

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*Custom sizes to meet total flow capacies, depending on the number of membrane modules installed. Flow rates shown are per membrane module at the maximum connuous operang temperature and maximum working pressure.

Recovery rates improve at lower temperatures (min recommended @ 35C/95F) but with lower flow capacies.

Model Number Module Type

Max Feed Pressure

Inert Purity (N2+Ar)

Flow Rate/module @ Max Pressure Pressure Drop

Barg Psig Product(N2+Ar) Feed Air

Product(N2+Ar) Feed Air Bar Psi

Nm3/hr CFM LOW PRESSURE MEMBRANES ( @60C/140F Operating Temperature) XNML1-*-9995 4121 15 219 99.95% 0.3 4.3 0.2 2.7 0.11 1.6 XNML2-**-9995 4241 15 219 99.95% 2.3 20.3 1.4 12.6 0.38 5.45 XNML3-***-9995 4640 15 219 99.95% 10.2 91.3 6.3 56.8 0.35 5 XNML4-****-9995 4240 15 219 99.95% 33.5 308.9 20.8 192.1 0.29 4.24 XNML1-*-9990 4121 15 219 99.90% 0.5 4.5 0.3 2.8 0.12 1.75 XNML2-**-9990 4241 15 219 99.90% 3 21.1 1.9 13.1 0.4 5.84 XNML3-***-9990 4640 15 219 99.90% 13.3 95.1 8.3 59.2 0.37 5.35 XNML4-****-9990 4240 15 219 99.90% 43.7 321.4 27.2 199.9 0.31 4.54 XNML1-*-9950 4121 15 219 99.50% 1.1 5.4 0.7 3.4 0.16 2.3 XNML2-**-9950 4241 15 219 99.50% 5.7 24.5 3.5 15.2 0.51 7.46 XNML3-***-9950 4640 15 219 99.50% 25.7 110.5 16.0 68.7 0.47 6.81 XNML4-****-9950 4240 15 219 99.50% 85.5 373.6 53.2 232.4 0.39 5.78 XNML1-*-9900 4121 15 219 99% 1.7 6.1 1.1 3.8 0.19 2.76 XNML2-**-9900 4241 15 219 99% 8 27.3 5.0 17.0 0.6 8.78 XNML3-***-9900 4640 15 219 99% 35.7 123 22.2 76.5 0.55 8 XNML4-****-9900 4240 15 219 99% 119.3 416.4 74.2 259.0 0.47 6.8 XNML1-*-9800 4121 15 219 98% 2.6 7.2 1.6 4.5 0.25 3.55 XNML2-**-9800 4241 15 219 98% 11.7 32 7.3 19.9 0.76 11 XNML3-***-9800 4640 15 219 98% 52.4 143.8 32.6 89.4 0.69 10 XNML4-****-9800 4240 15 219 98% 176.1 488.3 109.5 303.7 0.59 8.53 XNML1-*-9700 4121 15 219 97% 3.4 8.2 2.1 5.1 0.29 4.21 XNML2-**-9700 4241 15 219 97% 15 35.6 9.3 22.1 0.89 12.9 XNML3-***-9700 4640 15 219 97% 67 160.1 41.7 99.6 0.8 11.7 XNML4-****-9700 4240 15 219 97% 225.6 543.7 140.3 338.2 0.69 9.96 XNML1-*-9500 4121 15 219 95% 5.1 10.1 3.2 6.3 0.38 5.57 XNML2-**-9500 4241 15 219 95% 21.6 42.9 13.4 26.7 1.15 16.7 XNML3-***-9500 4640 15 219 95% 97.1 192.8 60.4 119.9 1.05 15.16 XNML4-****-9500 4240 15 219 95% 327.8 655.3 203.9 407.6 0.89 12.9 HIGH PRESSURE MEMBRANES ( @60C/140F Operating Temperature) XNMH1-**-9900 G6MP 36 523 99% 66.6 192.6 41.4 119.8 0.06 0.9 XNMH1-**-9800 G6MP 36 523 98% 79.2 207.5 49.3 129.1 0.08 1.2 XNMH1-**-9700 G6MP 36 523 97% 103.7 235.8 64.5 146.7 0.13 1.9 XNMH1-**-9500 G6MP 36 523 95% 156.7 287.6 97.5 178.9 0.17 2.5

RJ Engineering Systems, Inc 13805, West Road Suite 350 Houston, TX-77041 USA Tel: +1-281-897-0350 Fax: +1-281-897-0355 E-mail: [email protected] www.rjesusa.com

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