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Previously, the company relied on a 10,000-litre liquid nitrogen (LiN) storage vessel, which required regular refills by tanker at a rate of approximately 8,000m³ per month. With plans to invest in a third laser machine, the company anticipated a significant increase in nitrogen demand. The client reached out to Maziak Nitrogen to explore the feasibility of generating nitrogen on-site, aiming to reduce operational costs while supporting their expanding production needs. The Maziak Solution After a detailed analysis, Maziak calculated that with the installation of a third laser machine, switching to nitrogen generation would offer a payback period of under two years. Confident in the financial viability, the client was introduced to other laser users with nitrogen generation systems in place. These visits helped reinforce confidence in the technology and provided real-world insights into its performance. The solution proposed was an Atlas Copco N2SKID package, which is typically delivered as a "plug and play" unit. However, due to longer lead times for the pre-built skid, it was decided to install the same Atlas Copco components directly within the site’s plant area. This approach offered greater flexibility, improved alignment with the site’s requirements, and expedited the installation process. The recommended system included:

• An Atlas Copco GA22VSDFF compressor for optimal energy efficiency.

• An NGP70+PPM Nitrogen generator equipped with a 300-bar booster.

• Two K16 HP gas cylinder storage packs for nitrogen storage.

The generator is capable of producing 34.6m³/hour, translating to 830,400 litres of nitrogen per day. Each storage pack holds 232m³ of gas at 290 bar, providing a total storage capacity of 434,000 litres, with 374,000 litres of usable gas before replenishment is needed. As the system generates gas on demand, replenishment occurs continuously during operation. The package can also be easily scaled by adding additional storage capacity as required. The Results Since the implementation of the nitrogen generation system, the company has realised significant cost savings. In the first year, nitrogen gas costs were reduced by 57%, with projected savings increasing to 63% by Year 5. The return on investment (ROI) was confirmed at just under two years. Operationally, the system has consistently delivered high-quality nitrogen gas, meeting and exceeding the client’s expectations for the laser-cutting process. The consistent gas quality has even led the client to consider optimising the system further by reducing the gas purity—an option that was not possible with the previous liquid nitrogen supply. This added flexibility has enhanced operational efficiency and provided a sustainable, cost-effective solution for the long term.

https://maziak.co.uk/case-studies/operational-cost-reduction-of-over-60-for-laser-cutting-business