How is industrial oxygen produced?

Oxygen generators are designed to extract oxygen from ambient air. Since air is a mixture of gases, mainly nitrogen (about 78%) and oxygen (about 21%), the main goal is to separate oxygen molecules from the rest. Different technologies, such as PSA, VPSA, membranes, or chemical systems, can be used to isolate and concentrate oxygen, depending on purity and application needs.

Pressure Swing Adsorption (PSA) is the most commonly used technology for generating industrial oxygen. PSA is valued for its reliability and efficiency in on-site oxygen generation as the process ensures a continuous supply of oxygen at purities up to 95%.

Typically used in smaller applications:

• Medical
• Industrial applications  such as metal cutting, welding
• Wastewater treatment
• Aquaculture

The process uses a pair of pressure vessels filled with carbon molecular sieve (CMS). This porous material effectively traps nitrogen, carbon dioxide, water vapor, and other trace gases from compressed air, while allowing high-purity oxygen to pass through. As one vessel adsorbs, the other undergoes regeneration by depressurizing and releasing the captured gases, enabling continuous operation.

VPSA is an oxygen generation technology that works similarly to PSA but uses a vacuum during the regeneration phase, reducing energy use and improving efficiency. It's commonly used in large-scale operations where energy savings are important.

Typically used in larger applications:

• Steel and petrochemical industries
• Biogas production
• High-capacity production with energy efficiency focus

This method uses semi-permeable membranes to filter air. Nitrogen and other gases pass through the membrane walls differently than oxygen, allowing for a stream of oxygen-enriched air. The purity is lower (30–40%), but the setup is simple and compact.

Used in:

• Wastewater treatment
• Nitrogen reduction processes
• Applications not requiring high oxygen purity

Chemical oxygen generators produce oxygen through chemical reactions, such as decomposing sodium chlorate. These systems are compact and often used in enclosed or emergency environments.

Used in:

• Emergencies (aircraft, submarines)
• Portable oxygen supply in confined spaces

Oxygen generators are used in a wide range of industrial applications due to their efficiency and cost-effectiveness.

Here are a few uses of industrial oxygen:

• Metal production: Oxygen aids in burning fuel at higher temperatures, essential for processes like steelmaking and welding.
• Wastewater treatment: Oxygen improves bacterial efficiency in breaking down organic materials.
• Glass manufacturing: Oxygen-enriched flames produce higher temperatures, enhancing glass quality.
• Aquaculture: Increased oxygen levels in water boost fish growth and health.
• Medical facilities: Reliable oxygen supply for respiratory therapies and emergency care.

Remember to follow safety protocols when producing and storing oxygen on-site:

• Ensure proper ventilation in generator rooms and enclosed spaces.
• Keep oxygen systems away from flammable materials.
• Inspect filters and valves regularly.
• Use alarms to monitor oxygen purity and pressure levels.
• Wear PPE such as insulated gloves, safety glasses, and face shields.

Note: Industrial oxygen should not be used in a medical emergency unless it meets medical-grade standards.

Choosing the right oxygen generator depends on your required purity level, usage volume, and operational needs. On-site oxygen generation, especially using PSA (Pressure Swing Adsorption) technology, is often the most cost-effective and reliable solution, without the need for deliveries. 

To select the most suitable system, consider the following: 

• purity requirements (e.g., medical vs. industrial use), 
• flow rate (oxygen needed per minute/hour),  
• space and maintenance (available installation area and servicing capacity), 
• budget (upfront and long-term costs), 
• and safety regulations (compliance with relevant industry standards). 

While bottled or liquid oxygen may suit specific short-term or high-volume needs, on-site systems offer greater autonomy, efficiency, and safety across applications like healthcare, aquaculture, and manufacturing.