Compressed air is the driving force behind most nitrogen generators. Without clean, dry air, the system can’t do its job well. At higher altitudes and in prairie climates, air systems face added strain from fluctuating humidity, temperature swings, and dust. In Calgary and surrounding areas, we deal with those environmental challenges every day. That’s why planning proper air treatment ahead of nitrogen production is not optional—it’s essential.
We’ve broken this topic down into focused sections so each part gives practical, relevant insights. Let’s look at what really matters when preparing compressed air for nitrogen systems.
Air Quality: The First and Most Crucial Step
Every nitrogen system begins with atmospheric air. That air gets pulled in, compressed, and separated into nitrogen and oxygen. However, raw air contains contaminants that can clog or damage the membrane or PSA system. If we skip filtration or let oil vapor pass through, nitrogen purity drops and components wear out faster.
We usually start with a particulate filter to block dirt and rust. After that, a coalescing filter removes oil mist. Water vapor needs a dryer. That can be either a refrigerant or desiccant model depending on how dry the output needs to be. If any step is skipped, the nitrogen generator ends up working harder than necessary. As a result, energy use increases and output consistency drops.
To prevent long-term damage, we always make sure our systems include a reliable dryer setup. For some customers, we also recommend a carbon filter to handle odor and trace gases. This layered approach keeps our compressed air clean, helping us support dependable air solutions in Calgary.
Pressure Matters More Than Most Expect
Nitrogen generators depend on steady pressure to work correctly. Sudden drops or pressure swings throw off the separation process. In PSA systems, inconsistent pressure can shorten the life of the sieve material. In membrane systems, uneven flow reduces nitrogen purity.
We’ve seen this happen when facilities rely on a single compressor that cycles too often. Each time it cuts out, pressure drops across the entire air system. One way we solve this is by installing a buffer tank to reduce those fluctuations. In some cases, adding a pressure regulator at the nitrogen skid helps maintain constant input.
Another point many facilities overlook is pressure drop from poor piping. Long lines, undersized pipes, and leaky fittings all add resistance. When that happens, the generator may not receive enough air at the right pressure. We review every setup before commissioning and advise upgrades when needed.
If you’re not sure whether your compressor setup matches your nitrogen unit’s needs, we recommend browsing our equipment rental for compressed air systems to test short-term configurations without long commitments.
Drying: More Than Just Moisture Control
Moisture doesn’t only lower nitrogen quality. It corrodes internal parts, encourages bacteria, and affects flow. In dry climates, facilities often assume there’s little moisture to worry about. But pressure condensation changes that picture.
Air compresses quickly. When it does, water vapor condenses into liquid. Even low-humidity air becomes saturated once compressed. If we skip drying or rely on a weak setup, condensate passes into the generator. Over time, it saturates the membrane or damages the sieve beds.
We recommend desiccant dryers for nitrogen systems that demand 99.9% uptime or high-purity output. These dryers achieve dew points far lower than refrigerant models. For example, a -40°C dew point helps prevent ice or corrosion in colder months. That keeps equipment stable year-round.
Regular dryer maintenance is critical. Saturated desiccant, worn seals, or clogged drains reduce performance. As part of system checks, we schedule desiccant changes and moisture tests to ensure nothing slips through.
Oil-Free Doesn’t Always Mean Clean
Many compressors are labeled as oil-free. However, “oil-free” refers to the compression chamber—not the entire system. Pipes, fittings, and downstream gear can still carry oil vapors. That’s a risk for nitrogen generators, especially PSA types. Oil coats the carbon molecular sieve and reduces its separation ability.
To prevent this, we include coalescing filters even on oil-free systems. These filters catch vapors and aerosols before they reach critical parts. We also inspect all seals and lubricants used in nearby components to ensure nothing is leaking into the line.
Another common issue is poor filter maintenance. Filters clog over time, and without regular changeouts, pressure drops increase and bypass can occur. We track pressure differentials to schedule replacements before problems happen.
This is one of the many topics we cover during custom air system planning in Calgary—reach out if you’re building a nitrogen skid or modifying an existing layout.
Piping Design Impacts Purity and Throughput
Piping design rarely gets the attention it deserves, yet it has a major effect on air quality. Long loops, multiple elbows, and dead ends introduce pressure loss, moisture buildup, and contamination pockets. When piping routes are not planned around flow direction, it’s easy for water or oil to collect in low spots and then enter the generator during startup.
We use sloped lines to encourage drainage and place filters just ahead of nitrogen equipment to act as the last defense. That final filter is sometimes the only thing preventing months of buildup from contaminating clean air.
Using the correct material also matters. Black iron rusts, especially when exposed to moisture. Stainless steel or aluminum piping offers better corrosion resistance. These choices reduce particulate risks and keep air pathways smoother.
We also review isolation valves and bypasses. These let our team test, clean, or repair sections of piping without shutting the system down. With better routing, lower pressure loss, and easier maintenance, the nitrogen output stays reliable even during operational changes.
Maintenance Strategy Directly Affects System Health
Even the best-prepared air systems fail without routine checks. Filters clog. Desiccant becomes saturated. Drain valves stick open or closed. These small failures add up and push contaminants toward the nitrogen unit. That’s when purity issues and downtime begin to show.
We build maintenance schedules around air system components. That includes compressor oil changes, filter replacements, dryer regeneration, and sensor calibration. Tracking pressure drop across filters is one of the simplest ways to monitor clogging.
For larger facilities, we recommend pressure dew point sensors and filter monitors that log performance trends. This data helps our team catch issues before they become expensive repairs.
Every nitrogen system we support includes a tailored maintenance plan. We also train onsite teams so filters are not just replaced on a schedule, but inspected for signs of deeper issues. For example, if an oil separator shows heavy buildup, we check compressor internals for over-lubrication.
This kind of attention to detail helps us keep air systems stable and avoid costly emergency downtime.
FAQs
What is the minimum air quality required for nitrogen generators?
It depends on the generator type. Most PSA systems require ISO 8573-1 Class 1 for oil and Class 2 for particles. Membrane systems are more forgiving but still need dry, clean air to function properly.
Do I need a desiccant dryer for nitrogen generation?
If your system operates in cold climates, or if you need high-purity nitrogen, a desiccant dryer is the safer choice. It delivers lower dew points and reduces corrosion risks.
How often should filters be changed?
We recommend checking pressure drop across filters monthly. Most filters should be replaced every 3 to 6 months, depending on usage and air quality.
Can I use existing plant air for nitrogen generation?
Sometimes yes, but only if it’s clean, dry, and steady in pressure. Many facilities need to upgrade filtration or add dryers to meet nitrogen system requirements.
What happens if compressed air quality drops suddenly?
Contaminants will pass into the nitrogen system. That leads to lower purity, potential damage to filters or sieve beds, and reduced generator performance.