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How Nitrogen Generation Created A New Market For Coal

The Problem: A Customer Needed a Solution for Creating High Carbon Foam Molds

The state funded project required nitrogen for mold creation and Motion & Control Enterprises (MCE) generated the nitrogen solution that helped create an entirely new market for coal.

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The project initiative was to develop a mass production process for the repurposing of coal for use as extremely sensitive molds for the Aerospace Industry. This required utilizing high concentrations of coal compounded with other materials to create molds for sensitive metal aerospace components.

Normal molds made of alloy steel had too great a deflection co-efficient for the tolerance involved.

 

 

THE SOLUTION:

MCE INTEGRATED A N2 TWIN TOWER NITROGEN GENERATOR SYSTEM

The molds were introduced into a large sintering oven to harden them. After which they were cut to form the mold to which the alloy steel was to be injected. The nitrogen generation system was required to provide an inert non-flammable gas to fill the combustion oven during the entire sintering process.

Due to its high carbon content the mold had no variance or deflection from its original form and held within tolerances for repetitive use.

Creating the new market for coal and the overall project initiative was considered a resounding success. The custom solution for High Carbon Foam Molds were an instant hit!

blue siemens simatic hmi nitrogen equalizer control panel

Siemens Simatic HMI


Design Specification – MNG-US-2950

   » Ambient Temperature

   » 95° F

   » Compressed Air Inlet Flow to Generator

   » 411 CFM

   » Compressed Air Inlet Pressure to Generator

   » 116 PSIG

   » Compressed Air Inlet Dew Point Required

   » +40° F (Class 1.4.1 ISO 8573.1:2010)

   » Compressed Air Inlet Connection

   » 3” FLG

   » Nitrogen Outlet Flow Rate

   » 67.9 SCFM (4,074 SCFH)

   » Nitrogen Outlet Pressure

   » 93 PSIG

   » Nitrogen Outlet Purity

   » 99.99%

   » Nitrogen Outlet Connection

   » 2” NPT

   » Nitrogen Buffer Tank

   » 400 Gallon

 

nitrogen generating system in tan and brown with venting hood

N2 Generator System


Design Specification – MNG-US-2950 Twin Tower Type N2 Generator System

  • PSA (Pressure Swing Adsorption) Type Nitrogen Generator

  • Carbolescer 4-in-1 Inlet Pre-Filtration

    • 0.01-micron rated Mist Eliminator, Particulate, Coalescing & Activated Carbon Filter

  • Buffer Tank Post-Filter – 0.01-micron rated Filter

  • Nitrogen Generator

  • Silencer

  • Siemens HMI Color Touch Screen PLC with Modbus Capability Standard

  • Buffer Tank

  • Oxygen Sensor

  • Flow Sensor

  • Pressure Transmitter

 

 

THE RESULTS:

THE COMPANY DOUBLED IN SIZE & IS CONTINUING TO PARTNER WITH MCE ON FURTHER EXPANSIONS

 

The project was an enormous success and received the complete contract for aerospace molds!

 

TWO YEAR FOLLOW UP


The company has grown to double the size and has two locations now employing approximately 100 employees. Displaying massive growth from its original headcount of 16.

Current plans are to incorporate another system and another process for further development. The Techno-Innovation Team is forecasting the need for acquiring an additional system as the company continues scaling.

 

air compressors and nitrogen generation tanks on a facility floor with yellow safety poles

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