Carbon dioxide shortages are a growing concern in New Zealand, especially now that there is only one source of CO₂ in the country. For a lot of industries, particularly food and beverage, carbon dioxide is used to preserve and process products but now that it isn’t so readily available, many are looking for an alternative.
If you’re interested in finding an economical, sustainable and effective substitute for carbon dioxide, this article will give you all the information you need to decide if nitrogen is the right choice for your business. We delve into the cost of installing your nitrogen generator and which types are available so that you can be prepared when carbon dioxide is no longer feasible.
Shortages of carbon dioxide
Before we dive into nitrogen generator costs, it’s worth knowing exactly why carbon dioxide is in such short supply. Until this year, the Marsden Point oil refinery is where many New Zealand businesses sourced the carbon dioxide they needed. However, since the refinery was closed in March, the only remaining source of carbon dioxide is the Todd Energy Kapuni gas field in Taranaki. This is simply not enough to keep businesses adequately fuelled, and many have reported that they’re only able to get 50% of what they’ve ordered.
Another concern about using carbon dioxide is the fact that looming climate regulations are likely to lead to even further restrictions. Carbon dioxide is one of the most significant greenhouse gases contributing to global warming and, together with methane, makes up 88% of New Zealand's greenhouse gas emissions. Because of this, the government has pledged to halve the country’s greenhouse emissions by 2030, which means carbon dioxide will be increasingly difficult to source.
Can nitrogen replace carbon dioxide?
The most abundant element in Earth's atmosphere is nitrogen, which is colourless, odourless, and tasteless. In fact, nitrogen makes up over 78% of the earth’s atmosphere and is easy to extract for use in industrial processes.
Nitrogen is not a greenhouse gas and doesn’t require the combustion of fossil fuels to be produced, which makes it a far more sustainable option than carbon dioxide. It also means you can use a generator to affordably extract it yourself, rather than relying on expensive stores of carbon dioxide.
Nitrogen can replace carbon dioxide for preserving food, purging tanks and clean in place (CIP) pipework and has been used across key industries including dairy, food, wine, pharmaceutical, automotive, manufacturing and more. To find out if nitrogen would work for your processes you can talk to one of the experts on our team and get advice on the best solutions available.
Nitrogen generator costs
Typically, a nitrogen gas generator would include a compressor, dryer, air and nitrogen receivers, nitrogen generator, filtration, drains and necessary piping. A booster compressor and gas-bottle filling station can also be added for some high-pressure applications. So let’s explore the different types of nitrogen generators on the market and how much they cost.
Cost of a skid-mount nitrogen generator
A skid mount nitrogen generator is a practical, efficient and easily transported option to start extracting nitrogen for your business. This design is a relatively affordable option in terms of the upfront investment and the ongoing operating costs.
At Industrial Air Systems, our PneuTech skid mount generators come fully assembled on a solid steel base with forklift mounts so that it’s efficient to install and move if required. They’re commissioned, tested and fully charged with nitrogen in our factory so that the entire system is complete and ready for operation as soon as it’s on your site.
The pricing of a skid mount nitrogen generator depends on the pressure and size you need. Prices for a low-pressure N2 setup start from $55,000 +GST and are ideal for food/bottling flushing. However, for a medium-range high-pressure setup used mainly for laser cutting and high-pressure bottling, prices start from $220,000 +GST.*
Cost of a containerised nitrogen generator
Containerised nitrogen generators are all-inclusive generator packages assembled in a shipping container so that everything is secure and in one convenient place. They are typically used for outdoor placements because the generator is protected from the elements.
At Industrial Air Systems, our PneuTech containerised nitrogen packages are fully assembled in new 20ft or 40ft shipping containers and are ready to use as soon as they’re installed. This plug-and-play design includes a compressor, dryer, receivers, filtration, drains, pipes and the nitrogen generator so that you can immediately integrate it with your operations.
A containerised nitrogen generator typically starts from $320,000 +GST and would include the compressor, dryer, filtration, receivers, N2 generator, booster compressor and manpack cylinder storage.* These are large-range high-pressure setups and are predominantly used for laser cutting and filling pressure bottle packs for rental.
Cost of a factory-install nitrogen generator
A factory-install is where a generator is assembled and commissioned in its intended location so that it’s custom-designed to suit the existing layout and application.
At Industrial Air Systems, we pre-test each PneuTech factory install package before it is dispatched to ensure everything operates to a high standard. Once on site, our technicians re-assemble the entire package to fit seamlessly into your factory’s operations. Because of this process, you can have your nitrogen generator tailored to your requirements and be confident it will work effectively within its intended application.
The pricing of a factory-install nitrogen generator is similar to a skid-mounted generator. Depending on the size, smaller generators start from $55,000 +GST and medium-range setups start from $220,000 +GST.*
So there you have it, that’s everything you need to know about using nitrogen as an affordable alternative to carbon dioxide, along with starting prices. Our experienced team can advise which generator setup is right for you and complete the whole installation from start to finish. So, if you think a nitrogen solution sounds like a good fit for your processes, we’d love to help you make the switch.
*The starting prices in this article should be used as a guide only. For accurate pricing please get in touch with us to request a quote.
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